Product Information Bulletin

Date: 30 August 2016

Bulletin Number: 1000011765-PIB Revision: 01

Top Drive Drilling System

Subject: Reduced Life of Drill Stem Components Due to Misalignment

Product Model: All Top Drive Drilling Systems (Models TDS-3, TDS-4, TDS-5, TDS-6, TDS-7,
TDS-8SA, TDS-9SA, TDS-10SA, TDS-10SH, TDS-11SA, TDS-11SH, TDS-11HP,
TDS-150, TDH-150, TDH-250, TDS-1000, TDX-1000, TDX-1250, IDS-1, IDS-4A,
IDS-350P, IDS-350PE, PS-350/500, PS-500A, PS-500/500, PS2-500A, PS2-
500/500, PS2-650/650, PS2-650/750, PS2-750A, PS2-750, PS2-1000, HPS-02,
HPS-03, HPS-04, HPT-05, HPT-06, DTD-100, TD120P, TD120PE, TD120PEP,
TD120HTP, TD150P, TD150HTP, TD250HTP, TD250PLB, S-250TPA, TD350P,
TD350PB-2, TD500PAC)

Effectivity: All Top Drives Drilling Systems

Affected Assemblies: Drill Stem Components, (i.e, Upper/Lower IBOP, Saver Sub and Main Shaft
(Multiple Part Nos.)

Objective
Advise NOV Top Drive users of the potential for damaged Drill Stem Components and to notify customers
of available LASER Alignment Tool.

Issue
NOV has received reports of Upper and Lower Internal Blowout Preventer (IBOP) valves leaking as a
result of cracks in the IBOP Body. Bending stress in the drill stem has been shown to result in a shorter
life for Top Drive drill stem components, Upper and Lower IBOP valves, Saver Sub and Main Shaft. NOV
has received multiple reports of failures, typically isolated to specific drilling rigs.

Possible causes of bending are misalignment of the Top Drive (see examples Figure 1) and can result
from the following (Ref: API 8B):

1. Derrick or mast not in alignment with the gravitational axis of the drill-string.
2. Plane of traveling equipment guide rails misaligned to the derrick and/or the drill string.
3. Damage to the guide dolly structure.
4. Top drive mainshaft not in alignment with plane of guide dolly.
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5. More lines strung onto the sheaves on one side of the traveling block than the other side.
6. A malfunction in the retract dolly that prevents the traveling equipment from returning
properly to the rotary center.
7. Riser/conductor barrel may not be parallel and concentric with the mast/guide track/top drive
main shaft.

This Space
Intentionally
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Well Center

Parallel Offset Misalignment Angular Misalignment

Figure 1 – Examples of Misalignment

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Solution

Several failed IBOP valves were returned and a root cause analysis was performed to determine the
potential cause of the failures. Material analysis of the failed IBOP Valve was performed to rule out any
material issues contributing to the premature failures. However, finite element analysis (FEA) was
performed on the IBOP valve and has shown that varying degrees of bending in the drill stem
components results in an exponential reduction in component life.

NOV strongly recommends that the Upper and Lower IBOP Valves as well as all drill stem components
be routinely inspected to determine if any cracks are developing. All drill stem components should be
inspected on a regular basis as outlined in the Top Drive and IBOP Service Manual with special attention
to the crank bores, box and pin connections. Alignment of the Top Drive should be periodically checked
and confirmed after every rig move and after severe operating conditions, such as jarring events.
Inspection should include verification of alignment and observing for any bias of the drill string that
causes it to excessively rub against the rotary’s wear bushing. Additionally, the duration of link tilt
extension in the drill-down position should be reduced. Optimal use is to keep the links near vertical
until the elevator nears the drill floor, and then tilt to full drill down.

To assist customers in achieving proper alignment of their Top Drive Drilling System with well center, NOV
has developed a Kit, Assy, Tool, LASER Alignment (P/N 11412491-001), which is available for purchase
from your local NOV Service Center. This Alignment Tool Kit consists of a housing with a magnetic base,
which holds a battery-operated LASER, instruction placard, and a wire rope lanyard for secondary
retention (See Figure 2) housed in a durable weather-proof case (See Figure 3).
The LASER produces a beam that is visible at the rotary table from 100 feet above the drill floor. Once
installed, the top drive can be hoisted over the operating height range, allowing for alignment to be
checked throughout the travel of the Top Drive.

Note: This tool is battery powered and is not certified for hazardous area use.

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Figure 2 - Tool, LASER Alignment

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Figure 3 - Kit, Assy, Tool, LASER Alignment

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Ordering and Contact Information

Please contact your local National Oilwell Varco (NOV) Service Center, with reference to Product Bulletin
1000011765-PIB, for further assistance.

Economic Impact

All parts, necessary software updates and installation are at Customer cost for equipment
outside of Warranty period. Parts will be delivered NOV, Incoterms FCA. . If the equipment is
still under warranty, please contact your local service center with reference to Product Bulletin
1000011765-PIB, where cases will be handled on an individual basis in accordance with
contractual obligations.

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.