Saipem 770 Rig Manuals: Loadmaster Universal Rigs, Inc

Saipem 770 Rig Manuals
Volume 3 of 9
Loadmaster Universal Rigs, Inc

Saipem 770 Rig Manuals
Volume 3 of 9
Table of Contents
1. Drawworks User Manual
2. Hydraulic Disc Brake Operation, Maintenance Instruction
3. Gear Coupling Manual
4. Drawworks gear box manual
5. Air Dryer User Manual
6. SULLAIR PORTABLE AIR COMPRESSOR
7. Elevator Link
8. HPU Operation Manual
9. LM770 Rig Remote Control System
10. LM770 Rig Drilling Controls Operation Manual
11. GAI-TRONICS CORPORATION Installation, Operation,
and Maintenance Manual
12. VFD and MCC Control Manual

LM 770 Saipem 5964 Drawworks Manual
LM770 DRAWWORKS
USER MANUAL
(AC-6266-GA-2100)
Revision 0
CONTENTS
Introduction
Preface
General Information
LM 770 Drawworks Specifications

General Description
Technical Specifications
Drawworks Main Components

Main Drum Assembly
Gear Box Reducer
AC Motors
Hydraulic Disc Brake System
Drawworks Frame and Skid
Gear Box Lubrication System
Drawworks Operation and Maintenance

Wire line Installation
Drawworks Start Up
Operation and Maintenance of the Hydraulic Brake System
Operation and Maintenance of the Gear Box Lubrication System
Operation and Maintenance of AC Electric Motors
Maintenance of Couplings and Grease Fittings
Troubleshooting
Parts Manual
Drawworks assembly Z03000000040AA
Drawworks frame and guard Z03050000052AA
Drum shaft assembly Z03010000106AA
Drawworks skid assembly Z03090000028AA
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1. Introduction
1.1. Preface
This manual provides information for installing, repairing, maintaining, or adjusting the
LM770 Drawworks.
This information is intended for operators and servicemen who are thoroughly familiar
with drilling equipment. It is not intended to cover every possible condition which may
be encountered. Always use good, sound mechanical practices and safety precautions.
All specifications are in accordance with engineering designs and should be adhered to
in all repairs. Operation and maintenance information on equipment other than that of
LOADMASTER UNIVERSAL RIGS is taken in part from the various manufacturers’
manuals. If the equipment manufacturer has issued later instructions, or in the event of
conflict, the manufacturer’s information takes precedence over that shown in this
manual, unless specifically stated otherwise.
The manual sections follow the major components, and cover standard production
unless otherwise specified. Specifications and components covered are for standard
equipment current at the time this manual was released.
LOADMASTER UNIVERSAL RIGS reserves the right to discontinue models at any

time, or change specifications or design of any model without notice and without
incurring any obligation.
1.2. General Information
This manual contains instructions and recommendations on the operation and

maintenance of the LOADMASTER UNIVERSAL RIGS LM 770 Drawworks. All
instructions and recommendations are limited to normal operational and maintenance
procedures and may require some adaptation to accommodate equipment which has
been custom-made to customer’s specifications.
A serial number has been assigned to each individual drawworks. Always include
model and serial number of the equipment when making inquiries or when ordering
spare parts. Exercise extreme safety precautions and employ sound mechanical
practices when performing inspections, maintenance repairs, or when operating the
equipment under conditions for which it was intended.
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PRECAUTIONS TO BE TAKEN BEFORE DOING MAINTENANCE WORK ON

EQUIPMENT:
 Notify all employees on the rig location of the specific equipment that will be shut
down for maintenance.
 To make certain that no equipment on which you are working can be started, install
your Own padlock on the control switch, lever or valve before you start. If more than
one person is working on the equipment, each person should install his own lock.
(Use special lock-out hasp which provides space for more than one lock).
 If no padlock is available, place a tag on the switch or control indicating the unit is
down for maintenance, and block out the control.
 When you are through with your job, remove your padlock or your sign and blocking.
OTHER PRECAUTIONS:
 In addition to locks, lock-out tags, blocking and disconnects, fuses can be pulled.
When removing any fuse, open the operating switch, then remove the fuse with an
insulated fuse puller. If the fuse is no protected with a switch, pull out the supply end
of the fuse first. When replacing the fuse, insert the supply end first.
 Tag the open fuse box indicating why the fuse has been pulled.
 If it is necessary to work near live bus bars, conductors or switches, isolate them with
insulated barriers.
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2. LM 770 Drawworks Specifications
2.1. General Description
The LM 770 drawworks consists of a drum, gear box, two AC motors, a disc brake
system, and a lubrication system. It has a spool-shaped revolving drum around which
the drilling line is wrapped. The drum shaft is connected to the speed reducing gear
box output shaft with a crowned gear flexible coupling. The gear box provides a speed
reducing ratio from the two (2) AC high speed (HTM 1230 AC Vector Motors)
motors coupled to the input shafts with crowned gear flexible couplings. The torque
produced by the two AC Variable Frequency motors is transferred through the speed
reducer to the drum shaft assembly. The transmission of the drawworks is short and
direct driven consequently its overall mechanical efficiency is high.
The Hydraulic disc brake system consists of a brake caliper, actuating mechanism, and
a hydraulic power unit (HPU). These units are connected by hydraulic tubing network.
The hydraulic power unit (HPU) provides power for actuating the Brake Calipers
against the Air Cooled Disc mounted on the Drum Assembly flanges. The Braking
Calipers include normally open Service Calipers and also normally closed Safety
Calipers.
The drawworks is powered by two sets of 1230 HP AC motors. The drawworks control
system is connected to the driller’s control console in the driller’s cabin. The driller
controls the drawworks from a panel, or console within the driller’s cabin. The driller
can change the speed with which the drum revolves, thereby varying the speed with
which the drawworks raises the traveling block and hook.
An illustrative diagram of the drum shaft assembly, brake systems, geared speed
reducer and electric motor arrangement for the drawworks is shown next.
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LM770 DRAWWORKS ASSEMBLY
LM770 DRUMSHAFT ASSEMBLY
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2.2. Technical Specifications
Electric Drive: HTM 1230 AC Vector Motors

AC-Variable Frequency Drive Motor – 2 motors
Motor rated at 41 Hz @ rated rpm = 800
Rated Voltage = 600 V;
Input power of drawworks……………………………..1100KW

Maximum pull of fast line………………………………370kN
Gears………………………………………1+1R, step less speed regulation
Diameter x Length, drum (slotted)…………………….Ф644×1171.5mm
Hoisting speed………………………………………….0~1.5m/s
Diameter of wire line……………………………………. Ф35mm ( 1 3/8 dia )
Size of slotted drum……………………………………..Φ685x1314
Dimensions of brake disc (OD + thickness)…………. Φ1570x76
Model of main motor……………………………………..Joliet AC1500 (two pcs)
Length = 7,000 mm (275.60”)
Width = Basic Skid 2,122 mm (83.54”) Max width 2,568 mm (101.10”)
Height = 2,381 mm (93.75”) without pony sub
Weight (Est) = 28,000 kg (61,729.76 lbs.) without pony sub
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3. Drawworks Main Components
The AC Drawworks is powered by two (2) low speed/high torque AC motors. These two
motors are the heart of the full capacity hoisting system. The output shafts of these motors
are coupled to the input shafts of a two stage geared speed reducer. The output shaft of the
speed reducer is coupled to the drum shaft. The drum shaft is keyed to the hubs within the
drum assembly. The drum has machined grooving for the drilling line. The flanges of the
drum assembly have the two friction discs attached. The two frame support brackets are
bolted to the main skid and to the drawworks frame assembly. The disc brake calipers are
mounted to this support frame to provide the braking force to the drum through the friction
disc. A hydraulic power unit with pumps and controls is mounted behind the Drawworks
frame. All of this equipment is mounted to a unitized skid.
The two AC motors are also used as a main brake for the drawworks. The motor generated
energy from the braking is dissipated through a resistor bank. The motor power is selected to
be large enough so that it can stop the traveling block under maximum load at maximum
speed within a reasonable time frame. No auxiliary brake is needed. Thus, the braking
system is fully regenerative. The hydraulic disc brake consists of a safety brake (normally
closed) and a working brake (normally open). The safety brake is used for parking. It is
activated through a switch in the driller cabin.
Control of the drawworks is achieved through Variable Frequency Drive (VFD) and is
discussed in the VFD Control manual.
A suitable drillers control system should be provided by the user of this drawworks to
enhance the performance capabilities of the drawworks and utilize the full capacity of the
motor for hoisting and braking. This control system will interface with the drawworks
motors and hydraulic braking system for maximum safety and efficiency during operations.
Refer to the brake manual and motor manual for details of their functions and required
interface.
Optional sensors (encoders) can be provided on the gear reducer output shaft to provide feed
back regarding line speed and block positioning to the drillers control system. Encoders can
also be provided on the motor output shafts to provide feedback to the drillers controls and
VFD's regarding motor speed.
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3.1. Main Drum Assembly
Main drum is used to wind the drill line of the traveling system and drive traveling
block. Main drum mainly consists of drum body, shaft, left and right bearing boxes,
self-aligning bearing, bearing cap, brake disc, shaft system accessories, fixing parts
(coupling bolts, nuts, spring washers). Main drum shaft is manufactured of high quality
alloy steel. The drum shaft is connected with drum body by double keys. The two sides
are attached to the drawworks frame by two self-aligning roller bearings. The drum
body is a solid piece with a rope groove cut directly into it. The drum is high strength
for a long service life and to reduce the attrition rate of drill line, improving the service
life of the drill line. The main drum is connected with drawworks frame by the 18
coupling plates on the bearing boxes of both sides.
Maximum pull of fast line………………………………370kN

Diameter x Length, drum (slotted)…………………….Ф644×1171.5mm
Hoisting speed………………………………………….0~1.5m/s
Diameter of wire line……………………………………. Ф35mm (1 3/8)
Size of slotted drum……………………………………..Φ685x1314
After machining and installation the drum unit is subjected to a static balancing test,
dynamic balancing test, and a strength test equal to the pulling force of the fast line on
the main drum. The wire line is anchored on the drum with a wire line clamp.
A crown-o-matic valve is installed on the upper bracket of main drum. The valve body
can move along bracket and drum axle line. The length of actuator rod is adjustable.
The lifting height of traveling block is corresponding with the number of drilling line
wraps on the drum when the blocks are at the upper portion of the mast and the drilling
line is at its maximum level on the drum. Adjust the over winding saving valve in
advance to control the saving height of traveling block. When the indicator bar of
Crown-o-matic valve touches the top layer of the drilling line on the drum, the saving
signal is separated into two circuits. One circuit cuts hydraulic disc brake control valve
power supply to perform emergency braking of hydraulic disc brake. The other circuit
produces 24V switch system to inform electric control system to stop drawworks and
stop the traveling block to prevent the traveling block from hitting the crown.
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Note: The crown-o-matic and the encoder system should be set before operating
the drawworks.
3.2. Gear Box Reducer
The gear box is a speed reducer. It is a two-stage drive device. Its input shaft and
output shaft are parallel; its casing (box) is a welded structure and reinforced at highly
stressed locations.
All gears and gear shafts are high precision spiral gears; the teeth are carburized,
hardened and grinded; the teeth are revised with high strength and low noise.
The input and output shafts of the speed reducer are made of high quality Quench and
Tempered steel.
Technical Parameters
Rated Input Power: 917KWX2
Max Input Torque: 16,000 N.M
Input Rotate Speed: 0 to 2,292 rpm
Speed Reducing Ratio: 6.40584
Input Coupler: Drum shape tooth coupler
Lubrication System Forced lubrication
The speed reducer (Gear Box) has gears with high capacity transmission power. Input
shaft is connected with motor coupler by splinted shaft coupler. Output shaft is
connected with drum axle by splined shaft coupler. The connection is simple so that it
can be installed and maintained conveniently. Speed reducer uses a mechanical seal.
The speed reducer uses a forced lubrication system to ensure the gearbox will be
properly lubricated even for long periods at low working speed (auto bit feed working
condition). The lubrication system is equipped with filter, lubrication preheating unit,
pressure gauge, and thermometer to ensure the gear box will work reliably.
After the gear box installation is complete, the shaft should be manually rotated. The
gear box shaft should rotate easily, and without excessive noise..
Detailed description of the speed reducer can be seen in the Drawworks Gear Box
Operations and Maintenance Manual.
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3.3. AC Motors
AC motors are HTM 1230 AC Vector Motors designed for an AC Variable Frequency
electric driven drilling rig. Between the motor stator, iron core outer circle and motor
seat inner circle, there is a special air cooling machine for improve cooling efficiency.
The motor rotor is solid squirrel cage type. The outer circle of end ring is installed with
outer ring for improving the strength and reliability of the rotor. The rotor squirrel cage
strip and iron core are painted into a whole by vacuum pressure so as to improve the
cooling efficiency of squirrel cage.
Technical Parameters
Model: Joliet AC 1500
Rated Power: 1230 HP X 2
Rated Voltage: 600V
Rated Electric Current: 1120A
Rated Rotate Speed: 800 rpm
Rated Frequency: 41Hz
Rated Rotate Torque: 8.08 Kft.lb
.
Max. Working Rotate Speed: 2,300 rpm
Insulation Level: 200
Spacer Heater: AC110V, 60Hz, 200W
Duty: Continuous SI
Series: 6
Detailed description of the AC motors can be seen in the user’s manual for the AC
variable speed motor manual.
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3.4. Hydraulic Disc Brake System
The hydraulic brake system consists of brake calipers (safety brake and working brake),
actuating system, and a hydraulic power unit (HPU).
Parking Brake function: When the drilling operations need to be stopped or the driller
wants to leave the driller cabin, pulling down the parking brake handle will set the
“Safety” brake calipers to stop the drum from rotating, and the block will stop moving.
Emergency Brake function: Under an emergency condition, operating the emergency

braking button from the driller’s console both the “Service” and “Safety” calipers will
be activated to stop the drum from rotating within the drawworks. With both Calipers
working together, a bigger braking moment will be applied to stop the drawworks drum
completely.
Detailed description of the hydraulic disc brake can be seen in the user’s manual for the
hydraulic disc brake.
3.5. Drawworks Frame and Skid
The drawworks frame is a structural part which is used to install the main drum, disc
brake, and Crown-o-matic saver valve/switch. A top shield and disc brake shield are
designed to protect the personnel, main drum, and brake disc. Crown saver valve
brackets are located on the top shield of drawworks frame. The frame assembly also
integrates the mounting base of the drawworks, the system lubrication lines and other
accessories.
Braking fluid cylinder shield of hydraulic disc brake is connected to the drawworks
frame with bolts.
The drawworks components are mounted on a skid. All the components are
interconnected so that the drawworks can be transported as a package.
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3.6. Gear Box Lubrication System
SPEED REDUCER
4 AIR FILTER
3 3
5 DUAL BUCKET
MESH FILTER
3
1 2 1 2 4 SPEED REDUCER
AIR FILTER
1
DRUM SHAFT BEARINGS DAILY-
MOTOR HUB LUBE
GREASE OUTSIDE THE CASE
3 REPLACE EVERY 2
EVERY TOWER CHANGE MONTHS
2 1. CHK SERVICE CALIPERS
CHK AIR FILTERS EVERY
2. CHK SAFETY CALIPERS
3. CHK QUICK COUPLINGS 4 1-3 MONTHS
SEE MAINTENANCE PART
4. CHK RETURN OIL
FILTER OF GEARBOX MANUAL
5. CHK HIGH PRES OIL
FILTER 5 DUAL BUCKET
MESH FILTER
SEE HYD BRAKE MANUAL CLEAN WEEKLY
The gear box lubricating system consists of a lubricating pump, oil reservoir, and
piping. Only one pump is required for lubrication, however, there are two (2) pump
and motors for redundancy. The pumps are mounted vertically inside the oil reservoir.
The valve between the two pumps should be closed and only one pump should be
turned on. The oil reservoir is located at the bottom of the skid. It has a rectangular
shape, and has an approximate capacity of 229 gallons. A dipstick is installed inside
the tank and is used for checking the oil reservoir level. The piping connects the pump
to the gear box, and the gear box back to the oil tank. The oil level in the reservoir is
not critical, but there must be enough oil to maintain circulation. It is recommended to
fill the reservoir to about 50% to 80% full (approximately 115 to 180 gallons). Two oil
pressure gauges are installed before and after the oil filter in order to monitor the oil
flow and the filter status. (See also the Drawworks Gearbox Operation and
Maintenance Manual).
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4. Drawworks Operation and Maintenance
4.1. Wireline Installation
The wireline is anchored to the drum with a clamp called “dog knot”. Follow this
installation procedure:
4.1.1. Install the wire line clamp per slot provided in drum Loosen nut 4, insert wire
line extend about 4” (100mm) past clamp.
4.1.2. Leave proper length of wire line in the left side of dog knot, tighten the nut. The
tightening torque shall note exceed 400 ft lbs .
4.1.3. Check the wire line clamp to verify that it is tight enough, and put it inside the
side opening of the main drum.
4.1.4. Rotate main drum slowly to make dog knot move forward along the groove, until
it reach the end of opening. Keep on rotating the main drum, reel wire line wraps
onto main drum and make sure wire line wraps closely.
Caution: At least 7 wraps of wire line must remain on the main drum when the
traveling block is approaching the rig floor.
Figure – Drilling Line Installation
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4.2. Drawworks Start Up
Drawworks starting procedure:
4.2.1. Start the brake HPU in order to charge the brake system
4.2.2. Check the functionality of the disc brake and crown-o-matic valve
4.2.3. Start the gear box lubrication system
4.2.4. Start the blower motor on AC motors
4.2.5. Start the main AC motors
The drawworks shutdown procedure is the reverse of the starting procedure.
4.3. Operation and Maintenance of the Hydraulic Brake System
The Hydraulic Power Unit is an integral part of the drawworks hydraulic brake system.
Due to application of hydraulic system, the disc brake is more complicated than the
traditional band brake. In particular, some dirt sensitive high-performance components,
such as pumps, valves and hydraulic cylinder, need more careful maintenance than the
band brake.
The key point to maintenance of the disc brake is laid on the hydraulic loop and braking
caliper’s oil cylinders.
The maintenance plan must include the following:
4.3.1. Oil Level
Frequent checks of oil level and in-time oil refilling are necessary. When the oil
level in the system is below the lowest level, negative factors such as
temperature rising and non-soluble air accumulation may occur. Air pockets
may cause pump failure; exposed electrical heater may cause local temperature
rising, resulting in decomposition and deterioration of oil, and consequently
leading system failure.
Lowered oil level indicates oil penetration and leakage. To remove them, in-
time check and maintenance are necessary.
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4.3.2. Oil Temperatures
High temperatures can accelerate the aging of oil and reduce service life of seals
and hoses. Oil temperature of the oil tank must be frequently checked and
monitored. Rising temperatures may indicate contamination and formation of
colloidal matter, or damage of the plunger pump. Sudden oil temperature rising
is an alarming signal, and immediate shut down and check is absolutely
necessary.
4.3.3. Pressure Gauge
Observe readings on the pressure gauge of the hydraulic station, particularly,

pressure gauge of the system. The pressure gauge should stabilize at the set
values. Calibrate the pressure gauges regularly.
4.3.4. Oil Filter
Follow the manufacturer’s recommendations on oil filter inspection and

replacement.
4.3.5. Air Filter
Follow the manufacturer’s recommendations on air filter inspection and

replacement.
4.3.6. Accumulators
Refer to the manufacturer’s documentation on accumulator inspection, service,

and maintenance.
4.3.7. Crown Saver
The over winding valve should be checked frequently to guarantee its reliability.
Particularly in winter, the compressed air may contain moisture which may
freeze in the air pipe due to cold weather. Frozen ice may cause blockage in the
air pipes, which may result in failure of the colliding prevention function. Give
one trial operation of the colliding preventing system every day to guarantee
normal work.
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4.3.8. Service Calipers
At the shift relief, check the thickness of the brake pads and the sealing
performance of the oil cylinder. With the wearing of the brake pads (wearing on
one side 1-1.5mm), pulling force of the tension spring should be adjusted so that
the brake pads can return back when released and the clearance is not too big.
When the brake pad is worn to only 12mm thick, it must be replaced.
4.3.9. Safety Calipers
Check the released brake clearance frequently (at least once a week), the
thickness of the brake pads and the sealing performance of the oil cylinder. If
the clearance between the friction disc and the brake pad is >1mm, the braking
clearance must be adjusted to about 0.5mm. After application of emergency
brake operation, the released brake clearance also should be checked. When the
thickness of the brake pad is worn to only 12mm, it must be replaced.
CAUTION: Adjust the braking clearance of the safety calipers, otherwise failure of
emergency brake and parking brake may occur.
CAUTION: To guarantee the reliability of the safety caliper, replace the disc spring
group every 12 months.
4.3.10. Quick Coupling and Hydraulic Pipe
Check twice a day all quick couplings to guarantee good connections.
4.3.11. Structural Elements
Checks and maintenance for structural elements are concentrated mainly on

braking caliper’s levers, pin shafts, oil cylinders, caliper frames, friction discs,
couplings and tightening elements. Items to be checked include damage,
deformation, cracks and other problems, which may exist.
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4.3.12. Key points for check and maintenance for the friction discs include the
following:
Wearing: The allowable maximum wearing of the friction disc is 10mm

(unilateral allowable is 5 mm). Check and measure the thickness of
the working surface of the friction disc regularly.
Thermal Fatigue Cracks: The enormous heat produced by rolling friction
during braking of the friction disc causes expansion of the disc face,
which will contract when cooled down. Such alternative expansion
and contraction may result in fatigue cracks in the friction disc. With
extension of service time, when small stress cracks have expanded
into bigger ones, enough attention should be given and remedy
measures taken. For example, use a grinding tool to grind off a little
along the cracks to check the depth of the cracks, carry out repairing
weld and finally grind flat with a sand wheel.
Oil, Dirt: The working surface of the friction disc should be free of oil whether
stuck or splashed thereto to avoid reduction of friction coefficient,
consequently braking force. Lubricant on the wire rope sometimes
may be splashed to the working surface of the friction disc due to
rotating of the drum; therefore frequent checks and cleaning is
necessary.
Check welded elements, particularly the caliper frames and caliper

bodies, to see whether there are cracks and corrosion problems in the
welds. If necessary, repair or change any of them. These elements
and component should be checked at least once every half a year.
Check moving parts to see whether there is sticking, particularly, in

places like the pin shaft of the lever. Deposit of braking dust may
cause poor lubrication. Lubricate with grease once a month to
guarantee good lubrication.
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4.3.13. Maintenance Plan for Hydraulic Brake System
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(See also reference pages in Drawworks User Manual of Disc Brakes)
4.4. Operation and Maintenance of the Gear Box Lubrication System
There are two (2) electrical driven pumps for the gear box lubrication system. Only
one pump is needed for normal operation.
4.4.1. Check the dipstick of the oil reservoir to verify there is enough oil in the
reservoir.
Turn on one lubrication pump.
The oil should circulate from the pump to the oil filter, to the gearbox, and back
to the tank.
The capacity of the oil reservoir is approximately 229 gallons.
A dipstick in the tank is used to check the oil level. The dipstick is approx. 11
inches long.
If there is less than 4 inches of oil shown on the stick, then oil needs to be added.
At least 115 gallons of oil are needed.
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4.4.2. The lubrication system operating ambient temperature range is -30°C to 55°C.
If the pump starts when ambient temperature is lower than 0°C the lubricating
oil must be preheated to about 10°C, and the outside pipeline should be
protected for heat preservation.
4.4.3. Frequently inspect the oil flow quantity, and check the oil level in the reservoir
with the dipstick during operation. When the pump is not running, replace and
add lubricating oil as needed.
4.4.4. After the gearbox is put into use for the first time, and after the first 600 duty
hours or approximately three months of time passage (whichever comes first)
the lubricating oil must be replaced. The lubricating oil should be bled off
before the lubricating oil becomes cool.
4.4.5. Hereafter the lubricating oil should be replaced when the gearbox’s normal
working time surpasses 5,000 hours. This is also affected by the working
environment: ambient temperature and operating temperature of lubricating oil.
High temperature conditions can shorten the replacement schedule of the
lubricating oil.
4.4.6. When lubricating oil is replaced, the new lubricating oil should be the same
grade as the lubricating oil that was used before. It is not recommended to use
oil of a different grade or produced by another factory. Do not mix or combine
different types of lubricating oil.
The inlet temperature of the lubricating oil in the gearbox should stay within
15°C to 43°C, and the outlet temperature of the lubricating oil should be less
than 70°C. If the lubrication oil temperatures reach 85°C the gearbox should be
shutdown and checked, and the cause should be corrected immediately.
The gearbox temperature, noise, and vibrations should be monitored closely. If

there is a sudden change in these conditions, actions need to be taken.
The filter should be cleaned after the gearbox works 12 hours for the first initial
running time. Later it should be cleaned once a week and the user may decide
the cleaning schedule according to the operating conditions.
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The gearbox should be started and run for a period of time once a month. The
lubrication procedure should be followed before the gearbox works.
The air filter must be cleaned at least once every three months.
4.5. Operation and Maintenance of AC Electric Motors
The operation of the AC motors is controlled from the driller’s cabin through VFD
control. The program must be set so that the blower runs before motor operation and
the blower cannot be closed until the motor stops running.
For maintenance of the AC motor, the frame must be grounded safely and reliably.
Stator winding connection method is star connection from neutral point to terminal box,
as marked by N.
No point of N should be grounded.

Make that motor and blower are in off mode before opening the terminal box cover.
Four terminals inside the box are marked with U, V, W, and N from right to the left
respectively. Terminals are covered with a protection cover, which prevents terminals
from losing insulation. Double protection nets are set in exhaust cover so that any
sudden heat can be dissipated through air cooling.
Periodically check and ensure there is no block on the protection net.
4.5.1. Bearings
The motor bearings are not equipped with oil cups. In normal working
conditions, no grease needs to be added during three years. After the three years
have expired, disassemble the motor to clean, examine and replace its lubricant.
CAUTION: Do not wash the bearings with alkali cleaning agent.
During operation of the motor, it is suggested to use a contact thermometer to

measure bearings temperature rise on fixed points and for a fixed duration, and
to keep adequate statistics to determine the bearing’s working status and any
trends of temperature rise.
4.5.2. Fastening
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Check all motor screws for looseness and fasten them if necessary. It is
recommended to check for looseness after every maintenance job.
4.5.3. Cleaning the motor frame using Compressed Air
Because the working environment of the motor is poor, both its interior and
exterior surfaces may be covered with dirt or fouling, which may influence the
motor’s ventilation, and may result in dampness. Therefore, it is recommended
to blow clean its interior and exterior surface with compressed air of 0.6 mPa
after every maintenance job. To blow clean the motor’s interior surface take off
the motor exhaust cover.
4.5.4. Drawworks Motor Alignment
The drawworks motors are aligned at the factory, but handling or setting on an
unleveled substructure may change the alignment. If abnormal noise or
vibration is noted in the drawworks, the alignment must be checked. The
procedure is as follows:
4.5.4.1. Drain the gear oil from the couplings. Remove bolts form the
coupling sleeve flanges and slide the sleeves back far enough to
expose the coupling hubs. Clean the gear oil from the ends of the hubs,
and from the space between the hubs. Measure the gap between the
two hubs. This should be 5/16” +/- 1/32.
4.5.4.2. Check the parallel offset misalignment with a straight edge across the
hub diameters at four points 90 degrees apart. Use a feeler gauge to
measure the gap from a straight edge to the other hub. Maximum
allowable offset misalignment is .015” also note coupling alignment
procedure supplied with operations manual.
4.5.4.3. If measurements are not within tolerances, loosen bolts in motor
support and reposition as necessary.
4.5.4.4. Refill coupling with gear oil. See Maintenance of Couplings section.
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4.6. Maintenance of Coupling and Grease Fittings
4.6.1. Grease of Couplings and Main Drum Bearings
The two self aligning roller bearings on both sides of the main drum assembly
are lubricated with grease. The grease fitting port is connected with the bearing
with hydraulic tubing and fittings that extend through the frame wall outside the
guard. These grease fittings are grouped together and located for easy visibility
and access. Grease these fittings on a daily basis at the tower change. The
amount of grease to be used on a daily basis is based upon the bearing
consumption during the day. The discharged grease from the bearing box will
flow out and below the drawworks into the drip pan system for collection.
Refer to the drawing and lubricate the drawworks using approximately four to
six strokes of the grease gun at each point indicated.
Couplings for AC Motors and Drum Shaft – The forged steel, full flex
couplings should be greased once a month. Use a gear oil SAE 140, or AGMA
#8, or heavier oil. Oil capacity 1 ½ pints. Remove two lube plugs 180 deg.
Apart. Position the coupling so one hole is 45 deg above horizontal. Apply the
grease in this hole until the excess starts to flow out the lowering opening.
Before replacing the lube plugs, make sure that the copper ring gaskets are in
position and undamaged. Tighten plugs. The use of excessive amounts of grease
will not impair the operation of the coupling. The excess grease will be thrown
from the coupling during the operation.
4.6.2. Hub Fitting
To prevent a hub from slipping, it should have at least 75% fit on the shaft, i.e.
at least 75% of the tapered bore of the hub in contact with the tapered fit on the
shaft. Before mounting a hub, check and correct the fit as follows:
4.6.2.1. Lightly cover bore of the hub with bluing compound such as Prussian
blue.
4.6.2.2. Snap cold hub on shaft.
4.6.2.3. Mark relative position of hub on shaft with chalk.
4.6.2.4. Remove hub from shaft.
4.6.2.5. Inspect taper fit of shaft; bluing of the hub bore should now show on
shaft. If at least 75% of the shaft surface shows trace of bluing, the fit
is satisfactory. If, however, only a few spots of bluing show on the
shaft, the fit is insufficient.
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4.6.2.6. Dress down the blue spots on shaft very lightly, using fine emery cloth.
4.6.2.7. Blue the hub bore again as in Step 1 and repeat Steps 2, 4, 5 and 6. Be
careful to place hub on the shaft in the same position as indicated by
chalk marks.
The above procedures may have to be repeated several times until at least 75%
fit is obtained. Lapping compounds should not be used under any circumstances,
since lapping will produce a shoulder at the large end of the tapered fit. This
shoulder will prevent a perfect fit when the hub is hot-mounted; i.e. when it is
mounted in the advanced position.
After a good fit has been obtained, thoroughly clean the shaft and hub to remove
all bluing, oil or grease.
4.6.3. Drawworks Coupling Hub Installation
The couplings between motor and gearbox, gearbox and drawworks are
crowned-teeth type. Follow these instructions during installation:
4.6.3.1. Check the coupling matching surface for any burr or oil strain before
assembling, and clean the anti-corrosion oil on the surface
4.6.3.2. Remove the connecting bolts of coupling and dismantle the coupling.
Sort the coupling parts.
4.6.3.3. Grease the connecting shafts
4.6.3.4. Heat the half coupling with key groove to 100 C in oil bath; heating
should be slow and uniform, and the temperature should not exceed
120 C.
4.6.3.5. Install the heated half coupling onto the shaft with slight tapping.
Install the ends plate to the end of shaft with bolts, and cool down the
installed coupling and shaft with oil or water at once. Do not install
the coupling by knocks.
4.6.3.6. Install the half couplings to input and output shafts of gear box and to
the main drum shaft in the same way by following steps 1 thru 5
4.6.3.7. Install the coupling to the motor shaft as per the relevant requirements
4.6.3.8. Align the motor shaft and gearbox shaft, then bolt the two couplings
half together
4.6.3.9. Align the drum shaft and gear box output shaft, then bolt the two
couplings half together
After the installation, the gear box shaft should rotate manually without any
noise.
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4.6.4. Gear Coupling Hub Removal
When removing a gear coupling hub, use a suitable hydraulic puller employing
the float method of removal. Do not heat the hub before pulling it, and do not use
steel wedges between the hub and bearing cap.
4.6.4.1. Remove the set screw plug from the tapped hole in the end of the shaft.
4.6.4.2. Screw the packing plate, with the felt ring in place, to the end of the
shaft as tightly as possible by hand. Back off the backing plate to line up
the slot with tapped hole in the end of the shaft. This is to provide
sufficient clearance for the hub to pop off.
4.6.4.3. Screw the pressure filling adapter into the hole in the shaft until it seats
at the bottom.
4.6.4.4. Attach the pump by screwing the connector on one end of the pressure
tube into the adapter, and the other end into the pump.
4.6.4.5. Close the relief valve and work pump the oil with handle into the groove
of the armature shaft under the hub. When sufficient pressure has been
built up, the hub will “pop off” the shaft and be stopped by the felt
washer and backing plate.
Note: Capacity of the pump should be at least 20,000 PSI. It holds

sufficient oil to remove 8 to 10 hubs. Check at each use.
Periodically, remove the filling plug and refill with SAE-10
lubricating oil.
4.6.4.6. Open the relief valve, disconnect the pump from adapter, remove the
adapter and backing plate from shaft, and lift off the hub. Reinsert the
plug to prevent clogging of the hole.
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5. Trouble Shooting
The following chart shows some potential malfunction and possible cause.
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LM770 Saipem 5964 Drawworks User Brakes Manual

Operation and Maintenance
Instruction
LM 770 Saipem 5964 Drawworks User Brakes Manual
Foreword
In this manual of the PS series hydraulic disc brake system, its structure, principle and
application are introduced. Read the manual thoroughly before you operate or repair the disc
brake. Install, use and repair it correctly according to the manual.
The operation effects and service-life of the disc brake system are related to the design
and manufacturing, but further lie on proper operation and maintenance of customers. We supply
customers with high quality products in compliance with the quality assurance system of API,
and also hope that the operators will carefully read the manual to give full attention to the quality
and the performance of the product to successfully achieve the expectant drilling operations.
During product maintenance, it is necessary to use fittings provided by us so that the equipment
can realize its original performance and accidents can be avoided.
Because of continuous improvements to the products, some details in the manual may not
be the same as those in actual production. These differences don’t affect the understanding of the
product’s structure, performance and application. For any questions, please contact us.
You are welcome to contact us if you have new requirements for your application. We
will be very happy to improve our products continuously and to meet with your special
requirements.
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Contents
Description
Main Performance Parameters
Working Principle and Structural Characteristics
Installation
Adjustment and Tests
Maintenance
Troubleshooting
Disassembly, assembly and replacement of key components
Damageable Parts
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1. Description
The PS series hydraulic disc brake system which is a product of mechanical-electrical-liquid
integration is an important component of the draw works. To understand and be familiar with
its structure, principle and performance, and correctly perform maintenance is essential for
proper drilling rig operation and safety.
This PS hydraulic disc brake system consists of: brake actuation mechanism, the braking
calipers include normal open service calipers and normal closed safety calipers. Friction
discs are classified into water cooling, air cooling and solid discs.
2. Main Technical Parameters
Values of parameters
Types Description
PSZ65
Max. normal pressure on single 65 kN
Effective stroke 30 mm
Service Min. allowable thickness of the
brake pad 12 mm
caliper
Profile dimension (mm) 570x390x400
Weight 180 kg
Max. normal pressure on single 75 kN
Max. clearance of the brake pad 1 mm

Safety Min. allowable thickness of the
brake pad 12 mm
caliper
Profile dimension (mmm) 600x390x400
weight 200 kg
Table 1 Main Technical Parameters
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3. Working Principle and Structural Characteristics
The disc brake system mainly consists of the brake actuating mechanism.
3.1. Brake Actuating Mechanism

The brake actuating mechanism mainly includes the service calipers, the safety calipers, the
friction discs, and the caliper frame, whose structure is shown in Figure 1.
1. Friction disc 2. Drum 3. Caliper frame 4. Service caliper 5. Safety caliper 6. Base
Figure 1: Brake Actuating Mechanism
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3.1.1. Service caliper

The service caliper consists of mainly normal open single-action cylinder, disc springs,
lever and brake pad, the structure of which is as shown in Figure 2.
The principle is as follows: When oil is supplied into the cylinder, theoretical pushing
force F is generated, and F  P  A , where A is the area of the piston. the force F push
the piston (14) to stick out, at the same time work on back corner(11) to push the cylinder
(9) move backward. When the brake pad (1) contacts the friction disc, force F is
transmitted through lever (4) to the brake pads, producing normal pressure N and the
friction force, i.e., the braking force is produced. Due to the proportional relationship
between braking force and oil pressure P, the friction disc will be braked completely
when P reaches a certain value. With the decreasing of oil pressure P, the braking force
will decrease correspondingly. When oil pressure P=0, the lever returns to its original
position by reset spring (10), causing the brake pad to be released from the friction disc,
and consequently, the service caliper comes into completely released condition.
1. Brake pad
2. Caliper body
3. Clevis pin with head
4. Lever
5. Support lever
6. Semicircle retaining ring
7. Clevis pin with head
8. Cover of the cylinder
9. Cylinder
10. Extension spring
11. Back cover
12. Parallel pin
13. Adjusting nut
14. Piston rod
Figure 2: Service caliper
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3.1.2. Safety Caliper

The safety caliper consists of normal closed single-acting oil cylinder, disc spring, lever
and brake pad, seeing Figure 3.
The principle of the safety caliper is just opposite to that of the service caliper. When the
normal closed single-acting cylinder’s oil pressure is P=0, the set-in disc springs
transmits the force through the two levers to the brake pad and consequently acts on the
friction disc, producing normal pressure N and then realizing brake. When the oil
pressure of the cylinder P is not equal to 0, which means oil pressure exists, the oil
pressure will overcome the disc spring force to compress the disc spring, releasing the
brake through the lever.
1. Brake pad
2. Caliper body
3. Clevis pin with head I
4. Lever
5. Support lever
6. Semicircle retaining ring
7. Clevis pin with head II
8. Piston
9. Cover of the cylinder
10. Cylinder
11. Locknut
12. Adjusting nut
13. Clevis pin with head III
Figure 3: Safety Caliper
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3.1.3. Friction disc

The friction disc, which forms the brake pair together with brake pad, is one of the core
components. Usually, each set of product is equipped with two friction discs, which are
mounted on both ends of the draw works drum. Some smaller types are only equipped
with one friction disc，which is mounted on one end of the draw works drum.
According to structures, friction discs are classified into three types: water cooling, air
cooling and solid discs.
 The water-cooling disc has cooling water channels inside, and it has water inlet and
outlet ports at the inner diameter of the friction disc, and water draining port at the
outer diameter for draining all water in channels to prevent the friction disc from
being frozen and broken in cold weather. During normal operation, the water draining
port is sealed with a screw plug. When the braking system is working, cooling
circulation water is fed to the friction disc to balance the heat produced by friction of
the brake pair.
 The air-cooling disc internally has natural ventilation channels to discharge heat
through natural ventilation channels and surface.
 The solid disc discharges heat through the surface. Such type of friction disc is
mainly used for smaller drilling rigs.
CAUTION
For water cooled brake discs: to avoid cracking of the disc due to icing, when the
equipment is not operational during cold temperatures, the cooling water inside the
disc must be completely drained.
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3.1.4. Caliper frame

The caliper frame is the base of the actuating mechanism. The service caliper and the
safety caliper are mounted on this base.
4. Installation
4.1. Install the Friction Disc
1. Drake disc 2. Drum

Figure 4: Brake Disc Installation
4.1.1. The stagger of the working surface of the friction disc to the end surface
of rotary drum shaft should be less than 0.3mm.
4.1.2. The friction disc should be cleaned, with the friction surface free of oil
and dirt.
4.1.3. For water-cooled friction disc, water inlet and outlet pipes should be
connected.
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4.2. Install the Brake Calipers and Caliper frames

4.2.1. Fasten the upper and lower transit plates
firmly onto the caliper frames.
4.2.2. Install the brake calipers on the caliper
frames. On completion of installation, turn them to
see whether they rotate flexibly, whether there is
blockage or jam, and whether it is difficult to rotate.
When the safety calipers are installed, adjusting nut
should be rotated so that the interval between two
brake pads becomes the maximum for installation
of caliper body.
4.2.3. Install the whole actuating mechanism onto
the draw works. 1. Upper transit plate 2. Caliper frame 3. Lower transit plate
Figure 5: Caliper Frame
Requirements of Installation:
1. Must fasten the upper and lower transit plates firmly onto the caliper frames.
2. The gap between the outer circle of the friction disc and inner circle of the caliper
frame should be uniform; no interference with the caliper frame is permitted.
3. The caliper frame should be parallel and centered with the friction disc, with
allowable deviation  1mm .
4. The brake pads should be enclosed within the friction disc.
5. After adjustment and alignment, weld the upper and lower transit plates to the
designed location on the draw works base.
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Figure 6: Sketch for Caliper Frame Installation
CAUTION
The brake disc and caliper must be installed strictly in accordance with the descriptions,
otherwise, eccentric wear of brake block and brake disc will occur, which may result in the
non function of control, property damage, personal injury or death.
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5. Adjustment and Tests

5.1. Watch the pressure gauge of the hydraulic power unit, to see whether it is stabilized at
the set value.
5.2. Pull down the handle of the service caliper, watching whether the pressure of the meter
meet the change of handle. When the handle gets the max set, the meter of service caliper in
driller’s station should be the rating pressure, when the handle is restored completely, the
pressure should be 0.
Note: Close the shut-off valve immediately if the air bleeding has been finished.
5.3. Pull down the emergency button，push the handle of parking brake to “parking”
position, safety caliper should brake rapidly; push the handle of parking brake to “loosen”
position, safety caliper should release rapidly.
5.4. Push down the emergency button, the service and safety caliper brake at the same time,
pull out the emergency button, the service and safety caliper release at the same time.
5.5. Air Bleeding: pull the handle of brake valve ,when the pressure of service caliper get
0.5Mpa, unscrew the air bleeding screw a little on the cylinder of the service calipers until
there is no foam in the discharged oil. Bleed air in the cylinders of service caliper this way
one by one.
5.6. Contacting friction with braking block for the working caliper. In the low-speed
operation of the winch, pull the braking crank slowly for contact of the braking block and the
braking disc. Repeat it several times. It can be used only when the contacting run-in area of
the new braking block and the braking disc has reached more 75%. When contacting friction
is being made, pay attention to the braking oil pressure and the running-in is usually made at
about 2MPa.
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5.7. Fitting and Running-in of Brake pads of Safety Calipers. When pressure occurs in the
safety calipers, loosen the lock nut, turn the adjusting nut, Slowing contact the braking block
of safety caliper and the braking disc, then start the drum. Repeat the process again and again
until should be repeated until the contact area of the new brake pads reaches 75% of the
whole area, when it can be put into operation.
CAUTION
In the running-in process, if the temperature of braking disc is too high (over 240oC), the
running-in should be stopped and be started again when the temperature of braking disc
has decreased.
5.8. Adjustment of the Service calipers Clearance can be adjusted by means of the nuts at
the two ends of the spring. Clockwise turn is for tightening while counterclockwise turn for
loosing. The smaller the clearance is, the shorter the responding time will take for braking.
5.9. Adjust the Braking Clearance of the Safety Calipers. When the hydraulic unit is
working，pull down the brake handle to make the service caliper dead lock. You must not
loosen the handle during the clearance adjusting. When there is pressure in the safety calipers,
loosen the lock nut of safety caliper by special tool, turn the adjusting nut to make the safety
caliper’s brake pads fit completely with the friction disc, then turn the adjusting nut
counterclockwise about 2-3 regulation orifices (now the clearance between the friction disc
and brake pad is about 0.5mm), finally tighten the lock nut. The clearance between brake pad
and disc should be as small as possible.
CAUTION
If it is necessary to adjust the clearance of working caliper and safety caliper in drilling
state, the traveling block must be placed at lower dead center position. For safety’s
concern, during the adjustment, the clearance of safety caliper should be first adjusted
and then that of working caliper.
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5.10. Check over winding and crown block collision prevention devices.
5.11. On completion of on-site installation and adjustment, run the oil pumps for 1030
minutes and repeatedly operate the “braking handle” before its normal operation. Now check
for correct oil level and oil loops, particularly, the level in the oil tank should be maintained
at the middle between highest and lowest levels.
5.12. The machine can not be put into operation until everything is OK.
CAUTION
The braking force of safety caliper is attenuated in a parabolic function with the
increase of clearance between the braking block and the braking disc. If the clearance
is too big, the braking force will decrease abruptly and even be lost. It is required that
the maximum clearance for one side of safety caliper should not exceed 0.5mm;
otherwise, accidents may occur from lack of braking capacity during handling of the
drilling string.
If the hydraulic station is started while the clearance of braking caliper is being
adjusted, someone must be in the drilling room to monitor.
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6. Maintenance
The key point of maintenance of the disc brake is the hydraulic loop and braking caliper’s oil
cylinders. Items mentioned below and listed in the maintenance plan need routine maintenance.
6.1. Service Calipers
At the shift relief, check the thickness of the brake pads and the sealing performance of the
oil cylinder. With the wearing of the brake pads (wearing on one side 11.5mm), pulling
force of the tension spring should be adjusted so that the brake pads can return back when
released and the clearance is not too big. When the brake pad is worn to only 12mm thick, it
must be replaced.
6.2. Safety Calipers
Check and adjust the released brake clearance frequently (at least once a week), the thickness
of the brake pads and the sealing performance of the oil cylinder. If the clearance between
the friction disc and the brake pad is more than 1mm, the braking clearance must be adjusted
to about 0.5mm. After application of emergency brake operation, the released brake
clearance should be adjusted again. When the thickness of the brake pad is worn to only
12mm, it must be replaced.
CAUTION
Adjust the braking clearance of the safety calipers in time, otherwise failure of
emergency brake and parking brake may be caused. To guarantee the reliability of the
safety caliper, replace the disc spring group once every 12 mouths at least.
6.3. Quick Coupling and Hydraulic Pipe

Check twice a day all quick couplings to guarantee good connection. Particularly, after any
shifting of piping or accidental impact on the piping, strictly check to see whether severe
damage has been caused, or poor connection on the quick coupling exists, to guarantee there
is no damage to the hydraulic pipes and quick coupling are in good condition.
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6.4. Structural Elements

Checks and maintenance for structural elements are concentrated mainly on braking caliper’s
levers, pin shafts, oil cylinders, caliper frames, friction discs, couplings and tightening
elements. Items to be checked include damage, deformation, cracks and other problems,
which may exist.
 Check tightening elements, if necessary, tighten in time.
 Key points for check and maintenance for the friction discs include:
1. Wearing: The allowable maximum wearing of the friction disc is 10mm (unilateral
allowable is 5 mm)，meaning for the minimum thickness of the water and air cooling
disc is 66mm，of the solid disc is 30mm. Check and measure the thickness of the
working surface of the friction disc regularly.

2. Thermal Fatigue Cracks: The enormous heat produced by rolling friction during
braking of the friction disc causes expansion of the disc face, which will contract when
cooled down. Such alternative expansion and contraction may result in fatigue cracks in
the friction disc. With extension of service time, when small stress cracks have expanded
into bigger ones, enough attention should be given and remedy measures taken. For
example, use a grinding tool to grind off a little along the cracks to check the depth of the
cracks, carry out repairing weld and finally grind flat with a sand wheel.
3. Oil Dirt: The working surface of the friction disc must be free of oil whether stuck or
splashed thereto to avoid reduction of friction coefficient, consequently braking force,
leading to accidents due to loss of braking capacity. Frequently check for lubricant on the
wire rope that may sometimes may be splashed onto the working surface of the friction
disc due to rotating of the drum. Clean as frequently as necessary.
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Check welded elements, particularly; the caliper frames and caliper bodies, to see
whether there are cracks and corrosion problems in the welds thereof. If necessary, repair
or change any of them. These elements and component should be checked at least once
every half a year.
 Check moving parts to see whether there is sticking, particularly, in places like
the pin shaft of the lever. Deposit of braking dust may cause poor lubrication. So
feed lubrication grease once a month to guarantee good lubrication.
MAINTENANCE PLAN
No Items to be checked requirements frequency
.
1 Pressure of the system PSZ65 =6MPa
Clearance in the brake Service caliper: adjust the tension spring force
2
pad Safety caliper: ≤0.5mm
Thickness of the brake
3 Minimum thickness 12mm
pad
Oil cylinder sealing Every day
4 No leakage
performance
5 Pipes and connectors Sealing in good condition, no leakage, no damage
6 Quick couplings No leakage, no damage, no false connection

No load, push, pull and rotate pin shafts to see whether
7 Sticking of pin shafts Every week
free movement without sticking
8 Oil feeding to all parts Feed lubrication oil from oil feeding ports 1 month
9 Fixing bolts Check and tighten all fixing bolts and screws 3 months
Dismantle and clean
10 Check braking dust, change damaged parts
levers and pin shafts
Allowable maximum worn thickness 10mm, (single side
Wearing and cracks of
11 5mm)thermal fatigue cracks should not affect strength and
friction disc 6 months
cause water leakage, otherwise change any
12 Welds in caliper frames Check welds for cracks
13 Structure check Check all structural elements in braking system
14 disc spring Change all disc springs 12 months
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7. Troubleshooting
Ordinary operating procedures for resolving problems:
7.1. The drilling operations must be stopped and the assistant brake disc set at the brake
position when the hydraulic braking disc is found to be faulty,.
7.2. Push the emergency braking valve so that it is at “Braking” position and then use clip to
hold up the heavy load.
7.3. Disconnect the power supply of the motor of the hydraulic station and analyze the
reasons for the trouble in accordance the trouble phenomena.
7.4.
Troubles Possible Causes Solve Measure

Non lubricating bushing contaminated Exchange pin shaft or
braking calipers Deposit of braking dust on pin shaft non lubricated pin
skipping/sticking bushing per issued
Pin shaft is worn or corroded tolerance values.
(.05mm)
Adjust the braking
The braking clearance not set correctly
clearance
The braking pad is beyond wear indicators Replace brake pad
Slow releasing
of main Air in cylinder Bleed air
braking Check oil temperature is
calipers within operating
High returning oil resistance/back pressure perimeters check oil for
contaminates cleans oil
filter
The safety
caliper non
Reinstall disc
fictional after The disc spring installed in wrong order or not install
spring/verify assembly
exchange the
disc spring
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8. Disassembly, Assembly and Replacement of Key Components

8.1. The Disc Springs and Sealing Rings of the Caliper
The service life of the disc spring is one year. After one year in service, the disc spring must
be changed. The disc spring should be changed as a group. Only changing some pieces is not
allowed. In reassembling, the assembling sequence must be strictly followed; changes to the
installation sequence and position of pieces of disc spring are not allowed. Leakage of oil
cylinder indicates worn sealing rings. Worn sealing rings must be replaced.
Note item 11 is obsolete and item 12
have been upgrade
1. Dust-proof ring 2. Sealing washer 3. Bolt 4. Washer 5. Cover 6. Guide band 7. O-ring
8. C2 sealing ring 9. OK sealing ring 10. Guide band 11. Elastic guide sleeve (obsolete)
12. Disc spring (upgraded ) 13. Space washer 14. Oil cylinder 15. Lock nut 16. Bolt 17.
Washer
18. Adjusting nut 19. Back cover of cylinder
Figure 7: Safety Caliper Disassembling Sequence
8.1.1. With hydraulic oil being supplied to the system, adjust the adjusting nut to make
the braking calipers open to the maximum extent, release the oil pressure in the oil
cylinder, pull out quick coupling, remove pin shafts at both ends of the oil cylinder,
remove the oil cylinder as a whole, and clean its external part thoroughly with kerosene.
8.1.2. Disassemble all parts of the oil cylinder as shown in the Figure.
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8.1.3. Clean thoroughly every piece of disc spring with kerosene, dry them, and apply
sufficient grease evenly on every piece of disc spring. After the cleaned oil cylinder, oil
cylinder cover, piston and elastic guide sleeve are dried, assemble them.
8.1.4. Install new dust-proof ring, sealing ring and guide band in the oil cylinder cover.
8.1.5. Install new guide band and sealing rings on the piston.
8.1.6. Install the new disc spring group strictly in accordance with specified assembling
sequence and relationships; the piece of disc spring should be assembled with its concave
face downward, the second with its concave face upward, the third one downward, the
fourth one upward, the fifth one downward, the sixth one upward and the seventh one
downward, finally, put in the spring guide sleeve.
8.1.7. When assembling the piston, pay attention to the guide band. First feed some
hydraulic oil, with one person pressing the piston, another person lightly hammering the
piston with a copper bar to hammer it to position.
8.1.8. Install the hydraulic cylinder. Tighten the bolts symmetrically.
8.1.9. Install the hydraulic cylinder assembly in its original position. Connect pipes
correctly, and adjust the brake clearance. During assembly, cleanliness should be
maintained, and seals protected from damage and scratches.
8.2. Sealing Rings of the Service Calipers
8.2.1. Release oil pressure in the hydraulic cylinder, and after the piston moves back to
position, pull out the quick coupling, remove the adjusting nut, tension rod, tension
spring, split pin/retaining ring for the shaft, then take off the pin shaft, remove the oil
cylinder as a whole.
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8.2.2. Clean the cylinder assembly with kerosene.
1. Dust-proof ring 2. Bolt 3. Washer 4. Cylinder cover 5. Sealing ring 6. Guide band
7. Sealing ring 8. Piston 9. Guide band 10. Sealing ring 11. Cylinder
Figure 8: Disassembly Sequence of the Service calipers cylinder
8.2.3. Disassemble all parts of the hydraulic cylinder according to Figure 11.
8.2.4. First remove the air bleeding screw of the oil cylinder, remove bolts, cylinder
cover and pull out the piston.
8.2.5. Remove the old guide band, sealing ring and dust-proof ring in the cylinder cover;
remove the guide band and sealing ring in the piston.
8.2.6. Wash piston and dry it.
8.2.7. Put piston rings and sealing rings onto the piston rod.
8.2.8. Install new dust-proof ring, sealing ring and guide band in the cylinder cover, and
put new sealing rings on the piston.
8.2.9. Apply hydraulic oil on the internal surface of the cylinder, put piston into the
cylinder, install cylinder cover, then evenly and symmetrically tighten the bolts.
8.2.10. Install the oil cylinder assembly on its original place, connect oil piping and adjust
clearance.
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8.3. Brake Pads

When brake pads fail in function due to wearing or other causes, they should be replaced.
Otherwise the drilling string will not be well braked and free fall can occur.
Preparation for changing brake pads:
 Safety calipers: With pressure being provided, adjust the adjusting nut to make the
brake pads have maximum clearance, then release pressure in the oil cylinder.
 Service calipers With pressure being released, adjust the tension spring tight to bring
the piston into original position.
After the bolt connecting the braking block is screwed down, the old brake pads can be
removed. Remove in sequence all old brake pads which need to be changed. When removing
brake pads, the brake pads of the top or bottom braking calipers should be removed first,
removing the brake pads one by one along the circumference. Replace new brake pads in the
reversed order one by one in sequence.
CAUTION
After the new brake pads are replaced, the braking clearance should be readjusted. The
product of our company (original manufacturer) must be used for replacement of
spares of pan braking; otherwise, the user shall bear all the losses incurred therefore!
9. Damaged Parts
Damaged Parts List

No. Description Where to Use Remarks
1 Brake disc
2 Brake pad Braking calipers
3 Disc spring Before buying,
Safety caliper cylinder check No. of the
4 Safety caliper repair pack disc brake
5 Service caliper repair pack Service caliper cylinder system
Revision 0 Page 22
LM 770 Saipem 5964 Drawworks User Brake Parts List
Parts List
Revision 0 Page 1
Foreword
In this manual of the PS series hydraulic disc brake system, its structure, principle and
application are introduced. Read the manual thoroughly before you operate or repair the disc
brake. Install, use and repair it correctly according to the manual.
The operation effects and service-life of the disc brake system are related to the design
and manufacturing, but further lie on proper operation and maintenance of customers. We supply
customers with high quality products in compliance with the quality assurance system of API,
and also hope that the operators will carefully read the manual to give full attention to the quality
and the performance of the product to successfully achieve the expectant drilling operations.
During product maintenance, it is necessary to use fittings provided by us so that the equipment
can realize its original performance and accidents can be avoided.
Because of continuous improvements to the products, some details in the manual may not
be the same as those in actual production. These differences don’t affect the understanding of the
product’s structure, performance and application. For any questions, please contact us.
You are welcome to contact us if you have new requirements for your application. We
will be very happy to improve our products continuously and to meet with your special
requirements.
Revision 0 Page 2
Contents
Actuating Mechanism
Emergency Caliper
Emergency Caliper Cylinder Assembly
Service Caliper
Service Caliper Cylinder Assembly
Revision 0 Page 3
Actuating Mechanism
Revision 0 Page 4
Parts List
Sn Part № Description Qty Weight Volume
―― PSZ65-BE770-SJC-00 Actuating mechanism 4000 2.4X1.1X1.3m3
1 PSZ75A-70DB-B-01-05 Upper mounting base 2 14

2 PSZ75A-70DB-B-01-02 Hexagon head bolt 20 0.8
PSZ65-BE770-SJC-01-
3 Caliper frame 2 253
00
4 BK-00-6 Service calipers 4 200
5 BK-0-6 Emergency calipers 2 220
6 PSZ75A-70DB-B-01-01 Lower mounting base 2 32
7 Slotted countersunk head
scre
8 Hexagon slotted and castle
n t
9 Split pin
10 Drum
11 PSZ65B-40-S-04-00 Friction disc 2 906 1.7X1.7X0.5m3
12 FB09G Sleeve 12 0.9
Revision 0 Page 5
Emergency Caliper
Revision 0 Page 6
Parts List
(65C Emergency Caliper)
Sn Part № Description Q-ty Weight Remarks
―― BK-0-6 Emergency caliper 220 0.11m3

1 BK-1-6A Brake pad 2 5.8
2 GB93-87 washer 12 12
3 GB5782-86 Hexagon head bolt M12×30 12
4 BK-2-6C Steel backing 2 14.3
5 BK-3-6C Sleeve 4 0.15
6 BK-4-6C Clevis pin with head 2 1.7
7 BK-3-6C1 Sleeve 6 0.25
8 BK-5-6C Lever 2 44
9 BK-6-6A Cover plate 4 0.28
10 GB819-86 Slotted countersunk head screw M6 8
11 BK-4-6C1 Clevis pin with head 2 1.08
12 BK-3-6C2 Sleeve 4 0.17
13 GB894.2-86 Circlip for shaft 30 4
Emergency caliper cylinder
15 BK-7-6C 1 49 0.02 m3
assembly
16 BK-3-6C3 Sleeve 4 0.39
17 BK-3-6C5 Sleeve of Support arm 4 0.17
18 BK-4-6C2 Clevis pin 4 1.69
19 BK-8-6A Semicircle retaining ring 4 0.11
22 BK-9-6C Support arm 2 11.9
23 BK-10-6A baffle plate 4 0.08
24 GB93-87 washer 8 8
25 BK-3-6C4 Sleeve 4
Revision 0 Page 7
Emergency Caliper Cylinder Assembly
Revision 0 Page 8
Parts List
(65 Emergency Caliper Cylinder Assembly)
Sn Part № Description Q-ty Weight Volume

Emergency caliper cylinder
―― BK-7-6 49 0.02 m3
assembly
1 GB70-85 Socket cap head screw M12×30 12
2 GB93-87 Washer 12 12
3 BK-SR-1 sealing ring 1
5 BK-7-6A1 Cover of the cylinder 1 5.79
6 BK-GB-1 Guide band 1
8 BK-7-6C2 Piston 1 8.68
11 BK-7-6A3 Elastic guide sleeve 1 0.47
12 BK-7-6A4 Disc spring 7 0.79
13 BK-7-6A5 Copper bush 1 0.33
14 BK-7-6A6 Hydraulic cylinder 1 12.47
15 BK-7-6A7 Lock nut 1 1.36
16 BK-7-6C8 Axle sleeve 2 0.20
17 BK-7-6A9 Retaining ring 1 0.4
18 BK-7-6A10 Adjusting nut 1 9.57
19 BK-7-6C11 Back cover of the cylinder 1 4.72
20 GB1152-79 Grease cup M8x1 1
21 GB93-87 Washer 8 4
22 GB70-85 Socket cap head screw M8×25 4
Revision 0 Page 9
LM 770 Saipem 5964
Service Caliper Drawworks User Brake Parts List
Revision 0 Page 10
Parts List
(65C Service Caliper)
Sn Part № Description Qtty Weight Volume

―― BK-00-6 Service caliper 200 0.11 m3
1 BK-1-6A Brake pad 2 5.8
2 GB93-87 Lock washer 12 12
4 BK-2-6C Steel backing 2 14.3
5 BK-3-6C Sleeve 4 0.15
6 BK-4-6C Clevis pin with head 2 1.7
7 BK-3-6C1 Sleeve 6 0.25
8 BK-5-6C Lever 2 44
9 BK-6-6A Cover plate 4 0.28
Slotted countersunk head screw
10 GB819-86 8
M6×12
11 GB6170-86 Nut M16 4
12 BK-10-6A Baffle plate 4 0.08
14 BK-11-7A Adjusting screw 4 0.18
15 BK-3-6C6 Sleeve 4 0.17
16 BK-3-6C3 Sleeve 2 0.39
17 BK-7-7Bg Service caliper cylinder assembly 1 25.5 0.02 m3
18 BK-3-6C5 Sleeve of Support arm 4 0.17
20 BK-8-6A Semicircle retaining ring 4 0.11
22 GB93-87 washer 8 8
23 BK-12-7A Spring 2 0.58
24 BK-9-6C Support arm 2 11.9
26 GB894.2-86 Sir clip for shaft 35 6
27 BK-3-6C4 Sleeve 4
Revision 0 Page 11
Service Caliper Cylinder
Revision 0 Page 12
1/13
are mounted on a horizontal floating shaft, use
How To Use This Manual
a gap disc in each coupling. Where limited end
This manual provides detailed instructions on float is required or where sleeve bearing
installation, maintenance, and parts motors are used, consult factory for
identification for Falk style gear couplings. Use application: CAUTION: Consult applicable
the table of contents below to locate required local and national safety codes for proper
information. guarding or rotating members. Observe all
safety rules when installing or servicing
couplings.
Table of Contents
Instructions……………………………………..Page 1 WARNING: Lockout starting switch of prime
Lube Fittings……………………………………Page 1 mover and remove all external loads from
Limited End Float……………………………Page 1-2 drive before installing or servicing couplings.
Lubrication……………………………. …….Page 2-5
Balanced Couplings……………. …………….Page 5
Bi-Annual & Annual Maintenance……………Page 5
LUBE FITTINGS
Installation & Alignment Instructions………Page 5-8
Sleeves have 1 ″ NPT lube holes for sizes.
Installation & Alignment Data…………….Page 8-10 8
Parts Identification & Parts Interchangeability….Page Use a standard grease gun and lub fittings.
10-12
CAREFULLY FOLLOW THE

INSTRUCTIONSIN THIS MANUAL FOR
LIMITED END FLOAT
OPTIMUM PERFORMANCE AND TROUBLE Where limited end float is required or where
FREE SERVICE. sleeve bearing motors are used, consult the
Factory.
INSTRCUTION
This manual applies to standard coupling
Types G &GF with shrouded bolts, and GF ,
and GP with exposed bolts. For couplings
furnished with special features, refer to
assembly drawing furnished with coupling for
proper assembly arrangement and any
additional installation or maintenance
LUBRICATION
requirements. Refer to the specific manuals Adequate lubrication is essential for
for GV vertical gear couplings installation and satisfactory operation. Because of its superior
maintenance. lubricating characteristics and low centrifuge
IMPORTANT: Use G/GF couplings for floating properties, Falk Long Term Grease (LTG) is
shaft assemblies or as the fourth bearing in highly recommended for a USA brand,
three bearing systems. When gear couplings Gear couplings initially lubricated with Long
Loadmaster Universal Rigs, INC.
USA ADD: 3303 FM 1960 W., STE. 230 CHINA ADD: 12F,102# Dongsanhuan Southern Road,
HOUSTON, TEXAS, TX 77068 Chaoyang District, Beijing 100021
Tel: 281-586-8808 Fax: 281-586-9939 Tel: 86(10)67306060 Fax: 86(10)67306060-8023
2/13
Term Grease (LTG) will not require LTG grease.
re-lubrication for up to three years. Depending
on application.
Packaging
14 oz. (0.4 kg) CARTRIDGES – Individual or
USDA Approval case lots of 10 or 30.
LTG has the United States Department of 35 lb. (16 kg) PAILS, 120 lb. (54 kg) KEG &
Agriculture Food Safety @ Inspection Service 400 lb. DRUMS.
approval for applications where there is no
possibility of contact with edible products. (H-2
Specifications – Falk LTG (Long Term
ratings.)
Grease)
Long Term Grease (LTG)
TEMPERATURE RANGE – -20 ℉ (-29 ℃) to
The high centrifugal forces encountered in
couplings separate the base oil and thickener
250 ℉(121 ℃)
of general purpose greases. Heavy thickener,
which has no lubrication qualities,
Minimum pump = 20 ℉ (-7 ℃)
accumulates in the tooth mesh area of gear
couplings resulting in premature mesh failure MINIMUM BASE OIL VISCOSITY – 3300SSU
unless periodic lubrication cycles are
(715 cSt) @ 100 ℉ (38 ℃)
maintained. Falk Long Term Grease (LTG)
was developed specifically for couplings. It THICKENER – Lithium soap/polymer.
resists separation of the oil and thickener. The CENTRIFUGE SEPARATION
consistency of the Falk LTG changes with CHARACTERISTICS – ASTM # d4425-84
operating conditions. As manufactured, it is an (Centrifuge Test) – K36 = 2/2 4 max., very high
NLGI # 1/2 grade. Working of the lubricant resistance to centrifuging.
under actual service conditions causes it to NLGI GRADE (ASTM D-217) – 1/2
become semifluid, while the grease near the CONSISTENCY (ASTM D-217) – 60 stroke
seals will set to a heavier grade, helping to worked penetration value in the range of 315
prevent leakage.
to 360 measured @ 77 ℉(25 ℃)
LTG is highly resistant to separation, easily out
performing all other lubricants tested. The
DROPPING POINT – 350 ℉ (177 ℃ )
resistance to separation allows the lubricant to
be used for relatively long periods of time. minimum.
Although LTG grease is compatible with most MINIMUM TIMKEN EP O.K. LOAD- 40 lb (18
other coupling greases, the mixing of grease kg).
may dilute the benefits of LTG. ADDITIVES - Rust and oxidation inhibitors
CAUTION: Do not use LTG in bearings. Do that do not corrode steel or swell or deteriorate
not use LTG for low speed applications. Refer synthetic seals.
to Table 4, page 6 for coupling speed range of
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3/13
General Purpose Grease DROPPING POINT -- 300℉ (149℃) or higher
Bi-annual Lubrication – The following TEXTURE ---- Smooth or fibrous
specifications and lubricants for general MINIMUM TIMKEN EP O.K. LOAD- 30 lb
purpose grease apply to gear couplings that SEPARATION AND RESISTANCE — Low oil
are lubricated bi-annually and operate within separation rate and high resistance to
separation from centrifuging.
ambient temperature of -30 ℉ (-34 ℃) to 200
UQUID CONSTITUENT – Possess good
lubricating properties…equivalent to a high
℉ (93 ℃ ). For temperatures beyond this
quality, well refined petroleum oil with EP
range, consult Factory. For normal service, additives.
use a NLGI # 1 extreme pressure (EP) grease INACTIVE – Must not corrode steel or cause
EXCEPT when the coupling speed is less than swelling or deterioration of synthetic seals.
the minimum specified in Table 4, Page 9. At
Oil Lubrication
these lower speeds, use a NLGI # 0 extreme
pressure (EP) grease. When one more gear EP oils may be a more effective lubricant than
couplings in an application require NLGI # 0 grease when the required coupling speed is
grease, the same grease may be used in all of one half of the minimum speed range of
the couplings. DO NOT use cup grease. NLGI # 1 grease listed in Table 4, Page 9
If couplings leaks grease, is exposed to
(Minimum rpm ÷ 2). Oil lubricated couplings
extreme temperatures, excessive moisture or
experiences frequent reversals or axial must be sealed to prevent leakage, i.e.
movements; more frequent lubrication may be keyways, etc. Couplings must be drained and
required. refilled with new oil every six months for
Lubricants listed in Table 1, 2 & 3 are typical
operating temperatures up to 160 ℉ (71 ℃)
products only and should not be construed as
exclusive recommendations. and every three months for couplings
operating at temperatures of 160 ℉ (71 ℃) up
Specifications – General Purpose
Coupling Lubricants
to 200 ℉ (93 ℃).
COUPLING SPEED RANGE – See Table 4,
Page 9. For temperatures beyond this range, consult
Factory. The minimum operating temperature
TEMPERATURE RANGE – -30℉ to +200℉
must not be lower than the pour point of the oil.
The specified amount of grease listed in Table
(-34 ℃ to + 93 ℃)
4, Page 9, is in pounds and also applies to the
volume of oil in pints.
WORKED PENETRATION AT 77℉ (25 ℃)---
Specifications
NLGI # 1 ………310-340 (See Table1)
NLGI # 0 ………355-385 (See Table2) Type: Mild EP gear oil that meets AGMA
Specifications 520.04
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4/13
Grade: AGMA # 8 EP (ISO VG 680)
Viscosity: 612 – 748 cSt @ 20 ℉ (-7 ℃)
Maximum.
Must not corrode steel or swell or deteriorate
synthetic seals.
HORIZONTAL COUPLIN
INSTALLATION, ALL TYPES

Only standard mechanics tools, torque
wrenches, inside micrometer, dial indicator,
straight edge, spacer bar, and feeler gauges
are required to install gear couplings. Clean all
parts using a non-flammable solvent. Check
hubs, shafts, and keyways for burrs. DO NOT
heat clearance fit hubs. Use a lubricant that
meets the specifications on Page 2. Pack
sleeve teeth with grease and lightly coat seals
with grease BEFORE assembly. The required
amount of grease is listed in Table 4. Make
certain flange fasteners are tightened to the
required torque listed in Table 4.
Inference Fit Hubs – Unless otherwise
specified, gear couplings are furnished for on
interference fit without setscrews. Heat Hubs
to 275 ℉ (135 ℃ ) using an oven, torch,
induction heater, or an oil bath.
CAUTION: To prevent seal damage DO NOT
heat hubs beyond a maximum temperature of
400 ℉ (205 ℃) for Type G and 500 ℉ (260
℃) for Type GF.

When an oxy-acetylene or blow torch is used,
use an excess acetylene mixture. Mark hubs
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5/13
near the center of their length in several balanced couplings must not be replaced
places on hub body with a temperature without re-balancing the complete assembly.
sensitive crayon, 275 ℉ (135 ℃ ) melt
temperature. Direct flame towards hub bore
using constant motion to avoid overheating an
area.
WARNING: If an oil bath is used, the oil must
have a flash point of 350 ℉ (177℃) or higher. BI-ANNUAL MAINTENANCE
Do not rest hubs on the bottom of the Re-lubricate coupling if using general purpose
container. Do not use an open flame in a grease. If coupling leak grease, is exposed to
combustible atmosphere or near combustible extreme temperatures, excessive moisture or
materials. frequent reversals; more frequent lubrication
may be required.
Maximize Performance & Life

The performance and life of the couplings
ANNUAL MAINTENANCE
depend largely upon how you install and For extreme or unusual operating conditions,
maintain them. Before installing couplings, check coupling more frequently.
make certain that foundation of equipment to 1. Check alignment per stop Step 7, Page 10.
be connected meet manufacturers’ If the maximum operating misalignment
requirements. Check for soft foot. The use of values are exceeded, realign the coupling
stainless shims is recommended. Measuring to the recommended installation values.
misalignment and positioning equipment See Table 4, for installation and maximum
within alignment tolerances is simplified with operating misalignment values.
an alignment computer. These calculations 2. Check tightening torques of fasteners.
can also be done graphically or 3. Inspect seal ring and gasket to determine if
mathematically, and allow the incorporation of replacement is required.
“cold offsets”, which will compensate for shaft 4. Re-lubricate coupling if using general
position changes due to thermal growth. purpose grease.
Balanced Couplings
The fasteners provided are matched sets and
must not be mixed or substituted. Assembly
balanced couplings are match marked and
must be assembled with mating match marks
aligned. In some size, the flanges are not
match marked. Coupling flanges must
assemble with O.D.’s aligned to within. 0.02”
(0.05 mm). Component parts of assembly
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6/13
Use a spacer bar equal in thickness to gap
ALL TYPES G/GF/GP HORIZONTAL specified in Table 4. Insert bar, as shown
COUPLING INSTALLATION above, to some depth at 90 ° intervals and

1 – Mount flanged Sleeves, Seals & Hubs measure clearance between bar and hub face
Place the flanged sleeves WITH seal rings on with feelers. The difference in minimum and
shafts BEFORE mounting flex hubs. Mount maximum measurements must not exceed the
flex or rigid hubs on their respective shafts, as INSTALLATION ANGULAR limit specified in
shown above, so that each face is flush with Table 4.
the end of its shafts. Allow hubs to cool before
proceeding. Seal keyways to prevent leakage.
Insert setscrews (if required) and tighten.
Position equipment in approximate alignment
with approximate hub gap.
For Type G/GF 10 & 20 and GP 20, position
equipment in approximate alignment with gap
equal to that given in Table 4.
For Type G/GF 31 & 32 spacer and G/GF/GP 2B – G / GF 31 & 32 (Spacer), and Type G /
51 & 52 floating shaft, with rigid hubs on GF 51 & 52 (Short Floating Shaft, See Step
floating shaft, position equipment in 4 for Long Floating Shaft)
approximate alignment with approximate Use an inside micrometer as shown above
distance between shafts per Step 4A, Figure 2
and at 90°intervals to measure the distance
on Page 5.
For G/GF/GP 51 & 52 with flex hubs on the between hubs. The difference in minimum and
floating shaft, refer to Step 4A, Figure 1 on maximum measurements must not exceed the
Page 5, to determine distance between shafts. INSTALLATION ANGULAR limit specified in
Table 4.
2 – Gap & Angular Alignment for Close
Coupled, Spacer, Short Floating shaft, and
Insulated Couplings
2C – G/GF 51 & 52 & GP 52 (As Fourth

Bearing in Three Bearing System)
Use a spacer bar equal in thickness to the “x”
dimension specified in Table 4. Insert bar, as
2A – Type G / GF 10 & 20 & GP 20
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7/13
See Step 4 for Long Floating Shaft)
shown above to same depth at 90°intervals
Align so that a straight edge rests squarely (or
and measure clearance between bar and hub within the limits specified in Table 4) on both
face with feelers. The difference in minimum
hubs as shown above and also at 90°intervals.
and maximum measurements must not
exceed the INSTALLATION ANGULAR limit Check with feelers. The clearance should not
specified in Table 4. exceed the INSTALLATION OFFSET limit
specified in Table 4. Tighten all foundation
3 – Offset Alignment for Close Coupled, bolts and repeat Steps 2B and 3B. Realign
Spacer, Short Floating shaft, and Insulated coupling if necessary.
Couplings
3C – Type G/GF 51 & 52 & GP 52 (As Fourth

3A – Type G / GF 10 & 20 & GP 20 Bearing in Three Bearing System)
Align so that a straight edge rests squarely on Clamp a dial indicator to the rigid hub as
shown and rotate the rigid hub one comp0lete
both hubs as shown above and also at 90°
turn. The total indicator reading DIVIDED by
intervals. Check with feelers. The clearance two must not exceed the INSTALLATION
should not exceed the INSTALLATION OFFSET limit specified in Table 4. Tighten all
OFFSET limit specified in Table 4. Tighten foundation bolts and repeat Steps 2C and 3C.
foundation bolts and repeat Steps 2A and 3A. Realign coupling if necessary.
Realign coupling if necessary. Use a dial
indicator if hub extension is too short for
accurate use of a straight edge.
3B – Type G / GF 31 & 32 (Spacer), and

Shaft
Type G / GF 51 & 52 (Short Floating Shaft, 4A – Determine Distance Between Shafts
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8/13
For Figure 1 above, measure the length of the ANGULAR limit specified in Table 4.
floating shaft and add 2 items the gap 4B2 – Refer to Figure 3
dimension from Table 4 to get the distance Align coupling & floating shaft so that, with the
between the shafts to be coupled. square head (or depth micrometer) resting
squarely on the flange, equal clearance
measurements are obtained between flange
and the hub O.D. in four places 90°apart. The
difference in minimum and maximum feelers
readings should not exceed the
INSTALLATION ANGULAR limit specified in
For Figure 2 above, measure the overall Table 4 divided by 2. The above measurement
floating shaft or spacer assembly length from is TIR.
flange to flange and add 2 times the “x” 4C – Position Second Drive
dimension from Table 4 to get the distance Position second drive for the correct “x”
between the shafts to be coupled. dimension and align per Steps 4B1 and 4B2.
DO NOT move the floating shaft. Bolt drive in
4B – Position First Drive & Floating Shafts place and recheck alignment and gap. Realign
Set the drive most difficult to move to true level if necessary. For greater accuracy, checking
and bolt it in place. Set the floating shaft on alignment with a depth micrometer or dial
V-blocks. Then align coupling on fixed drive as indicator.
follows:
5 – Assemble Coupling – G and GF Only

Insert gasket between flanges and gap disc
into counterbore of each rigid hub for floating
4B1 – Refer to Figure 3 shaft assemblies and bolt flanges together.
Use a spacer bar equal in thickness to the “X” Use only the fasteners furnished with the
dimension specified in Table 4. Insert the bar coupling. IMPORTANT: Tight fasteners to
torque specified in Table 4.
to the same depth at 90 ° intervals and
5A – Assemble Coupling – Insert Insulator
measure the clearance between the bar and Parts and Join Flanged Sleeves (GP 20 &
hub face with feelers as shown. The difference GP52)
in minimum and maximum measurements Clean flange face and coat with Permatex # 2
must not exceed the INSTALLATION or equivalent. DO NOT install gaskets. Insert
Tel: 281-586-8808 Fax: 281-586-9939 Tel: 86(10)67306060 Fax: 86(10)67306060-8023
9/13
insulator bushings into flanged holes. Draw 6 – Lubricate
one sleeve onto hub and position insulator Remove all grease plugs and fill with
center plate on flange face. Draw other sleeve recommended grease until an excess appears
onto hub and assemble fasteners with at an open hole; then insert plug. Continue
insulator washers. Use only fasteners procedure until all plugs have been inserted.
furnished with coupling. IMPORTANT: Tighten CAUTION: Remove grease fitting and make
fasteners to torque specified in Table 4. certain all plugs are inserted after lubricating.
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10/13
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11/13
7 – Assembled Coupling Alignment Check –
All Styles
The alignment can be checked without
dissembling the coupling as shown at left.
Determine “w” by measuring distances “w” max.
and “ w” min. between flex hub and sleeve using
a depth micrometer for feeler gauges. The
difference between “w” max. and “w” min. must
not exceed the “w” value given in Table 4. Check
“w” at each coupling end.
PARTS IDENTIFICATION AND PART
NUMBER LOCATION
Coupling parts have identifying size and part
numbers as illustrated below. When ordering part,
always SPECIFY SIZE, TYPE, HUB BORE,
KEYWAY, and PART NUMBER found on each
item.
Contact your Rexnord Distributor or Rexnord for
price and availability.
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12/13
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13/13
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Saipem Rig 5964 Drawworks Gearbox Operation and Maintenance
DRAWWORKS GEARBOX
OPERATION AND MAINTENANCE MANUAL
Revision 0 Page 1
Saipem 5964 Drawworks Gearbox Operation and Maintenance
Contents
1. Main Technical Specifications
1.1 Lubrication Oil Trademark
2. Transportation
3. Installation of Shaft Coupling
4. Installation of Gearbox
5. Test Run
6. Maintenance
7. Troubleshooting
8. Consumable Parts Replacement, Overhaul and Reassembles
9. Operation Instructions for Lubricating System
9.1 Application
9.2 Working Principle
9.3 Installation, Adjustment and Operation of Lubrication System
9.4 Technical Specification of Lubrication System
10. Repair and Maintenance
Revision 0 Page 2
GB770-AC-1 (SJLY 450)

1. Main Technical Specifications
Main Technical Specifications

Rated input 800KWx2
Rated input revolution 0~659/2292 /min
Fixed input 8695N·m
Maximum input torque
(continuous 1 1300N·m
Main transmission 6.40584
Transmission ratio
to the drilling 2.9524
LxBx =2400x2006 (include input shaft and output shaft)
Overall 1408mm (include air filter) (7'-10-12" x6' 7'x4 '-7'-1/2")
The lubrication system includes the following: pump and electrical motor, oil filter, lubricating
oil preheating element, oil-pressure gauge and thermometer. The lubricating oil uses the heavy
duty industry gear oil. Before assembly each component must be cleaned.
The bearing inner loop must abut the end surface of the axial step. The axial clearance of the
high-speed shaft bearing is 0.06-0.12mm.
Gear meshing smallest normal direction lateral clearance: the first level of transmission is 0.28
mm; the second level is 0.32 mm.
Contact area of the gear-pair meshing: not smaller than 85% along the tooth length direction, and
not smaller than 70% along the tooth depth direction.
The gear and the bearing use lubrication oil to cool, trademark is heavy load industry gear oil L-
CKD220. The oil pressure is 0.2-0.3 MPa, oil discharge is 100 l/min.
During idling test run the rotational speed range is 661-2300 rpm. All shafts should rotate at
uniform speed. The couplings may displace but should not come into contact so as to extrude
the seals or leak oil.
The high speed shaft should reach transient equilibrium; the transient equilibrium precision is
G1.6
The gearbox primer uses the epoxy rich zinc primer, the finish uses the splendid diluted acid to
gather the amine fat to finish, and the color is a pale bluish.
1.2. Lubricating oil trademark

Summer: (the oil’s kinematical viscosity is 198-242 mm2/S at 40°C, average 220mm2/S)
or Mobil 630.
Winter: (the oil’s kinematical viscosity is 135-165 mm2/S at 40°C, average 150mm2/S)
or Mobil 627, Mobil 629.
Oil-pressure: 0.15 - 0.3Mpa
Discharge rate: 80 – 100 l/min.
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2. Transportation
After all of the performance tests are completed at the factory the gearbox is carefully sealed.
The gearbox may be transported by truck, train, or boat, and it generally does not have to be
packed. If necessary, use the bolt to fix the gearbox onto a wooden pallet. Accessories such as
electric gauges should be packed separately. When transporting the gearbox by boat, a rust
inhibitor must be applied to the machined finished surfaces. The proper coatings or preventative
measures should be taken for the remainder of the shipping.
When hoisting the entire machine, lift with the hoisting hole or hoisting hook located on the
bottom housing. Do not lift with either device located on the upper housing. (They are used to
assemble the upper housing portion).
The lubrication system is to be disassembled for shipping and the ports are to be plugged to
prevent foreign matter from entering the unit.
Do not ship the gearbox with lubricating oil in the gear case.
3. Installation of Shaft Coupling
The shaft and the coupling shaft hole must be clean before installation. Remove the rust-
preventer or any rust stain and burrs on the surface of the shafts and couplings. To assemble the
coupling on the shaft of the gearbox, use the heat shrink method.
Do not hammer the coupling onto the shaft; this will do permanent damage to the shaft of the
gearbox. The alignment of the two halves of the coupling must be kept ± 0.1mm.
4. Installation of Gearbox
Check carefully whether anything becomes damaged or loose while moving the gearbox. It
should be attached correctly and firmly to the specified frame and base. It is connected to the
motor by a crowned teeth coupling.
Lubricate the hole of the coupling and gearbox shaft with grease before installing the coupling,
and press coupling in with bolt and its screw. Slight shaking is permitted when pushing the
coupling in order to decrease friction. If the coupling is installed by heating the temperature
should not exceed 120°C. After the coupling is installed, it should be cooled by oil or water. It is
not proper to install the coupling by tapping.
Installation tolerance of gearbox should not be more than the specified tolerance of coupling
(allowable rotary angle is 1.5°, radial permitted compensation is 50um, coupling screw pre-
tightening torque is 470NM).After the gearbox is installed and regulated well, connect bolt and
base firmly.
Input shaft driven at the hand wheel should be flexible, and no jamming should occur.
Bearing gaps and gears have been adjusted before delivery; do not adjust unless something is
damaged or loose.
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5. Test Run
5.1. Before each test run, fastening devices must be inspected to make sure all of them are
securely fastened. To meet the specifications before the test run, the cooler, oil filter, the oil-
pressure gauge and the flow-meter must be intact.
5.2. The lubricating oil should be of sufficient industrial quality. There should be more than
approx. 115 gallons of oil in the oil tank for normal operation.
5.3. Start the lubrication system, inspect the oil-pressure, and monitor the appliance and oil
circuits to make sure all of them are working properly. Also be sure that every lubrication
place has adequate amount of oil. The oil pressure should be less than 50 psi.
6. Maintenance
The operating ambient temperature range is -30°C to 55°C. If the gearbox starts when ambient
temperature is lower than 0°C the lubricating oil must be preheated to about 10°C, and at the
same time the outside pipeline should be carried on dredges for heat preservation. Frequently
inspect the oil flow quantity, oil-pressure, and the oil reserves.
Replace and add lubricating oil when needed.
After the gearbox is put into use for the first time and after the first 300 - 600 duty hours in use
or approximately three months of time passage (whichever comes first) the lubricating oil must
be replaced. The lubricating oil is to be bled off as soon as gearbox stops revolving and before
the lubricating oil becomes cool.
Hereafter the lubricating oil should be replaced when the gearbox’s normal working time
surpasses 5,000 hours. This is mainly decided by the working environment, and when the
ambient temperature or the operating temperature of lubricating oil is high. This can make the
replacement schedule of the lubricating oil shorter.
When lubricating oil is replaced, the new lubricating oil should be the same grade as the
lubricating oil that was used before. It is not recommended to use oil of a different grade or
produced by another factory. Do not mix or combine different types of lubricating oil.
The drum shape tooth shaft coupling uses the grease lubricant and already contains enough
lubricant when assembled. The lubricant should be replaced every two months after the gearbox
is put into use. When in repair, one should replace the lubricant by spreading enough lubricant
over the drum shape tooth. Lubricant should be poured into the cavity in an amount equal to
approximately 60 to 70 percent of the cavity’s volume.
With seasons changing, the temperature of the lubricating oil in the gearbox should stay between
15°C to 43°C, and the temperature of the lubricating oil which streams out of the gearbox
≤70°C. If the lubrication oil temperatures reach 85°C the gearbox should be shutdown and
checked, and the cause should be corrected immediately.
Monitor the cycle noise and vibrations. The gearbox should be shutdown and inspected if any
unusual sudden changes occur. The cycle problems should be eliminated immediately.
The gearbox temperature, noise, and vibrations should be monitored closely, and when changes
appear suddenly, actions need to be taken.
The filter should be cleaned after the gearbox works 12 hours for the first initial running time.
Later it should be cleaned once a week and the user may decide the cleaning schedule according
to the special details.
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The gearbox should be started and ran for a period of time once a month. The lubrication
procedure should be followed before the gearbox works.
The air filter must be cleaned at least once every three months.
7. Troubleshooting
7.1. Bearing heats and oil temperature surpasses allowable value

7.1.1. Lack of Lubrication oil: Check oil level of lubrication oil station; add lubrication oil
to specified level.
7.1.2. Lubrication oil loop or oil pipe or oil tank is jammed: Remove sundries and add or
repair oil filter, or replace with clean oil filter.
7.1.3. Lubrication machine is damaged: Replace with approved lubrication machine.
7.1.4. Wrong lubrication oil: Replace with approved lubrication oil.
7.1.5. Poor working environment or inadequate ventilation: Improve working environment
and cooling method, oversize or change air filter.
7.1.6. Running with overload for a long period: should run with normal load.
7.1.7. Wrong installation and adjustment: Reinstall and readjust gearbox.
7.2. Oil Leakage
7.2.1. Seals are damaged: Change seals as soon as possible.
7.2.2. Pipe connector is loose because of vibration: Fasten pipe connector and apply right
sealer.
7.2.3. Oil leakage at screw connecting with bearing cover: Fasten screw; provided that
there is little oil leakage, clean up junction plane and apply sealer, then fasten sealer.
7.3. High noise
7.3.1. Improper bearing gap adjustment: readjust bearing gap.
7.3.2. Lubrication oil loss is excessive or oil quality deteriorates: replace with clean
lubrication oil.
7.3.3. Parts are coming loose: Stop the gearbox, reinstall and readjust parts, and solve
malfunctions.
7.3.4. Incorrect installation and adjustment: reinstall and readjust gearbox.
7.3.5. Gear meshing goes bad, either tooth breaks or the components lose alignment:
immediately shut the engine off, identify cause and fix properly.
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8. Consumable Parts Replacement, Overhaul and Reassembles
Replacement of the consumable parts or damaged parts during overhauling and reassembling of
the gearbox should be carried on according to the manufacturer specifications.
Removal of the top cover requires that the covers on the two holes used for observation be
removed. These covers are found over the top cover and are attached with dismountable
junctions located at the start of a pipeline. If they are opened forcefully, the pipeline may be
damaged (see A in chart below).
9. Operation Instructions for Lubricating System
9.1. Application
The lubricating device is an oil recycling lubricating system that provides lubricant for the
moving parts (gears) inside the gearbox. It also removes heat from the moving parts to
facilitate normal operation of the machinery and to increase the service life. Features
The system consist of two sets of gear pumps, two sets of dual bucket mesh filter, air filters,
various valves (safety valve, check valve and ball valve etc.), and pipelines. All of the parts
are installed on gearbox and oil tank; so it can be hoist and transported as a whole.
9.1.1. Oil Pumps Installation: The safety valve, check valve and air filter are all installed
on the oil pump unit.
9.1.2. Oil Filter: This unit adopts dual bucket mesh filter, precision is 0.08 mm, when one
filter works, and another is for backup. When the working filter net is jammed by
filth, and the pressure differential increases to the rated value, switch the reversing
valve so the backup valve works. Then clean the filthy filter net, and reinstall it into
the bucket.
9.1.3. Heating System: There are three (3) explosion proof electrical heaters installed in
the oil tank. Each heater power is 1 KW, total 3 KW fixed on the front plate of tank.
9.1.4. All the gauges and pressure transmitters are installed on pipeline.
9.1.5. A thermo coupler (Pt100) is installed on the oil tank, and can be read and auto
controlled.
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9.2. Working Principle

9.2.1. During operation, the oil is pumped from the tank through the check valve, dual
bucket mesh filter, and through gate valve to the gearbox lubricating points. The
maximum output oil pressure is 0.4MPa.
9.2.2. The unit includes a safety valve, which can ensure that the oil pump is not
overloaded. If the pressure drops to certain value (setting value is 0.15MPa), restart
the backup pump. If pressure drops below the minimum setting, (value is 10 psi), the
system should be stopped in order to check the pump and the filter.
9.2.3. One of the dual buckets mesh filter is used as a backup when the working filter
pressure differential is exceeded.
9.2.4. The platinum thermo coupler is used to monitor oil temperature in the tank. When
the temperature is lower than 5°C, the heater works automatically. If the temperature
rises to 40°C, the heater stops automatically.
9.2.5. Electric contact thermometer, which is located at the oil inlet, is used to monitor that
the oil temperature remains between 37°C to 43°C.
9.3. Installation, Adjustment and Operation of Lubrication System

9.3.1. Before connecting the pipelines, flush the pipe with hydrochloric acid to remove rust,
then flush with pure water, finally blow with compressed air.
9.3.2. After completing the assembly, conduct a seal test with a testing pressure of 0.8MPa,
for a minimum of 10 minutes. Then lower the pressure to the rated pressure to check
if any leakage happened on the weld lines and connections.
9.3.3. First test Pump #1 by starting and stopping several times. Inspect the rotating
direction, read oil pressure, and verify that the filter works normally. The normal
operation pressure of the lubrication pump is 0.2-0.3 MPa. If the pressure is higher
than 0.4MPa, regulate the outlet valve to relieve the pressure. When oil pressure is
lower, inspect lubrication point to ensure that the oil supply is sufficient. When finish
testing the pump #1, test the pump #2 with the same method. The initial pressure of
the safety valve should be adjusted according to the outlet oil pressure, normally
0.05MPa higher than outlet. Steps are: loosen safely valve spring gradually, close the
valve to oil tank and the nearest outlet valve. Then raise the oil pump outlet pressure,
until it is 0.08MPa higher than the normal pressure. Then tighten safely valve spring
slowly, until the gauge indicator rotates clockwise (means safety valve works), and
lock the valve spring.
9.4. Technical Specification of Lubrication System

There are two (2) types of lubrication systems. The specifications are slightly different.
9.4.1. Technical Parameters of GB770AC-1 Gearbox Lubrication System
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Nam Unit Value Remark

Flo L/mi 100
Working MPa 0.4
Working medium N22-N460 Lubricate oil
Working Degrees 40±3
Pump Mode CB- Two
Flo L/mi 100
Max. MPa 0.63
Mode YB112M-4 Two
Pump Powe KW 4 Class: dIIBT4
Moto Rotate r/min 1440
Voltag V 460
Frequency H 60
Mode SPL-
Filtering area m2 0.40
Filte
Precisio mm 0.08
Pressure differential MPa 0.15
NA Mode SRY2-2/460 Class: dIIBT4
Electri Powe KW 1
heater Quantity Set 3
Voltag V 460
9.4.2. Technical Specifications for GB770AC-2 Gearbox Lubrication System

Nominal flow rate: 100 L/Min Nominal pressure: 4kg/cm²
Filtration fineness: 0.08mm Power of electric heater: 3×2kw
Motor power: 2×4kw Degree against explosion: dIIBT4
Protective degree: IP55 Temperature of oil supplied: 35-43°C
Dia. of oil supply port: DN50 Dia. of oil scavenging port: DN125
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10. Repair and Maintenance

10.1. Keep the unit clean; oil tank should be flushed periodically. Inspect the oil quality and
add some to the rated oil level.
10.2. Check the gauges on the pipeline periodically, and change the damaged parts.
10.3. Monitor the oil pressure.
10.4. Monitor that there is no leakage on weld lines and connections; if this happens fix them
immediately.
10.5. Oil pressure should not be higher than 0.4MPa, and oil temperature should not be higher
than 45°C.
10.6. The pressure differential in the filter should be less than 0.15MPa. If the pressure
differential is higher than 0.15MPa turn the valve lever to use another filter (operate it
without stopping the pumps), inspect the filter net and clean it. Then re-install it and
monitor that the pressure differential reaches the specifications.
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Common Spare Parts List
Code Description Qty. Remark
Spherical roller bearing 23228CC/W33

GB/T288-1994 4 SKF Made
（140×250×88）

（160×290×104）

（240×360×92）
Wearing Parts List
S/N Code Description Material Qty. Remarks Parts
No.
1 GB/T5781-2000 Hexagon head bolts 4.8 3 Surface 9
M16x40 galvanizing
M20x50 galvanizing
M30x130 galvanizing
M36x160 galvanizing
M42x110 galvanizing
6 GB93-87 Spring washer 42 65Mn 3 Surface 3
galvanizing
galvanizing
galvanizing
9 GB/T41-2000 Nut M30 35 3 Surface
galvanizing
10 Air filter QUQ2.5-40X30 1 36
11 GB/T118-2000 Taper pin with internal 45 1 48
thread B20x80
Heatless regenerative dryer user’s manual
KXD- 5~ 800
Hangzhou Kelinaier Qiyuan Equipment Co., Ltd.

Inform User
Thank you for your purchasing from Hangzhou Kelinaier. It’s our honor to supply
the best service for you.
Hangzhou Kelinaier Qiyuan Equipment Co., Ltd. is a professional manufacture of
compressed air purifying equipment. We cover eight main field and 1,020 varieties,
such as refrigerated dryer, desiccant dryer, combined dryer etc. Kenlinaier’s products
have been used throughout china, and well sold to Asia, Europe. Sastifying the
different requirements of compressed air purifying like automobile, power station,
electronics, food manufacturing, chemicals, steel, shipbuilding, etc.
Our tenet: Emphasizing innovation, striving for perfection. user satisfaction, to be

number one
Compressed air purifying equipment is industrial product, pleases read this

manual carefully mastering its characteristics and requirements before operating.
Only through your correct operation it’s functions can be utilized perfectly. It’s our
pleasure if our products work well in your company.
We reserve the right to not hold responsible for warranty under the circumstances
that operate and routine maintenance not in accordance with the manual.
We try out best to expatiate the characteristics and points in this manual, so this
manual includes our know-now, here we would tell that :You are not permitted to
provided this manual to the third party in any way without our permission.
We reserve the right to investigate the company and individual revealing its content.
The accuracy of the manual has already verified seriously, but we do not ensure all
the contents are meeting your requirement. If any question, please contact us, we will
do out utmost to relieve your trouble.
Tel:0571-88790991/88790997
Customer service: 0571-88791788
Fax: 0571-88792222
E-mail: hzklqy@163.com
Website:www.klqy.com
Address: Liangzhu Anxi Industrial Zone,Yuhang,Hangzhou
Postcode:311113
Content
1. Summary
2. Specification and technical parameter
3. Flow and Process
4. synopsis of all parts
5. Installation
6. Preparation before operating
7. Operating
8. Routing maintenance
9. Trouble shooting
10. technical specifications of delivery
11. drawing process flow diagram
safety criterion
1. This installation carries a pressure vessel, its system working pressure
mustn’t exceed the maximum pressure indicated on the nameplate. You mustn’ t
disassemble or repair before reducing the system pressure to zero.
2. This installations belong to electric equipment, which should comply with the
local power rule of the nation .Do not install them in dangerous
environment ,disconnect the system power when maintain.
I. Summarize
Heatless regenerated desiccant dryer is an adsorptive purifying device. The
purpose is to remove the water in the air through the principle of adsorption and
purifying.
The heatless regenerative dryer utilizes the porous-surface desiccant
selectable feature absorbing the water in the air into the cavity of the desiccant to
dry the air. When the desiccant will reach the saturation after using for a certain time,
it has to be regenerated by the dry air to restore its adsorptive capability. The
desiccant can be reuse through adsorption and regeneration so as to working
constantly and safely.
Heatless regenerative dryer adopts the technique of PSA heatless regenerative,
it just utilizes the different adsorption capacity of the desiccant under the different
pressure to absorb under the work pressure and regenerate when approach to
normal pressure. Through short cycle switch, and to adsorption, regenerate between
the two absorbers, then to achieve regeneration with no heat, ensure continuously
absorbing operation.
Heatless regenerative dryer is mainly made up of following components: two
alternative absorbers, one muffle, one set of switch valve, one set of controlling
system and gas processing unit.
Heatless regenerative dryer feature

 Adopt technology of pressure swing adsorption ,regenerate with no heat.
 Short switch cycle
 Simple process flow, low fault rate, low capital cost.
 Easy to operate and maintain
 Use self-dry air as regenerated air supply, need to consume certain amount of air.
 Automatic mode of operation, unattended.
 Integrated delivery
II. Specification and technical parameter

1. Product series
type KXD-5 KXD-10 KXD-20 KXD-30 KXD-60 KXD-75 KXD-100 KXD-120
Rated handling 0.7 1.6 2.6 3.8 7.0 8.5 11.5 13.5
capacity(m3/min)
type KXD-150 KXD-200 KXD-250 KXD-300 KXD-400 KXD-500 KXD-600 KXD-800
Rated handling 17 23 27 34 45 55 65 87
capacity(m3/min)
2, technical parameter
1) Air handling capacity see list.
2) Rated air pressure 0.7MPa
Min 0.4MPa Max 1.0MPa
3) Rated air inlet temperature ≤45°C Min 5°C
4) Air inlet impurity
Water content saturated wet air
Oil content ≤0.01ppm(w)
5) outlet dew point -40°C(PDP)
6) Switch time 5min (adjustable)
7) system pressure drop ≤0.021MPa
8) Regenerative consumption
Medium self dry air
Gas consumption ≤14.5% rated handling capacity
9) Way of regenerative heatless
10) Power supply AC 220V/1PH/50Hz
Power ＜100W
11) ambient temperature ≤45°C
III. Flow and process

1. Flow (picture attached)
The wet air which from the former compressor first removes the oil and moisture
in the compressed air through fore precise filter, then enter to the heatless
regenerative dryer (we call it “dryer” for short).Compressed air flow into the absorber
through the air inlet valve V11(V12),then into fixed bed layer from the bottom to top,
then the water in the air will be absorbed by the adsorbent . After drying, the
compressed air from the outlet valve V13(V14) to the following craftwork. It is
requested to regenerative when the adsorbent adsorption achieves saturated,
drawing out a pipeline from the main outlet pipeline to deflate about 14.5% product air
as regenerative air, then through the regenerative regulating valve V15, Throttle
orifice reduced pressure to atmospheric pressure, make this regenerative air has the
very dried ability of regenerate and desorption. The regenerative air through the
regenerative air inlet valve V17(V18) opposing enter the absorber from top to bottom
to absorb bed layer, at the condition of approximate atmospheric pressure to
regenerate desorption the saturated adsorbent. The vapor after desorbing out by the
regenerative air through the outlet valve of regenerative air V19(V20), and muted by
muffle, then discharges the atmosphere.
(Dryer of type below 100, its regenerative air directly through throttle orifice to
enter the regenerative absorber, other flow same as type above 100)
2. process
Two desiccant towers in the adsorption dryer can be used alternate. Compressed
air is dried through one tower while the other desiccant tower is being regenerated.
As following picture: (AD1 for adsorption, AD2 for regenerative)
AD1 adsor pt i on, AD2 r egener at i on AD1 r egener at i on, AD2 adsor pt i on
t 0 adsor pt i ve t i me t 0 adsor pt i ve t i me
V11
V12
V19
V20
a1 t1 t2 c1 a1 t1 t2 c1
a1:regeneration delay t1:regeneration

t2:repressurization c1:switch advance
diagram1 process drawing
Adsorption: the air through air inlet valve V11 (V12) to enter the adsoption bed layer
when the absorber works, and then come out from V13 (V14).
Regeneration: the absorber’s regeneration divides into two steps, regeneration and
repressurization.
1) Regeneration: when the two absorbers finished working in absorbing time, AD1
starts to absorb and AD2 regenerate, and then prolong the a1 time to open V20
and discharge the rest pressured air in the AD2. when the pressure in AD2
approach to normal pressure, the regenerative air through the flow path
regenerates and desorbs the absorb bed layer , caused by the different pressure
open the valve V18 automaticly, time is controlled in t1.
2) repressurization: when AD2 is going to start to next absorb time, the AD2
absorber pressure must change from atmosphere pressure to adsorption
pressure. The way is closing V20, the air is still through the regenerative air flow
path from AD1 to AD2 automatically. When the times up, the air reaches the
balances of pressure in AD1 and AD2, the two absorbers have the condition to
switch, this controlled in t2. Opening V12 in advance before the absorbing time
finished, at this time open V14 automatically with the help of different pressure.
Switchover: when AD2 finishes regeneration, AD1 finishes adsorption; the two
absorbers start to switch operating and closing V11. The two absorbers finish
switching and go to next cycle.
The process of adsorption and regeneration at normal work pressure. See Fig.2
AD1 adsor pt i on, AD2 r egener at i on AD1r egener at i on , AD2 adsor pt i on
adsor pt i on adsor pt i ve t i me adsor pt i ve t i me

pr essur e
0. 7MPa
r egener at i on
pr essur e
0. 01MPa
adsor pt i on
pr essur e
0. 7MPa
r egener at i on
pr essur e
0. 01MPa
r egener at i on r egener at i on r epr essur i zat i on
r epr essur i zat i on
Diagram 2 variation diagram of process pressure
IV. Synopsis of all parts

1.absorber
The interior of the absorber is the spatial vessel structure; it is used to fill with the
absorbent. Bed layer arrangement is single-layer, and the filled absorbent is special
activated alumina for air dryer, it has the excellent ability for absorbing water. There
are all set assignment air current and special diffuser with the function of preventing
absorbent grain at the bottom inlet and top outlet in the absorber. The diffuser has
stainless steel cloth with appearance is fold stack-up. Its purpose is to prevent
extremely small powder. It sets in the top and bottom with the filling alleyway to
loading and unloading the adsorbent conveniently.
2.silencer
When blows down the regenerative air, the air must be muffled by silencer for its
noise caused by itself.
The silencer is composed with extremely thin glass silence material; it has the ability
to muffle. And air from which can depress the noise above 30dB (A).
3. switch valve
The dryer absorbs and regenerates through a set of switch valves which open and
close at different time.
Switch valve is mainly composed with a set of air operated valve and check valve.
Pneumatic operated valve: V11, V12, V19, and V20. Check valve: V13, V14, V17,
and V18 (below the type 100 without V17 and V18).
Type Air Inlet Valve Regenerative Air Outlet Valve

KXD-5~75 Pneumatic Operated Valve T Pneumatic Operated Valve T
KXD-100~120 Pneumatic Operated Angle Pneumatic Operated Angle
Valve Place Valve
KXD-150~300 Pneumatic Operated Butterfly Pneumatic Operated Angle
Valve Place Valve
KXD-400 above Pneumatic Operated Butterfly Pneumatic Operated Butterfly
Valve Valve
1) Pneumatic operated butterfly valve

Working principle: opening and closing butterfly valve by external gas source
drive actuator. Pneumatic valve is mainly consist with valve body and actuator.
Opening and closing butterfly valve by turning the circular butterfly board by
valve stem, then make the valve open and shut. There is valve seat in the valve
interior, the material is EPDM. It has very close relation with butterfly board, easy to
open and close. Also can sealing medium. It has features of elastic and self airtight.
The valve actuator takes the compressed air as power，the compressed air pushes
piston displacement through the piston impelling the rack, gear's machinery rotating
and revolving traveling schedule output torque by angle. This actuator form is a
double-acting and single electrical control. When supplying the power, open air that
inlet actuator opens the valve, and closing the valve opposite.
Air inlet valve is seen as normally open valve, air regenerative outlet valve as
normally shut valve. The former means opening the gas and valve when power out,
on contrary, normally shut valve means opening the gas and valve when power
supply.
2) Pneumatic angle seat valve
Working principle: when the control gas enters the valve actuator, medium
pressure impelling the piston, driving the valve stem. Then it makes the valve board
moving to open the valve.
The part of actuator of valve is similar like pneumatic butterfly valve actuator, but
normal-shut air operated angle seat valve has set replied spring inside it. When the
solenoid valve has no electrical power, actuated valve in the condition of close
caused the replies of spring of the valve.
3) Pneumatic T-valve
Its structure principle is similar as air operated angle seat valve. The gas flows
with the valve seat becomes vertical approaches, it mainly suit for small machine.
4) Check valve
Air outlet valve and regenerative air inlet valve adopt check valve, the valve will
open automatically when the different pressure appears between the medium in the
valve. And the valve will shut automatically if the medium different pressure
disappears. So come to being the technical process of air path switch using of the two
absorbers.
The type structure of check valve is elevating to clamps, by the medium pressure
impelling the valve petal moving to open valve. When the medium pressure
disappears, the spring replying on its primary position, thus to make the valve close.
4. Control gas unit
Its function is to offer clean air control gas with certain pressure, it is composed by
gas processing unit and pneumatic element.
It adopts dried air as control gas, the flowing method is drive out a pipeline from
the main pipeline, first entering gas processing unit, then depressing the pressure to
0.5MPa requirement. Then supplying the clean dry gas for the pneumatic valve.
In the system, the pneumatic valve actuation is finished by pneumatic element
solenoid valve. The solenoid valve is made up of magnet coil, magnetic core and
valve chest with several holes. When the coil circular telegram or loses the electricity,
the coil load magnetic core has the displacement to cause the gas through exclusive
manhole, then becomes special gas flow. Our system adopts “two five solenoid
valves”, it has opening gas, closing gas connection and the electronic voltage of
power supply AC220V.
5. control system
Control system is formed by PIC controller, Number tube monitor and controlling
element. All the elements are installed in control box, details in controlling instruction.
During the process of the valves in the dryer, the program controller makes the
automatically control and the program controller can set the parameters through
display monitor. From this it can ensure the dryer work safely.
Before the dryer operating, it needs to set the process parameters. Setting menu:
the time for each steps (adsorption, regeneration) in the technical process, these
parameters have already set before the machine leaving factory, see fig.3. You can
find the details in controller instruction.
Number Name Parameter Setting Value
1 t0 Adsorption time 300s
2 a1 Regeneration delay time 4s
3 t1 Regeneration time 242
4 t2 Repressurization time --
5 c1 Switch time 4s
Remark: the repressurization time is t2=t0-(a1+t1+c1), this time automatic created

after other time setting.
Dryer has equips some special measuring appliance, such as left absorber
pressure meter, right absorber pressure meter and regeneration air adjustment
pressure meter. The left and right absorber pressure is used to look on the pressure
in the absorber, especially for repressurization and depressurization. The
regeneration air adjustment pressure meter is for looking on the flow of regenerative
air.
(Type below 100 without regenerative air adjustment circuit, so it does not set
with the regeneration air adjustment pressure meter.)
V. Installation
1. Process configuration
Drawing 3 is indicated the standard configuration of dryer in compressed air
system. To satisfy with day-to-day running and following quality air, it’s indispensable
to install process configuration in front and rear part of the dryer according to the
configuration in dashed frame. That is: Configure class C, class A precise filter
respectively to clear the oil before the dryer, configure class T precise filter after the
dryer to clear particulate. The user may add relevant configuration in accordance with
self requirement, please consult us soon when you change the configuration.
1 2
3 4
5 6
1.compressor 2. gas tank 3. class C precise filter

4. class A precise filter 5. dryer 6. class T precise filter
Drawing 3 Process Configuration
Technical requirements for process configuration:

Impurity content inlet of the dryer
Moisture saturated moist air
Oil ≤0.01ppm(w)
Impurity content outlet of the dryer
Particulate dia ≤1μm
The user need to install necessary shut-off valve and by-pass valve at the process
flow node according self features and requirements in order to repair and maintain.
2. Unpacking &accepting
Our dryer has been inspected by the inspector before delivery.
When the equipment has been arrived, the user should unpacking and accepting
by self, inspection points:
1) Check out weather there is any missing part and document integrality in
accordance with packing list.
2) Examine the apparent damage & fault for transportation reasons.
If the equipment is not installed for the time being, it should be leaved
in dry and ventilated indoor ,do not leave in outdoor.
Please give us feedback in time if you find the equipment is defective, or it will be
considered as qualified after two weeks you receive the machine.
3.Installation instruction
1) This skid mounted equipment is integrated with all parts before delivery , so the
user only need to connect with front & rear pipeline and power on electricity on the
scene.
2) For safety transportation, the silencer is packed separately with the integration.
The user need to install the silencer at the regeneration gas vent, transfer the pipe to
external installation is permitted, but must comply with followings:
Consult us for the transfer pipe diameter
Keep the silencer out of the rain under outdoor installation
3) Please cut off or seal up the front and rear air channel before operation avoiding
moist gas flow into the dryer.
4) No need foundation when installation. When then equipment is ready for use,
fasten the equipment on the floor reliably and firmly by metal expansion bolt.
5) All the pipelines have been connected, adsorbent has been filled, electrical and
pressure test have been tested. Please do not change the internal pipeline and other
parts optionally. Please consult us for any question.
4.Installing specification
1) please install in the building which is well-ventilated and clean(indoor
installation),also far away from the air compressor reducing vibrative influence
caused by the air compressor. Besides, it is not allowed to install at the place which is
full of air pollution or with danger.
2) Environment temperature blew 45°C
3) Leave minimum 1m space around the dryer for easy maintain and repair.
4) Only use fork to move& transfer. Hoist in the vessel or pipeline may lead to
equipment damage.
5) Dryer must be connected on the ground with electrics.
VI. Preparation before operating

The user need to make good preparations for well operating when first-use the dryer
or reuse after a long time’s stop .Operator should master all requirements in this
manual for a better idea. Please contact us for help if you have any problems.
No operating against rules

1. Inspecting & Identifying
① Confirm control system can be used , check and confirm parameter-setting in
controller meet the requirement of drawing 3. Bring program controller into operation
for a few cycles before operating the equipment (no-load frowst ) so as to the
program controller is in working order. As to inspection and parametric setting method,
please refer to the controller manual.
② Check the airproof of every valve and flange
③ Confirm front and rear part of pipelines are clear and pollution-free, degrease
treatment is needed in the case of pollution.
④ Tightness test according requirements of general drawing is needed for system
under the circumstance that the dryer is not running more than half a year after
delivery. If the dryer has no leakage after test, it is regarded as OK.
⑤ Check out the external voltage is three phase 220V/1PH/50Hz.
⑥ Check out if the dryer’s upstream maximum working pressure exceed it’s
maximum working pressure 0.95Mpa or not.
⑦ Examine all electrical connection is right and firm.
2. Adsorbent activization
Activation processing is required for adsorbent when use the dryer for the first time
or being halted exceed half a year. Please operating strictly in accordance with
activization request because activated effect is critical for outlet quality air.
The requirement for activated technics is : shut off the rear shun-off valve at the
outlet of dryer, but unclose the front shut-off valve of the dryer. Just make the inflow
air equal to regeneration air, other steps the same as normal steps. The activation
time commonly lasts 2 to 4 hours. After activation, shut off the front and rear shun-off
valves of the dryer, holding insulate from the external pipeline, wait for the running.
VII. Operation
1. start-up
Please handle the dryer strictly according to order when operation.
First step: startup turn on system power
Second step: air supply Slowly unclose the front and rear shut-off valves enabling
the compressed air flow into the dryer, thus the air pressure rise to
working pressure.
Third step: Put into operation Press the start button on the operation panel,
the program auto start, relevant valves continue to work on the basis of
drawing 1,the equipment start to work.
Forth step: adjustment When one of the adsorber continually work within
regenerating time, it will adjust regenerating and regulating pressure to
0.35MPa through regeneration gas regulating valve .If the system’s
working pressure has changed, adjust as table 4.(no need adjustment
for type below 100)
Working 0.5 0.6 0.7 0.8 0.9

pressure
Regulating 0.43 0.38 0.35 0.32 0.28
pressure
Table 4 table for purge gas regulating pressure setting unit MPa
2. Shut down
① Please avoid overpressure in system ,in the operation of shut down whenever
the dryer is needed.
② It is better for the dryer choosing to shut down at the repressurization step.
③ Press the stop button on operation panel, program auto stop.
④ Shut down the front and rear shut-off valve, unclose bottom blow-down valve,
make sure the pressurized air in vessel has low to zero (remark: choose other
released place for Type 200 below)
⑤ keep dryer and its front and rear pipelines in insulated state in order to prevent
moist air flowing into adsorber.
3. Attention in running
① Unclose blow-down valve under the adsorber in order to release liquid water in
air inlet pipeline which is possibly leave at the bottom of the equipment.
Meanwhile, unclose all blow-down valves at the rear of dryer and release the
residual liquid water.
② Pay attention to front and rear shut-off valve when operating in the startup stage.
Preventing gas shock caused by compressed air for fear that incidental water
flow into the dryer, and affect the dryer.
③ When the dryer is running, note the valve is in good condition, the two absorber
pressure change regularly at their steps.
④ To adjust in time the regeneration gas control valve and regeneration gas flow
according to the variety of system working pressure.
⑤ Examine gas tightness of the valve itinerantly and frequently.
⑥ Frequently examine the dryer. When a fault is noted, stop the machine
immediately, otherwise the fault will become more serious.
⑦ check out the control gas pressure is above 0.5MPa stated.
II. E
III. E
IV. E
V. E
VI. E
VII. E
VIII. E
IX. E
X. W
XI.
VIII. Daily maintenance

1. Everyday inspection
① Check and record the working pressure, and adjusting pressure of the
regenerative air in the left absorber and right absorber make sure every
specification is within the designed range.
② Check the pressure of absorber is below it’s maximum working pressure.
③ Check and confirm the pressure is on the same step with the procedure.
④ Check and confirm the draining of front filter flows well.
⑤ Check and confirm the system regeneration pressure is below 0.02Mpa.
2. Monthly inspection
① Check the working conditions of the dryer like handling capacity, inlet pressure,
inlet temperature, make sure they are within the rang of design.
② Check the pressure drop of front and rear filters.
3. Quarterly inspection
① Check the pressure difference of front and back filter and sure if it exceeds
tolerance
② Check the control gas filter to see if clear inside.
4. Annual inspection
① Check the efficiency of the desiccant, fill in or replace
if not.
② Check the solenoid valve is flexible, replace it if necessary.
③ Check the pneumatic butterfly valve, pneumatic angle seat valve, check valve are
no defect, and replace if necessary.
④ Check the electrical circuits, electrical components in electrical box is out of aging .
IX. TROUBLE SHOOTING
SYMPTOM PISSIBLE CAUSE SOLUTION MEANS

shortage of regenerative air ①Check the regeneration
①adjusting valve opening pressure set value, as required
inadequate. adjustment
1. Out Dew point out of
requirement ②adjusting valve be plugged ② Solve the adjusting valve
with something. failure
Regeneration time not As request to adjust
enough Regeneration time up to
requirements
①confirm if former liquid water
Liquid water into absorber
into absorber
then result in adsorbent
saturated. ②check front drainer working
situation
③close shut off valve, to
reactivate desiccant Against the
operating method.
①check the source of oil and
Desiccant be contaminated
confirm if the front filter failure.
by oil
②replace front filter core
③replace desiccant.
Close or repair shut off valve
By-pass shut off valve open
or leak
Check and confirm if fill in
Not fill in desiccant desiccant
Operation conditions is Do something to correct air, inlet

deviate the design conditions parameter, under rating
1) lower inlet pressure Technical parameters to operate
2)higher inlet temperature
3)handling capacity too big
1) pressure of 1)air inlet valve not be ①look out failure valve

absorber not closed.
catch working 2)Spring inside air outlet ②check Pneumatic pipe and
pressure, it’s valve and regenerative air element and electricity first, then
similar in right inlet valve be entangled, and check valve body if failure from
2.pressure of dryer is not normal
and left tower not be closed. pneumatic valve.

③solve failure, repair or replace
2) regenerated 1)air inlet valve not be ①solve the failure of valve,
pressure bigger closed well.
repair or replace parts.
than 0.2Mpa 2)air outlet valve and inlet
valve of regenerative air not ②repair or replace silence.
be closed well.
3)silence be plugged
3)absorber can’t 1)outlet valve for ①solve the failure of valve,
re-pressure or regenerative air can’t close
repair or replace
slowly or close not well.
2)purge adjusting valve be ②solve the failure of adjusting
plugged. valve.
4) compressor Air Inlet valve can’t open repair or replace valve
air flow 1)controller be interfere, ①confirm it if trouble is from
interrupted procedure is abnormal or
program controller.
suddenly workless
2)loose or wrong connection ②check wire connection and
for electric wire.
correct it.
5) regenerated Purge Outlet valve for ①check Pneumatic circuit
absorber can’t regenerative air can’t open.
discharge ② repair or replace valve.
pressure
1)electric connection ①check and correct connection
3. switch failure incorrect
2)program controller ②confirm if program controller
workless workless, to replace it.
3) control gas filter be ③change filter
plugged.
4.system pressure drop 1)handling air capacity too ①adjust handling air capacity
bigger than 0.021Mpa. big.
2)air outlet valve not open ②check and repair valve
full. ③check diffuser and replace
3)diffuser of absorber be
plugged ④check or replace adsorbent
4)adsorbent broken or
become powder
X. TECHNICAL CONDITIONS FOR DELIVERY

1. Delivery range
1) equipment heatless regenerative air dryer 1 set
2) Attachment
①technology file of pressure vessel
1 paper
a.. as built drawing of pressure vessel
1set
absorber
(note: technical file by mail)
b. rest file of pressure vessel
② Heatless regenerative air dryer operation manual 1pc
③ Controller operation manual 1pc.
④ Qualified certificate 1pc
⑤ Packing list 1pc

2: CUSTODY
Keep good custody when equipment reach your site and before using. Place indoor in dry, flowing air,
avoid moisture and be rained
V13 V14
ai r out l et
V13 V14 OR
V15
sui t f or KXD -5~75
CAF
OR l ef t absor ber
AD1
V17 V18 AD2 r i ght absor ber
SL si l encer
AD1 AD2 CAF cont r ol gas f i l t er
V11 l ef t ai r i nl et val ve
V12 r i ght ai r i nl et val ve
SL V13 l ef t ai r out l et val ve
V14 r i ght ai r out l et val ve
V15 pur ge adj ust ment val ve
V17 l ef t pur ge i nl et val ve
V19 V20
V18 r i ght pur ge i nl et val ve
V11 V12 V19 l ef t pur ge out l et val ve
V20 r i ght pur ge out l et val ve
OR t hr ot t l e or i f i ce
PI - 1 l ef t absor ber pr essur e

PI - 2 r i ght absor ber pr essur e
PI - 3 pur ge adj ust ment pr essur e
ESC- 1 pr ogr am cont r ol l er
t echni cal pi pel i ne
ai r i nl et
measur ement pi pel i ne
gas conr eol si gnal
pr ocess f l ow
sui t f or KXD -100 above i t em heat l ess dr yer pat t er n dr awi ng
el ect r i cal si gnal st abdar d t ype, ver si on
t ype
f our val ve number 2007- 12
LM770 Saipem Rig 5964 HPU Operation Manual
YZ3600-17 HPU
Operation Manual
Loadmaster Universal Rigs Inc
1
Safety Operation
 Wear personal protective equipment when operation or maintenance of HPU to
prevent damage to the human body or equipment. HSE precautions must be taken
when maintaining and operating equipment to prevent bodily harm or damage to
equipment
 Use recommended brand/s of hydraulic oil. Mobil DTE 25 for normal operating
conditions and Mobil DTE 15 for cold weather application temperatures below 4*
C or equivalent Do not mix brands of oil.
 Hydraulic oil testing is recommended after 600 Hrs. of operation. Intervals of oil
replacement will be determined by operating conditions. Use of
polluted/contaminated hydraulic oil will increase wear, lead to frequent failures,
and shorten life of equipment.
 Use precautions when connecting and disconnecting hydraulic lines during rig
operation and rig moves to prevent contamination of fluids. Protective caps
should be used when lines are disconnected.
 Hydraulic system should operate for 5 minutes at idle speed before loading. A
cool down period of 5 minutes at idle condition is also recommended before shut
down.
 The engine normal operating speed is 1800r/min, with lower limit at 1600r/min and
upper limit at 2000r/min.
 The pressures of the variable pump and by-pass valve on valve bank are preset at
factory. Do not make adjustments without consulting manufacturer.
 Follow lock out tag out procedures before maintenance on HPU system,
(disconnect power sources).
 Use precautions before refueling engine. Points to consider are open flame,
engine temperature and static electricity.
2
 Refer to engine operating manual for recommended engine cooling fluids.
Reference operating conditions for proper selection.
 For battery replacement or starting the engine with an auxiliary power source,
make sure that the “+” and “-“ wires are connected to respective “+” and
“-“ wiring terminals at the new battery or auxiliary power supply. Do not reverse
the connection!
 Caution: To prevent damage to electrical system of HPU, welding on assembly is
not recommended.
 HPU should be inspected daily to insure proper operation. Regular maintenance
interval should be determined by operating conditions/environment.
3
Contents
I. Overview 5
II. Major Technical Parameters 6
III. Working Principles 8
IV. Equipment Installation 14
V. Operation 16
VI. Maintenance 24
VII. Normal Wear Parts List 28
VIII. Hose Summary 29
IX. Spare Electrical Parts List 31
X. List of Supplied Tools 32
XI. Appendix I. Hydraulic Schedule 26
XII. Appendix II. Electrical Schematic 26
Information on HPU accessories:
1. Diesel Engine Use Manual
2. Variable Piston Pump Brochure
3. Oil Filter Brochure
4. Manual Directional Valve Brochure
5. Overflow Valve Brochure
6. Explosion-proof Motor Brochure
7. Explosion-proof Electric Heater Brochure
8. Electrical Apparatus Brochure
4
I Overview
YZ3600-17 HPU is designed for LM770 series drilling rigs. It provides hydraulic power by
offering required pressure and flow rate for rig operating conditions
For normal operation, and to keep the equipment in good operating condition, the user is
required to understand and familiarize himself with the principles, structure, and functions of
the HPU, as well as implementation of routine maintenance.
5
II Major technical parameters

Rated pressure: 17MPa (2465PSI)
Flow Rate: 230L/min (60 GPM)
Volume of Hydraulic Oil Resevior: 3600L / (950Gallon)

Diesel Engine:
Model: CAT3056E-DITAAC
Rated Power: 103 KW / (138HP)
Speed (rev/min): 2500
Fuel Consumption: 218 g/KWh
Diesel Tank Volume: 80 L / (21Gallon)
Battery: 12V/165Ah
AC motor
Model: WWE100-18-405TC
Power: 75 KW / (100HP)
Speed (rev/min): 1785
Voltage: 460V AC
Frequency: 60Hz
Hydraulic Variable Displacement Pump:
Model: HPF135-02 R2611
Rated Pressure: 17.5Mpa (2538PSI)
Rated Displacement: 135 ml/r
Heater
Power: 3kW / (4HP)
Voltage: 460AV
Frequency: 60Hz
6
Hydraulic Oil
Environmental temperature ＞-25 deg C Anti-wear hydraulic oil: N46
Or (Mobil DTE 25)
Environmental temperature ＜-25 deg C Low-freeze anti-wear hydraulic
oil N46D, Or (Mobil DTE 15)
Working oil temperature: 35~65 deg C
Total dimensions (length × width × height) mm: 5100×2200 ×1920
Weight:
Net Weight: 6700kg
Operating Weight: 10000kg
Figure 1-Appearance
7
III Working Principles

YZ3600-17 HPU is comprised with two axial variable displacement piston pumps driven by
one each diesel engine and one each AC electric motor.
The diesel engine pump is used mainly during installation and dismantling of drilling
rigs when electric power is not available at the well site. The diesel engine can also be used
as standby hydraulic power supply for emergencies in case of accidental failure of the
electric motor driven pump system.
The electric motor pump is used mainly during drilling operation when electrical supply
is available.
1. Diesel engine
CAT3056E engine, integrated with control console, battery, and diesel tank:
Engine Speed:
 Idling Speed: 800rpm
 Working Speed: 1600~2000rpm
Caution; Battery power switch is located under the electric motor. When the diesel
engine pump unit is not running, disconnect this power switch to prevent battery discharge.
2. AC motor:
Explosion-proof three-phase asynchronous motor.
Working Speed: 1785rpm
Rotating direction: Clockwise
(viewed from the cooling fan)
8
3. Hydraulic Oil Pumps
Two axial variable displacement piston pumps are driven respectively by diesel engine
and electric motor.
Two control types:
 Load-sensing control is used for the raising of the mast and substructure. The pump load
port LS is connected to the LS port of the proportional multi-section valve bank. The
load pressure controls the pump displacement. During idle operation of the hydraulic
system, LS signal feedback pressure adjusts the swash plate of variable pump to the
minimum tilt angle allowing the pump to maintain required pressure during this
operating mode using the by-pass valve.
 Pressure compensation control is adopted for operating the BOP equipment. The pump
load port LS is connected to P port of pump pressure output. Pressure compensation
control operates in the same manner as load sensing control by using the by-pass valve to
maintain constant pressure.
4. Valve Bank
The valve bank is integrated with overflow valve, manual directional valve,
high-pressure check valve, pressure sensor, and LS check valve. The valve bank is
equipped with a port to allow connection of a pressure gauge to measure pump system
pressure.
Manual operated change-over directional valve selection between A or B oil ports:
 Port A: Load-sensing variable displacement control. LS signal port must connect to
the raising valve bank LS port for mast and substructure raising.
 Port B: Pressure compensation variable displacement control. LS signal port must
be disconnected for BOP operations.
9
Mast and Substructure Raising Rig Equipment Operation

Loop Load-Sensing Pressure Compensation
Manual Directional Valve A B
Port A √ ×
Port B × √
Port LS √ ×
Note:
√: Indicate connection.
×: Indicate disconnection.
Oil Ports:
Pressure Oil Port A: NPT1.1/4”
Pressure Oil Port B: NPT1.1/4”
Return Oil Port T: NPT1.1/2”
Drainage Port X: NPT3/4”
Feedback Signal Port LS: NPT1/4”
Test Port M: NPT1/4” (sealed with plug under normal operations)
5. Hydraulic Oil Reservoir

The hydraulic oil reservoir is equipped with a level gauge, temperature sensor, oil drain
ball valve, level monitor, air filter, return oil filter, pressure gauges, suction filters, and heater.
 Level Gauge: Installed on the chiller side of the oil reservoir. Composed of upper
and lower sections to display the oil level in the oil tank. The upper level defines
oil level with mast and substructure at down position, the lower defines the oil level
for the mast and substructure in the raised position.
 Temperature Sensor: Installed on the chiller side of the oil reservoir. Measures the
hydraulic oil temperature in the reservior. The sensor sends the signal to the
temperature controller which is located inside the electrical component enclosure.
Temperature sensor activates heater when oil temperature is below 5deg C. The
10
chiller motor is activated when oil temperature is higher than 50deg C. If oil
temperature exceeds 70deg C the temperature sensor will shut down the
motor/engine. The temperature sensor activates the high temperature alarm and
send signal to remote controller. . The minimum/maximum temperature levels are
adjustable depending on owner’s requirements and oil used.
 Level Sensor: Installed on the top cover of the oil reservoir. The level sensor
provides two level detections; one for motor/engine shut-down and one for warning
alarm. When hydraulic oil level reaches the warning level, the level sensor sends a
warning signal which prompts low oil level. When the oil reaches the shutdown
level, the pump motor/engine power is cut off automatically for emergency stop.
Warning level: 900 mm (from top cover of oil reservoir to oil surface)
Shutdown level: 1000 mm (from top cover of oil reservoir to oil surface)
 Air Filter: Installed on the top cover of the oil reservoir. The air filter maintains
the passage of environmental air into the oil reservoir and is equipped with a screen
to guarantee the cleanliness of the air. When removed, the air filter is also the fill
point for the oil reservoir.
 Oil Return Filter: Installed on the top cover of the oil reservoir. The oil return
filter head extends out of the oil reservoir and return pipe into the reservoir. A
check valve provides convenience for cleaning and filter core replacement. Oil
by-pass valves and filter core pollution indicators are provided to enhance the
reliability of the hydraulic system.
 Pressure Gauges: There are two pressure gauges installed on the top cover of the oil
reservoir to display the pressure output of the diesel engine and electric motor
pumps respectively.
 Suction Filters: Installed on the engine side of the oil reservoir. The suction filter
head extends out of the oil reservoir and the suction pipe into the reservoir and is
equipped with check valves to provide convenience for cleaning and filter
replacement. The suction filters may be removed during repair of the hydraulic
11
system to prevent hydraulic oil from draining out of the reservoir oil by-pass valves
and filter core pollution indicators to enhance the reliability of the hydraulic system.
 Heater: Installed on the engine side of the oil reservoir. Mounted with tubular
structure and is used during cold weather operation.
 Oil Drain Ball Valve: Installed on the lower area of the rear side panel of the oil
reservoir and is used to drain fluid from the oil reservoir.
 Cleaning Cover: One cleaning cover is installed respectively on each side of the oil
reservoir and may be opened for cleaning of the tank interior during maintenance
intervals. Internal reservoir cleaning should be done at least every 6 months to
insure the reliability of the system.
Figure 2-Hydraulic Oil Tank
6. Chiller:
The chiller consists of a high performance radiator, low noise tube axial fan and
explosion-proof motor installed on the return side of the system. The fan motor starts
automatically when the oil temperature reaches 50deg C. The chiller is equipped with a
bypass circuit with pressure valve. If system pressure exceeds 0.15MPa (21PSI), the
12
pressure valve will open the bypass circuit. The bypass valve connects the choke valve in
series, adjusting the return’s flow.
7. Electrical System
Power requirements:
Voltage: 460V AC
Current: 130A
Frequency: 60HZ
Control power: 120V
The electrical system provides HPU electric motor power supply, as well as motor
overload protection; level signal and temperature signal process; chiller and heater on/off
control. The power disconnect handle, motor on/off push buttons, local/remote control
select switch, E-stop push button, and alarm indicators are located at the enclosure front
panel.
8. Automation Control
1) Level Control
 Controls the upper and lower levels of the system
2) Oil Temperature Control
 Starts the heater automatically when oil temperature is lower than 5deg C.
 Start the chiller automatically when the oil temperature is higher than 50deg C.
 When oil temperature reaches 70°C, the system activates high temperature
alarm (indicator), sends electric signal to remote control console and shuts down the
system
3) Overload Protection
 Helps to prevent damage to system pumps. Alarm must be cleared before
system can be reset in failure mode.
13
IV Equipment Installation
1. Installation
 HPU shall be installed horizontally on a level surface
2. Hydraulic Oil Reservoir Filling
 Thoroughly clean the hydraulic oil reservoir, air filter, suction filters, pipe filters
and return filter elements. Replace any damaged or polluted filter cores when
necessary. Confirm all the parts are in conformance with the design
specifications.
 Verify the hydraulic oil meets recommended standards..
 Use an approved transfer pump with a filter system to install oil into the oil
reservoir. The initial oil level shall be measured at the middle of upper level
gauge when raising cylinders are not extended.
 Fill the oil into the piston pump from the drain port. If possible, rotate the pump
motor until the oil is filled full. To prevent cavitation of the pumps fill/prime each
pump at noted ports to insure the pumps are not trapping air in the system.
3. Diesel Fuel Tank Filling
 Inspect tank before each filling
 Use only approved filling methods
 Caution: Do not fill tank more than ¾ full due to heat expansion.
4. Engine Oils
 Check engine oil level daily. Change oil per OEM recommended practices
5. Engine Coolant
 Check engine coolant level per scheduled maintenance intervals
6. Engine Inspection
 Visually inspect HPU daily on regular intervals
7. Connect to AC power as per below requirements
 Voltage: 460V AC
14
 Current: 130A
 Frequency: 60Hz
8. Connect Hydraulic Pipelines
The connectors must be cleaned thoroughly of dirt and/or any contaminants.
 A: Pressure oil port for mast raising valve station.
 B: Pressure oil port connects the BOP/ well equipment hydraulic line.
 X: Drain port connects hydraulic system return line.
 T: Return oil port from return oil manifold.
 LS: Load-sensing control oil port. When system is working on load sensing
condition (Mast Raising),
 Caution: LS port must be connected for load sensing operation
9. Pressure Adjustment
 Pressure of variable displacement pump: 17 MPa
 Pressure of the By-pass valve on valve bank: 17.5 MPa
Caution
System pressure is preset from factory. OEM must be notified before additional
adjustments/corrections are implemented.
15
V Operation
1. Safety operation:
 Precautions must be taken to protect individuals doing inspections or maintenance
on HPU Unit.
 Follow lock out tag out procedures before maintenance on HPU system (disconnect
power sources).
 Do not operate the equipment if you are not familiar with the HPU system.
 Before operation begins, confirm that all hydraulic components and accessories are
fit for service. The filters must be intact and the pollution indicator shall work
normally. Preform daily visual inspection of unit report/correct any abnormalities.
 Check oil level before starting diesel engine.
 Check engine cooling fluid, engine lube level, and fuel level before starting diesel
engine.
 Make sure electric cable connections are dry and equipment is well grounded.
Inspect electrical connection for corrosion or moisture before starting unit.
 System should be considered flammable and all proper precautions must be taken to
protect unit and environment.
 Caution: HPU system is not designed for movement during operation. Unit must
be shut down before system is moved or relocated.
2. Start and Shut-down of Diesel Engine:

a. Check and confirm below conditions before starting the diesel engine
 Before starting engine confirm all system checks have been completed.
b. Operation of valve bank for normal operating conditions:
 Manual valve handle positions shall be at “A” position.
 Output pressure hose shall be connected to “A” port.
16
 LS signal hose shall be connected to “LS” port.
Figure 3- Operation of Valve Bank

c. Caution: Battery power switch must be in remote operation to start engine, the
engine control panel will be illuminated.
Figure 4-Battery Power Switch-Closed
17
Figure 5-Engine Control Panel

e. Engine Startup
 From Engine Control Panel turn the power key switch clockwise from Stop position
(12 O’clock) to “Run” position (1.5 O’clock), the indicators at either side of the
display screen will flash once.
 Continue to turn the key switch clockwise to “Start” position (3 O’clock) and hold
until the engine starts. Caution: Do not engage switch for more than 30 seconds. If
engine does not start, reset key switch to “Off” position. Inspect system for faults
before trying to restart engine.
 Run engine at idle speed (800r/min) for 3~5min.
Check Engine:
 Engine Oil Pressure
 Water Temperature
 Engine Speed
Adjust Engine Speed: Confirm engine and pump system are operating normally.
Adjust engine speed to 1800r/min. using the toggle switch located on control panel
Check/Inspect for:
 Pressure gauge A of valve bank: P=3MPa ( gauge installed at this port)
18
 No leakage
 No abnormal noise
 Over heating
 No abnormal vibration
 The core pollution indicators, needles or indicators of the filters are in the green
area.
Caution: If any abnormalities are noted the problem must be addressed immediately.
f. Engine stop
 Using the toggle switch on the engine control panel, lower engine speed to idle at
800r/min for 2~3min.
 Turn the key switch counter-clockwise to stop the engine.
 Turn battery power switch counter-clockwise 90 degrees to disconnect DC power.
Figure 6-Battery Power Switch-Disconnected
3. BOP/ Rig System Supply Valve Bank Operation
19
a. Operation of Valve Bank

 Place the manual directional valve handle to “B” position.
 Connect pressure line to “B” port.
 Disconnect LS signal line from “LS” port.
Figure 7-Run Motor Pump -Operation of Valve bank

c. Local Control (Electrical)
 Confirm electrical power source. Close the general power switch on HPU electric
control panel. Turn the handle clockwise to “On” position.
 Confirm that the emergency switch is released (the button is pulled out).
 Confirm the “Select” switch is at the local position.
To start the electric motor, press the green startup button. The run indicator will illuminate
confirming the HPU is running in electric motor mode.
20
d. Remote Control Operations
 Confirm electrical power source. Close the general power switch on HPU
electrical control panel.
 Confirm that the emergency switch is released (the button is pulled out).
 Confirm the “Select” switch is at “Remote” position.
 HPU is now in remote control mode.
Figure 8-Electrical Control Panel – power connected

e. Indicators
 Red: High oil temperature alarm light indicating that HPU hydraulic oil
temperature is above 70deg C. HPU electric motor is shut down.
 Red: Low oil level alarm light indicating the hydraulic oil is below the required
level. HPU will shut down when the level of hydraulic oil continues to decline
for 100mm.
21
 Red: Overload alarm light indicating overload of main motor. HPU is shut down.
 Green: Running light indicating HPU is running in motor mode.
Electric Motor Drive Mode Shut Down
 Press the red stop button. The motor will stop and the run indicator will not be
illuminated. HPU will also stop.
 Disconnect the general power switch at the HPU electric control panel by turning
the handle counter-clockwise to vertical position.
Figure 9-Electric Control Panel-power disconnected
Note:
In case of leakage, abnormal noise, abnormal heating or abnormal vibration of the
hydraulic system, shut down the motor promptly for troubleshooting and repair.
Caution: Do not run electric power HPU with the electrical enclosure door open.
22
4. Visual Inspection
Follow the visual inspection requirements when running diesel engine and or electric
driven system. Early detection of problems, and implementation of good preventive
maintenance, will decrease the possibility of severe equipment damage and down time.
Visual Inspection Items
 Pressure gauge B: P=17MPa
 Temperature of oil in the hydraulic tank: 35~65deg C.
 No abnormal vibration, leakage, noise, or heating.
 The core pollution indicators, needles or indicating plugs of the oil filters are in
the green area.
23
Maintenance
For normal operation and to keep the equipment in good condition, the user is required to
understand and familiarize himself with the principles, structure, and functions of the HPU,
as well as implementation of good maintenance. Daily walk around inspections and
preventive maintenance are good practices for keeping the HPU in operating condition.
Eighty percent of hydraulic system failures are caused by contaminated hydraulic oil. Please
keep hydraulic oil clean during the installation, use and maintenance of the HPU.
1. Visual/Daily/Weekly/Monthly Inspections
.
 Remove and inspect air filters monthly. Wash or replace polluted filter cores when
required.
 Remove and inspect suction filters monthly. Wash or replace polluted filter cores
when required.
 Remove and inspect return oil filters monthly. Wash or replace polluted filter cores
when required.
 Remove and inspect pipe filters monthly. Wash or replace polluted filter cores when
required.
 Inspect high-pressure hoses monthly. Replace the hoses when damaged or badly
worn.
 Inspect and calibrate pressure gauges once every three months. Replace when
required.
24
c. Hydraulic Oil Inspection and Testing

 Perform oil sample testing once for every 600 operating hours. Sampling “hot oil”
during operation from the hydraulic system is recommended.
 Test Parameters:
Items Unit Limits
Viscosity Percentage of viscosity ±10
changes at 40deg C
Mechanical mg/100mL 10
Impurities
Moisture % 0.1
Total Acid mgKOH/g 0.3
Number
d. Hydraulic Oil Purification or Replacement

Hydraulic oil plays the important role of power transfer, lubrication, cooling, and
flushing the hydraulic system. The bench mark for oil replacement, depending on
conditions and operating conditions is 2000 operating hours.
e. Filter
Replace the filter core after each trial run of a new system. First filter core replacement
shall not exceed 100 working hours.
f. Regular Cleaning
 Clean the external of the HPU daily.
 Friction crumbs, pitch, and oil slag, etc. may not be able to be removed thoroughly from the
hydraulic system. Impurities accumulated in the oil passages of hydraulic components will
block the oil route and choke filter cores, and disable the components. The hydraulic
components shall be cleaned once a production year. Routine inspection and cleaning of the
oil system is required for continued operation to prevent failure. Oil system should be
25
flushed at each oil change to insure all contaminates are removed. This includes flushing
any residue from the tank.
.
g. Regular Maintenance
 Refer to the maintenance manual provided by the supplier for regular maintenance
of diesel engines.
of electric motors.
of variable displacement pumps/valves.
.
26
Analysis of Hydraulic System Failures

Phenomena Reasons Remedy
1. Cavitation/air in system. (a)Check connections and seals
2．Un-concentricity between (b) Check oil levels
(c) Check return line for obstructions

pump axle and motor axle.
(d) Lower engine rpm
Abnormal noise
(e) Adjust flow at pump ( Caution: This is preset form

3．Excessive pump speed
factory only return to factory settings)
4．Excessive pump pressure (f) Check coupling alignment
5．Air leakage at shaft seal
6．Improper adjustment of the
stop screw of variable pump
1．Excessive oil temperature (a) Improve the heat dissipation of the oil tank and/or
shield it from the sun.

2．Excessive high oil viscosity
Excessive heating
(b) Use the hydraulic oil with recommended viscosity

3．Excessive high working (c) Lower the pressure to the rated pressure
pressure (d) Adjust the pressures of overflow valves
4．Improper adjustment of
overflow valves in the system
27
1. Un-concentricity between Reinstall to meet the accuracy required per the manual
pump axle and motor axle Tighten up the screws
2. Screw loosening Adjust to the rated range
3. Excessive high speed or

Excessive vibration
pressure
4. Cavitation (a)Check connections and seals
(b) Check oil levels
(c) check return line for obstructions
(d) lower Rpm’s on engine
(e) adjust flows are pump, ( Caution this is preset form
factory only return to factory settings
1. Damage seals Replace the seals
2. Loosening of connection Tighten connections
at inlet and outlet ports

Leakage
3. Sealing surface damaged Repair/replace the seals
4. Piping cracks Replace the piping
5. Excessive low viscosity of Replace the hydraulic oil
hydraulic oil
VII. Normal Wear Parts List
No. Specifications Names Quantity Note

1 TFX-800X80 Suction filter cores 2
2 FBX-630X20 Return oil filter cores 1
3 LH0330DXBN3HC Pipe filter cores 2
4 YN-100III (M20X1.5) Pressure gauges (40Mpa) 2
5 Engine oil filters 1 CAT attached
28
VIII. Hose Summary
No.
Specifications Names Note
Quantity
1 φ32-01 φ32 hydraulic hose 1 Pump~Filter
Working pressure: 17MPa\length：1450 Pressure
A end: 11/4“, 90 bent flange
B end: JIC, 1.5/8×12 straight joint
2 φ32-02 φ32 hydraulic hose 1 Pump~Filter
End A: 11/4“, 90 bent flange
B end: JIC, 1.5/8×12 straight joint
3 φ32-03 φ32 hydraulic hose 1 Filter~Valve Bank
Ends A, B: JIC, 1.5/8×12 straight joint
4 φ32-04 φ32 hydraulic hose 1 Filter~Valve Bank
5 φ20-01 φ20 hydraulic hose 1 Pump
Working pressure: 8MPa\length：1100 Oil drain hose
Ends A, B:JIC, 1.1/16×12 straight joint
7 φ20-03 φ20 hydraulic hose 1 Valve bank~oil tank
Ends A, B:JIC, 1.1/16×12 straight joint
Working pressure: 17MPa\length：1150 LS oil hose
Ends A, B: JIC, 9/16×18 straight joint
10 φ8-03 φ8 hydraulic hose 1 Valve bank
11 φ32-05 φ32 Hydraulic hose 4 Valve bank
Work pressure : 8MPa\Length: 2000 Oil tank
Ends A, B: JIC, 1.5/8×12 straight
connector
12 φ32-06 φ32 Hydraulic hose 4 Valve bank
Work pressure : 8MPa\Length: 1000 Cooler
29
connector
13 φ3-07 φ32 Hydraulic hose 4 Cooler
Work pressure : 8MPa\Length: 1000
connector
14 φ3-08 φ32 Hydraulic hose 4 Cooler
Work pressure : 8MPa\Length: 1150 Oil tank
connector
15 Testing high pressure hose assembly 8
Length: 1800
Pressure gauge connector: Pressure gauge
connector: M20X1.5
Connector: M14X1.5, combination
washer sealing ring
IX. Spare Electric Parts List

NAME TYPE BRAND QUANTITY
FUSE LPCC 1 BUSSMANN 2
FUSE FNM 3 BUSSMANN 2
RELAY SR3B-05 IDEC 1
pilot light 9001 KP1G9 SQUARE D 1
pilot light 9001 KP1R9 SQUARE D 1
fuse 1A (used with RT28 base) CHNT 2
30
X. List of tools attached

No. Specifications Names Quantity Note
1 Engine key 2
2 Key to the inlet cover of 2
diesel tank
3 Spanner (11 pieces) 1 Metric system
4 Inner hexagon spanner (9 1 Metric system
pieces)
5 8“ adjustable spanner 1
6 10“ adjustable spanner 1
7 4“ flat-blade screwdriver 1
8 6“ flat-blade screwdriver 1
9 8“flat-blade screwdriver 1
31
Appendix I (Hydraulic Schematic)
32
Appendix II (Electrical Schematic)
33
LM770 Saipem Rig 5964 LM770 Rig Remote Control System
LM 770 Rig Remote Control System
User Manual
Page 1 of 10
Note：
Pay attention to the following notices and operation

explanations.
Only fully trained and qualified personnel are allowed to
perform the following operations using correct procedures, or
damage is possible to happen.
All state policies should be obeyed during maintenance.
Power supply (both positive and negative) should be removed
from system if/when welding jobs are being completed.
I. Technical Parameters:
Page 2 of 10
1. Power supply: 12V DC

2. Protection class: IP65
3. Industry remote control
4. One channel of pressure signal input
5. One channel of on/off valve control output
6. Six pairs of channels of proportional valve control output
II. Working Environment

1. Environment temperature lower than +40 degree centigrade higher than -10 degree
centigrade.
2. Humidity less than 85 % (under 20±5 degree centigrade)
3. Altitude lower than 2000m
4. No strong vibration or shaking
5. No flammable or explosive materials exists, no gas which damages insulation, no
conductive atomy
6. No strong high-frequency interference
Page 3 of 10
III. Electric components descriptions
1. Heavy-duty connector （XP）

：
Power Supply Pin Definition:

1
PIN 1：GND
PIN 2：+12VDC 3 2
PIN 3：0VDC
PIN 4：Not used 4

2. Main power supply switch SA: Power-off at
position 0, power-on at position 1.
3. Power indicating lamp HL1: Will be lit when power is supplied.
4. Emergency stop button SE: In case of an emergency situation, this button should be
pressed, this results in instant power “OFF” for all outputs.
5. Alarm Lamp HL2：Flashing indicates DC electric malfunction(s). Being lit without
flashing means no electric malfunction. Please find detail in malfunction table below.
6. Buzzer HA：Generates warning before operation by the operator, or warns of a potential
safety malfunction during operation.

7. Branch breaker QF1: Beaker for remote control
QF2: breaker for PLVC1 circuit
QF3: breaker for PLVC2 circuit
a. Controller PLVC1, PLVC2: System controller responsible of input/output signals,
logic calculation and communication with remote control receiver via CANBUS
b. Programming port DSUB：Used for downloading PLVC program for online
monitoring and debugging
c. Wireless Remote control receiver RADIO：Receives control signal from remote
Page 4 of 10
control transmitter and forwards signal to PLVC via CANBUS

Note: Receiver and transmitter must be coupled, which means that TRANSMITTER
2# works only for RECEIVER 2#
d. Terminals (XT)：System I / O interface
IV. Power-on Steps

a. Shut down the battery power supply.
b. Make sure that all of the breakers and switches are in the OFF position. Emergency stop
button (SE) must be pushed down and wireless transmitter is switched to power-off (the
emergency button on transmitter is pushed down).
c. Connect the heavy-duty plug connector to the socket connector (XP).
d. Switch on battery power supply.
e. Switch SA to position 1. The indicating lamp HL1 should be lit.
f. Switch on the breaker QF1、QF2、QF. The red LED by the terminal X1 of PLVC1 is lit
which means PLVC is powered and ready. One orange LED and one red LED on
receiver RADIO are lit which indicates that the receiver is ready. Buzzer HA is audible
which means that system is in Emergency Stop mode.
g. Switch on Emergency button on panel, the buzzer HA alarm should be silent (transmitter
will function).
h. Make sure that the two selection switches on remote control transmitter are in the OFF
position. Switch on the Emergency-stop button which is on the right side of the panel.
Press the START button which is at the right side and hold until the green signal LED at
right-bottom is lit and flashing. Remote control operation service is now available.
Buzzer HA should be silent.
V. Use of Remote Control Transmitter

1. The left joystick on receiver panel controls cylinders on left side (DS) while the
Page 5 of 10
right joystick controls cylinder on the side (ODS). Under synchronization mode
(Optional), left joystick is blocked.
2. The right selection switch is for cylinder driving selection
a. Mast is for Master cylinders
b. Inter is for intermediate cylinder
c. Snub is for snubbing cylinder
d. Off is no cylinder to drive, as the stand-by position
3. The left selection switch is to choose synchronization mode
a. Sync On is to select the electric logic synchronization mode, this is for raising/
Lowering the basement (Optional Function)
b. Sync Off is to select the hydraulic synchronization mode, it is for all the
synchronization jobs except the basement’s (Optional)
c. Off is the option for asynchronous mode (Standard Function)
4. The red Emergency-stop button on the right is to block all output in case of
emergency situations; also it is used to shut down the transmitter.
5. The START button on the right side is to start the transmitter to establish
communication with the receiver；keep pressing until the signal LED is flashing
green.
6. The HORN button on right side is to send warning which is generated by the
operator, pressing causes prompt and unconditional warning from the buzzer. This
will warn people nearby that the operation has begun and to keep alert.
7. The led on the right-bottom corner is to show status of communication; Flashing
green indicates good communication and work can be going on, or, it is not ready to
work Use of multi-position selection switch
Page 6 of 10
switch Right selection switch(to choose Left selection switch(to

cylinder) choose async/sync-mode)
function Mast Inter Snub off Sync On Sync Off
Off
Basement ● ●
async-mode
Basement ● X
sync-mode
derrick ● ●
async-mode
derrick ● X
sync-mode
Inter ● ●
async-mode
Inter ● X
sync-mode
Snub ● ●
async-mode
nub ● X
sync-mode
No action ● ●
Note: X is optional function.
VI． Power-off Steps
a. Press the red emergency button to disable the transmitter. Buzzer HA will sound audible
warning indicating that there is no connection with transmitter.
b. Press Emergency-stop button SE.
c. Switch off the breaks: QF1、QF2、QF3, indication LEDs on PLVC and remote control
receiver will turn-off.

d. Turn main switch to position 0. HL1 LED will turn off.
Page 7 of 10
e. Shut down power supply from battery.

f. Pull out heavy-duty connector plug XP from plug socket.
VII．Dealing with Malfunctions
a. Power indicating lamp HL1 is always off: Confirm power supply is available, confirm
heavy-duty connector is well connected.
b. Alarm Lamp HL2 is flashing：Indicates a malfunction within DC system. Check DC
system such as connections of valve and sensor, communication between remote control
receiver and PLVC controller (table below is for reference).
c. Buzzer HA is audible: General warning including DC system malfunction,

communication failure, excessive pressure, or Emergency Stop. All these things which
are possibly dangerous are activated by the operator.
d. Breaker protected: Check all component wiring.
e. Electric malfunction from remote control: Read manual of remote control HBC for
reference.
Page 8 of 10
Appendix, DC malfunction list

Malfunction Alarming Buzzer HA Leds PLVC Dealing with tasks
\Warning from Lamp HL2 by cylinders, and
how to get rid of the
malfunction
Proportional Lit when Warn when Open, left led flashes Under async mode
valve there’s current there’s by 0,5s cycle time, good valve can
Open or output(there’s synchronization less time for on than work, but synchro
Shortcut of action being action being off actions will be
power is not done, no action done, and action Shortcut, left led flash canceled;
enough no detection) is canceled by 0,5s cycle time, Check wiring of
more time for off than solenoid
on
Inclinometer Lit when wire Warning when Left led flashes by 1s Synchro actions by
broken wire broken Synchro cycle, more time for on master cylinder lost
movement of then off the closed-loop
basement going adjusting capability,
on, means poor but could do
signal from synchronization with
inclinometer exactly same current
sensor; but no output under
warning for open-loop mode, no
synchro affect on the others;
movements Check wiring on
except basement, sensor
because sensor is
not used
Pressure sensor Be lit when Left led flashes by 1s No effect on action;
broken wire wire broken cycle time, more time check the wiring of
for on then off sensor
Too high Warn when
pressure pressure higher
than
limit(limited by
170 Bar)
CANBUS Be lit when Actions canceled;
communication communication Check the wiring of
interrupt interrupted, no communication
any action cables
Page 9 of 10
Emergency stop Warn when Left led turns off No action;

Emergency-stop Check Emergency
buttons on stop button, and turn
transmitter or it on
cabinet pressed
(When
transmitter shut
off, the button is
also pressed)
Warn by Pressing HORN No effect on actions
operator button
PLVC does not Two leds both turn off No work can be done,
work no warning either;
Check power supply
for PLVC(such as if
the breaker
protected or
switched on, etc.）
Receiver does Leds turn off on No work can be done;
not work receiver Check power supply
for PLVC(such as if
the breaker protected
or switched on, etc.）
Page 10 of 10
LM 770/Saipem 5964 Driller’s Control Manual
LM770 Rig
(00372-Saipem)
Drilling Controls
Operation Manual
00372-OMN-0004_0 LM 770 Driller’s Control Manual Page 1 of 48

Table of Contents
1. Introduction
2. Emergency Stop Controls
2.1 Rig E-Stop (Master E-Stop)
2.2 Engine E-Stop
2.3 VFD Drive E-Stop
2.4 Drawworks E-Stop
2.5 Top Drive E-Stop
3. HMI (Human Machine Interface or “Touch Screen”)
3.1 Description
3.2 Driller’s Cabin HMI
3.3 VFD House HMI
3.4 Alarms
3.4.1 Alarms List
3.4.2 Messages
3.4.3 Status & Icon color
3.4 Independent equipment
4. Drawworks and Disk Brake
4.1 Description
4.2 Operation of the Drawworks
4.3 Drawworks Joystick
4.4 Speed range Selection
4.5 Drawworks Alarms
4.6 Auto Drill
4.6.1 Description
4.6.2 Operation of Autodrill
4.7 Block Travel Control and Protections
5. Mud Pump Control
5.1 Description
5.2 Mud Pump Operation
6. Rotary Table Control
7. Cathead Control
8. Rotary Mouse Control
9. Top Drive Control
10. BOP control
11. Iron Roughneck
Appendix A: Power System and Control
Appendix B: Driller’s Chair Armrest Consoles
Appendix C: CCTV
Appendix D: Gai-tronics
Appendix E: Cable Connection between Top and Bottom Mast Sections

1. Introduction
The control system for LM770-AC Drilling Rig is an advanced system able to
meet and exceed the challenging needs of the oilfield industry and our customer.
The Drill crew has full control of the drilling related machinery. The drilling and
the various processes are monitored by on-screen instrumentation, and aided by
integrated live feed from CCTV-cameras (installed in key areas of the rig), also a gas
detection system monitoring the levels of LEL and H2S at well and shakers are provided.
The rig is powered by 4 engine/generator systems; each comes with an 1101KW engine
and an1500 KVA/600VAC/60Hz generator. The maximum output of each
engine/generator set is 950KW.
The VFD (Variable Frequency Drive) system is designed to provide power and control to
the following loads:
- One Drawworks, 1500HP, driven by two 1230HP AC motor.
- Three mud pumps, each driven by one 1500 HP AC motor.
- One Rotary Table, driven by one 1230HP AC motor.
- One Top Drive, driven by one 1000HP AC motor (which shares the same inverter for
the Rotary Table)
All the mud system pumps are powered by 460VAC tapped from the main 600VAC bus.
Basically, there are three levels of controls for this system:

1. Operation stations: There are two identical HMI (Human Machine Interface) stations at
driller’s cabin and one HMI at VFD house for controlling and monitoring functions.
2. PLC stations and I/O equipment’s: For interfacing and task automation
3. Machinery and instrumentation
This manual describes the operation and control systems for Mud Pumps, Drawworks,
Rotary Table, built-in iron roughneck, rotary mouse hole, Cathead, HPU, and other rig
equipments. Mainly focus on the control from driller’s cabin HMI.

2. Emergency Stop Controls
There are 5 types of Emergency Stop Buttons on Driller chair.
2.1 Rig E-Stop (Master E-Stop)
There are 3 Rig E-Stop buttons. 1).A pull/push rig E-Stop button located on the front left
corner of the driller’s chair left armrest. Pull to reset and push to activate the E-stop
condition. 2). A pull/push rig E-Stop button located on the VFD house HMI cabinet door,
pull to reset and push to activate the E-stop condition. 3).A optional (customer provide)
Rig E-Stop button will be located on the rig manager office, pull to reset and push to
activate the E-stop condition.
When any of them are activated, all the prime running generators will be shut down. The
rig electrical power will be cut off. Both drawworks service and safety disc brakes will
automatically engage in order to hold the load on the drill string.
2.2. Engine E-Stops

At each engine Electronic Control Module and each VFD house generator control cabinet
there is a pull/push Engine E-Stop button, pull to reset and push to activate the E-stop
condition. Pressing any one of them will shut down the related running engine
correspondingly.
2.3 VFD Drive E-Stop

VFD Drive E-Stop push button is located on the driller’s chair left armrest, pull to reset
and push to activate.
When activated, all VFD drive power shuts off. Both drawworks service and safety disc
brakes will automatically engage in order to hold the load on the drill string.
2.4 Drawworks E-Stop

The drawworks pull/push E-Stop button is located on the front left corner of the left
armrest of the driller’s chair, pull to reset and push to activate the E-stop condition.
When activated, this immediately stop the Drawworks VFD system, and engages the
drawworks service and safety disc brakes to hold the load on the drill string.
2.5 Top Drive E-Stop

Top Drive pull/push E-Stop button is located at middle of driller’s chair right armrest,
pull to reset and push to activate E-Stop condition.
When E-Stop activated, the top Drive control system is powered down (Note: Top Drive
controls are provided by Canrig. See Top Drive Manuals and drawings for details).

3. HMI (Human Machine Interface or “Touch Screen”)
3.1 Description
Most of the control operations are by means of the HMI (Human Machine Interface or
“touch screen”). There are 2 HMIs (Siemens MP377, 12”) located on the front left and
front right of the driller’s chair. Both are swing arm mounted and location adjustable. The
HMI touch screens are identical. Another HMI (Siemens MP370, 12”) is located inside
the VFD house on the PLC cabinet. This HMI it mainly work as rig system monitor with
less control functions. For more detail about the HMI please refer to the Siemens MP
serial manual for more information.
Bellow will focus on the description of the driller’s cabin HMI operation.
3.2 Driller’s Cabin HMI
On the bottom left corner of each screen there is a Menu button. Pressing the button will
pop up a menu list on the left side of the screens to allow the operator to select the screen
he wants to access. To access a given screen, simply touch the associated button. Touch
the Menu button will cancel the pop up list. The menu list on One Line screen is a little
different than the other screens.
One Line Screen Access Menu Other Screen Menu

The actual pop up menu list may little differ as it does not includes the icon for the
current displayed screen. For same sub screens like Calibration and Load Control they
just have easy menu and exit icon to go to One Line screen only.
The Load Control and Calibration screens are password protected, only authorized person
can access.
Clean screen is for clean the screen only, without any monitor and control functions.
See below for all HMI touch screens functions:
All icon status is shown by color

Fault or Off: Red
Ready and not started: Yellow
Running: Green
All messages are pop up type with 3 different colors

Alarm message: Red
Warning message: Yellow (or blink icon)
Prompt message: Grey
HMI user name: Saipem

Password: 00372

This One Line screen displays the power system diagram, shows the status of the
engine/generator, DSU, Inverter, VFD Motor, BU, AC & DC buses and main circuit
breakers.
This Logical Control (one line) screen shows the MP, DW, RT and TD running status, as
well as their auxiliary equipment status. With this diagram each VFD motor running
status can be easily diagnosed.

This MCC screen shows status of all rig motors (pumps), including the remote start &
stop for HPU, disk brake pumps and trip tank pumps.

Drill/DW touch screen, it provides drilling control functions and status. With this screen
the driller can select DW motor(s), speed range, start/stop DW. Also provide an access to
control the block travel.
At the left banner shows 6 VFD statuses;
At right banner shows each system pressures;
At the middle of second banner line shows the drawworks parking status;
At the middle left area are drawworks control functions, includes
Drawworks start/stop control icons
Drawworks speed range selection icon
Display of hook load and WOB (weight on bit)
Display of travel block velocity
Entry of travel block high limit
Entry of travel block low limit
Drawworks motor selection icon, with these icons you can select motor A, B or A
and B
At the middle area shows some important drilling information, they are
Graphic display of rig total power limit (set from VFD HMI) and actual power
consumption
Drawworks drum speed
Drawworks motor A current
Drawworks motor B current
Drawworks motor A torque
Drawworks motor B torque
Rotary table speed
Stand pipe pressure
Disk brake system pressure
Air system pressure
Tong torque
Graphic display of drawworks motor speed request and actual speed
Right area is the travel block animation; includes,
Total height scaled mast, with scale rule
Current height of travel block, digital read out and animation
High limit, low limit and current positions marked at scale rule
“Zero” height position set icon
Bottom of screen there are three icons for over travel control
Override icon is to by-pass the high limit and low limit. When travel block is in
limit areas, touch this icon will enable the “Override” function (this icon changes
to green color) and let travel block pass the limit position; touch it again will
disable the override function (this icon changes color back to black); When
traveling block get out of the limit area icon color change back to black.
Resume icon is to by-pass the low limits of travel block to go down and pass “0”
height. The operation of this icon is same as Override.
Maint. Mode icon is to by-pass the height proximity limit switch which is
installed at 115 feet (from drill floor), equivalent to top drive elevator at height of
106’8”. When this proximity limit switch is reached a yellow warning message
“Crown Saver Activated” will pop up to the HMI.
This Drill/MP screen is similar to the previous one, without the DW and travel block
control with some mud pump parameters added. They are mud pump motor currents,
mud pump speeds (SPM)

Mud pump control screen

The left banner shows the 4 engine/generator sets status, other banner icons are same as
drilling screens
Main area there are 3 mud pump control panels, they are identical, discussed as:
Start and Stop icons are for mud pump start and stop control;
Zero to set mud pump speed to zero;
The display area at the left of “Zero” displays the SPM request;
<< and >>: increase and decrease 10 SPM;
< and >: increase and decrease 1 SPM;
The graphic display of requested SPM and actual SPM;
Digital display of the mud pumps SPM;
Mud pump speed;
Mud pump current;
Mud pump torque.
Bottom area there is a
Total counter strokes on left and A stroke counter reset box, touch the slide bar
under “Zero” will set total stroke counter to zero.

Rotary table and top drive share same VFD drive. Only one motor can be powered by the
drive, either rotary table or top drive.
Rotary Table screen provides the selection between top drive and rotary table as well as
provides the rotary table control.
At the left panel
RT (rotary table) and TD (top drive) icons to select rotary table or top drive
Requested torque display
“Zero” torque
<< or >> to decrease or increase rotary table torque by 10 %, per touch
< or > to decrease or increase rotary table torque by 1 %, per touch
Graphic display of set torque and actual torque
Rotary table motor current and torque display
At the right panel
“Forward” and “Reverse” icon to start rotary table in forward or reverse direction,
and “Stop” icon to stop rotary table;
Requested speed
“Zero” speed
<< or >> to decrease or increase rotary table speed by 10 rpm, per touch
< or > to decrease or increase rotary table speed by 1 rpm, per touch
Graphic display for requested speed and actual speed
Digital display for rotary table speed and motor speed

Auto Drill screen provides the Auto Drill control: WOB (Weight of Bit), ROP (Rate of
Penetrate) and Delta P (Mud Pressure for down hole motor).
Three control panels are similar
For operation of Auto Drill please see section 4.8 for detail description.
At the top of 3 panels
ZERO WOB for zeroing the weight hold
WOB for selecting WOB Auto Drill function
ROP for selecting ROP auto drill function
ZERO Delta P for zeroing the mud pressure
Delta Pressure for selecting Delta P auto drill
The bottom below 3 panels
VFD shows what DW motor(s) is(are) running
Motor speed
Motor current (for one motor)
Motor torque (for one motor)
Manual/Auto Drill, for selection between Manual and Auto drill operation
Set travel block lowering maximum speed
Set travel block raising maximum speed
(These 2 maximum speeds work both for auto and manual drilling
operations)
Mud pump 1 SPM
Mud pump 2 SPM
Mud pump 3 SPM

Iron Roughneck Main Interface control screen, provides the Iron Roughneck running
status display.
For detail Iron Roughneck operation please see Iron Roughneck manual.
Top of the screen

Most left entry is for make up torque set
2 gauges for make up torque display (psi and ft.klbs)
1 system pressure gauge
Main area displays status of each function
3 menu buttons for go to;
Iron roughneck Preset Mode screen
Iron Roughneck Operation Mode screen
One Line go back to drill HMI one line screen

Iron Roughneck Operation screen provides the selection for the control between the
Remote Controller and this HMI touch screen. Also provides step by step controls, make
up and break out controls for the IR from this HMI screen.

Iron Roughneck Preset screen. The top section is for torque and system pressure
calibration. The bottom sections are for auto make up and break out timer inputs.
Load Control screen (password protected) provides load control for mast scoping and
DW pulling force. Authorized worker can override the load limit settings.
For Detail description please see Load Control sub-section on section 4.9
Control panel
Right slide let you enable or disable load control function, the load control status
is shown on the left side as
Left box shows black Load Control OFF or Green Load Control On
Mast Scoping Load Limit Control is used for scoping mast and DW Pulling Load
Limit Control is used for drilling process. The differences are they are preset with
different loads.
Menu line
Reset for overload alarm reset
Maximum Load Default will load the factory default maximum value to both load
settings

This Mud Level screen displays the mud levels for monitored tanks. Actual mud level is
shown with graphic bar and digital number. The height graphic bar will change to yellow
color when the tank is over filled.
Generator power and consume screen.

It shows graphic power limit set and actual power consumption: AC bus
voltage/frequency; 4 generators and their main circuit breaker status; and KW/KVA of
each generator.
The above Calibration screen provides the access for pressure sensors, level sensors and
travel block height calibration. In case the sensor is not accurate or different range sensor
is used / retrofitted you can calibrate the sensors.
In case of HPU or disk brake pressure sensors failure the “BYPASS” may be used to
temporary bypass the control, to release the drawworks brake. (Warning: This action
can only be taken during emergency situation, not for normal operation!!!)
At the top there are 4 sensor calibration fields for disk brake sensors. To calibrate them
just input the sensor psi reading (sensor arrange, marked on sensor) to the sensor field.
Incase it is not accurate you can modify the input for correction.
The middle screens there are 10 mud level sensor calibration field. To calibrate there
sensors, you put sensor target on the bottom of the tank, copy the current reading to the
low field. Then you set sensor target on the maximum height (liquid surface or a plate,
2.3 meters for tank1 and 2, 2.7 meters for other tanks) and copy the current reading to the
high field.
For the Auxiliary Sensor calibration (Stand Pipe, Tong Torque, Travel Block, Air and
HPU pressure sensors), calibration procedures are same as disk brake pressure sensors,
just copy the sensor arrange psi reading to the sensor calibration input field.
The last calibration is for travel block height. Follow below calibration procedure for the
calibration; this must be recalibrated each time the drawworks is reeved:
1). Lower the travel block all the way down to where you want to mark it as “zero”
position. Touch the “zero height” icon at the drill screen. The height of travel block will
change to “0”;
2). Raise travel block until fast line wrap up all second layer on the drawworks drum,
touch and hold ACK icon until a yellow “OK” pup on.
This screen displays the current alarm message. With History icon you can go to alarm
history screen.

This screen provides the alarm history record
This is blank screen just for clean purpose only. No function icons in the screen so when
you clean the screen it will not cause wrong rig implications/functions.

3.3 VFD House HMI
Some of VFD HMI screens are identical to Driller’s cabin but for monitoring only. Some
screens are differ and illustrated below.
Right figures are VFD House HMI screen menus.

Left one is for one line screen and right one is
for Logical screen. Other screen menus do not
have VFD reset, Set Up and Set Date and Time.
VFD Reset is not for screen access but is a

function icon only. It is used to reset VFD fault.
After start up the VFDs if you see VFD fault
(VFD icon with red colors, in One Line screen),
touch this VFD Reset icon will reset the VFD
fault.
The Generator #1 screen shows #1 engine/generator status and critical data, includes
Graphic power %
Battery voltage (for engine battery)
Engine rpm
Generator voltage
Generator current
Engine run time and
KW gauge
KVA gauge
PF gauge
Kvar gauge
Hz gauge
Generator #2, #3 and #4 are identical.
This Motor Status screen shows all the VFD drive status and running parameters, the
motor lock out status also provided at screen banner.

This is the power limit screen, showing the 4 generator power output. The top area allows
the driller to input or modify the power limit. Normally the power limit Set Point should
be lower than 95%.
This screen lets driller set up the blower, oiler, and washer shut down timer. When any of
the listed motor failed during rig operation, it will turn off the related VFD motor in
setting time, in case the failed motor did not resume in the setting time.
RT oiler is optional and not applicable for LM770 rig.
All HMI are time synchronized. The clock is set by this screen and sent to other HMI.
Touch the data field will pop up a digital key panel let you input the number. Touch
“OK” will set the updated date and time.

The DP Diagnose screen shows all communication status. Upper part for VFD house
PLC communication and lower part for Driller’s Cabin PLC communication. In above
screen the good communication node will show green color and bad communication node
will show red blink.
For communication between two PLC please consult with Internet stations. At the station
the good communication port will light up orange LED.
For Communication between HMI and PLC, bad communication will prohibit HMI read
data from PLC.
3.4 Alarms
All alarm messages will lock on any active screen until you acknowledge it. Also an
alarm history is kept and can be accessed from the Alarm screen.
3.4.1 Alarms List
Rig E-Stop
VFD E-Stop
Lost of Communication
High Power Load
Gen 1 Fault / E-Stop

Gen 1 High Water Temperature
Gen 1 Low Oil Level
Gen 2 Faults /E-Stop
Gen 2 High Water Temperatures
Gen 2 Low Oil Level
Gen 3 Faults / E-Stop
Gen 3 Low Oil Level
Gen 4 Faults /E-Stop
Gen 4 Low Oil Level
DWA VFD Fault

DWA VFD Over DC Voltage
DWA VFD Over Current
DWA VFD High Temp
DWB VFD Fault
DWB VFD Over DC Voltage
DWB VFD Over Current
DWB VFD High Temp
Crown-O-Matic Tripped
Low DW Motor Start Torque
DWA Blower Fault
DWA Oiler Fault
DWB Blower Fault
DWB Oiler Fault
DW CH2 Communication Fail
VFD Room High Temperature
Dynamic Braking Resistors Bank High Temperature
MP1 VFD Fault

MP1 VFD Over Current
MP1 VFD Over DC Voltage
MP1 VFD High Temp
MP2 VFD Fault
MP2 VFD High Temp
MP3 VFD Fault
MP3 VFD High Temp
MP1 Blower Fault

MP1 Oiler Fault
MP1 Liner Washer Fault
MP1 Charging Pump Fault
MP2 Blower Fault
MP2 Oiler Fault
MP3 Blower Fault
MP3 Oiler Fault
RD/TD VFD Fault

RD/TD VFD Over Current
RD/TD VFD Over DC Voltage
RD/TD VFD High Temp
RD Blower Fault
Main HPU Motor Overload

Main HPU Low Oil Level
Main HPU High Oil Temperature
Disk Brake Low Pressure

Disk Brake 1 Low Pressure Fault
Disk Brake 2 Low Pressure Fault
Disk Brake Oil High Temp
Disk Brake Oil Low Level
Mast Scoping Overload

DW Pulling Overload
Brake resistor blower #1 fault

Brake resistor blower #2 fault
Chopper #1 fault
Chopper #2 fault
Chopper #3 fault
Chopper #4 fault
Chopper #5 fault
Chopper #6 fault
Chopper #7 fault
Chopper #8 fault
DSU #1 fault
DSU #2 fault
Transformer High Temp
VFD House High Temp
MCC Room High Temp
3.4.2 Messages
Tank #1 High Level warning with yellow height graphic at tank level screen
Communication Error One Channel Lost

Crown Saver Activate
3.4.3 Status & Icon color
Beside the alarm and warning messages, the icon color on each screen also prompts the
equipment status.
3.4 Independent equipment
Some independent equipment （not PLC controlled）has no alarm and warning message
displayed on the HMI screen.
TD has its own alarm and warning messages on the TD HMI screen.
Cathead, Rotary Mouse Hole, Gai-Tronics, and CCTV are not rig PLC related; please
refer to the manual for troubleshooting.
4. Drawworks and Disk Brake

4.1 The electric Drawworks motor is powered by Drawworks VFD, which is in turn
powered by main VDC bus from VFD house. Hydraulic disk brake is powered by the

disk brake HPU. All Drawworks, disk brake unit, Disk brake HPU and TD HPU are
located in the Drawworks skid on the Drawworks foundation.
The drawworks and Disk Brake system is controlled by driller’s cabin PLC, the operation
control and the monitoring is located in the touch screens.
The drawworks system mainly consists of:

Drawworks VFD drive 2 motors. According to the running load driller can select to run
one or 2 motors, from the driller’s cabin HMI;
2 of 460 VAC blower motors for main motor cooling that come with an air pressure
switches. The switches detect the state of the cooling fan status.
2 of 460 VAC oiler motor comes with an oil pressure switch, this switch is used to detect
lubrication status.
Both (2) main motors have a motor encoder installed in the motor shafts. They are wired
to the drawworks VFD to form the main motor speed control loop.
The drawworks drum encoder is installed to drawworks drum shaft and it is wired to the
driller’s cabin PLC. The encoder signal is used for traveling block positioning control and
display.
The brake system consists of 1 pairs of safety calipers (on the bottom) and 2 pair of
service calipers (on the top). The emergency braking will close both service and safety
calipers. The parking braking will close the safety calipers. Pulling the disk brake
joystick will activate the service calipers. The service brake force applied is proportional
to the disk brake joy stick pulling angle. More angle you pull the joystick more pressure
is applied to the calipers.
4.2 Operating Drawworks

The (O) driller is able to control and monitor Drawworks operations on either driller’s
cabin HMI.
Refer to One Line and Logical screen for power up sequence.
1. Make sure at least one generator (Gen1, Gen2, Gen3 or Gen4) has been started
and the related Circuit Brake (CB1, CB2, CB3 or CB4) has been turn on, the
AC power on the main bus voltage is 600VAC. On the One Line screen the
powered generator icon should be green color and main bus should be red color.
2. Drawworks VFD controllers in VFD house needs to be set to remote mode (see
VFD operations manual for details).
3. Dynamic brake “Chopper On” verification. Verify that chopper cooling fans are
running (via HMI one line screen).
4. Close SW1 and/or SW2 (DW VFD main DC switch disconnect). Turn on DW
VFD(s). Verify icon’s green color.
5. Verify that DW motor lockouts are off (verify from Logical Screen).
6. From MCC cabinet close breakers for DW Blower and DW Oiler, make sure the
selector switches are in AUTO position.
Go to MCC Screen and press one of disk brake HPU Start icon (or Auto icon) to start one
of disk brake pump. For LM770 there are 2 disk brake pumps, it is a redundant design.
Turn parking switch to “Parking On” position (at driller’s chair left armrest). Pull to
release disk brake E-stop to reset Emergency parking condition (open service calipers and
keep safety calipers on). On the Drill/DW screen banner it will show the disk hydraulic
system pressure about 1000psi, safety caliper pressure around 0 (below 100) psi and both
working caliper pressures below 100psi. This means Disk Brake HPU is running, safety
calipers are closed and working calipers are open.
Drawworks system is now ready for operations.
From any screen on HMI, press Menu and select Drill/DW screen. Select the
Drawworks Motor(s) you going to run, DWA, DWB or Both DWA & DWB, by the
lower left corner select PB.
On Drill/DW screen, press Start PB.
On the second HMI select Logical screen. The Start, Crown-O-Matic, DWA work
(and/or DWB work), Lock out, ready, blower, and oiler icons should turn green for the
selected Motor. This verifies that all DW auxiliaries started and the Drawworks VFD is
enabled for speed command (The drawworks start icon change to green color).
If any DW auxiliary fails to start, the associated icon will not turn green and after 10
seconds the DW will not start. An audible alarm (horn) will be activated and a flashing
alarm will be displayed. If DW failed to start up then PLC will keep the safety calipers
closed.
Once drawworks starts, pull the disk brake joystick and turn disk brake parking switch to
“off” position, the banner “Parking On” will change to “Parking Off” (also the icon will
change from blue color to green color) and at the same time open the safety calipers.
Slowly release braking joystick and the drawworks VFD motor will hold the load.
Go to Auto Drill screen and make sure the travel block maximum down and up speeds
are not set to “0”. If this speed is set to “0” then motor will no run
4.3 Drawworks Joystick

The Drawworks joystick is used for hoisting and lowering the travel block (with speed
control). The joystick self-returns to zero (neutral) position when released and auto-locks.
When it is in zero position, it is locked by the safety trigger.
To operate the joystick, depress the safety trigger with the right hand. Pulling back on the
joystick raises the travel block. Pushing forward on the joystick lowers the travel block.
The control is proportional whereas the further from neutral the joystick is positioned, the
faster the Drawworks drum turns, within the selected speed range.
Warning Do not pull disk brake joystick (to apply service brake) when travelling
block is moving (or when drawworks joystick is pulled/pushed)!!! This may cause
drawworks VFD shut down, due to VFD over current
4.4 Speed Range Selection

There are 3 speed selection pushbuttons on Drill/DW touch screen for 3 difference speed
ranges.

When maximum up and down speed at the Auto Drill screen set at maximum speeds, that
is 2300rpm, then
Low speed range, 100% of Joystick equal to 50% rated speed, motor speed 0-600rpm.
Mid speed range, 100% of Joystick equal to 100% rated speed, motor speed 0-1200rpm.
High speed range, 100% of Joystick equal to 200% rated speed, motor speed 0-2300rpm.
Max torque on high speed is 20% of rated torque.
Before the driller presses the DW Stop PB, the DW joystick should be in the zero
position and the motor should be running at “0” speed. Driller has to engage
Parking Brake to hold the load before Stopping drawworks. With drawworks is
stopped by press Stop PB, drawworks VFD will shut down; motor will ramp down
to zero speed.
Motor blowers will keep running for a predetermined amount of time after main
drawworks motor is stopped, to cool down motor. Other Auxiliaries will shutdown at the
moment the Stop PB is pressed.
4.5 Drawworks Alarms

Alarm messages will be displayed on the HMI screen and will indicate the failure/s. In
the case of oiler or blower failure, the associated alarm/warning will pop up and the
Drawworks will continue to operate for a predetermined amount of time. The amount of
time is customer adjustable via the HMI in the VFD house (Set up screen). Oiler and/or
Blower failure will shut down DW in XX minutes. When the time expires, the
Drawworks will shut down and the brakes set.
4.6 Auto Drill
4.6.1 Description
The auto driller sets user adjustable parameters to allow controlled drilling. The LM770
rigs have 3 parameters or "Autodrill functions" for Autodrill control. They are:
 WOB (weight on bit)

 ROP (rate of penetration)
 Delta P (pump pressure)
WOB is to control the weight on the drill bit by means of a weight indicator sensor. The
user inputs the amount of weight desired on the drill bit or what he wants the weight
indicator to read with the desired weight on the drill bit. The program will feed line off of
the Drawworks drum to maintain the desired weight.
ROP controls the rate of penetration or how fast you drill using input from the
Drawworks encoder. The user inputs the desired rate of penetration and the program
should feed line off of the Drawworks drum as needed to drill at the desired rate.
Delta P controls the mud pump pressure when drilling with a downhole mud motor. A
downhole motor is driven off of the mud pumps. The pump pressure rises with the
amount of torque on the motor. The user would input a pre-determined pump pressure
value and the program will feed line off of the drawworks drum to add weight on the bit
increasing the motor torque and increasing the pump pressure.
These three drilling parameters can/should be used together in combination to set desired
limits.
4.6.2 Operation of Autodrill
Getting the system ready for the Autodrill is the same as getting it ready for manual
drilling. Once the mud pumps are set to the correct pressure, the top drive is turning the
drill string, and the bit is off bottom, the Autodrill can be turned on.
The Autodrill is designed to function with the joystick in the neutral position. If a hook
height calibration request is made by the system, emergency stop is pressed, the joystick
is moved, or then the Autodrill will revert to manual drilling. To restart the Autodrill,
simply use the switch on procedure below.
To start the Autodrill, do the following:
1. Once the driller is ready, select one of the Autodrill modes: Rate of Penetration
(ROP), Weight On Bit (WOB), or differential pressure (delta P).
2. Set the limits on the touchscreen for ROP, WOB, and Delta P (if running in delta
P mode). NOTE: The ROP and WOB limits work for ALL MODES (ROP, WOB,
and delta P).
3. Zero WOB by pressing the ‘Zero WOB’ button on the touchscreen. If using delta
P, zero it by pressing the ‘Zero delta P’ button. This should be done with the bit
off bottom to get an accurate reading of the string weight. Note: The ‘Zero WOB’
and ‘Zero Delta P” buttons can be pressed again as needed, as long as the bit is
off-bottom.
4. On the main Autodrill screen, select ‘Auto’. The brakes will release, and the
system will automatically lower the drawworks, applying weight to the drill string.
Notes on the different modes of operation:
ROP – The system will ramp up the ROP slowly, and will also watch the WOB setting. If
the WOB exceeds the setting, the system will stop feeding out, until the WOB drops
below the setting. If the off-bottom WOB reading is not zero, then press the ‘Zero WOB’
button while the bit is off bottom.
WOB – The system will ramp up the WOB slowly, and will also watch the ROP and
WOB settings. If the ROP exceeds the setting, the system will slow down feeding out,
until the ROP drops below the setting. If the WOB exceeds the setting, the system will
stop feeding out, until the WOB drops below the setting.
Delta P - The system will ramp up the delta P slowly, and will also watch the ROP, WOB,
and pressure settings. If the ROP exceeds the setting, the system will slow down feeding
out, until the ROP drops below the setting. If the pressure or WOB exceeds the setting,
the system will stop feeding out, until the pressure and/or the WOB drops below the
setting.
4.7 Block Travel Control and Protections
Traveling Block high & low limits (Over travel protection)

There are 4 PLC controlled travel limits:
1. High-High (106 feet from Zero)
2. High
3. Low
4. Low-Low (“Zero”)
And 2 proximity limit switches:
1. Mast Crown Proximity Switch
2. Mast Floor Proximity Switch (optional)
High-High and Low-Low Limits are programmed inside PLC and can only be changed
by “zero” position setting. High Limit and Low limit are user adjustable from the HMI.
DW will be forced to stop at High-High limit & Low-Low limit if the High & Low
limits are not set up properly.
Crown Saver and Floor Saver

The ZERO Height PB is located at the bottom right area of the Drill / DW touch screen.
Pressing the Zero Height button sets the Low-Low Limit where the traveling blocks are
positioned at the time the button is pressed. High-High Limit will be 106 feet above this
point.
Low-Low Limit is 0 feet where the Driller pressed ZERO Height PB.
High-High Limit is 106 feet from ZERO Height point.
High Limit is set up on HMI by Driller and it should be less than 106 feet. Block will
travel normally up to 5 feet below the set point. At 5 feet below the set point the PLC will
ramp down the Drawworks to creep speed. Driller may continue go up at creep speed to
the high limit set point. When the set point is reached, the Drawworks will stop. At this
point, the blocks can only be lowered.
Low limit is set up on HMI by Driller. It should be greater than 0 foot. Block will travel
normally down to 5 feet above the set point. At 5 feet above the set point the PLC will
ramp down the Drawworks to creep speed. Driller may continue down at creep speed to
the low limit set point. When the set point is reached, the Drawworks will stop. At this
point, the Drawworks can only be raised.
Caution must be used while changing the High and/or Low Limit value that runs
the travel block, as not to collide with the floor or crown!

Override The High Limit and Low Limit can be overridden by use of the Override PB.
This button is located in the lower middle area of the Drill / DW touch screen.
When raise the travelling block into High Limit area, pressing the Override PB (change
to green color) will allow the Driller to raise the traveling block beyond the High Limit
set. Press the PB again will cancel the override function (change color back to black) and
prohibit travelling block moving up. Move travelling block down and pass the High Limit
will also cancel the Override (change back to black).
When lowering the travelling block into Low Limit area, pressing the Override PB
(change to green color) will allow the Driller to lower the traveling block beyond the
Low Limit set. Press the PB again will cancel the override function (change color back to
black) and prohibit travelling block going down. Move travelling block up and passing
the Low Limit will also cancel the Override (change back to black).
Resume The Low Limit and Low-Low Limit can be disabled by the Resume button. The
PB is located in the lower middle area of the Drill / DW touch screen. Press Resume
(change color to green) will by-pass the Low Limit and Low-Low Limit, lets travelling
block go pass the Low Limit and Low-Low Limit. Press Resume again will cancel the
resume function (change color back to black) and prohibit travelling block moving down.
Moving travelling block up and pass the Low-Low Limit will also cancel the Resume
(change back to black).
Caution must be used while using Override or Resume function, as not to collide
with the floor or crown!!!
Elevator Position Safety is PLC set protection. When Top Drive is in unsafe mode, the
travel limit is 65 feet above the floor as not to clash with racking board. When Top Drive
is in safe mode there is no limitation for it.
Mast upper proximity switch is installed on the upper mast about 115 feet height
(equivalent, elevator at 106 feet height). The switch will detect the traveling block as it
approaches the crown and will send a signal to stop the Drawworks. Also a warning
message displayed on the HMI. The driller can only lower the traveling block at this
point.
Maint.-Mode PB is located at the bottom of Drill/DW screen. With it you can by-pass
the Mast Upper Proximity switch. When raise the travelling block and flag this switch, it
will stop moving up and a message “Crown Save activated…” pops up. Press Maint-
Mode PB (change color to yellow) will allow you move travelling block up beyond this
point. Press this PB again will get you out of Maint Mode (change color back to black)
and prohibit going up.
Caution must be used while in maintenance mode not to collide with the crown!!!
Crown-O-Matic is a mechanical fail-safe device which will prevent the traveling block
from hitting the crown in case that the programmed limit switches and the Crown
Proximity Limit Switch fail. The toggle switch is set by the user to trip when a
predetermined amount of drilling line is spooled onto the drum. Normally this should be
when the traveling blocks passed the uppermost limit of travel in the mast, allowing some
margin of safety before colliding with the crown. The Crown-O-Matic is installed inside
the D.W. drum housing. It can also detect fouling of the drilling line on the D.W. drum.
When this toggle switch trips the rig control system will shut down the drawworks VFD,
and engage the disk brake safety as well as service calipers. (system set into disk brake E-
Stop condition).
Crown Saver By-Pass push button is located at middle of driller’s chair left armrest,
with it you can release the Crown-O-Matic trip condition, by below procedure:
A. Turn disk brake in “parking on” condition by means of Brake Parking switch
B. Press and hold the Crown Saver By-Pass push button
C. Start drawworks VFD and wait for the VFD start up
D. Pull working brake joystick, turn parking switch to “parking off” then release
the disk brake joystick (Release the parking condition)
E. Run drawworks down until out of trip condition
F. Release the Crown Saver By-Pass push button
G. Put Crown-O-Matic back to straight down.
Before releasing the Crown-O-Matic trip condition, a careful analysis must be taken
for causes of the trip of Crown-O-Matic.
Pass High-High Limit

When approaching the crown, the system will stop at this High-High limit (the
programmed 106’ Height) further height movement will be negated. In this case the
driller need to keep move the travel block up for a special height operation he can reset
travel block “zero” height position. By changing the “zero” HEIGHT will allow him to
proceed going up with normal joystick control.
Caution must be used while running travelling block when reset “0” height, as not
to collide with the floor or crown!!!
After completing special height operation, lower the travelling block and set correct
Low-Low limit immediately!!!
Torque Proving
When starting the Drawworks, the system will make sure that the Drawworks motor is
putting out enough torque to support the load, before releasing the service brake. A timer
is also started, in case of a problem. If the timer expires before the torque level is reached,
then the system will abort out of proving the torque, leaving the service brake set.
Restarting the Drawworks will reset the system and retry torque proving.
This is done by PLC the operator cannot intervention in this action.
Load Control
The Load Control is provided when scoping the mast and pulling the load to protect the
rig (refer to Load Control screen and description).
The default setting of Mast Scoping load is 120 Klbs and DW Pulling load is 650 Klbs.
When Load Control is activated for Mast Scoping or DW Pulling, overload the preset
load will cause system warning and stop the travel block. The driller can modify the
preset maximum load with the arrow icon, 1% for each arrow icon hitting and 10% for
maximum change. Default setting can be changed by adjusting the Maximum Load
display field.
Power Limit and Phase Back

The Power limit is set at the Power Limit screen on VFD house HMI.
When system power consumption reaches the preset limit, “High Power Load” will pop
up on the screen.
The system will compensate for required power by taking power from the mud pumps
and applying to requirement, if the Mud pumps are not running the system will default
and the system will over load and shut off.
Hook Load is shown on front counter Load Gauge also the drill screens

5. Mud Pump control
5.1 Description
There are 3 mud pump electrical systems, Mud Pump 1, Mud Pump 2 and Mud pump 3 .
Each mud pump system consists of a mud pump main motor, a blower motor, a
supercharger motor, a liner washer motor, and an oiler motor.
The Main motor is powered by mud pump VFD, which is powered by main DC bus. The
DC bus is powered by rectifier DSU1 and/or DSU2. The power supply of DSU1/2 is
600VAC.
All other motor are powered by 460 VAC.
All motor power cables are direct connected to VFD house via VM plug panels.
The blower motor comes with a fan air pressure detect switch installed in main motor
Junction box.
The liner washer motor comes with a wash pressure detect switch installed in pump outlet
line.
The oiler motor comes with an oil pressure detect switch installed in pump outlet line.
The blower motor, supercharger motor, liner washer motor, and the oiler motor can be
automatic or manual start/stop. To manually start these motors, go to the VFD house
MCC cabinet and close the related disconnect switches and turn the select switch to
manual position. For automatic start, close the related disconnect switches and turn the
select switch to auto position, then the motors can be automatic start from the driller’s
cabin HMI.
The mud pump main motor power flows in below route:

The 600VAC goes through DSU1/2 and converted to DC voltage on the DC bus. From
the DC bus mud pump VFD send variable frequency power to mud pump.
5.2 Mud Pump Operations
To get power to mud pump VFD, close the CB5 and/or CB6 to turn DSU1 and/or DSU2
on. Depends on what mud pump/s you want to run and which DSUs is/are running, you
may need to turn the OETL isolation switch on.
From MP1, 2 or 3 VFD cabinet(s) turns SW3, SW4 or SW5 to power MP VFD(s).
From the driller’s cabin HMI, go to “MP control” to get to the mud pump control panel.
Use “Start” and “Stop” icon to start and stop the mud pump.
When “start” is pressed, the blower, line washer, oiler and supercharger will be started
immediately. If in 10 seconds all air pressure, water pressure and oiler pressure are OK
and the supercharger is started (signal from supercharger soft starter) then the mud pump
will start; if not then an alarm will appear and the mud pump won’t be started. During the

mud pump start up, you can access Logical screen for the start up process. The Green
icon shows a ready state and Yellow shows not ready.
When the mud pump starts, you can use the touch screen associate mud pump control
icons to control the mud pump speed, by direct speed input or by speed increase and
speed decrease icons. Also you can view the mud pump status from this screen, or stroke
meter at the front counter.
If the mud pump cannot be started, or mud pump failed after start up, the related prompt
message will show on the screen.
If any auxiliary fails during the pump running, a warning message will pop up. After the
predetermined time elapsed, the mud pump will shut down. For the shut down timer
setting please go to VFD touch screen and look at the Set Up screen.
Mud Pressure (or Stand Pipe mud pressure) is shown on the front counter Stand Pipe
pressure gauge as well as drill screens

6. Rotary Table control
The Main motor is powered by RT/TD VFD, which is powered by main DC bus. The DC
bus is powered by rectifier DSU1 and/or DSU2. The power supply of DSU1/2 is
600VAC.
The RT blower motor is powered by 460 VAC.
The RT main motor power flows as following:

The 600VAC goes through DSU1/2 and converted to DC voltage on the DC bus. From
the DC bus the RT/TD VFD send variable frequency power to RT or TD motor.
To get power to the RT/TD VFD, close the CB5 or/& CB6 to turn DSU1 or/& DSU2 on.
Depends on which DSU is running, you may need to turn the OETL isolation switch on.
From RT/TD VFD cabinet turn SW6 on to power RT/TD VFD.
From the driller’s cabin touch screen, press “RT control” to get to the RT control panel.
On the top of the left side control panel there are 2 select icons, left for RT and right for
TD. Make sure the RT is in green color that indicates RT is in use (RT and TD share the
same VFD drive). Or you need to press RT to make it active. Just bellow the select icons
is the RT torque control area, with this control panel you specify the % of maximum
torque, by direct torque input, or by torque increase and torque decrease icons.
Right control panel is for RT Start (Forward or Reverse), Stop and speed control. When
Forward or Reverse is pressed, the blower will turn on. If the air pressure is detected in
10 seconds then the RT will start; if not then an alarm will appear and the RT will not
start.
With the RT started, you can control the RT speed by direct speed input, or by speed
increase and speed decrease icons.
If the RT does not start, or RT failed after start, you can go to the logical screen to check
the logical interlock status. The Green sign shows a ready state and Yellow shows not
ready.
If any auxiliary fails during RT running, a warning message will pop up. After the preset
timer elapsed, the RT will shut down. For the shut down timer setting please go to VFD
touch screen and reach the Set Up screen.

7. Cathead and Control
There are 2 cathead cylinders installed on the mast legs. They are driven by HAWE
proportional valves, which in turn controlled by a HAWE amplifier. The controls are
proportional whereas the further from neutral the lever is positioned, the stronger the pull
of the tong. The operator uses the left and right levers on the chair right armrest to
operate these 2 catheads. Pulling for torque (pulling the tong) and push for release.
The make up cathead hydraulic line is installed with a pressure relief valve to prevent
over tight during the make up process.
Cathead control is independent with the rig electric control system, no associated with
PLC and HMI control except the pressure reading of make up torque.
Local Cathead manual control is by means of valve control levers from valve station.
Torque pressure is shown on the front counter Tong Torque gauge and drill screens.

8. Rotary mouse hole and Control
The rotary mouse hole is driven by a HAWE proportional valve, which in turn controlled
by HAWE amplifier, with a control lever located on the chair left armrest. The control is
proportional whereas the further from neutral the lever is positioned, the faster the rotary
table running. Pulling the control lever to run the rotary table forward and pushing for
reverse.
Rotary mouse hole control is independent with the rig electric control system, not
associated with PLC and HMI control.
Local Mouse Hole manual control is by means of valve control levers from valve
station.

9. Top Drive Control

(Refer to Top Drive Manuals)
10. BOP Control

(Refer to BOP manuals)
11. Iron Roughneck

Appendix A
Power System and Control
A.1 Description
There are 4 engine/generator sets. Each set consist of a CAT 3512B Engine with a
600VAC, 1950kVA, 60Hz, 0,7pf, 3 phase generator and a generator control cabinet that
is inside the VFD house. You can run any set of engine/generator (Engine1/generator1
with control cabinet Gen 1, Engine2/generator2 with control cabinet Gen 2,
Engine3/generator3 with control cabinet Gen 3, or Engine4/generator4 with control
cabinet Gen 4). If more power than one power set is required you can run more than one
power sets by any combination (set1, set2, set3, and/or set 4). See following Power
Supply Diagram for reference.
A.2 Start Engine/Generator

(Following is the example running engine/generator #1.To Fire and run other
engine/generator sets please go to the engine/generator/control cabinet you are going
to run and follow the same procedure)
A.2.1 Engine side:

Compressed air exceeds (100 psi) at the air receiver and open valves for air to the engine
you want to start. With fuel supply ready for the engine and open valves for fuel to the
engine you want to start. Make sure the fuel/water separator valves are open.
Go to the engine you want to start up, make sure battery power supply is ready for the
engine control. From the engine Electronic Control Module turn the engine control
switch clockwise to "Auto". After self-diagnostic all red lights on the dash board should
go off and the engine is ready to start from the VFD house. If any self diagnostic light
does not go off it indicates abnormal engine status, consult with the engine technician.
A.2.2 From the VFD house side:

Open SYN cabinet, turn on the engine control battery power double pole circuit breaker
(most right side circuit breaker, just below the big transformer) to get 24V battery power
for prime generator control. Wait until cabinet GEN1 engine control EGCP-3 to start up
(initialization need 50 seconds).
In GEN1 cabinet from the door panel turn Generator Control Module switch from “0” to
“1” then to “2”. (“0” for stop engine, “1” for start engine and “2” for close CB1 which
connect generator power line to Main AC Bus).The engine #1 will be started and run 3
minutes at idle speed (900rpm). Then the engine speed will be raised to 1200rpm. The
generator produces 600V/60Hz AC power supply. The circuit breaker CB1 will be
energized to bring the 600VAC to the Main AC bus builds up to 600V/60Hz. If any other
engine(s) had been fired and the associated CB (2, 3 and/or 4) is closed the CB1 will be
closed when Gen1 is synchronized with main bus power supply.
If you stop the switch at “1” you will fire the engine but will not bring the AC power to
main AC Bus when the generator built up the 600VAC/60HZ power supply. You can
turn from “1” to “2” later to close the CB1 to power up the Main AC Bus. If any other
engine(s) had been fired and the associated CB (2, 3 and/or 4) is closed the CB1 will be
closed when Gen1 is synchronized with main bus power supply.
A.2.3. Follow the same procedure for fire engine #2, 3# and #4.
A.3. Power supply delivery management

Refer to One Line screen or power supply diagram
600V AC Go to SW cabinet and press Close PB. This will close CB7 and deliver the
main AC power to 600V/480V transformer, also bring up power supply to VFD house air
conditioners and lighting.
VFD House Air Conditioners Go to the air conditioner control panels and press
the start PB to turn on the VFD air conditioners.
Power UP PLC Rig Control System Open the VFD House PLC cabinet (The cabinet
with HMI on it) door. Press the UPS On button to start UPS power supply, which deliver
power supply to PLC and HMI touch screens.
MCC 460 V AC Go to M.CB cabinet to press the Close Button, which delivers
460V AC to all MCC cabinet.
DC Bus Power Supply Make sure on OETL cabinet the manual circuit breaker is
closed so it will deliver DC power to all the VFD Inverters (for all MP, DW, and RT or
TD motors). In case you just want to run one DSU and only the same side of inverters
you can keep this circuit breaker off. Please be note this manual circuit breaker can
only operate when the DC bus is not powered.

From the DSU1 cabinet select one or two DSU you will run (each one for 1816 KVA) by
the Single/Double.
1)To run DSU1 you select Single Mode , put Local/Remote on Local, turn the
manual circuit breaker (DSU1 CTRL SWITCH) on, and turn DSU1 Single Main
Breaker Control from “0”, “1” to “2” to start the DSU1. Hold the switch until
DSU1 is started, the switch will go back to “1” when released. To stop DSU1,
remove all DC bus loads first and then turn DSU1 Single Main Breaker Control to
“0”. Turn off the manual circuit breaker.
2) To run DSU2 you select Single Mode , keep Local/Remote on Local, go to

DSU2 Control Cabinet turn the manual circuit breaker (DSU2 CTRL SWITCH)
on, and turn DSU2 Single Main Breaker Control from “0”, “1” to “2” to start the
DSU2. Hold the switch until DSU2 is started, the switch will go back to “1” when
released. To stop DSU2, remove all DC bus loads first and then turn DSU2 Single
Main Breaker Control to “0”. Turn off the manual circuit breaker.
3) To run DSU1 and DSU2 together you select Double Mode , turn DSU1 and
DSU2 cabinets the manual circuit breakers (DSU1 CTRL SWITCH and DSU1
CTRL SWITCH) on, and turn DSU1 cabinet Double Main Breaker Control from
“0”, “1” to “2” to start the DSU1and DSU2. Hold the switch until DSU1 and
DSU2 are started, the switch will go back to “1” when released. To stop DSU1
and DSU2, remove all DC bus loads first and then turn DSU1 Double Main
Breaker Control to “0”. Turn off the manual circuit breakers.
Inverter Power From Cabinets for the Inverters you want to run turn on the
Manual Circuit Breakers (MP1/MP2/MP3/DWA/DWB and/or TD/RD Switch) to bring
DC power supply to the inverter(s). From Driller’s Cabin touch screen start the
inverter(s). To stop the inverter(s), make sure the inverter(s) had been stopped from touch
screen, turn the manual circuit breaker(s) off.
A.4. Shut off engine power

Turn off non-last running engine Make sure after turning off the engine the remaining
running engine(s) can offer enough power for the running loads. Go to the VFD house
engine control cabinet for the engine you want to stop and turn the engine control mode
switch from 2 to 1 then to 0. It will open the generator power-in Circuit Breaker and
speed the engine down to 900rpm (idle speed). In 5 minutes it stops the engine
automatically. From the engine Electronic Control Module turn the engine control switch
counterclockwise to "OFF" position, shut off the air and fuel line feed in valves.
Turn off last running engine Make sure all VFD inverters and MCC loads have been
turned off. Go to the VFD house engine control cabinet for the engine you want to stop
and turn the engine control mode switch from 2 to 1 then to 0. It will open the generator
power-in Circuit Breaker and speed the engine down to 900rpm (idle speed). In 5 minutes
it stops the engine automatically. From VFD house turn off the UPS power (inside the
VFD House PLC cabinet) and turn off Engine control module battery power (double pole
circuit breaker, inside the SYN cabinet). From the engine Electronic Control Module turn
the engine control switch counterclockwise to "OFF" position, shut off the air and fuel
line feed in valves.
Appendix B
Driller’s Chair Armrest Console
Above Figure shows driller’s chair left and right armrest control consoles push button
and switch arrangement. They are grouped as below:
Red: Disk Brake
Light Blue: Rig E-Stop and Drive E-Stop
Pink: Crown-O-Matic Release, Cathead and Mouse Hole Control
Green: Top Drive Control
Black: Drawworks Joystick
Yellow: Gai-tronics telephone System

Appendix C
CCTV
The CCTV system consists of 4 ES31CBW24-5W cameras, 1 MX4009CD multiplexer, 1

KBD4000 keyboard with control joystick, and 1 PMCL315 monitor.
Illustrated as below control diagram
ES31CBW24-5W camera:
Digital Position and Zoom Control with Auto Focus
360° Continuous Pan Rotation
+33° to -83° Tilt Range
Integrated Automatic Window Wiper
MX4009CD multiplexer:
9-channel, color duplex multiplexer
KBD4000 keyboard:
Remote Control of Multiplexer Functions including:
Select 1 or 4 screen display on the monitor,
Select and control each camera pan, tilt and zoom
PMCL315 monitor:
15 Inch Flush LCD screen with sunlight readable Screen
For more detail please refer to the related manual.

Appendix D
Gai-Tronics
The Gai-Tronics rig telephone system consists of:

1 Telephone center with microphone, handset and speakers located in the Driller’s cabin
1 Talkback station located in the Monkey board
1 stand alone Outdoor Horn mounted on the Driller’s cabin out wall;
5 Outdoor horn / telephone sets for HPU/closing unit, mud pump, mud tank #1, mud tank
#3, one stand alone.
5 Indoor horn / telephone sets for VFD house, MCC, Office, Electrical/mechanical, and 1
spare.
From driller’s cabin the driller can

Talk with microphone or handset (select with a Handset/Mic switch);
Call Monkey board, talk to driller floor or page/party (select with Monkey Board,
Page/Party, and Driller floor switch);
When microphone is used, the driller needs to press the party & Driller Floor push button
or Monkey Board push button to talk.
From any other telephone can call and talk to the driller.
For more detail please refer to Gai-Tronics manual.

Appendix E
Cable Connection between Top and Bottom Mast Sections
There are three cables route from the upper section of bottom mast to the lower section of
top mast. They are one of height sensor cable and 2 of lighting cables.
The connections are made by means of plugs and sockets located just under the monkey
board, behind the cage ladder, as shown below Fig.
Before scoping down the top mast, the 3 cable connections must be disconnected, the
plugs and cables must tie secure to the top section cable brackets, (to the back side, in this
Fig.), make sure cables won’t be cut during mast scoping.
After scoped up and latched the top mast, connect the 3 cables as above Figure

Issued As-Built
Issued As-Built
Issued As-Built
Issued As-Built
Issued As-Built
Issued As-Built
VFD & MCC Control Manual
LM770
(00372-Saipem)
Page 1 of 23
TABLE OF CONTENTS
1 - GENERATOR UNIT
1.1 DESCRIPTION
1.2 CONTROL FUNCTION DESCRIPTION
1.3. POWER AND CONTROL OPERATION
2 - IGBT DRIVE SYSTEM

2.1 DESCRIPTION
2.2 THE DIODE SUPPLY UNIT (DSU)
2.3 THE VFD UNIT
2.4 DYNAMIC BRAKING UNIT
3 - MOTOR CONTROL CENTER

3.1 DESCRIPTION
3.2 MCC FUNCTION AND CONTROL
Appendix A - Power Supply for Lighting, Motor Space Heating and

VFD Air Conditioner
Appendix B – 480V Emergency Engine Power Supply Input Circuit and
600V Camp Power Supply Output Circuit
Page 2 of 23
1. GENERATOR UNIT
1.1 DESCRIPTION
The rig power generator system consists of 4 Engine/Generator sets. Each set has a
control cabinet inside the VFD House. (Caterpillar engine 3512B, 1101 KW; Kato
generator 1365 KW, 1950 KVA, 0.7PF, 600VAC, 3∅, 60HZ). Subtract the engine
radiator power consuming and consider of the generator efficiency, each power set can
produce up to 950 KW power supply.
The Generator Unit (the engine/generator control cabinet) controls the engine/generator
set to develop 600V, 3∅, 60HZ AC power supply. The outputs of 4 generators are fed to a
common AC bus (refer to DWG AC-00372-EQ-0001). Each engine/generator control
cabinet consists of an Engine Generator Control Package WOODWARD EGCP-3, a
Digital Load Sharing and Speed Controls WOODWARD 2301D, a Digital Excitation
Control System BASLER DECS-100 and a circuit breaker (refer to AC-00372-EE-0111
to 0147). The circuit breaker is interlocked with a protection module integrated in the
EGCP-3 which automatically trips the breaker for malfunctions such as Over
Current(910A), Over/Under Voltage( 640V, 569V), Over/Under Frequency (63Hz, 57Hz),
and Reverse Power. A Synchronization Panel located at SYN cabinet is provided to
synchronize each power system, the frequency, the voltage and the phase, with the main
AC bus. See bellow diagram for reference.
Fig.1 LM770 Power Supply One Line

Page 3 of 23
Fig.2 VFD House Control Cabinet Layout
The LM770 Engine-Generator Control System includes Four (5) control cabinet (refer to
VFD House Cabinet Layout illustrated above),
SECTION 4: GEN #1 control cabinet
SECTION 8: SYN control cabinet
There are 2 types of communications used for the power system control, MODBUS for
communication among the rig PLC Power Management System and the WOODWARD
EGCP-3 and LON data for active/inactive load sharing. On the cabinet #2 HMI, the PMS
screens are used to display the parameters and status of each E/G set and programmed in
the main PLC. A communication module SIEMENS CP341 on the main PLC rack
converts the EGCP-3's MODBUS to PROFIBUS DP. With the connection of LON data
interface of each EGCP-3, a MASTER-SLAVE PID regulation function for load sharing
automatically comes to action.
Engine/Generator Controls
The Generator Unit controls the engine/generator set to deliver a constant AC supply to
the Main AC Bus (refer to AC-00372-EQ-0001 ELECTRICAL ONE LINE 1). Note that
the Engine/Generator Control Package EGCP-3 contains the digital Engine Governing
PID, Generator Voltage Regulation PID, Protection and Master/Slave function.
Generator Circuit Breaker

The Generator Circuit Breaker isolates the Main AC Bus from the generator. It has an
electronic trip unit which trips the circuit breaker if current exceeds a preset value (910A).
The circuit breaker has a UV (Under Voltage) coil which is interlocked with the EGCP-3
Module Protection circuit. This circuit trips the circuit breaker for various abnormal
conditions such as reverse power, under/over frequency and over/under voltage.
Engine/Generator Control Package EGCP-3

EGCP-3 is a Multi-unit Load Share Generator System Control Package and a powerful
microprocessor-based generator system control and management package designed for the
most demanding power generation applications. The package combines engine, generator,
power system, switchgear, bus and generator monitoring, protection, and control functions
in a single, compact package. For more detailed information, please see the Operation
Page 4 of 23
Manual (WOODWARD Manual) and Installation Manual (WOODWARD Manual) of the
EGCP-3 Engine Generator Control Package.
The WOODWARD EGCP-3 has been configured during the rig the engine/generator
commissioning and it is ready for use. All configuration points that are necessary for
standard operation are available from the front panel display. These configuration points
plus additional points are available when using Watch Window software through the
ServLink communications serial link. The additional configuration points enable
additional features but are not required for basic operation.
The EGCP-3 is the central control package of an Engine/Generator set. There are two
outputs, one for engine speed close loop control and the other for generator voltage close
loop control. The frequency of generator AC power is regulated by the engine speed loop
and the voltage by the voltage or field loop.
The EGCP-3 engine speed control signal commands the WOODWARD 2301D unit
which controls the position of engine's throttle. The EGCP-3 voltage signal commands the
BASLER DECS-100 unit which controls the field voltage of the generator exciter.
Active/inactive Load Sharing is important and necessary in Multi-unit Generator System
Control. The LON port of an EGCP-3 package is used to communicate with up to 16 other
EGCP-3 devices. LON communication allows controls to share start/stop sequencing,
breaker status, and load share information between generator sets.
For more detailed information about the EGCP-3, please see the WOODWARD Manual.
Engine Governor Woodward 2301D

The WOODWARD 2301D is a digital engine governor which controls the engine speed
and horsepower, and thereby regulate the generator frequency (refer to AC-00372-EE-
0113/0114, AC-00372-EE-0123/0124, AC-00372-EE-0133/0134, AC-00372-EE-
0143/0144). Located in the lowest rack of the generator control cabinet, the Engine
Governor receives the speed signal from the EGCP-3 and controls the position of engine’s
throttle.
The engine speed MPU (magnetic pick up) is connected to the TERMINAL 25(+) and
26(-) of Engine Governor 2301D and the TERMINAL 51(+) and 53(-) of the EGCP-3
package for a feedback control with a shielded pair.
The WOODWARD 2301D has been configured during the rig the engine/generator
commissioning and it is ready for use. For more detailed information about the
WOODWARD 2301D, please see the WOODWARD 2301D installation and operation
Manual.
Voltage Regulator Basler DECS-100

The BASLER DECS-100 is a digital voltage regulator which controls the current of the
generator field coil to regulate the voltage and VAR level, and thereby regulate the
inactive power of each generator. Located in a box above the engine governor
WOODWARD 2301d, the voltage regulator receives the voltage from EGCP-3 and
controls the generator field current.
The generator voltage is feedback to the BASLER DECS-100 through a 3 Φ PT
connected to the generator side main BUS. The second terminals X1, X2 and X3 must
connect to the terminals E1, E2 and E3 of the DECS-100, and have the same polarity with
the first terminals H1, H2 and H3. The phase B CT must connect to the terminals CT1 and
CT2 of the DECS-100. The FIELD OUTPUT terminals F+ and F- connect to the field coil
of the generator.
Page 5 of 23
The DECS-100 has been configured during the rig engine/generator commissioning and it
is ready for use. For more detailed information about the BASLER DECS-100, please see
the INSTRUCTION MANUAL for DECS-100 Digital Excitation Control System.
1.2 CONTROL FUNCTION DESCRIPTION
The AC power of LM770 rig is supplied by up to four (4) KATO generators

which are driven by CAT engines. Each generator is rated
1365KW/600VAC/60Hz. The AC power supply control subsystem consists of
four (4) generator control cabinet and one (1) synchronization control cabinet. The
control cabinets are arranged on the engine side of VFD house and numbered as
SECTION #4, #5, #6, #7, and #8. They are :
SECTION #4: Engine/Generator #1 control cabinet;
SECTION #8: Synchronization control cabinet.
FOUR (4) ENGINE/GENERATOR CONTROL CABINETS have the same control

topology except the wiring and the component numbering system.
The control instruments and operation switches of each Engine/Generator control

cabinet are arranged as the Power Supply One Line (AC-00372-EQ-0001). Each switch
function on the Engine/Generator control cabinet door panel is described as follow:
E-Stop Mushroom Pull/Bush Button is used as the engine/generator emergency switch.

Press will activate the Emergency stop condition. This PB will not affect other
engine/generator working condition.
Voltage Select Switch is used to select Line-to Line voltage which is indicated on the
voltmeter. Four (4) positions are available and the most left position is OFF which turns
off the voltmeter. From the next to the most right position are L1-L2 for the Phase A-B
voltage; L2-L3 for the Phase B-C; and L3-L1 for the Phase C-A.
Current Select Switch is used to select the Line current which will be indicated on the
Amperometer. Four (4) positions are for OFF/L1/L2/L3. The position OFF means that
Amperometer is turn off.
Engine speed adjust switch is used to adjust the engine speed manually. Three (3)
positions “1”/”0”/”2” are available and the switch is auto-reset. The middle position “0”
turns off the adjustment function. Throwing the switch to the “1” position will lower the
engine speed. Throwing the switch to “2” position will raise the engine speed. When the
generator has been merged into an energized BUS, throwing this switch to UP or DOWN
will change the VAR level.
Generator Voltage Adjust switch is used to adjust the generator voltage manually. Three
(3) positions “1”/”0”/”2” are available and the switches are auto-reset. The middle
position “0” turns off the adjustment function. Throwing the switch to the “1” position
will lower the output voltage of a generator. Throwing the switch to “2” position will raise
Page 6 of 23
the generator voltage. When the generator has been merged into an energized BUS,
throwing this switch to UP or DOWN will change the VAR level.
Generator Control mode select switch is used to select multi-unit parallel operation
mode. Three (3) positions “0”/”1”/”2” are available and the “0” position is the normal
position for engine stop. After Engine/Generator is ready for start then turn this switch to
“1” position will fire the engine. The started engine will run at the idle speed (900rpm) for
3 minutes and then raises to 1200rpm and the generator produces 600VAC 3Ф 60Hz.
Position “2” is for closing the main engine circuit breaker which connect the generator
power to the main AC bus. If the main AC bus is not powered with other
engine/generator, turning the switch to position”2” will close the main circuit breaker
immediately. If the AC bus is already powered with other engine/generator(s), turning
the switch to position”2” won’t close the main circuit breaker until synchronized the
generator AC power with Main AC bus AC power.
If the switch is turned to “1” and then to”2” without waiting for engine/generator start up,
it will automatically start up the engine, run idle speed for 3 minutes, close the main
circuit breaker to merge the engine/generator power into main AC bus when seeing the
generator produced the 600V AC and it is synchronized with the main AC bus.
Turning the switch from”2” to “1” after main switch closed will have nothing happen
(functioning like engine start/ignite switch). Turning the switch from”1”to “0” will open
the main circuit breaker and stop the engine. The engine will speed down and running at
idle speed for “5” minutes before it full stops.
Main CB Control Switch used to close the main breaker to or trip from the main BUS.
Three (3) position “0”/”1”/”2” are available and this switch is auto-reset. The “0” position
is for reset status. Before manual close the circuit breaker you need to go to SYN cabinet
and turn the Generator Select switch to match the engine/generator you are operating.
When the selected engine/generator is synchronized with the main AC bus the
synchronization light on the SYN cabinet door panel will ON, at this time throw the
switch to Position “2” will closed the main circuit breaker and connect generator power to
the main AC bus.
If this is the first engine going to send power to maniac bus then no synchronization is
needed, just directly throw the switch to “2”.
When Generator Control mode select switch is at position “1”, throwing the switch to “1”
position will open the main breaker and cut off the generator from the main AC bus.
When Generator Control mode select switch is at position “2”, throwing the switch to “1”
position will open the main breaker and cut off the generator from the main AC bus. But
once you relief and let it go back to position “0” the main circuit breaker will go close, or
go synchronization close.
THE SYNCHRONIZATION CONTROL CABINET (SECTION #8) is dedicated for

engine/generator synchronization control. Three (3) traditional analogue meters are
mounted on the door panel and there are one Dual-voltmeter, one Dual-frequency meter
and one synchronizing scope indicator. The Dual-voltmeter and frequency meters indicate
the main AC BUS and Generator voltage and frequency simultaneously. This is very
convenient for an operator to observe the generator running status. Although the
Engine/Generator control package EGCP-3 can complete the generator synchronization
automatically, the traditional synchronizing scope is very useful for multi-
engine/generator parallel operation.
Page 7 of 23
Generator Select Switch is used to select which generator going to merge into the main
AC BUS. Five (5) positions “0”/”1”/”2”/”3”/”4” are available for this switch. Position”0”
for no generator is selected. The next four (4) positions ”1”/”2”/”3”/”4” are for generator
#1, #2, #3, or #4 correspondingly. For example, with this switch in position “2”, the
generator #2 voltage and frequency will be indicated on the meters, the synchronization
status between the generator #2 and the main AC bus will be shown in the Syncroscope.
There is a Ground Current Meter on the SECTION #8 cabinet door panel to monitor the
current flowing from main AC bus to the ground. Three (3) yellow ground indicators
(PHASE A, PHASE B, and PHASE C) are available, which indicate the three phases
insulation (to the ground) status. When they are light on and the ground current meter has
a very low indication indicate good insulation between the main AC BUS and ground.
Any bad phase-ground insulation will dim the phase lamp. A TEST pushbutton is
provided for lamps and insulations testing, push the button will light up the lamps to
normal light. So it tells if the three phases are in good insulation condition.
1.3. POWER AND CONTROL OPERATION
Manual connect generator AC power to the dead main AC bus when the main AC bus
is not powered (dead main AC bus). Dead main AC bus means that there is no any
running engine/generator connected to the main AC bus or there is no any
engine/generator is started, the main AC bus is not powered up.
Warning: Before operation, make sure the main circuit breaker of the generator is
open, and all switches on the control panel are off or in un-functioning position.
(Take the generator set #1 as an example, as following).
STEP1: Put the Generator Select Switch on the synchronization control panel (SYN) from
“0” to “1” position. Generator set #1 synchronization is selected.
STEP2: Turn the Generator Control Mode select switch on the Engine/Generator #1
control panel (GEN #1) from “0” to “1” position. The Engine #1 will be started and
speeds up to IDLE (900RPM).
STEP3: When IDLE time (3 minutes) programmed in EGCP-3 control package has been
elapsed, the Engine #1 ramps to the RATED speed (1200RPM).
STEP4: Throwing the Engine Speed adjust switch on the Engine/Generator #1 control
panel (GEN #1) to “1” or “2” position, it will adjust the engine speed within ±10% of the
rated speed, and thereby maintains the generator frequency to 60Hz, if it is not 60Hz.
STEP5: Throwing the Generator Voltage adjust on the Engine/Generator #1 control panel
(GEN #1) to “1” or “2” position, , it will adjust the generator voltage within ±10% rated
voltage, and thereby maintains the generator voltage to AC600V, if it is not 600 V.
STEP6: Make sure the indicator Control Power Available is on.
STEP7: Turn the Voltage Select Switch on the Engine/Generator #1 control panel (GEN
#1) to L1-L2, L2-L3 and L3-L1 positions to verify 3-phase voltages are normal.
STEP8: Turn the Main CB Control switch on the Engine/Generator #1 control panel
(GEN #1) to “2” position, the main breaker of generator #1 will close and the generator #1
AC power is connected to the main AC bus.
Page 8 of 23
STEP9: Check the BUS and Generator voltage and frequency meters, they must be in
same scale.
STEP10: Turn the Generator Select Switch on the synchronization control panel (SYN) to
“0” position.
Manual parallel generator AC power to the energized main AC bus (the main AC bus
has already been powered by other engine/generator(s)).
open, and all switches on the control panel are off or in un-functioning position
To merging generator AC power into the main AC bus the two parties must be
synchronized, same voltage, same frequency and same phase.
Let’s take the generator set #2 as an example:
“2” position. The generator set #2 is selected. The Syncroscope and SYN pilot will show
the phase relationship between the generator AC power and the powered bus.
control panel (GEN #2) from “0” to “1” position. The Engine #2 will be started and
speeds up to IDLE (900RPM).
STEP3: When IDLE time programmed in EGCP-3 control package (3 minutes) has been
elapsed, the Engine #2 ramps to the RATED speed (1200RPM).
STEP4: Turn the Engine Speed adjust switch on the Engine/Generator #2 control panel
(GEN #2) to “1” or “2” position, to adjust the engine speed within ±10% of rated speed,
and get the generator frequency to 60Hz, if it is not 60Hz.
STEP5: Turn the Generator Voltage adjust switch on the Engine/Generator #2 control
panel (GEN #2) to “1” or “2” position, to adjust the generator voltage within ±10% of
rated voltage, and get the generator voltage to AC600V, if it is not 600 V.
STEP6: Make sure the indicator Control Power Available on the Engine/Generator #2
control panel (GEN #2) is on.
STEP7: Turn the Voltage Select switch on the Engine/Generator #2 control panel (GEN
#2) to L1-L2, L2-L3 and L3-L1 positions to verify 3-phase voltages are normal.
STEP8: Watch the Sync-Scope and Sync pilot on the synchronization control panel
(SYN). The Sync-Scope rotates clockwise or anti-clockwise and the Sync lamps flashes
periodically.
STEP9: Carefully adjust the generator frequency and focus on the Sync-Scope indicator.
STEP10: When sees the point before and within 10 degree of right up position, turn the
Main CB Control switch on the Engine/Generator #2 control panel (GEN #2) to “2” to
close the GEN#2 main circuit breaker and merge the generator AC power into main AC
bus.
STEP11: Once the generator parallels the main BUS, all generators share the active and
inactive load automatically. Check each generator load level.
STEP12: Turn Generator Select Switch on the synchronization control panel (SYN) to “0”
position.
Automatically connect generator AC power to the dead main AC bus when the main
AC bus is not powered (dead main AC bus). There is no any running engine/generator
Page 9 of 23
connected to the main AC bus or there is no any engine/generator is started, the main AC
bus is not powered up.
The AUTO mode is the most common operation mode. With AUTO operation, all
operation functions such as starting the engine, synchronizing and closing the main
breaker will be accomplished by the Engine/Generator control package EGCP-3
automatically. .
open, and all switches on the control panel are off or in un-functioning position.
STEP1: Turn the Generator Select Switch on the synchronization control panel (SYN)
from “0” to “1” position. The generator set #1 paralleling is selected.
control panel (GEN #1) from “0” to “1” and stop at “2” position. The Engine #1 will be
started and speeds up to IDLE (900RPM) and run at IDLE speed automatically.
STEP3: Check the engine IDLE speed and engine/generator status from the EGCP-3 front
window.
STEP4: With the expiration of IDLE time configured in EGCP-3 (3 minutes), the engine
speed ramps to the RATED speed automatically.
STEP5: With the expiration of voltage settlement time configured in EGCP-3, the EGCP-
3 control package closes the generator main circuit breaker and power up the dead bus
(main AC bus), and all protections come to functioning.
STEP6: Check the voltage of the BUS and generator, they must be normal.
“0” position.
Automatically parallel generator AC power to the energized main AC bus (the main
AC bus has already been powered by other engine/generator(s)).
The AUTO mode is the most common operation mode. With AUTO operation, all
operation functions such as starting the engine, synchronizing and closing the main
breaker will be accomplished by the Engine/Generator control package EGCP-3
automatically.
open, and all switches on the control panel are off or in un-functioning position
To merging generator AC power into the main AC bus the two parties must be
synchronized, same voltage, same frequency and same phase
Let’s take the generator set #2 as an example:
STEP1: Turn the Generator Select Switch on the synchronization control panel (SYN)
from “0” to “2” position. The generator set #2 is selected.
control panel (GEN #2) from “0” to “1” then stop at “2” position. The Engine #2 will be
started and speeds up to IDLE (900RPM) automatically.
STEP3: Check the engine IDLE speed and engine/generator status from the EGCP-3 front
window.
Page 10 of 23
STEP4: With the expiration of IDLE time configured in EGCP-3 (3 minutes), the engine
speed ramps to the RATED speed automatically.
STEP5: With the expiration of voltage settlement time configured in EGCP-3, the EGCP-
3 control package begins synchronization by regulating the frequency and voltage of the
generator automatically. Check the sync-scope and sync lamps on the synchronization
control panel (SYN) to verify the synchronizing process.
STEP6: At the quasi-synchronization point, the Engine/Generator control package EGCP-
3 closes the generator main breaker to the parallel the generator AC power with the main
AC bus automatically, and all protections come to functioning.
STEP7: Check the load sharing between generators.
“0” position.
Power Off the engine/generator is an easy operation. Normal power off operation
procedure is 1). Disconnect the generator from the main AC bus; 2). Stop the Engine.
Warning: Before operation, make sure cutting off the generator will not cause the
main AC bus running overload, or you need to do some unload before operation. If
this is the only running engine/generator (the last running engine/generator) in the
main AC bus please unload the main loads before operation.
STEP1: Go to engine/generator #1 control cabinet (GEN #1), from the control panel turn
the Generator Control Mode select switch from position “2” to “1” if it is in position”2”
and throw the Main CB Control switch to “1”. This operation will open the generator
main circuit breaker.
STEP2: From engine/generator #1 control cabinet (GEN #1) control panel turn the
Generator Control Mode select switch from position “1” to “0”.This operation will stop
the engine/generator. The engine/generator will ramp to and run at idle speed (900RPM)
for 5 minutes (cold down) before full sop.
2. IGBT DRIVE SYSTEM
2.1 DESCRIPTION
The IGBT Drive System provides electrical power conversion and control for the
AC motors on the drilling rig. The system regulates AC power from
engine-generator sets and delivers continuously variable frequency AC power to
Page 11 of 23
traction motors which are coupled to functions such as Drawworks, Rotary Table,
Top Drive, and Mud Pumps (see DWG AC-00372-EQ-0001).
The IGBT Drive System is consisted of:

Two (2) DSUs (Diode Supply Unit) which convert the AC power from the main AC
BUS to DC power at the DC bus. The DC bus is separated into two sections (DC bus 1
and DC bus 2) by the SW1 disconnect at the OETL cabinet.
Three (3) VFDs for mud pumps, two (2) VFDs for Drawworks and one (1) VFD for
Top/RT Drive
Two Drawworks Dynamic Braking Choppers connected to the DC bus directly and two
braking resistors with ventilation fans connected to the Chopper. The DW Dynamic Brake
is automatically applied when the DC Bus voltage is over the Braking set point.
2.2 THE DIODE SUPPLY UNIT (DSU)
The DSU is a 6-pulse rectifier which rectifies the three-phase AC supply to provide
continuously constant DC power for the VFDs. The DSU is isolated by a circuit breaker
from the Main AC Bus. Two DSUs feed the DC bus 1 and DC bus 2 accordingly, and the
SW1 disconnect switch at the OETL cabinet connects them together. During normal
operation the SW1 is closed and the two DC buses work as one DC bus. In some case you
may need to open the SW1 to separate the DC buses for maintenance or troubleshooting.
Two (2) DSUs (each consists of three ABB ACS800-

704-0910-7) are applied in LM770 drilling rig drive
system. Three cabinets (DSU1-CTR, DSU1-POWER
and DSU1-MODULE) are for DSU 1 and another
three cabinets (DSU2-CTR, DSU2-POWER and
DSU2-MODULE) for DSU 2. The DSU1-CTR door
control panel has control switches, indicating lamps
and meters shown on the right.
DSU1 CTRL SWITCH: the control power circuit

breaker;
LINE VOLTAGE: the AC line voltage indicator;
LINE CURRENT: the AC line current indicator;
V-METER SWITCH: AC line selector;
SINGLE MAIN BREAKER CONTR: start DSU1;
DOUBLE MAIN BREAKER CONTR: start DSU1
and DSU2; Fig.3 DSU1 CTR
SINGLE/DOUBLE: select between single or double DSUs;
LOCAL/REMOTE: select local or remote control (remote is an option);
SUPPLY RESET: reset bush button;
RUNNING SIGNAL: running indication (green);
FAULT SIGNAL: fault indication (red);
The DSU2 CTR is similar with DSU1 except that DSU2 CTR does not have switches
DOUBLE MAIN BREAKER CONTR, SINGLE/DOUBLE and LOCAL/REMOTE.
Before working on the DSU2 CTR, the operation mode must be set at DSU1 CTRL.
Page 12 of 23
For detail information of DSU, please refer to the ABB DSU1 and DSU2 Drawings, as
well as ABB Diode Supply Unit installation and operation manual.
2.3 THE VFD UNIT
There are Six (6) VFDs connected to the DC bus. They convert DC power to
continuously variable frequency AC power for the VFD motors.
Three (3) Mud Pump Inverter Drives (Each consists of 3 of ABB ACS800-104-0580-7 )
for mud pump 1 (MP1), mud pump 2 (MP2) and mud pump 3 (MP3)
Two (2) Drawworks Inverter Drives (Each consists of 3 of ABB ACS800-104-0580-7 )
for Drawworks A (DWA) and Drawworks B (DWB)
One (1) RT/TD Inverter Drive which consists of 2 of ABB ACS800-104-0580-7 for Top
Drive and Rotary Table (RT/TD).
The Inverter Drives and the control panels (mini HMI) are located inside the VFD House
as listed bellow (Table 1), also refer to the VFD House Control Cabinet Layout (Fig.2)
Inverter Drive Location Control Panel (mini

(section #) HMI) location
1 MP1 15 AXU4 Bottom
2 MP2 19 AXU3
3 Mp3 20 AXU2
4 DWA 13 AXU1 Top
5 DWB 21 AXU4 Top
6 RT/TD 14 AXU1 Bottom
Table 1. Inverter Drives and controller location
For detail information of VFDs, please see the ABB MP1, MP2, MP3, DWA, DWB and
RT/TD drawings, as well as ABB VFD installation and operation manual.
2.4 DYNAMIC BRAKING UNIT
Two (2) ABB ACS800-607-1600-7 assemblies (each consists of four (4) NRA669C units)
of Dynamic Braking Chopper (DB) are located in Section #16 and #18. The braking
resistor is settled in the ventilation box. When the DC bus voltage is over the chopping set
point the chopper IGBT is turned ON, and thereby the regenerative energy from the
Drawworks motor is consumed by the braking resistors, so the DC bus voltage maintains
constant.
For detail information of DB, please refer to the ABB BU1 and BU2 drawings as well as
ABB Dynamic Chopper installation and operation manual.
Page 13 of 23
L M 7 7 0 D r i l l i n g C o n t r o l s O p e r a t i o n M a n u a l ( R e v 0 )
3. MOTOR CONTROL CENTER (MCC)
3.1 DESCRIPTION
There are all together 1 of MCC Power Control (main circuit breaker) cabinet and 13 of
MCC control cabinets.
The MCC Power Control is located in VFD house (Section # 25).
The MCC cabinets #1 to #4 are located in the VFD house (section #26 to #29, refer to Fig
2. VFD House Control Cabinet Location). They provide powers & controls to the motors,
and deliver power supplies to the equipments for those located in engine/generator
trailers, Mud pump trailers, Fuel tank, DW skid, Rig and Closing Skid.
The MCC cabinets #5 to #13 are located in the MCC house (Section #1,#2, #4 to #14).
They deliver power supplies to equipments and provide power supplies & controls to
motors for mud systems.
Fig 4. MCC Control Cabinet Location
MCC Power up sequence:

Make sure the 600V main AC bus is ON.
Close the Main Transformer switch circuit breaker located in SW cabinet (Section #3 in
VFD house). It powers up the 480VAC MCC transformer. From the M.CB cabinet
(Section #25 in VFD house) turn on the Main 480VAC. Now 480VAC is delivered to all
the MCC input sides and further operation on the MCC drawers will send power to the
related motors and equipments.
Before and when operate any unit, make sure the corresponding power indicating lamp is
in correct status.
Page 14 of 23
Version 2.1
VFD house and MCC house MCC drawer are arranged as following:
Fig 5. VFD House MCC layout
Page 15 of 23
Version 2.1
Fig 6. MCC house MCC layout
Page 16 of 23
Version 2.1
3.2 MCC FUNCTION AND CONTROL
VFD House MCC1

MCC Equipment Eqpt. Outlet HP MCC Auto HMI Local Remark
lct. Lct. Lct. Ctrl Ctrl Ctrl Ctrl
01A MP1 Line MP1 VM1S 3 X X HOA
Washer 3
01B MP1 Oiler MP1 VM1S 3 X X HOA
4
01C MP1 MP1 VM1S 20 X X HOA
Blower 5
01D MP2 Line MP2 VM2S 3 X X HOA
Washer 3
01E MP2 Oiler MP2 VM2S 3 X X HOA
4
01F MP2 MP2 VM2S 20 X X HOA
Blower 5
01G MP3 Line MP3 VM3S 3 X X HOA
Washer 3
01H MP3 Oiler MP3 VM3S 3 X X HOA
4
01I MP3 MP3 VM3S 20 X X HOA
Blower 5
01J SPARE VSD1 3 X X HOA / Spare
01K SPARE 60 X Spare
VFD House MCC2

MCC Equipment Equip. Outlet HP MCC Auto HMI Local Remark
Lct. Lct. Lct. Ctrl Ctrl Ctrl Ctrl
02A DWA Oiler DWA VSD2 3 X X HOA
02B DWA DWA VSD3 15 X X HOA
Blower
02C DWB Oiler DWB VSD4 3 X X HOA
02D DWB DWB VSD5 15 X X HOA
Blower
02E RT Oiler D.F VSD6 3 X X HOA / Spare
02F RT Blower D.F VSD7 15 X X HOA
02G Engine Fan Eng/G VG1S 50 X X HOA / Spare
#1 en #1 2
02H Engine Fan Eng/G VG2S 50 X X HOA / Spare
#2 en #2 2
02I Engine Fan Eng/G VG3S 50 X X HOA / Spare
#3 en #3 2
02J Engine Fan Eng/G VG4S 50 X X HOA / Spare
#3 en #4 2
Page 17 of 23
Version 2.1
VFD House MCC3

03A Fuel Pump Fuel VAS2 30 X Power
(Transfer) Tank
03B Fuel Pump Fuel VAS3 10 X Power
Tank
03C SPARE VSD8 10 X Power / Spare
03D SPARE VSD9 10 X Power / Spare
03E RESISTOR VFD 3 X X HOA
FAN #1 House
03F RESISTOR VFD 3 X X HOA
FAN #1 House
03G COMPRES Eng/G VG1S 60 X Power
SOR #1 en #1 1
03H COMPRES Eng/G VG2S 60 X Power
SOR #2 en #2 1
03I SPARE VSB2 60 X Power / Spare
03J SPARE VSB3 60 X Power / Spare
VFD House MCC4

04A DISK DW VSD10 10 X Power
BRAKER SKID
04B SPARE VSD11 10 X X HOA / Spare
04C SPARE VSD12 10 X X HOA / Spare
04D TD CIP Dog VSB4 60 X Power
House
04E BOP BOP VSB5 60 X Power
Station
04F Bug Blower VSB6 60 X Power/Spare
04G HPU BOP VSA1 100 X Power
Station
04H SPARE VSA2 100 X Power/Spare
04I SPARE VSB7 50 X X HOA / Spare
04J SPARE VSB8 60 X Power/Spare
Page 18 of 23
Version 2.1
MCC House MCC5

05A Suction Tank MSC1 60 X Power
Tank DB
05B Intermediate Tank MSC2 60 X Power
Tank DB
05C Shaker Tank Tank MSC3 60 X Power
DB
05D Reserve #1 Tank MSC4 60 X Power
DB
05E Reserve #2 Tank MSC5 60 X Power
DB
05F Bug Blower MSC6 30 X Power
MSC7
05G SPARE MSC8 30 X Power/Spare
05H SPARE MSC9 60 X Power/Spare
05I Water Pump MSA1 100 X Power
05J SPARE MSA2 100 X Power/Spare
MCC House MCC6

06A Trip Tank Tank MSD1 20 X X HOA
Pump1
06B Trip Tank Tank MSD2 20 X X HOA
Pump1
06C SPARE MSD3 60 X HOA / Spare
06D SPARE MSC1 60 X Power / Spare
0
06E SPARE MSA3 60 X X Soft Starter
/Spare
MCC House MCC7

07A Reserve Tank MSA4 100 X X Soft Starter
Pump #1
07B Reserve Tank MSA5 100 X X Soft Starter
Pump #2
Page 19 of 23
Version 2.1
MCC House MCC7

07A Reserve Tank MSA4 100 X X Soft Starter
Pump #1
07B Reserve Tank MSA5 100 X X Soft Starter
Pump #2
MCC House MCC8

08A Transfer Tank MSA6 100 X X Soft Starter
Pump #1
08B Transfer Tank MSA7 100 X X Soft Starter
Pump #2
MCC House MCC9

09A Super Tank MSA8 100 X X Soft Starter
Charger #1
09B Super Tank MSA9 100 X X Soft Starter
Charger #2
MCC House MCC10

10A Super Tank MASA 100 X X Soft Starter
Charger #3 10
10B Desander Tank MASA 100 X X Soft Starter
11
MCC House MCC11

11A Desilter Tank MASA 100 X X Soft Starter
12
11B Degaser Tank MASA 100 X X Soft Starter
13
MCC House MCC12

12A Suction Tank Tank MASA 100 X X Soft Starter
Mixer 1 14
12B Suction Tank Tank MASA 100 X X Soft Starter
Mixer 2 15
Page 20 of 23
Version 2.1
MCC House MCC13

13A Low Pressure Tank MASA 100 X X Soft Starter
Pump #1 16
13B Low Pressure Tank MASA 100 X X Soft Starter
Pump #2 17
Page 21 of 23
Version 2.1
Appendix A - Power Supply for Lighting, Motor Space Heating and

VFD Air Conditioner
Make sure the 600V AC main bus power is on.

From the inside of VLP/AC Cabinet (Section #30, in VFD House) turn Main GEN Power
circuit breaker (CB9) on, which close the 480/120VAC transformer primary side circuit
breaker and deliver 480VAC to the power transformer.
From the inside of VLP/AC Cabinet, close the Lighting Transformer secondary circuit
breaker named Lighting Main Power (CB11) which turns on the 208VAC, 3Ф for Rig
lighting and Motor Space Heating.
From sub-circuit breakers located in VFD House VLP/AC cabinet, MCC PLC/VLP and
Driller’s Cabin back wall you can control all the rig lighting.
The Generator and Motor space heater circuit breakers are located in VFD House
VLP/AC cabinet door panel. The heating is provided with automatic control. When the
mentioned circuit breaker is on, running of any generator or motor will automatically shut
off the heating for it.
VFD Air conditioner control panel is located in the VFD house end wall (close to VFD
house mud pump door).
Engine/Generator Dryer power supply circuit breaker also located in the VFD House
VLP/AC cabinet door panel.
In case all rig engine/generator are off and need to turn on rig lighting. You plug
auxiliary 460 VAC, 3Ф power supply to VFD house auxiliary 100Amps socket (located
in VFD house outside wall, close to #4 Engine/generator trailer). From inside the VFD
house VLP/AC cabinet, turn off the Main GEN Power circuit breaker (CB9) and turn on
the Aux Gen Power circuit breaker (CB10) to switch the lighting power to emergency
generator. And follow the same procedures for lighting, A/C, and heating control.
The Main Gen Power (CB9) and Aux Gen Power (CB10) circuit breakers are mechanism
interlocked. Only one can be turned on.
Page 22 of 23
Version 2.1
Appendix B – 480V Emergency Engine Power Supply Input Circuit and

600V Camp Power Supply Output Circuit
1). 460V Emergency Engine Power Supply Input Circuit
With 460V emergency engine/generator power supply input circuit is implemented. You
can supply 460V MCC power and lighting power to rig, when rig prime engine(s) is not
running.
The 460V emergency engine/generator power supply input connectors are 3 of single
pole connectors located at the end of the VFD house.
The 460V emergency engine/generator power circuit breaker is located inside cabinet
section #1 (CIP cabinet), in VFD house. This circuit breaker is equipped with motor
operation mechanism. The operation of this circuit breaker is by means of the 2 push
buttons at the cabinet door, green push button for “Close” and red push button for “Open”.
There are 2 indicate lights located at the cabinet door, “green” on shows that 460V
emergency engine/generator power is available and “red” on shows that the circuit
breaker is closed ( 460V emergency engine power sent to rig).
This circuit breaker is electrically interlocked with the rig 600V/460V transformer prime
side circuit breaker (CB7, at SW cabinet, section #3). When rig is powered with rig prime
engine/generator the 460V emergency engine power circuit breaker is locked to open
position and will not allowed to close; vice versa.
2). 600V Camp Power Supply Output Circuit
The 600V camp power supply circuit breaker is located inside cabinet section #1 (CIP
cabinet), in VFD house. This is a manual operation circuit breaker.
The input of this circuit breaker is connected to the rig 600V AC bus; the output of this
circuit breaker is routed to the 3 pole connectors located at end of VFD house, next to the
600V emergency power input connectors.
Warning
When connecting the 480V emergency engine/generator power supply input and/or
600V camp power supply output cables, please pay attention for the correct phase
sequence and connect to right connectors.
Page 23 of 23
Version 2.1

Saipem 770 Rig Manuals: Loadmaster Universal Rigs, Inc

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Saipem 770 Rig Manuals: Loadmaster Universal Rigs, Inc

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Saipem 770 Rig Manuals

Loadmaster Universal Rigs, Inc

2. Hydraulic Disc Brake Operation, Maintenance Instruction

3. Gear Coupling Manual

4. Drawworks gear box manual

5. Air Dryer User Manual

6. SULLAIR PORTABLE AIR COMPRESSOR

8. HPU Operation Manual

9. LM770 Rig Remote Control System

10. LM770 Rig Drilling Controls Operation Manual

11. GAI-TRONICS CORPORATION Installation, Operation,

and Maintenance Manual

12. VFD and MCC Control Manual

LM 770 Drawworks Specifications

Drawworks Main Components

Drawworks Operation and Maintenance

LOADMASTER UNIVERSAL RIGS reserves the right to discontinue models at any

1.2. General Information

This manual contains instructions and recommendations on the operation and

PRECAUTIONS TO BE TAKEN BEFORE DOING MAINTENANCE WORK ON

2. LM 770 Drawworks Specifications

2.1. General Description

LM770 DRAWWORKS ASSEMBLY

LM770 DRUMSHAFT ASSEMBLY

2.2. Technical Specifications

Electric Drive: HTM 1230 AC Vector Motors

Input power of drawworks……………………………..1100KW

3. Drawworks Main Components

3.1. Main Drum Assembly

Maximum pull of fast line………………………………370kN

3.2. Gear Box Reducer

3.4. Hydraulic Disc Brake System

Emergency Brake function: Under an emergency condition, operating the emergency

3.5. Drawworks Frame and Skid

3.6. Gear Box Lubrication System

4. Drawworks Operation and Maintenance

4.1. Wireline Installation

Figure – Drilling Line Installation

4.2. Drawworks Start Up

Drawworks starting procedure:

The drawworks shutdown procedure is the reverse of the starting procedure.

4.3. Operation and Maintenance of the Hydraulic Brake System

The maintenance plan must include the following:

4.3.1. Oil Level

4.3.2. Oil Temperatures

4.3.3. Pressure Gauge

Observe readings on the pressure gauge of the hydraulic station, particularly,

4.3.4. Oil Filter

Follow the manufacturer’s recommendations on oil filter inspection and

4.3.5. Air Filter

Follow the manufacturer’s recommendations on air filter inspection and

Refer to the manufacturer’s documentation on accumulator inspection, service,

4.3.7. Crown Saver

4.3.8. Service Calipers

4.3.9. Safety Calipers

4.3.10. Quick Coupling and Hydraulic Pipe

Check twice a day all quick couplings to guarantee good connections.

4.3.11. Structural Elements

Checks and maintenance for structural elements are concentrated mainly on

Wearing: The allowable maximum wearing of the friction disc is 10mm

Check welded elements, particularly the caliper frames and caliper

Check moving parts to see whether there is sticking, particularly, in

4.3.13. Maintenance Plan for Hydraulic Brake System