Академический Документы
Профессиональный Документы
Культура Документы
T o p D r i v e S y s t e m
Motor Cooling Counterbalance
System System
AC Drilling
Motors (2)
Transmission/
Motor Housing
Electrical
System
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
PH-50
Pipehandler
Specifications 2
Lubrication 3
Installation, Commissioning 4
and Decommissioning
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
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.
The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.
Note
Caution
Warning
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.
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.
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.
Isolate, lock out, and tag the hydraulic and electrical power and
controls.
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.
Isolate, lock out, and tag the pneumatic and electrical power and
controls.
Isolate, lock out, and tag the cooling water and electrical power and
controls.
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.
TDS-11SA
General Information
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.
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
Safety wiring
1 2
1
3 4 5
TDS-11SA 1-5
General Information
Torque values
(Unless otherwise specified)
Basic useage
Drilling ahead with singles
1
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
Start
Circulation
Stop
Circulation
Stab Makeup
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
Hoist and
Rotate
Breakout
TDS-11SA 1-9
General Information
TDS-11SA consumables
Consumables Quantity Part Number Page Ref.
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
Stabilizers
Tong Dies
Stabbing Guide
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
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
Size specifications
Rear
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)
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)
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
AC Power and
AC Cables Control Cables
TDS-11SA 2-5
Specifications
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.
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.
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
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
Hydraulic system
Precautions
Lubrication schedule
Description Frequency
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
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
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
Lubrication schedule
Description No. of Points Frequency Type
Manufacturer
Chevron Black Pearl EP2 (Do Not Substitute)
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)
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
TDS-11SA 3-9
Lubrication
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
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
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
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
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)
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
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
TDS-11SA
Installation, Commissioning
and Decommissioning
Installation, Commissioning
and Decommissioning
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
Connect the incoming power cables (isolation circuit breaker is turned OFF).
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
Make the connection between the control house and derrick service loop using
jumper cables as required, torque the connector and lockwire the connector nuts.
Guide Beam Check the gearbox for proper oil flow. Check the red pop-up dirt alarm.
Top Section
Install the counterbalance system.
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
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
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
Illustrated index
Counterbalance
Page 4-27
Rotary Hose
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
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.
Drawworks fastline
Preinstallation
Installing the crown padeye and hang-off link
Recommended installations
Dimension Description
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
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
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
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
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.
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
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
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
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
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
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
Installation
Completing guide beam installation
Ensure the
Top Drive does
not contact
the rig
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
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
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
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
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
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
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
Installation
Installing the pipe elevator and links
Catch
Link Bolt
Rear
Motor
Guard
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
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
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
Commissioning
Adjusting the link tilt
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
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
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
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
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
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
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
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.
TDS-11SA 4-43
Installation, Commissioning
and Decommissioning
TDS-11SA
Guide Beams
and Carriage
Yearly
2.1"
Crown Padeye (52 mm)
minimum
Monthly
Crown Padeye
Visually inspect weld for cracks
Monthly Shackle
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
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
!
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
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.
Mast Leg
See Installation
for assembly/disassembly
TDS-11SA 5-5
Guide Beams
and Carriage
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 Installation
for assembly/disassembly
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
TDS-11SA 5-7
Guide Beams
and Carriage
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
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
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
4. Let the sled to move freely, allowing the belt tension spring to
apply the proper tension to the belt.
TDS-11SA 6-5
Motor Housing
and Transmission
Sled
Hold-down
Screws
Belt Tension
4 Places
Spring
View from Side
6 Electrical
Connector
Sled
Encoder Belt
Encoder
Sled
Belt Tension Hold-down
Spring Screws
4 Places
1. Drain the gearbox oil and disconnect the hydraulic lines from
the pump assembly
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
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
Gear backlash
Inspection (yearly)
A 6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash
A B
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.
TDS-11SA 6-9
Motor Housing
and Transmission
Wear allowances
Component Replace when
Bail
Yearly
Bushing
2 Places
Yearly
Main Body
5 Years
Bail Pin
2 Places
Yearly
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
TDS-11SA 6-11
Motor Housing
and Transmission
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
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.
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).
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.
10. Install the upper and lower o-rings using grease to hold them
in place.
TDS-11SA 6-13
Motor Housing
and Transmission
Washpipe assembly
Inspection
!
The wash pipe nut and
the packing box have
left-handed threads
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
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
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
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
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
Mainshaft
Inspection
Wear allowances
Component Replace when
Stem
5 Years
0.620
max
Retainer Ring
TDS-11SA 6-17
Motor Housing
and Transmission
Mainshaft
Inspecting mainshaft end play (yearly)
Dial
Indicator
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
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
Caliper
Mounting Steel
6 Bolts Plate
0.09 in.
Min.
Adjust
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
Internal
Retaining Ring
Upper Stem
Compound Gear Liner
Internal
Retaining Ring Poly Pack
Seal
Oil
Spacer Ring Gallery
O-Ring
Lower Compound
Roller Bearing
Tapered Roller
6 Thrust Bearing
Main Body
Main Shaft
Sleeve
Wear Sleeve
Lube Plate
Oil Assembly Bearing
Lock Washer Retainer
Cap Screw
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
Bail
Link adapter
Power swivels
Elevator links
TDS-11SA 6-25
Motor Housing
and Transmission
TDS-11SA
TDS-11SA 7-1
PH-50 Pipehandler
Rotating Link
Adapter
Page 7-25
Link Tilt
Page 7-9
IBOP Actuator
Yoke and Cylinder
Page 7-19
Stabilizer
Page 7-16
7
Stabbing Guide
Page 7-14
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 clamp cylinder gate pins and retainer bolts See page 7-11
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 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:
Elevator links
Disassembly/assembly
1. Disconnect and remove the drill pipe elevator from the
elevator links.
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.
TDS-11SA 7-5
PH-50 Pipehandler
Elevator links
Inspection
Recess in
Motor Guard
Rear
2
Lift and
remove
Link Tilt
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
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
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.
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
TDS-11SA 7-9
PH-50 Pipehandler
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.
12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.
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.
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.
TDS-11SA 7-11
PH-50 Pipehandler
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
Rear Stabilizer
Front Stabilizer
Hinge Pin Spring
Retainer
Cylinder Head Ring Hex Head
Screws
Clamp Cylinder
Body
Body Seals
Cylinder Head
Gate
Wear Bushing
Socket Head
Cap Screws
Hinge Pin
Stabilizer
Retaining Plate
Spring
TDS-11SA 7-13
PH-50 Pipehandler
Tugger
Line
V
A
R
C
O
P
H
5
0
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
TDS-11SA 7-15
PH-50 Pipehandler
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
Wear allowances
Component Replace when
TDS-11SA 7-17
PH-50 Pipehandler
2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.
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.
! Never tighten locking screws before the tool joint lock is at the
correct location, otherwise it will not slide freely.
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.
TDS-11SA 7-19
PH-50 Pipehandler
1.4"
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
Wear allowances
Component Replace when
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
5. Inspect the shot pin bearing and press the bearing out of the
shot pin mounting bracket if the bearing is scored or
damaged.
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
Cover
Wear allowances
Component Replace when
TDS-11SA 7-23
PH-50 Pipehandler
2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.
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.
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.
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.
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
TDS-11SA 7-25
PH-50 Pipehandler
2. Install the gear with its rotating seal and wiper in place.
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.
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.
14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.
6. Install the link tilt crank and pin, and secure in place.
8. Install tubing.
12. Turn on the top drive and perform all pipehandler functions
several times, checking for proper function and any leaks.
! 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
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
Bail
Link adapter
Power subs
Power swivels
Elevator links
7
Details on MPI procedures are in the following publications:
TDS-11SA 7-31
PH-50 Pipehandler
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.
Illustrated index
Specifications
10 HP AC
Motor and
Front Pump Assembly
Page 8-17
Rear
8
TDS-11SA 8-3
Hydraulic System
Link Tilt
Counterbalance Manifold
Accumulator
Rotating Head
(Elevator Positioner)
Rotating
Head Gearbox Lube
Motor Oil Distribution
Counterbalance
Manifold
M
Variable Fixed
10 HP A.C. Displacement Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
8
Reservoir
Inspection
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
8
Read and understand all safety precautions and
warnings before performing maintenance procedures.
TDS-11SA 8-5
Hydraulic System
Inspection
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
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
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
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
Inspection
Hydraulic reservoir bladder (yearly)
Hydraulic Oil
Reservoir
Between AC
Drilling Motors
Reservoir
Breather Reservoir
Cover
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
Inspection
Using the hydraulic system test ports
* 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.
TDS-11SA 8-13
Hydraulic System
Inspection
Precharging the accumulators
Accumulator Setting Port
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
Inspection
IBOP timing circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 4.00" Stroke
1.750" Dia. Rod
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
-6
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
Number A B
b
C04
P T
-6
-6
-6
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
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
Pump Pressure
Compensator
Adjustment Point
8
Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump
TDS-11SA 8-17
Hydraulic System
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.
i Make sure the variable displacement pump case is filled with clean
hydraulic oil.
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.
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
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
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
L1
S
TDS-11SA 8-21
Hydraulic System
2. To set the relief valve, make sure the pumps are operating.
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.
17. Reduce the pressure slowly (25 psi) to allow the pressure to
stabilize.
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.
23. Switch back to STAND JUMP mode and observe the pressure
CB increase by 190 psi.
TDS-11SA 8-23
Hydraulic System
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
1
RUN
P/N 0181
XC
PV MV
SHUTDOWN
DF
CB
-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
TF
System Pressure 8
T-5A CTF
30 PSI
SA To Tank
TDS-11SA 8-25
Hydraulic System
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
i The electrical system jogs the rotating head until the pin engages a
hole.
3. When the pin stalls out, measure the pressure at B5. Set the
relief valve pressure to 200 psi.
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)
TDS-11SA 8-27
Hydraulic System
10 HP AC Motor
and Pump Assembly
Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin Relief Valve
B5
Adapter Relief Valve
C5
Link Adapter
A5
Rotation Gear
Shot Pin
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.
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.
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
2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.
Hydraulic
Drive Motor Relief
Valves
Manifold
Link Adapter
Rotation Gear
Test
Points
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.
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.
Pumps are rotating in the wrong direction. Inspect hydraulic connections and
correct rotation.
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
10 HP
1800 RPM 4 PSI
L1 Filter Vent
S
(Strainer)
Variable Fixed
Displacement Displacement
Pump Pump
Reservoir Assembly
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.
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:
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
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:
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.
Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.
TDS-11SA 8-35
Hydraulic System
Troubleshooting
Counterbalance and stand jump schematic diagram
-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
SA To Tank
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.
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.
TDS-11SA 8-37
Hydraulic System
2 Position
Solenoid Valve
Brakes On
Cable ID
Number
A B
b
C01
P T -4
P1
Test Point
1400 PSI
PC1 1 T-11A
Reducing 2 3
8 Valve
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.
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.
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
-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
Troubleshooting
Link tilt cylinders
Problem Probable cause Remedy
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.
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
Mousehole
Drill Down
C1 C1 C1 X1 C2 C2 C2
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
-8
-8
A8 D1 Manifold Assembly
X
Troubleshooting
Gearbox lubrication hydraulic system
Problem Probable cause Remedy
Oil leaking from lower seal. Worn oil seals. Replace seals.
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.
Oil pump loss alarm is on. Oil level is too low. Oil overheated. Add oil.
Broken lube pump adapter plate spline. Replace adapter plate spline.
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.
Hydraulic Hydraulic
Motor Heat Exchanger
Tank
2 T-10A
RV2
400 PSI
Manifold PF
Troubleshooting
Problem Probable cause Remedy
Tool does not rotate. Direct control valve or relief valve is sticking. Inspect, repair or replace the valve.
Solenoid valve is not electrically operating. Check electrical connections and valve functions.
Motor is worn out or gear teeth are broken. Replace the motor.
Directional valve does not shift. Test pressure left and right. Replace the valve.
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.
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
A B
Fixed
Displacement
Motor
1 2
Pressure
Relief Valves
T-10A 1600 PSI
2 1
A B
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
Troubleshooting
IBOP actuator schematic diagram
IBOP Actuator Cylinder
2.500" Dia. Bore X 4.00" Stroke
1.750" Dia. Rod
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
-6
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
Number A B
b
C04
P T
-6
-6
-6
2 3 8
PC4
System
Tank
Pressure
TDS-11SA 8-47
Hydraulic System
33-2
Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3
Fixed Displacement
33-4
Pumps
Variable Displacement
33-5
33-6
Pressure
Relief Ventable Relief Valve RV1
Valves
33-7
33-8
33-9
33-10
8
CDF, CTF, CV2, CTR,
Chack Valve CDR, CXCD
Prefill valve assembly
33-11
CV1, CV2
TDS-11SA 8-49
Hydraulic System
1
3
Cavity Plug PC5
2
33-14
Internal Plug
33-15
33-16
33-17
33-19
Logic 33-20
Cartridge
8 33-21
33-22
33-23
33-24
33-25
33-26
33-27
33-29
Hydro-Pneumatic Accumulator
33-30
33-31
Hydraulic Cylinder
33-32
Tank (Reservoir) 8
33-33
Test Point
33-34
TDS-11SA 8-51
Hydraulic System
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
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