Product Safety Alert

Date: 05 May 2017

Bulletin Number: 1000012026-SA Revision: 01

Top Drive

Subject: Unintended Rotation of Rotating Link Adapter and Links during

Troubleshooting of Pipe Handler

Product Model: TDS-9SA, TDS-10SA, TDS-10SH, TDS-11SA, TDS-11HP and TDS-11SH Top Drive
Drilling System

Effectivity: All TDS-9SA, TDS-10SA, TDS-10SH, TDS-11SA, TDS-11HP and TDS-11SH

Affected Assemblies: Driller’s Console Assembly (P/N 120546)

Objective
Advise customers of a recent report of a fatality after the hose connections to the clamp cylinder on a PH-
75 Pipe Handler were reversed by Rig personnel during troubleshooting of the Pipe Handler.

Issue
NOV received a report that a rig was running drilling pipe in the hole, had lowered the TDS-11SA Top Drive
to the rig floor with the elevator links extended in DRILL mode, and had clamped on the tool joint to break
out the connection. After breaking out the connection, the Pipe Handler did not unclamp as normal when
the TORQUE WRENCH PUSH & HOLD button (Switch, Pushbutton (P/N 30087708-02)) on the Driller’s
Console Assembly (P/N 120546) was released. Rather than verifying whether the Switch and the
solenoids that it operates were functioning correctly, the rig personnel went to well center to investigate
and made the decision to reverse the hose connections to the clamp cylinder. This action resulted in the
Pipe Handler unclamping from the tool joint.

The Rig personnel then made the decision to command the Top Drive to drill with the hoses reversed.
With the hoses in the correct position, the TDS-11SA Top Drive has controls which are designed to not
allow rotation of the Top Drive’s main shaft when the Pipe Handler is clamped on drill pipe. With the hoses
in the correct position, if the Top Drive is commanded to drill, the clamp cylinder will unclamp to prevent
damage to the Top Drive. Since the hoses to the clamp cylinder were reversed (and in the improper
position), these controls were bypassed. When the Top Drive was commanded to drill, this resulted in
the Pipe Handler improperly clamping on the drill pipe while it was rotating and subsequently causing the

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 Product Safety Alert

Rotating Link Adapter, elevator links and drill pipe elevator to suddenly rotate as well and make contact
with rig personnel. This incident resulted in a fatality and injuries to two other rig personnel.

Solution
NOV personnel were dispatched to the rig to investigate the incident. From function testing of the Top
Drive at the site under different scenarios with the original Switch installed, and alternatively with a
replacement Switch installed, and having the hoses connected improperly, and alternatively connected
properly, it was determined that the reason the Pipe Handler did not initially unclamp was likely due to a
malfunctioning Pushbutton Switch on the Driller’s Console Assembly. The Switch was retained for further
testing and investigation. The testing at the rig confirmed that because of the Rig personnel reversing the
hose connections to the clamp cylinder, the controls were bypassed that would have prevented the Pipe
Handler from clamping on the rotating drill pipe. The reversed hoses allowed the Pipe Handler to
improperly clamp on the drill pipe while it was rotating. The Switch was replaced and the hoses on the
Pipe Handler were reconnected to their proper locations and the function testing was performed with no
issues reported.

In the event of the Switch not operating as expected, troubleshooting procedures should focus on the
Switch to verify whether it and the solenoids it controls are operating correctly. Under no circumstance
should the hoses of the Top Drive be reversed. Modification or alteration of NOV equipment should not
occur without the written consent of NOV. The Maintenance section of the TDS-11SA Service Manual
recommends that proper operation of the TDS controls be verified on a daily basis.

Ordering and Contact Information

Please contact your local National Oilwell Varco (NOV) Service Center, with reference to PB
1000012026-SA, for further assistance.

Economic Impact
No Economic Impact

Customers should also refer to previous NOV Product Bulletins for additional information related to this
issue and information regarding safe operation, maintenance, and inspection criteria by signing in to your
MYNOV account at https://portal.mynov.com and then searching with the Product Bulletin Search
available below the heading ‘Application Groups’. For information on registering, please visit
https://www.nov.com/Search/register.aspx.

Failure to follow the recommendations and/or guidance in NOV Manuals and Product Bulletins may
result in death, bodily injury or property damage.

Please contact your local National Oilwell Varco (NOV) Service Center if you have any questions
regarding this bulletin.
1000012026-SA / Rev. 01 2
 Product Safety Alert

Revision History
Revision Date Change Description
00 Month 0000 (vertical line to the side of a paragraph indicates a change)
01 05 May 2017 Initial release

1000012026-SA / Rev. 01 3