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1. TANDEM DOUBLE ACTING HYDRAULIC CYLINDERS e P DRIVE rh MAKE BREAK TDMBT 5 BREAK BREAKOUT N AKEUP TDMBT BULKHEADS AND Q ue GRO DISCONNECTS MANUALLY OPERATED HYDRAULIC HOSES lt lt 4 SPRING RETUR ES SH PANEL MOUNTED S CONTROL CONSOLE DIRECTIDNA PANEL MOUNTED BULKHEADS AND CONTROL VALVE SYSTEM PRESSURE Q Q QUICK DISCONNECTS GAGE W MAKE AND INLET RELIEF VALVE BREAK TORQUE SCALE SET 2500 PSI MAIN ADJUSTABLE 2 RELIEF VALVE ISOLATION BALL VALVE ER F L MAKE SET 2500 PSI Be PANEL MOUNTED mayan RELIEF VALV REMOTE ADJUSTABLE L RIG OR OTHER gt lt HYD SUPPLY M TDMB CONTR RELIEF VALVE CONSOLE TOP DRIVE MAKE BREAK TOOL HYDRAULIC SCHEMATIC AIN ADJUSTABLE BREAK SET 2500 PSI ADJUSTABLE TO 2500 PSI UPERIO 4225 HWY 90 EAST R_ BROUSSARD LA 70518 Ww Manufacturing amp Hydraulics 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 01 12 05 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT2. 4225 HWY 90 EAST FLEXIBLE INSERT ASSEMBLY enc THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 12 16 04 ASS E M BLY NO TD M B20 1 3 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMA TION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS REF Equip zen Page8 4 LOWER EXTENSION ASSEMBLY ASSEMBLY NO TDMB2040 Page 8 4 1 Item Qty Part Number Part Description 1 1 TDMB2019 LOWER EXTENSIONWELDMENT 2 1 2019 53 BOTTOM PLATE 3 2 TDMB2013 FLEXIBLE INSERT ASSEMBLY 4 2 TDMB2012 SOLID INSERT 5 16 1151 5 8 LOCKWASHER 6 8 201 5 8 11 X 2 1 4 HHCS 7 8 204 5 8 11 X3 1 4 SHCS 8 24 1171 3 4 LOCKWASHER 9 24 1190 3 4 10 X 2 HHCS 10 1 TDMB1025 32 5 8 1 4 BOLT TYPE SHACKLE Ab SUPERIOR 354 P LA 70518 w Manufacturing amp Hydraulics 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 02 23 05 MAY NOT BE USED DISCLOSED COPIED ORREPRODUGEDINANY LOG DATE THIS PAGE LEFT BLANK INTENTIONAL LY Page 8 4 2 G 8 PROOF TEST TO 9000 LBS INSTALL METAL TAG WITH TEST DATE LOAD WWL CONT
3. C SAVER SUB D1 i HANDLER CLAMP i CYLINDER ASSEMBLY OPEN POSITION DRILL PIPE RIG STRUCTURE TYPO TOP DRIVE PIPE HANDLER AND ROTARY TABLE GENERAL ARRANGEMENT ROTARY TABLE SUPERIOR w Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 THIS DOCUMENTIS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND ISCONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 04 28 04 REV LOG DATE REF S Equip Manuals Dwgs TDMB1000 01 Gen Arrang wpg 5 23 MOTOR BRAKE IN PIPE HANDLER IN MAKE UP AND BREAK OUT POSITION RELEASED POSITION MAKE BREAK POSITION SPLINES ENGAGED PIPE HANDLER ACTIVATED TO MAKE OR BREAK SAVER D SUB amp DRILL PIPE CONNECTION PIPE HANDLER CLAMP CYLINDER IN GRIPPING POSITION gt 5 24 4225 HWY 90 EAST Ab SUPERIOR BROUSSARD LA 70518 w Manufacturing amp Hydraulics 318 837 8847 THIS DOCUMENT IS THE PROPERTY O
4. Acceptable Task Risk Reduction Measure Residual Risk Tolerable 1 Place the spare UIBOP valve in the receiving collar on UIBOP breakout tool Apply thread compound to the main shaft and Upper IBOP in preparation of make up 3 With link tilt fully extended and pipe handler held back lower TD stab in and torque With TD brake off cycle the Superior UIBOP tool fully to break position torque with Superior UIBOP tool break out tool from the rotary table valve connections FORM No OP 018 Rev 1 Page 1 of 4 Generic Superior Upper IBOP Installation and Make Up JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 13 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations CATEGORY _ DEFIMITIDONS 1 Unacceptable Damage MePellution Tolerable meo MED 4 First Aidinjury Minor Damage Minor Pollution Probable JRA Felten Reference Ix THERE SAFER WAT TO COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK HSE hh Release the pipe handler carefully to be sure that IBOP arms correctly engage shell higher in the slips connection to the Lower IBOP Using pipe handler torque the upper to lower IBOP torque connection to req torque Reset the pipe handler torque to the required
5. Address Address City State Postal Code Country Telephone Fax Make Break Model No Serial No Assembly Date CLINCHER Make Break Tool Technical Manual Registration Form Name Return To Company Address SUPERIOR Mfg amp Hyd Address 4225 Hwy 90 East Broussard LA 70518 City _ USA Postal Code Country Telephone Fax Telephone 337 837 8847 Facsimile 337 837 8839 Web Site www superior manf com Make Break Model No Serial No Assembly Date TABLE OF CONTENTS Hazard Warnings n Description Features amp Specifications Schematics Assembly Pre Order Considerations Operational Instructions amp Illustrations Job Risk Assessment Forms Installation amp Make Up Break Out amp Removal Maintenance Instructions amp Trouble Shooting Spare Parts Recommendations Make Break Tool Illustrations Valve Technical Data Oo N A to Section CLINCHER MAKE BREAK TOOL REVISION TABLE Description 02 2005 Changed illustrations to show new lower extension assembly 02 2005 Added illustration TDMB2040 Lower Extension Assembly Revised illustra tion Make Break Tool Assy to show TDMB2040 Lower Extension Assy Revised illustration TDMB1036 Air Booster Panel 04 18 05 Revised Specs Makeup Torque from 110 000 ft Ibs to 130 000 ft Ibs SUPERIOR Manufacturing amp Hydraulics
6. Inc CLINCHER Make Break Tool TDMB2000 Revision 0405 Page 0 1 CLINCHER Make Break Tool HAZARD WARNING Nomenclature used in this manual WARNING concerns an operating procedure practice that if not strictly observed can result in injury to personnel or loss of life Caution concerns an operating procedure or practice that if not strictly observed can result in damage to or destruction of equipment Note concerns an operating procedure or practice that needs highlighting CLINCHER Make Break Tools are manufactured to provide a means of making up or breaking out high torque tubular connections between Varco TDS3 TDS4 amp TDS5 Top Drives and their upper internal blowout preventer IBOP valves This tool utilizes high pressure hydraulic fluid power which can cause the tool to move suddenly and with great force if it is not properly rigged up and operated CLINCHER Make Break Tools contain rotating and reciprocating parts which can severely or fatally injure personnel who are operating repairing or near this equipment during its operation WARNING Make Break Tools are not to be operated by untrained personnel or per sonnel with diminished physical or mental capacity No work of any type is to be carried out while the Make Break Tool is connected to any hydraulic power unit CLINCHER Make Break Tools are heavy tools When lifted vertically they should be suspended from a secure high strength 5 8 IWRC minimum diameter wi
7. control valves hydraulic lines and cylinders may contain high pressure fluid even when the power unit is de energized and the fluid supply hoses are disconnected During normal operation the temperature of the hydraulic fluids as well as hoses piping valves etc can rise to a level which can cause burns WARNING Personal protective gear including safety glasses face shields protective gloves and protective clothing must be worn to guard against the hazards of high pressure fluids Tight fitting clothing is required to prevent entanglement in rotating components These tools should be serviced by thoroughly trained and qualified hydraulic technicians using procedures to safely insure hydraulic pressure is bled from these circuits No attempt should be made to operate the CLINCHER Make Break Tool for any purpose other than which it is intended This system is capable of generating very large torsional loads which if improperly applied or controlled could result in damage to the tubular to the tool or could possibly result in injury or death of personnel Do not attempt to operate the unit without correct dies and the proper size tubular being in the tool SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 1 2 HYDRAULIC PRODUCT cR 055 GENERAL INFORMATION SAFETY HYDRAULIC PRODUCT SAFETY certain conditions allowing the hydraulic equipment to continue to WARNING Valve lever spool m
8. 19 ID to accommodate drillpipe tool joints suspended by rotary slips Slip handles must be removed before landing Make Break Tool and Extension The RF Make Break Tool is provided with two torque drive subs and two lockdown drive subs Lockdown drive subs feature CLINCHER grit face coating to engage sockets without requirement for modifications Drive subs may be attached directly to the bottom of the RF Make Break Tool or to the bottom of the RF Make Break Lower Extension The RF Make Break Tool is also provided with a separate free standing hydraulic control console The console is provided with quick disconnects for supply return and work circuits It includes a directional control valve for make break connections and includes a gauge which allows monitoring of make break torques and pressures An adjustable pressure control valve allows the operator to regulate the amount of make up torque developed This control system is set up for closed style pressure compensated hydraulic power systems with pressures up to 3 000 psi Control valves for open hydraulic systems are available upon request System includes Haskel MAA gas booster 3 way air valve and air regulator to boost top drive braking force installed by others A Handling Sling with welded padeyes features two 1 2 6x19 IWRC galvanized cables 48 long with swaged open socket on lower ends for pinning to two padeyes welded to the upper extension tube The upper end of the cables are loop
9. 6 Nm Breakout Torque 1 130 000 ft lbs 176 256 6 Nm Maximum Operating Pressure 2 000 psi 137 9 bar Minimum ID through Make Break Tool 10 1 8 25 7 cm Upper Extension OD for compatibility with rig tongs 7 1 4 18 4 cm Upper Extension OAL approximate 20 1 4 51 4 cm Lower Extension ID to accommodate drill pipe tool joint 19 48 26 cm suspended by rotary slips Drive Sub Maximum OD 14 0 35 6cm Drive Sub Minimum ID 6 65 16 9 cm Drive Sub OAL 10 5 26 7 cm Overall Length Make Break Tool 30 5 16 77 0 cm Overall Width Make Break Tool 68 1 2 174 0 cm Overall Height Make Break Tool w o Sling 106 7 8 271 5 cm Weight approximate 3 540 Ibs 1 605 7 kg Torque ratings are based upon 2 000 psi operating pressure Standard Equipment Handling sling Control console Hoses to connect control console to Make Break Tool Hoses to connect control console to hydraulic power loop SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 04 05 Page 2 7
10. BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV _ LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS REF S Equip Manuals Dwgs TDMB2000 Sche matic wpg MOTOR SHAFT Z bed 3 BRAKE MECHANISM TOP DRIVE EXHAUST MAY BE REPLACED WITH OPTIONAL EXPLOSION EXISTING SOLENOID 7 EXHAUST PROOF ELECTRICALLY OPERATED AIR VALVE OPERATED VALVE P N TDMB2028 TO RIG AIR SUPPLY TOP DRIVE BRAKE CYLINDER BOOSTER SCHEMATIC Description 1 4 MRO 1 4 MALE RUN TEE 3 8 FF 3 8 MALE PIPE NIPPLE MALE BRANCH TEE 38 MNPT X 318 FNPT 4 2 3 8 MRO 3 8 MALE RUN TEE 3 8 NPT X 1 4 NPT EXPANDER ADAPTER 6 2 3 8 X 1 4 38 NPT X 1 4 NPT PIPE THREAD REDUCER MALE CONNECTOR 1 4 MJIC X 1 8 MNPT 8 1 44etx 14 1 4 STRAIGHT 9 2 erm har MNPT X 3 8 MALE CONNECTOR MALE ELBOW 3 8 X 3 8 MNPT AIR POP OFF VALVE 185 PSI 1 4 NPT 12 1 1478 BALL VALVE BRASS 3 8 FNPT 13 1 B18 02 FK00 _ AIR FILTER REGULATOR 1 4 NPT PORTS BAC 600 25 GAUGE 600 2 1 2 DIA BRASS CM4554 3 8 CHECK VALVE GPA 96 606 AIR FILTER MOUNTING BRACKET FOR WILKERSON B18 02 FK00 1 25 GAS BOOSTER 25 1 RATIO TDMB1036 S1_ AIR BOOSTER MOUNTING PLATE 1036 52 2 POSITI
11. NO AND P N TDMB1025 Y yr CH 1 2 x 64 GALVANIZED 2 LEG SPREADER WITH THIMBLES ON ENDS P N TDMB1025 S1 3 25 TON ANCHOR SHACKLE 5 8 BOLT TYPE 2X W P N TDMB1025 S2 WORKING LOAD LIMIT SLING 4 5 TONS AT 65E 50E INCLUDED ANGLE APPROXIMATE WEIGHT LBS 11 045865 4225 HWY 90 EAST SLING ASSEMBLY THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING 8 1 09 17 04 HYDRAULICS AND ISCONSIDERED CONFIDENTIAL THIS INFORMATION ASSEMBLY NO TDMB1025 MAY NOT BE USED DISCLOSED COPIED ORREPRODUCEDINANY REV d LOG DATE FORM WITHOUT THE EXP TTEN INSENT UPERIOR MANUFACTURING amp HYDRAULICS EF _S Equip Manuak Dwgs TDMB1000 01 Sling wpg PRESSURE ADJUSTMENT 185 PSI MAX 3 8 MJIC ON OFF tem Qy Part Number Part Description NOT SHOWN IN THIS ILLUSTRATION 1 2 1 4MRO 1 4 MALE RUN TEE item Qty Part Number Part Description 2 3 aert 3 8 MALE NIPPLE 4 1008 83 1 4 20 X 1 2 HHCS 3 2 3 8 MMS MALE BRANCH TEE 3 8 X 3 8 FNPT 4 101 1 4 LOCKWASHER 4 2 38MRO 3 8 MALE RUN TEE 1 1456 1 4 HEX NIPPLE 5 1 38 14 3 8 NPT X 1 4 NPT EXPANDER ADAPTER 1579 3 8 NPT VENT 6 1 38X1APTR 3 8 NPT X 1 4 NPT PIPE THREAD REDUCER 1 1599 3 8 MNPT BRANCH TEE 7 1 4FTX MALE CO
12. function and torque the valve to main shaft connection as high as possible with the top drive motor to minimize the required number of torque cycles with the Make Break Tool SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 5 7 19 20 21 22 23 24 23 26 27 28 29 30 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS With the top drive brake switched off cycle the torque cylinders to their full break position by holding the selector in the break position Have the driller set the top drive brake and allow the air pressure to reach 175 psi Reduce the torque regulator setting on the control console Place the Make Break valve on the Superior console to the make position while watching the torque gauge Slowly raise the torque adjustment until the desired torque setting is reached and hold for the required time interval 30 seconds Release the top drive brake and recycle the tool for another torque stroke Set the brake and torque again to be sure that the torque cylinders have not reached the end of stroke on the previous sequence Repeat these steps until connection is properly torqued Raise the top drive remove the Superior IBOP Make Break Tool from the rotary table and return it to the storage base using the same lifting methods utilized during installation Lower the top drive Release the pipe handler when it is just above the lowe
13. of the tool is recommended This process is rig dependent and should be discussed thoroughly in the JRA 8 Place the Superior IBOP Make Break Tool over the pipe stick up and lock into the rotary table by tightening the bolts on the expandable feet to approximately 80 to 100 ft Ibs Caution Do not tighten bolts to expand feet unless engaged in rotary tables sockets Doing so will damage feet Rotate the rotary table until the Make Break Tool is perpendicular to the V door and the hydraulic connections are facing the control panel skid Connect the make and break hoses to the Superior Make Break Tool and connect the supply and return hydraulic hoses to a suitable location that will provide a 2000 psi supply Caution Always be sure that the supply valves are closed and that the return line valve has been opened before connecting the supply hose 9 Open the isolation valve on the side of the control console and function test the tool 10 Fully extend the link tilt toward the V door and lower the top drive until the pipe handler is just above the Make Break Tool Attach a tugger line to the sling on the back of the pipe handler and slowly pull clear of the upper IBOP Caution If the torque tube on the pipe handler will not clear the bottom of the upper IBOP it may be necessary to loosen the four bolts on the lift cylinder rod attachment point in order to allow the pipe handler to drop slightly lower 11 Lock the rotary table dogs to pre
14. A Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 21 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations CATEGORY Unacceptable Low Damage Pellution Tolerable MED 1 El Acceptable Probable HIGH Last Time Injur JRA Policy Reference 15 THERE SAFER WAT TO COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK IKELIHOOO HSE Ph 26 FORM No OP 018Rev 1 Page 4 of 4 Generic Superior Upper IBOP Breakout and Removal JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 22 DRIVE amp TRAVELING BLOCK MOTOR BRAKE DRIVE MOTOR GUIDE RAILS TOP DRIVE SWIVEL LZ TRANSMISSION MOTOR DOLLY EXTERNALLY SPLINED UPPER SAFETY VALVE INTERNAL BLOWOUT N PREVENTION OR IBOP PIPE HANDLER FRAME HANDSLIPS SLIP HANDLES RIG FLOOR ROTARY TABLE DRIVE MOTOR GEARS amp BRAKE ASSEMBLIES i PIPE HANDLER LIFT CYLINDER SHOWN IN NORMAL OPERATING POSITION B PIPE HANDLER INTERNALLY SPLINED TORQUE TUBE LOWER SAFETY VALVE H
15. ARE THERE ALTERHATITES WITH LESS RISK IKELIHOOO HSE Ph 26 FORM No OP 018 Rev 1 Page 4 of 4 Generic Superior Upper IBOP Installation and Make Up JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 16 JRA Number Job Risk Assessment JRA Work Permit Type No CoshniiazeomNo Isolation Certiticate TASK EQUIPMENT No CerificationConfirmed Who inspects GSF Superior Clincher Upper IBOP Breakout Tool GSF Superior Clincher Upper IBOP Breakout Tool installed lift sling Inspection 3 Rdn and safety 4 TStepladder 414 7 5 8 RH lift cap for Upper IBOP handling 6 10 ft or longer sling with minimum 5 ton rating 7 with a minimum 5 ton ing PARTICIPANTS S ee Dermickman Roughnek2 Rouge E Pf rane Operator 04 8 Roustabout tt O 9 O o TASK PROCEDURE Step Task Detal Who Performs WhoSupervises 6 Place the top drive in low gear if possible Only TDS4 models _ Drile TeofPusher 8 JOrient the TD so that tilt is toward the Vdoor Deiler 2 2 Toolpusher 9 up and torque the top drive to the dril string Pusher____ FORM No O
16. Bb SUPERIOR Manufacturing amp Hydraulics TECHNICAL MANUAL TOP DRIVE MAKE BREAK TOOL covers MODEL TDMB2000 4225 Highway 90 East Broussar d Louisiana 70518 www superior manf co Published 02 2005 Copyright 2005 SUPERIOR Manufacturing amp Hydraulics Inc All rights reserved This document is the property of SUPERIOR Manufacturing amp Hydraulics Inc It is supplied as reference information to users of our products This document is considered confidential and is not to be disclosed copied or reproduced transmitted transcribed in any form or stored in any type of system without the express written consent of SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER LOCKJAW amp Grit Faced Die are trademarks of SUPERIOR Manufacturing amp Hydraulics Inc The products described in this manual are covered by U S and foreign Patents and or pending Patent Applications This manual is not a controlled document and is subject to revision without notice To receive updates and insure you have access to the latest information concerning the CLINCHER Make Break Tool we request you complete this form and return the lower half to SUPERIOR Manufacturing and Hydraulics by mail or facsimile Access to our manuals can also be acquired through our web site www superior manf com Click the tab CLINCHER Products click the equipment from the list to get Specs page click the tab Download Manual Name Company
17. E UPWITH OUTPUT SHAFT 7 UPPER IBOP BOX DOWN PIN UP IF LOWER IBOP VALVE we LOWER IBOP 7 SAVER SUB CROSSOVER gt DRILL PIPE Page 5 28 __SUPERIOR_ uy Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 818 837 8847 THIS DOCUMENT IS THE PROPERT Y OF SUPERIOR MANUFACTURING 8 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 1 09 17 04 REV LOG DATE REF S quip Manuals Dwgs TDMB1000 01VBOP illustration revi wpg MAINTENANCE INSTRUCTIONS Superior recommends that owners of Make Break Tools and accessories adapt a regularly scheduled maintenance program Implementation of this type of program offers several benefits First you increase the life of your equipment secondly you may find a problem before it escalates to a costly repair or down time on the job and most importantly prevent injury to operating personnel A major inspection should be carried out if equipment is suspected to have been damaged during transit or is to be mobilized to a remote location where maintenance operations are difficult to carry out Routine Maintenance Cleaning A Pre wash unit to remove majority of dirt and grease build up as to allow inspection of overall condition of unit B Clean and
18. F SUPERIOR MANUFACTURING amp 04 28 04 HYDRAULICS AND ISCONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR 64 T MANUFACTURING amp HYDRAULICS REF SAEquip Manuals Dwgs TDMB1000 01 MU BO position wpg 04 28 04 DATE REF S Equip Manuals Dwgs TDMB1000 01 Rot Trip Mode wpg REV LOG 318 837 8847 5 gt 2 5 DIGZ m WD NS 5 Fa F lt D a lt K x POSITION Manufacturing amp Hydraulics NTI 2 Yams o 2552 85526 ug 4225 HWY 90 EAST SUPERIOR BROUSSARD LA 70518 THIS DOC DRAULI Y NO 5 W NUFAC POSITION IN NORMAL OPERATING MODE FOR ROTATING AND TRIPPING TOP DRIVE CONNECTED TO DRILL PIPE Page5 25 MOTOR BRAKE LOCKED AND BOOSTED NOTE PIPE HANDLER REMOVED A TOP DRIVE MAKE BREAK TOOL GENERATES TORQUE TO MAKE UP BREAK TIUT UPPER IBOP CON
19. Felten Reference HSE 108 24 Original Issue Date Date Last Revised 25 May 04 Break out of the UIBOP valve using the Last Revised Robert Walsh GSF Superior Tool with Acceptable Risk Reduction Measure Residual Risk Tolerable Connect the hydraulic supply and return hoses to the rig supply lines Function test the tool to verify correct torque direction is correct Function test the make up pressure regulator and then set well below required torque Place the top drive in low gear if possible Only TDS4 models Riding belt operations to open the top drive brake booster valve Orient the TD so that link tilt is toward the V door FORM No OP 018Rev 1 Page 1 of 4 Generic Superior Upper IBOP Breakout and Removal JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 19 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations L LIKELIHOOD d 5 CATEGORY DEFINITION CATEGORY DEFIMITIOHS Unacceptable Low LOw DU Ne injury Ne Damage Pollution Tolerable MED 21 First Aid injury Minor Damage Minor Pollution Probable JRA Palicy Reference Ix THERE SAFER WAT COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK HSE hh Make up and torque the top drive to the drill string and set slips Close both the
20. NECTION SPLINES ENGAGED TOP DRIVE MAKE BREAK AUXILLARY IBOP VALVE NOTE HANDSLIPS HANDLES REMOVED LOCKING PINS NS Rd ROTARY TABLE BRAKE IN LOCKED POSITION N N N N N N 4225 HWY 90 EAST Ab SUPERIOR BROUSSARD LA 70518 TOP DRIVE MAKE BREAK TOOL w Manufacturing amp Hydraulics 318 837 8847 IN MAKE BREAK POSITION b a TI oo 2 FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR HEF SAEqui p Manuals Dwgs TDMB1000 01 MB position wpg Page 5 26 ZZ G DRIVE PIN ILLUSTRATION LA TIGHTEN 80 TO 100 FT LBS TO LOCK INTO ROTARY TABLE SOCKET DO NOT TIGHTEN UNLESS INSTALLED IN SOCKET DOOOOOOOOO JAVAVAVAVAYAVAVAVAVAVAV A aVAVAVAVA A NAY W S VAVAVAVAVAVAVAV AV AV AV AY AAACN IVAVAVAVAVAVAVAVAVAVAVAY VAVAVAVAVAV AV AV NN VAVAVAVAVAVAVAVAVAVAV AV AV VAVAVAVAVAVAVAVAVAVAVAVA VAVAVAVAVAVAVAVAVAVAV AV AY IVAVAVAVAVAVAVAVAVAVAVAVA AVAVAVAVAVAVAVAVAVAVAVAY VAVAVAVAVAVAVAVAVA
21. NNECTOR 1 4 MJIC X 1 8 MNPT 2 1606 1 4 FLUSH PLUG 8 1 44FTX 1 4 MNPT X 1 4 MJIC STRAIGHT 1 1609 3 8 NPT FLUSH PLUG 9 2 66 3 8 MNPT X 3 8 MJIC STRAIGHT 1 6CTX 3 8 1 4 MNPT 90 ELBOW 10 1 6 6CTX MALE ELBOW 3 8 MJIC X 3 8 MNPT 11 1 9889K19 AIR POP OFF VALVE 185 PSI 1 4 NPT OPTIONAL 12 1 1478 BALL VALVE BRASS 3 8 r or R 14 1 jBAC 60025 GAUGE 600 2 1 2 DIA BRASS 3 1491 1 2 MNPT X 3 8 REDUCER BUSHING 5 1 4554 3 8 CHECK VALVE 1 1402 3 8 X 3 PIPE NIPPLE 17 1 1 25 GAS BOOSTER 25 1 RATIO 18 1 TDMB2039 __ AIR BOOSTER MOUNTING PLATEWELDM 19 1 TDMB1036 S2 2 POSITION 4WAY PILOTED AIR VALVE 20 1 H4 11 FJFJ9 174 HOSE X 11 LONG FJIC X FJIC 90E 21 1 H6 16 FJFJ9 _ 3 8 HOSE X 16 LONG X FJIC 90E 22 1 H6 18 FJFJ___ 3 6 HOSE X 18 LONG 3 8 BOTH ENDS AR SUPERIOR BR USSARD L 70518 Manufacturing amp Hydraulics 318 837 8847 Al R BOOSTE R P AN E L THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 1 02 23 05 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION LE LOG DATE ASSEMBLY NO TDMB1036 ee e Page 8 6 SECTION 9 VALVE TECHNICAL DATA To request copy of Valve Technical Data please contact superior Manufacturing amp Hydraulics 4225 Hwy 90 East Broussard LA 70518 Phone 337 837 8847 Fax 337 837 8839 www superior manf co
22. ON 4 WAY PILOTED AIR VALVE 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 AB SUPERIOR w Manufacturing amp Hydraulics THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 01 13 05 HYDRAULICS AND ISCONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPROD UCED IN ANY REV 4 LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS REF S Equip Manuals Dwgs TDMB2000 Sch Brake wpg ASSEMBLY FASTENER LUBRICATION AND MAKE UP TORQUE REQUIREMENTS Most bolts nuts and other threaded components are to be lubricated with Never Seez or equivalent before assembly Certain fasteners are to be assembled using permanent or removable Loctite as indicated in the assembly instructions All tapered pipe threads are to be treated with a Teflon based pipe dope to assist in makeup and prevent leakage CAUTION Do not use teflon tape Improper application of teflon tape can cause joint failures Teflon tape can release large particles which can plug small passages in hydraulic equipment All standard fasteners used in CLINCHER products are to be GRADE 8 or better DO NOT SUBSTITUTE lessor grades of fasteners All fasteners are to be made up to the torque charted below Failure to properly assemble these fasteners can result in their loss product malfunction and ultimately result in situations where personnel can be exposed t
23. P 018 Rev 1 Page 1 of 2 Generic Superior Upper IBOP Breakout and Removal JRA xls JRA Planning Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 17 Work Permit Type No JRA Number Job Risk Assessment JRA oik INTER oshh Hazcom No solation Certificate Job Planning Outline 12 Tool Pusher 13 Tool Pusher 14 Tool Pusher 15 Tool Pusher 16 Tool Pusher 17 Tool Pusher Spin out connection and slowly raise the top drive to allow access to the UIBOP Roughnecks Tool Pusher Install lift cap 20 ft sling and multiple tag lines to the UIBOP and remove from fixture Roughnecks ToolPusher Environmental Precautions Step Task Detail Who Performs Who Supervises 1 Ensure that spill materials are readily available during operation of hydraulics Roughnecks Remove any oil that may drip while disconnecting hydraulic hoses Roughnecks 02202 0 FORM No 018 Rev 1 Page 2 of 2 Generic Superior Upper IBOP Breakout and Removal JRA xls JRA Planning Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 18 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations L LIKELIHOOD CATEGORY DEFINITIONS O Unacceptable Damage MePellution Tolerable MED 4 First Aidinjury Minor Damage Minor Pollution JRA
24. R EXTENSION WELDMENT 2 1 TDMB2003 TOP PLATE ASSEMBLY 3 1 TDMB2004 BOTTOM PLATE MID BODY WELDMENT 4 1 2006 HUBWELDMENT 5 4 TDMB2007 CYLINDER 5 BORE 10 STROKE 2 ROD 6 1 TDMB2017 DRIVE SUB PH85 OR TDMB2018 DRIVE SUB PH60 7 1 TDMB2027 POINTER 8 1 TDMB1025 SLING 9 1 TDMB2040 LOWER EXTENSION ASSEMBLY 10 2 BUCST7623 BULKHEAD CONNECTOR 11 30 1171 3 4 LOCKW ASHER 12 30 1183 3 4 10 X 2 1 2 HHCS 13 24 1218 1 LOCKWASHER 14 2 11219 1 1 4 12 JAM NUT 15 1 1337 1 4 14 X 3 4 HHCS SELF DRILLING TAPPING 16 24 74053 1 8 X 3 3 4 HHCS DETAIL B SCALE 1 4 4B SUPERIOR ss TOP DRIVE MAKE BREAK TOOL w Manufacturing amp Hydraulics 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 02 23 05 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS REF S Equip Manuals Dwgs TDMB2000 Assembly 2nd Gen wpg ASSEMBLY NO TDMB2000 Pages 3 Part Number Part Name TDMB2010 FLEXIBLE INSER TDMB2011 FLEXIBLE INSERT CAP TDMB2014 ALL THREAD WELDMENI lt p C2 21
25. RE MAKE BREAI TORQUE GAUGES MAKE UP PRESSURE CONTROL VALVE ISOLATION VALVE MAKE BREAK DIRECTIONAL CONTROL VALVE MAKE BREAK CONTROL CONSOLE DIMENSIONAL VIEWS ASSEMBLY NO TDMB2020 39 3 8 Ad SUPERIOR w Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 12 16 04 REV LOG DATE REF S Equip ManualsiDwgs TDMB2000 Console Dimen wpg SPLINED DRIVE SUB DIMENSIONS Page 2 4 PH60 DRIVE SUB SUPERIOR w Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 09 16 04 LOG DATE REF SAEgup ManualsDwgs DESCRIPTION and APPLICATION The CLINCHER RF Rig Floo
26. VAVAVAN VAVAVAVAVAVAVAVAVANAVAVAVA VAVAVAVAVAVAVAVAVAVAVAVAN VAVAVAVAVAVAVAVAVAVAVAVAVA VAVAVAVAVAVAVAVAVAVAVAVAN VAVAVAVAVAVAVAVAVAVAVAVAVI AVAVAVAVAVAVAVAVAVAVAVA Ud mi kkl B bee i H H H KERPRERT D ag Se RISA H H gg Se J MN VAVAVAVAVAVAVAV AY AVAVAVAVAVAVA ZA SLLLIZAL KI gt RISRISRISRI 4 4 Kl KODI KT D KDKDKDKI DKDKPKDI KT PRERESI KEKO 4 Gelz D K D CRISIS LD KT 24 D RRS x SSA AV AV AV AV AV AY AV AV AV ANANAS 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 _ SUPERIOR w Manufacturing amp Hydraulics THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 12 16 04 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMA MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR E MANUFACTURING amp HYDRAULICS REF S3Equip Manuals Dwgs TDMB2000 Drive Pins wpg BREAK OUT WITH OUTPUT SHAFT IBOP ILLUSTRATION KN a TOP DRIVE E PUT SHAFT MAK
27. ak Tool See illustration below ROTATION SCALE TORQUE READING SCALE SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool TDMB2000 Revision 01 05 Page 5 10 JRA Number Job Risk Assessment JRA Work Permit Type No EST Isolation Certiticate Emwee EQUIPMENT No Equipment 7 Cerification Confirmed Who inspects 1 GSPSupenor Cncher Upper BOP Breakout To GSF Superior Clincher Upper IBOP Breakout Tool installed lift sling Po Rig Lift Inspection dng 4 i 7 5 8 RH lift cap for Upper IBOP handling PARTICIPANTS E J Tipster tle 5 10 pf Demeema Hougmek2 251 Hougmek3 6 Hougmek4 fRoustabut fRousabot2 TASK PROCEDURE L Sep Me Performs Who Supervises 6 the top drive and remove the Superior UIBOP break out tool from the rotary table Roughnecks ToolPusher 8 Release the pipe handler carefully to be sure that arms correctly engage shell Aa Derrickman 9 Raise top drive and use elevators to set the pipe higher inthe slips Drier Roughnecks ToolPusher FORM No OP 018 Rev 1 Page 1 of 2 Generic Superior Upper IBOP Installation and Make Up JRA xls JRA Planning Su
28. ay stick not center under operate and could cause serious injury death or equipment failure VALVE SAFETY Read and follow instructions carefully Failure to observe instructions and guidelines may cause serious injury death or equipment failure A sticking valve spool bind may be caused by one or more of the following factors DIRTY OIL Oil must be filtered to a minimum of 25 microns Filters should be changed regularly spin on types after 50 hours of initial use and then after every two hundred fifty hours of use Use of a condition indicator is recommended Consult your tractor or implement owner s manual for filtra tion and changing recommendations for internal systems OIL REQUIREMENTS Premium quality anti wear type oil with a viscosity between 100 and 200 SSU at operating temperatures Certain synthetic oils may cause spool seals to swell and the valve to stick If in doubt call CROSS Engineering IMPROPER UP OR MOUNTING Always use the proper size fittings Hook up in amp out as noted on the valve body Do not overtorque pipe fittings Mounting surfaces should be flat and care should be used when tightening mounting bolts Over tightened bolts can cause spool bind and casting breakage When hooking a valve in series always use a power beyond sleeve Con sult your tractor or implement manual to make sure you have the proper quick disconnect line connected to the inlet of the remote valve MISAPPLICATION Always u
29. ed through a 1 sling link and feature galvanized thimbles with swaged retaining sleeves Sling is proof tested and equipped with a metal tag SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 01 05 Page 2 5 DESCRIPTION and APPLICATION Two 3 4 x 10 long two wire hydraulic hoses with 2 500 psi working pressure are provided to connect control console to RF Make Break Tool These have a braided fabric protective cover to guard against abrasion They are equipped with a 3 4 male NPT x 3 4 female JIC swivel hose ends Two 3 4 x 20 long standard two wire hydraulic hoses with 2 500 psi working pressure are provided to connect control console to rig s hydraulic power loop They are equipped with a 3 4 male NPT x 3 4 female JIC swivel hose ends An optional storage base incorporating the control console pressure torque gauge torque control valve and quick disconnects associated with hydraulic control console This storage base 1 fabricated using 6 17 25 PPF carbon steel S beams and 1 2 flat plate The plate contains openings for torque drive subs and lockdown drive subs Hold downs are provided to lock RF Make Break Tool to storage base during transit Storage base features provisions for handling using forklift or four part sling not included SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 2 6 SPECIFICATIONS Makeup Torque 1 130 000 ft lbs 176 256
30. iller s console is required this will require the addition of an indicator light at the driller s console along with the minor software change to drive the indicator light output 9 Document drawing and software changes and burn a spare EPROM for the PLC that includes these programming changes SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 5 2 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS The purpose of this document is to familiarize the drill and maintenance crews with the safe operation of the Global Santa Fe Superior Upper IBOP Make Break Tool If this procedure is followed correctly it will allow removal and replacement of the upper IBOP on the Varco TDS3 TDS4 and TDS5 models Basic Tool Design Features Personnel Safety The tool has been designed with Safety in mind It will allow removal and reinstallation of the upper IBOP without the use of rig tongs and other higher risk activities It will allow reliable break out and accurate torque of the main shaft to the upper IBOP connection Most of this work can be accomplished at rig floor level and without the requirement to remove any attachments or components from the top drive Although generic JRA s Job Risk Assessment for removal and re installation of the upper IBOP are included in this manual it is required to prepare and perform an accurate rig specific JRA before this operation is performed The a
31. inspect for damage or excessive wear cracks breakage and uneven wear patterns C Inspect all hoses for wear replace as necessary D Lubricate zerts on reels and bearings E While maintaining pressure visually inspect hoses stainless steel lines fittings etc for seepage of hydraulic fluid Repair or replace parts causing leaks If you see no visible external leaks and you are still losing pressure there may be an internal leak in the load holding valve It is recommended that the unit be returned to the manufacturer for repair F Test Re inspect hydraulic system for leaks SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 05 04 Page 6 1 TROUBLE SHOOTING Problem A Unit does not function B If fluid is heard flowing through console within the directional control valve in the neutral position C Unit does not generate maximum break out torque or reach 2000 psi D Unit does not generate maximum make up torque or reach 2000 psi SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 6 2 Solution Insure all hoses are properly con nected and isolation valve is open Adjust inlet section pressure relief valve setting to pressure greater than hydraulic power unit supply pressure Check hydraulic power unit supply pressure If greater than 2000 psi verify break out pressure relief valve 5 setting inside console i
32. ize rig downtime In most cases to fully install the remote operated air valve the following will be required 1 Add a two position switch at the driller s console which will be used to select high or low brake pressure With most of our systems these switches are simply connected to 24 volt input modules on the PLC and then there are either direct outputs from output modules on the PLC or output modules with isolated contacts that are used to switch the solenoid for a particular function Assure that the solenoid valve used for remote operation is of the correct voltage which will minimize modifications to the top drive control system at the time of installation 2 Check for an available spare input at one of the PLC input modules 3 Check for available spare output or isolated contact on one of the PLC output modules 4 Check for one additional spare conductor from the transfer panel to the derrick junction box 5 Check for an additional spare conductor in the service loop 6 Check for an available entry on the top drive control junction box to install a cable gland and run cable to the new solenoid valve coil on the booster 7 Make software changes to the PLC program to accept the new input and drive the new output accordingly SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page5 1 CLINCHER UPPER IBOP MAKE BREAK TOOL PRE ORDER CONSIDERATIONS 8 If indication on the dr
33. m SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 05 04 Page 9 1
34. n the Varco pipe handler can be used as the supply to the control console Caution Always connect and open any valves in the return line before connecting the supply Tool Storage The tool should be anchored to the optional storage base when used using binders chains or straps and should be stored in a convenient location for quick and easy access possibly even on the rig floor Caution The tool should be bound to the storage base before any lifting for transport The control panel should be protected SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 01 05 Page 5 4 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS as well as the hose ends to prevent contamination If the tool is stored outside in an area that is convenient to the drill floor a heavy tarp should be secured over the unit to maintain the unit is clean and ready condition All hose ends should be cleaned preserved with a grease coating and wrapped to prevent contamination Spare Upper IBOP Storage The spare upper IBOP should be equipped with the operating shell a set of cranks and have a 7 5 8 lift cap installed This will minimize any time lost when doing an emergency valve change out by preventing the requirement to stop and transfer these items from the removed valve It may be possible to add a permanent storage rack for the spare Upper IBOP on the tool base Operating Sequence With drill pipe in the slip
35. o dangerous situations FASTENERS Size Torque 5 8 11 166 ft Ibs 3 4 10 295 ft Ibs 1 8 715 ft Ibs 114 12 1 584 ft Ibs LUBRICATION STANDARDS Bearings and gears must be lubricated to minimize friction cool exclude foreign matter and prevent corrosion CLINCHER recommends using Texaco Marfak 2 or equivalent for all grease zerts and bushings SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 05 04 Page 4 1 CLINCHER UPPER IBOP MAKE BREAK TOOL PRE ORDER CONSIDERATIONS Information needed from rig before ordering 1 What is the master bushing manufacturer and model 2 Isthe rig equipped with a PH 60 or PH 85 Pipe Handler 3 What is the Upper IBOP manufacturer and model 4 What is the distance from the top drive guide rail stops to the top of the rotary table Additionally rigs that want the remote operated air valve will need to be notified of the following The remote solenoid option requires some modifications to the top drive control system and will increase the time required to make the brake booster operational For this reason Superior supplies the brake booster with the standard issue manual ball valve installed so that the booster kit can be installed relatively quickly on the initial use of the tool The remote operated air valve and all associated electrical system and controls modifications can be installed at a suitable time This should avoid minim
36. ompletely portable Some rigs may make semi permanent installation by removing the control console from the skid and permanently installing on the rig floor With the controls installed and hoses stored on a local hose reel it will only be required to lock the tool into the rotary table and hook up two hoses SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 01 05 Page 5 3 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS Back Up In the very unlikely event of a hydraulic failure the tool 1 strong enough to allow us to apply a manual tong at a reasonable height above the floor so that the Upper IBOP can be removed or torqued manually The diameter of the tong bite area on the tool is small enough that it will not be required to use the larger SDD tongs The standard drill pipe tongs can be used Preparations Brake Booster Installation On receipt of the tool it will be necessary to permanently mount the top drive brake booster kit and connect according to the air schematic As there a number of differences in the various top drive configurations it was not practical to design a mounting for each model and configuration The air booster is supplied on a 15 square mounting plate that is drilled in each corner and will require some field fitting by the maintenance department In addition it will be necessary to make hoses to allow installation in the air circuit for the motor brake per
37. on so that it will be easier to see the movement as the connection loosens Once the upper IBOP valve connection has been broken switch the top drive brake off lift the top drive very slightly to remove the 1000 2000 Ibs of set down weight and spin the main shaft out leaving the upper IBOP valve sitting in the receiving collar on the breakout tool Raise the top drive until the elevators will clear the upper IBOP when the link tilt is retracted release the link tilt and raise further until the sling on the elevators is near the top of the IBOP Using a step ladder attach a lifting cap to the top of the IBOP and attach the sling and a tag line to lift cap Using the blocks slowly raise the IBOP out of the drive collar on the Make Break Tool and lower to the drill floor Dope the upper connection on the replacement valve and transfer the lift cap lifting sling and at least two tag lines to the fully outfitted replacement IBOP Use this rigging to raise the valve and dope the lower connection prior to placing the new valve into the drive collar The actuator collar and cranks should already be installed and adjusted on the new valve to save time The valve needs to be in the closed position so that the pipe handler arms will realign later when the pipe handler is moved back into place With the brake released and top drive in spin mode slowly lower the top drive and spin into the replacement valve Follow through with the top drive torque
38. perior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 11 JRA Number Job Risk Assessment JRA gob Planning Outline 12 Reset the pipe handler torque to the required value for drill pipe being used if needed AD or Derrickman Tool Pusher 13 Replace stop tubes on pipe handler AD or Derrickman Tool Pusher Tool Pusher Environmental Precautions Step Task Detail Who Performs Who Supervises 1 Ensure that spill materials are readily available during operation of hydraulics Roughnecks Remove any oil that may drip while disconnecting hydraulic hoses Roughnecks FORM No 018 Rev 1 Page 2 of 2 Generic Superior Upper IBOP Installation and Make Up JRA xls JRA Planning Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 12 GlobalSantaFe Rig JRA Number H form HSE References J O B R S K ASS ESS M E NT 1 ar review ALL generic JRA considerations L LIKELIHOOD CATEGORY DEFINITION CATEGORY DEFIMITIOHS Unacceptable Low LOw DU Melnjurv Ne Damage Pollution Tolerable 21 First Aid Injury Minor Damage table Probable JRA Palicy Reference 15 THERE SAFER WAT COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK LIKELIHOOD HSE 188 2 Location Rig ALL Rigs with Varco DC top drives Original Issue Date Bau GSF Superior Tool with pipe in the slips Last RevisediBy Robert Walah
39. r Make Break Tool is manufactured to service upper internal blow out preventer valves associated with Varco TD3S TD4S and TD5S top drives This compact hydraulically operated tool generates a minimum of 110 000 ft lbs of make up torque and 130 000 ft lbs of break out torque when used with a 2000 psi hydraulic power supply not included Each cycle will generate 45 degrees of rotation The RF Make Break Tool s upper flanged hub allows a variety of accessories to be bolted in place to satisfy rig floor torquing needs The bottom of the RF Make Break Tool accepts pins which engage a 27 1 2 or 37 1 2 API Rotary Table Kelly Drive System per API 7K other configurations upon request The bottom is also flanged to accept a lower extension or accessories which are available to allow the bottom side to directly grip tubulars The RF Make Break Tool is provided with an Upper Extension with flanged connections compatible for the tool and drive subs for Varco PH60 and PH85 Pipe Handlers upper extension BOP valve Approximate overall length is 20 1 4 The Extension OD of 7 1 4 is for compati bility with ring tongs The drive sub maximum OD is 14 minimum ID is 6 65 and OAL is 10 5 Customer will need to specify if the RF Make Break Tool is to be used with Varco PH60 or PH85 Pipe Handler The RF Make Break Tool is provided with a Lower Extension with a flanged connection to raise the Make Break Tool 54 above the Rotary Table This extension offers a
40. r IBOP being careful to align the IBOP operating arms with the actuator shell Release the top drive brake and close the permanently installed selector valve on the top drive brake booster system Place the top drive in spin mode and lower to stab into the lower IBOP while carefully guiding the pipe handler back over the lower IBOP valve Use the top drive torque function to make this connection up as high as possible with the DC motor Set the make up torque on the pipe handler to the required torque for the upper to lower IBOP connection and use the pipe handler to complete the torque sequence on this connection Replace the stop tubes on the pipe handler lift cylinder to prepare for normal drilling mode Reset the make up torque on the top drive console for the type of drill pipe connection that is being used and proceed with drilling operations SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 5 8 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS PRESSURE ADJUSTMENT 185 PSI MAX RIG AIR IN 3 8 MJIC INTENSIFY ON OFF SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 5 9 INSTRUCTIONS FOR MEASURING TORQUE To find the estimated torque take the reading from the Torque Reading Scale on the console Multiply it by the Correction Factor of the Angle which corresponds to the reading on the Rotation Scale on the Make Bre
41. re cable with a 20 6 ton minimum breaking strength The wire cable should be hung as close to the center of the wellbore as possible without interfering with drilling equipment operation to allow the tool to be readily swung into the working position WARNING Users must insure the entire lifting system including cables rig mounting points lift cylinders lifting brackets bridles winches pulleys counter weights etc are capable of handling the static weight of the tool PLUS any shock loads which may be seen during operation A 2 IWRC minimum diameter wire cable with a 198 ton minimum or better breaking strength should be attached at a 90 degree angle to the Make Break Tool and at the same level to insure proper readout of optional external torque indicator If optional external torque indicator is used the rotary table must be unlocked and free to rotate A SNUBBING LINE should always be attached to provide additional safety in the event of a rotary table lock slippage WARNING Users must provide a means of safely controlling the Make Break Tool movements in all directions when it is in use Failure to account for its size weight movement and the amount of torque developed could result in personnel injury or death SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Pagel 1 CLINCHER Make Break Tool HAZARD WARNING CLINCHER Make Break Tools utilize high pressure hydraulic fluids Portions of the tool
42. ring and set the pipe as low as possible in the slips Caution This total stick up height must not exceed 74 inches Remove the slip handles so that the UIBOP tool can be set over the pipe with the slips in place SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 01 05 Page 5 5 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS 4 Unlatch the elevators and raise the top drive until the elevators have cleared the pipe stick up height 5 Attach a 20 ft sling to the elevators and allow it to hang down for later use This sling will be used for handling the Superior Make Break Tool 6 Attach a 10 ft or longer sling to the pipe handler frame and allow it to hang down for later use This sling will be used later in the process to pull the pipe handler clear of the Make Break Tool 7 Attach the other end of the 20 ft sling to the Make Break Tool handling sling and connect an air tugger to the base for handling Slowly raise the blocks until the Make Break Tool is raised high enough to clear the drill pipe while tailing in with the tugger line Slowly lower the Make Break Tool over the drill pipe saver sub and lower IBOP valve that are in the slips If only air tuggers are used for handling it is desirable to attach two tuggers to the Make Break Tool on opposite sides of the top drive to minimize swinging and help center the tool over the rotary table Proper use of tag lines attached to the bottom
43. s Pull and review the JRA for this activity before proceeding A generic JRA has been prepared for your convenience and will serve as a basis for a job specific JRA that must be completed before proceeding If the top drive is a TDS4 place the machine in Low gear before proceeding Before starting this operation drain the drill Kelly hose so that there will not be a column of mud to drain when the upper IBOP 1 removed 1 Unlock and open the permanently installed selector valve on the top drive brake booster system This will allow the brake booster to run when the brake 15 activated from the driller s console and the pressure will build up to 175 psi It should be possible to hear the booster pump cycle and the pressure will be at or near 175 psi when the pump stops cycling Caution If the booster pump does not stop then there is a leak in the brake quick release valve or brake piping that must be corrected prior to continuing with this operation Make up into the drill string or a single joint that is sitting in the slips and torque up as normal close both the lower and upper IBOP valves With the UIBOP in the closed position remove lift cylinder stop tubes on the PH60 or 85 so that the pipe handler can raise and break out the connection between the upper and lower IBOP valves Spin out with the top drive leaving the saver sub and the lower IBOP valve on the drill pipe Raise the top drive latch the elevators on the drill st
44. s greater than 2000 psi Check panel mounted adjustable relief valve to insure it is not backed off Verify make up pressure relief valve s setting inside console is greater than 2000 psi SECTION 7 PARTS LISTS RECOMMENDED SPARE PARTS LIST Part Number Superior PN 1001 6533N T2NV 6633N T2NU A20 STDBK 26 58475 0 Superior CRSS20009 Superior TDMB1010 TDMB1025 SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Quantity 8 N N N N Page 7 1 Description 1 8 NPT Zerts Cylinder Rod Seal Kit Cylinder Piston Seal Kit Valve Seal Kit Dump Valve Seal Kit Remote Operated Relief Valve 2 Pin Sling Assembly SECTION 8 MAKE BREAK TOOL ILLUSTRATIONS TOP DRIVE MAKE BREAK TOOL ASSEMBLY TDMB2000 8 3 FLEXIBLE INSERT ASSEMBLY Assy No TDMB2013 es 8 4 LOWER EXTENSION ASSEMBLY Assy TDMB2040 8 4 1 SLING ASSEMBLY Assy No TDMB1025 csscssssssesssessesssessesssssessesssecsessusesessveseesees 8 5 AIR BOOSTER PANEL Assy No TDMBIO36 ens 8 6 SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool TDMB2000 Revision 02 05 8 1 SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool TDMB2000 Revision 02 05 Page 8 2 Item Qty Part Number Part Description 1 1 TDMB2001 UPPE
45. se the proper valve for the job CONVERTA CD CS or CA valves should never be used for metered heavy load lifting loaders or similar applications Use an open center valve for open center applications and a closed center valve for closed applications If in doubt check with your tractor dealer Contact CROSS if the valve allows the hydraulic equipment to creep excessively MAINTENANCE Make sure all bolts are tightened and torqued to the recommended specification Bent or broken parts should not be used Replace immediately Always use exact replacements Always protect valve spool from paint overspray Faulty quick disconnects can cause high back pressures and sticking spools Check quick discon nects periodically to make sure they are functioning properly lf valve spool does not center or appears to stick do not use PUMPS amp MOTORS SAFETY relief bypass your hydraulic system is necessary to prevent pump from breakage due to overpressurization Use correct fittings and proper oil as noted in the technical service manual packed with each unit Change oil as recommended by your implement or tractor manufacturer CYLINDER SAFETY Check clevis clearances before during and after extending the cylinder and before using the cylinder under pressure to avoid possible injury or bent or broken rods caused by binding Never operate a cylinder above recommended pressures Never use a cylinder as a safety device when trans porting eq
46. the air control schematic that is included with the tool documentation As such this one time installation will require the assistance the rig welder and chief or mechanic for a short time In most cases the booster will be mounted on top of or near the motor brake on the top drive being sure to use good sound methods that incorporate secondary retention on all fasteners to prevent falling object hazards Hydraulic Installation The Superior Make Break Tool is provided with interconnecting hoses that run between the tool and control station These are equipped with hydraulic quick disconnect couplings for easy tool set up In addition there is a set of 3 4 supply and return hoses supplied with the equipment On receipt of the tool it will be necessary to locate the nearest hydraulic supply and return lines and be sure that all quick disconnect fittings on the supply and return hoses are correct Open the isolation valve on the side of the control console The tool should be function tested and the make up regulator tested to be sure that the tool 1 set for the correct make up torque prior to use This can be accomplished by cycling the tool in the make up mode while adjusting the panel mounted regulator Break out requires no adjustment and will always provide maximum available torque These preparations will prevent delays when the tool might be needed for an emergency valve change out If absolutely necessary the supply and return lines o
47. ttached JRA s will serve as guidelines for preparation of the rig specific JRA s Efficiency In addition to Safety the tool has been designed to increase efficiency Replacement of the upper IBOP can now be accomplished in a very short time and in most cases without having to remove any components from the top drive With proper preparations and planning in place which requires that the spare valve and tooling be maintained in a ready condition this operation can be completed safely in approximately 1 2 hours rather than the original 6 12 hours that were normally experienced in many different fleet wide operations Simplicity The tool is extremely simple with very few moving parts yet it is robust and capable of approximately 130 000 ft Ibs of break out torque with 2000 psi hydraulic supply Once the brake booster plate has been installed on the top drive it will remain permanently in place There are no additional or complicated hook up requirements and the top drive can be prepared for tool use by simply switching a valve on the brake booster controls The break out tool can be set in place and locked down to the rotary table in minutes Storage The tool can be designed with an optional storage base and can be moved around as a package The control console may be attached to the storage base Caution The tool should be attached to the base with chain and binders to ensure safe handling if the unit is kept c
48. uipment PINHOLE LEAKS If you observe pinhole leak discontinue use of the component If oil has penetrated your skin or contacted your eye seek medical attention immediately AB SUPERIOR wy Manufacturing amp Hydraulics SLING ASSEMBLY P N TDMB1025 BREAK OUT MAKE UP CONTROL CONSOLE P N TDMB2036 DRIVE SUB TOP DRIVE MAKE BREAK TOOL P N TDMB 2000 POSITION INDICATOR EXTENSION LOCKING DRIVE PIN 4225 Highway 90 East Broussard Louisiana 70518 Phone 337 837 8847 Fax 337 837 8839 PUBLISHED 02 2005 Page 2 1 www superior manf com Z z ebed 10 1 8 MN D THRU TOOL 76 1 8 MAX ALLOWABLE TOOL JOINT HEIGHT DIMENSIONAL VIEWS 417 8 106 7 8 1 1 0 7 8 AB SUPERIOR uy Manufacturing amp Hydraulics B HWY 90 EAST USSARD LA 70518 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 1 02 23 05 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THS INFORMATION MAY NOT Bl DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULIC S Equip Manuals Dwgs TDMB200 decem BEZEL RING PRESUU
49. upper and lower IBOP valves Remove stop tubes from pipe handler and store Using the pipe handler break out and spin out of lower IBOP Attach a 10 ft sling to back of pipe handler and allow to hang down for later use 14 Using elevators pick up the string and set low in slips Total stick up less than 74 15 Raise top drive place the breakout tool in the rotary and lock down 16 Connect the hydraulic make break hoses to the tool and cycle fully to make position Lower top drive while holding pipe handler back to stab 17 i UIBOP into receiving collar the UIBOP to main shaft conn allow access to the UIBOP Install lift cap tugger line and multiple tag lines to the UIBOP and remove from fixture FORM No OP 018Rev 1 Page 2 of 4 Generic Superior Upper IBOP Breakout and Removal JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 20 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations CATEGORY Unacceptable Low Damage Pellution Tolerable MED 1 El Acceptable Probable HIGH Last Time Injur JRA Policy Reference 15 THERE SAFER WAT TO COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK IKELIHOOO HSE Ph 26 FORM No OP 018Rev 1 Page 3 of 4 Generic Superior Upper IBOP Breakout and Removal JRA xls JR
50. value for drill pipe being used if needed Riding belt operations close the TD brake booster valve and lock in place Replace stop tubes on pipe handler GES FORM 018 Rev 1 Page 2 of 4 Generic Superior Upper IBOP Installation and Up JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 14 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations CATEGORY Unacceptable Low Damage Pellution Tolerable MED 1 El Acceptable Probable HIGH Last Time Injur JRA Policy Reference 15 THERE SAFER WAT TO COMPLETE THE JOE ARE THERE ALTERHATITES WITH LESS RISK IKELIHOOO HSE Ph 26 FORM No OP 018 Rev 1 Page 3 of 4 Generic Superior Upper IBOP Installation and Make Up JRA xls JRA Risk Assessment Superior Manufacturing Hydraulics Inc CLINCHER Make Break Tool Revision 08 04 Page 5 15 GlobalSantaFe Rig JRA Number Ho w to use the form HSE References J O B RIS K ASS ESS M E NT 1 Crew performing task review ALL generic JRA considerations CATEGORY Unacceptable Low Damage Pellution Tolerable MED 1 El Acceptable Probable HIGH Last Time Injur JRA Policy Reference 15 THERE SAFER WAT TO COMPLETE THE JOE
51. vent the table from turning during torquing operations SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER Make Break Tool Revision 09 04 Page 5 6 12 13 14 15 16 17 18 CLINCHER UPPER IBOP MAKE BREAK TOOL OPERATIONAL INSTRUCTIONS Lower the Top Drive slowly while holding the pipe handler back to clear the Make Break Tool until the splines on the upper IBOP engage the receiving collar on the top of the Make Break Tool Apply a slight set down force on the Make Break Tool 1000 2000 Ibs to ensure that the valve bottoms out in the receiving collar Caution Be sure that the top drive brake is off so that the shaft can rotate and align with the splines in the drive collar With the main hydraulic unit switched on and top drive brake off cycle the Superior hydraulic cylinders by holding the handle to the make up position allowing the top drive shaft to turn as the tool rotates Have the driller set the top drive brake and allow enough time for the brake booster to increase the brake pressure to 175 psi You can hear the booster cycle and then stop as the correct pressure is reached Once the brake is locked move the control lever on the Make Break Tool to the break position and watch for breakout movement between the upper IBOP and main shaft If necessary release the top drive brake recycle the tool and repeat the breakout sequence It may be helpful to put a mark across the main shaft to UIBOP connecti
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