SNR.

ELECT
1- What are PMS on Top drive?
• Check AC main Motor JB (Bolt tightness, megger with cable removed from Derrick JB,
and winding continuity) Cleaning with compressed air.
• Blower and Oiler Motors.
• RTD, Proximity Sensors, solenoid’s, Load Cell cables, encoder, air pressure switch,
pressure transmitter and 2 JB for PLC and power cables
• Service loop condition.
2- What are functions of Top drive?
• Rotation FWD and Reverse
• Link Tilt
• IBOP
• Back Wrench (Gripper)
• Pipe Handler Lock unlock
• Brake
• Make up and break out torque.
• Torque boost

3- What are causes of gripper malfunctioned and sequence of troubleshooting?

• Interlocks with alarm massage at TTS.
• Mechanical problem
• Solenoid operation (override, Power, coil resistance)
• Open TD JB to check PLC output module indication light.
• Check the wiring at top drive side
• Profibus cable

4- What are Top Drive Interlocks?

• Back-Up Wrench Gripper closed while DW movement.
• Brake on with the throttle on for more than 2 seconds
• Apply the brake while in SPIN or TORQUE mode
• Close LWCV with mud pumps running
• Close the Back-Up Wrench Gripper with the Handler UNLOCKED
• Close the BUW Gripper while the Top Drive is rotating.

5- What is the signal route (network) from DCR to Top drive motor to let is rotate?
• DCR TP – LER TD control panel – LER MI TTS - .

6- What are causes of Top drive not move and sequence of troubleshooting?
• VFD Cooling skid Pumps not running
• Phase Loss
• Recharge Breaker Not Engage.
• Blower loss of air (Blower stopped, Pressure switch)
 • Low Lube Oiler (Oiler stopped Pressure Switch)
• Encoder Failure (torque without RPM)
• RTD
• E-Stop Activated
• Lockout Pressed
• Break ON

7- What are PMS on DW?

• Check AC main Motor JB (Bolt tightness, megger with cable removed from VFD panel,
and winding continuity) Cleaning with compressed air.
• Blower and lube oil Motors, brake HPU motors.
• RTD, solenoids, Load Cell cables, encoders, air pressure switches, pressure transmitters.

8- What are causes of DW not move and sequence of troubleshooting?

• VFD Cooling skid Pumps not running
• Phase Loss
• Recharge Breaker Not Engage.
• Blower loss of air (Blower stopped, Pressure switch)
• Low Lube Oiler (Oiler stopped Pressure Switch)
• Drum Encoder Failure
• E-Stop Activated
• Break on
• Low or High Pressure brake caliper
• Brake oil high Temp.
• ZMS (IR & Casing Basket)

9- What are interlocks of drilling system?

• Link Tilt extend while reaching Monkey board (alarm or Stopped)
• Mud Pump Running while IBOP closed
• ZMS (IR with DW and Casing Basket)
• Close LWCV with mud pumps running
• Close the Back-Up Wrench Gripper with the Handler UNLOCKED
• Close the BUW Gripper while the Top Drive is rotating.
• Block Position proximity sensor.
• Lube oil of DW Transmission low or high temperature.
• Cooling skid pumps run feedback to run drilling equipment

10- What are types of rig PLCs?

• Siemens Simatic S7-400 (vms)
• Siemens Simatic S7-300 (VFD, AWD, DW, MI, CAD unit)
• Allen Bradley (top drive)
• NOV (jacking system
11- What are components of PLC
• Power supply (PS)
• CPU
• Communication processor (CP)
• I/O modules (D and A)

12- Mention if there was any problem with any PLC on the rig and reason
There was nor readings displayed of engine 4 and 5 on VMS screen, found the cause was
firmware of PLC was not updated, contact OEM and received new updated firmware then
installed and readjusts all set points of engine parameters.

13- Did you replace any PLC or any of its components and how?
CP of MP PLC due to miss communication between MP PLC and the network, and there was no
parameter displayed of any pump.

14- How can you download and upload software program of PLC?

15- What are components of VFD system on the rig?

Drilling transformers
Rectifier
DC-Bus
Inverter
Brake chopper
Motor

16- What are PMS on VFD system?

- Check INPUT MAIN POWER SUPPLY AND AUX. POWER FOR VFD SYSTEM :
o ELECTRIC a- Check fuses. b- Check leakage detector switch. c- Check Heat sink
switches.
o Check monitoring functions for the following signals: ET MAN (Fuse fault - High
temp monitoring - High-High temp monitoring ? Cooling water leakage -
Voltage OK).
o Check Bus Tie Breaker between Switchboard A-side and B-side: a- Check that
the 230V UPS control voltage is working conditions.
o Check that the 230V AC Fan and Heating supply are working conditions.
o CHECK BRAKING RESISTOR SKIDS SYSTEM
o CHECK COOLING SKID OF VFD AND BRAKING RESISTOR SYSTEMS
o Check Common Alarm relay output.
o Check PLC main tasks and status
o Check Braking chopper and Braking resistor for Draw Work VFD
o Remove dust by using a brush and/or vacuum cleaner, compressed air may be
used with caution
o Keep the connections tight and re-torqueing as required.
 o Replacing the fan, Motor Module depending on average service life which is
50000hr

17- What are internal components of inverter?

IGBT’S
Firing boards
Capacitors
CIP (control interface board)

18- What are procedures of replacing an inverter?

o Make sure that capacitors of new inverter has been reformed if new module stored for
more than 2 years.
o Make sure the Main Breaker (Q1, Q1A or Q1B) to the respective motor module is open
and pad-locked.
o Remove the DC fuses on the top of the motor module (F1-F4, F1A-F4A or F1B-F4B). See
the next chapter for instruction.
o Disconnect the signals (X9) and network wires (X400 and X401) on the inverter module.
o Close the water valves in front, rear shackle connected to the motor module, and
disconnect the water tubes between valve and inverter.
o Disconnect the connection bars on the motor module, both on the top and bottom of
the motor module.
o Loosen the six screws on the back of the motor module holding the motor module.
There are three screws in the top and three in the bottom of the motor module.
o Fasten the crane in the front lifting eye through the switchboard doorway.
o Draw, and lift if necessary, the motor module 30 cm out from the original placing. Make
sure that the motor module does not tip forward. If necessary, fasten the motor module
at the back. The weight of the module is 220kg.
o Connect the other lifting eye to the crane/tackle.
o Draw/lift the motor module out of the switchboard.
o Do not put the weight of the motor module on the connection bars at the bottom of the
motor module.
o You must put the motor module down on the back or on the side.
o To re-install the motor module, carry out the above steps in reverse order.
o Remember to change the tension washers at the bus bar screws. These screws (M12)
should be tightening with 70 Nm. The six screws at the back of the motor module should
be tightening with 20 Nm.

19- What is software used in VFD and HMI?

SIMATIC STARTER

20- What is the function of chopper circuit?

A braking chopper is an electrical switch that limits the DC bus voltage by switching the
braking energy to a resistor where the braking energy is converted to heat. Braking choppers
are automatically activated when the actual DC bus voltage exceeds a specified level
depending on the nominal voltage of the VFD
21- What are PMS of chopper circuit?
Limits the DC bus voltage by switching the braking energy to a resistor where the braking energy
is converted to heat

22- What are settings of chopper circuit?

DC voltage of DC bus bar =1045VDC

23- What is regenerative brake?

Motor inverts the current direction and starts feeding current into the brake resistor to dissipate
this power into heat energy, while developing a counter torque that acts as a brake.

24- What are Ex types and how can differ between them?
Exd (flameproof)
Exe (increased safety)
Exp (pressurized enclosure or purge)
Exi (intrinsically safe)
Exn (Non-sparking)
Exo (oil immersed)
Exm (encapsulation) = electrical equipment covered with solid compound such as epoxy.
Exq (sand filled enclosure)

25- What is T-class of Ex equipment and what is the difference between it and ambient temp?
T-class is max surface temperature of equipment without ignition anything at hazard
atmosphere.
T ambient is max atmosphere temperature can electrical equipment works normal in it.

26- What are types of main and emg engines?

Main engine is CAT 3516c (1600kw)
Emergency engine is CAT 3508b (900kw)
Crane engine (

27- What are types of main and emg generators?

KATO 2150kva, 1720kw, 690v, 1200rpm, 60hz
KATO 1278kva, a030kw, 480v, 1800rpm, 60hz

28- What are PMS on AC generators?

- Clean the inside of the outlet box, air screens, bearing housings, and air
baffles with compressed air and electrical solvent if needed.
- Check machine vibrations and bearing condition with a spectrum analyzer or shock
pulse.
- Re-grease the bearings
- Check AVR connections and wiring
- Check RTD’s and bearing temp sensors.
- Check bolts tightness of bus bar and check insulators.
 - Check rotating rectifier diodes of exciter.
- Megger test for main field, main arm, exciter field, and exciter arm and measure continuity.

29- What is difference between single bearing gen and double bearing gen?

A single bearing alternator has no bearing on the driven end. It uses the bearing of prime mover
for support (through the coupling). This type of engine-alternator system cannot use a flexible
coupling, because the weight of the alternator would place excessive shear force on it.
Assembling this type of system requires very small tolerances on alignment, and the
foundation/support system must be very stiff to prevent excessive vibration from damaging the
unit.

A two bearing unit has support on both ends of each machine (driver and Non-drive), and can
used in situation with higher vibration or lower quality foundations. They can use any type of
coupling, since they have support on both ends of the shaft.

30- What is interval of replacing generator bearings?

Every 5 years or depends on bearing conditions.

31- What is DGM and communication between DGM’s of all generators?

DGM (digital generator management) it is using to:
- Circuit breaker, status control, close, open.
- Control the set of engine and generator.
- Synchronization by engine speed control and regulation of the generator voltage via the
generator excitation system.
- Equal load sharing between engine generator sets.
- Smooth loading and unloading of the generator via ramp functions and control of the
delivered power by fuel supply regulation and reactive generator power control via the
generator excitation system.
- Protective functions to prevent desired loads by monitoring the operational data of the
generator and tripping the circuit breaker, if necessary.

Types of DGM are:

( Basic – Medium – Extended – Group to Group – Group to Main )
Used Type is DGM-02 Extended
▪ Communication between DGM’s via CAN1
▪ CAN is the ( Controller Area Network ) 2 wires high speed data bus that allow many devices
to communicate with each other and let any device to take a control and transmit the data.
▪ Communication between DGM and PC via PC program DcDesk 2000 to view parameters and
measured values of the device and load firmware.
▪
32- What are procedures of replacing DGM?
- Disconnect 24VDC fuses, generator 690VAC fuses from back side
- Open C.B of 220VAC from bus bar (C.B installed at ASRY shipyard by SWTS for each
generator)
 - Disconnect all i/o cables
- Remove old DGM
- Install new DGM and make sure that its RTC is the same RTC and with same serial numbers
of certain engine generator set.
Note: RTC components are also saved the main PCB belong calibration values. Therefore, a
RTC module for replacement needs to be prepared according to your given serial numbers
and can be used only for this particular board

33- What are causes of no output power from AC generator and sequence of troubleshooting?
- First, check if Generator is spinning at rated speed.
- Second, check alarm indication light of DECS-100
- Overexcitation ( you can check this cause from Overexcitation Shutdown indicator on DECS-
100 if it is lit)
- Open of PMG and no power from it to DECS-100 exciter board.
- Shorted or grounded exciter armature
- Shorted or grounded rotating rectifier
- Open in generator field
- Open in rotating rectifiers
- DECS-100 soft start settings are not correct (you can adjust the settings).
- Malfunction of automatic voltage regulator {Basler Digital Excitation Control System (DECS-
100)}
Note: Input power to DECS-100 is 1ph (88 - 250Vac) from PMG of generator.

34- What is software of exciter board and how upload or download its parameters?
BESTCOMS-DECS100 software
Upload by clicking the SendToDECS button
Download by clicking the GetFromDECS button

35- What are PMS of jacking system?

Jacking type is BMPL J800-2P
- Check wiring and connections inside jacking panels.
- Check contactors, breakers, transformers.
- Megger jacking motors, measure winding continuity, and check motor space heater.
- Megger jacking brake coil and measure its resistance, cleaned brake unit with compressed
air.
- Check brake air gap and micro switch operation.
- Check load cell reading and calibrate if needed.
- Check leg high sensors and oil level of its gear box
- Check jacking console and screens.

36- What is air gap value of jacking braking system?

2 to 2.5mm for new condition brake lining, and max allowable is 6mm and beyond this value has to
replace brake lining.
 37- Idea re torque operation mode?
Choosing the torque percentage by activate its button then signal goes to PLC which give order
to Auto control transformer to apply required voltage via energizing own contactor of required
torque percentage on jacking

38- What is type load watch system of cranes?

Crane type is BMC 2250E and load watch system is RaycoWylie i3000

39- What are causes of not moving boom and sequence of troubleshooting?
Limit switches.
Control relays.
Solenoid of Control Valve
Solenoid Coil of Swing Control Valve or wiring.
Amplifier Card
Joystick potentiometer
Brake malfunction
Cylinder faulty of lock mechanism.

40- What are causes of not moving swing and sequence of troubleshooting?
Limit switches if installed.
Control relays.
Solenoid of Control Valve
Solenoid Coil of Swing Control Valve or wiring.
Amplifier Card
Joystick
Brake malfunction

ET
1- What are types of encoders on the rig?
Linear and Rotary

2- What is difference between incremental and absolute encoders and why absolute encoder is
not used on the rig?
Absolute is used for angular position while incremental used for distance, speed and
position.

3- What is shape of encoder waveform?

Square wave

4- What are possible effects if encoder malfunctioned?

 Inaccurate torque reading and overtemperature of motor winding while no rotation.

5- What is importance of 90-degree shift between encoders?

Incremental encoder
Incremental encoders have three output signals as standard:
•a signal A consisting of n pulses per revolution (this signal can be a block or sine-wave)
•a signal B, identical to A but 90° displaced
•a signal Z (= zero marker output)
From the combination A, B and Z we can:
1) Determine the shaft position. For this the Z pulse, the initialization pulse, is used and there
after the pulses A or B are counted.
2) determine the direction of rotation (comparing A with B!)
The rotating code disc of an incremental encoder consists of a disc that allows light through
and which has a number of darkened strips to prevent light shining through. Fig. 18-
15 shows what this involves. Notice also how A and B channels and the Z pulse are formed
with the transparent parts. The code disc can be made of glass, metal or plastic.

1- How to make encoder less?

From either AOP panel, or from starter.

2- What is effects of encoder less?

Inaccurate torque reading and overtemperature of motor winding while no rotation.

3- Why using encoders with mud pumps?

To monitor the speed deviation between both motors driving the same shaft (same as sprocket
slip).

4- Can mud pump work with one encoder only?

Yes and the other motor will go into encoder-lss mode

5- What is use of SIMANTIC manager and how to use?

Monitor alarms, monitor trends and sensors, change parameters, update firmware’s….
6- How to find hardware problem of PLC?
Diagnostic Buffer option

7- How to replace damaged PLC module, CPU and CP?

8- Can you use same type of CP but different version?

9- Can you use different CP types and how?

10- Did you force any function of PLC and how and what is advantage of it?

11- What is deference between SF and BF?

- SF (system fault) due to any error in the system
• Software fault such as error in the program.
 • Hardware such as power loss of any modules or CPU unable to read data from any
I/O module, short circuit of any I/O devices connected to I/O modules
- BF (bus fault) due to an error in the communication in network such as bad contact,
profibus cable broken, wrong position of the switch for end resistance of the bus
plug, or overlap between the addresses in the network configuration.
 12- What is indication of burned module (BF or SF)?
SF

13- Does illumination of BF indication has to illuminate SF indication and vice versa?
Each indication illuminate separately unless there is error in communication processor CP

14- What is interval of DW brake burn test?

After replacing brake pads only.

15- What is importance of DW brake burn test?

To burnish new brake pads which increased friction force.

16- What is capacity value of DW brake burn test and min and max values?

17- What is interval of DW brake capacity test?

Every 6 month or before planning to lift heavy abnormal load.

18- What is importance of DW brake capacity test?

- Test newly installed brake pads to confirm sufficient braking capacity.
- As a precaution if going to handling heavy loads and it may be necessary to engage brakes
with full braking capacity.
- At regular intervals to measure braking capacity and ensure that, braking performance is
good.

19- How to make brake burn or brake test?

To make Brake Burn or Brake test you need to make first few things:

1. Draw Works Must be ON.

2. Choose Low Gear (Test and burn brake done only in the low gear).
3. Don’t choose drill or trip mode.
4. The travelling assembly must be higher than 10 meter from Drill Floor and no load must be
suspended in the travelling assembly(Block Position > 6 meter and hook load < 10 mT ).
5. Use a temp stick of approximately 210°C.
6. Brake HPU motor will run all the time without stop during the Brake burn, but while normal
operation or Brake Test, it will run only under 2 condition, first if the pressure dropped to 2500
PSI so it will start to build up the pressure until reach 2700 PSI and then stop, second if the oil
temperature is below 20 Deg C so it will start to heat up the oil until reach 25 Deg C and then
stop.
7. After done these steps you will found that now you can click on Brake Burn or Test.
Burn BrakeTest:
1. To start the test first make sure all the above steps is done.
2. Clear the area around the travelling assembly and make sure that the travelling assembly can
move freely.
3. Activate the Brake Burn button and select the caliper you wish to burn on the front screen HMI
(Caliper 1 or Caliper 2).
4. Press the (Test Activate) button on the Touch Pad to start the burn procedure. This button
works as a toggle switch for this test, so it is not necessary to hold it. Pressing the button again
will stop the drum rotation.
5. Brake Caliper High Pressure alarm will happen for the off caliper, acknowledge and continue.
6. The Draw works drum will start alternating between forward and reverse rotation, moving the
block approximately 0.6 meter which is equal 2 drum round, also the motor torque will varying
to read +ve and –ve readings, also the clipper pressure for one of them about 2700 PSI and the
other one which we burn about 500 PSI.
7. After about one minute or a high increase in HP, check the temperature of the disc and make
sure that it never goes above 260ºC. Check if the brake burning is OK according to the manuals
for the brakes.
8. If pads are not fully burned, repeat the burning when the temperature of the disc allows for this.
 9. When temperature reaches 240 C stop and swap to the other Caliper (Temperature can be
checked by Infra-red Multi-meter).

BrakeTest:
1. To start the test first make sure all the above steps is done.
2. Clear the area around the travelling assembly and make sure that the travelling assembly can
move freely.
3. Activate the Brake Test button and Open the Brake test setting display. Enter the minimum
brake torque percentage you will use during the test which is 100% normally all calipers are set
to the same number.
4. Press and hold the Test Activate button on the X-Com Chair’s touchpad.
5. The system will proceed to test the holding force of each caliper. Status of the currently active
caliper is shown in the first column. If the test passed it is shown in the next column. If the test
failed it is shown in the last column. The actual torque the brake vas verified to hold is shown in
the column over.
6. Torque reading for both motors while test will start from 0 lbft and decrease with –ve value
about -6000 lbft, if the test is passed
7. We can redo the test with different Block Position value until reach 100% reading and test is
passed indication is green.

20- What are types of PLC modules and examples of DI, DO, AI, AO?
DI, DO, AI, AO
AI: Potentiometer , level transmitter, pressure transmitter
AO: Proportinal valve, servo valve, current/ speed meter
DI: Limit switches, bush buttons, pressure switch, relay feedback, level switch
DO: Indication light, bulb, contactor, solenoid valve, shutoff valve, ON/OFF valve.

21- What is PLC arrangement?

PS----CPU----CP----AIM----DIM----AOM----DOM

22- What is importance of 5VDC indication on PLC power supply?

 Because the processor and internal ICs operating using +/- 5VDC and when indication is ON that
means PLC is ok.

23- What is WINCC

HMI SW interface with PLC

24- How to download backup of new HMI?

From Control Panel on the HMI there is an option for backup and restore or by taking an image
of CF card.

25- Can system work without CF card and is it important in operation or not?
Yes, it can work without CF card but will not save alarms.

26- Do you have download all program or can download a certain data block or function block?
can download a certain data block or function block.

27- What is meaning of red line between 2 PLC and CP and troubleshooting sequence?
Communication loos

28- How many networks and what is the head of these networks?
- C-Net (control network) it is low network level and for communication using fiber optics
cables and profibus cables, connect X-com with PLC, PLC with PLC, PLC with server.
- I-Net (information network) it is upper network level using Ethernet cables and switches,
(TCP/IP) to connect PC’s together.
- MPI (multi point interface) it is a bus used for programing and diagnostic network.
-
29- What is reforming of inverter and how to make it and its importance?