Manual

iTDS-11SAPreliminary

Lubrication and Maintenance 3

4Installation, Commissioning

and Decommissioning

Hydraulic System 5

Electrical System 6

PH-50 Pipehandler 7

8

9

1

Specifications

General Information

2

Motor Housing,Transmission

Guide Beamsand CarriageC

on

ten

tsC

on

ten

tsC

on

ten

ts

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.

This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system.

Where applicable, each section includes:

1. A table of contents, or an illustrated view index showing: Major assemblies, systems or operations Page references to descriptions in text

2. Disassembly / assembly information and tools3. Inspection information4. Testing / troubleshooting information5. Repair information6. Adjustment information7. Torque values

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains warnings about proceedures which could damage equipment or make it unsafe, and 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.

Special Information

Notes, Cautions and Warnings

REV A 1998 Varco Systems Top Drive Technical Publications Department All rights reserved

How to Use This Manual

i

!

!

(Note) Gives helpful information.

(Caution) Indicates a possibility of personal injury or equipment damage if instructionsare not followed.

(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructionsare not followed.

ii Varco Systems

Introduction

34

5

6

7

8

9

1

General Information

2

1-1TDS-11SAPreliminary

Major components................................................. 1-2

Identification numbers .......................................... 1-3

Lifting points .......................................................... 1-4

Safety wiring .......................................................... 1-5

Torque values ........................................................ 1-6

Basic useage ......................................................... 1-7Drilling ahead with singles ............................... 1-7Drilling ahead with triples................................. 1-8Backreaming...................................................... 1-9

1-2 Varco Systems

1

General Information

Major components

AC DrillingMotors (2)

Hydraulic DiscBrakes (2)

Motor CoolingSystem

Carriage

GuideBeam

HydraulicSystem

ElectricalSystem

PH-50Pipehandler

Gooseneck(S-Pipe)

CounterbalanceSystem

Transmission/Motor Housing

Rotating LinkAdapter

Left Side Front

Rear

Rear

Right Side Front

1General Information


Identification numbers

SALES ORDER NO.ASSY NO. REVTRACE CODEDATE OF MANUFACTURE

Encoder Instruction LabelOn the side of brake housing

Warning LabelOn the side of bonnet

Warning LabelsOn the side of each AC motor

AC Motor Identification LabelOn the side of each AC motor

Top DriveIdentification Plate

On the front of motor housing

1-4 Varco Systems

1

General Information

Lifting points

!

!

Bail LockMust be installed

before lifting top drivefrom the skid or attaching

top drive to the skid

Lifting PointFor removal or

attachment to the skid

37,000 lbs(16,798 kg)

TDS-11SA on skid

34,500 lbs(15,663 kg)

TDS-11SA

Lifting PointsFor skid attached to top drive

Lifting PointsFor skid attached to top drive

Locking pinsMust be in place

prior to moving skidwith top drive



Safety wiring

3 4 5

21

1-6 Varco Systems

1

General Information

Torque values

Diameter

1/45/163/8

7/161/2

9/165/83/47/81

1 1/81 1/41 3/81 1/2

1/45/163/8

7/161/2

9/165/83/47/81

1 1/81 1/41 3/81 1/2

2018161413121110

987766

Threadsper inch

2824242020181816141412121212

Bolts Lubricated withLight Machine Oil

Grade 5

7.616294871

105143247409608760

1,0641,3871,843

Min.Torque(ft lb)

9.518335286

114162285447665836

1,1781,5962,090

8.418325379

116158273452672840

1,1761,5332,037

Max.Torque(ft lb)

10.520375895

126179315494735924

1,3021,7642,310

2,0203,3404,9406,8009,050

11,60014,40021,30029,40038,60042,30053,80064,10078,000

ClampForce

(lb)

2,3203,7005,6007,550

10,70012,95016,30023,80032,40042,20047,50059,60073,00087,700

5.712.121.4

365378

107185306456570798

1,0401,382

Min.Torque(ft lb)

7.113.5

25396486

121214335499627884

1,1971,568

6.313.423.6

395987

118205339504630882

1,1501,528

Max.Torque(ft lb)

7.915.0

28437195

134236370551693977

1,3231,733

2,0203,3404,4906,8009,050

11,60014,40021,30029,40038,60042,30053,80064,10078,000

ClampForce

(lb)

2,3203,7005,6007,550

10,70012,95016,30023,80032,40042,20047,50059,60073,00087,700

Bolts Lubricated withAnti-seize Compound

Grade 5

Coarse Thread Series, UNC

Fine Thread Series, UNF

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psiT.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi



Basic useage

Drilling ahead with singles

1 2 3 4 5

n Set slips on string

n Stop circulation

n Close IBOP

n Breakout connection using pipehandler and drilling motor (in reverse)

n Lower block to stab motor into top of single

n Spin in motor and single

n Makeup both connections with motor in torque mode

n Pull slips

n Open IBOP

n Start circulation

n Begin drilling

n Tilt links to mousehole

n Latch drill pipe elevator around single

n Pickup single with elevator

n Release link tilt

n Stab bottom of single onto string

Stab

OpenIBOP

Makeup

Close IBOPLink Tilt

Makeup

1-8 Varco Systems

1

General Information

Drilling ahead with triples

1 2 3 4 5


n Stop circulation

n Breakout connection using pipehandler and drilling motor (in reverse)

n Raise block

n Tilt link tilt to derrickman

n Pickup stand with elevator

n Stab bottom of stand onto string

n Lower block to stab motor into top of stand

n Spin in motor and stand

n Makeup both connections with motor

n Pull slips

n Start circulation

n Begin drilling

Stab

StopCirculation

Link Tilt

Makeup

Makeup

StartCirculation



Backreaming

1 2 3 4 5

n Hoist while circulating and rotating

n When 3-rd connection surfaces, stop rotation and circulation

n Setback standusing link tilt

n Lower block, stab motor into string

n Spin in motor and makeup connection with motor

n Start circulation, pull slips, hoist and rotate

n Hoist free stand with elevator


n Breakout connection using pipehandler and drilling motor (reverse)

n Breakout and spinout stand at floor

Setback

Breakout

Breakout Hoist

Hoist andRotate

1-10 Varco Systems

1

General Information

34

5

6

7

8

9

1

Specifications

2


Design specifications............................................ 2-2Size specifications ............................................ 2-2Size specifications (continued) ........................ 2-3General specifications ...................................... 2-4

Typical mast interface ........................................... 2-5

2-2 Varco Systems

2

Specifications

Design specifications

Size specifications

Front and side view

233.0 in.(5918 mm)

= 37,000 lb= 16,798 kg

To Centerof Gravity

112.4 in.(2855 mm)

71.9 in. (1826 mm) 62.5 in.(1588 mm)

56.0 in.(1422 mm)

To Centerof Gravity

28.2 in.(716 mm)

18.5 in. (470 mm)

Bail120 in.

(3048 mm)

Bail88 in.

(2235 mm)

2-3TDS-11SA

2

Specifications

Preliminary

Size specifications (continued)

Plan view

33.7 in. (856 mm)

31.0 in. (787 mm)32.6 in. (828 mm)36.9 in. (937 mm)26.0 in. (660 mm)

22.8 in.(579 mm)

Well

Front

Rear

33.8 in.(859 mm)

21.1 in.(53 mm)

22.1 in.(561 mm)

30.0 in.(762 mm)Setback

(Standard)

CL

WellCL

2-4 Varco Systems

2

Specifications

General specifications

Top Drive

Drilling Motor

Pipe Handler

Drill Pipe

Variable Frequency Drive

Motor Braking

Motor Cooling System

Gearcase

Gearcase Lubrication

Hydraulic System

Electrical House

WeightStack-up HeightPower RequirementsHorsepowerOutput torque (continuous)Tool torque (intermittent @ stall)Maximum Speed @ full powerHoisting capacity

Sizes

Type

Type

Type

Type

TypePowerSpeed

Type

Gear ratio

TypeReservoir capacityFully internal flowGear Type

PowerFlowSpeedReservoir capacityOil Type

SizeTypeWeightInput requirement

Items

34,500 lb17.8 ft700 KVA @ 575-600 VAC, 50/60 Hz800 hp37,500 ft lb (800 hp)55,000 ft lb228 rpm500 ton

3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)

PH-50 (55,000 ft lb torque)

Reliance AC-575 VAC (2 x 400 hp)

IDM Yaskowa Drive (800 hp, 575 VAC) orSiemens (800 hp, 600 VAC)

Hydraulic caliper disc brakes

Local intake pressure blower(2) 5 hp AC motors3,600 rpm

Single speed, double reduction spur gearsystem (helical gears optional)10.5:1 (4.??:1 optional)

Pressure feed15 gal

10 hp, AC motor(1) 6 gpm, (1) 4 gpm1800 rpm25 gal

125.4 in. x 84.0 in., 91.2 in. height (Siemens)140.0 in. x 90.0 in., 91.0 in. height (IDM)9,500 lb600 VAC(60 Hz), or 600 VAC(50 Hz),or 750 VDC, or 690 VDC(50 Hz)

DescriptionComponents

2-5TDS-11SA

2

Specifications

Preliminary

Typical mast interface

*

**

Dimensions are Subject to Verification

Standard TDS Configuration-Two IBOPs with 108 in. Elevevator Links

AC Cables

Existing Traveling Equipment350-ton Hook/Block Combo-Typ.

TDS-11SVarco Portable

Top Drive System

Crown

Block Top

Bail Rest

Tool Joint

Tool Joint

BeamService Loop

CL

Sectional Guide Beam

Mud Hose75 ft. (22,9 m)*

Connected to Standpipeat 73 ft. (22,3 m) Level

Service Loop200 ft. (61 m)*

Service Loop Saddle at ~80 ft. (24,4 m) Level*

Portable Torque Reaction BeamU- Bolted to Spanners - (by Customer)

2 Custom SpannersOn A-Frames or Mast Side Panels (by Customer)

Varco Drillers Control

Control Cable with Connectors150 ft. (45,7 m)

Local Power SupplyDiesel/Alternator Set/AC Buss

Unitized Variable FrequencyInverter & Varco Control Panel

Drill Floor

AC Power andControl Cables

Drill StandMade-up at4 ft. (1,2 m)

Level93 ft. (28,3 m)

Clearance13.5 ft. (4,1 m)**

TDS Work Height18.0 ft. (5,4 m)**

Stroked-Typ.13.5 ft. (4,1 m)*

4.0 ft. (1,2 m)

10.0

ft. (3

m)-M

inimu

m*

7.0

ft. (2,

1 m)-M

inimu

m

Cle

ar

Wo

rkin

g H

eig

ht

142

ft. (43

,3 m)

2-6 Varco Systems

2

Specifications

Lubrication

3

4

5

6

7

8

9

1

2


Transmission ......................................................... 3-2Selecting the proper gearbox oil...................... 3-2Lubrication schedule ........................................ 3-2Recommended gear oils ................................... 3-3Gearbox lubrication .......................................... 3-4

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

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

General purpose lubrication ................................. 3-10Lubrication schedule ........................................ 3-11Recommended lubricants ................................ 3-11General lubrication ........................................... 3-12General lubrication (continued) ....................... 3-13General lubrication (continued) ....................... 3-14General lubrication (continued) ....................... 3-15

3-2 Varco Systems

3

Lubrication

Transmission

Selecting the proper gearbox oilTDS transmissions operate under a combination of heavy and shockloads. 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 anAGMA extra pressure rating (EP), and a minimum viscosity of 100 SUSat internal operating temperature.

Varco Top Drives also operate under a wide variety of temperatures.Select lubrication for the TDS based on the minimum ambienttemperature (surrounding air) to be expected before the next oil change.Under all but the most severe operating conditions, Varco recommendschanging the oil every six months. Introducing an oil viscosity greaterthan required by the ambient temperature can:

o Damage the gearbox due to reduced oil flow

o Damage the oil pump because of excessive load

Lubrication schedule

Replace the Gearbox Oil and Perform an Oil AnalysisOil viscosity should be adjusted based on expected ambient conditions for next six months

Replace the Gearbox Oil Filter (P/N 111013)

1 x every 6 Months

1 x every 3 Months

Description Frequency

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

3-3TDS-11SA

3

Lubrication

Preliminary

Recommended gear oils

Ambient Temperature Range

Manufacturer

Viscosity Index

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

NGLI

AGMA

ISO Viscosity Grade

Above 21 C(Above 70 F)

Alpha LS-320NL Gear 320

Spartan EP320EP Lube HD320MobilGear 632

Omala 320Loadway EP320

Meropa 320Carter EP 320

Extra Duty NL6EP

N/R6EP320

7 to 30 C(45 to 85 F)





Extra Duty NL4EP

N/R4EP150

-6 to 16 C(20 to 60 F)





Extra Duty NL2EP

N/R2EP68

e Oils of insufficient viscosity can damage gears by allowing metal tometal contact.

z For minimum temperatures below 20F, the TDS must be warmed up byrotating at a very light load (less than 200 Amps) and at very slowspeeds (less than 50 rpm) until the oil temperature climbs above 20F. Ifdrilling conditions dictate oil temperatures below 20F, consult Varcoengineering.

If the oil temperature rises above 200F, Varco recommends shuttingdown or reducing drilling loads to stabilize the oil temperature below200F If drilling conditions dictate oil temperatures above 200F, consultVarco engineering.

3-4 Varco Systems

3

Lubrication

Gearbox lubrication

Gear OilSight Gauge

Check withTop DriveOFF

Gearbox Oil FillUse a 1 3/8 inch, 12 point

socket to remove plug

Cork Ball(Level Indicator)

SightGlass

Pop-upDirt Alarm

Gear Oil Filter

3-5TDS-11SA

3

Lubrication

Preliminary

Hydraulic system

Precautions

n Release all hydraulic oil pressure by bleeding accumulators beforedisconnecting hydraulic lines. Turn the counterbalance valve toshutdown mode to bleed the hydraulic system. Hydraulic oil underpressure can penetrate skin and cause serious injury.

n Before opening the hydraulic system, thoroughly clean work area,and maintain system cleanliness by promptly capping alldisconnected lines. Dirt is extremely harmful to hydraulic systemcomponents and can cause equipment failure and subsequentinjury to personnel.

e Use care when handling components to prevent nicking close tolerancefinishes.

e Use care to prevent contamination from entering the hydraulic systemduring maintenance activities.


Perform Hydraulic System Oil Analysis

Replace the Hydraulic Fluid

Replace the Hydraulic System Filter (P/N 114416-1)

1 x every 6 Months1 x Year, or Earlier Based on Oil Analysis

1 x every 3 Months

Description Frequency

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

3-6 Varco Systems

3

Lubrication

Recommended hydraulic fluid

Hyspin AWS-46AW Hyd oil 46

Nuto H46Harmony 46AW

DTE 25Tellus 46

Hydraway HMA 46Rando oil HD46

Azolla ZS 46Unax AW46

46



DTE 24Tellus 32



32

-10 to 85 C(14 to 185 F)

-15 to 75 C(5 to 167 F)

Oil Temperature Range

Manufacturer

Viscosity Index

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

ISO Viscosity Grade

3-7TDS-11SA

3

Lubrication

Preliminary

Hydraulic lubrication

Red Pop-upDirt Alarm

Hydraulic Oil Filter

Hydraulic Oil Fill

HydraulicOil SightGauge


SightGlass

Hydraulic OilFill Quick

Disconnect

LubricationKit Quick

Disconnect

n Ensure that the area is clean prior to adding hydraulic fluid

n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill

n Remove dust plug from the female quick disconnect on the lubrication kit

n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as shown

HydraulicLubrication Kit

55 gal Drum

3-8 Varco Systems

3

Lubrication

Motors

n Varco recommends that lubrication of all AC motors should bedone by the rig electrician.


Description No. of Points Frequency Type

Lubricate the AC Drilling Motor

Lubricate the Blower Motor

Lubricate the Hydraulic Pump Motor

Motor GreaseMotor GreaseMotor Grease

1 x every 3 Months1 x every 3 Months1 x every 3 Months

442

Recommended motor grease

Black Pearl EP2 (Do Not Substitute)

Motor Grease

Manufacturer

Chevron

3-9TDS-11SA

3

Lubrication

Preliminary

Motor lubrication

AC BlowerMotor (2)

3 pumps(2 grease fittings

each motor)

AC DrillingMotor (2)


each motor)

1/8 inchPipe Plug(remove andreinstall afterlubricating)

1/8 inchGrease Fitting

(Varco P/N53201)

3 Months

3 Months

3 Months

Hydraulic PumpAC Motor


each motor)

As Viewed From Below

Grease Fittings

Apply grease to designatedgrease fittings with grease gun

3-10 Varco Systems

3

Lubrication

General purpose lubrication

e The lubrication intervals described in this manual are based on lubricantsupplier recommendations. Severe conditions such as extreme loads ortemperature, corrosive atmosphere, etc., may require more frequentlubrication.

e Worn bushings, binding parts, rust accumulations, and other abnormalconditions indicate more frequent lubrication is necessary. Be careful notto over lubricate parts. For example, too much grease forced into a fittingcan pop out a bearing seal. Over lubrication can also affect safety sinceover lubricated parts can drip, creating a potential slipping hazard forpersonnel.


Washpipe Assembly

Upper Bonnet Seal

Bail Pins

Rotating Link Adapter Gear

Rotating Link Adapter

IBOP Actuator Yoke, Cylinder Pins

IBOP Actuator Cranks

Stabilizer Bushing

Clamp Cylinder Gate

Carriage Assembly

Torque Arrestor at Clamp Cylinder

Elevator Link Eyes

Wireline Adapter

General Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose Grease

112

252428442

DailyWeeklyWeeklyWeeklyWeeklyDailyDailyDailyDaily

WeeklyWeeklyWeeklyWeekly

Description No. of Points Frequency Type

3-11TDS-11SA

3

Lubrication

Preliminary

Recommended lubricants

Above -20 C(Above -4 F)

Below -20 C(Below -4 F)

MP GreaseAvi-MotiveLidok EP2

Gulf Crown EP32Mobilux EP2Alvania EP2

Uniway EP2NMultifak EP2Multis EP2Unoba EP2

2N/RN/R

N/RAvi-Motive W

Lidok EP1Gulf Crown EP31

Mobilux EP1Alvania EP1

Uniway EP1NMultifak EP1Multis EP1Unoba EP1

1N/RN/R


Manufacturer

Viscosity Index

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

NGLI

AGMA

ISO Viscosity Grade

3-12 Varco Systems

3

Lubrication

General lubrication

Wash PipeAssembly

Apply one pumpat beginning of tour

Apply general purposegrease to designatedgrease fittings with

grease gun. Use a brushwhen greasing other parts.

Daily

Upper Bonnet SealOne pump

Use Hand Pump Only

Weekly

Bail Pins (2)Two pumps each side

Weekly

Rotating LinkAdapter Gear

Weekly

Elevator Link Eyes (4)

Weekly

Rotating Link AdapterThree pumps each

Weekly

3-13TDS-11SA

3

Lubrication

Preliminary

General lubrication (continued)

IBOP Actuator Cylinder PinsOne pump each

(if equipped)

Daily

IBOPActuator Yoke

One pump(if equipped)

Daily

IBOPActuator Yoke

One pump each side

Daily

IBOP Actuator CranksOne pump each side

Daily

Stabilizer BushingOne pump each

DailyStabilizer Bushing

One pump each side

Daily

Clamp Cylinder GateOne pump each side

Daily

ElevatorLink Eyes (4)

Weekly

TorqueArrestor Tubes

Weekly

Apply general purpose greaseto designated grease fittingswith grease gun. Use a brushwhen greasing other parts.

3-14 Varco Systems

3

Lubrication


Rollers (4)One pumpeach side

Weekly

Bogies (4)One pumpeach side

Weekly

Apply general purpose greaseto designated grease fittings

with grease gun

3-15TDS-11SA

3

Lubrication

Preliminary


Wireline AdapterOne pump each

Weekly

Apply general purpose grease to designated grease

fittings with grease gun

3-16 Varco Systems

3

Lubrication

34

Installation, Commissioningand Decommissioning

5

6

7

8

9

1

2


Illustrated index................................................. 4-3Preparation and preinstallationconsiderations................................................... 4-4

Preinstallation........................................................ 4-5Installing the crown padeye andhang-off link....................................................... 4-5Locating the control house .............................. 4-6Installing incoming power cables .................... 4-7

Installation ............................................................. 4-8Pre-installation checklist .................................. 4-8Moving the TDS-11SA to the drill floor ............ 4-9Removing the TDS-11SA from the skid ........... 4-10Disengaging the lower carriage latch .............. 4-11Moving guide beam sections ........................... 4-12Present and hook the firstguide beam section........................................... 4-13Hoist the first guide beam section ................... 4-14Stab and pin the first guide beam section ...... 4-15Completing the guide beam installation ......... 4-16Hanging the guide beam................................... 4-17Disengaging the upper carriage latch ............. 4-18Installing the main tieback ............................... 4-19Installing the intermediate restraints............... 4-20Installing derrick termination ........................... 4-21Installing the service loop ................................ 4-22Service loop connection diagram .................... 4-23Installing the drillers console .......................... 4-24Installing the mud hose .................................... 4-25Installing the counterbalance........................... 4-26Installing the rotary hose.................................. 4-27

4-2 Varco Systems

4


Commissioning ..................................................... 4-28Hydraulic system checkout procedure ........... 4-28Electrical system checkout procedure ............ 4-29Mechanical checkout procedure...................... 4-30

Decommissioning.................................................. 4-35Removing and storing the electrical cablesand service loops .............................................. 4-35Securing the TDS-11SA for rig-down .............. 4-36Setting the latches and locking the bail .......... 4-37Disconnecting the guide beam ........................ 4-38Unpinning each guide beam section ............... 4-39Lowering each guide beam section................. 4-40Unhooking and removing eachguide beam section........................................... 4-41Returning the TDS-11SA to the skid ................ 4-42Removing the TDS-11SA from the drill floor... 4-43Long term storage procedures ........................ 4-44Returning the TDS-11SA to serviceafter storage ...................................................... 4-44

4-3TDS-11SA

4


Preliminary

Illustrated index

AC CablesPage 4-X

VarcoDrillers Console

(VDC)Page 4-X

Control Cablewith Connectors

Page 4-X

Local Power SupplyDiesel/Alternator Set/AC Bus

Unitized VariableFrequency Inverter and

Varco Control Panel (House)Page 4-X

AC Power andControl Cables

Page 4-X

DerrickTermination

Page 4-X

Main TiebackPage 4-X

Service LoopPage 4-X

Rotary HosePage 4-X

Crown Padeye andHang-off Link

Page 4-X

CounterbalancePage 4-X

IntermediateRestraints

Page 4-X

Guide BeamPage 4-X

4-4 Varco Systems

4


Preparation and preinstallation considerationsThe TDS-11SA interfaces with the rigs hoisting system and electricalpower system. Derrick and electrical system modifications are requiredwhen installing the TDS-11SA on existing rigs.

For derricks that handle triples, the required top drive travel is about 100ft. compared to about 75 ft. when using a Kelly. It is generally necessaryto replace the regular rotary hose (which is normally 60 ft. long) with a 75ft. hose, and extend the standpipe height to 70 ft.

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

The location of the electrical loop and mud hose is an importantinstallation consideration for pipe setback purposes, to ensure properclearance and to help prevent wear to the service loop and mud hose.Other important installation considerations include the location of:

o The casing stabbing board

o Floor and derrick accessories

o Drawworks fastline

o Guide beam hang-off bracket

o Torque reaction beam

o Mud stand pipe extension

o Varco drillers console location

o Variable frequency inverter/Varco control panel location

Derrick height is a critical interface requirement. Handling a93 ft. stand typically requires 97 ft., resulting in an overall height from thefloor to the top of the traveling block of at least 126 ft.

Derrick Clear Working Height Derrick Crown Clearance152 ft. 25 ft.147 ft. 20 ft.142 ft. 15 ft.136 ft. 9 ft.

Each rig has different crown clearance for efficient tripping. Installing theTDS-11SA with existing traveling equipment may require an adapterfurther reducing crown clearance.

4-5TDS-11SA

4


Preliminary

Preinstallation

Installing the crown padeye and hang-off link

See Table

Well

CL

Crown PadeyeWeld accordingto table below

Crown

Shackle

Hang-off Link

36.8 inches

33.8 inches

30.0 inches

Standard height configuration (adustable)Varcos IDS Top Drive requirementsOriginal setback for TDS-9S

DescriptionDimension

Recommended Installations

4-6 Varco Systems

4


Locating the control house

VarcoDrillersConsole

ControlHouse

Recommended Area forControl House Location

9,500 lb(4300 kg)

Control House

V-DoorRamp

TDS-11SA

Dra

ww

ork

s

Well

CL

Well

CL

91.00 in.(2311.4 mm)

90.00 in.(2286 mm)

140.00 in.(3556 mm)

Recommendations

n Position the control house off the drillers side or behind the drawworks.

n Position as close to derrick plate as possible to minimize cable lengths.

n Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts).

n Location of the control house must ensure accessibility from all sides.

4-7TDS-11SA

4


Preliminary

Installing incoming power cables

F-W INCOMING 575VAC

C-AUX. POWER CONNECTOR

B-SERIAL CONNECTOR

G-U OUTGOING 575VACH-V OUTGOING 575VAC

I-W OUTGOING 575VAC

D-U INCOMING 575VACE-V INCOMING 575VAC

A-COMPOSITE CONNECTOR

Plug Panel

Plug PanelIncoming

PowerCables

Varco Control Panel(House)

Recommendations

n Connect the incoming power cables with the isolation circuit breaker turned OFF.

n Connect cables in accordance with the electrical schematic provided in the Technical Drawings book.

n Earth the control house with the Varco Ground Rod Kit. Grounding locations are at the lower corners of the control house.

4-8 Varco Systems

4


Installation

Pre-installation checklist

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

o Make sure the derrick/mast is vertical, with the block over the centerof the rotary table.

o Derrick/mast modifications are completed (if required) and the guidebean support bracket and torque reaction beam are installed andinspected to conform to Varco specifications as detailed in FIP00003.

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

o The control panel and frequency drive are installed.

o Rigging of tong lines, etc. is inspected to ensure that they will not foulwith the TDS-11SA.

o The hook or adaptor becket is installed. The hook should opentoward the drawworks.

4-9TDS-11SA

4


Preliminary

Moving the TDS-11SA to the drill floor

!

!

V-DoorRamp

LiftingSling

Backup Line

TDS-11SAIn position

prior to liftingfrom skid

2

Be sure that theBail Lock Assembly

is installedTube (P/N 113498)U-Bolt (P/N 113497)

2x 3/4" nuts

Be sure thatthe Top Driveis pinned to

the Skid priorto hoisting

Lifting SlingAttached to bail

for hoisting

TDS-11SAon Skid

3

1

DrillFloor

LiftingBlock

Hoist usingthe drawwork

37,000 lb(16000 kg)

TDS-11SA on Skid

4-10 Varco Systems

4


Removing the TDS-11SA from the skid

!

SkidRemove from drill floor

after hoisting TDS-11SA

Lock PinRemove prior to

hoisting from skid

TDS-11SALifted from

skid

TDS-11SAPrior to lifting

from skid

2

1

3

LiftingBlock

Hoist fromskid using

the drawwork

DrillFloor

Be sure that the Bail Lock Assemblyis installed. Remove only after

installation is complete.

TDS-11SA

2,500 lb(1100 kg)

Skid

34,500 lb(15700 kg)

TDS-11SA

Pin

Pin

LatchesEngaged

for hoisting

4-11TDS-11SA

4


Preliminary

Disengaging the lower carriage latch

!

As viewed fromrear of Carriage

Pin

Guide BeamWings

Guide BeamTop Section

Carriage

Upper Latch

Engaged

Lower Latch

Disengaged

After hoisting the TDS-11SA from the skid, disengage the lower carriage latch and pin it as shown.

TDS-11SAprior to lifting from skid

4-12 Varco Systems

4


Moving guide beam sections

Guide Beam SectionsPrior to Installation

DrillFloor

TDS-11SA

Sling

Lifting Eyes

Guide BeamSection

2,100 lb(953 kg)

Guide Beam Section

4-13TDS-11SA

4


Preliminary

Present and hook the first guide beam section

DrillFloor

Guide BeamSection

Hooked

Present and Hookthe first guidebeam section

Hook Pin Saddle

Hook Pin

Hook PinIn fully

engagedposition

Present

Hook

Guide Surface

Greasethe bores on

both joint halves Greasethe bores on

both joint halves



Radius locks joint fromunhooking at 8 rotation

1

2

4-14 Varco Systems

4


Hoist the first guide beam section

Bar and RadiusLocates pin bores foreasy insertion of pins

Hook Pin

First GuideBeam Section

Initially hoistedby the hook pin

Hoist

DrillFloor

HoistUsing the drawwork


4-15TDS-11SA

4


Preliminary

Stab and pin the first guide beam section

Stab and Pinthe guide beam joint

Block asRequiredDrill

Floor

Stabthe guide beamjoints together

Joint PinInstall after

stabbing

RetainerPin

LynchPin


Securewith thelynch pin

1

2

34

4-16 Varco Systems

4


Completing the guide beam installation

(36.8 in.)(934.72 mm)

Standard adjustableheight configuration

Note:Use these pin positionsif crown padeyeinstallation is based on:

(33.8 in.)(858.52 mm)Varcos IDS

top driverequirements

(30.0 in.)(762 mm)Original

TDS-9S or ifplate extension(36.8 in.) needsto be cut off dueto interference.

Well

CLGuide BeamTop Section

CL

CrownPadeye

ShackleEnsure that the shackle

is pinned and thecotter pin is in place

Crown

TDS-11SAHoistinglatches

disengaged


Safety Pin

Hang-offLink

Pin

DrillFloor

Main Tieback andSpreader Beam

FloorClearance

7 ft.(2,133.6 mm)

Guide BeamAssembled

4-17TDS-11SA

4


Preliminary

Hanging the guide beam

36.8 in.(934.72 mm)

Standard adjustableheight configuration

Note:Use these pin positions ifcrown padeye installationis based on:

33.8 in.(858.52 mm)

Varcos IDS Top Driverequirements

30.0 in.(762 mm)

Original TDS-9S or ifplate extension (36.8 in.)needs to be cut off due

to interference.

Well

CLGuide BeamTop Section

CL

CrownPadeye

ShackleEnsure that the

shackle is pinnedand the cotter pin

is in place

Crown

TDS-11SA


Safety Pin

Hang-offLink

Pin

DrillFloor

FloorClearance

7 ft.(2,133.6 mm)

GuideBeam

Assembled

4-18 Varco Systems

4


Disengaging the upper carriage latch

!

As viewed fromrear of Carriage


Carriage

Upper Latch

Disengaged

Pin

Lower Latch

Disengaged

After hanging the guide beam on the

hang-off link and prior to lowering the Top Drive, disengage the upper carriage latch and pin it as shown.

DrillFloor

Guide BeamAssembled

4-19TDS-11SA

4


Preliminary

Installing the main tieback

Mast Leg

AuxiliarySpreader Beam

Guide BeamBottom Section

MainSpreader

Beam

Apply Anti-seizeCompound

Typical

Tieback Link

TiebackPlate

DrillFloor

Main Tieback andSpreader Beam

SeeTable

GuideBeam

Assembled

36.8 inches Standard height configuration (adjustable)

33.8 inches Varcos IDS Top Drive requirements

30.0 inches Original setback for TDS-9S

Dimension Description

Recommended Installations

Well

CL

4-20 Varco Systems

4


Installing the intermediate restraints

DrillFloor

105Feet

55Feet

Guide BeamAssembled

Guide BeamAssembled

Girt

IntermediateTieback Plate

(2)

Apply Anti-seizeCompound

Padeye (2)(If greater than

3 inches from girt)

Padeye (1)(If less than

3 inches from girt)

Pin andCotter Pin

Space between girtand guide beam

3 inches

n Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor

n Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches

n Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches

4-21TDS-11SA

4


Preliminary

Installing derrick termination

Hoist LineAttachment

Points

Service LoopBrackets

75 ft/83 ftfrom Drill Floor

Hoist LineAttachment

Point

Derrick/Mast Leg

DerrickLeg Plate

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

n Mount as far as practical from well center, to maintain a 36 inch minimum bend radius. Maintaining a larger radius increases loop life and reduces damage due to pinching.

n Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc.

4-22 Varco Systems

4


Installing the service loop

!

!

Service Loopand Storage Tub

3,600 lbs(1,634.4 kg)

DerrickService Loop

Lifting EyesDo not remove

TDSService Loop

DerrickTermination

To avoid damage to theservice loop maintain a36 inch minimum

bend radius

To avoid damage to the service loop

use care when dragging it near sharp edges

and allow room for passing under the

V-door

Hoist

Sling

n Do not unpack the service loops until they are ready to hang

n Use a sling attached to the lifting eyes to hoist each service loop. Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting.

n The TDS service loop connects electrical service to the top drive and the derrick service loop connects electrical service to the control house

n Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package

1,000 lbs(454 kg)

Service Loop

4-23TDS-11SA

4


Preliminary

Service loop connection diagram

4-24 Varco Systems

4


Installing the drillers console

PIPEHA

NDLER

IBOP

TORQUE

BRAK

EEM

ERGENC

Y

STOP

!

VarcoDrillersConsole

V-DoorRamp

Pigtail CablesConnect to

control house

TDS-11SA

Dra

ww

ork

s

Well

CL

Well

CL

Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system, as it is specifically made for use with the TDS-11SA.

n Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated

n Location must ensure that the gauges are easily seen by the driller during drilling operations

n Location must be visible and readable at night

4-25TDS-11SA

4


Preliminary

Installing the mud hose

4-26 Varco Systems

4


Installing the counterbalance

For use withHooks

4-27TDS-11SA

4


Preliminary

Installing the rotary hose

8

5

4

3

1

5

4

3

2

69

7

8

10

10

11

12

11

12

6

13

14

O

4-28 Varco Systems

4


Commissioning

Hydraulic system checkout procedure

Checking hydraulic fluid level

4-29TDS-11SA

4


Preliminary

Electrical system checkout procedure

Checking connections and motor rotation

PIPEHA

NDLER

IBOP

BRAK

EEM

ERGENC

Y

STOP

TORQUE

OFF

MAKE-

UP

CURREN

T LIMIT

OIL

PRESS

LOSS

LINK T

ILT FL

OAT

DRILL

MOTOR

OVERTE

MP

TORQUE

WRENC

H

PUSH &

HOLD

LINK T

ILT

OFF

BLOWE

R LOSS

ROTATE

LEFT

DRILL

TILT

RIGHT

SPIN

DRILL

TORQUE

HYDRAU

LIC PO

WER

AUTO

ON

IBOP

CLOSED

ALARM

SILENCE

LAMP

CHECK

BRAKE

ON

BRAKE

AUTO DRI

VE

FAULT

IBOP

OPEN

CLOSE

BRAKE

ON

/

OFF

DRILL

TORQUE

0

0

MAX

TORQUE

RPM

MAX

0

MAX

REVERS

E

FORWA

RD

n Operate each control on the Varco drillers console

n Assign the cooling motors and inverter by selecting FORWARD or REVERSE on the drillers console

n Rotate the drill stem using the THROTTLE on the drillers console and observe proper operation

n Check for alarm conditions and resolve any alarms at this time

n Check all connectors for tightness and lockwire

n Check operation of meters

n Check operation of ? stop

n Check the latches on the drillers console for tightness

Throttle

Latches

VarcoDrillers Console

Forward/ReverseControl

4-30 Varco Systems

4


Mechanical checkout procedure

Checking gearbox oil level

Pop-upDirt Alarm

GearOil Filter

Gear OilSight Gauge

Check withtop driveOFF


SightGlass

GearboxOil Fill

Clean area beforeremoving plug


CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion

NGLIAGMAISO ViscosityGrade

Above 21 C(Above 70 F)





Extra Duty NL6EP

N/R6EP320

7 to 30 C(45 to 85 F)





Extra Duty NL4EP

N/R4EP150

-6 to 16 C(20 to 60 F)





Extra Duty NL2EP

N/R2EP68

GEAR OIL

Recommended Lubricants

n 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

n Always check the oil level after the unit has been running and the transmission oil is warm. Look for oil level (oil is dark brown); not foam level (foam is tan).

n Check filter condition pop

4-31TDS-11SA

4


Preliminary

Adjusting the link tilt

Link TiltCrank Assembly

inches(mm)

Typical

Pin

Latch

Link

ClampMousehole

Position CablePull up or downto set mousehole

position

Elevator

Drill DownPosition

Bottom of elevatorshould be above

bottom ofstabbing guide

(inches)(mm)

MouseholePosition

DerrickmansPosition

Well Center(Float Position)

4-32 Varco Systems

4


Selecting the proper saver sub and clamp cylinder jaws

53

43

21

20

37

36

23

22

26

25

21

20

19

18

17

16

11

12

1

24

45

44

37

36

51

13

3550

34

33

32 28

27 49

48

35

31

13

57

58

12

34

33

32 30

29 28

27

15

10 6 4 3

2

5

9

8

7

14

15

14

41

60

59

47

46

19

18

17

16

40

39

38

21

20

40

42

41

52

54

55

56

S

4-33TDS-11SA

4


Preliminary

Removing and installing the saver sub

Upper IBOP

Lower IBOP

Saver Sub

Upper Tool Lock Joint

Shell Actuator

Intermediate Tool Lock Joint

Lower Tool Lock Joint

4-34 Varco Systems

4


Removing and installing the clamp cylinder jaws

9

21

24

25

23

26

28

29

34

27

35

9

42

41

26

3

36

11

12

40

56

58

57

64

60

59

17

20

16

18

19

67

66

61

62

15

65

63

54

5552

52

50

45

48

7673

757472

10

69

68

80

71

70

51

6

8

10

13

14

5

44

7

38

37

4

49

47

53

46

35

30

34

31

35

32

22

34

331

43

42

2

12

39

40

Q

R

R

81

77

7879

77

4-35TDS-11SA

4


Preliminary

Decommissioning

Removing and storing the electrical cablesand service loops

!

!

Lower

Service Loopand Storage Tub

3,600 lbs(1,634.4 kg)

DerrickService Loop

Lifting EyesDo not remove

TDSService Loop

DerrickTermination

To avoid damage to theservice loop maintain a36 inch minimum

bend radius

To avoid damage to the service loop

use care when dragging it near sharp edges

and allow room for passing under the

V-door

n Do not pack the service loops until the service loop storage tub is in position

n Use a sling attached to the lifting eyes to lower each service loop. Use the swivel at the tugger line attachment to allow each service loop to coil without twisting.

Sling1,000 lbs(454 kg)

Service Loop

4-36 Varco Systems

4


Securing the TDS-11SA for rig-down

233.0 in.(5918 mm)

= 37,000 lb= 16,798 kg

To Centerof Gravity

112.4 in.(2855 mm)

71.9 in. (1826 mm) 62.5 in.(1588 mm)

56.0 in.(1422 mm)

To Centerof Gravity

28.2 in.(716 mm)

18.5 in. (470 mm)

Bail120 in.

(3048 mm)

Bail88 in.

(2235 mm)

4-37TDS-11SA

4


Preliminary

Setting the latches and locking the bail

4-38 Varco Systems

4


Disconnecting the guide beam

CrownPadeye

Do not remove

Crown

TDS-11SACarriage latchesremain engaged


Shackle

Hang-offLink

Pin

DrillFloor

n Be sure that the bail lock assembly is installed

n Be sure carriage latches remain engaged

n Disconnect the guide beam from the main tieback and intermediate tiebacks

n Disconnect the guide beam from the hang-off link

4-39TDS-11SA

4


Preliminary

Unpinning each guide beam section

4-40 Varco Systems

4


Lowering each guide beam section

4-41TDS-11SA

4


Preliminary

Unhooking and removing each guide beam section

4-42 Varco Systems

4


Returning the TDS-11SA to the skid

Lock PinInstall after lowering

TDS-11SA onto the skid

TDS-11SA

TDS-11SALoweredonto skid

2,500 lbs(1,135 kg)

Skid

Skid

2

3

1

LiftingBlock

DrillFloor

PinInstall after lowering

TDS-11SA onto the skid

n Hoist skid to the drill floor

n Using the drawwork, lower the TDS-11SA onto the skid

n Pin the TDS-11SA to the skid at the top and bottom of the guide beam top section

n Install pin retainers

TDS-11SA

34,500 lbs(15,663 kg)

TDS-11SA

4-43TDS-11SA

4


Preliminary

Removing the TDS-11SA from the drill floor

!

V-DoorRamp

LiftingSling

Backup Line

TDS-11SAOn the skid priorto removing from

the drill floor

2

1

3

DrillFloor

LiftingBlock

Lower usingthe drawwork

Be sure that theBail Lock Assembly

is installed

Sling

TDS-11SAon Skid37,000 lbs(16,798 kg)

4-44 Varco Systems

4


Long term storage procedures

1. Drain the oil from the gearbox prior to rigging down.

2. Remove the saver sub.

3. Disconnect guide beam from lower attachment and connecting link.

4. Rig down the guide beam.

5. Bring the shipping and handling skid to the drill floor.

6. Install the TDS-11SA into the skid and pin.

7. Release the hook and remove the TDS-11SA.

8. For indoor storage, cover the TDS-11SA in its shipping and handlingskid. A cargo container is appropriate for outdoor storage.

9. Avoid wide variations in temperature and high humidity. The preferredenvironment is clean and dry at 60F ambient.

10. All exposed unpainted metal surfaces are coated with a rustpreventive prior to shipment; however, check these surfacesperiodically to be sure that no corrosion is taking place. Therecommended rust preventive (slushing compound) for bare metalsurfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.

11. Cover all openings to prevent water or dust from entering. Leaveenough space around the drilling motors for ventilation. Do not usesilica gel or a dehydrating agent.

11. During storage, rotate the motors and gear train periodically todistribute lubricant. Perform this at three month intervals if storedindoors, and at one month intervals if stored outdoors.

12. For long term storage recommendations dealing with the AC drillingmotors, see the motor manufacturers manual.

Returning the TDS-11SA to service after storage

Before placing the TDS-11SA back into service after storage, verify thefollowing items:

1. Remove all rust preventive and any corrosion that may have takenplace, taking special care with all load carrying components.

2. Follow the return to service procedures in the AC drilling motormanufacturers manual.

34

5

6

7

8

9

1

2

Guide Beamsand Carriage


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

Inspecting the top section of the guide beam..... 5-3

Inspecting the guide beam joints ......................... 5-4

Inspecting the main tieback.................................. 5-5

Inspecting the intermediate restraints ................. 5-6

Inspecting the carriage ......................................... 5-7

Illustrated part lists ............................................... 5-9Guide beams (roller) ........................................... 5-10Guide beams (slider) .......................................... 5-12Universal tiebacks ............................................. 5-14Tiebacks (sliding) ............................................... 5-16Carriage/accumulator (roll) ................................ 5-18Carriage assembly, right (roller) ........................ 5-20Carriage assembly, left (roller) .......................... 5-22Carriage/accumulator (skid) .............................. 5-24Carriage assembly, right (skid) .......................... 5-26Carriage assembly, left (skid) ............................ 5-28

5Guide Beamsand Carriage

5-2 Varco Systems

Inspecting the crown padeye and hang-off link

Crown PadeyeVisually inspect weld for cracks

Monthly

Crown Padeye

Crown

Yearly

ShackleInspect and replace if worn

Shackle

Monthly

Hang-off Link BoresInspect and repair if worn

Hang-off Link Bores

Monthly

MPI

Cotter PinReplace if missing

Monthly

2.1"(52 mm)minimum

2.0"(50 mm)minimum

1.5"(37 mm)minimum



Inspecting the top section of the guide beam


Crown

Bolt Assembly

Hang-off Link BoresInspect and repair if worn

Hang-off Link Bores

MonthlySafety Pin

Replace if missing

Monthly

2.1"(52 mm)minimum

1.5"(37 mm)minimum


5-4 Varco Systems

Inspecting the guide beam joints

Retainer Pin

Weekly

Lynch Pin

Verify that the joint pins,retainer pins and lynch pins are

in place and secure. Replaceany missing or damaged pins.

Secure

Weekly

Joint Pin

Weekly

Typical GuideBeam Joint

Yearly

MPI

Inspect weldsfor cracks

Monthly



Inspecting the main tieback

Mast Leg

Auxiliary Spreader Beam

Guide BeamBottom Section

Check that the tool is aligneddirectly over well center

MainSpreader Beam

TiebackLinkTieback Plate

Weekly

Yearly

MPI

Daily

Typical all weldsand connections

Inspect clamped connectionsfor tightness and double nuts.

Inspect welds for cracks.

Typical all welds


5-6 Varco Systems

Inspecting the intermediate restraints

Pin and Cotter PinVerify that all pins arein place. Replace any

missing or damaged pins.

Guide Beam

Mast Girt

Weekly

Check for tightnessof cotter pins, and

double nuts. If thereare signs of shifting,

verify alignment.

Weekly

Yearly

MPITypical all welds

Check that the toolis aligned directlyover well center

Daily



Inspecting the carriage

Typicalall rollers

Inspect for unevenwear or damage.Replace yearlyor as required.

Weekly

Detent PinsVerify that pins

are in placeand secure

Daily


5-8 Varco Systems



Illustrated part lists

On the following pages xxxxxxx


5-10 Varco Systems

E

4 6 5

2

3

8

7

1

Top SectionPart of

Shipping Package

RollingGuide Beam/Carriage

Configuration

Guide beams (roller)



Key to Guide beams (roller)

Item # Part # Description Qty

1 116414-505 Guide Beam, Bottom Section 1

2 115954 Guide Beam, Intermediate Section 4

3 115954-500 Guide Beam, Special Intermediate Section 1

4 116644 Retaining Pin 12

5 116643 Hinge Pin 12

6 51403-8-S Cotter Pin 12

7 89035-1 Shackle, 25 Ton 4

8 99873-650 Connection Link, 65" 1


5-12 Varco Systems

F

1

2

3

9

10

11

12

13

14

8

4

5 6

7

Top SectionPart of

Shipping Package

SlidingGuide Beam/Carriage

Configuration

Guide beams (slider)



Key to Guide beams (slider)


1 117618 Guide Beam, Bottom Section (18 ft) 1

2 117618-500 Guide Beam, Bottom Section (36 ft) 1

3 117616 Guide Beam, Intermediate Section (18 ft) 4,5,6

4 117616-500 Guide Beam, Intermediate Section (36 ft) 2

5 117783 Retainer Pin 3,5,6,7

6 117782 Joint Pin 3,5,6,7

7 117496-1 Lynch Pin 3,5,6,7

8 95523 Shackle, 25 Ton 1

9 117788-136 Hang-Off Link 1

10 117788-142 Hang-Off Link 1

11 117788-147 Hang-Off Link 1

12 117788-152 Hang-Off Link 1

13 117788-126 Hang-Off Link 1

14 117788-156 Hang-Off Link 1


5-14 Varco Systems

G

9

11

10

11

4

7

14

10

11

5

14

3

16

15

8

10

11

13

6

14

17

4

5

1

2

11

12

Mast Leg

Guide Beam(Bottom Section,

Rolling Configuration)

Universal tiebacks



Key to Universal tiebacks


1 117698 Tieback Link 2

2 117699 Attachment Plate 2

3 117700-1 Strap 4

4 117700-2 Strap 12

5 117700-3 Strap 6

6 117701 Strap 8

7 117702 Tieback Plate 1

8 117731 Flange Clamp 20

9 50016-32-C5 Screw, 1-8 UNC x 4.0 long 4

10 50416-C Nut, 1-8 unc 112

11 50916-C Lock Washer, 1" 72

12 50016-20-C5 Screw, 1-8 unc x 2.5 long 12

13 50816-R-C-5 Flat Washer, 1" 16

14 112893-1 Threaded Rod, 1-8 x 36" long 28

15 117659-15 Plate, 1.00 Thick 1

16 117659-16 Beam, W 12 x 72 x 384.0 long 1

17 117659-17 Beam, W 8 x 18 x 144.0 long 2

18 117659-DWG Universal Tieback Kit Drawing 1


5-16 Varco Systems

H

10

16

11

15

1

10

11

15

7

14

15

11

10

11

5

14

3

9

12

8

6

13

11

10

142

4

Mast Leg

Guide Beam(Bottom Section,

Sliding Configuration)

Tiebacks (sliding)



Key to Tiebacks (sliding)


1 117976 Tieback Link 1

2 117977-2 Beam, W 8 x 18 x 180.0 long 2

3 117700-1 Strap 4

4 117700-2 Strap 8

5 117700-3 Strap 4

6 117701 Strap 8

7 117982 Tieback Plate 1

8 117731 Flange Clamp 6,8

9 117977-9 Beam, W 12 x 72 x 384.0 long 1

10 50416-C Nut, 1-8 unc 16,32,64

11 50916-C Lock Washer, 1" 8,20,32

12 117977-12 Plate, 1.00 thick 1

13 50816-R-C-5 Flat Washer, 1" 16

14 112893-1 Threaded Rod, 1-8 x 36" long 4,8,16

15 119973 Strap 6

16 50016-64-C5D Bolt, 1.00 unc x 8.0 long 5


5-18 Varco Systems

Front

CC

9

2

1

3

4

5

6

5

8

7

EE

DD

Carriage/accumulator (roll)



Key to Carriage/accumulator (roll)


1 113450 Carriage Assembly, Right (30" setback) 1

2 113448 Carriage Assembly, Left (30" setback) 1

3 110562 Hydro-Pneumatic Accumulator, 6" 1

4 113370 Accumulator Strap, 6" dia. 1

5 50908-C Lock Washer, Regular 6

6 50108-10-CD Socket-head Cap Screw, 1/2 UNC x 1.25 2


8 88710 Align Accumulator Mount Strap 2

9 50008-10-C5D Hex-head Cap Screw 4


5-20 Varco Systems

Front

DD

4

1

12

17

16

4

5

9

9

722

8

11

13

13

8

3

6

2

10

21

8

13

15

14

11

18

19

20

Carriage assembly, right (roller)



Key to Carriage assembly, right (roller)


1 113449 Carriage, Right 1

2 112875 Bogey Pivot Pin 2

3 112876 Bogey 2

4 109903 Shim, 1/8" 12

5 113285 Cam Follower, 6" dia. 2

6 80784 Roller, 4" dia., Crowned, Modified 8

7 109904 Side Roller Bracket 2

8 51132-C Lock Washer, Hi-Collar, 2" dia. 12

9 53000-4-C Plug, 1/4" NPT 10

10 109944 Flanged Bushing, 2.75 ID 4

11 53209 Grease Fitting, 1/8"-27 NPT 12

12 10994 Sandwich Plate 2

13 80569 Jam Nut, 2"-12 UN-2B 12

14 50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long 3

15 51016-C Lock Washer, 1.0" dia. 3

16 50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long 6

17 51012-C Lock Washer, 3/4" 6

18 51220-2 Retaining Cable, .063 dia.

19 51219-2 Cable Ferrule 2

20 51221-6-K Detent Pin, 1/2" dia. x 2.75" long 1

21 109995 Chock 1

22 53000-2-C Plug, 1/8" NPT 2


5-22 Varco Systems

Front

EE

5

14

2

10

21

9

11

7

8

22

4

13

11

9

6

3

8

13

8

13

15

1

18

19

20

4

12

17

16

Carriage assembly, left (roller)



Key to Carriage assembly, left (roller)


1 113447 Carriage, Left 1

2 112875 Bogey Pivot Pin 2

3 112876 Bogey 2

4 109903 Shim, 1/8" 12

5 113285 Cam Follower, 6" dia. 2

6 80784 Roller, 4" dia., Crowned, Modified 8

7 109904 Side Roller Bracket 2

8 51132-C Lock Washer, Hi-Collar, 2" dia. 12

9 53000-4-C Plug, 1/4" NPT 10

10 109944 Flanged Bushing, 2.75 ID 4

11 53209 Grease Fitting, 1/8"-27 NPT 12

12 10994 Sandwich Plate 2

13 80569 Jam Nut, 2"-12 UN-2B 12

14 50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long 3

15 51016-C Lock Washer, 1.0" dia. 3

16 50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long 6

17 51012-C Lock Washer, 3/4" 6

18 51220-2 Retaining Cable, .063 dia.

19 51219-2 Cable Ferrule 2

20 51221-6-K Detent Pin, 1/2" dia. x 2.75" long 1

21 109995 Chock 1

22 53000-2-C Plug, 1/8" NPT 2


5-24 Varco Systems

Front

HH

GG

FF

7

8

6

5

8

4

3

101

2

9

Carriage/accumulator (skid)



Key to Carriage/accumulator (skid)


1 117594 Carriage Assembly, Right 1

2 117593 Carriage Assembly, Left 1

3 117621-1 Accumulator Strap, Long 1

4 117621-2 Accumulator Strap, Short 1


6 88710 Align Accumulator Mount Strap 2






5-26 Varco Systems

Front1

2

3

4

4

4

4

7

7

4

4

12

813

11

10

9

5

6

5

6 GG

Carriage assembly, right (skid)



Key to Carriage assembly, right (skid)


1 117592 Carriage, Right (machining) 1

2 117586 Carriage Angle (machining) 1

3 117588 Skid Pad 6

4 51608-8 Roll Pin 34



7 51608-12 Roll Pin 2

8 117870 Chock 2

9 117871 Plunger, Hand Retractable 2

10 56412-30-SHP Clevis Pin 2

11 51402-10-S Cotter Pin 2

12 50812-N-C Flat Washer, Narrow 4

13 50310-C Hex-Jam Nut 2


5-28 Varco Systems

Front

1

2

4

5

6

5

64

3

4

11

10

7 12

13

9

8

4

7

4

4

HH

Carriage assembly, left (skid)



Key to Carriage assembly, left (skid)


1 117591 Carriage, Left (machining) 1

2 117586 Carriage Angle (machining) 1

3 117588 Skid Pad 6

4 51608-8 Roll Pin 34



7 51608-12 Roll Pin 2

8 117870 Chock 2

9 117871 Plunger, Hand Retractable 2

10 56412-29-SHP Clevis Pin 2

11 51402-10-S Cotter Pin 2

12 50812-N-C Flat Washer, Narrow 4

13 50310-C Hex-Jam Nut 2


5-30 Varco Systems

34

Hydraulic System

5

6

7

8

9

1

2


Hydraulic system................................................... 8-3

Illustrated index ..................................................... 8-4

Hydraulic system diagram .................................... 8-5

Inspection .............................................................. 8-6Precautions........................................................ 8-6Maintenance schedule ...................................... 8-8Hydraulic fluid level and filter .......................... 8-9Hydraulic reservoir bladder.............................. 8-12Heat exchanger ................................................. 8-13Using the hydraulic system test ports ............ 8-14Precharging the accumulators......................... 8-15IBOP timing circuit ............................................ 8-16IBOP pressure switch ....................................... 8-17

Setting up the circuits ........................................... 8-18Hydraulic pumps and unloading circuit .......... 8-18Counterbalance circuit andstand-jump circuit ............................................. 8-22AC motor brake circuit...................................... 8-24Shot pin circuit .................................................. 8-24Link tilt cylinder circuit ..................................... 8-26Gearbox lubrication relief circuit ..................... 8-27Rotating link adapter hydraulicmotor relief circuit ............................................. 8-28

Troubleshooting .................................................... 8-29HPU and reservoir bladder ............................... 8-29Counterbalance and stand jump...................... 8-31AC motor brake circuit...................................... 8-35Shot pin cylinder and clamp cylinder .............. 8-37Link tilt cylinders............................................... 8-39

8Hydraulic System

8-2 Varco Systems

Gearbox lubrication hydraulic system ............ 8-41Rotating link adapter......................................... 8-43

Solenoid valve replacement procedures ............. 8-46Double A UL-type valve .................................... 8-46Atos EEx-type valve .......................................... 8-47

Hydraulic schematic symbols .............................. 8-49

8Hydraulic System


Hydraulic system

The hydraulic control system is a completely self-contained, onboardsystem. A 10-horse power, 1800 rpm, AC motor, drives two hydraulicpumps and powers the hydraulic system. A fixed displacement pumpdrives the lube oil system motor. A variable displacement pump provideshydraulic power for the AC motor brakes, powered rotating head, remoteactuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalancesystem. Three hydro-pneumatic accumulators are located on the mainbody.

The hydraulic manifold attaches to the main body and contains solenoid,pressure and flow control valves.

A sealed stainless steel reservoir supplies hydraulic oil, eliminating theneed for draining and refilling during normal rig moves. The reservoir ismounted between the AC drilling motors and is equipped with strainersand an oil level sight gauge.

8Hydraulic System

8-4 Varco Systems

Illustrated index

Power

Reservoir Capacity

10 hp, 1,800 rpm, AC motor

25 gal

Specifications

10 HP ACMotor and

Pump AssemblyPage 8-X

Rotating HeadMotor andShot Pin

AssemblyPage 8-X

IBOPDelay CircuitAccumulator

Page 8-X

HydraulicOil FillPage 8-X

HydraulicManifoldPage 8-X

VariableDisplacement

PumpAccumulator

Page 8-X

CounterbalanceAccumulator

Page 8-X

HydraulicOil FilterPage 8-X

Hydraulic OilReservoir

Page 8-X(Between AC

Drilling Motors)

Front

Rear

Front

Rear

8Hydraulic System


Hydraulic system diagram

MReservoir

FixedDisplacement

Pump (Mtr. Lube)


Pump

10 HP A.C.Motor

RotatingHeadMotor

Lock-upCylinder


DrillingMotor Brake

Upper IBOPActuator Cylinder

Link TiltCylinders

PipehandlerClamp Cylinder

CounterbalanceCylinders

Lube OilDistribution

SystemAccumulator

Lube OilPump

PV PF

Rotating Head(Elevator Positioner)

System Control Manifold

Low SpeedHydraulic

Motor

Upper IBOPUnloading

Accumulator

Gearbox Sump

8Hydraulic System

8-6 Varco Systems

Inspection

PrecautionsTo avoid serious injury or death, read and understand the followingwarnings before performing inspection and maintenance procedures:

n Properly lockout the main power source before performinglubrication, inspection, or replacement procedures, unlessspecifically noted in this manual.

n Wear protective glasses to prevent eye injuries from fluids underpressure, as well as other hazards.

n Do not attempt any adjustments while the machine is moving.

n Use caution when draining lubricant. It can be hot.

n Never check for hydraulic leaks with your hands. Oil underpressure escaping from a hole can be nearly invisible and canpenetrate skin causing serious injury. Always check for leaks with apiece of wood or cardboard and always wear protective eyewearwhen working on hydraulic components.

n Always discharge the three hydro pneumatic accumulators beforeperforming repairs on the hydraulic system.

n Do not attempt repairs you do not understand.

n Read and understand all safety precautions and warnings beforeperforming maintenance procedures.

8Hydraulic System


n Release all hydraulic oil pressure by bleeding accumulators beforedisconnecting hydraulic lines. Turn the counterbalance vlave toshutdown mode to bleed the hydraulic system. Hydraulic oil underpressure can penetrate skin and cause serious injury.

n Before opening the hydraulic system, thoroughly clean work area,and maintain system cleanliness by promptly capping alldisconnected lines. Dirt is extremely harmful to hydraulic systemcomponents and can cause equipment failure and subsequentinjury to personnel.

e Use care when handling components to prevent nicking close tolerancefinishes.

n Hydraulic fluid escaping under pressure can penetrate the skincausing serious injury. Avoid injury by discharging the threeaccumulators and relieving pressure before disconnectinghydraulic lines. Always search for hydraulic leaks with a piece ofcardboard or wood-not with your bare hands. Get immediatemedical attention for hydraulic fluid injuries. Fluid injected into theskin must be surgically removed within a few hours or gangrenemay result. Do not tighten hydraulic fittings while they are underpressure.

Inspect the hydraulic system daily for leaks at fittings, damaged hosecovers, kinked or crushed hoses, hard or stiff hoses, and damaged orcorroded fittings. In addition, during the inspection, tighten or replace anyleaking port connections, and clean any dirt buildup from hydrauliccomponents.

n Replace worn or damaged hydraulic system componentsimmediately.

Inspect the hydraulic fluid level in the hydraulic reservoir located betweenthe AC drilling motors daily. Inspect the hydraulic filter located on theupper left AC drilling motor daily.

8Hydraulic System

8-8 Varco Systems

Maintenance schedule

Oil Temperature Range

CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion

NGLIAGMAISO ViscosityGrade

-10 to 85 C(14 to 185 F)

HYDRAULIC OIL



DTE 25Tellus 46



N/R246

-15 to 75 C(5 to 167 F)



DTE 24Tellus 32



N/RN/R32

DESCRIPTION FREQUENCY

Perform Hydraulic SystemOil Analysis

Replace Hydraulic Fluid

Replace Hydraulic SystemFilter (P/N 114416-1)

1 x every 6 Months

1 x Year, or EarlierBased on Oil Analysis

1 x every 3 Months

Hydraulic System OilLubrication Schedule

Recommended Lubricants

1.

2.

3.

Check condition of the hydraulic filter indicator

Check hydraulic fluid levels

Check for hydraulic fluid leaks

Daily Inspections

8Hydraulic System


Hydraulic fluid level and filter

HydraulicOil Fill

RedPop-up

Dirt Alarm

HydraulicOil Filter



SightGlass

Hydraulic OilFill Quick

Disconnect

n Check the red pop-up alarm on the hydraulic filter daily. Replace it if the indicator has popped up.

n Use care to prevent contamination from entering the hydraulic system during maintenance activities.

n The first oil change should be performed sooner than six months since new installations often contain metal contamination caused by connecting slightly damaged threaded parts.

Daily

8Hydraulic System

8-10 Varco Systems

Adding the hydraulic fluid

HydraulicOil Fill



SightGlassHydraulic OilFill Quick

Disconnect

LubricationKit Quick

Disconnect

n Ensure that the area is clean prior to adding hydraulic fluid

n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill

n Remove dust plug from the female quick disconnect on the lubrication kit

n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm

Reservoir Capacity

HydraulicLubrication Kit

55 gal Drum

25 gal

Specifications

8Hydraulic System


Draining the hydraulic fluid


Pump

FixedDisplacement

Pump

10 HP ACPump Motor

PumpInlet/Drain

Adapter

8Hydraulic System

8-12 Varco Systems

Hydraulic reservoir bladder

Hydraulic Oil Reservoir(Between AC Drilling Motors)

ReservoirCover

Reservoir Bladder(Varco P/N 110191-501

or 110191-500)Check for holes, tears,

wear and cracks

Hydraulic OilReservoir

Front

Rear

n Clean area before inspecting the reservoir bladder

n Remove the 10 cap screws and lock washers from the cover

n Remove cover with bladder attached

n Check yearly for holes, tears, wear and cracks

Yearly

8Hydraulic System


Heat exchanger

Drill MotorAssembly

Blower andBrake Covers

Oil HeatExchanger

(Varco P/N 110170)Inspect for leaks, corrosion,blockage, and cleanliness.

Replace yearly or as required.

Yearly

8Hydraulic System

8-14 Varco Systems

Using the hydraulic system test ports

* These test ports are on sides or bottom of manifold.

T1

SA

P

PV

P1

A4SV4

SV5

Clamp/Shot Pin Float Link

TiltSV8SV6

G5

B8

B6

A6

B5C5

C4

L4

B1

SV2Rotating

LinkAdapter

Z1 B9

PF

SV1SV9Stand Jump Brake

IBOP*

*

*

*

As Viewed From Below

CB

8Hydraulic System


Precharging the accumulators

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

n Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge

n Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge

Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above.

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.

Note that there is a time delay in pressure decay on port C4.

Test the precharge pressure on the following three nitrogen filled accumulators, using part number 114446-1.

IBOPDelay CircuitAccumulator

HydraulicManifold


PumpAccumulator


Front

Rear

8Hydraulic System

8-16 Varco Systems

IBOP timing circuit

Full Page

ARTWORK PLACEHOLDER

FP

105 20 30 40 50 60 70 80 90 0.1 0.2 0.5 0.8 1.0 1.5 2.0 2.5

0.1

0.2

0.5

0.8

1.0

1.5

REV.B 09.01.95

DRILLING SYSTEMS

8Hydraulic System


IBOP pressure switch

Full Page

ARTWORK PLACEHOLDER

FP

105 20 30 40 50 60 70 80 90 0.1 0.2 0.5 0.8 1.0 1.5 2.0 2.5

0.1

0.2

0.5

0.8

1.0

1.5

REV.B 09.01.95

DRILLING SYSTEMS

8Hydraulic System

8-18 Varco Systems

Setting up the circuits

Hydraulic pumps and unloading circuitThere are two pumps a fixed displacement pump runs the transmissionlubrication system and a variable displacement pump provides hydraulicflow to the hydraulic system.


Pump

FixedDisplacement

Pump

10 HP ACPump Motor

Motor and PumpAssembly

Allen Wrench

Valve

Front

As Viewed from Below

8Hydraulic System


1. Locate the tube connecting manifold port PF to the lubrication motor.Disconnect the tube at the manifold end, cap the tube and plug thePF port using steel fittings.

2. Set the relief valve RV1 for the variable displacement pump to aminimum setting, fully counterclockwise, which allows the hydraulicsystem to operate without building up pressure.

3. Set the relief valve RV2 to minimum pressure, fully counterclockwise.

z Make sure the variable displacement pump case is filled with cleanhydraulic oil.

4. Jog-start the electric motor to make sure the direction of rotation iscorrect (clockwise when looking into pump shaft/electric motor fan).Correct as required.

5. Start the electric motor and allow both hydraulic pumps to circulateoil. Listen for unusual noises that would indicate cavitation; check forleaks.

6. Connect a gauge to test point PF. Increase the pressure by adjustingrelief valve RV2 clockwise until the pressure increases to 400 psi attest point PF. Set the jam nut on RV2. A steel cap is installed over theadjustment screw to discourage unauthorized adjustment.

z While adjusting valves, verify a linear relationship between turning theadjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between manifold portPF and the lubrication motor.

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

9. Restart the hydraulic system electric motor.

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

11. Adjust UV1, fully clockwise, to maximum pressure.12. Connect a gauge to test point PV. Note the ammeter reading while

RV1 is at minimum setting.

8Hydraulic System

8-20 Varco Systems

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

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

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

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

17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.18. Install steel cap over the adjustment screw to discourage

unauthorized adjustment.19. Adjust unloading valve UV1 counterclockwise until the pressure at

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

20. Observe the unloaded pressure at PV (about 0 psi) while SA readsabout 2,000 psi. The pressure at SA decays until UV1 reloads. Afterreloading, the pressure rapidly rises to the unload pressure.

8Hydraulic System


Pressure at SA

Approximate Time (Seconds)

Pressu

Manual

Documents

Transcript of Manual