Rev.01
TM120 / TM80
Canrig Drilling
Technologies Canada 10/10/2006
Commissioning Manual
Rev.01
Table of Contents
1. PLC Setup
3.1. Pump
3.1.1 Compensator
3.1.2 Differential
3.1.3 4VP01 Pressure Control
3.1.4 Torque Limiter
3.2 Tong Assembly
3.3 Spinner Assembly
3.4 Arm Assembly
Canrig Drilling
Technologies Canada 10/10/2006
Commissioning Manual
Rev.01
5. Calibration
5.1. Pump
5.2. Pressure Transducers
5.3. Hawe Cards (Flow)
5.4. Hawe Cards (Pressure)
6.1 General
6.2 Vertical / Rotate
6.3 Horizontal Slide
6.4 Clamps
6.5 Torque Cylinder
6.6 Spinner
7. Functional Testing
7.1. Spinner Test
7.2. Torque Test
7.3. Interlock / ErrorTest
Canrig Drilling
Technologies Canada 10/10/2006
Commissioning Manual
Section 1 Rev.01
1. PLC Setup
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Once you have the project file open in CX Programmer, you can connect to the PLC. This is done by
clicking the PLC drop down menu and selecting Work Online.
You can also use the shortcut: Ctrl + W.
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Select all the corresponding option boxes and click OK. The program will begin the transfer process.
This may take up to a few minutes. Depending on what state the PLC was in before the transfer
attempt, it may warn you that you are about to
change the state of the PLC and to make sure
that all connected devices are stopped. In this
case, check to make sure nothing is running,
as it will stop once you hit Yes. The transfer
is now started and this box will show the
progress as the files are written to the PLC.
When the transfer is finished, this box will
notify you that it has successfully completed
the transfer and ask you if you would like to
put the PLC to run mode. Click Yes and the
program will launch.
Use the File dropdown menu and select Open File. Use the navigation window to locate the “Generic
Wrench Memory” file and select Open. Load all the settings from that memory file to the open
window.
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Depending on what state the PLC is in when you open the memory, you may need to change it to
allow a memory transfer. To change the state of the PLC, right-click on the PLC name at the top
of the navigation plan in CX Programmer and select “Program” mode from the operating mode
list. You can now go back to the memory transfer and complete the upload.
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The next step is to transfer the screen project data to the NS12 screen. From the File menu, select
“Transfer Data”. This will
bring up a window to connect
to the NS Screen. Press the
Connect button and check to
make sure the screen displays
are connected. If you have
trouble connecting to the NS
Screen, check that you are
using a CBL210 Omron cable
and that the correct port is
displayed in the “Comms
Method” area. To change the
Comm. Port, click Comms
Method and select the desired
Comm. Port.
If the Boot Screen does NOT appear, check the communication settings for the screen. To check these
settings, press any two corners of the screen simultaneously. You can now look at all the system
settings in the NS Hardware. Press the communications tab at the top. Check that the Comm. Port A
is set to NT Link 1:N, then select “Details”, and set the speed to “High”.
If you are still experiencing communication problems between the screen and the PLC, check the
cable pin out and that the settings in the CPU are correct. If you have followed the instructions from
the start, all the CPU settings should have been transferred in the PLC Program Installation.
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Section 2 Rev.01
Using the PLC Diagnostic Screen, you can operate all the
inputs from the Driller’s Console to check wiring and
cable pin out to the PLC enclosure. This screen will
allow you to confirm that the labeled output on the
console corresponds with the input on the PLC. This can
be done for all the inputs on the Driller’s Console, Radio
and HPU. Use the devices and check each output before
starting the HPU.
2.2 Radio IO
As with the Driller’s Console, this screen will allow you to confirm that the labeled output on the radio
or wired remote corresponds with the input on the PLC. This can be done for all the inputs on the
radio. Use the devices and check each output before starting the HPU.
All of the analog inputs for the system are displayed on the PLC Diagnostic Input screen. Refer to this
screen for the next steps for checking the analog inputs.
All analog inputs when connected should read between 3.98 at 4.05 mA and the low end of the scale.
If the numbers displayed are less than 3.98, the analog signal coming back to the PLC may be
interrupted. To check this, click the “PLC Output” button at the lower right corner of the screen and
look at the analog card error box. Channel 1 = 2001, Channel 2 = 2002….etc. If the light on the
screen is red, then there is no loop between the PLC and the Analog Device.
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Section 2 Rev.01
Actuate the joystick and check that the input goes from 0-10 VDC in both directions. While actuating
the joystick, a digital input light for “Spin In” and “Spin Out” should be displayed. If these inputs are
not displayed, there is a problem in the Radio or Wired Remote Harness. Have the Electrical
Department check the wiring and re-test.
Before starting the HPU and adding trapped pressure to the Transducer Circuit, the Pressure
Transducers can be zeroed. With the PLC input screen visible, use a small flat blade screwdriver in
the “Zero Adjust” port on the side of the Transducer. Turn the screw in to increase the milliamps,
and out to decrease. Adjust the analog inputs for all Transducers to 4.00 – 4.02. This will zero the
Pressure Transducers before adding oil to the systems and trapping air/oil in the Transducer Lines.
Note: If you have already started the HPU and have readings more than a few PSI on the
screen, then you must bleed the Transducer Lines to eliminate any trapped pressure before
zeroing the Transducers.
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Note: This test is for a unit that has an attached Power Pack. For units that have no Power
Pack, this test can be skipped as the unit will be run from the Test Pack in the shop. Alternately,
you can still perform the test if the cable is connected to the shop Power Pack.
Once you have checked that all the inputs are correct, the PLC outputs can be tested. The only outputs
you can test with the HPU off are the Motor Start, Cooler Fan Start and the Heater Start. Check that
the Main Motor Overload Breaker is in the “Off” position and all the ESD buttons are off, then press
“Motor Start.” Check that the Main Motor Contactor pulls in and latches. Next, pressure the “Cooler
Fan Start” button in the Device Test Screen and ensure the Cooler Fan starts and rotates the right
direction. Finally press the “Heater Start” button and ensure the Heater Contactor pulls in.
Once you have confirmed that all the inputs and outputs are correctly wired, check the rotation on the
Main Power Pack Motor.
Press the “Motor Start” button momentarily and view the rotation of the pump. The rotation
indicator for the pump is located on the rear of the pump. If the rotation is correct, the test is finished.
If it is incorrect, consult the Electrical Department to correct the rotation.
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Section 3 Rev.01
3.1 Pump
After completing all the IO testing, the HPU Startup should be addressed. If the wrench system that is
being commissioned does not include an HPU, the following “Pump 3.1” section should be performed
on the rig at the time of install. The remaining sections 3.2 – 3.4 should be completed to ensure proper
direction of movement and function before attempting to set any of the Hydraulic or Electrical
parameters.
After confirming the Rotation, Suction Valve and Compensator settings in the previous section, we
can start the HPU.
Compensator
Adjustment
Ensure that the 4VP01 line is disconnected
and the pump is set to 2500.
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To set the 4VP01 Valve, use the “Pump Test” button in the Device Test Screen and set the Pump
Output to 2000. From the diagram, you can see the Adjustment Screw and the Bleed Screw at
opposite ends of the Valve.
Before you start to set the Max
Pressure, use the Bleed Screw
Max Pressure Adjust
to release any air that is trapped (Caution when adjusting see Note)
behind the Spool. If this air is
not released, the Pump will
“hunt” while trying to adjust
the pressure. Denison 4VP01 Pressure Control Valve
This in turn sets the PR Driver Card to 75.0 (750mA) Max Output. With one hand on the Reset,
stretch your arm to the 4VP01 Valve and adjust the screw on the Valve until the pressure reads 5000 –
5075 psi. Unless you have 40ft arms you may need some help with this step. Once the pressure is set
at 5000-5075, lock the nut then re-check the settings by turning the “Pump Test” button “On” and
“Off.”
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With the Compensator, Differential and 4VP01 adjusted, the Torque Limiter setup is the last step.
Because all of the settings affect one another, we set the Torque Limiter to “High” to eliminate it from
changing all the other settings.
Hawe Tong Valve Inlet Section
If all of the settings are correct after performing the test, turn the Main System Relief all the way in
(5200 psi) and then lock and reinstall the cap.
Note: With the Main System Relief Valve set lower than the Pressure Compensator, all pump
flow is traveling over the Relief Valve. This will create high amounts of heat in a very short
period of time. For this setting, you may need to manually turn on the Oil Cooler to limit the
amount of heat in the system.
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Enter 2500 psi in the Pump Test window and 1500 in the
Make/Break Press test window. Press Pump Test, Make Up Test, and Make Break Press Test. The
“Make Spin In” pressure should be reading 1500 -2500 psi. If there is no pressure reading, then check
the break out by switching the “Make Up” test to “Break Out” test.
If there is still no pressure displayed in the corresponding box, check the wiring to the Pressure
Control Coil on the Torque Cylinder Valve. If wires 2 & 3 are swapped, the coil tries to control the
pressure in the return side of the valve. Swap wires 2 & 3 and retest. If the retest fails, there may be a
problem with the internal pressure control Darts below the Pressure Control Coil. Refer to the Hawe
Valve Disassembly Manual for instructions for valve disassembly.
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To test the Spinners, you must use the Device Test Screen and the Radio. Rotate the Spinner Clamps
in and out to confirm the correct direction of travel.
Select the Settings screen and turn on the Horizontal Transducer Override to allow the spinners to spin
in any position. Using the Radio, press the “Spin In” and confirm the direction of rotation.
For “Spin In” the rollers should be turning in the direction labeled below. Check the direction
and correct if necessary.
Spin In Roller Directions
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The last functional test before starting the calibrations and final setup is the Arm Test. Using the
joystick, rotate the arm in and out. Make sure the direction of travel corresponds with the label on the
Drillers Console.
• In – towards hole center.
• Out – away from hole center.
If the directions for the Horizontal Travel are backward, check the wiring for 2012 wires 2 & 3. If the
arm does not move, check the Manual Horizontal Values in the advanced settings screen and increase
the numbers if necessary.
The second step is to test the Vertical Lift. Check the Vertical Extend and Retract pressures in the
Advanced Settings screen. These values should be approximately 2500 psi. Move the joystick up and
down and ensure the wrench travels in that direction. Again, if the function is backward check the
wiring and the plumbing.
The final step is to rotate the wrench right and left. Using the Device Test screen, or the Manual
Operation screen, press the rotate button for right. Looking from the front of the wrench, the arm
should rotate to the right; pressing the left button should rotate it left. If the wrench reacts incorrectly,
check the wiring and the plumbing.
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until the arm starts to drift rearward. This setting needs to be done with the arm in the retracted/home
position. Extend the arm until the cylinder shows approximately 2 inches of rod. Loosen the Lock
Nut on the correct valve and turn the adjustment in until the arm starts to move slowly.
Caution: DO NOT put your arm in between the Link Arm and the Main
Boom to adjust the valve. The arm may move without warning.
Turn the adjustment CCW (out) 1 full turn and ensure that the arm will not move in any position. If
the arm still creeps at the fully retracted position, increase the setting on the valve (CCW) ¼ turn at a
time.
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To set the extend side of the Counterbalance Valve, extend the arm fully and set the pump to 1000 psi
in the Device Test screen. Increase the valve to the maximum set point (full CCW). Actuate the
Horizontal Retract Leave manually on the side of the wrench arm. The arm should not move.
Decrease the Counterbalance Valve setting until the arm moves slowly and then increase it by ½ turns.
The Extend Valve is now set.
The Vertical Counterbalance Valves are set in a similar way to the Horizontal Retract. Set the Vertical
Counterbalance Valves on either side of the Vertical Tubes to the maximum setting (full CCW).
Extend the wrench fully and lower and raise the vertical lift to synchronize the cylinders. This is
achieved when the cylinder bottoms on the stop and oil is allowed to pass from side to side in the Flow
Divider.
to the next side and do the same. Once both valves are set,
operate the vertical lift through its complete stroke and
ensure the cylinders are moving in sync. If one cylinder is
lagging the other, you can increase the setting from the
Counterbalance Valve of the faster cylinder by ¼
increments to sync the movement.
The vertical speed must now be set using the spool stops.
This is an initial setting and will need to be adjusted after
the horizontal motion has been tuned. Set the spool stop so 1
4" - of Stop
that ¼” is past the handle base (see diagram). Operate the
vertical lift to check the speed, while ensuring that it is not
bottoming out the cylinders at high speed. This is all that needs to be set at this time.
The Rotate Counterbalance Valve is the final valve to set on the arm system. Set the valve to the
minimum setting (full CW). Extend the wrench fully and lower the vertical lift half way. Push on the
side of the Vertical Lift Tube and the wrench should rotate. Slowly increase the Counterbalance Valve
setting until you are unable to rotate the wrench by hand. Then increase that setting by ½ turn. Do the
same for the opposite direction.
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Once you have set the Rotate Counterbalance Valve, set the rotate speed. Initially, set the Spool Stops
on the valve ¼” out from the handle base. With the wrench retracted to home position, use the buttons
on the Device Test screen to actuate the rotate function. When the rotate speed is set correctly, the
wrench should rotate 90 degrees in 4 seconds. Readjust the Spool Stops until this speed is achieved.
To set the Spinner Clamp Pressure, install one gauge in either gauge port on the work section. In the
Device Test screen set the pump to 3000 psi.
SLF Valve Section
Remove the caps on the Work Port Relief
Valves using a 12 mm wrench. Actuate the A&B Port Relief Control
(Remove Cap and use a 4mm
valve to close the Spinner Clamps, and using a alen key, and 12mm wrench to adjust
Using the Device Test screen, set the pump at 3500 psi. Actuate the Spinner Motor Valve by hand and
adjust the Max Pressure for each port to 3000 psi. Turn off the HPU, remove the gauges, reconnect
the hoses and install the caps.
Note: Do not cap only one motor line to set the pressure. This can back pressure the motors and
cause the Shaft Seals to leak.
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Section 5 Rev.01
5. Calibration
To calibrate the pump for the Pressure Control Valve, you must first complete all the Pump Setup
Steps in Section 3. If you have not completed these steps and calibrated the pump, you calibration will
be off once the pump settings have been complete.
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This is the window that will give you the calibration information. A=Offset, and B=Scale are the 2
numbers that you are looking for. Remember that
the number that is entered into the PLC for the
scale is multiplied by 1000. For example, in the
window to the left B=0.733. The number that you
want to enter into the PLC should be 733.
If the output is low on the bottom end and low on the top end, adjust the offset higher.
If the output is high on the low end and low on the high end, increase the scale.
The output number can be higher than what was requested. Generally, the limit is 150-200 psi above
what was requested. If the numbers are any higher than this, a new pump curve should be done.
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In Section 2.3 the analog signals from all three pressure transducers were zeroed. Check that these
pressure transducers are reading the correct values. Note that running the pump traps pressure in the
transducer lines; so these values are not going to be zero.
To recalibrate the transducers after the pump has been run, see Section 2.3.
To calibrate the Hawe cards, you must have first set all the counterbalance valves for the horizontal
extend and retract. The pump differential must be set at 250 psi as outlined in section 3.1.2. Using the
PLC Output Diagnostic Screen, you can enter raw
numbers from 0 – 2000 positive and negative to
make the valve move.
Before starting
the calibration,
install a meter
(set to Amps) into the test ports on the front of the Hawe card. This
meter is for reference only; the values that are displayed on the
meter should not be used to calibrate the card to the valve. The
object of the calibration is to set the card and the valve movement
in a linear line. This is the final setting of the valve.
Setting Qmin
Start the calibration with the horizontal flow at 2012. Using the
Calibrate box, enter 80 in the value window and press “Calibrate”.
The indicator light for the channel that is currently energized is lit.
Using a small flat blade screwdriver, adjust the Q Minimum on the
card until the valve handle moves the correct amount.
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Setting Qmax
0 - Clearence Between
Stop and Handle
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Setting Dither
After setting the Qmin and Qmax, we can use the meter to set the Dither. Enter 80 into the calibrate
value, and set your meter to AC milliamps. Adjust the Dither until the meter reads 30 mA. This is
now set and can be checked by placing your hand on the valve handle. You should feel a distinct
vibration of the handle back and forth.
To set the manual ramps on the card, change the manual move settings in the advanced screen to 60-
70%. Adjust the ramp pots on the card to Max. Run the horizontal slide back and forth to see that the
ramps are working. Reduce the ramp settings until the wrench stops moving within 1-4 inches, once
you have removed your hand from the control. Do the same from ramp up.
Repeat all these steps for all of the cards for each function. Do not use this calibration process for the
torque pressure control. Record all of the Qmin and Qmax for every card in the commissioning check
sheet at the back of this manual.
To set the pressure control card for the Toque cylinder, use the Device Test screen and a meter in the
test ports on the Hawe card. Enter 250 psi in the test pressure box. With the meter connected, press
the “Make Test” and the “Make/Break Pressure” test buttons. Set the Qmin for the channel that is
lit to the absolute minimum setting by turning the post CCW until the meter does not change.
Set the pump test pressure to 4500 psi and press the pump test button. Increase the Make/Break Test
Pressure to 4000 and Adjust the Qmax pot until 4000 or slightly above is achieved. This is as close to
the final setting. You must now enter 500 – 5000 in the Make/Break pressure Test in 1000 psi
increments and adjust the pot until the values are close to all the way up the scale. Repeat the same
process for the Break Pressure by changing the Make Test Button to Break Test.
This may take some time as every valve is slightly different. Use your judgment; if your setting is
high at the bottom but correct at the top, adjust the min. Remember that this is a Zero and Span card,
so every adjustment at the low end affects the high end and vise versa. If you have adjusted either low
or high, check the complete scale before recording your values in the table.
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Section 6 Rev.01
The Memory File that was initially installed at the start of the setup procedure has all of these settings
located in the Advanced Settings screen. This loads all of the settings from a generic file, but any one
of these settings may need to be altered to make each wrench run consistently.
Below are screen shots of each tab in the Advanced Screens with data that was collected from an
install on a rig (Rowan-Hank Boswell). These setting were altered from the file that was loaded to
smooth the operation of the wrench.
6.1 General
The General Setting Screen is where most of the HPU settings are located, as well as any Global
Timers that are used in various places in the system. You can also select the options that are on this
particular wrench. This should be done before tuning any of the other parameters. This also may
need to be
completed
before the
functional
testing in
Section 3 to
override any
errors associated
with the HPU on
a non-HPU
wrench.
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The Vertical/Rotate Settings screen is for setting the pressures to extend and retract. A timer for the
proximity and a position for the vertical clear.
The Vertical Clear Timer allows you to set how far the vertical lift retracts after the clear proximity
turns on. This timer does not need to change on an arm type wrench - but on a carriage unit, this can
be used to lower the wrench farther past the flag for clearance with the Torque Tube.
The Vertical Clear position is used to block the vertical motion until the wrench is far enough forward
not to collide with the floor or the derrick. This value should be set the same as the Trip Position.
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On the right side of the screen, you will find all the manual settings and error timers, as well as the
Extend and Retract pressures.
Note: Retract Pressure and Vertical Retract Pressure should be set very close to the same.
When the wrench is moving in Auto Mode, the pressure that is produced by the pump is driven
from the retract pressure of the Horizontal Cylinder. If you require more pressure than that to
lift the Vertical Cylinder, you must increase this setting to the Vertical Retract Pressure.
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The Clamp Setting screen is also very basic. The labels on the field should tell you what these settings
change.
Clamp Close PCheck - Timer runs for the set time after the 1500 psi is reached keeping the
pump at 1500 psi until the timer expires.
Clamp Close Depressure Time -Timer runs for after the pressure check is compete for set
time with the pump at 250 psi.
Auto Clamp Open – Turns the clamps on after make or break is complete to extend the
clamps for the set time before retracting.
Auto Clamp Full Open - Runs the clamps for the set time once the wrench is finished
retracting.
Clamp Extend Pressure – Sets clamp extend pressure.
Clamp Extend Pressure Offset – Set the lower side of the window for the Pcheck.
Clamp Pressure Scale – Used in setting the clamp pressure while making or breaking, should
be set from 75 – 85.
Clamp Pressure Offset – Add this amount of pressure to the make pressure to set pump
pressure output should be set to 1800-2200 psi.
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The Torque Settings screen is the most complicated. Most of these setting will not need to be
adjusted. If you require a description of all the functions, it is attached in the appendix of this manual.
The main focus of this page should be on the speeds. These speeds may need to be increased or
decreased to achieve the correct torque output. This can only be done while the final testing is
completed. If a torque value is overshooting, you will need to slow the speed down to allow the PLC
time to control the torque.
These speeds should also be set that when the tong rotates the cylinder does not bottom out. If the
cylinder bottoms out while making a connection, the toque valve reading is incorrect. The same is true
for breakout.
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The Spinner Clamps work the same as the Main Clamps. The Times and Pressure settings are labeled
the same. The Spinner Flows are a little different than anything that we have set so far. There are 3
different flows that you can set, one for “Spin In” and “Spin Out”, and the last for Remote. The first
2 are used to set the spinner speed while running in Auto Mode or Manual Mode from the screen. The
last Spinner Flow is used to limit the maximum speed when running from the Radio.
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