ABB ACS800-104-0580-7 Drive Repair for NOV Top Drive Application – Land Rig Operations

This case study covers the rapid repair of an ABB ACS800 drive in a NOV top drive system, restoring full operation within 72 hours and minimizing costly rig downtime.

Client Overview

Industry: Oil & Gas
Application: NOV Top Drive System
Location: Texas
Equipment: ABB ACS800-104-0580-7 Industrial Drive

Background

National Oilwell Varco (NOV) top drive systems are a critical component in modern drilling rigs, replacing traditional rotary tables by providing more precise and efficient drilling. At the heart of these systems is the ABB ACS800-104-0580-7 drive, which controls the AC motor responsible for the top drive’s rotation and torque.

In August 2023, a land rig operator in West Texas experienced erratic behavior and eventual failure of an ACS800 drive unit integrated within the top drive system. Due to the high cost of downtime in drilling operations, a rapid and effective repair solution was essential.

Services

Problem Description

Symptoms:

Intermittent drive faults
resets during operation
Drive not responding to control signals from PLC
Visual signs: Bulging capacitors, heat discoloration on PCBs

Root Cause Analysis:

Capacitor degradation due to high ambient temperatures (> 50°C)
Power board damage caused by harmonic distortion and inadequate surge
protection
Environmental contamination (dust ingress) affecting heat sinks and internal
cooling

Repair Process

1. Initial Inspection

Drive removed from service and sent to workshop
Diagnostic logging via ABB’s FlashDrop tool and DriveWindow software
Internal inspection revealed aged electrolytic capacitors and corroded solder joints

2. Component Replacement

Replaced:

DC bus capacitors
IGBT module
Control and power board
Internal fans

3. Cleaning & Preventative Measures

Cleaning of PCB boards
Heat sink realignment and reapplication of thermal paste

4. Testing

Drive ran in test stand for 4 hours
Verification of communication with PLC (Modbus RTU protocol)
Thermal imaging used during operation to verify temperature stability

5. Reinstallation and Commissioning

Drive reinstalled in the top drive system
Field testing conducted during rig up
System returned to full operation without recurring faults

Results

Downtime Mitigated: Drive was repaired and returned to service within 72 hours
Performance: Top drive operated with no faults for 6 months post-repair under continuous duty
Customer Benefit: Avoided extended rig downtime, minimized non-productive time, and extended equipment lifecycle

Relevant Industries

Lesson Learned

Environmental Controls: Need for improved ventilation and air filtration in drive cabinets on land rigs
Proactive Maintenance: Recommend capacitor replacement every 9 years and fan replacements every 6 years, especially in harsh climates
Surge Protection: Installation of proper line filters and MOV-based surge arrestors upstream of ACS800

Conclusion

Repairing the ABB ACS800 proved cost-effective and efficient, restoring the NOV top drive system to full function with minimal downtime. This case highlights the importance of robust maintenance practices and quality repair processes in mission-critical oilfield applications.

ABB ACS800-104-0580-7 Drive Repair for NOV Top Drive Application – Land Rig Operations

This case study covers the rapid repair of an ABB ACS800 drive in a NOV top drive system, restoring full operation within 72 hours and minimizing costly rig downtime.

Client Overview

Background

Services

Problem Description

Repair Process

1. Initial Inspection

2. Component Replacement

3. Cleaning & Preventative Measures

4. Testing

5. Reinstallation and Commissioning

Results

Relevant Industries

Lesson Learned

Conclusion

Locations

Who we help

Services

Quick Links

Get to know us

News & Insights

Connect