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TDS-11SA

T o p D r i v e S y s t e m
Motor Cooling Counterbalance
System System

Hydraulic Disc Gooseneck


Brakes (2) (S-Pipe)

AC Drilling
Motors (2)
Transmission/
Motor Housing

Electrical
System
Hydraulic
System

Rotating Link
Adapter

Guide Beam
and Carriage

PH-50
Pipehandler

Rear Right Side

Left Side Front


General Information 1

Specifications 2

Lubrication 3

Installation, Commissioning 4
and Decommissioning

Guide Beams and Carriage 5

Motor Housing, 6
Transmission

PH-50 Pipehandler 7

Hydraulic System 8

Electrical System 9

TDS-11SA
1 General Information

2 Specifications

3 Lubrication

4 Installation, Commissioning
and Decommissioning

5 Guide Beams and Carriage

6 Motor Housing,
Transmission

7 PH-50 Pipehandler

8 Hydraulic System

9 Electrical System

Varco Systems
Preface

Manual conventions
This Preface contains the conventions used throughout this manual.
Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or servicing
the equipment.

Notes, cautions, and warnings

The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.

Note

i Provides additional information on procedures involving little or no risk of


injury to personnel or equipment damage.

Caution

! Alerts the reader to procedures involving a risk of equipment damage.

Warning

Warns the reader of procedures involving a definite risk of injury to


rig personnel.

Product Bulletins
The Product Bulletin tab, if included in your manual, defines a section of
the manual in which you can store Product and Safety bulletins that may
be issued by Varco.
Overall equipment safety requirements
Varco drilling equipment is installed and operated in a controlled drilling
rig environment that involves hazardous operations and situations.

i To avoid injury to personnel or equipment damage, carefully observe the


following safety requirements.

Personnel training
All personnel installing, operating, repairing, or maintaining equipment,
or those in the vicinity of this equipment, should be trained in rig safety,
tool operation, and maintenance as applicable. This measure helps
ensure the safety of everyone exposed to the equipment for whatever
purpose.

i During installation, operation, maintenance, or repair of this equipment,


personnel should wear protective equipment.

Contact the Varco Service Department to arrange for training for


equipment operation and maintenance.

Systems safety practices


The equipment covered by this manual may require or contain one or
more utilities such as electrical, hydraulic, pneumatic, and cooling water.

i Before installing or performing maintenance or repairs on the equipment,


read the following instructions to avoid endangering exposed persons or
damaging equipment.

Isolate all energy sources before beginning work.

Avoid performing maintenance and repairs while the equipment is in


operation.

Wear proper protective equipment during the installation,


maintenance, or repair of this equipment.
Electrical systems and components
All electrical wiring, junction boxes, sensors, glands, and related
equipment are designed for the specific application, environment and
particular zone where the equipment is intended to be used.

Before beginning work on this equipment, familiarize yourself with


the electrical schematics, as well as the equipment power and
voltage requirements.

When performing installation, maintenance, or repairs on the


equipment, isolate all power. Lock out switches and tag them to
prevent injury.

Prior to disconnecting wires, verify that all wires and terminals are
properly labeled to ensure proper reconnection.
Hydraulic systems and components
Hydraulic systems and components are designed for specific use in the
drilling industry. The hydraulic pressure for this equipment can be as high
as 3,000 psi.

Before beginning work on any portion of the hydraulic system,


familiarize yourself with the hydraulic and electrical schematics.

Isolate, lock out, and tag the hydraulic and electrical power and
controls.

Take precautions when bleeding down residual system pressure,


using bleed valves or equivalent techniques.

n Hydraulic fluids can be extremely hot and under high pressure.

Properly discharge all system accumulators.


Collect all residual hydraulic fluid in a container to prevent rig or
environmental contamination.

Take precautions to prevent hydraulic oil from leaking into other open
electrical or mechanical components, such as junction boxes.
Pneumatic systems and components
Pneumatic systems and components are designed for specific use in the
drilling industry. The pneumatic pressure for this equipment can be as
high as 150 psi.

Prior to beginning work on any portion of the pneumatic system,


familiarize yourself with the pneumatic and electrical schematics.

Isolate, lock out, and tag the pneumatic and electrical power and
controls.

Take precautions when bleeding down residual system pressure


using bleed valves or equivalent techniques.

Properly discharge all system accumulators.


Water cooling systems and components
Water cooling systems and components are designed for specific use in
the drilling industry. The water can reach temperatures high enough to
cause scalding.

Prior to beginning work on any portion of the cooling system


familiarize yourself with the plumbing and electrical schematics.

Isolate, lock out, and tag the cooling water and electrical power and
controls.

Take precautions when bleeding down residual system pressure


using bleed valves or equivalent techniques.
Collect all residual cooling water in a container to prevent rig or
environmental contamination if necessary.

Take precautions to prevent cooling water from leaking into other


open electrical or mechanical components such as junction boxes.
General safety
Equipment motion hazards
Some of the Varco equipment travels either horizontally, vertically on
rails, or both.

i Avoid placing objects in or near the path of motion for this equipment.
Such interference could cause personnel to be trapped or crushed by
equipment.

i Keep the working envelope/zone of the equipment free from personnel.

When replacing components


During disassembly and reassembly of any equipment, verify all
components such as cables, hoses, etc. are tagged and labeled to
ensure reinstalling the components correctly.

Replace failed or damaged components with Varco certified parts.


Failure to do so could result in a hazard, equipment damage, or
personal injury.
During routine maintenance
Equipment must be maintained on a regular basis. See the body of the
service manual for maintenance recommendations.

i Failure to conduct regular maintenance can result in a hazard,


equipment damage, or injury to personnel.

Visibility of equipment operation


Clear, unobstructed visibility of all equipment functions is critical to safe
operation. Do not block or impair the equipment operators field of view.
In cases where this is not possible, the customer must install video
cameras to ensure adequate visibility.

Proper use of equipment


Varco equipment is designed for specific functions and applications and
should be used only for the intended purpose.

i Do not hoist personnel using this equipment.

Contact the Varco service center for questions regarding equipment


operation, maintenance, hazards, and designed function.
General Information

How to use this manual ...................................... 1-2


Identification numbers ....................................... 1-3 1
Lifting points ....................................................... 1-4
Safety wiring ....................................................... 1-5
Torque values ..................................................... 1-6 2
Basic useage ...................................................... 1-7
Drilling ahead with singles ............................................. 1-7
Drilling ahead with triples............................................... 1-8
Backreaming ................................................................. 1-9 3
TDS-11SA consumables ..................................... 1-10

TDS-11SA
General Information

How to use this manual


This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up
with the thumb index tabs for each section and the back cover. You can quickly find each section without looking
1 through a full table of contents. Use the symbols printed at the top corner of each page as a quick reference system.
Each section uses a different symbol.

Where applicable, each section includes:


1. A table of contents, or an illustrated view index showing:
Major assemblies, systems or operations
Page references to descriptions in text
2. Disassembly / assembly information and tools
3. Inspection information
4. Testing / troubleshooting information
5. Repair information
6. Adjustment information
7. Torque values

Notes, Cautions and Warnings

i (Note) Gives helpful information.

(Caution) Indicates a possibility of personal injury or equipment damage if instructions


! are not followed.

(Warning) Indicates a strong possibility of severe personal injury or loss of life if


instructions are not followed.

Special Information

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included.
! Please note that this may manual contain warnings about proceedures which could damage equipment, make it
unsafe, or cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in
which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous
consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service
procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither
personal safety nor equipment safety will be jeopardized.

All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make
changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any
means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text,
figures and tables.

1-2 Varco Systems


General Information

Identification numbers

1
Encoder
Instruction Label
Located on the side
i Trace code identifies the
configuration of your equipment
of the brake housing

AC Motor
Identification Label SALES ORDER NO.
Located on the side ASSY NO. REV
of each AC motor TRACE CODE
DATE OF MANUFACTURE

Top Drive
Identification Plate
Located on the front
Warning Labels of the motor housing
Located on the side
of each AC motor

Warning Label
Located on the
side of the bonnet

TDS-11SA 1-3
General Information

Lifting points
27,000 lb
(12300 kg)
1 TDS-11SA

Lifting Point
For lowering/hoisting the
Top Drive to/from the skid

!
Bail Lock
Must be installed before
lowering/hoisting the
Top Drive to/from the skid

Lifting Points
For the skid with
Top Drive attached

i
For information on
Center of gravity
see pages 2-2 and 2-3

30,000 lb
(13600 kg)
TDS-11SA on the skid

Lifting Points
For the skid with
Top Drive attached

! Locking pins
Must be in place ! Locking pins
Must be in place
prior to moving the skid prior to moving the skid
with Top Drive attached with Top Drive attached

1-4 Varco Systems


General Information

Safety wiring

1 2
1

3 4 5

TDS-11SA 1-5
General Information

Torque values
(Unless otherwise specified)

1 Bolts Lubricated with Bolts Lubricated with


Light Machine Oil Anti-seize Compound
Grade 5 Grade 5

Min. Max. Clamp Min. Max. Clamp


Threads Torque Torque Force Torque Torque Force
Diameter per inch (ft lb) (ft lb) (lb) (ft lb) (ft lb) (lb)

Coarse Thread Series, UNC


1/4 20 7.6 8.4 2020 5.7 6.3 2020
5/16 18 16 18 3340 12.1 13.4 3340
3/8 16 29 32 4940 21.4 23.6 4490
7/16 14 48 53 6800 36 39 6800
1/2 13 71 79 9050 53 59 9050
9/16 12 105 116 11600 78 87 11600
5/8 11 143 158 14400 107 118 14400
3/4 10 247 273 21300 185 205 21300
7/8 9 409 452 29400 306 339 29400
1 8 608 672 38600 456 504 38600
1 1/8 7 760 840 42300 570 630 42300
1 1/4 7 1064 1176 53800 798 882 53800
1 3/8 6 1387 1533 64100 1040 1150 64100
1 1/2 6 1843 2037 78000 1382 1528 78000

Fine Thread Series, UNF


1/4 28 9.5 10.5 2320 7.1 7.9 2320
5/16 24 18 20 3700 13.5 15.0 3700
3/8 24 33 37 5600 25 28 5600
7/16 20 52 58 7550 39 43 7550
1/2 20 86 95 10700 64 71 10700
9/16 18 114 126 12950 86 95 12950
5/8 18 162 179 16300 121 134 16300
3/4 16 285 315 23800 214 236 23800
7/8 14 447 494 32400 335 370 32400
1 14 665 735 42200 499 551 42200
1 1/8 12 836 924 47500 627 693 47500
1 1/4 12 1178 1302 59600 884 977 59600
1 3/8 12 1596 1764 73000 1197 1323 73000
1 1/2 12 2090 2310 87700 1568 1733 87700

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi


T.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi

1-6 Varco Systems


General Information

Basic useage
Drilling ahead with singles
1

Step 1 Step 2 Step 3 Step 4 Step 5


 Set slips on string  Tilt links to  Pickup single  Lower block to  Pull slips
mousehole with elevator stab motor into
 Stop circulation top of single  Open IBOP
 Latch drill pipe  Release link tilt
 Close IBOP elevator around  Spin in motor  Start circulation
single  Stab bottom of and single
 Breakout connection single onto string  Begin drilling
using pipehandler  Makeup both
and drilling motor connections
(in reverse) with motor in
torque mode

Makeup

Open
IBOP

Link Tilt
Close IBOP
Stab Makeup

TDS-11SA 1-7
General Information

Basic useage
Drilling ahead with triples
Step 1 Step 2 Step 3 Step 4 Step 5
1
 Set slips on string  Raise block  Pickup stand  Lower block to  Pull slips
with elevator stab motor into
 Stop circulation  Tilt link tilt to top of stand  Start circulation
derrickman  Stab bottom of
 Breakout connection stand onto string  Spin in motor  Begin drilling
using pipehandler and stand
and drilling motor
(in reverse)  Makeup both
connections
with motor

Link Tilt Makeup

Start
Circulation

Stop
Circulation

Stab Makeup

1-8 Varco Systems


General Information

Basic useage
Backreaming
Step 1 Step 2 Step 3 Step 4 Step 5
1
 Hoist while  Set slips on string  Hoist free stand  Setback stand  Lower block, stab
circulating and with elevator using link tilt motor into string
rotating  Breakout
connection using  Spin in motor
 When 3-rd pipehandler and and makeup
connection drilling motor connection with
surfaces, stop (reverse) motor
rotation and
circulation  Breakout and  Start circulation,
spinout stand pull slips, hoist
at floor and rotate

Breakout Hoist Setback

Hoist and
Rotate

Breakout

TDS-11SA 1-9
General Information

TDS-11SA consumables
Consumables Quantity Part Number Page Ref.

1 Tong Dies 4 16781 See page 7-14

Stabilizer, Front 1 118368 See page 7-15


Stabilizer, Rear 1 118367 See page 7-15
Flippers, Stabbing Guide 2 76442 See page 7-15

Wash Pipe 1 123289 See page 6-11

Wash Pipe (Tungsten Coated) 1 123289-TC See page 6-11


Wash Pipe Packing Kit, 3" Standard 1 123290-PK See page 6-11
(Use with Wash Pipe 123289 or 123289-TC)

Wash Pipe Packing Kit, 3" High Pressure 1 123290-PK-1 See page 6-11
(Use with Wash Pipe 123289-TC only)
Hydraulic Oil Filter 1 114416-1 See page 4-30
Gear Oil Filter 1 111013-1 See page 4-32

Hydraulic Oil Filter Wash Pipe

Gear Oil Filter

Stabilizers

Tong Dies

Stabbing Guide

1-10 Varco Systems


Specifications
Specifications

Size specifications ............................................. 2-2


General specifications ....................................... 2-4 1
Typical mast interface ....................................... 2-5

22

TDS-11SA
TDS-11SA 2-1
Specifications

Size specifications
Bail
120 in.
(3.05 m)
18.5 in. (.47 m)

Bail
88 in.
(2.24 m)
2

214.0 in. 233.0 in.


(5.43 m) (5.82 m)

To Center
of Gravity
112 in.
(2.85 m)

To Center To Center
of Gravity of Gravity
28 in. 37 in.
(.71 m) 56 in. (.94 m)
(1.42 m)

62 in. = 30,000 lb
(1.58 m) 72 in. (1.83 m) = 13600 kg

2-2 Varco Systems


Specifications

Size specifications

Rear

33.7 in. (856 mm)

33.8 in.
(859 mm)

30.0 in.
(762 mm) 22.8 in.
Setback (579 mm)
(Standard)

C
L
Well
21.1 in.
(53 mm)

22.1 in.
(561 mm)

31.0 in. (787 mm)


32.6 in. (828 mm)
26.0 in. (660 mm) 36.9 in. (937 mm)

C
L
Well

Front

TDS-11SA 2-3
Specifications

General specifications
Components Items Description

Top Drive
Weight 27,000 lb
Stack-up Height 17.8 ft
Power Requirements 700 KVA @ 575-600 VAC, 50/60 Hz
Horsepower 800 hp
2 Output torque (continuous) 37,500 ft lb (800 hp)
Tool torque (intermittent @ stall) 55,000 ft lb
Maximum Speed @ full power 228 rpm
Hoisting capacity 500 ton
Load Path Single
Drill Pipe
Sizes 3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
Pipe Handler
Type PH-50 (55,000 ft lb torque)
Drilling Motor
Type Reliance AC-575 VAC (2 x 400 hp)
Variable Frequency Drive
Type IDM Yaskowa Drive (800 hp, 575 VAC) or
Siemens (800 hp, 600 VAC)
Motor Braking
Type Hydraulic caliper disc brakes
Motor Cooling System
Type Local intake pressure blower
Power (2) 5 hp AC motors
Speed 3,600 rpm
Gearcase
Type Single speed, double reduction helical gear
system
Gear ratio 10.5:1 (4.38:1 optional)
Gearcase Lubrication
Type Pressure feed
Reservoir capacity 15 gal
Full internal flow
Oil Type EP Grade
Hydraulic System
Power 10 hp, AC motor
Flow (1) 6 gpm, (1) 4 gpm
Reservoir capacity 25 gal
Oil Type Mineral based hydraulic oil
Electrical House
Size 125.4 in. x 84.0 in., 91.2 in. height (Siemens)
Type 140.0 in. x 90.0 in., 91.0 in. height (IDM)
Weight 9,500 lb
Input requirement 600 VAC(50/60 Hz), or 750 VDC,
or 690 VDC(50/60 Hz)

2-4 Varco Systems


Specifications

Typical mast interface


Existing
* Dimensions are Subject Traveling Equipment
to Verification Crown
500-ton Hook/Block Combo-Typ.
** Standard TDS Configuration- Clearance
Two IBOPs with 108 in.
Elevator Links
13.5 ft. (4.1 m)**
Block Top
TDS-11SA
Varco Portable
Top Drive System Stroked-Typ.
13.5 ft. (4.1 m)* 2
Bail Rest

Sectional Guide Beam TDS Work Height


18.0 ft. (5.4 m)**
Tool Joint
Derrick Termination
at ~73 ft. (24.4 m) Level*

Mud Hose
75 ft. (22.9 m)* Drill Stand
Connected to Standpipe Made-up at
at 73 ft. (22.3 m) Level 4 ft. (1,2 m)
Level
93 ft. (28.3 m)
Service Loop

Portable Torque Reaction Beam


U- Bolted to Spanners - (by Customer) Clear
Working
Height

10.0 ft. (3 m)-Minimum*


142 ft.

7.0 ft. (2.1 m)-Minimum


2 Custom Spanners
(43.3 m)
On A-Frames or Mast Side Panels (by Customer)

Varco Drillers Control

Control Cable with Connectors


150 ft. (45.7 m)
C
L
Beam
Unitized Variable Frequency Service Loop
Inverter & Varco Control Panel Tool Joint
4.0 ft. (1.2 m)
Local Power Supply Drill Floor
Diesel/Alternator Set/AC Buss

AC Power and
AC Cables Control Cables

TDS-11SA 2-5
Specifications

2-6 Varco Systems


Lubrication and
Maintenance

Transmission ...................................................... 3-2


Selecting the proper gearbox oil .................................... 3-2 1
Lubrication schedule ..................................................... 3-2
Recommended gear oils ............................................... 3-3

Gearbox lubrication ............................................ 3-4


2
Hydraulic system ................................................ 3-5
Precautions ................................................................... 3-5
Lubrication schedule ..................................................... 3-5
Recommended hydraulic fluid ....................................... 3-6
3
Hydraulic lubrication ...................................................... 3-7

Motors ................................................................. 3-8


Lubrication schedule ..................................................... 3-8
Recommended motor grease ........................................ 3-8
4
Motor lubrication ............................................................ 3-9

General purpose lubrication ............................... 3-10


Lubrication schedule ..................................................... 3-10
Recommended lubricants .............................................. 3-11 5
General lubrication ........................................................ 3-12

TDS-11SA
Lubrication

Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of the
gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA extra pressure rating (EP), and a
minimum viscosity of 100 SUS at internal operating temperature.

Varco Top Drives also operate under a wide variety of ambient


temperatures. Select lubrication for the TDS based on the minimum
ambient temperature (surrounding air) to be expected before the
next oil change. Under all but the most severe operating
conditions, Varco recommends changing the oil every six months.
Introducing an oil viscosity greater than required by the ambient
3 temperature can:

Damage the gearbox due to reduced oil flow


Damage the oil pump because of excessive load

Lubrication schedule
Description Frequency

Replace the Gearbox Oil Following Intial Break-in Following first month of operation
Replace the Gearbox Oil and Perform an Oil Analysis 1 x every 6 Months
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 111013) 1 x every 3 Months
Remove, clean and replace the Magnetic Drain Plug 1 x every Year

The first oil change should be performed after the first month of
operation since new units often contain metal contaminates and
contaminates caused by initial break-in.

3-2 Varco Systems


Lubrication

Transmission
Recommended gear oils
Ambient Temperature Range
-6 to 16 C 7 to 30 C Above 21 C
(20 to 60 F) (45 to 85 F) (Above 70 F)

Manufacturer
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 68 Omala 150 Omala 320
Statoil Loadway EP68 Loadway EP150 Loadway EP320 3
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP

Viscosity Index
AGMA 2EP 4EP 6EP
ISO Viscosity Grade 68 150 320

! Oils of insufficient viscosity can damage gears by allowing


metal to metal contact.

i For minimum temperatures below 20F, the TDS must be warmed


up by rotating at a very light load (less than 200 Amps) and at very
slow speeds (less than 50 rpm) until the oil temperature climbs
above 20F. If drilling conditions dictate oil temperatures below 20F,
consult Varco service center.

If the oil temperature rises above 200F, Varco recommends shutting


down or reducing drilling loads to stabilize the oil temperature below
200F If drilling conditions dictate oil temperatures above 200F,
consult Varco service center.

TDS-11SA 3-3
Lubrication

Gearbox lubrication

Gearbox Oil
Drain

3
Cork Ball
(Level Sight
Indicator) Glass

i i
Gear Oil
Sight Gauge Gearbox Oil Fill
Check with Top Drive Clean area before removing plug,
OFF then use a 1 3/8 inch, 12 point
socket to remove plug

Pop-up
Dirt Alarm

Procedure
 Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
 Ensure that the unit is turned OFF
 The area must be wiped clean
Gear Oil Filter prior to adding gearbox oil
 Recheck oil level and replace the
plug after adding oil
Yearly  Run the unit and recheck the oil
level (not foam level), after the unit
Magnetic Drain Plug has been running and the
Remove and clean contamination transmission oil is warm

3-4 Varco Systems


Lubrication

Hydraulic system
Precautions

Release all hydraulic oil pressure by bleeding


accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean


work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is 3
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent injury
to personnel.

! Use care when handling components to prevent nicking close


tolerance finishes.

! Use care to prevent contamination from entering the hydraulic


system during maintenance activities.

Lubrication schedule
Description Frequency

Perform Hydraulic System Oil Analysis 1 x every 6 Months


Replace the Hydraulic Fluid 1 x Year, or Earlier Based on Oil Analysis
Replace the Hydraulic System Filter (P/N 114416-1) 1 x every 3 Months

TDS-11SA 3-5
Lubrication

Hydraulic system
Recommended hydraulic fluid
Oil Temperature Range
-15 to 75 C -10 to 85 C
(5 to 167 F) (14 to 185 F)

Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
3 Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46

Viscosity Index
ISO Viscosity Grade 32 46

3-6 Varco Systems


Lubrication

Hydraulic system
Hydraulic lubrication
Procedure
 The area must be clean prior to adding hydraulic fluid
 Remove dust plug from the male quick disconnect at
the TDS-11SA hydraulic oil fill
 Remove dust plug from the female quick disconnect
on the lubrication kit and connect it to the male fitting
 Pump fluid until the level reaches the middle of the
sight glass as shown
Cork Ball
 After adding fluid, replace the dust plugs (Level Indicator)

3
Red
Pop-up
Dirt Alarm Sight
Glass

Hydraulic
Oil Sight
Hydraulic Gauge
Oil Filter

Hydraulic Oil Fill


Male Quick Disconnect

Dust Plug

Hydraulic
Oil Fill

Female
Quick
Disconnect

Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643

Hydraulic
Oil Drain

TDS-11SA 3-7
Lubrication

Motors

Varco recommends that lubrication of all AC motors


should be done by the rig electrician.

Lubrication schedule
Description No. of Points Frequency Type

Lubricate the AC Drilling Motor 4 1 x every 3 Months Motor Grease


Lubricate the Blower Motor 4 1 x every 3 Months Motor Grease
Lubricate the Hydraulic Pump Motor 2 1 x every 3 Months Motor Grease

3 Recommended motor grease


Motor Grease

Manufacturer
Chevron Black Pearl EP2 (Do Not Substitute)

3-8 Varco Systems


Lubrication

Motors
Motor lubrication
i Grease Fittings
Apply motor grease
to designated Grease
grease fittings Fitting
with hand grease gun 1/8 inch
Varco P/N
53201

3 Months
!
Pipe Plug 3
AC Blower 1/8 inch
Motor (2) (remove and
3 pumps reinstall after
(2 grease fittings lubricating)
each motor)

As Viewed From Below

3 Months
AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months
Hydraulic Pump AC Motor
3 pumps
(2 grease fittings)

Procedure

 Remove the lubrication point plug


 Install a grease fitting
 Grease with a hand pump only
 Re-install the plug

TDS-11SA 3-9
Lubrication

General purpose lubrication

! The lubrication intervals described in this manual are based


on lubricant supplier recommendations. Severe conditions
such as extreme loads or temperature, corrosive atmosphere,
etc., may require more frequent lubrication.

! Worn bushings, binding parts, rust accumulations, and other


abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example,
too much grease forced into a fitting can pop out a bearing
3 seal. Over lubrication can also affect safety since over
lubricated parts can drip, creating a potential slipping hazard
for personnel.

Lubrication schedule
Description No. of Points Frequency Type
Washpipe Assembly 1 Daily General Purpose Grease
Upper Bonnet Seal 1 Weekly General Purpose Grease
Bail Pins 2 Weekly General Purpose Grease
Rotating Link Adapter Gear Weekly General Purpose Grease
Rotating Link Adapter 2 Weekly General Purpose Grease
IBOP Actuator Yoke, Cylinder Pins 5 Daily General Purpose Grease
IBOP Actuator Cranks 2 Daily General Purpose Grease
Upper IBOP Valve 1 Weekly General Purpose Grease
Stabilizer Bushing 4 Daily General Purpose Grease
Clamp Cylinder Gate 2 Daily General Purpose Grease
Carriage Assembly 8 Weekly General Purpose Grease
Torque Arrestor at Clamp Cylinder 4 Weekly General Purpose Grease
Wireline Adapter 2 Weekly General Purpose Grease
Elevator Link Eyes 4 Weekly Pipe Dope

3-10 Varco Systems


Lubrication

General purpose lubrication


Recommended lubricants
Ambient Temperature Range
Below -20 C Above -20 C
(Below -4 F) (Above -4 F)

Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N 3
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2

Viscosity Index
NGLI 1 2

TDS-11SA 3-11
Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose
grease to designated
grease fittings with
grease gun. Use a brush
when greasing other parts.

Daily
Wash Pipe
Assembly
Apply one pump
at beginning of tour

Weekly Weekly
Bail Pins (2) Upper Bonnet Seal
Two pumps each side One pump
Use Hand Pump Only

Weekly
Weekly
Rotating Link
Rotating Link Adapter
Adapter Gear
Three pumps each

3-12 Varco Systems


Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose grease
to designated grease fittings
with grease gun. Use a brush
when greasing other parts.

Daily
IBOP 3
Actuator
Cylinder Pins
One pump each (if equipped)

Daily
IBOP Actuator Yoke
One pump (if equipped)

Daily
IBOP Actuator Yoke
One pump each side

Daily Weekly
IBOP Actuator Cranks Upper IBOP Valve
One pump each side Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps
Weekly Replace
Torque
Arrestor Tubes ! plug before
operating

Daily
Clamp Cylinder Gate
One pump each side Daily
Stabilizer Bushing
One pump each
Weekly
Elevator Link Eyes
(4)
Daily
Pipe Dope
Stabilizer Bushing
One pump each side

TDS-11SA 3-13
Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose grease
to designated grease fittings
with grease gun

Weekly
Rollers
One pump each
(if equipped)

Weekly
Rollers
One pump each
(if equipped)

3-14 Varco Systems


Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose grease
to designated grease fittings
with grease gun

Weekly
Wireline Adapter
One pump each

TDS-11SA 3-15
TDS-11SA Lubrication
and Maintenance Guidelines
See Service Manual for More Detail

Guide Beam
1 Weekly
Grease Fitting
(4, if equipped)
Apply one pump of
general purpose grease

1 Weekly
Grease Fitting
(1 each per Bogie,
Hydraulic if equipped)
Oil Level Apply one pump of
Sight Gauge general purpose grease
Carriage Bogie
(4)

Hydraulic
Oil Filter
As Viewed Slide-type
from Rear Carriage does
(Roller-type not have
Grease Fitting Carriage Only Grease Points
Apply one pump of
general purpose grease
at beginning of tour
Daily 1
Grease Lubrication Schedule
Gear Oil DESCRIPTION NO. OF POINTS DAILY WEEKLY TYPE
Sight Gauge
Check with Gearbox Wash Pipe Assembly 1 1
Top Drive Oil Fill 2
OFF Upper Bonnet Seal 1 1
Bail Pins 2 1
Grease Fitting
Apply one pump of Rotating Link Adapter Gear 1
general purpose grease
Using hand Rotating Link Adapter 2 1
pump only IBOP Actuator Yoke and Cylinder Pins 5 1
3 Hydraulic Weekly 1 IBOP Actuator Cranks 2 1
Oil Fill
(Disconnect) Stabilizer Bushing 4 1
Grease Fittings Clamp Cylinder Gate 2 1
To each fitting apply
1 Weekly
three pumps of Carriage Assembly 8 1
Grease Fitting general purpose grease Torque Arrestor at Clamp Cylinder Area 4 1
(1 each side)
Weekly 1
Apply two pumps of Elevator Link Eyes 4
general purpose
grease See lubrication section of the TDS-11SA service manual for lubrication of electric motors
Grease Fitting
(1 each side)
Gear Oil Filter Apply one pump of
general purpose grease
Oil Lubrication Schedule
DESCRIPTION FREQUENCY TYPE
Daily 1
Replace Gearbox Oil and Perform an Oil Analysis 1 x every 6 Months 2
1 Weekly
Grease Fitting Replace Gearbox Oil Filter 1 x every 3 Months
Apply light
coat of grease (1 each side) Perform Hydraulic System Oil Analysis 1 x every 6 Months 3
to gear teeth Apply one pump of
general purpose grease Replace Hydraulic Fluid 1 x Year, or Earlier 3
Based on Oil Analysis
Daily 1
Replace Hydraulic System Filter 1 x every 3 Months
1 Daily
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Grease Fittings
(if equipped)
Apply one pump of
general purpose Recommended Lubricants
grease Lubricant
Code and
1 2 3
Type General Purpose Grease Gear Oil Hydraulic Oil
Torque Arrestor
Tubes Grease Ambient
Above -20 C Below -20 C Above 21 C 7 to 30 C -6 to 16 C -10 to 85 C -15 to 75 C
Temperature
Locations Range
(Above -4 F) (Below -4 F) (Above 70 F) (45 to 85 F) (20 to 60 F) (14 to 185 F) (5 to 167 F)

Apply grease
Castrol MP Grease N/R Alpha LS-320 Alpha LS-150 Alpha LS-68 Hyspin AWS-46 Hyspin AWS-32
to torque arrestor Chevron Avi-Motive Avi-Motive W NL Gear 320 NL Gear 150 NL Gear 68 AW Hyd oil 46 AW Hyd oil 32
tubes with a brush. Grease Fittings Exxon Lidok EP2 Lidok EP1 Spartan EP320 Spartan EP150 Spartan EP68 Nuto H46 Nuto H32
To each fitting Gulf Gulf Crown EP32 Gulf Crown EP31 EP Lube HD320 EP Lube HD150 EP Lube HD68 Harmony 46AW Harmony 32AW
1 Weekly apply one pump of Mobil Mobilux EP2 Mobilux EP1 MobilGear 632 MobilGear 629 MobilGear 626 DTE 25 DTE 24
general purpose grease Shell Alvania EP2 Alvania EP1 Omala 320 Omala 150 Omala 68 Tellus 46 Tellus 32
Statoil Uniway EP2N Uniway EP1N Loadway EP320 Loadway EP150 Loadway EP68 Hydraway HMA 46 Hydraway HMA 32
Daily 1 Texaco Multifak EP2 Multifak EP1 Meropa 320 Meropa 150 Meropa 68 Rando oil HD46 Rando oil HD32
Total Multis EP2 Multis EP1 Carter EP 320 Carter EP 150 Carter EP 68 Azolla ZS 46 Azolla ZS 32
Union Unoba EP2 Unoba EP1 Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP Unax AW46 Unax AW32

NGLI 2 1 N/R N/R N/R N/R N/R


AGMA N/R N/R 6EP 4EP 2EP 2 N/R
ISO Viscosity N/R N/R 320 150 68 46 32
1 Daily Grade

Grease Fittings
(1 each side) General Condition Checks Daily
To each fitting
apply one pump of 1. Check for missing lockwire
general purpose grease
2. Check for loose or broken parts and leaks

Lubricate the link eyes 3. Check for damaged guide beam rollers
with pipe dope 4. Check condition of both filter gauges
Weekly 5. Check for missing cotter pins
6. Check for loose electrical connectors and check lockwire
7. Check gear oil and hydraulic fluid levels
Varco P/N 125770
Lubrication

3-16 Varco Systems


Installation, Commissioning
and Decommissioning

Illustrated index ................................................. 4-3


Preinstallation .................................................... 4-4
1
Preparation .................................................................... 4-4
Installing the crown padeye and hang-off link ............... 4-5
Locating the control house ............................................ 4-6
Installing power cables .................................................. 4-7
2
Earthing the control house (land rigs) ............................ 4-8
Checklist ........................................................................ 4-9

Installation .......................................................... 4-10


Moving the TDS-11SA to the drill floor .......................... 4-10 3
Removing the TDS-11SA from the skid ......................... 4-11
Disengaging the lower carriage latch ............................ 4-12
Moving guide beam sections ......................................... 4-13
Present and hook the first guide beam section ............. 4-14 4
Hoist the first guide beam section ................................. 4-15
Stab and pin the first guide beam section ..................... 4-16
Completing guide beam installation............................... 4-17
Hanging the guide beam ............................................... 4-18 5
Installing the main tieback ............................................. 4-19
Installing the intermediate restraints .............................. 4-20
Disengaging the upper carriage latch ............................ 4-21
Installing derrick termination .......................................... 4-22 6
Installing the service loop to the derrick ........................ 4-23
Installing the drillers console......................................... 4-24
Installing the drillers console cabling ............................ 4-25
Motor rotation checkout procedure ................................ 4-26 7
Installing the pipe elevator and links.............................. 4-27
Installing the counterbalance ......................................... 4-28

Commissioning ................................................... 4-29


8
Checkout procedure ...................................................... 4-29
Hydraulic system checkout procedure........................... 4-30
Electrical system checkout procedure ........................... 4-31
Mechanical checkout procedure .................................... 4-32
9
Adjusting the link tilt ....................................................... 4-33
Removing and installing the saver sub .......................... 4-34

TDS-11SA
Installation, Commissioning
and Decommissioning
Installation, Commissioning
and Decommissioning

Decommissioning ............................................... 4-35


1 Securing the TDS-11SA for rig-down ............................ 4-35
Removing and storing the electrical cables
and service loops .......................................................... 4-36
Setting the latches and locking the bail ......................... 4-37
2 Disconnecting the guide beam ...................................... 4-38
Unpinning each guide beam section ............................. 4-39
Lowering each guide beam section ............................... 4-40
Returning the TDS-11SA to the skid ............................. 4-41
3 Removing the TDS-11SA from the drill floor ................. 4-42
Long term storage procedures ...................................... 4-43

44

4-2 Varco
Varco Systems
Systems
TDS-9SA and TDS-11SA
Rig-Up Checklist
See the Top Drive Service Manual for more detail

Rig-Up Preparation
Hoisting the Top Drive from the Skid
Check for proper installation of the crown padeye and install the hang-off link.
Figure
1 Install the isolation circuit breaker at the power source and incoming power
! cables to the Varco control house location (power is OFF).
The Bail Lock must be
installed prior to hoisting Check for proper height of the mud standpipe/gooseneck.
the Top Drive from the Correct as required per the service manual.
Skid

Varco Control House


Locate the Varco control house (9,500 lb) for proper derrick service loop and
incoming power cable configuration.

Connect the incoming power cables (isolation circuit breaker is turned OFF).

As viewed from rear of Carriage Ground the Varco control house.

Guide Beam
Top Section Top Drive and Guide Beam Installation
Check for proper installation of the spreader beam (if required).
Guide Beam
Wings
Set the Top Drive and storage skid (30,000 lb total) at the bottom of the V-door ramp.

Hoist the Top Drive and storage skid to the drill floor and stand upright at well center.
Upper See
Latch
!
With the bail lock installed and upper carriage latches engaged, attach Figure 1
Engaged hoisting equipment, unpin the guide beam from the bottom of the storage
After hoisting skid, and hoist the Top Drive from the storage skid.
the Top Drive
from the Skid, See
Lower
Latch
disengage the
lower latches
Disengage the lower hoisting carriage latches. Figure 1
Disengaged as shown Remove the storage skid from drill floor.
Carriage Pin
Sort the guide beam sections (2,000 lb each 18 ft) in order of installation.
See
Hoist the next guide beam section to the drill floor.
Grease the pin bores, hook, hoist, stab, pin, and install the retainer pin.
Figure 2
Assembling the Guide Beam Repeat this step for each guide beam section until complete.
Figure
2 Do not
over-rotate
Hang the complete guide beam from the hang-off link.
See
Figure 3
2 the relative angle
to less than 90 Disengage all carriage latches before lowering the Top Drive.
1 Hook
Present Install the lower tieback assembly.
!
Check for proper alignment of the Top Drive mainshaft over well center.
Grease Remove the bail lock.
bores

Drill Floor Install the intermediate guide beam restraints as required.

Position and attach the derrick termination plate.


3 4 Position the service loop tubs (6,000 lb) at the bottom of the V-door ramp. Hoist
Hoist Stab and Pin and install the derrick and top drive service loops to the derrick termination plate.

Make the connection between the two service loop connectors,


torque the connector and lockwire the connector nuts.
!
Secure Make the connection between the Top Drive and the Top Drive service loop,
Pin torque the connector and lockwire the connector nuts.

Make the connection between the control house and derrick service loop using
jumper cables as required, torque the connector and lockwire the connector nuts.

Locate and install the Varco Drillers Console.


Hanging the Guide Beam
Make the connection between the Varco Drillers Console and the control house,
Figure
3 Use these pin positions if crown
torque the connector and lockwire the connector nuts.
Crown i padeye installation is based on:
Install the mud hose.
Crown 36.8 in.
Padeye (935 mm)
Move the Top Drive SLOWLY up and down the guide beam to check for
Standard adjustable height configuration interferences and proper motion of the service loops and the mud hose.
Shackle
Ensure that the 33.8 in. Recheck the alignment over well center.
shackle is pinned (859 mm)
and the cotter pin Varcos IDS Top Drive requirements
is in place
30.0 in. Startup
(762 mm)
Hang-off Original TDS-9S hang-off or if Grease the Top Drive per the Service Manual or Lubrication Guide.
Link plate extension (36.8 in.) needs to
be cut off due to interference.
Check the hydraulic fluid level and the gear oil level.
Bolt
Check ALL electrical connections for tightness and lockwire connector nuts.
Safety Pin
Power up the control house per the checkout procedure (located inside of house).
C
L C
L
Guide Beam Well Power up the hydraulic system. Check for leaks. Check the red pop-up dirt alarm.
Top Section

Guide Beam Check the gearbox for proper oil flow. Check the red pop-up dirt alarm.
Top Section
Install the counterbalance system.

Install the links and the drill pipe elevator.

Run a function test to verify Varco Drillers Console functions.


Varco P/N
126723
TDS-9SA and TDS-11SA
Rig-Down Checklist
See the Top Drive Service Manual for more detail

Rig-Down Preparation
Rig-Up/Run/Shutdown Valve
Lower the Top Drive to the rig floor.
Figure
1 Remove the mud hose, drill pipe elevator and links. Power may be needed
to turn rotating head into position for removing the links.
See
RUN
Locate the RIG-UP/RUN/SHUTDOWN valve on the hydraulic manifold.
With the hydraulic power ON select the RIG-UP position and remove
Figure 1
SHUTDOWN

Hydraulic the extended counterbalance cylinders from the hook ears.


RIG-UP

Manifold
See
Select the SHUTDOWN position and turn off the Top Drive. Figure 1
COUNTERBALANCE MODE
Isolate and lock out ALL power to the Varco control house.
N
W
O

R
D

U
T

N
U
H

Rig-up/Run/Shutdown
S

CO
UN
TE
RB
R
IG

ALA
-U

NC
P

EM
Valve See
2
OD

Position the service loop tubs for convenient loading of the service loops.
E

Figure

Disconnecting the Service Loops


Disconnecting the Service Loops
See
Figure
2 Derrick Lower
Disconnect the derrick service loop from the derrick termination plate and Figure
from the Varco control house. Disconnect jumper cables (if installed). Cap
2
Termination
all connectors. Lower the derrick service loop (1,000 lb) into a service loop tub.
See
1,000 lbs
Service Loop
Disconnect the Top Drive service loop at the Top Drive and then at the
derrick termination plate. Cap all connectors. Lower the Top Drive service
Figure 2
loop (1,000 lb) into a service loop tub.
Sling
Remove the service loop tubs (6,000 lb each) from the work area.

Remove the derrick termination plate, if necessary.

Top Drive and Guide Beam Removal


See
Install the bail lock. Figure 3
TDS Hoist the Top Drive to the crown.
Service
Loop See
Engage the upper and lower carriage latches. Figure 4
! Derrick
Service
Remove the intermediate guide beam restraints (if installed).
Avoid damage Loop
to the service loop Remove the lower tieback assembly.
by using care when
dragging it near
sharp edges Hoist the Top Drive and guide beam to take the load off the hang-off link.
and under the
V-door
Remove the hang-off link from the guide beam. Replace the bolt, nut and
safety pin on the upper guide beam. Remove the hang-off link from
Service Loop
Storage Tub the crown padeye, if necessary.

Using the Top Drive, lower the bottom of the guide beam to the drill floor.

! Remove the retainer pin, lynch pin and joint pin at the joint between the See
Figure 5
Avoid damage two lower guide beam sections. Hoist the guide beam to open the joint.
to the service loop
Recommendations by maintaining a See
n Do not disconnect the service loops
36 inch minimum
bend radius
Using a tugger or crane, pull the lower guide beam section to a horizontal
position (do not allow the angle at the guide beam joint to become less
Figure 5
until the service loop tubs are in position
than 90 degrees) and lower the Top Drive and guide beam to the drill floor.
n Use a sling attached to the lifting eyes
to lower each service loop. Use the
swivel at the tugger line attachment to Unhook the lower guide beam section (2,000 lb) and remove from the drill floor.
allow each service loop to coil
without twisting.
Repeat the previous four steps for each of the remaining guide beam sections
until only the upper section remains.
Installing Engaging the
Hoist the Top Drive storage skid (3,000 lb) to the drill floor.
the Bail Lock Carriage Latches
Lower the Top Drive and upper guide beam section onto the storage skid.
Figure
3 Figure
4 ! Check to ensure that the lower carriage latches are engaged.
After hoisting
Pin the Top Drive to the Hook the guide beam to the top of the storage skid and pin the guide beam to the
crown, engage the bottom of the storage skid. Check to ensure that all carriage latches are engaged.
upper and lower
carriage latches
Lower the Top Drive and storage skid (30,000 lb total) down the V-door ramp or
Upper
and Lower remove them from the drill floor with a crane.
Latches
Engaged Guide

!
Beam
Top
Securing the Varco Control House
Section
The Bail Lock Pin Cap all connectors at the control house plug panel.
must be installed
prior to hoisting
the Top Drive Disconnect jumper cables (if installed) and store in service loop tubs.
from the Skid
Guide Remove or secure any items inside of the control house which may be loose.
Beam
Wings

Disassembling the Guide Beam


Figure
5 1 2 3 4
Remove Hoist Rotate Unhook
Pins
Lynch Do not
Pin over-rotate
Retainer
Pin
! the relative
angle to less
Carriage than 90

As viewed from rear of Carriage Joint


Pin Drill Floor
Varco P/N
126723
Installation, Commissioning
and Decommissioning

Illustrated index

Crown Padeye and


Hang-off Link
Page 4-5

Counterbalance
Page 4-27
Rotary Hose

Guide Beam Derrick


Page 4-13 Termination
Page 4-22

Service Loop
Page 4-23
Intermediate
Restraints
Page 4-20

Varco
Drillers Console
(VDC)
Page 4-24

Control Cable
with Connectors
Page 4-25 Main Tieback
Page 4-19
Unitized Variable
Frequency Inverter and
Varco Control Panel (House)
Page 4-6

Local Power Supply


Diesel/Alternator Set/AC Bus

AC Cables
Page 4-7
AC Power and
Control Cables
Page 4-7

TDS-11SA 4-3
Installation, Commissioning
and Decommissioning

Preinstallation
Preparation
The TDS-11SA interfaces with the rigs hoisting system and
electrical power system. Derrick and electrical system modifications
are required when installing the TDS-11SA on existing rigs.

For derricks that handle triples, the required top drive travel is
about 100 ft. compared to about 75 ft. when using a Kelly. It is
generally necessary to replace the regular rotary hose (which is
normally 60 ft. long) with a 75 ft. hose, and extend the standpipe
height to approximately 73 ft.

Although many rig floor layouts are possible, installing the guide
beam on the drawworks side of the derrick, or mast, and opposite
the V-door is an ideal arrangement for handling tubulars from the V-
door.

The location of the electrical loop and mud hose is an important


installation consideration for pipe setback purposes, to ensure
proper clearance and to help prevent wear to the service loop and
4 mud hose. Other important installation considerations include the
location of:

The casing stabbing board

Floor and derrick accessories

Drawworks fastline

Guide beam hang-off bracket

Torque reaction beam

Mud stand pipe extension

Varco drillers console location

Variable frequency inverter/Varco control panel location

Derrick height is a critical interface requirement. Handling a


93 ft. stand typically requires 97 ft., resulting in an overall height
from the floor to the top of the traveling block of at least 126 ft.

Derrick Clear Working Height Derrick Crown Clearance


152 ft. 25 ft.
147 ft. 20 ft.
142 ft. 15 ft.
136 ft. 9 ft.

Each rig has different crown clearance for efficient tripping.


Installing the TDS-11SA with existing traveling equipment may
require an adapterfurther reducing crown clearance.

4-4 Varco Systems


Installation, Commissioning
and Decommissioning

Preinstallation
Installing the crown padeye and hang-off link
Recommended installations
Dimension Description

36.8 inches Standard height configuration (adjustable)


33.8 inches Varcos IDS Top Drive requirements
30.0 inches Original setback for TDS-9S/11S

Crown

Crown Padeye
Weld according
to table above

See Table
Shackle

Hang-off Link

C
L
Well

TDS-11SA 4-5
Installation, Commissioning
and Decommissioning

Preinstallation
Locating the control house

Recommended Area for


Control House Location

Drawworks

V-Door
Ramp
4 C
L
Well
TDS-11SA

Varco
Drillers
9,500 lb Console
(4300 kg)
Control House

C
L
Well
Control
House

Recommendations
 Position the control house off-drillers side or
91 in. behind the drawworks
(2310 mm)
 Position as close to derrick plate as possible
to minimize cable lengths
 Ensure a safe distance from direct sources of
heat (i.e. diesel engines, general exhausts)
140 in. 90 in.  Location of the control house must ensure
(3560 mm) (2290 mm) accessibility from all sides
 Do not expose the control house to H2S

4-6 Varco Systems


Installation, Commissioning
and Decommissioning

Preinstallation
Installing power cables

COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL
Ground Lug CON
NEC
TOR
to Top Drive
Plug Panel

UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
WI
NC
OM
Incoming Power Cables
ING
575
VA
575VAC to main circuit breaker
C
(3 Places)

UO
4
UT
GO
ING
575
VA
C
VO
UT
GO
ING
575
VA
Outgoing Power Cables
C
WO to Top Drive
UT
GO
ING
575
(3 or 6 Places)
VA
C

Varco
Rain Cover Control House

Plug Panel

Procedure
 Clean all connector contacts
 Connect the power cables with the isolation
circuit breaker turned OFF
 Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
 Lockwire all connector nuts
 Earth the control house with the Varco
Ground Rod Kit (See page 4-8)

TDS-11SA 4-7
Installation, Commissioning
and Decommissioning

Preinstallation
Earthing the control house (land rigs)

Copper Plated
Steel Rod

Cable Clamp

Cable Lug

Copper Wire
10 ft

The control house must


be properly grounded to
prevent injury to personnel

Procedure
 Insert the grounding rod into the soil (the rod
Ground Rod Kit
must be in contact with ground water) Grounding Points
P/N 116004
 Connect the rod to the control house Located at opposite
(connection must be clean) corners of the house floor
For offshore installations the control house
i must be grounded to the ground point on the
rig structure

4-8 Varco Systems


Installation, Commissioning
and Decommissioning

Preinstallation
Checklist
The following assumes that all pre-installation planning and rig-up
is complete prior to installation of the guide beam assembly and
TDS-11SA. This includes:

Make sure the derrick/mast is vertical, with the block over the
center of the rotary table.

Derrick/mast modifications are completed (if required) and the


guide bean support bracket and torque reaction beam are
installed and inspected to conform to Varco specifications as
detailed in FIP00003.

The service loop bracket is installed in the derrick/mast.

The control panel and frequency drive are installed.

Rigging of tong lines, etc. is inspected to ensure that they will


not foul with the TDS-11SA.

The hook or adaptor becket is installed. The hook should open 4


toward the drawworks.

TDS-11SA 4-9
Installation, Commissioning
and Decommissioning

Installation
Moving the TDS-11SA to the drill floor
Procedure
Ensure the safety of all personnel
 Locate the Top Drive at the bottom of the
V-Door ramp
 Ensure that the bail lock assembly is installed
 Attach a lifting sling to the bail
 Attach backup lines to the skid
 Hoist the Top Drive and skid to the drill floor

!
The Bail Lock Assembly
must be installed
Tube (P/N 113498)
U-Bolt (P/N 113497)
2x 3/4" nuts

TDS-11SA
Lifting on Skid
Block
Hoist using Lifting Sling
the drawwork Attached to bail
for hoisting

Lifting
Sling

!
Be sure that the Top Drive
is pinned to the skid prior
to hoisting it to the drill floor
3 Drill 2 30,000 lb
Floor (13600 kg)
TDS-11SA TDS-11SA on Skid
In position
prior to lifting Backup Line
from skid V-Door Ramp
1

4-10 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Removing the TDS-11SA from the skid

! 27,000 lb
The Bail Lock Assembly (12300 kg)
must be installed. Remove only TDS-11SA
after installation is complete.

View of
Carriage
from Rear

4
Pin

1
Latches
Both sides
engaged TDS-11SA
for hoisting

Pin

3
2
Hoist the
TDS-11SA Lock Pin
from the skid Remove prior to
using the drawwork hoisting from skid

Drill Procedure
Floor
 Ensure that both carriage latches are
Ensure the Top Drive engaged for hoisting from the skid
does not contact the rig  Ensure that the bail lock assembly is installed
 Engage the hook with the bail
 Remove the lock pin
 Hoist the Top Drive from the skid

TDS-11SA 4-11
Installation, Commissioning
and Decommissioning

Installation
Disengaging the lower carriage latch

Guide Beam
Top Section

Carriage

Guide Beam
Wings

2
4
TDS-11SA
Lifted from
the skid
!
27,000 lb After hoisting the TDS-11SA
(12300 kg) from the skid, disengage the
Lower Carriage Latch
and pin it as shown.

Pin

1
Upper
Latch
Engaged

Lower
As viewed from Latch
rear of Carriage Disengaged
TDS-11SA
In position
to disengage Pin
lower latch
3
Drill
Floor Skid Procedure
Remove from drill floor
 Ensure that the lower carriage latch is disengaged
after hoisting the TDS-11SA
3,000 lb (1360 kg)  Ensure that the upper carriage latch is engaged
 Hoist the Top Drive
Ensure the Top Drive or the guide beam
does not contact the rig
 Remove the skid from the drill floor

4-12 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Moving guide beam sections

Procedure
 Locate the guide beam sections near the
V-Door
 Attach lifting slings to the lifting eyes of the
first guide beam section to be hoisted
 Hoist the guide beam section to the drill floor

2,100 lb
(950 kg)
20 ft. Guide Beam Section

Sling

Ensure the
Top Drive does
not contact
the rig

TDS-11SA
Guide Beam
Section

3 2
Guide Beam Section Lifting Eyes
Hoist to the drill floor Attach slings
for hoisting

Drill
Floor

1
Guide Beam Sections
Prior to Installation

TDS-11SA 4-13
Installation, Commissioning
and Decommissioning

Installation
Present and hook the first guide beam section

Guide Beam
Top Section
1 2
Present Match
Grease
the bores on
both joint halves
Guide
Surface

Radius locks joint


from unhooking
at 8 rotation

Hook Pin Grease


the bores on
both joint halves

4
3 4
Engage Hook
Ensure the
Top Drive does
not contact Hook Pin
the rig In fully engaged
position

Present
and Hook
the first guide
beam section Hook Pin
Saddle

Procedure
Guide Beam
Section  Locate the guide beam to be hooked
Hooked under the top guide beam section
Drill  Grease the bores on both joint halves
Floor  Align the guide surface with the hook pin as
shown
 Lower the top guide beam to match and
engage the hook pin to the hook pin saddle
 Hoist the top guide beam to fully engage the
hook pin
 Manually stabilize the back end of
the guide beam

4-14 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Hoist the first guide beam section

Guide Beam
Top Section

Hoist

Hook Pin

First Guide
Beam Section 4
Initially hoisted
by the hook pin

Bar and Radius


Locates pin bores for
easy insertion of pins
Hoist
Using the
drawwork

Ensure the
Top Drive does
not contact
the rig

Drill
Floor

TDS-11SA 4-15
Installation, Commissioning
and Decommissioning

Installation
Stab and pin the first guide beam section

Guide Beam 1
Top Section Stab
the guide beam
joints together

Lynch Pin
2
Joint Pin
4 Install after stabbing

4 3
Secure Retainer Pin
with the Apply grease
lynch pin and insert

Stab
and Pin
the guide
beam joint

Block as Procedure
Ensure the
Required
Top Drive does
Drill  Lower the guide beam to drill floor and stab
not contact
Floor the guide beam joints together
the rig
 Block the guide beam in a vertical position if
required
 Install the joint pin
 Grease and install the retainer pin
 Secure the retainer pin with the lynch pin as
shown

4-16 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Completing guide beam installation

Ensure the
Top Drive does
not contact
the rig

Repeat previous steps until


Guide Beam Installation
is complete

Procedure
 Move the next guide beam section to the drill floor
 Present the end of the guide beam to be hooked
 Ensure that the bores on both joint halves have
been greased
Drill  Engage the hook pin saddle around the hook pin
Floor  Hoist the guide beam with the drawwork
 Lower the guide beam to the drill floor and stab
the guide beam joints together
 Install the joint pin
 Install the retainer pin
 Secure the pins with the lynch pin

TDS-11SA 4-17
Installation, Commissioning
and Decommissioning

Installation
Hanging the guide beam

Crown i Note:
Use these pin positions if
Pin the crown padeye installation
Guide Beam is based on:
to the hang-off
link
Ensure the 36.8 in.
Top Drive (935 mm)
does not Standard adjustable
Crown Padeye height configuration
contact
the rig
33.8 in.
! (859 mm)
Varcos IDS Top Drive
Ensure that requirements
the Shackle is
pinned and the 30.0 in.
cotter pin is in place (762 mm)
Original TDS-9S/11S or
Hang-off Link if plate extension (36.8 in.)
needs to be cut off due
to interference.
4
Pin

Safety Pin

C
L C
L
Guide Beam
Guide Beam Well
Top Section
Top Section

Procedure
 Using the drawwork, hoist the top guide beam
Drill to the hang-off link
Floor Floor Clearance  Ensure that the shackle is pinned and its
cotter pin is in place
 Pin the guide beam to the hang-off link in the
+.5 ft appropriate position
7 ft. -0 ft
+150 mm  Check for 7 ft clearance from bottom of guide
(2100 mm -0 mm ) beam to the drill floor
 Secure the pin to the hang-off link with the nut
and safety pin

4-18 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Installing the main tieback

Procedure
 Check for Top Drive mainshaft alignment over Guide Beam
well center Bottom Section
 Install the main spreader beam at the
appropriate distance from well center
 Install the tieback plate and tieback link
 Check for Top Drive mainshaft alignment over
well center
 Torque and lock wire all bolts

Tieback Link

Guide
Beam
Assembled
Tieback
Plate
4

Main
Spreader
Beam

Apply Anti-seize
Compound
Typical

Auxiliary
Spreader Beam

Main Tieback and


Spreader Beam
Install after guide
beam is assembled
Mast Leg
Drill
Floor
Recommended Installations
See Table Dimension Description

36.8 inches Standard height configuration (adjustable)


C
L 33.8 inches Varcos IDS Top Drive requirements
Well 30.0 inches Original setback for TDS-9S/11S

TDS-11SA 4-19
Installation, Commissioning
and Decommissioning

Installation
Installing the intermediate restraints
Apply Anti-seize
Compound
Typical

Intermediate
Tieback Plate
2 Places

Girt Padeye
2 places if greater than
3 inches from girt

3 inches

4
105
Feet
i
Double nut Padeye
1 place if less than
3 inches from girt
Space between girt
and guide beam

Pin and
Cotter Pin
Guide Beam
Assembled
55
Feet
Procedure
 Intermediate tiebacks are installed on girts
closest to 55 feet and 105 feet above the drill
floor
 Weld two padeyes to the guide beam if the
Drill space between the girt and the guide beam is
Floor greater than 3 inches
 Weld a single centered padeye if the space
between the girt and the guide beam is less
than 3 inches
 Install intermediate tieback plates as required
 Torque and lock wire all bolts
 Secure all pins with cotter pins

4-20 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Disengaging the upper carriage latch

Guide Beam
Top Section

2 Carriage
Remove the
Bail Lock
Assembly
Guide Beam
Wings

3 !
Slowly After hanging the guide beam,
lower the installing the tiebacks, and prior
TDS-11SA to lowering the Top Drive, 4
disengage the Upper Carriage
Latch and pin it as shown.

Pin

1
Upper
Latch
Disengaged

Lower
Latch
Disengaged
As viewed from
rear of Carriage
Pin

Drill Procedure
Floor  Ensure that the lower carriage latch is
disengaged
 Ensure that the upper carriage latch is
disengaged
 Remove the bail lock assembly
Bail Lock Assembly  Ensure the mast is clear of all obstructions and
Remove slowly run the Top Drive down the guide beam

TDS-11SA 4-21
Installation, Commissioning
and Decommissioning

Installation
Installing derrick termination
Hoist Line Derrick/
Attachment Point Mast Leg

Derrick
Leg Plate
Hoist Line Service Loop
Attachment Brackets
Points

4
Mount the
Derrick
Termination
Plate
as recommended

83 ft
from drill floor

Recommendations
 Mount on the side of the derrick adjacent to the
service loop brackets on the TDS-11SA

Drill  Mount as far as practical from well center, to


Floor maintain a 36 inch minimum bend radius

! Maintaining a larger radius increases loop life and


reduces damage due to pinching
 Location must ensure that the loops do not
catch under the guide beam during operations
and provide clearance for tong lines, the
stabbing board, tugger lines, etc

4-22 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Installing the service loop to the derrick
Hoist
Derrick
Termination Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

!
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the
V-door

Lifting Eyes
Do not remove

Derrick
Service Loop

! Recommendations
Avoid damage to the
service loops by maintaining a  Do not unpack the service loops until they are
36 inch minimum ready to hang
bend radius  Use a sling attached to the lifting eyes to hoist
each service loop
Service Loop  Use the swivel at the tugger line attachment to
and Storage Tub allow each service loop to uncoil without
3,600 lb twisting
(1600 kg)

TDS-11SA 4-23
Installation, Commissioning
and Decommissioning

Installation
Installing the drillers console
Drawworks

V-Door
TDS-11SA Ramp

Recommended Area
for Varco Drillers
Console Location

!
UE
RQ
TO

P
IBO
Y
NC
Customers who choose to use control BR
AK
E
EM ST
GE
ER OP

systems that are not manufactured by Varco PIP


EH
AN
DL
ER

should be aware that Varco systems are


specifically designed with operational
interlocks and safety devices to prevent
possible injury to personnel and damage to
the system. Other control systems must
meet Varco requirements outlined in the QA
00098 document. Varco highly recommends
the use of its system, as it is specifically
made for use with the TDS-11SA.

Recommendations
 Mount within easy reach and in plain view of the
driller while the drawworks brake and clutches
are being operated
Pigtail Cable  Location must ensure that the gauges are easily
Connect to seen by the driller during drilling operations
control house  Location must be visible and readable at night

4-24 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Installing the drillers console cabling

COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL Profibus Serial Link
CON
NEC
TOR to Drillers Console

UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
Plug Panel
WI
NC
OM
ING
575
VA
C

UO
4
UT
GO
ING
575
VA
C
VO
UT
GO
ING
575
VA
C
WO
UT
GO
ING
575
VA
C

Varco
Rain Cover Control House

Plug Panel

Recommendations
 Ensure that the Varco Drillers Console is
properly located
 Connect the power cables with the isolation
circuit breaker turned OFF
 Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
 Tighten connector nuts
 Lockwire connector nuts to prevent loosening

TDS-11SA 4-25
Installation, Commissioning
and Decommissioning

Installation
Motor rotation checkout procedure
Direction
of Rotation
Counterclockwise
Procedure
 Assign the Top Drive and inverter by selecting Direction
FORWARD or REVERSE on the drillers console of Rotation
Clockwise
 Check the rotation direction of the cooling and oil
pump motors
 Rotate the drill stem using the THROTTLE on the
drillers console and observe proper operation

Cooling Motors
2 Places

UE
RQ
TO

RQ
TO
X
MA
IB POP
IBOSED Y
CL
O NC
GE
MER OP RQ
UE
E ST 0 TO
ILL
DR

D
SE AR
P LO RW
IBO C OF
F
FO
X
N MA
OPE SE
R
VE
IVE RE 0
DRULT
FA Throttle Direction
of Rotation
Counterclockwise
Forward/Reverse
Control
Varco
Drillers
Oil Pump
Console
TO
RQ
UE
Motor
OP
IB
Y
NC
E GE
AK ER OP
BR EM ST

ER
DL
AN
EH
PIP

Drill Stem

Direction Reverse
of Rotation

Forward

4-26 Varco Systems


Installation, Commissioning
and Decommissioning

Installation
Installing the pipe elevator and links

Catch
Link Bolt

Rear
Motor
Guard

Catch Link 600-2,400 lb


Pin (270-1100 kg)
Elevator Link
AT
LO
ER T F
DLK TIL
ANLIN
EH Catch
PIAPTE IGHT
T R
RO Link 4
FT
LE
ILT
KT LT
LINOFF TI
H
NC LL
RELD DRI
E WHO
R QUH &
TOPUS
Front

Pipehandler
Rotate Switch
Link Tilt

Varco
Drillers
Console Link
UE
RQ
TO

OP
IB
Y
NC
E GE
AK ER OP
BR EM ST

ER
DL
AN
EH
PIP

Clevis
Pin

Procedure
 Using the Varco Drillers Console, rotate the
pipehandler 90 (positioning the catch link under
the front of the motor guard)
 Lubricate the elevator link eyes with pipe dope
 Hoist the elevator link onto the rotating link adapter
(the small link eye at the bottom)
 Secure the catch link with the pin and bolt
 Secure the elevator link to the link tilt
 Rotate the pipehandler 180 and install the other
elevator link
 Install the pipe elevator in accordance with the pipe
elevator manual

TDS-11SA 4-27
Installation, Commissioning
and Decommissioning

Installation
Installing the counterbalance
Procedure
 Refer to Setting up the circuits in the
Hydraulic section of this manual for initial
system set up Hook
 Install the pear links to the ears on the hook
 Turn on the Top Drive power
 Rotate the counterbalance mode valve from Pear Link
the RUN position to the RIG-UP position 2 Places
 When the cylinders reach the end of stroke,
slide the cylinder clevis over the pear link
and install the cylinder clevis pin
Cylinder
 After securing the counterbalance cylinder to Clevis
the pear link, rotate the counterbalance 2 Places
mode valve to the RUN position
 Adjust PCC clockwise to raise the pressure
at test port CB until the bail just begins to lift
off of the block
 Reduce the pressure slowly (25 psi) to allow
pressure to stabilize
4 Cylinder
Clevis Pin
2 Places

Rig-up/Run/ Counterbalance
Shutdown Valve Cylinder
Shown in RIG-UP 2 Places
position (switch to RUN (8.5 inch stroke)
after the counterbalance
is installed) Bail

RUN
SHUTDOWN

RIG-UP

COUNTERBALANCE MODE
N
W
O

R
D

U
T

N
U
H
S

CO
UN
TE
RB
Hydraulic
R
IG

ALA
-U

NC
P

EM
OD
E

Manifold

4-28 Varco Systems


Installation, Commissioning
and Decommissioning

Commissioning
Checkout procedure
Initial Rig-Up
 Pre-charge all accumulators (See the
Hydraulics System section of this manual)
 Adjust the hydraulic system
 Bleed the air from the hydraulic system Cork Ball
(Level Indicator)
 Constantly monitor the hydraulic fluid level, and
never allow the level to fall below the middle of
the sight glass (system power OFF)

Checkout Procedure
 Lubricate all grease points (See Lubrication)
 Check for loose or missing connectors Sight
Glass
 Lockwire all connector nuts
 Check for interference along entire mast Hydraulic
 Remove exhaust covers from AC drilling motors Oil Sight
Gauge
 Check blower inlets and outlets for blockage
 Set the air conditioner to 75F (27C)
4
 Turn on the main breaker

Air Inlet
Between motor
and brake housing,
2 Places

Exhaust Cover
4 Places
TOP DRIVE

INS
T
WH ALL
UN EN
ST IT IS
VARCO

OR
ED

Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places

TDS-11SA 4-29
Installation, Commissioning
and Decommissioning

Commissioning
Hydraulic system checkout procedure
Checking hydraulic fluid level

Cork Ball
(Level Indicator)

Red
Pop-up
Dirt Alarm
Sight
Glass

4 Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter

Procedure
 Ensure that the pipehandler clamp cylinder is
unclamped, the counterbalance cylinders are
connected to the hook, the bail is resting in the
hook, and the system power is OFF
 Check to see that the hydrulic fluid level is at
the middle of the sight glass
 If the fluid is low, add hydraulic fluid (see the
Lubrication and Maintenance section of this
manual
 Check the red pop-up alarm on the hydraulic
filter for contamination
 Replace the filter (P/N 114416-1) if the
indicator has popped up
 Use care to prevent contamination from
entering the hydraulic system during
maintenance activities

4-30 Varco Systems


Installation, Commissioning
and Decommissioning

Commissioning
Electrical system checkout procedure

Emergency Stop

Latch
9 Places

M
RP

UE
RQ
TO
UE
RQ RPM Meter
TO
X
MA
P
IBOOP
IB SED Y
CL
O NC
GE
AK
E ER OP RQ
UE
BRRAKE EM ST 0
ILL
TO

ER OA
T
B N
O

P LO
SE AR
D
DR

Torque Meter 4
FL RW
DL ILT IBO C OF
F
FO
H AN KT MA
X
N
P IPE LIN
O PE
RS
E
HT E E VE
TE RIG AK AK IVE RE 0
TA BR TO BRON DRULT
RO AU FA
FT F
S LE ILT OF
OILLOS
S KT ILT
ES LINOFF T
PR
P CH
-U IT EN ILL
KE LIM WR LD DR
MAENT UE HO
RR RQ H &
CU TOPUS
OR
OT P R
L M EM WE
X RIL RT PO N
MA DOVE LIC O
R AU
YD
MP H
0 LA ECK U TO
A
AR
M CH /
AL NCE
S ILE

O SS
E RL
OW
BL
UE
RQ
SP
IN TO

ILL
DR

Procedure
All personnel must stand clear
 All personnel operating the Top Drive should be
trained in rig safety and tool operation
 Operate each control on the Varco drillers console
(See Varco FIP00003)
 Check for alarm conditions and resolve any alarms
at this time (See Varco FIP00003)
 Check all connectors for tightness and lockwire
 Check operation of meters
 Check operation of emergency stop
 Check the latches on the drillers console for
tightness
Pigtail Cable
Connected to
control house

TDS-11SA 4-31
Installation, Commissioning
and Decommissioning

Commissioning
Mechanical checkout procedure
Checking gearbox oil level
Procedure
 With the drive motors and hydraulic
system off, check to see that the oil level
(identified by a floating cork ball) is at the
middle of the glass located on the lube
pump adapter plate mounted on the side
of the gearbox
 Always check the oil level, not foam level
(oil is dark brown, foam is tan) after the
unit has been running and the
transmission oil is warm
 If the oil level is low, add gear oil (see the
Lubrication and Maintenance section of
this manual
 Check the red pop-up alarm on the gear
oil filter for contamination
 Replace the filter (P/N 111013-1) if the
4 indicator has popped up

Cork Ball
(Level Sight
Indicator) Glass

i i
Gear Oil Gearbox Oil Fill
Sight Gauge Clean area before removing plug,
Check with Top Drive then use a 1 3/8 inch, 12 point
OFF socket to remove plug

Pop-up
Dirt Alarm

Gear Oil Filter

4-32 Varco Systems


Installation, Commissioning
and Decommissioning

Commissioning
Adjusting the link tilt

i See the PH-50 Pipehandler


section of this manual for
Jam Nut inspection and disassembly/
Adjust the derrickman position assembly details
with the adjusting screw and
lock in position with the jam nut

Link Tilt
Crank
Assembly

Pin

4
26 inches
(660 mm)
Typical

Clamp

i
Mousehole
Position Cable 3-4 inches
Pull up or down (76-102 mm)
to set mousehole
position

i
Drill Down
Position
Bottom of elevator
should be above
Link the bottom of the
Mousehole stabbing guide
Position

Derrickmans Position
Link clamps should be adjusted
so that the elevator does not Elevator
hit the diving board in this position Well Center
Float Position

TDS-11SA 4-33
Installation, Commissioning
and Decommissioning

Commissioning
Removing and installing the saver sub
Torque values for drill stem components
Component I.D. Connection O. D. Torque

Mainshaft to Upper IBOP Valve 3 in. 6 5/8 API Reg. 7 3/4 in. 52,000 ft-lb
Upper IBOP Valve to Lower IBOP Valve 3 in. 6 5/8 API Reg. 7 3/8 in. 48,000 ft-lb
Lower IBOP Valve to Saver Sub 3 in. 6 5/8 API Reg. 7 3/8 in. 46,000 ft-lb
Crossover Sub to Lower IBOP Valve 3 in. 6 5/8 API Reg. 7 3/8 in. 46,000 ft-lb

Crossover Sub
Tugger
Cylinder Pins Line
Remove
Torque
4 Arrestor

V
A
R
C
O
P
H
Upper IBOP 5
0

i IBOP Crank
See the Technical and Shell
Drawing Package for Remove
configuration details
RCO
VA

Lower IBOP

Gate Pin
Swing Remove one
Clear

Short Saver Sub


For use with
Long Saver Sub
For use without
i
lower IBOP lower IBOP Use Tongs for torquing
the components together

4-34 Varco Systems


Installation, Commissioning
and Decommissioning

Decommissioning
Securing the TDS-11SA for rig-down
Procedure
 Lower the Top Drive to the drill floor
 Remove the mud hose, drill pipe elevator
and links
 Power may be needed to turn rotating head
into position for removing the links
 Locate the RIG-UP/RUN/SHUTDOWN valve
on the hydraulic manifold
 With the hydraulic power ON select the
RIG-UP position and remove the extended
counterbalance cylinders from the hook ears
 Select the SHUTDOWN position and turn
off the Top Drive
 Isolate and lock out ALL power to the Varco
control house

Hydraulic
Manifold
N

RU
W
O

N
D
T
U
H
S
C
O
U
N

R
TE

IG
R
BA

-U
LA

P
N
C
E
M
O
D
E

Rig-up/Run/
TDS-11SA Shutdown Valve
Lower to the Rotate from RIG-UP to
drill floor SHUTDOWN for Top Drive rig-down

RUN
Drill
SHUTDOWN

Floor
RIG-UP

COUNTERBALANCE MODE

TDS-11SA 4-35
Installation, Commissioning
and Decommissioning

Decommissioning
Removing and storing the electrical cables
and service loops

Derrick Lower
Termination Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

Derrick
! Service Loop
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the Lifting Eyes
V-door Do not remove

Procedure
 Position the service loop tubs for convenient
loading of the service loops
 Disconnect the derrick service loop from the
derrick termination plate and the control house
 Disconnect jumper cables (if installed)
!  Cap all connectors and lower the derrick service
loop into a service loop tub
Avoid damage to the
service loops by maintaining a  Use a sling attached to the lifting eyes to lower
36 inch minimum each service loop and a swivel at the tugger line
bend radius attachment to allow each service loop to coil
without twisting
 Disconnect the Top Drive service loop and repeat
Service Loop
the above procedure
and Storage Tub
3,600 lb  Remove the service loop tubs from the area
(1600 kg)  Remove the derrick termination plate if necessary

4-36 Varco Systems


Installation, Commissioning
and Decommissioning

Decommissioning
Setting the latches and locking the bail

View of
Counterbalance
TDS-11SA Carriage
Cylinders
Hoist to from Rear
Disconnect
the crown from the hook
2 Places

Exhaust
Cover
4 Places

!
TOP DRIVE
INS
TA
WH LL
UN EN
ST IT IS

VARCO
OR
ED

The Bail Lock


Assembly
must be installed
4

Pin

Latches
Both sides
engaged

Pin

Procedure
 Install the bail lock assembly
Drill
Floor  It is NOT necessary to drain gear oil or
hydraulic fluid for rig down
 Disconnect the counterbalance cylinders
from the hook
 Install exhaust covers
 Hoist the Top Drive to the crown
 Engage the upper and lower carriage
latches as shown

TDS-11SA 4-37
Installation, Commissioning
and Decommissioning

Decommissioning
Disconnecting the guide beam
Crown
TDS-11SA
Disconnect
from the
hang-off link

Crown Padeye
Do not remove

Shackle
Intermediate
Tiebacks
Disconnect
from the Hang-off Link
guide beam

Bolt
Pin

Safety Pin Guide Beam


Top Section

Procedure
 Ensure that the bail lock assembly is installed
Main Tieback and that both carriage latches are engaged
Disconnect (See page 4-37, Setting the latches and locking
from the the bail)
Drill guide beam  Disconnect the guide beam from the main
Floor tieback and intermediate tiebacks
 Hoist the Top Drive and guide beam to take the
load off the hang-off link
 Remove the guide beam from the hang-off link
 Replace the pin, bolt and safety pin on the
guide beam top section as shown
 Remove the hang-off link if necessary

4-38 Varco Systems


Installation, Commissioning
and Decommissioning

Decommissioning
Unpinning each guide beam section

Ensure the
Top Drive
does not
contact
the rig

3
Guide
Beam
Hoist
Lynch Pin
Remove
2
Hook Pin 4

Retainer Pin
Remove

Joint Pin
Remove

1
Guide Beam
Lower to
the drill floor

Block as Procedure
Required
Drill  Lower the guide beam to drill floor
Floor  Block the guide beam in a vertical position if
required
 Slightly compress the guide beam
 Remove the retainer pin, lynch pin and joint
pin at the joint between the two lower guide
beam sections
 Hoist the guide beam to open the joint

TDS-11SA 4-39
Installation, Commissioning
and Decommissioning

Decommissioning
Lowering each guide beam section

Procedure
 Using a tugger or crane, pull the lower guide
Ensure the beam section to a horizontal position
Top Drive  Do not allow the angle at the guide beam
does not joint to become less than 90 degrees 2,100 lb
contact (950 kg)
the rig  Lower the guide beam to the drill floor Guide Beam
 Attach lifting slings to the lifting eyes of the Section
lower guide beam section to be removed
2  Unhook the lower guide beam section and
Guide remove from the drill floor
Beam  Repeat the previous steps for each of the
Lower to remaining guide beam sections until only the
the drill floor upper section remains

Sling
4

Guide Beam
Section

3
Lifting Eyes
Attach slings,
and unhook the
Lower Guide guide beam section
Beam Section
Horizontal position
must remain
greater than 90

1
Drill
Floor
Tugger

4-40 Varco Systems


Installation, Commissioning
and Decommissioning

Decommissioning
Returning the TDS-11SA to the skid
Pin 27,000 lb
Hook onto the (12300 kg)
top of the skid TDS-11SA

2
TDS-11SA Ensure the 4
Lowered Top Drive
onto skid does not
contact
the rig

3
Lock Pin
Install after lowering
TDS-11SA onto the skid

Skid

Procedure
Drill  Ensure that the bail lock is installed
Floor  Hoist the storage skid to the drill floor
1  Using the drawwork, lower the TDS-11SA onto
3,000 lb the skid
(1360 kg)  Ensure that all carriage latches remain engaged
Skid
 Hook the TDS-11SA at the top of the skid and
pin it at the bottom of the skid
 Install pin retainers

TDS-11SA 4-41
Installation, Commissioning
and Decommissioning

Decommissioning
Removing the TDS-11SA from the drill floor
Procedure
 Ensure that the bail lock assembly is installed
 Using the drawwork, lower the TDS-11SA and Sling
skid down the V-door ramp or from the drill floor
using a crane

!
The Bail Lock
Assembly
must be installed

4
Lifting
Block
Lower using
the drawwork

Lifting TDS-11SA
Sling with Skid
30,000 lb
(13600 kg)

Lower the
TDS-11SA on the Skid
Drill from the drill floor
Floor

Backup Line

4-42 Varco Systems


Installation, Commissioning
and Decommissioning

Decommissioning
Long term storage procedures
TDS-11SA Long Term Storage Procedures
 For indoor storage, cover the TDS-11SA in its shipping and handling skid. A cargo
container is appropriate for outdoor storage.
 Avoid wide variations in temperature and high humidity. The preferred environment is
clean and dry at 60-80F ambient.
 All exposed unpainted metal surfaces are coated with a rust preventive prior to
shipment; however, check these surfaces periodically to be sure that no corrosion is
taking place. The recommended rust preventive (slushing compound) for bare metal
surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.
 Cover all openings to prevent water or dust from entering. Leave enough space
around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent.
 During storage, rotate the motors and gear train periodically to distribute lubricant.
Perform this at three month intervals if stored indoors, and at one month intervals if
stored outdoors.
 For long term storage recommendations dealing with the AC drilling motors, see the
motor manufacturers manual.

Returning the TDS-11SA to Service After Storage 4


 Remove all rust preventive and any corrosion that may have taken place, taking
special care with load carrying components.
 Repaint the tool if necessary.
 Follow the return to service procedures in the AC drilling motor manufacturers manual.
 Check for water and remove if any is found.
 Change the hydraulic fluid and gearbox oil.
 Lubricate the cooling and oil pump motors.
 Lubricate the tool with general purpose grease.
 Megger all connectors.

TDS-11SA 4-43
Installation, Commissioning
and Decommissioning

4-44 Varco Systems


Guide Beams and Carriage

Inspecting the crown padeye and hang-off link 5-2


Inspecting the top section of the guide beam ... 5-3 1
Inspecting the guide beam joints....................... 5-4
Inspecting the main tieback .............................. 5-5
Inspecting the intermediate restraints .............. 5-6 2
Inspecting the carriage ...................................... 5-7

TDS-11SA
Guide Beams
and Carriage

Inspecting the crown padeye and hang-off link


Crown

Yearly
2.1"
Crown Padeye (52 mm)
minimum

Monthly
Crown Padeye
Visually inspect weld for cracks

Monthly Shackle

Cotter Pin 2.0"


Replace if missing (50 mm)
minimum

Monthly
5 Shackle
Inspect and replace if worn

1.5"
(37 mm)
minimum

Monthly
Hang-off Link Bores
Inspect and repair if worn
Hang-off Link Bores

5-2 Varco Systems


Guide Beams
and Carriage

Inspecting the top section of the guide beam


Crown

2.1"
(52 mm)
minimum
1.5"
(37 mm)
minimum

5
Bolt Assembly Hang-off Link Bores

Monthly
Safety Pin
Replace if missing Monthly
Hang-off Link Bores
Inspect and repair if worn

Guide Beam
Top Section

TDS-11SA 5-3
Guide Beams
and Carriage

Inspecting the guide beam joints

!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Replace
any missing or damaged pins.

Secure

Daily
Lynch Pin

Weekly
Joint Pin

Yearly
Typical Guide
Beam Joint
Daily
Retainer Pin

Monthly
Inspect welds
for cracks

5-4 Varco Systems


Guide Beams
and Carriage

Inspecting the main tieback


Guide Beam
Daily Bottom Section
Check that the tool is aligned
directly over well center

Main
Spreader Beam

Tieback
Tieback Plate Link

Yearly
Typical all welds
5

Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.

Auxiliary Spreader Beam

Mast Leg

See General Information


for torque values

See Installation
for assembly/disassembly

TDS-11SA 5-5
Guide Beams
and Carriage

Inspecting the intermediate restraints


Daily
Check that the tool
is aligned directly
over well center

Weekly
Check for
tightness of
cotter pins, and double
nuts. If there are signs of
shifting, verify alignment.

Weekly
5 Pin and Cotter Pin
Verify that all pins are
in place. Replace any
missing or damaged pins.

Mast Girt

Yearly
Typical all welds

Guide Beam

See General Information


for torque values

See Installation
for assembly/disassembly

5-6 Varco Systems


Guide Beams
and Carriage

Inspecting the carriage

Weekly
Typical
all rollers
Inspect for uneven
wear, damage and
looseness.
Replace
as required.

Daily
Typical all
detent pins
Verify that pins
are in place
and secure

See General Information


for torque values

TDS-11SA 5-7
Guide Beams
and Carriage

5-8 Varco Systems


Motor Housing,
Transmission

Illustrated index ................................................. 6-2


Inspection schedules ......................................... 6-3 1
Inspecting the internal lubrication flow
(monthly) ............................................................. 6-4
Adjusting the encoder ........................................ 6-5
2
Gearbox lube pump assembly ............................ 6-7
Disassembly/assembly .................................................. 6-7
Inspection (yearly) ......................................................... 6-8

Gear backlash ..................................................... 6-9 3


Inspection (yearly) ......................................................... 6-9

Bail and main body ............................................. 6-10


S-pipe .................................................................. 6-11
4
Upper mainshaft liner ......................................... 6-12
Washpipe assembly ............................................ 6-13
Assembly ....................................................................... 6-13
Inspection ...................................................................... 6-14 5
Upper bonnet seals (yearly) ............................... 6-16
Mainshaft ............................................................ 6-17
Inspection ...................................................................... 6-17
Inspecting mainshaft end play (yearly) .......................... 6-18 6

Blower motor assemblies (monthly) .................. 6-19


Motor brakes (monthly) ...................................... 6-20
AC drilling motors (weekly) ................................ 6-21 7
Transmission disassembly/assembly ................. 6-22
Nondestructive Examination (NDE) ................... 6-23
Visual inspection ........................................................... 6-23
8
Magnetic Particle Inspection (MPI) ................................ 6-24
Ultrasonic Inspection ..................................................... 6-25
Safety valve inspection procedures (IBOP) ................... 6-25

TDS-11SA
Motor Housing
and Transmission

Illustrated index

AC Motor
Bail
Blower
Page 6-10
Assembly (2)
Page 6-19

S-Pipe
Page 6-11
AC Motor
Brakes (2)
Page 6-20

AC Drilling Washpipe
Motors (2) Assembly
Page 6-21 Page 6-13

Gearbox
6 Lubrication
Gearbox
Assembly
Pump Assembly
Page 6-4, 6-7
Page 6-7

For AC motor and


transmission lubrication
see Page 3-2 thru 3-12

6-2 Varco Systems


Motor Housing
and Transmission

Inspection schedules
Daily Page Number
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings

Check the wash pipe assembly for leaks See page 6-14
Check fluid levels and filter condition See page 3-4

Weekly
Check the AC motor louvers for damage See page 6-19
Check the AC motor screens for contamination See page 6-19

Monthly
Check the flow of oil throughout the main body while the lube pump is running See page 6-4
Check the S-pipe for pitting, corrosion, or erosion See page 6-11
Check the upper mainshaft liner for erosion caused by leaking wash pipe packing See page 6-18
Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear See page 6-18
Check the blower motor assemblies for loose bolts See page 6-19
Check brake pads for wear See page 6-20

Yearly
Check the gearbox lubrication pump assembly for wear or damage See page 6-7
Check the gear teeth for pitting and corrosive wear See page 6-8

Check for primary and secondary gear set backlash See page 6-9
Check the mainshaft for axial movement See page 6-18
6
Check bail, bushings and bail pins for wear See page 6-10
Check the radial grooves on the stem and the load collar for wear See page 6-17
Megger motors

5 Years
Magnetic particle inspection (MPI) See page 6-24

TDS-11SA 6-3
Motor Housing
and Transmission

Inspecting the internal lubrication flow


(monthly)
Procedure
 Remove the 3 in. pipe plugs from the main
body and check the flow of oil coming from
the four spray nozzles (two in the body, two in
cover) while the lube pump is operating
 Check that oil is running out of the upper gear
drain holes in each compound gear set
(indicates upper orifice is not blocked) and
that oil is running through the spillway running
from the thrust bearing (indicates orifice is not
blocked)

Pipe Plug

Pipe Plugs

Monthly
Upper
Compound
Gear Drain Hole
Check flow

Monthly
Body Spray
6 Nozzles
Cover spray Monthly
nozzles not shown
Spillway
Check flow

Pipe Plug
Remove using a
2 inch, 12 point socket

Main Body

6-4 Varco Systems


Motor Housing
and Transmission

Adjusting the encoder


Use the following procedure to adjust the encoder belt tension:

1. Remove the access covers

2. Disconnect all of the electrical connectors from the encoder.

3. Remove the lockwire and loosen the four sled hold-down


screws.

4. Let the sled to move freely, allowing the belt tension spring to
apply the proper tension to the belt.

! Do not tension the belt by hand.

5. Carefully tighten the sled hold-down screws and torque them to


7 ft lb.

6. Lockwire the sled hold-down screws.

7. Reconnect the encoder electrical connections.

8. Replace both access covers and tighten the access cover


screws to 15 ft lb and lockwire them.

TDS-11SA 6-5
Motor Housing
and Transmission

Adjusting the encoder

Sled
Hold-down
Screws
Belt Tension
4 Places
Spring
View from Side

Encoder Belt Sled

View from Top


(Blower Motor
removed for clarity)

6 Electrical
Connector
Sled
Encoder Belt

Encoder

Sled
Belt Tension Hold-down
Spring Screws
4 Places

6-6 Varco Systems


Motor Housing
and Transmission

Gearbox lube pump assembly


Disassembly/assembly
Disassemble the gearbox lubrication pump assembly and inspect
the pump assembly components yearly for wear and damage as
follows:

1. Drain the gearbox oil and disconnect the hydraulic lines from
the pump assembly

2. Remove the pump assembly by removing the eight lockwired


capscrews that attach the pump adapter plate to the main
body

3. Disassemble the spline adapter, pump, and housing using the


pump vendor service instruction HS15 (located in the Vendor
Documentation Package)

4. Inspect the pump assembly components, replacing any parts


that are worn or damaged. Pay particular attention to the
spline between the pump and motor, the gears, and the motor
and pump sideplates.

5. Assemble the lubrication pump assembly in the reverse order


of disassembly

i Follow the pump vendor service instruction HS15 (located in the


Vendor Documentation Package) when assembling the lubrication
pump components, and torque all fasteners in accordance with
DS00008, located in the Supplemental Materials book.

i When reinstalling the pump assembly into the main body, inspect
the O-ring for damage and replace the O-ring if any flat spots,
nicks, or other damage is found.

6. Install the pump assembly into the main body. Torque the
fasteners in accordance with DS00008, and reconnect the
hydraulic and electrical connections.

TDS-11SA 6-7
Motor Housing
and Transmission

Gearbox lube pump assembly


Inspection (yearly)
End Cover

Thrust Plate
Yearly 2 Places
Ring Seal
Gearbox Lubrication
Body Seal
Pump Assembly
2 Places
Check parts for wear or damage
Gear
Housing

Gear Set
Roller Bearing
4 Places

Pump
Adapter Plate

Capscrew
10 Places

6
Hydraulic Motor
Low-Speed/High-Torque
O-ring Main Body

Procedure
 Drain the gearbox oil and disconnect the
hydraulic lines from the pump assembly
 Remove the pump assembly by removing the
ten lockwired capscrews that attach the pump
adapter plate to the main body
 Disassemble using the drawings in the
Technical Drawing Package as well as the
pump vender service instruction
 Inspect and relace any parts that are worn or
damaged

6-8 Varco Systems


Motor Housing
and Transmission

Gear backlash
Inspection (yearly)

A 6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash

B Solid Wire Solder

A B

Dim. A + Dim. B = Backlash

Procedure
Inspect the pump adapter plate at the same
i time the gear backlash is checked
6
 Drain the gearbox oil
 Remove the access cover and the pump
adapter plate to check primary and secondary
gear set backlash
 Run a piece of solid wire solder through the
primary and secondary gear meshes and
measure the thickness of the two flat spots
made by the gear teeth surfaces with a
micrometer. If the primary gear mesh backlash
exceeds .030 in. or the secondary gear mesh
backlash exceeds .040 in., excessive gear
wear or bearing failure is indicated.

i Check the gear teeth for pitting or corrosive


wear at the same time the gear set backlash
is checked

TDS-11SA 6-9
Motor Housing
and Transmission

Bail and main body


Inspection

Wear allowances
Component Replace when

Bushing Inner diameter is less than 4.450 in.


Bail Pin Outer diameter is less than 4.125 in.

Bail
Yearly

Bushing
2 Places
Yearly

Main Body Cover


5 Years

Main Body
5 Years

Bail Pin
2 Places
Yearly

6-10 Varco Systems


Motor Housing
and Transmission

S-pipe
Inspection
Procedure
 Unscrew the two nuts that hold the S-pipe in Wing Nut
place along with the six bolts that secure the
clamp to remove and inspect the S-pipe
 Clean the bore of the S-pipe and inspect for Seal Ring
visible signs of pitting, corrosion, or erosion
Plug
Use a flashlight and mirror to visually inspect the Monthly
i bore of the S-pipe. A Bore-o-Scope is best for
inspection, if available. Pressure test to
rated working pressure
 Remove and perform an ultrasonic inspection
on the S-pipe if visual inspection indicates
erosion or corrosion
Monthly
 Check condition of the seals
 Apply pipe dope to the threads before S-Pipe
re-installing Check for
visible signs of pitting,
corrosion, or erosion
(pitting or corrosion
should be no deeper
than 0.125 inch)

Clamp

6
Bolts

Seal Ring

Right-hand (inside of guard)


Wing Nut
configuration shown. Your S-pipe
configuration may vary.

TDS-11SA 6-11
Motor Housing
and Transmission

Upper mainshaft liner


Inspection
Procedure
 Remove the wash pipe assembly
 Check the upper mainshaft liner for erosion
caused by leaking wash pipe packing and
replace the liner if erosion is found
The 3.875 in. OD polypack seal must also be
i replaced whenever the upper stem liner is
replaced
 Grease the polypack seal and clean the
mainshaft bore before re-installing
 Make sure the O-ring of the seal is facing
down when the seal is installed on the liner Wash Pipe
Assembly

Monthly
Upper
Mainshaft Liner
Replace if erosion
is found during
inspection

Polypack
Seal
6
Polypack Seal
Replace OD polypack
seal when the upper
mainshaft liner is replaced
Main
Shaft

Upper
Mainshaft Liner

6-12 Varco Systems


Motor Housing
and Transmission

Washpipe assembly
Assembly
1. With the packing box upside down, assemble the packing
seals and spacers into the packing box using care to line up
the upper spacer slot with the dowel pin.

2. Hand pack all seals with multipurpose lithium-based or high


temperature moly-based grease using care not to grease the
outside diameter of the spacers.

3. Install the socket head dog nose screw, ensuring that the
screw nose is fully engaged in the groove of the lower spacer.

4. Install the grease fitting and turn the packing box upright.

5. Install the wash pipe into the packing box assembly (slotted
end up).

6. Install the wash pipe nut onto the wash pipe.

7. Grease the packing seal and install into the holding ring using
care not to grease the outside diameter of the holding ring.

8. Install the packing seal and holding ring over the slotted end
of the wash pipe.

9. Install the snap ring.

10. Install the upper and lower o-rings using grease to hold them
in place.

11. Compress the assembly to the length of the wash pipe.


6
Disassemble the washpipe packing in the reverse order of the
above procedure. Refer to the Washpipe Assembly Guide, P/N
128844.

TDS-11SA 6-13
Motor Housing
and Transmission

Washpipe assembly
Inspection

!
The wash pipe nut and
the packing box have
left-handed threads

Dowel Slide the


Pin wash pipe nut
and the packing box
together for installation

Hand pack all seals


with multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void

6
Ensure that the nose of the
socket head dog nose screw
is fully engaged in the groove of
the lower spacer

Special Tools

3" Bore
Wash Pipe Wrench
30150084

Recommended for proper


tightening of the wash pipe
nut and packing box

6-14 Varco Systems


Motor Housing
and Transmission

Washpipe assembly
Inspection

O-Ring

Snap Ring

Holding Ring

Upper Spacer
Packing Seal
Daily 5 per set

Wash Pipe
Assembly Wash Pipe
Inspect for leaks Nut

Middle Spacer

Wash Pipe

Middle Spacer

Packing
Assembly Box 6

Straight Ext. Lower Spacer


Grease Fitting

Socket Head
Dog Nose Screw
O-Ring

Procedure
 Visually inspect the wash pipe assembly for leaks
 Replace any worn or damaged parts
 Apply pipe dope to the threads before installing in
the Top Drive

TDS-11SA 6-15
Motor Housing
and Transmission

Upper bonnet seals (yearly)


Inspection

Procedure
 Remove the bearing shield, the bearing retainer Bearing
cap screws, and the bearing retainer Retainer
 Inspect the bearing isolator, the oil seal, and the Cap Screw
retainer o-ring for wear 6 Places
 Replace any worn or damaged parts

i Align the shims so that the bearing lube


tube bore is not blocked
Bearing
Shield

Bearing
Retainer

Lube Tube
Bearing
Oil Isolator Bearing
Seal Retainer Lube Tube O-Ring
Cap Screw 2 Places
Bearing 6 Places
Shield
Bearing
Retainer
Retainer Yearly
O-Ring Retainer O-Ring

Yearly
Bearing Isolator

6
Yearly
Lube Tube Oil Seal

Shims

Hand pack the


void with grease

6-16 Varco Systems


Motor Housing
and Transmission

Mainshaft
Inspection
Wear allowances
Component Replace when

Stem Grooves Groove width exceeds 0.650 in.


Load Collar Groove width exceeds 0.620 in.
Grooves

Stem
5 Years

Split Load Collar


Radial Grooves
Inspect for groove wear 5 Years
and pitting
0.650 Yearly
max Radial Grooves
Inspect for groove wear
and pitting
Yearly 6

0.620
max

Retainer Ring

TDS-11SA 6-17
Motor Housing
and Transmission

Mainshaft
Inspecting mainshaft end play (yearly)

Dial
Indicator

Mainshaft Bearing Retainer


Check for Cap Screw
axial movement 6 Places
Yearly

Shims
Bearing
Retainer

Procedure
6  Remove the washpipe packing
 Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator
 If axial shaft movement is not .001 in. to .002 in.,
remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .002 in. of axial
shaft movement (end play) with the bearing
retainer capscrews tightened to 250-270 ft lb

6-18 Varco Systems


Motor Housing
and Transmission

Blower motor assemblies (monthly)


Inspection
Bolts
Drip Shield 4 Places,
lock wire
in pairs

Motor
Fan Cover
Bolts
4 Places,
lock wire
in pairs
Motor Fan

Bolts
6 Places

Top Bearing
Housing

Monthly
Check for
loose bolts

Procedure
 Check bolts for tightness
 Tighten as needed
 Check motor cables for damage
 Megger motors yearly

TDS-11SA 6-19
Motor Housing
and Transmission

Motor brakes (monthly)


Inspection
Procedure
 Remove the brake housing covers to access
the drilling motor brakes
 Inspect the brake pads for wear, and replace
the pads if worn below the allowable lining wear
limit given by the manufacturer
 If the brake pads are wearing unevenly,
adjust the pads by adjusting the bolts on the Calipers and Pads
brake calipers Check pads for wear

 Inspect the brake hydraulic lines for leaks Monthly

Never check for hydraulic leaks


with your hands. Oil under Brake Disc
pressure escaping from a hole
can be nearly invisible and can
penetrate skin causing serious
injury. Always check for leaks
with a piece of wood or
cardboard.

Caliper
Mounting Steel
6 Bolts Plate

0.09 in.
Min.

Adjust

Caliper Brake Equal


Mounting Pads Gap
Bracket

6-20 Varco Systems


Motor Housing
and Transmission

AC drilling motors (weekly)


Inspection
Procedure
 Check for missing or damaged louvers
 Check screens for contamination
 Check motor leads for damage
 Check for missing lockwire
 Megger motors yearly

Weekly
Motor Leads
Check for damage

Weekly
Louvers
Check for damage

Weekly
Screen
Check for contamination

TDS-11SA 6-21
Motor Housing
and Transmission

Transmission disassembly/assembly
Stem Sleeve

Taper Roller
Main Body Cover Bearing

Cap Screw Dowel Pin


Upper Spray Nozzles
Dowel Lock
Pin Washer
Upper Compound Bull Gear
Roller Bearing

Internal
Retaining Ring

Upper Stem
Compound Gear Liner

Internal
Retaining Ring Poly Pack
Seal
Oil
Spacer Ring Gallery
O-Ring
Lower Compound
Roller Bearing

Bearing Lock Washer


Main Shaft
Stem
Internal
Locknut Retainer

Main Body O-Ring

Tapered Roller
6 Thrust Bearing
Main Body

Main Shaft
Sleeve

Lower Main Main Lower


Bearing Roller Bearing

Wear Sleeve
Lube Plate
Oil Assembly Bearing
Lock Washer Retainer

Cap Screw

6-22 Varco Systems


Motor Housing
and Transmission

Nondestructive Examination (NDE)


Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path items.
NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-
ray examination, and other methods of nondestructive testing for
metallurgical integrity.

Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.

TDS-11SA 6-23
Motor Housing
and Transmission

Nondestructive Examination (NDE)


Magnetic Particle Inspection (MPI)
Once a year, or every 3,000 operating hours, Varco recommends
performing a Magnetic Particle Inspection (MPI) of the exposed
surfaces of all load carrying components to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are cause for replacing the
suspect component.

After approximately five years, or 15,000 operating hours,


depending on the severity of operating conditions, Varco
recommends performing a MPI of all load carrying components over
their entire surface (including internal bores) to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are cause for replacing the
suspect component. The load carrying components are:

Mainshaft (lower portion)

Bail

Landing collar (yearly)

Upper and lower IBOP

Link adapter

Saver, crossover, and spacer subs


6
Power subs

Power swivels

Elevator links

Details on MPI procedures are in the following publications:

I.A.D.C. Drilling Manual, 9th Edition

ASTM A-275 Std. Method for Magnetic Particle Inspection of


Steel Forgings

ASTM E-709 Std. Recommended Practice for Magnetic Particle


Inspection

6-24 Varco Systems


Motor Housing
and Transmission

Nondestructive Examination (NDE)


Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capability of the part. Any subsurface irregularity can also
compromise a components integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.

Safety valve inspection procedures (IBOP)


Upper and lower IBOP valves, because of their internal grooves and
shoulders, are particularly susceptible to corrosion fatigue cracking.
These internal diameter changes act as stress risers for bending
and tensile loads. It is especially important to properly inspect the
IBOP valves on a frequent basis. Read and use the IBOP valve
inspection procedures described in the IBOP Service Manual
(SM00611).

TDS-11SA 6-25
Motor Housing
and Transmission

6-26 Varco Systems


PH-50 Pipehandler
PH-50 Pipehandler

PH-50 Pipehandler illustrated index .................. 7-2


Inspection schedule ........................................... 7-3 1
Precautions ......................................................... 7-4
Elevator links ...................................................... 7-5
Disassembly/assembly .................................................. 7-5
Inspection ...................................................................... 7-6 2
Link tilt ................................................................ 7-8
Disassembly/assembly .................................................. 7-8
Inspection ...................................................................... 7-9
Torque wrench assembly ................................... 7-10 3
Clamp cylinder body disassembly/assembly ................. 7-10
Inspecting the clamp cylinder body ............................... 7-14
Inspecting the stabilizer ................................................. 7-15
Inspecting the IBOP actuator cylinder and yoke ............ 7-17 4

Well control system ............................................ 7-19


Tool joint locks disassembly/assembly .......................... 7-19
Inspecting the tool joint locks......................................... 7-20
5
Inspecting the IBOP valves and saver subs .................. 7-21
Shot pin assembly .............................................. 7-22
Disassembly/assembly .................................................. 7-22
Inspection ...................................................................... 7-23
6
Rotating link adapter/load stem ......................... 7-24
Removing the pipehandler and link tilt from the top drive
(while in mast) ............................................................... 7-24
Disassembling the link tilt assembly .............................. 7-24
77
Assembling the link adapter .......................................... 7-26
Assembling the link adapter to the top drive
(while in mast) ............................................................... 7-27
Wireline adapter ................................................. 7-28
8
Inspection ...................................................................... 7-28
Nondestructive Examination (NDE) ................... 7-29
Visual inspection ........................................................... 7-29
Magnetic Particle Inspection (MPI) ................................ 7-30
9
Ultrasonic Inspection ..................................................... 7-31
Safety valve inspection procedures (IBOP) ................... 7-31

TDS-11SA
TDS-11SA 7-1
PH-50 Pipehandler

PH-50 Pipehandler illustrated index

Rotating Link
Adapter
Page 7-25

Link Tilt
Page 7-9

IBOP Actuator
Yoke and Cylinder
Page 7-19

Stabilizer
Page 7-16

Well Control System


Page 7-20
Clamp Cylinder
Body
Page 7-11

7
Stabbing Guide
Page 7-14

Drill Pipe Elevator


For pipehandler lubrication and Elevator Links
see Page 3-13 Page 7-6

7-2 Varco Systems


PH-50 Pipehandler

Inspection schedule
Each Use Page Reference
Check wireline adapter sheaves for excessive wear or damage See page 7-30

Daily
Check for missing lockwire and cotter pins

Check for loose or broken parts and leaks

Check for damaged hoses and fittings

Check clamp cylinder gate pins and retainer bolts See page 7-11

Check tong dies for wear See page 7-14

Check upper and lower IBOP valves for proper operation See page 7-21

Weekly
Check link tilt clamps for position and tightness See page 7-9

Check stabbing guide and flippers for damage and wear See page 7-11

Check front and rear stabilizers for wear See page 7-16

Check IBOP actuator cylinder for leaks, tighten fittings See page 7-17

Check IBOP actuator rollers for wear or excessive play See page 7-19

Check tool joint locks for loose bolts See page 7-20

Check upper and lower (if equipped) IBOPs for damage See page 7-22

Monthly
Check elevator link eyes for wear See page 7-8

Check link tilt bushings for wear See page 7-9

Check link tilt actuator cylinder clevis pins for wear See page 7-19

Check IBOP actuator yoke for wear or excessive play See page 7-19

Check shot pin assembly for wear or damage See page 7-23
7
Yearly
Check piston ring for pitting and chipping See page 7-25

Check stem for pitting, grooves and chipping See page 7-25

Replace GLYD rings, o-rings and bushings on rotating link adapter See page 7-25

5 Years
MPI Inspection See page 7-31

TDS-11SA 7-3
PH-50 Pipehandler

Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:

Properly lockout the main power source before


performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from


fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is


moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil


under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious injury.
Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.

Always discharge the three hydro pneumatic


accumulators before performing repairs on the
hydraulic system.
7

Do not attempt repairs you do not understand.

Read and understand all safety precautions and


warnings before performing maintenance procedures.

7-4 Varco Systems


PH-50 Pipehandler

Elevator links
Disassembly/assembly
1. Disconnect and remove the drill pipe elevator from the
elevator links.

2. Using the Varco Drillers Console (VDC), rotate the


pipehandler 90 to position one of the elevator links directly
below the front of the motor guard.

3. Remove the catch link bolt from the catch link.

4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.

5. Using the sling, hoist the elevator link away from the
pipehandler.

6. Rotate the pipehandler 180, repeat the procedure to remove


the other elevator link.

TDS-11SA 7-5
PH-50 Pipehandler

Elevator links
Inspection
Recess in
Motor Guard

Rear

2
Lift and
remove

Link Tilt

Catch Link Pin Upper


Catch Link 950 lb
(431 kg)
Elevator Link

Front

26"
(635mm)
P
LE RO IPE
FT T
AT HA
Typical
E ND
L
RIG LI ER
HT NK
TIL
TF
LO
AT
TO
RQ
PU UE
Link
SH WR
& H EN
OL CH
D
DR LINK
ILL O TI
FF LT

TIL
T

Pipehandler
Rotate Switch
Weekly Clevis
Pin
Link Clamps
Inspect for position
1 and tightness
7
Rotate
PIP
EH
AN
DL
ER

BR
AK
E

IBO
P

EM
ER TO
G
ST EN RQ
UE
OP CY

Varco TO
RQ
Monthly
UE

Drillers Console Elevator Link Eyes


RP
M
Inspect for wear (see table)

7-6 Varco Systems


PH-50 Pipehandler

Elevator links
Inspection (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 3 1/2 in., 350-Ton
5 inches 2 3/4 inches 350

4 13/16 inches 2 9/16 inches 300


4 5/8 inches 2 3/8 inches 225

7 7/16 inches 2 3/16 inches 175

B = 4 1/2 in., 500-Ton B

6 inches 3 1/2 inches 500


5 3/4 inches 3 1/4 inches 420
5 1/2 inches 3 inches 325
B
5 1/4 inches 2 3/4 inches 250

B = 6 1/4 in., 750-Ton


7 1/2 inches 7 1/2 inches 350
A
7 1/4 inches 7 1/4 inches 300
7 inches 7 inches 225
6 3/4 inches 7 3/4 inches 175

Lower
To determine the strength of worn links, measure (with calipers) Eye
the amount of eye wear and compare the measurements (Elevator)
with the above Wear Chart to find the current capacity.
The capacity of the set of links is determined by the weakest link.
A

TDS-11SA 7-7
PH-50 Pipehandler

Link tilt
Disassembly/assembly
1. Shutdown the power and bleed the system (turn the valve on
the bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines from the link tilt cylinders and
cap all connections.

3. Unpin and remove the link tilt cylinders.

4. Unpin and remove the link tilt crank.

i Use the recommended spanner wrench to remove the rod gland


seal.

7-8 Varco Systems


PH-50 Pipehandler

Link tilt
Inspection

Pins
Inspect for wear
replace as needed
Monthly

Monthly
Bushings
Inspect for wear
replace as needed

Monthly
Link Tilt
Actuator Cylinders
Inspect the hydraulic
connections for leaks
Link Tilt

Monthly
Bushings
Inspect for wear
replace as needed
7

Wear allowances
Component Replace when
Pins Wear exceeds .06 in. on diameter
Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear

Bushings should be pressed in using the mating pin


i as an installation mandrel.

TDS-11SA 7-9
PH-50 Pipehandler

Torque wrench assembly


Clamp cylinder body disassembly/assembly
1. Shutdown power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines on the clamp cylinder body and


cap all connections.

3. Support the clamp cylinder body.

4. Remove the two hex-head capscrews and lockwashers that


hold the end cap in place.

5. Remove the end cap, spring spacer, spring sleeve, and spring.

6. Slowly lower the clamp cylinder body off the torque wrench
frame and move it to a suitable work area.

7. Remove the 16 hex-head screws and lockwashers that hold


the wear bushings on the clamp cylinder body.

8. Remove the four wear bushings, and replace the wear


bushings as necessary.

9. Remove the two hinge pin retainer hex-head screws.

10. Swing out the two hinge pin retainers.

11. Remove the two hinge pins.

12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.

13. Remove the two socket-head capscrews and hi-collar washers


from the front jaw.

14. Remove the front jaw from the gate.


7 15. Repeat steps 11 and 12 for the rear jaw.

16. Push the cylinder head in enough to relieve the load on the
cylinder head ring. Remove the cylinder head ring. Use care in
this operation.

7-10 Varco Systems


PH-50 Pipehandler

Torque wrench assembly


17. Slowly pull out the cylinder head using the threaded holes.
Remove and discard the piston seal.

18. Carefully push the piston out of the body. Remove and discard
the piston seal.

19. Remove the wiper rod and rod seal from the body. Discard the
seals.

20. Clean the piston, cylinder head, and the body. Clean and lightly
lubricate the new seals and seal surfaces prior to reassembly.

i Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

TDS-11SA 7-11
PH-50 Pipehandler

Torque wrench assembly

RUN

SHUTDOWN

RIG-UP
Hydraulic
COUNTERBALANCE MODE
Manifold
Rig-up/Run/
Shutdown Valve
Shown in SHUTDOWN
position

(Shown with
link tilt removed)

Torque Arrestor

Spring

Spring Spacer

Spring Shims
Adjust to ensure
the torque wrench
clamps fully onto
the saver sub Support clamp
cylinder body
before removing
7 end cap.
End Cap

Clamp Cylinder
Body

7-12 Varco Systems


PH-50 Pipehandler

Torque wrench assembly


Manifold

Rear Stabilizer
Front Stabilizer
Hinge Pin Spring
Retainer
Cylinder Head Ring Hex Head
Screws

Clamp Cylinder
Body

Body Seals
Cylinder Head

Piston Seals Jaw Assembly


Tong Dies
Piston

Gate

Wear Bushing
Socket Head
Cap Screws

Hinge Pin

Rear Stabbing Guide Front Stabbing Guide

Stabilizer

Retaining Plate
Spring

TDS-11SA 7-13
PH-50 Pipehandler

Torque wrench assembly


Inspecting the clamp cylinder body

Tugger
Line

V
A
R
C
O
P
H
5
0

Front and Rear


Stabilizers
Inspect for wear
Weekly

Tong Dies
Inspect for
RCO
excessive wear
VA
Daily

Stabbing Guide
Inspect for damage
7 Weekly

Clamp
Cylinder Gate
(Shown open) Weekly
Flippers
Inspect for damage
and excessive wear
Swing Clear
Wear allowances
Component Replace when

Stabilizer Wear exceeds 1/8 in.


Flippers Wear exceeds 1/8 in.

7-14 Varco Systems


PH-50 Pipehandler

Torque wrench assembly


Inspecting the stabilizer
Remove the two bolts (with slotted nuts and cotter pins) that hold
the front stabilizer. Check the springs for damage and replace if
needed. Pack spring cavities with grease and reassemble. Be sure
all safety wire, cotter pins, and capscrews are tight, and tighten or
replace as necessary.

TDS-11SA 7-15
PH-50 Pipehandler

Torque wrench assembly


Inspecting the stabilizer

Stabilizer Springs Monthly


Check for damage,
replace as necessary. Stabilizers
Inspect for wear.
Monthly Replace if wear exceeds
1/8 in.
Cotter Pin

7-16 Varco Systems


PH-50 Pipehandler

Torque wrench assembly


Inspecting the IBOP actuator cylinder and yoke

Weekly
IBOP
Actuator Cylinder
Check for leaks,
Daily tighten fittings
Hoses
Replace if worn Monthly
or damaged
Pins and Bushings
Check for wear
or excessive play

Monthly
IBOP Weekly
Actuator Yoke IBOP
Check pins and Actuator Yoke
bushings for wear Check cam followers for wear
or excessive play or excessive play

For IBOP Actuator Yoke lubrication


see Page 3-13 7

Wear allowances
Component Replace when

Pins Wear exceeds .03 in. on diameter


Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear

Bushings should be pressed in using the mating pin


i as an installation mandrel.

TDS-11SA 7-17
PH-50 Pipehandler

Torque wrench assembly


Inspecting the IBOP actuator cylinder and yoke
Disassembling the IBOP actuator cylinder and
yoke
1. Shutdown the power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).

2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.

3. Disconnect the hydraulic lines from the IBOP actuator cylinder


and cap all connections.

4. Unpin and remove the IBOP actuator cylinder and yoke.

5. Replace the hydraulic lines as necessary.

6. Check for cylinder leaks.

7-18 Varco Systems


PH-50 Pipehandler

Well control system


Tool joint locks disassembly/assembly

! Do not reuse locking screws.

1. Lubricate the locking screw threads, screw head bearing area,


and the tapers of the inner rings with molybdenum disulfide
grease, such as Molykote Gn paste.

2. Make sure the save sub, IBOPs, and main shaft are free of
high spots, such as tong marks. If high spots exist, remove
with file or light grinding.

3. Slide the tool joint lock over the main shaft, IBOP valves, and
saver sub.

4. Clean the IBOP valves, main shaft, and saver sub surfaces
thoroughly. Make sure these surfaces are smooth and free of
grease, oil, and pipe dope.

5. Locate the tool joint lock symmetrically at each joint.

! Never tighten locking screws before the tool joint lock is at the
correct location, otherwise it will not slide freely.

6. Take any three or four locking screws equally spaced and


tighten them to establish parallel or perpendicular position of
the tool joint lock collars relative to the main shaft, IBOP
valves, and saver sub respectively. This properly seats the
collars on the taper of the inner ring and aligns the collars.

7. Using a torque wrench, tighten all locking screws gradually in


either a clockwise or counterclockwise sequence (not in a
7
diametrically opposite sequence). Continue tightening all of
the screws until they reach 1855 ft lb.

8. Make sure no screw turns any more. The gap between the tool
joint collars should be as equal as possible all the way around.

9. Safety wire all screws.

TDS-11SA 7-19
PH-50 Pipehandler

Well control system


Inspecting the tool joint locks
Tool Joint Lock to be Equally
Spaced on Upper IBOP and
Main Stem Joint Connection

1.4" Tool Joint


Shoulder

1.4"

Remove O-Ring Tapered


and Look through Inner Ring
this Space and
Split on Inner Ring
Tool Joint Lock to
be Offset on Upper
and Lower IBOP
Joint Connection

Tool Joint
1.0" Shoulder

I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring

Daily
Tool Joint
Locks
7 1.4" Tool Joint Inspect for loose bolts.
Shoulder Repair or replace if necessary.
Torque to 1855 ft lb.
1.4"
Tool Joint Lock to be Equally
Spaced on Lower IBOP and
Saver Sub Joint Connection

Removing the Tool Joint Locks


 Gradually release the locking screws all the way around. Initially release each screw
about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the
screws completely at this time, otherwise the collars may spring off.
 Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws
are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.

7-20 Varco Systems


PH-50 Pipehandler

Well control system


Inspecting the IBOP valves and saver subs

Wear allowances
Component Replace when

Saver Sub Threads have been recut to a minimum


shoulder-to-shoulder length of 5 in.

i See the IBOP Service Manual for IBOP


disassembly/assembly and servicing
information.

Weekly Daily
Upper IBOP Valve
(Remote) Check for
Inspect for damage proper operation
and pressure test
for leaks

Weekly
IBOP Crank
(Remote)
Inspect for damage

Weekly Daily 7
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks

5 Years
Upper and Lower IBOP

TDS-11SA 7-21
PH-50 Pipehandler

Shot pin assembly


Disassembly/assembly
1. Disconnect the hydraulic and electrical lines.

2. Remove the capscrews that attach the shot pin assembly to


the main body.

3. Remove the capscrew and lockwasher holding the shot pin


cover in place

4. Remove the shot pin components as shown in the illustration


on Page 7-24 (end cap, o-rings, rod seal assembly, shot pin)

5. Inspect the shot pin bearing and press the bearing out of the
shot pin mounting bracket if the bearing is scored or
damaged.

6. Remove the capscrew and lockwasher that hold the pinion


gear in place, and remove the gear.

7. Remove the capscrews and lockwashers that hold the


hydraulic motor in place and remove the motor.

Inspect the disassemble parts and replace any worn or damaged


parts. Assemble the shot pin in the reverse order of disassembly.

7-22 Varco Systems


PH-50 Pipehandler

Shot pin assembly


Inspection

Shot Pin
Assembly
Shot Pin Base

Dowel Pin

Rod Seal
Hydraulic
Assembly
Shot Pin Motor
Remove burrs

Rod Seal
Assembly
Dual Port
Shot Pin Manifold
Sleeve

O-ring

Shot Pin Bushing

Shot Pin Cap


Pinion Gear 7

Shot Pin
Cover
Wear allowances
Component Replace when

Shot Pin Outer diameter is less than 1.375 in.


Shot Pin Sleeve Inner diameter is greater than 1.510 in.
Shot Pin Bushing Inner diameter is greater than 1.475 in.

TDS-11SA 7-23
PH-50 Pipehandler

Rotating link adapter/load stem


Removing the pipehandler and link tilt from the top drive
(while in mast)
1. Drain the oil from the gearbox.

2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.

3. Build a support over well center to support the weight of the


link adapter.

4. Lower the top drive to the support built in Step 3.

5. Remove the bolts that attach the load stem to the main body.

6. Raise the top drive slowly to separate the link adapter from
the main body.

7. Move the link adapter assembly to a clean, safe work area.

8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.
Disassembling the link tilt assembly
1. Attach a 3-point sling to the stem and pull the stem out of the
link adapter.

2. Turn the stem over and place it on its flange.

! Protect the internal surfaces of the rotating link adapter and


the surfaces of the drive stem when separating the two
components. When removing the rotating link adapter from the
stem, carefully tap with a mallet. There can be misalignment
between the two bores when raising the drive stem and gear
assembly.
7

i The piston ring is assembled with a light press fit. Provide a


support under the gear so that it does not drop when it breaks
loose.

3. Remove and discard all rotary seals, O-rings, thrust ring, and
the wear bushings from inside the rotating link adapter and
gear inside dimension.

4. Remove and discard the stem flange O-rings and stem bore
shaft seals.

7-24 Varco Systems


PH-50 Pipehandler

Rotating link adapter/load stem


Inspecting the rotating link adapter

Rotary GLYD Ring


Remove, discard and replace
Yearly

Rotary Link Adaptor


O-Ring
Remove, discard
and replace
Yearly

Thrust Ring
Retainer Ring Remove, discard and replace
Yearly

Turcite Bushing
Remove, discard and replace
O-Ring
Yearly
Rotary GLYD Ring

Wiper Seal

Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear (Heat to 175-200 F
to install)

Wear allowances
Component Replace when Yearly

Thrust Ring Thickness is less than 0.105 in. Stem


Inspect for pitting,
Turcite Thickness is less than 0.112 in. grooves and chipped plating 7
Bushing

Index Mark Stem O-Ring


Indicates front of stem Remove, discard and replace
Yearly

Level Work Surface

TDS-11SA 7-25
PH-50 Pipehandler

Rotating link adapter/load stem


Assembling the link adapter
1. Orient the stem so the drive stem flange is down on a suitably
protected surface.

2. Install the gear with its rotating seal and wiper in place.

3. Install the O-ring for the piston ring.

4. Install the piston ring by tapping on it lightly with a mallet to


press it into place (Heat to 220-250)

5. Install the retainer ring.

6. Install all of the rotary seals on the rotating link adapter, and
an O-ring on the top surface.

7. Install the two wear bushings and the thrust ring in the rotating
link adapter.

8. Rest the rotating link adapter on its bottom surface.

9. Clean and then lubricate (with hydraulic oil) the sealing


surface of the stem and the inside diameter of the rotating link
adapter.

10. Attach three lifting slings symmetrically through the holes on


the top of the stem flange and slowly lower the assembly into
the rotating link adapter body. Hammering with a large plastic
mallet is an aid when assembing the stem to the link adapter.

i Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts.

12. Pressure test each port at 1,000 psi and inspect for leaks at
7
the adjacent ports.

13. Grease all lubrication points on the assembly.

14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.

7-26 Varco Systems


PH-50 Pipehandler

Rotating link adapter/load stem


Assembling the link adapter to the top drive (while in
mast)
1. Check the condition of the manshaft wear ring and replace if
there is any evidence of grooving.

2. Place the rotating link adapter assembly back on the support


built over well center, orienting the assembly so that the stem
flange is up, and so that the idex mark faces forward.

3. Carefully lower the top drive to engage the mainshaft in the


stem bore and then the stem flange pilot diameter is in the main
body bore.

4. Install the flange bolts.

5. Install the link tilt cylinders, pin, and secure in place.

6. Install the link tilt crank and pin, and secure in place.

7 Install all hose assemblies.

8. Install tubing.

9. Install the shot pin assembly.

10. Fill the gearcase with gear oil (see Lubrication).

11. Check and fill the hydraulic oil as necessary.

12. Turn on the top drive and perform all pipehandler functions
several times, checking for proper function and any leaks.

13. Re-check the hydraulic oil level and fill as necessary.

! Always install a new mainshaft seal and use care not to


damage the seal or the case. 7

i A light coating of grease applied to the O-ring helps in installing the


rotating link adapter assembly into the main body.

! Always install a new drive stem O-ring and use care not to
damage the O-ring or the case.

TDS-11SA 7-27
PH-50 Pipehandler

Wireline adapter
Inspection
i
Inspect the condition of the
sheaves before and after each use.

Each Use
Sheaves
Replace or repair damaged
parts as necessary

7-28 Varco Systems


PH-50 Pipehandler

Nondestructive Examination (NDE)


Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path items.
NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-
ray examination, and other methods of nondestructive testing for
metallurgical integrity.

Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.

TDS-11SA 7-29
PH-50 Pipehandler

Nondestructive Examination (NDE)


Magnetic Particle Inspection (MPI)
Once a year, or every 3,000 operating hours, Varco recommends
performing a Magnetic Particle Inspection (MPI) of the exposed
surfaces of all load carrying components to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are cause for replacing the
suspect component.

After approximately five years, or 15,000 operating hours,


depending on the severity of operating conditions, Varco
recommends performing a MPI of all load carrying components over
their entire surface (including internal bores) to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are cause for replacing the
suspect component. The load carrying components are:

Mainshaft (lower portion)

Bail

Landing collar (yearly)

Upper and lower IBOP

Link adapter

Saver, crossover, and spacer subs

Power subs

Power swivels

Elevator links
7
Details on MPI procedures are in the following publications:

I.A.D.C. Drilling Manual, 9th Edition

ASTM A-275 Std. Method for Magnetic Particle Inspection of


Steel Forgings

ASTM E-709 Std. Recommended Practice for Magnetic Particle


Inspection

7-30 Varco Systems


PH-50 Pipehandler

Nondestructive Examination (NDE)


Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capability of the part. Any subsurface irregularity can also
compromise a components integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.

Safety valve inspection procedures (IBOP)


Upper and lower IBOP valves, because of their internal grooves and
shoulders, are particularly susceptible to corrosion fatigue cracking.
These internal diameter changes act as stress risers for bending
and tensile loads. It is especially important to properly inspect the
IBOP valves on a frequent basis. Read and use the IBOP valve
inspection procedures described in the IBOP Service Manual
(SM00611).

TDS-11SA 7-31
PH-50 Pipehandler

7-32 Varco Systems


Hydraulic System

Hydraulic system ................................................ 8-2


Illustrated index ................................................. 8-3 1
Hydraulic system diagram.................................. 8-4
Inspection ........................................................... 8-5
Precautions ................................................................... 8-5
Maintenance schedule .................................................. 8-7 2
Hydraulic fluid level and filter ......................................... 8-8
Adding the hydraulic fluid .............................................. 8-9
Draining the hydraulic fluid ............................................ 8-10
Hydraulic reservoir bladder (yearly) ............................... 8-11 3
Heat exchanger ............................................................. 8-12
Using the hydraulic system test ports ............................ 8-13
Precharging the accumulators ....................................... 8-14
IBOP timing circuit ......................................................... 8-15 4
IBOP and oil pressure switch ........................................ 8-16
Setting up the circuits ........................................ 8-17
Hydraulic pumps and unloading circuit .......................... 8-17
Fixed displacement (lube) and variable displacement 5
pumps ............................................................................ 8-18
Counterbalance circuit and stand-jump circuit ............... 8-22
AC motor brake circuit ................................................... 8-26
Shot pin circuit ............................................................... 8-27 6
Link tilt cylinder circuit.................................................... 8-29
Rotating link adapter hydraulic motor relief circuit ......... 8-30
Troubleshooting .................................................. 8-31
HPU and reservoir bladder ............................................ 8-31 7
Counterbalance and stand jump.................................... 8-33
Stand jump testing ......................................................... 8-34
Counterbalance and stand jump schematic diagram .... 8-36
Troubleshooting the brakes ........................................... 8-37
8
Shot pin cylinder and clamp cylinder ............................. 8-39
Link tilt cylinders ............................................................ 8-41
Gearbox lubrication hydraulic system ............................ 8-43
Rotating link adapter motor schematic diagram ............ 8-46
9
IBOP actuator schematic diagram ................................. 8-47
Hydraulic schematic symbols ............................ 8-48

TDS-11SA
Hydraulic System

Hydraulic system
The hydraulic control system is a completely self-contained,
onboard system. A 10-horse power, 1800 rpm, AC motor, drives
two hydraulic pumps and powers the hydraulic system. A fixed
displacement pump drives the lube oil system motor. A variable
displacement pump provides hydraulic power for the AC motor
brakes, powered rotating head, remote actuated IBOP, pipe backup
clamp cylinder, link tilt, and counterbalance system. Three hydro-
pneumatic accumulators are located on the main body.

The hydraulic manifold attaches to the main body and contains


solenoid, pressure and flow control valves.

A sealed stainless steel reservoir supplies hydraulic oil, eliminating


the need for draining and refilling during normal rig moves. The
reservoir is mounted between the AC drilling motors and is
equipped with strainers and an oil level sight gauge.

8-2 Varco Systems


Hydraulic System

Illustrated index
Specifications

Pump Motor 10 hp, 1,800 rpm, AC motor


Reservoir Capacity 25 gal

Hydraulic Oil Filter


Page 8-8 Counterbalance
Manifold
Page 8-22
Counterbalance
Accumulator
Page 8-14 Main Hydraulic
Manifold
Upper IBOP Time- Page 8-13
Delay Accumulator
Page 8-15
Link Tilt
Hydraulic Oil Fill Manifold
Page 8-9 Page 8-29

Oil Pressure Link Tilt


Switch Cylinders
Page 8-16 Page 8-29 Counterbalance
Cylinders
System Page 8-22
Accumulator
Page 8-14
Hydraulic Oil
IBOP Pressure Reservoir
Switch Front Page 8-11
Page 8-16
Rotating Head
Upper IBOP Motor and
Actuator Cylinder Rear
Shot Pin
Page 8-15 Assembly
Page 8-27

10 HP AC
Motor and
Front Pump Assembly
Page 8-17

Rear
8

TDS-11SA 8-3
Hydraulic System

Hydraulic system diagram


Drilling Upper IBOP Link Tilt Pipehandler
Motor Brake Actuator Cylinder Cylinders Clamp Cylinder

Link Tilt
Counterbalance Manifold
Accumulator

Rotating Head
(Elevator Positioner)

Counterbalance Shot Pin Rotating


Cylinders Cylinder Link Adapter
Lift

Rotating
Head Gearbox Lube
Motor Oil Distribution
Counterbalance
Manifold

Main Hydraulic Manifold

Low Speed Lube Oil


Hydraulic Pump
Motor

Upper IBOP System


Time-Delay Accumulator Gearbox Sump
Accumulator

M
Variable Fixed
10 HP A.C. Displacement Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
8
Reservoir

8-4 Varco Systems


Hydraulic System

Inspection
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:

Properly lockout the main power source before


performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from


fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is


moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil


under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious injury.
Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.

Always discharge the three hydro pneumatic


accumulators before performing repairs on the
hydraulic system.

Do not attempt repairs you do not understand.

8
Read and understand all safety precautions and
warnings before performing maintenance procedures.

TDS-11SA 8-5
Hydraulic System

Inspection

Release all hydraulic oil pressure by bleeding


accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean


work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent
injury to personnel.

! Use care when handling components to prevent nicking close


tolerance finishes.

Hydraulic fluid escaping under pressure can penetrate


the skin causing serious injury. Avoid injury by
discharging the three accumulators and relieving
pressure before disconnecting hydraulic lines. Always
search for hydraulic leaks with a piece of cardboard
or wood-not with your bare hands. Get immediate
medical attention for hydraulic fluid injuries. Fluid
injected into the skin must be surgically removed
within a few hours or gangrene may result. Do not
tighten hydraulic fittings while they are under
pressure.

Inspect the hydraulic system daily for leaks at fittings, damaged


hose covers, kinked or crushed hoses, hard or stiff hoses, and
damaged or corroded fittings. In addition, during the inspection,
tighten or replace any leaking port connections, and clean any dirt
buildup from hydraulic components.
8
Replace worn or damaged hydraulic system
components immediately.

Inspect the hydraulic fluid level in the hydraulic reservoir located


between the AC drilling motors daily. Inspect the hydraulic filter
located on the upper left AC drilling motor daily.

8-6 Varco Systems


Hydraulic System

Inspection
Maintenance schedule
Hydraulic system oil lubrication schedule
Description Frequency
Replace hydraulic system filter (P/N 114416-1) 1 x every 3 months
Perform hydraulic system oil analysis 1 x every 6 months
Replace hydraulic fluid 1 x every year, or earlier based on oil analysis
Inspect hydraulic reservior bladder 1 x every year
Replace hydraulic reservior bladder 1 x every 2 years

Daily inspections
Description
Check the condition of the hydraulic filter indicator
Check hydraulic fluid levels
Check for hydraulic fluid leaks
Check the condition of hydraulic hoses

Recommended hydraulic lubricants


Oil Temperature Range
-15 to 75 C -10 to 85 C
(5 to 167 F) (14 to 185 F)

Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
8
Viscosity Index
ISO Viscosity Grade 32 46

TDS-11SA 8-7
Hydraulic System

Inspection
Hydraulic fluid level and filter

Cork Ball
(Level Indicator)

Daily
Red
Pop-up Sight
Dirt Alarm Glass

Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter

Procedure
 Check the red pop-up alarm on the hydraulic
filter daily
 Replace the filter (Varco P/N 114416)if the
indicator has popped up or as recommended
8
 Use care to prevent contamination from
entering the hydraulic system during
maintenance activities

8-8 Varco Systems


Hydraulic System

Inspection
Adding the hydraulic fluid
Specifications
Reservoir Capacity 25 gal

Procedure
Cork Ball
 Turn the TDS-11SA off (Level Indicator)
 Ensure that the area is clean prior to adding
hydraulic fluid
 Remove dust plug from the male quick
disconnect at the TDS-11SA hydraulic oil fill
 Remove dust plug from the female quick
disconnect on the lubrication kit
 Connect the two fittings and pump fluid until
the level reaches the middle of the sight Sight
glass as showm Glass
 See Lube Schedule for specifications
Hydraulic
 After adding fluid, replace the dust plugs Oil Sight
Gauge

Hydraulic Oil Fill


Male Quick Disconnect

Hydraulic
Oil Fill

Female
Quick
Disconnect

Hydraulic
Lubrication Kit 8
55 gal Drum
Varco P/N 92643

TDS-11SA 8-9
Hydraulic System

Inspection
Draining the hydraulic fluid

Precautions
 Hydraulic fluid may be hot
 Use care when opening the valve
 Avoid spills
 Holds 25 gallons

Pump
Valve
Inlet/Drain
Handle
Adapter

10 HP AC
Pump Motor
Procedure
 Isolate power to the pump motor Fixed
 Ensure that the valve is closed Displacement
Pump
 Remove the plug and attach a hose
 Open the valve and drain the fluid
 Close the valve and remove the hose Variable
8 Displacement
 Replace the plug Pump

8-10 Varco Systems


Hydraulic System

Inspection
Hydraulic reservoir bladder (yearly)
Hydraulic Oil
Reservoir
Between AC
Drilling Motors
Reservoir
Breather Reservoir
Cover

Apply gasket sealing


compound to prevent leaks

Yearly
Reservoir Bladder
Varco P/N 110191-501
Check for wear and damage

Gasket
Varco P/N 110132
Front
Apply gasket sealing
compound to prevent leaks

Rear

Hydraulic Oil
Reservoir

Procedure
 Drain hydraulic fluid and clean area before
inspecting the reservoir bladder
 Remove the 10 cap screws and lock
washers from the cover 8
 Remove cover with bladder attached
 Check yearly for wear or damage
 Replace the bladder every two years
 Replace the bladder if fluid escapes the
reservoir breather when the Top Drive is on
its back

TDS-11SA 8-11
Hydraulic System

Inspection
Heat exchanger

Blower and
Brake Covers

Monthly
Oil Heat
Exchanger
Remove any dirt
and inspect for leaks,
corrosion, and cleanliness

Drill Motor
Assembly
Left side

8-12 Varco Systems


Hydraulic System

Inspection
Using the hydraulic system test ports

Stand Jump Brake Clamp/


SV9 SV1 P1 Shot Pin Float
Link
IBOP SV5 SV8 Tilt
L4 PV PF * B8
SV4 SV6
A4 G5
CB

* SA

* P

* T1
C4
A6
SV2
C5
Rotating B6 8
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.

As Viewed From Below

TDS-11SA 8-13
Hydraulic System

Inspection
Precharging the accumulators
Accumulator Setting Port

System Accumulator (125-cubic inch displacement) 800 psi precharge SA


Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge CB
Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge C4

Bleed the accumulator if the pressure is higher, or add


i nitrogen if the pressure is lower than specified above.

Procedure
Counterbalance
 Disconnect the hydraulic lines to the
Accumulator
accumulators and drain them of all hydraulic
fluid.
 With the hydraulic system shut down, and
the counterbalance mode valve in the shut
down position, test the hydraulic pressure at
CB, SA and C4 on the hydraulic manifold,
mounted to the transmission housing. Verify
that all three points measure 0 psi.
Upper IBOP
i Note that there is a time delay in pressure
decay on port C4.
Time- Delay
Accumulator
 Test the precharge pressure on the following
three nitrogen filled accumulators, using part
number 114446-1.

Hydraulic
System Manifold
Varco Part Number
Accumulator (Reference)
114446-1

Front

Rear

8-14 Varco Systems


Hydraulic System

Inspection
IBOP timing circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 4.00" Stroke
1.750" Dia. Rod

Open Test Point Typical


Close

Hydraulic Cylinder

CR

LODC 30 PSI

2 CXCD 1 Time-Delay
1
T-13A Accumulator
30 Cubic Inches
Logic Cartridge 800 PSI Precharge
3 2

50 PSI
CP T-11A VR
Gas Charged
Accumulator
(Small)
-6

-6

A4 B4

A4 B4

IBOP Close Solenoid


-6

-6

(Solenoid Valve 4)
Double Solenoid Valve IBOP Close

Cable ID
Number A B
b
C04
P T
-6

-6
-6

A4 SV4 B4 C4 Manifold Assembly


.055
D03

500 PSI CV4


D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
.010

2 3 8
PC4

System
Tank
Pressure

TDS-11SA 8-15
Hydraulic System

Inspection
IBOP and oil pressure switch

Hoses
Inspect for wear
or damage.
Replace yearly
or as required.
Yearly

IBOP Pressure Switch Oil Pressure Switch


Configuration Configuration

Pressure
Adjusting Screw

Yearly
Wires
Inspect for wear
Switch Pressure Settings or lose connections.

Component Setting
8
IBOP Pressure Switch Factory preset at 102.0 BAR (1500 psi) rising
+0
Oil Pressure Switch Factory preset at 18.0 -1.0 psi decreasing

8-16 Varco Systems


Hydraulic System

Setting up the circuits


Hydraulic pumps and unloading circuit
There are two pumps a fixed displacement pump runs the
transmission lubrication system and a variable displacement pump
provides hydraulic flow to the hydraulic system.

Guide Beam Pump/Motor

Pump Pressure
Compensator
Adjustment Point

8
Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump

TDS-11SA 8-17
Hydraulic System

Setting up the circuits


Fixed displacement (lube) and variable displacement
pumps
1. Jog-start the electric motor to make sure the direction of
rotation is correct (clockwise when looking into pump shaft/
electric motor fan). Correct as required.

2. Start the electric motor and allow both hydraulic pumps to


circulate oil. Listen for unusual noises that would indicate
cavitation; check for leaks.

3. Locate the tube connecting manifold port PF to the lubrication


motor. Disconnect the tube at the manifold end, cap the tube
and plug the PF port using steel fittings.

4. Set the relief valve RV1 for the variable displacement pump to
a minimum setting, fully counterclockwise, which allows the
hydraulic system to operate without building up pressure.

5. Set the relief valve RV2 to minimum pressure, fully


counterclockwise.

i Make sure the variable displacement pump case is filled with clean
hydraulic oil.

6. Connect a gauge to test point PF. Increase the pressure by


adjusting relief valve RV2 clockwise until the pressure
increases to 400 psi at test point PF. Set the jam nut on RV2.
A steel cap is installed over the adjustment screw to
discourage unauthorized adjustment.

i While adjusting valves, verify a linear relationship between turning


the adjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between


manifold port PF and the lubrication motor.

8. Connect an ammeter to the electric motor. Note the full-load


8
amps on the motor nameplate.

9. Restart the hydraulic system electric motor.

10. Set the counterbalance mode valve to the RUN position.

11. Adjust UV1, fully clockwise, to maximum pressure.

8-18 Varco Systems


Hydraulic System

Setting up the circuits


Fixed displacement (lube) and variable displacement
pumps
12. Connect a gauge to test point PV. Note the ammeter reading
while RV1 is at minimum setting.

13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a
steady rate. During the pressure rise, observe the ammeter. The
motor current should rise to a maximum value at 800 psi, then
drop off and begin to rise again. The point where the current
drops is the pump pressure compensator setpoint.

14. Adjust relief valve RV1 to its minimum setting. If maximum motor
current does not occur at 800 psi, adjust the pump pressure
compensator as required.

15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.

16. Connect a gauge to test point SA, and leave the gauge on PV.

17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.

18. Install steel cap over the adjustment screw to discourage


unauthorized adjustment.

19. Adjust unloading valve UV1 counterclockwise until the pressure


at PV drops off, then an additional two turns counterclockwise.
The pressure cycles like a sawtooth wave.

3000 Pressure at PV
Pressure at SA

2000

Pressure 1700
(psi)

1000
800 8

150

0 10 20 30 40 50 60
Approximate Time
(seconds)

TDS-11SA 8-19
Hydraulic System

Setting up the circuits


Fixed displacement (lube) and variable displacement
pumps
20. Observe the unloaded pressure at PV (about 0 psi) while SA
reads about 2,000 psi. The pressure at SA decays until UV1
reloads. After reloading, the pressure rapidly rises to the unload
pressure.

21. Observe several unload-reload cycles to determine the unload


pressure.

22. Adjust the setting of UV1 as required to a 2,000 psi unload


pressure.

! Perform the adjustment with reasonable speed. The process


takes no longer than two minutes. Taking longer increases the
temperature of the hydraulic fluid.

23. Observe the cycle of loading and unloading of the relief valve.
To verify the setting of UV1, note the difference in pump noise
level between the loaded and unloaded condition.

RV2 RV1
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A2 B2

Manifold
Side View

Manifold
Bottom View B6 A6 DR Z1

TF
B5 B4
B5 C5 B9
TR
T1

SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5
C4
B8
PF

RIG-UP

G5 SV4 PF

8
COUNTERB NCE MODE
RUN

P/N 0181

PV MV
SHUTDOWN
DF

PF

8-20 Varco Systems


Hydraulic System

Setting up the circuits


Fixed displacement (lube) and variable displacement
pumps

Manifold Assembly

UV1
2200 PSI
2 T-10A
RV2
3
T-11A
1
Z1
1 2 400 PSI

RV1
PV PF

800 PSIG

Pump-Motor
Assembly
B

1.00 IN^ 3/REV.


L

1.10 IN^ 3/REV. MAX.


.50 IN^ 3/REV. MIN.

L1
S

TDS-11SA 8-21
Hydraulic System

Setting up the circuits


Counterbalance circuit and stand-jump circuit
1. For the counterbalance circuit there are three adjustments:
Relief valve (on counterbalance cylinder)
PCC operator set
SJR operator set

2. To set the relief valve, make sure the pumps are operating.

3. Adjust pressure reducing valve PCC to the maximum setting,


fully clockwise.

4. Connect a gauge to test port CB.

5. Adjust the cylinder-mounted relief valve to mid-scale to lower


the pressure setting.

6. Increase the pressure clockwise using a 5/32 in. Allen wrench


and 9/16 in. open-end wrench.

7. Observe the relationship of turning the relief valve adjustment


clockwise to pressure increase.

8. When the relief valve reaches system pressure, turn the


setting one full turn clockwise beyond the setting and set the
jam nut.

9. Install a steel cover over the valve.

10. Adjust PCC to 1,200 psi.

11. Measure pressure at test port CB.

12. Prepare the hardware to attach the cylinder pear links to the
hook.

13. Rotate the counterbalance mode valve from the RUN position
to RIG-UP position. This causes the counterbalance cylinders
to slowly extend.

8
! Cylinders stroke to the end of stroke with the mode valve in
the RUN position.

8-22 Varco Systems


Hydraulic System

Setting up the circuits


Counterbalance circuit and stand-jump circuit
14. Once cylinders reach end of stroke, attach hardware to the pear
links on the hook.

15. Rotate the counterbalance mode valve back to the RUN


position.

16. Adjust PCC counterclockwise to raise the pressure at test port


CB until the rail just begins to lift off of the hook.

17. Reduce the pressure slowly (25 psi) to allow the pressure to
stabilize.

18. Rotate the counterbalance mode valve to the SHUTDOWN


position to bleed down counterbalance cylinders and system
accumulator before shipping or performing maintenance.

19. Adjust pressure reducing valve PCC counterclockwise until the


bail rests on the hook. Note the pressure at CB.

20. Reduce PCC an additional 25 psi. The pressure at CB is about


1,600 psi.

21. Connect a gauge to test point B9. Activate the STAND JUMP
mode on the drilling console. Adjust relief valve SJR until the
bail lifts off the hook. The gauge at B9 should read about 190
psi.

22. Switch back to DRILL counterbalance mode and observe the


pressure at test point CB.

23. Switch back to STAND JUMP mode and observe the pressure
CB increase by 190 psi.

TDS-11SA 8-23
Hydraulic System

Setting up the circuits


Counterbalance circuit and stand-jump circuit
PCC
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A2 B2

Manifold
Side View

Manifold
Bottom View B6 A6 DR Z1
Manifold

P
TF
B5
End View
B5 C5 B4
B9

CTR

SA
TR
T1

SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5

CB

SA
C4
B8
PF

UV1
RIG-UP

G5 SV4 PF

COUNTERB NCE MODE

1
RUN

P/N 0181

XC
PV MV
SHUTDOWN
DF

CB

8-24 Varco Systems


Hydraulic System

Setting up the circuits


Counterbalance circuit and stand-jump circuit
Pressure 2500 PSI
Relief Valve T-3A 1

-4 2
ZC CP
OR1 OR2
CP -12
.075 .075

75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T

-12 Counterbalance
Normally-Open Accumulator
T
.010 Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16

5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047

Counterbalance Mode Stand


Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6

3 Position D03 MV .055 CB SV9 Manifold Assembly


Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
1600 PSI
SJR
PCC 4
T-13A 2 190 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1

TF
System Pressure 8
T-5A CTF
30 PSI

SA To Tank

TDS-11SA 8-25
Hydraulic System

Setting up the circuits


AC motor brake circuit
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 1,400 psi. The pressure reducing valve
regulates the pressure to 1,400 psi. The solenoid valve operates to
apply pressure, setting the brakes, or stop pressure to release the
brakes.

To test the system, turn the auto brakes switch on the drillers
console to the ON position. Attach a pressure gauge to B1 in the
manifold. The pressure reading should be 1,400 psi. If the reading
is not 1,400 psi, adjust the pressure control reducing valve PC 1 to
1,400. Turn the auto brakes switch to the OFF position. The
pressure reading should be very low. If the pressure is high, the
solenoid valve might be sticking.
RV2
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A2 B2

Manifold
Side View

Manifold
Bottom View B6 A6 DR Z1

TF
B5 B4
B5 C5 B9
TR
T1

SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5
C4
B8
PF

RIG-UP

G5 SV4 PF
COUNTERB NCE MODE
RUN

P/N 0181

PV MV
SHUTDOWN
DF

B1

8-26 Varco Systems


Hydraulic System

Setting up the circuits


Shot pin circuit
1. Set the adjustable relief valve near the body of the cylinder.
The shot pin often misses the hole in the rotating gear. The
force the shot pin exerts is limited until the pin engages a
hole.

i The electrical system jogs the rotating head until the pin engages a
hole.

2. To limit the amount of force, you set the valve by operating


solenoid valve SV5 manually, forcing the pin to stop on the
face of the gear.

3. When the pin stalls out, measure the pressure at B5. Set the
relief valve pressure to 200 psi.

4. Tighten the jam nut on the relief valve.

5. At rest, the SV5 valve is de-energized.

6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi.

Hydraulic
Drive Motor
SV5

C5

Link Adapter
Rotation Gear

Hydraulic Manifold

Shot Pin
(As Viewed from Below)

(Simplified for Clarity) 8

TDS-11SA 8-27
Hydraulic System

Setting up the circuits

Rotating Link Adapter


Drive Motor and
Shot Pin Assembly

10 HP AC Motor
and Pump Assembly

(Simplified for Clarity) Hydraulic


Drive Motor

Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin Relief Valve
B5
Adapter Relief Valve

C5

Link Adapter
A5
Rotation Gear

Shot Pin

8-28 Varco Systems


Hydraulic System

Setting up the circuits


Link tilt cylinder circuit
1. There is nothing to adjust on the manifold for the link tilt
circuit.

2. Adjust the four load holding valves in pairs the upper pair
and lower pair. Adjust all four counterbalance valves fully
clockwise, then one turn counterclockwise.

i If the valves are not adjusted correctly, link tilt operation is not
synchronized.

3. The correct pressure setting is 1,500 psi. The procedure is the


same for all four valves. Adjust the valves one at a time.

4. There is a test point on each loading manifold.

5. From the drillers console, move the link tilt to go to the


mousehole position.

6. The cylinder goes to full extension and the pressure at the test
port TP is 2,000 psi.

7. Command the link tilt to the OFF position and observe the
pressure delay at TP. This delayed pressure is the setpoint of
the counterbalance valve.

8. Raise the valve setpoint by turning the adjusting screw 1/4


turn counterclockwise.

9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

i This is an iterative process. Continue to set the drillers console


control to the mousehole position and OFF, taking present and
decayed pressure readings.

! Turning the counterbalance valve counterclockwise increases


the pressure.
8

10. Repeat the procedure above for the other cylinder at the
mousehole position.

11. Command the link tilt to the DRILL position and repeat the
procedure above to set both counterbalance valves on the
DRILL side.

TDS-11SA 8-29
Hydraulic System

Setting up the circuits


Rotating link adapter hydraulic motor relief circuit
1. Set the relief valves mounted on rotation motor.

2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.

3. Turn the manual override on the SV2-rotation circuit to drive the


head in the counterclockwise direction. Test the pressure at A
and adjust the relief valve to 1,600 psi.

4. Turn the manual override on the SV2-rotation circuit to drive the


rotating head in the clockwise direction and test the pressure at
B. Adjust the relief valve to 1,600 psi.

Hydraulic
Drive Motor Relief
Valves

Manifold

Link Adapter
Rotation Gear

Test
Points

(Simplified for Clarity)

8-30 Varco Systems


Hydraulic System

Troubleshooting
HPU and reservoir bladder
Problem Probable cause Remedy

Hydraulic system Relief valves RV1 and RV2 out of adjustment. Test pressures and adjust relief valves.
overheating
Unloading valve is not working. Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down Check system pressure.


position too long and pressure bleeds down.

No precharge in system accumulator. Charge system accumulator.

Hydraulic components System pressure is down. Test pumps and motors. Test relief valve
do not operate. pressures. Adjust as required. Check for leaks,
loose fittings, loose cylinders, worn hoses,
fluid levels and seals.

Piston pump is not working. Replace the piston pump.

Flexible coupling is damaged. Replace the flexible coupling.

Lubrication pump is not working. Replace the lubrication pump.

Pressure at UV1 is too low. Adjust pressure at UV1.

Pumps are rotating in the wrong direction. Inspect hydraulic connections and
correct rotation.

Suction valve closed. Open suction valve.

Low oil level in reservoir. Fill hydraulic reservoir.

TDS-11SA 8-31
Hydraulic System

Troubleshooting
HPU and reservoir bladder schematic diagram

PV PF TR DR Manifold Assembly

Hydraulic Fill
Disconnect
System
Pressure

6m

50 PSID

Prefill Valve
Pressure -12
Compensator T
Filter with
Control Bypass
T -16
800 PSIG Valve
-6
XC

B
1.00 In^ 3/Rev.
L

1.10 In^ 3/Rev. Max.


M .50 In^ 3/Rev. Min.

10 HP
1800 RPM 4 PSI
L1 Filter Vent
S
(Strainer)

Variable Fixed
Displacement Displacement
Pump Pump

Reservoir Assembly

8-32 Varco Systems


Hydraulic System

Troubleshooting
Counterbalance and stand jump
The accumulator, with precharge pressure of 900 psi, along with
check valve CV3, maintains a hydraulic pressure. Refer to the
vendor documentation material located in the Vendor
Documentation Package, for the gas charging procedure for the
accumulator.

A three-position manually operated valve controls counterbalance


operation for rig-up, run, and shut down modes. In the rig-up mode,
system pressure is applied to XC and the prefill valve, causing both
cylinders to extend. When the cylinders extend, you make up the
mechanical connection to the bail. In the run mode, for
counterbalance operation, approximately 1,600 psi is needed at the
counterbalance cylinders to lift the TDS-11SA off the hook.

The optional stand jump feature is controlled by solenoid valve


SV9. With the counterbalance in the run mode and the stand jump
switch on, additional pressure of approximately 300 psi is applied
to over the normal counterbalance pressure to lift the TDS-11SA
and drill string off the hook.

In the shutdown mode, the hydraulic system bleeds down the


system accumulator and the counterbalance accumulator pressure.

Counterbalance testing
For the counterbalance operation, a lift of approximately 30,000 lb
is achieved with a pressure of 1600 psi at CB. Perform the
following steps to adjust the force:

1. Set the counterbalance mode valve on the bottom of the


manifold to the RUN mode. Set the pressure control valve
PCC to the minimum setting (fully counterclockwise).

2. Test the pressure at port B9. There should be a 0 psi reading.

3. Test the pressure at port CB. Observe the position of the top
drive on the hook.

4. Adjust the pressure at pressure control valve PCC clockwise,


observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on
the hook. 8

TDS-11SA 8-33
Hydraulic System

Troubleshooting
Stand jump testing
For the optional stand jump feature, a lift of about 33,000 lb is
achieved with a pressure of approximately 1800 psi at CB. The
additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve
SV9. Perform the following steps to adjust the pressure:

1. Set the counterbalance mode switch to RUN and engage the


stand jump switch. Test the pressure at port CB and B9. Adjust
relief valve SJR fully counterclockwise to the minimum setting.

2. Slowly increase the pressure at CB by adjusting relief valve SJR


clockwise until the bail lifts off the hook with a stand of pipe in
the elevator.

i Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

8-34 Varco Systems


Hydraulic System

Troubleshooting
Problem Probable cause Remedy

Counterbalance does not Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.
function.
No hydraulic pressure. Test pressure and ajust pressure reducing valve.

Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on the accumulator is low. Charge the accumulator.


Stand jump does not
function. Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.

No hydraulic pressure. Test pressure and adjust pressure


reducing valve.

Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on the accumulator is low. Charge the accumulator.

TDS-11SA 8-35
Hydraulic System

Troubleshooting
Counterbalance and stand jump schematic diagram

Pressure 2500 PSI


Relief Valve T-3A 1

-4 2
ZC CP
OR1 OR2
CP -12
.075 .075

75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T

-12 Counterbalance
Normally-Open Accumulator
T
.010 Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16

5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047

Counterbalance Mode Stand


Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6

3 Position D03 MV .055 CB SV9 Manifold Assembly


Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
1600 PSI
SJR
PCC 4
T-13A 2 190 PSI
T-21A
System DF 2 3
8 Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI

SA To Tank

8-36 Varco Systems


Hydraulic System

Troubleshooting
Troubleshooting the brakes
Problem Probable cause Remedy

Brake does not release. Directional valve is stuck. Test the valve and replace if necessary.

Brake releases but still drags. Check valve is blocked or tube is pinched. Replace the check valve or tube as required.

Mechanical problems with brakes. Repair brake mechanism.

Brakes do not engage or slip. Hydraulic oil on brake pads. Check for hydraulic leaks and repair.

Pressure is not 1,400 psi or does not rise Reducing valve is plugged or needs to be
crisply to 1,400 psi. adjusted or replaced.

Directional valve is stuck Replace valve or check electrical signal.


(check pressure at B1).

Delay in brakes actuating Hydraulic oil is contaminated. Replace hydraulic oil.


after console switch is
turned on. Pressured reducing valve is faulty. Replace valve.

TDS-11SA 8-37
Hydraulic System

Brake circuit schematic diagram


Brake Calipers

2 Position
Solenoid Valve
Brakes On

Cable ID
Number
A B

b
C01

P T -4

SV1 B1 Manifold Assembly


.071
D03
Non-Adjustable
Orifice

P1
Test Point

1400 PSI

PC1 1 T-11A

Reducing 2 3
8 Valve

System Tank Drain


Pressure

8-38 Varco Systems


Hydraulic System

Troubleshooting
Shot pin cylinder and clamp cylinder
Problem Probable cause Remedy

Shot pin does not engage. Solenoid valve is not operating or relief valve Check electrical actuation and test pressure.
is not adjusted. Adjust as required.

Abnormal pressure change at B5 and C5 Replace directional control valve.


indicates valve problem.

Normal pressure change indicates plumbing Repair plumbing or shot pin cylinder.
or shot pin cylinder are faulty.

Shot pin applies Relief valve is not operating or Test pressures and adjust as required.
excessive force to out of adjustment.
rotating head gear.

Clamp cylinder does No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.
not actuate.
Cylinder is damaged. Inspect cylinder and repair or replace.

To provide high pressure to the clamp circuit, Repair plumbing, rotating head, or clamp cylinder.
i pressure at C5 must be 2,000 psi and G5 must
be less than 100 psi. If this condition is met,
pressure at CP should increase from less than
100 psi to higher than 2,000 psi. If not, check
the plumbing, rotating link adapter, and
clamp cylinder.

While clamping, pressure at CR should be Clean or repair CNEC valve.


2.7 times the pressure at CP. When the dies
contact the pipe, pressure at CR should be
less than 100 psi. If the pressure does not
fade, check valve CNEC for contamination.

Shot pin engages Control valve not operating. Check pressure at C5. Replace valve CV5
but clamp cylinder if required or the regenerate manifold.
does not activate.

TDS-11SA 8-39
Hydraulic System

Troubleshooting
Shot pin cylinder and clamp cylinder schematic diagram
Clamp Cylinder
10.000" Dia. Bore X 2.0" Stroke
8.000" Dia. Rod

Hydraulic Cylinder

Cavity Plug CP CR

1 3
Pilot-to-Close CKEB
T-2A
Check Valve 2

30 PSID
2 1
CNEC
Shot-Pin Cylinder 3 T-2A
2.000" Dia. Bore X 2.31" Stroke 1 T-5A
Relief Valve 1.500" Dia. Rod COFA
.047
2 400 PSI 2 30 PSID
Shot Pin
Cylinder 2x .094 2
VP VR

1
2 Position
T-10A Non-Adjustable
Solenoid
B5 C5 Flow Control
Valve 5
Clamp/Shot Pin
-8

-8
Clamp
E5 G5

Cable ID Rotating Link


A B
Number b E5 G5 Adapter Assembly
C05
-8

-8

P T
-6

-6

A5 SV5 .039 B5 C5 E5 G5
D03
Pressure
.159 .031 T-11A 1
50 PSI .031 Reducing
3 AR5 Valve
3
1 2
LC5 2
Logic .031 500 PSI
T-11A
Cartridge
Externally-Drained
Pilot-to-Open
3 2 Valve
T-21A
4 75 PSI
CV5 1
P5
Drain 1
T-11A 3
System Pressure
PC5 2
8 Tank Drain

System Pressure

Tank

T1 T1 D5 Manifold Assembly

8-40 Varco Systems


Hydraulic System

Troubleshooting
Link tilt cylinders
Problem Probable cause Remedy

Drill pipe elevator does Link clamp incorrectly adjusted. Readjust


not reach mouse hole/
derrickman position.

Links drift when Pressure at B8 does not decay to Replace the pilot to open check valve.
valve is released. less than 100 psi.

Pilot to open check valve is stuck open Replace the pilot to open check valve.
or contaminated.

Faulty cylinder seal. Replace the seal.

Load holding relief valves are out of Adjust or replace the load holding relief valve.
adjustment, stuck open, or contaminated.

Drill pipe elevator Use manual override. If the link tilts, the Test the solenoid and connectors.
does not float back problem is electrical. If the links do not tilt, Test the hydraulic system.
to center position. the problem is hydraulic.

Link tilt does not tilt. Solenoid valve is not shifting. Check electrical continuity.

Links do not move Load holding valves are out of adjustment. Adjust the pressure for all four valves
together. to 1,500 psi.

TDS-11SA 8-41
Hydraulic System

Troubleshooting
Link tilt cylinders schematic diagram

Link Tilt Cylinder


3.250" Dia. Bore X 10.3" Stroke
1.380" Dia. Rod

Mousehole
Drill Down

C1 C1 C1 X1 C2 C2 C2

1500 PSI T-11A 1500 PSI T-11A


CV1
T-11A 1 CB1 1 CB2
1 CV2 1 X2
3 3 T-11A 3 3
2 2 2 2
V1 V2

V1 V2
FL
-6

-6

-8

-8

-8

-8

X -8

X -8
X

X
B8 B8 E6 E6 G6 G6 H J

B8 E6 G6 H J

-8 X

-8 X
-8

-8

Rotating Link -8
Adapter Assembly

Link Tilt Link Tilt Link Tilt


"Float" Solenoid "Drill Down" Solenoid "Tilt" Solenoid
(Solenoid Valve 8) (Solenoid Valve 6) (Solenoid Valve 6)

Link-Tilt Float Link Tilt


Cable ID
A B A B Logic
Number b b a Cartridge
C08 C07 C06
P T Drill Down P T M'hole
-6

-8

-8

SV8 D03 B8 E6 .031 .031 SV6 D03 .031 G6


Logic
Cartridge LA6 T-11A .071
.031
75 PSI B6
1 2
50 PSI 2 3 T-11A
4 3
CA6 1
8 3 1 T-21A
.071
.031 50 PSI 2
A6
LB6 2
4 3
1
Pressure
CB6 75 PSI
Tank T-21A

A8 D1 Manifold Assembly
X

8-42 Varco Systems


Hydraulic System

Troubleshooting
Gearbox lubrication hydraulic system
Problem Probable cause Remedy

Oil leaking from lower seal. Worn oil seals. Replace seals.

Oil leaking from upper Worn oil seals. Replace seals.


bearing retainer.

Gearbox oil temperature Oil level too low or too high. Adjust oil level to middle of sight glass.
(less than 230F).
Incorrect lubricant used. Check recommended lubricants chart
and replace as needed.

Damaged gears or bearings. Repair or replace as needed.

Oil pump loss alarm is on. Oil level is too low. Oil overheated. Add oil.

Oil pressure switch is out of adjustment. Adjust per page 8-16.

Gear spray nozzle missing. Replace spray nozzle.

Excessive oil viscosity. Lower oil viscosity.

Faulty motor. Intermittent operation. Replace motor.

Oil pump hydraulic motor failure. Replace motor.

Broken lube pump adapter plate spline. Replace adapter plate spline.

Faulty fixed displacement pump. Check pressure at PF.


Replace pump if pressure is low.

Low hydraulic fluid in reservoir. Add hydraulic fluid.

Suction valve closed on fixed displacement pump. Open suction valve.

Water/mud in oil. Missing inspection plugs. Replace inspection plugs.

Upper gearbox seals worn. Replace seals.

Excessive foaming. Water in oil. Replace oil.

Excessively viscous oil. Cold oil. Lower oil viscosity.


8

Metal in oil. Worn gears or damaged bearings. Replace gears or bearings.

Damaged oil pump. Replace oil pump.

Restricted oil flow. Foreign particles blocking orifice or nozzle. Clean orifice or nozzle.

TDS-11SA 8-43
Hydraulic System

Troubleshooting
Gearbox lubrication hydraulic system schematic
diagram
Pressure Spray
Switch Nozzles (4) Orifices (6)

S04 18 PSI
Decreasing

-16
1.0 1.5 .062 .205 .059 .059 .047 .047 L4
GPM GPM
Ea. Ea.
Upper Lower Upper Lower Upper Lower
Compound Compound Mainshaft Radial/Main Compound Compound
Gear Gear Bearing Thrust Bearing Bearing
Bearings

Lube-Oil
Filter
Lube Pump 5.10 In.^ 3/Rev. 60m

L1 -16
Lube-Oil Pump

-10
A B
Tank
-10
3.0 In.^ 3/Rev.

Lube Pump Motor

Hydraulic Hydraulic
Motor Heat Exchanger

Tank

2 T-10A
RV2

400 PSI

Manifold PF

1.00 IN^ 3/REV.


8
Part of
Pump Motor
Assembly Reservoir
Assembly

8-44 Varco Systems


Hydraulic System

Troubleshooting
Problem Probable cause Remedy

Tool does not rotate. Direct control valve or relief valve is sticking. Inspect, repair or replace the valve.

When you override a directional valve, you


bypass the safety interlock and top drive
components move, possibly causing serious
injury or death.

Solenoid valve is not electrically operating. Check electrical connections and valve functions.

Motor is worn out or gear teeth are broken. Replace the motor.

Shot pin is engaged. Adjust the relief valve.

Mechanical interference. Inspect and repair.

Directional valve does not shift. Test pressure left and right. Replace the valve.

Fixed valve orifice is plugged. Clear orifice or replace the valve.

Hydraulic lines are damaged. Replace hydraulic lines.

Tool does not return Valve is sticking or relief valve is Test pressures and inspect valves.
to home position. out of adjustment. Adjust the relief valve as required.

Sensor is broken. Replace sensor.

If the motor will drive normally, but not drive Checkout control system.
to the home position, the cause could be
the control system.

Links are not Counterbalance valves are out of adjustment. Adjust valves together-pressure is the same
synchronized. for all four valves.

TDS-11SA 8-45
Hydraulic System

Troubleshooting
Rotating link adapter motor schematic diagram

Rotating Head Motor

A B

Fixed
Displacement
Motor

1 2
Pressure
Relief Valves
T-10A 1600 PSI

1600 PSI T-10A

2 1

A B

Rotate Left Rotating Head Rotate Right


Solenoid Solenoid

Cable ID A B Cable ID
Number Number
b a
C03 C02
Left P T Right
-6

-6

A2 SV2 B2 Manifold
Assembly
8 .071 D03

Non-Adjustable Pressure Tank 3 Position


Orifice Solenoid Valve

8-46 Varco Systems


Hydraulic System

Troubleshooting
IBOP actuator schematic diagram
IBOP Actuator Cylinder
2.500" Dia. Bore X 4.00" Stroke
1.750" Dia. Rod

Open Test Point Typical


Close

Hydraulic Cylinder

CR

LODC 30 PSI

2 CXCD 1 Time-Delay
1
T-13A Accumulator
30 Cubic Inches
Logic Cartridge 800 PSI Precharge
3 2

50 PSI
CP T-11A VR
Gas Charged
Accumulator
(Small)
-6

-6

A4 B4

A4 B4

IBOP Close Solenoid


-6

-6

(Solenoid Valve 4)
Double Solenoid Valve IBOP Close

Cable ID
Number A B
b
C04
P T
-6

-6
-6

A4 SV4 B4 C4 Manifold Assembly


.055
D03

500 PSI CV4


D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
.010

2 3 8
PC4

System
Tank
Pressure

TDS-11SA 8-47
Hydraulic System

Hydraulic schematic symbols


The following hydraulic troubleshooting section provides a
schematic diagram and description for each TDS-11SA hydraulic
circuit. Following each schematic is a group of troubleshooting
charts to help you quickly locate and correct hydraulic system
problems.

When performing hydraulic troubleshooting, be aware that:

The electrical control system can be bypassed for


troubleshooting by manually overriding the solenoid valve for
each operational system.

Alert all personnel near the top drive before overriding


a solenoid valve. When you override a solenoid valve,
you bypass the safety interlock and top drive
components will move possibly causing serious injury
or death.

Test points shown in the hydraulic schematic with a box (e.g.,


A4) can be found on the manifold under the main body. There
are also test points on the rotating link adapter motor.

The system is preadjusted. Hydraulic problems are usually


related to faulty valves, contamination, or other damage to the
system rather than misadjustments. Changes to adjustments
should be made only after all other possible causes have been
eliminated.

8-48 Varco Systems


Hydraulic System

Hydraulic schematic symbols


Description Symbol Schematic Reference

2 Position 4 Way Valves


SV1, SV4, SV5, SV8, SV9
(Single Solenoid)
Solenoid
33-1
Operated
Valves
3 Position 4 Way Valves
(Double Solenoid) SV2, SV6

33-2

Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3

Fixed Displacement

33-4
Pumps

Variable Displacement

33-5

Standard Valve RV2, A2R, B2R, SJR

33-6

Pressure
Relief Ventable Relief Valve RV1
Valves
33-7

Differential Unloading Valve UV1

33-8

Pressure Reducing Valve PC1, PC4

33-9

Pressure Reducing/Relieving Valve PCC

33-10
8
CDF, CTF, CV2, CTR,
Chack Valve CDR, CXCD
Prefill valve assembly
33-11
CV1, CV2

TDS-11SA 8-49
Hydraulic System

Hydraulic schematic symbols


Description Symbol Schematic Reference

Pilot-To-Open CKCB (Link Tilt)


Check 33-12
Valves
CA6, CB6, CV3, CV4
Pilot-To-Close
(Clamp Body)
33-13

1
3
Cavity Plug PC5
2
33-14

Internal Plug

33-15

Non Adjustable Flow Control Valves CV1

33-16

Non Adjustable Orifice Diameter in inches

33-17

3 Port (Internal Drain) CBCA (Link Tilt Circuit)


Counter-
33-18
balance
Valves
4 Port (External Drain) CWCK (Link Tilt Circuit)

33-19

Standard Cartridge LA6, LB6, LC5, LODC

Logic 33-20

Cartridge

With Metering See Prefill Assembly

8 33-21

Quick Disconnect Coupling

33-22

8-50 Varco Systems


Hydraulic System

Hydraulic schematic symbols


Description Symbol Schematic Reference

Non Bypass Filter See Lube Oil Circuit

33-23

Filter with Bypass See Return Circuit

33-24

Manual Shutoff Valve

33-25

Thermostat Lube Oil Circuit

33-26

Pressure Switch Lube Oil Circuit

33-27

Heat Exchanger Hydraulic Circuit


(Inside Brake Housing)
33-28

Pressure Compensator Control Part of the Pump

33-29

Hydro-Pneumatic Accumulator
33-30

Hydraulic Motor (Bi-Directional)

33-31

Hydraulic Cylinder
33-32

Tank (Reservoir) 8
33-33

Test Point
33-34

TDS-11SA 8-51
Hydraulic System

8-52 Varco Systems


March 11, 1998

2 Technical Drawing Package: TDS-11S EX2


Contents
Technical Drawings
Drawing list (assembly order).............................................. 5
Drawing list (numeric order) .............................................. 7

Technical Drawing Package: TDS-11S EX2 3


March 11, 1998

4 Technical Drawing Package: TDS-11S EX2


Technical Drawings

Drawing list (assembly order)

General
General Arrangement ....................................................... 121767
Electrical System Schematic with IS VDC ....................... 122433
Hydraulic Schematic ........................................................ 109550
Software Package .............................................................. 116282
Siemens Parameters Drive ................................................ 123096
Electrical Package ............................................................. 122785
Hydraulic Kit ................................................................... 121403

Top Drive
Motor Housing/Carriage Assembly .................................. 120900
Counterbalance Package .................................................. 112190
S-Pipe Package ................................................................. 120037

Technical Drawing Package: TDS-11S EX2 5


March 11, 1998

Pipe Handling
Pipe Handler Package, PH-50 .......................................... 117820
Pipe Handler Kit, PH-50 ................................................. 119054
PH-50 Tool Joint Adapter Kit .......................................... 122747

Cabling
VDC Cable Kit ................................................................ 117367
Incoming Power Cable Kit ............................................... 114735
Termination Kit ............................................................... 121506

Control System
Control House Assembly ................................................. 118412
Filter/Regulator Kit for VDC Z-Purge ............................... 88550
Drillers Recorder Transducer Kit ....................................... 85836

Rigging
Padeye, Guide Beam Support ........................................... 106046
Traveling Equipment Attachment Kit .............................. 118244

Auxiliary Equipment
Fluids/Lubrication Kit ....................................................... 92643
Ground Rod Kit .............................................................. 116004
Service Loop Tub ............................................................. 108684
Elevator Links, 2 3/4 Weldless ........................................... 26940
Elevator Links, 3 1/2 Weldless ........................................... 25469
Oil Field Skid .................................................................. 117211
Master Bushing ID Wear Guide ......................................... 85974
Wireline Adapter .............................................................. 114032
Swivel Adapter, 350 Ton .................................................... 89737
Connector Kit .................................................................. 114738

6 Technical Drawing Package: TDS-11S EX2


Drawing list (numeric order)
Elevator Links, 3 1/2 Weldless ........................................... 25469
Elevator Links, 2 3/4 Weldless ........................................... 26940
Drillers Recorder Transducer Kit ....................................... 85836
Master Bushing ID Wear Guide ......................................... 85974
Filter/Regulator Kit for VDC Z-Purge ............................... 88550
Swivel Adapter, 350 Ton .................................................... 89737
Fluids/Lubrication Kit ....................................................... 92643
Padeye, Guide Beam Support ........................................... 106046
Service Loop Tub ............................................................. 108684
Hydraulic Schematic ........................................................ 109550
Counterbalance Package .................................................. 112190
Wireline Adapter.............................................................. 114032
Incoming Power Cable Kit ............................................... 114735
Connector Kit.................................................................. 114738
Ground Rod Kit .............................................................. 116004
Software Package .............................................................. 116282
Oil Field Skid .................................................................. 117211
VDC Cable Kit ................................................................ 117367
Pipe Handler Package, PH-50 .......................................... 117820
Traveling Equipment Attachment Kit .............................. 118244
Control House Assembly ................................................. 118412
Pipe Handler Kit, PH-50 ................................................. 119054
S-Pipe Package ................................................................. 120037
Motor Housing/Carriage Assembly .................................. 120900
Hydraulic Kit ................................................................... 121403
Termination Kit ............................................................... 121506
General Arrangement ....................................................... 121767
Electrical System Schematic with IS VDC ....................... 122433
PH-50 Tool Joint Adapter Kit .......................................... 122747
Electrical Package ............................................................. 122785
Siemens Parameters Drive ................................................ 123096

Technical Drawing Package: TDS-11S EX2 7


March 11, 1998

8 Technical Drawing Package: TDS-11S EX2

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