Product Bulletin No.

: 10504139-PIB
Release Top Drive Drilling System
Date: 7/15/2010

Subject: Possibility of Induced Voltage on Portable AC Top Drive Power Service Loops
with Connectors in a Hazardous Area

Product: All connectorized NOV AC Top Drive Drilling Systems with Amphenol Ex Star-
Line Connectors

Affected
Assemblies: AC Top Drive Power (Main Power and Auxiliary) Service Loops with Amphenol
Ex Star-Line Connectors for Hazardous Areas

Objective: Advise operators of potential electrical spark from connectorized power service
loops and connectors.

Issue: National Oilwell Varco (NOV) recently received notification of an incident

where rig personnel observed sparks when the stainless steel braided armor
and aluminum shell power connectors used for the individual power conductors
on a TDS-11SA power service loop contacted ground or one another. It was
determined that the connectors and the armor were not connected to an earth
ground. Once the armor and the external component parts of the connector
were connected to an earth ground, the potential voltage was eliminated. No
injuries occurred as a result of this incident.

Analysis: NOV initiated and has completed a full investigation to ascertain the cause and
any potential hazard as a result of the reported incident. Through this
investigation, NOV has determined that there is a possibility of voltage being
induced onto the stainless steel braided armor and the aluminum connectors
when attached to single-core and multi-core cables powered with a variable
frequency drive (VFD). This voltage potential is the result of capacitive
coupling between the insulated conductors and the stainless steel braiding and
aluminum connector shells, and is caused by high frequency switching of the
VFD output.

© 2009 National Oilwell Varco 10504139-PIB

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 This investigation also confirmed that if the braided armor and the aluminum
connector shells are attached to an established earth ground, the induced
voltage is drained and any potential hazard is removed.

Solution: NOV recommends that owners/operators carry out the following procedure for
all top drive installations that make use of power conductors and associated in-
line connectors powered by a VFD source:

1. Immediately perform an installation inspection, including electrical

continuity checks to ensure the following:

a. that the stainless steel braided armor installed on single-core power

cables exiting the Top Drive and Derrick Service Loops and fed by a
VFD source are grounded to a local earth point;

b. that all ground cables exiting the Top Drive Service Loop are
grounded to a local earth point; and

c. that the installation facility is equipotentially grounded throughout

(i.e. has a good common ground from the drive house to the top
drive).

2. All Amphenol Connectors installed on VFD powered cable in a hazardous

area installation should have electrical continuity between specific sections
of the connector and they should be grounded to a local earth point. If there
is not continuity across these sections then National Oilwell Varco
recommends that Amphenol grounding clamps be installed on them. The
grounding clamps will provide a path of continuity between the sections
allowing them to be attached to a local earth point. Refer to appendices A,
B, C, and D for more information on the specific connector sections that
must have electrical continuity between them and illustrated examples of
grounding clamps installed on the connectors.

Failure to follow these recommendations may result in death, bodily injury and/or
property damage.

Operators should also refer to previous NOV Product Information Bulletins and Safety Alerts at
http://www.nov.com/drilling for additional information related to this issue and information
regarding safe operation, maintenance, and inspection criteria.

Please contact your local National Oilwell Varco (NOV) Service Center if you have any
questions regarding this safety alert.

© 2009 National Oilwell Varco 10504139-PIB

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Appendix A:

The specific sections that make up the receptacle and the plug and that must have electrical
continuity between them when assembled are illustrated below:

Receptacle: there should be electrical continuity between the cable gland, cable adaptor, and
receptacle shell when all three sections are threaded together.

Cable Gland Cable Adaptor Receptacle Shell

Plug: there should be electrical continuity between the cable gland and the cable adaptor
when both sections are threaded together.

Cable Adaptor Cable Gland

© 2009 National Oilwell Varco 10504139-PIB

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Mated Plug and Receptacle: In the photo below, the plug and receptacle are shown
assembled as well as mated together.

Receptacle Plug

Cable Gland Cable Adaptor Receptacle Shell Cable Adaptor Cable Gland

Appendix B:

The photo below provides an illustrated example of Amphenol grounding clamps installed on a
mated plug and receptacle that are attached to an unarmored cable. The grounding clamps
connect together the specific sections of the connector identified in Appendix A, to provide
electrical continuity between them. As shown below there is one clamp on the plug and two on
the receptacle. In this example, ground wires are attached to the clamps at each end to
provide a means of grounding the plug and receptacle to a local earth point.

© 2009 National Oilwell Varco 10504139-PIB

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Appendix C:

The photo below provides an illustrated example of Amphenol grounding clamps installed on a
mated plug and receptacle that are attached to an armored cable. The grounding clamps
connect together the specific sections of the connector identified in Appendix A, to provide
electrical continuity between them. As shown below there is one clamp on the plug and two on
the receptacle. In this example, ground wires are not attached to the clamps at each end since
the armor provides the grounding path to a local earth point for the plug and receptacle.

Appendix D:

Listed below are National Oilwell Varco grounding clamp retrofit kit part numbers for the
Amphenol Ex Star-Line connectors. Each kit comes with three grounding clamps, one clamp
for the plug and two for the mating receptacle.

Shell size 20 connectors require ground clamps only when used on top drives that have
auxiliary motors driven by a VFD which is powered with a 50 HZ system.

Amphenol Ex Star-Line Shell Size 20 Connector Grounding Clamp Kit:

• NOV Kit Part Number – 10508625-001

Shell size 24 connectors are used on AC top drive drill motor power cables.

Amphenol Ex Star-Line Shell Size 24 Connector Grounding Clamp Kit:

• NOV Kit Part Number = 10508626-001

© 2009 National Oilwell Varco 10504139-PIB

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