Training Manual

Company Owner

Top DriveTraining Manual

Varco Technical Education CentreMontrose Scotland

TOP DRIVETraining Manual

Description

Training Manual



Installation

Training Manual June 99

Chapter 1

Preparation

Preinstallation checklist

The following assumes that all preinstallation planning and rig-uphas been accomplished prior to installation of the TDS. Thisincludes:

1. Guide rails and bracing are installed and inspected toconform to Varco specification and installation tolerances(Figures 1, 2, and 3).

2. Stops are ready for installation at the bottom of the rails.

3. Hydraulic and air standpipes are installed in the derrick,flushed clean and pressure tested. Water piping is installed,flushed and pressure tested as well for configurations withclosed loop cooling systems.

4. All electronics are installed up to the derrick junction box:DC power leads, AC leads for blower motor, and control/alarm signals.

5. The transfer panel is installed.

6. Rigging of the tong lines, etc. are inspected to ensure thatthey will not foul with the TDS and other rig equipment.


Chapter 2

Installation

Derri ck electrical termination kit

InstallationRefer to Figures 1, 2 and 3 for typical mounting dimensions ofthe plate assembly. Mount it at racking board height within 15' ofthe service loop support bracket. Remember to provideconvenient access for wiring and maintenance.

Usually, mounting the plate so that the J-box is four to five feetabove the walk-around and near the service loop support bracketis adequate. If a walk-around does not exist, then construct awork platform to allow access to the J-boxes. Manufactureappropriate brackets and clamps to attach the plate to the derrickstructure.


OPERATIONAL CLEARANCE BETWEEN TOP DRIVE& NEAREST GIRT OR FASTLINE SHOULD BE 3“ MINIMUM

DOLLYOVERHANG

± 1/4"OVER FULL LENGTH

± 3/8" OVER FULL LENGTH± 1/8" WITHIN 25' OF FLOOR

± 3/8 OVER FULL LENGTH± 1/8" WITHIN 25' OF FLOOR

C WELLL

10' 6" +0"/-4"

SUPPORT SPACINGMAXIMUM RAIL

16 FT FOR W12x53 RAILS25 FT FOR W14x74 RAILS

NEAREST GIRT

GUIDE RAILS

LC WELL

LC RAIL

SPLICECLEARANCE

DRILL FLOOR

6" RAILSTOP

TDS BACK

LC RAIL

LC WELL

SPLICE PLATESOR BOLTS ARENOT PERMISSABLEON INSIDESURFACES OFBEAM

39 X 66 W14X7448 X 62 W14X7430 X 72 W12X5330 X 72 W14X74

3.33.3

2.33.3

001.60.5

RAILSIZE

SPLICECLEAR

DOLLYOVERHANG

INCHES

GUIDEDOLLYCONFIG

LC RAIL LC RAIL

Figure 1. General rail installation data


10' 6"+0"/-4" 7 FT REF

73 FT. MUD HOSECONNECTION

83 FT. HYD, AIR & WATERSTANDPIPE HEIGHT &SERVICE LOOP BRACKETLOCATION

TYPICAL EQUIPMENT STACK-UP

* CUSTUMER SUPPLIED** VARCO SUPPLIED

86 FT.SERVICELOOPS

B

B

16.00

ELECTRICAL SERVICE LOOP **

BRACES *

INSTRUMENT J-BOX **MOTOR J-BOX **

DERRICK J-BOX PLATE16.0

16.0

16.0

MUST SUPPORT4000 LBS

VIEW A-ATYPICAL SERVICE LOOP TERMINATION

GUSSETS *

EXISTING GIRT *

VIEW B-B

HYDRAULICSTANDPIPESTO BE1-1/2”SCHED 80 PIPE*

AIRSTANDPIPESTO BE1-1/2”SCHED 40 PIPE*

WATERSTANDPIPESTO BE 2” SCHED 40 PIPE*

CLEARANCE HOLEFOR .75 DIA BOLT4 PLACES

CONVENIENTWORKING HEIGHTABOVE WALKAROUND

SERVICELOOPBRACKET**

75 FT.MUDHOSEREF

A

A

Figure 2. Derrick services/general installation data


Rail Stops

42,600 LBS for a typical TDS-3S48,000 LBS for a typical TDS-4S52,000 LBS for a typical TDS-7S

Motor FrameSetback

L

L

L

L

Rails

9'3" TDS-3S10'3" TDS-4S 7'0" TDS-3S

8'0"TDS-4S,TDS-6S

Rail Loading while Drilling - 38,000 FT LBS for TDS-3S, 60,000 FT LBS for TDS-4S, 68,000 FT LBS for TDS-6S, and 34,000 FT LBS for TDS-7S.

Rail Spacing TDS-3S TDS-4S

Load L - LBS

39 x 66 3450

TDS-6S

--

48 x 62 3680 --

30 x 72 3170 --

--91/101 x 108 --

5450

5800

5000

3330

3090

3290

2840

3780

TDS-7S

P

P

Rail Loading with TDS in Setback position

Rail Spacing

39 x 66

48 x 62

30 x 72

TDS-3S TDS-4S

Load P - LBS

18,600

18,600

17,500

18,900

18,900

17,800

Figure 3. General installation data


Rail Stops

48,000 LBS for a typical TDS-4H

Motor FrameSetback

L

L

L

L

Rails

10'3" TDS-4H

7'0"TDS-4H,

Rail Loading with TDS in Setback position

Rail Spacing TDS-4H

Load P - LBS

39 x 66

48 x 62

30 x 72

18,900

18,900

17,800

Rail Loading while Drilling - 60,000 FT LBS

Rail Spacing TDS-4H

Load L - LBS

39 x 66 5450

48 x 62 5800

30 x 72 5000

91/101 x 108 3330

Figure 1c. General installation data (cont.)


WiringThe electrical installation requires routing power to the transferpanel and then to the TDS through the service loops (Figure 4).In addition, control cables are required between the service loop,the transfer panel, the SCR, the TDS driller’s console, the SCR’sdriller’s console, the hydraulic and water pumps and the drillingrecorder.

Transfer Panel

#12AWG/20C#10AWG/4C#14AWG/2 Pr Shld#6AWG/2C*Shunt Field

TopDrive

System

DerrickA.C.

J Box

DerrickPowerJ Box

Ser

vice

Loo

p

RotaryTable

ExistingPowerCables

#14A

WG

/2 P

r S

hld

#12A

WG

/3C

#14A

WG

/37C

#12A

WG

/20C

#16A

WG

/10C

#12A

WG

/20C

#12A

WG

/20C

#10A

WG

/4C

#10A

WG

/4C

#6A

WG

/4C

#6A

WG

/4C

#12A

WG

/3C

#14A

WG

/2 P

r S

hld

#10AWG/4C

#16AWG/10C#16AWG/10C

#16A

WG

/10C

#16A

WG

/10C

#6AWG/2C*Shunt Field

#16AWG/10C

SCRRoom

ACPower

E/PTorq

E/PRPM

RBSControls

#12A

WG

/3C

TDSDriller's Console

ExistingDriller's Console

HYDPump

#1

HYDPump

#2WaterPump

#1

WaterPump

#2

(4)646MCM*

Figure 4. Typical cabling diagram


The cable requirements, depending on options selected are:

Cable Runs

646MCM (4 Shunt) SCR room to transfer panel

(8 Series) Transfer panel to derrick J-boxTransfer panel to rotary

#6AWG/2C (Shunt only) SCR Room to transfer panelTransfer panel to derrick J-boxTransfer panel to rotary

#6AWG/4C AC Power to hydraulic pumps

#10AWG/4C AC Power to water pumpsAC Power to transfer panelTransfer panel to derrick J-box

#12AWG/20C Transfer panel to derrick J-boxTransfer panel to hydraulic pumpsTransfer panel to water pumps

#12AWG/3C Transfer panel to RBS unitTransfer panel to driller’s consoleRBS unit to driller’s console

#14AWG/37C Transfer panel to driller’s console

#14AWG/2PR SHLD Transfer panel to derrick J-boxTransfer panel to driller’s consoleTransfer panel to drilling recorder

#16AWG/10C Transfer panel to SCR consoleTransfer panel to SCR room

Purge control system (not shown)

#12AWG/3C Purge control unit to transfer panelIsolation unit to floor air control unitTransfer panel protection unit to isolation unit

#16AWG/10C Purge control unit to transfer panelDriller’s console protection unit to isolation unit

#14AWG/2PR SHLD Transfer panel to derrick J-box

Terminate the J-boxes per the electrical schematic. Followapplicable electrical codes during installation. Cable glands areprovided for the service loop cables. Cable glands for theincoming power, control and signal cables are not provided.


Plumbing

The plumbing connections should terminate near the service loopbracket. The mating halves are preassembled on the service loop.Specifications for specific lines are described in the followingsections.

HydraulicHydraulic lines should be cleaned and pickled, black pipe lines(one pressure and one return) 1 1/2" or 2" schedule 80 pipe.Install shut-off valves at the drill floor or racking board level. Thederrick connections are reduced to 1" NPT female pressure andfluid return for connection to the service loop.

AirAir lines should be schedule 40, 1" or 1 1/2" pipe in the case ofthe purge supply for the TDS. Install a shut-off valve at drill flooror racking board level. The air lines connect to the filtered andlubricated supply. The derrick connections are reduced to 1"NPT female for the purge line (if required) and 1/2" for the airline in order for the fluids service loop to match.

z Do not connect purge air lines to the lubricator. Only use clean,dry air in the purge air system.

WaterThe two cooling lines should be schedule 40, 2" pipe. Installshut-off valves at the drill floor or racking board level. See thecooling system specifications for water supply requirements. Thederrick connections are reduced to 1 1/4" NPT female pressureand return for connection to the fluids service loop.

September 16, 1996

16 TDS-4H Installation and commissiioning

Rig-up procedure

z Refer to the engineering drawings to install the TDS.

1. Change out the swivel bail pins with the longer ones supplied(Figure 3). A welder may be required to weld in the pinretainers, depending on the manufacturer of the swivel.

z Unless a new or recently-overhauled swivel is used, the old bailpins may need to be machined out.

2. Install the nipple and female union sub for the S-tube ontothe swivel gooseneck.

3. Hang the swivel from the hook or block and makeup themain shaft to the swivel stem using a thread compound of60% lead by weight (Refer to the IBOP Service Manualincluded as a separate book in this manual for torquespecifications).

z Generally, a swivel saver sub is not used unless a crossover sub isrequired.

The connection on the main shaft is 7-5/8 API regular left hand.The bail bumper on the swivel faces the guide rails. On someswivel/rail setback combinations, the bumper side ears mayrequire trimming to clear the motor guide dolly.

4. Loosely install the bearing shield around the flange on themain shaft with the T-bolt clamp supplied. After the mainshaft is stabbed into the quill shaft, adjust the shield andtighten the clamp.

September 16, 1996

TDS-4H Installation and commissioning 17

5. Use the four lift slings from the crane, one attached at eachcorner of the guide dolly, to lift the top drive motor and dollyassembly onto the rig floor. If possible, set it on the rig floorwith the crane - do not drag it up the V-door. Position it on therotary table with the swivel end under the guide rails. Theslings must be a minimum of 15' long (equal length) andcapable of lifting 40,000 lb combined. (BOP lift slings areusually adequate.)

Figure 3. Swivel assembly

September 16, 1996


6. Attach lifting slings to the pad eyes located at the swivel endof the motor frame and lift the TDS into the guide rails.

z On some configurations it may be necessary to remove the upperroller brackets from the dolly to allow the unit to engage theguide rails.

7. Once the TDS is fully engaged on the guide rails, install thestops at the bottom of the guide rails and lower the TDS ontothe stops.

8. Apply a liberal amount of grease to the main shaft from 6"below the splines up to the top flange. Also grease the top andbottom 18"of the quill shaft I.D. Pack both the main shaftand bull gear splines flush with grease. Check the O-ring inthe groove located 12" inside the quill shaft to be sure it isgreased and located properly.

9. Spread apart the swivel links and stab the swivel/main shaftthrough the quill shaft with care, until the drive splines arefully engaged. Slide the swivel links onto the extended bailpins and install the retainers with the bolts, lockwashers andsafety wire supplied.

10. Slide the link adapter onto the main shaft and support it upagainst the rotating head with adequate rigging and an airwinch. Be certain that the link tilt mounting bosses areopposite from the torque wrench mounting clevis on therotating head.

11. Slide the landing collar retainer onto the drive stem as shownin Figure 4. Install the O-ring in the uppermost groove on thestem. Load the O-ring and remaining grooves with awaterproof grease. Place the split landing collar around thegrooves of the drive stem, and drive in the remaining roll pin.Grease the O.D. liberally, and slide the retainer down,covering the split landing collar. Use a hammer and drift tobend all 32 tabs on the retainer to secure the split landingcollar. Wipe off excess grease.

12. Use the pipehandler to tighten the connection between thelower IBOP/saver sub assembly to the upper IBOP.

September 16, 1996


DriveStem

LandingCollarRetainer

Landing CollarRetainer Tabs

Safety Link (4)

Roll Pin (4)

Split LandingCollar (2)

O-Ring

Figure 4. Landing collar installation

September 16, 1996


13. Pull up on the release handle and unlock the rotating head.Rotate the link adapter and the rotating head so that themounting point for the torque wrench is at the front of thetool. Raise the torque wrench with the air winch and pin intoplace. Adjust hanging position per the procedure described inBook 4. Rotate the pipehandler assembly to the rear andconnect the two air hoses and two hydraulic hoses. Quickdisconnects on the hoses allow connection in only one way sothat the hoses cannot be interchanged.

14. Connect the hose to the back of the link tilt actuator. Use thefour bolts, lockwashers and safety wire provided to install thelink tilt acutator to the link adapter. Connect the oppositeend of the hose to the quick disconnect on the rotating headassembly.

15. Install the elevator links and drill pipe elevator. Attach thelink tilt clamps to the bails (U-bolts on the inside). Allow for1/2" slack in the chains.

16. Install the counterbalance system as follows (Figure 5):

a. Install pear links to ears on hook-block.

b. With the hook supporting the top drive, measure distancefrom bottom of pear link to top of mounting lug onswivel link (Dimension A).

c. Subtract 37 1/4" from dimension A.

d. Cut chain to the length obtained in step c (measure insidechain links per illustration). The tolerance is: +3 1/4"/-0".

e. Assemble remaining components and install per theillustration.

September 16, 1996


Figure 5. Counterbalance system

September 16, 1996


17. Attach the service loops to the bracket on the top drive frame.Use the cable clamps provided on the motor frame to routethe electrical cables over the gear box and into the junctionboxes. The front guard swings aside for access to the junctionboxes by removing the attachment bolts on one side.

Use the electrical schematic (refer to the engineeringdrawings) to make the connections. Be certain that the cablesare securely tied or clamped to the structure along theirlength. Route the hoses to the bulkhead and plug in the quickdisconnects. Follow the stamped code numbers to confirmeach type and identify spares.

18. Attach the S-tube to the swivel gooseneck and the side of themotor frame as follows (Figure 6):

a. Makeup the upper union just before clamping S-tube toside of motor frame.

b. Install the drill pipe rubber onto the S-tube aligned withmounting saddle on the frame.

c. Attach the mud hose to the bottom connection of S-tube.

d. Position 15° S-tube elbow on bottom of S-tube to adjustthe hanging direction of mud hose.

September 16, 1996


Figure 6. S-Tube installation

August 22, 1997

16 TDS-4S Installation

Rig-up procedure

z Refer to the engineering drawings to install the TDS.

1. Using four lift slings from the crane, one attached at eachcorner of the guide dolly, lift the TDS motor and dollyassembly to the V-door.

2. Attach the lifting slings from the hook or block to the padeyes located at the swivel end of the motor support bonnetand lift the TDS into the guide rails. The slings must be aminimum of 15' long (equal length) and capable of lifting40,000 lb combined. (BOP stack lift slings are usuallyadequate.)

z On some configurations it may be necessary to remove the upperroller brackets from the dolly to allow the unit to engage theguide rails.

3. Once the TDS is fully engaged on the guide rails, install thestops at the bottom of the guide rails and lower the TDS ontothe stops.

4. Slide the link adapter onto the drive stem and support it upagainst the rotating head with adequate rigging and an airwinch. Be certain that the link tilt mounting bosses areopposite from the torque wrench mounting clevis on therotating head.

5. Slide the landing collar retainer onto the drive stem as shownin Figure 5. Install the O-ring in the uppermost groove on thestem. Load the O-ring and remaining grooves with awaterproof grease. Place the split landing collar around thegrooves of the drive stem. Grease the O.D. liberally, and slidethe retainer down, covering the split landing collar. Use ahammer and drift to bend all 32 tabs on the retainer to securethe split landing collar. Wipe off excess grease.

6. Use the installation procedure in the IBOP Service Manual(included as a separate book in this manual) to install thepipehandler assembly.

7. Use the pipehandler to tighten the connection between thelower IBOP/saver sub assembly to the upper IBOP.

TDS-4S Installation 17

DriveStem

LandingCollarRetainer

Landing CollarRetainer Tabs

Split LandingCollar (2)

O-Ring

Figure 5. Landing collar installation

August 22, 1997


8. Connect the hose to the back of the link tilt actuator. Use thefour bolts, lock washers and safety wire provided to install thisassembly to the link adapter. Connect the opposite end of thehose to the quick disconnect on the rotating head assembly.

9. Install the elevator links and drill pipe elevator. Attach thelink tilt clamps to the bails (U-bolts on the inside). Thereshould be about 1/2 inch slack in the chains.

10. Install the counterbalance system as illustrated in Figure 6.When using chain, use the following procedure to determinethe chain length required:

a. Install pear links to ears on hook-block.

b. With the hook supporting the TDS, measure the distancefrom the point of contact inside the pear link to the topof the mounting lug on the integrated swivel bail.

c. Subtract 37 1/4" from the measurement in step b.

d. Cut the chain to the length obtained in step c. Thetolerance is: +3-1/4" or -0".

e. Assemble remaining components and install per Figure 6.

Pear Link

HydraulicAccumulator(Inside Motor Frame)

Motor Frame &Guide Dolly Assy.

CounterbalanceCylinder Assy. (2)

ConnectingLink

Counterbalance Manifold(On Guide Dolly)

Counterbalance Lug(Bolted to Bail)

IntegratedSwivel

Bail

Figure 6. Counterbalance system


11. Attach the service loops to the bracket on the TDS dollyframe. Using the cable clamps provided on the motor supportbonnet, route the electrical cables over the gear box and intothe junction boxes. The front guard folds down for access tothe junction boxes.

Use the electrical schematic (refer to the engineeringdrawings) to make the connections. Be certain that the cablesare securely tied or clamped to the structure along theirlength. Route the hoses to the bulkhead and plug in the quickdisconnects. Follow the stamped code numbers to confirmeach type, and identify spares.

12. Attach the S-tube to the swivel gooseneck and the side of themotor frame as follows:

a. Make up the upper union just before clamping theS-tube to the side of the motor frame.

b. Install the drill pipe rubber onto the S-tube aligned withthe mounting saddle on the frame.

c. Attach the mud hose to the bottom connection of theS-tube.

d. Position the 20° S-tube elbow on the bottom of theS-tube to adjust the hanging direction of mud hose.

13. Remove the exhaust duct shipping cover from the sparkarrestors on the air exhaust duct at each side of the DCmotor. Save the covers for use during future shipping orstorage.

n Never operate the top drive with the exhaust duct coversattached to the spark arrestors on the air exhaust ducts. Doingso severely restricts air flow through the motor, causingoverheating and potential damage. They can also fall offduring operation and injure personnel working below. Attachthe covers only during shipping and storage.

August 22, 1997


Counterbalance system

Figure 6 illustrates the installation arrangement for this system.Please see the Maintenance and troubleshooting book for theadjustment procedures.

This assembly is pre-charged when it is shipped by land or watertransport. When this assembly is shipped by air freight, it must bepre-charged according to the instructions inthe Maintenance andtroubleshooting book.


Motor alignment cylinder system

Figure 7 shows the motor alignment cylinder installed on atypical motor frame.

The split shipping brace, shown exploded from the cylinder rod,is only removed after unit is fully installed. If the brace is removedbefore the hydraulic system is powered, the motor will tend torotate on its trunnions.

If the cylinder is removed for service, use the three bleed holes(located along the top of the cylinder barrel) to remove trappedair from the cylinder before operating the unit. Refer to theMaintenance and troubleshooting book for the adjustmentprocedure, as this dimension can vary.

MotorAlignmentCylinder

MotorFrame Dolly (Ref)

Split Shipping

Brace

Figure 7. Motor alignment cylinder

August 22, 1997


Driller’s controls and instrumentation

The controls and instrumentation described in the followingsections are, or must be, supplied for operation of the TDSsystem.

Driller’s consoleMount the driller’s console within easy reach and in plain view ofthe driller while he is operating the drawworks brake andclutches. The gauges must be easily seen by the driller duringdrilling operations. Provide appropriate cable glands for theelectric cables.

Throttle and torque limit controlsThe throttle and torque limit controls are the standard controlsused for the independent rotary drive table. If not using anindependent rotary drive, then these controls must be added bythe SCR manufacturer.

WiringRefer to the electrical schematics in the engineering drawings.

n Customers who choose to use control systems not manufacturedby Varco should be aware that Varco systems are specificallydesigned with operational interlocks and safety devices toprevent possible injury to personnel or damage to the system.Other systems must meet Varco requirements. Varco highlyrecommends the use of its system as it is specifically made foruse with the TDS system.


Service loops

InstallationInstall the service loops as follows:

1. Fabricate the appropriate brackets and clamps to attach theservice loop mounting bracket to the derrick structure.

2. Place the service loop derrick mounting bracket at the heightspecified on the derrick interface drawing provided in theengineering drawings. Locate the bracket on the side of thederrick adjacent to the hinges on the TDS and as far aspractical toward the corner where the guide rail bracing isattached. The bracket must be located far enough from thecorner to insure the loops do not catch under the guide railsduring operations, but far enough back to provide clearancefor tong lines, the stabbing board, tugger lines, etc.

3. Do not unpack the service loops from the shipping protectivecrate until they are ready to hang in the derrick. Lift theservice loops onto the rig floor (still in the crates) and thenremove them from the crates with the lifting eyes provided.

e Use care in lifting gear rigging so as not to damage electricalconductors. Use lifting eyes only. Do not bend the service loops tighterthan a three foot bend radius. Tighter bends damage the loops.

4. Attach a sling to the top drive end of the service loop and liftusing the lifting eyes only. Allow enough room for the 86-footlong service loop to hang and untwist.

5. Use the lifting eyes to pull the derrick end of the loopthrough the "V" door and attach it to the air tugger. Hoistthis end of the loop into the derrick while slacking off at thecrane end. Do not drag the loop on any sharp areas on thederrick . Disconnect the crane from the sling and continuehoisting the loop into the derrick.

6. Check that the derrick end of the loop is hanging toward thecrown. Attach the derrick end to the derrick service loop bracketand hold in place with flange clamps (Figures 1 and 2).

August 22, 1997

Training Manual June 99n

7. Pick up the TDS end of the loops and attach them to theservice loop bracket at the bottom of the motor frame.

8. Complete the terminations of the two loops as outlined in thefollowing sections.

Electrical loop1. Connect the pre-terminated wire ends at the motor J-boxes

using the appropriate glands. Refer to the electrical schematicprovided to ensure proper terminal block assignments.

2 Cut wires and cables to length and terminate them at thederrick end to attach them to the derrick J-boxes.

Terminal ends and lugs are supplied, but proper assemblyequipment (crimping pliers, wire strippers, and hydraulic crimperfor the DC power lugs with the correct dies for the cable) must beprovided by the installer. Installation practices should complywith applicable electrical codes (i.e., NEC, etc.).

Fluids loop1. Before connecting the hoses from the service loop, be certain

that the service stand pipes have been flushed free of anycontamination.

z Use only 10 wt. hydraulic oil or non-detergent motor oil as alubricant in the air system. Use of any other type of oil (i.e., MarvelMystery Oil, etc.) or synthetic additive will cause the seals in the airvalves to swell and cease to function.

2. Plug the quick disconnects into the appropriate mating endon the TDS. The quick disconnects are arranged to connectonly one way so that the hoses cannot be mixed up. Thehydraulic and air lines are identification stamped at both endsso they can be verified and connected properly.

An assortment of pipe fittings are supplied with thetermination kit to attach the fluid service loop hoses to thetop of the standpipes in the derrick (Figure 2).


3. Connect the service loop to the standpipes, noting the codes(i.e., A for air, H for hydraulic, etc.) to separate the hoses.

z The hoses in the fluid loop only extend 11' from the mountingbracket. It may be necessary to make jumper hoses to reach thestandpipes.

Air loop

e To reduce the possibility of accidental opening of the air operatedelevator attach the airlines from the air operated elevators to the spareport S1 on the rotating head whenever possible. Port S1 is locatednext to the hydraulic return port in the rotating head. Port S2 is nextto the hydraulic press port.

Install a pressure relief valve on the elevator and set at 200 psi.


Chapter 3

Commissioning

Checkout p rocedure1. Turn on the hydraulic and air power and check for leaks.

Repair as required.

2. Turn on the electric power (driller’s controls only).

3. Check the function of switches and solenoids. There is anaudible click when each solenoid is actuated.

4. Actuate the link tilt. Be sure that it operates smoothly and theelevator reaches a joint in the mousehole.

5. Adjust the intermediate stop so that the elevator clears themonkey-board when actuated. Refer to the Maintenance andtroubleshooting book if a problem occurs.

6. Actuate the motor brake. There is a loud sound as the airescapes when the brake releases.

7. Move the make/break valve located on the manifold at the backof the pipehandler torque wrench to the BREAK position.

8. Turn on the hydraulic power supply and adjust the pressurereducing valve (also located on the torque wrench manifold)to the appropriate pressure for the lower IBOP connection.

August 22, 1997


9. Return the Make/Break valve to the MAKE position.

10. Torque the connection between the upper and lower safetyvalves. The torque wrench automatic sequence is adjusted atthe factory, but be sure that it follows the proper sequence. Ifnecessary, refer to the Maintenance and troubleshooting bookfor the adjustment procedure.

11. Push and hold the control button on the driller’s console asufficient number of times to make up the connection.

12. Make up the lower IBOP to the saver sub.

13. Reset pressure to the appropriate setting for drill pipeconnections (you can preset the pressure with the Make/Breakvalve in the MAKE position).

14. Use the procedure outlined in the Maintenance andTroubleshooting book to adjust the safety valve actuatormechanism.

15. Actuate the safety valve. Verify that the stroke adjustment iscorrect and that no binding occurs.

e It is extremely important to verify that the stroke adjustment is correctand that no binding occurs as the valve will fail prematurely (washout) if it does not open and close fully.

16. Verify that the indicator light on the driller’s console lights upwhen the safety valve is closed.

17. Assign the TDS at the driller’s console and check that theblower operates.

18. Advance the throttle and be sure that the motor is operatingproperly in both directions.

19. Calibrate the Amp meter and RPM meter.

20. With the hydraulic power unit off, bleed down the TDSaccumulators (HYD SIDE, not gas side).

21. Remove the split shipping brace (Figure 12 book 1) from themotor alignment cylinder.

22. Open the two flow control valves 1-1/2 turns off their seats.

24. Set a joint of drill pipe in the slips.


25. Bring the TDS down as if stabbing the saver sub into box.The pin and box should be in alignment. If adjustment isnecessary, use the following procedure:

a. Measure how far and in what direction (toward or awayfrom the rails) the pin must move to line up with the drillpipe box.

b. Turn off the hydraulic power unit and bleed down thecylinder accumulator (open the needle valve on the backof the manifold). This allows the motor alignmentcylinder to relax and the motor to rotate on its trunnionsuntil the integrated swivel bail contacts the motor supportbonnet.

c. Loosen the lock tab and jam nut on the cylinder clevis.

d. With a wrench located on the cylinder rod flats, screw therod into or out of the clevis, in the same direction thesaver sub pin is to be moved.

e. Secure the jam nut and lock tab.

f. The nominal position of the two cylinder flow controlvalves is 1-1/2 turn off their seats. If you experience heavydrill pipe vibration, first attempt to control it with non-rotating stabilizers if the casing shoe is close to the surface.If motor movement becomes excessive due to continuedvibration, (more than 1/2" of total cylinder stroke) closethe flow controls to 3/4 turn off their seats.

August 22, 1997


Long term TDS storage procedures

1. Palletize the main unit for indoor storage. A cargo container isappropriate for indoor/outdoor storage.

2. Avoid wide variations in temperature and high humidity. Thepreferred environment is clean and dry at 60˚ F ambient. Ifhigh humidity is unavoidable, 70˚ F is recommended.

3. All exposed unpainted metal surfaces are coated with a rustpreventive at the factory prior to shipment, however, checkthese surfaces periodically to be sure that no corrosion istaking place. The recommended rust preventive (slushingcompound) for bare metal surfaces is Kendall Grade 5(GE-D6C6A1) or equivalent.

4. Cover all openings to prevent water or dust from entering. Leaveenough space around the drilling motor to allow the machine tobreathe. Do not use silica gel or a dehydrating agent.

5. During storage, lubricant drains from the top half of the rollerbearings in the motor, allowing corrosion to take place on theexposed areas. In order to counteract this, rotate the motorand gear train periodically to distribute lubricant over the topof the bearings. Perform this at three month intervals if storedindoors, and at one month intervals if stored outdoors.

6. The drilling motor is equipped with AC space heaters inorder to keep the internal motor temperature above ambient,preventing condensation. Connect power to the space heatersat terminals 1 and 2 in the AC motor J-box (see electricalschematic in the back of this section for proper voltage).Be sure to reseal the protective covering after connection.

7. Megger the drilling motor armature and field (static voltage of1,000 VAC and 2 meg ohm minimum) when placed intostorage and at three month intervals thereafter (one month ifstored outside). Keep a record of the readings, as a dropbetween readings indicates an increase in moisture in thewindings created by inadequate storage protection. If meggerreadings drop, bake the motor as soon as possible to restoreproper resistance and avoid further damage.

8. Varco recommends adding one gallon of Mobilarma 524 RustPreventive prior to shutdown. Or drain the oil and mix with arust preventive, then replace the oil, run the oil pump androtate motor to insure 100% coverage.


Returning the TDS to service after storage

Before placing the TDS back into service, verify the followingitems:

1. Remove all rust preventive and any corrosion that may havetaken place, taking special care with all load carryingcomponents.

2. Follow the procedure in the drilling motor service manualincluded in this manual. To verify the condition of the motor,take note of the following:

a. Blow out all dust and dirt that may have accumulated inthe windings with clean, dry air.

b. Visually inspect for spring corrosion, sticking brushes andgeneral defects.

c. Remove the brushes from holders, inspect and replacethem as necessary prior to operation.

d. Check the winding insulation continuity to ground with a1000 volt megger. If the reading is less than two megohms, bake the winding until the moisture content issufficiently reduced to produce an acceptable reading.

3. Perform a complete system test and adjustment as detailed inthe next section.

TDS Installation checklists (QA00026)

Use the checklists on the following pages to rig up the TDS.



Counterbalance

Counterbalance System---------------------------------------------------------------------------------------------------------------------------------------------------

Counterbalance systems vary widely in configurationThe principles are the same regardless of whichcounterbalance configuration the drilling rig uses. Fordescription purposes this section of the moduledescribes all Varco counterbalance arrangementsused in the Varco Top Drive Systems.

Q. What does the counterbalance do

A. The counterbalance system prevents damage tothe threads of the saver sub and drill pipe by offsettingthe weight of the Top Drive while stabbing into aconnection.

Q. What does the counterbalance system consist of.

A. The counterbalance system consists primarily oftwo hydraulic cylinders, a counterbalance manifold,cartridge valves, two hydraulic accumulators, andconnecting links

Q. How does the counterbalance function.

A. The two hydraulic cylinders are connected to thetwo hydraulic accumulators, the accumulators are pre-charged to 900 psi, When properly adjusted thecounterbalance systems supports all but about 800lbsof the weight of the Top Drive over full 8 to 10 in strokeof travel.

Q. What is the function of the accumulators and whereare they situated.

A. The counterbalance accumulators are situated ineach leg of the dolly frame. The two accumulatorsconstantly maintained at system pressure, are alwaysable to provide pressure to the counterbalancecylinders if the main hydraulic power unit is switchedoff. The accumulator is charged with nitrogen and apredetermined hydraulic pressure setting by thecounterbalance circuit in the hydraulic control manifold.

Q. What type of accumulators do Varco use

A. They are piston type with a shreader valve

Q. How many different counterbalance configurationdoes Varco have, and what are the differences in eachof the systems.

A. The are four different configurations, TDS-ACSystem, IDS (Integrated Drilling System) with onboard hydraulics and IDS without onboard hydraulicsand the TDS DC system. There is also the PRS (PipeRacking System) that uses a counterbalance system.Each system uses different types of cartridge valves

Q. What system uses what cartridge valves

A. The TDS AC System uses a pressurereducing/pressure relieving valve to set the systemalong with a pilot to open check valve.

The IDS with onboard hydraulics uses a pressurereducing pressure relieving valve with a pilot to opencheck valve and a needle valve.

The IDS without onboard hydraulics uses a pressurereducing valve and a flow control valve.

The TDS DC System uses a pressure reducing valvealong with a needle valve and pilot open check valve.

All systems have a pressure relief valve for safety


TOP DRIVE

Installation

Installation of Counterbalance System

Install counterbalance system as illustrated.When using chains use the following procedure todetermine the chain length required.

a) Install Pear links onto hook-blockb) With the hook supporting the TDS, measure the

distance from point of contact inside the pear link totop of the mounting lug on the integrated swivelbail.

c) Subtract 37/-14” from the measurement in step b.d) Cut the chain to length obtained in step c. The

tolerance is + 3-1/4” or – 0”e) Assemble remaining components and install.

Precha rging the counterbalancesystemPlease read these instructions completely before precharging,making note of the special cautions at the end of the section.

1. Use an inert gas such as Nitrogen for prechargingaccumulators. If oil-pumped is not available, use dry, water-pumped Nitrogen gas.

2. Before precharging, make certain:

❏ The accumulator end caps are screwed flush into theaccumulator body.

❏ The gas valve is screwed in tight.

❏ No oil remains trapped in the top end of the accumulator.

3. Remove the gas valve protector and the gas valve cap.

4. Attach the charging hose to the nitrogen bottle and to the gasvalve using the following procedure:

a. Use thread sealing and lubricating compound on the pipethreads of the gauge.

b. Back the gas chuck stem completely out of the way beforeattaching the assembly to the accumulator gas valve.

c. Use a wrench to tighten the gas chuck swivel nut onto thegas valve. Close the bleeder valve.

d. Turn the gas chuck stem all of the way down, depressingthe core in the accumulator gas valve.

e. Only crack open the nitrogen bottle valve to slowly fill theaccumulator. Shut it off when the gauge indicates 900 psi.

f. If the 900 psi pre-charge pressure is exceeded, make surethe nitrogen bottle valve is closed, then open the bleedervalve (opposite gas valve below gauge) slightly, but onlymomentarily, to reduce pressure.

g. Before loosening the swivel nut, turn the gas chuck stemout all of the way, then open the bleeder valve.

h. Prevent the gas valve from turning, loosen swivel nut, andremove the assembly.



Hydraulic Components

Accumulators

The main task of an accumulator is to take a specificamount of fluid under pressure from the hydraulicsystem and store it until it is required within thesystem.

As the fluid is under pressure, accumulators are treatedas pressure vessels and must be designed taking intoaccount the max operating pressure. How ever theymust also pass the acceptance standards in thecountry in which they are being used.

In order to store energy in accumulators, the fluid in anaccumulator is weight or spring loaded or pressurisedby gas. Therefore a balance is maintained between thepressure in a fluid and opposing pressure produced bythe weight, spring or pressure created by gas.

In most hydraulic systems hydro-pneumatic (gaspressurised) accumulators with a separating elementare used. Depending on the type of separating elementused, accumulators are categorised into Bladder,Piston and membrane accumulators.

Function

Accumulators have to carry out various functions in ahydraulic system:-Energy storageFluid reserveEmergency operationBalance in forcesDamping of mechanical shocksDamping of pressure shocksCompensation of oil leakageDamping of shocks and vibrationsDamping suspensionReclaiming of deceleration energyMaintaining constant pressureCompensation of flow (expansion tank)

Pressure Relief Valve

Pressure relief valves are used in hydraulic systems tolimit the system pressure to a specific set level. If thisset level is reached the pressure relief valve isactivated and feeds the excess flow from system totank

Theory of Operation

The basic principle of all pressure relief valves is thatthe inlet pressure is fed to a measuring surface whichis acted on by force. The inlet pressure loads thepoppet or lower side of the control spool with hydraulicforce. The force of the pre-tensioned spring acts in thedirection of the closure. The spring chamber isunloaded to tank. As long as the spring force is largerthan the pressure force, the seating element stays onits seat. If the pressure force exceeds the spring forcethe element pushes against the spring and opens theconnection. The excess fluid returns to tank. As thefluid flows away via the pressure control valve,hydraulic energy is converted into heat

Pilot Operated Check Valves

The pilot operated check valve positively locks apressure load, but releases the load upon applicationof a pressure signal at the pilot port. This valve isnormally used to lock an actuator in position when thedirectional control valve is centered. It it used inapplications where overrunning load control and or arelief function is not needed or is provided by othermeans.

Theory of Operation

A pilot operated check valve consists of a valve bodywith inlet and outlet ports and a poppet held against aseat by a spring. Directly opposite the check valvepoppet are a plunger and a plunger piston that arebiased by a light spring. Pilot pressure is sensed at theplunger piston through the pilot port. The valve allowsfree flow from its inlet port to its outlet port. Fluid flowattempting to pass through the valve from the outletport to the inlet forces the poppet to its seat, blockingflow through the valve. When enough pilot pressure issensed at the plunger piston, the plunger moves andunseats the check valve allowing fluid to pass. Theratio of the load pressure to the pilot presure requiredto release the load is called the pilot ratio.

Needle Valve

Needle valves are commonly used to meter accurateand precise flow of the fluid within a hydraulicsystem. It can also be used to as a positive shut off forthe hydraulic system.

Reducing /Relieving Valve

These valves are dual purpose valves the Reducingpart of the valve maintains pressure at steady flow ratewhile ensuring that the hydraulic system does notbecome over pressurised

Pressure relief valves are used in hydraulic systems tolimit the system pressure to a specific set level. If thisset level is reached the pressure relief valve isactivated and feeds the excess flow from system totank.

The pressure reducing valves are used to influence theoutput pressure.The reduction of input pressure or the maintenance ofoutput pressure is achieved at set value, which isbelow the charging pressure available in the maincircuit. It is thus possible to reduce the pressure in onepart of the system to a level lower than systempressure.

Theory of Operation

The basic principle of all pressure Reducing /Relievingvalve is not to let the output pressure rise above acertain level, the relief valve monitors the pressure onthe system, when the system pressure rises above aset pressure it returns the fluid back to tank. Thispressure can be influenced by the relief port .(See hyd schematic)


TOP DRIVE

Set Up Procedure

Set up ProceduresTDS DC System

The way to set up the TDS DC System is as follows:-

e Check you have the following tools:-

9/16” Spanner and a 5/32” Allen Key

e Check you have the following drawings available:-

Drawing VM 2126 SHEETS 1 T0 5Drawing 92114Drawing 75420Drawing 107530Drawing 110407

e Check the following valves are correctly installed:-

Pilot to open check valve P/N 77616Needle Valve P/N 76419Pressure Reducing Valve P/N 77615Pressure Relief Valve P/N 94522-21N

e Check all connecting liks are secure and all bolts aresafety wired.

e Check TDS is not sitting on the guide stops .e Check the Hydraulic reservoir is full and all quick

disconnects are installed properly.e Check all hose connections are tight.e Check the 2 accumulators are pre-charged with 900

psi of Nitrogen.e Check hydraulic power supply is set to 2000 psi.

Adjustment Procedure

Screw needle valve counterclockwise until fully open.Screw pressure reducing valve counterclockwise untilfully open.Start hydraulic power unit and let hydraulic oil flow for2 minutes.Bleed system cylinders.Screw needle vale clockwise until fully closed.Screw pressure reducing valve clockwise untilcylinders start to retract raising the TDS.Slowly screw the pressure reducing valvecounterclockwise reducing the pressure to thecylinders.When the swivel bail just contacts the hook note thepressure and decrease it by 25psi tighten lock nut.

Troubleshooting the counterbalance

Symptom Probable cause Remedy

System does not holdpressure.

Needle valve is not closed. See adjustment procedure and checkneedle valve.

Cylinder rod seals leak. Replace seals.

Fittings or hoses leak. Tighten or replace as required.

Dirty or defective PRV valve . See adjustment procedure. Clean or replace.

Dirty or stuck check valve. Clean or replace.

Counterbalance control valvein rig down position.

Return valve to drilling position.

Cylinder rods remainretracted (closed).

Pressure setting too high. Adjust per adjustment procedure.

z When activating or reactivating the counterbalance system, neverstart an empty system with the needle valve closed. Always starthydraulic unit first, run for 3-5 minutes, then slowly close needlevalve with hydraulic unit running. If an empty system is started upwith needle valve closed there is a good potential for damagingcounterbalance cylinder seals.

1) Where is the counterbalance manifold situated?

________________________________________________________________________________________________________________________________________________

2) Name the three valves in the counterbalance manifold?

_____________________________________________________________________________________________________________________

3) What stops the counterbalance system from being over pressurized?

________________________________________________________________________

4) Where are the Counterbalance Accumulators situated ?

________________________________________________________________________________________________________________________________________________

5) What type of valve is on the Counterbalance Accumulators ?

____________________________________________________________________________________________________________

6) What type of Accumulators are the Counterbalance Accumulators?

________________________________________________________________________

7) What is the reason for having a counterbalance system ?

________________________________________________________________________

8) What indicates that the Counterbalance is faulty or not set up properly?

9) Check the following drawings and mark up any defects missing parts.

___________________________________________________________

___________________________________________________________

___________________________________________________________

10) What tools are required to set up the counterbalance system?

___________________________________________________________

____________________________________________________________

____________________________________________________________



Alignment

Training Manual

Alignment

Motor Alignment System

All Varco DC Top Drives have an AlignmentSystem, One Top Drive System Model that differsfrom the other DC Models is the TDS 6S, and this isdue the size and weight of that particular model.

Q What does the Alignment System do

A The alignment cylinder is not intended tobe used to align the pinwith the box at the well bore. It is adevice to counterbalance theoffset weight of the DC motor and allowthe system to accommodateexternal forces. It is adjustable to ensurethat the mainshaft is straightat well center—to compensate fordesign tolerances in the guide railsand dolly. To work properly, the guiderails must be properly located,and the dolly must fit within designtolerances..

Q What does the system consist of

A The earlier Top Drive systems (TDS 3)Modelsdid not have a separate accumulator system, butall other models do have a separate accumulatorfor the system. The system with the separateaccumulator consist of a duplex counterbalancecylinder with 2 flow control valves attached,hydraulic accumulator, hydraulic manifold with apressure reducing cartridge valve a needlevalve, and a pilot to open check valve.

Q Where is the system fitted

A The duplex cylinder is attached to a pad eye onthe lower gear case and another pad eyeattached to the motor guide frame.

Training Manual

Alignment

Adjusting the motor alignment cylinder

For units without a separate alignment cylinder accumulator

The counterbalance system must be properly adjusted beforeattempting to adjust the alignment cylinder.

Turn off the hydraulic power unit and bleed down the TDSaccumulators by opening the needle valve located on thecounterbalance valve manifold. Remove the split shipping bracefrom the motor alignment cylinder, then open the two flow controlvalves by 1 ½ turns each these valve are located on the motoralignment cylinder supply and return lines. Close the needle valveand turn the hydraulic unit back on, then verify the pressure is1100-psi +/- 100 psi.

Set a joint or stand in the rotary slips, (do not use a pup joint asthis could give a false position). Bring the TDS down until it isstabbed into the box. The pin and box should be in alignmentwithin +/ - ¼”. The OD of the pin should clear the shoulder of thebox so that the connection can be made up without damaging thethreads. If adjustments are necessary, use the followingprocedure.

a) Measure how far and in what direction the pin has to move toline up the pin and box.

b) Turn off the hydraulic power unit and bleed down the systemthen loosen the lock tab and jam nut on the cylinder clevis.

c) Using an open ended spanner (wrench),(do not use a pipewrench) on the cylinder rod flats screw the rod in the directionrequired. ¾ turn on the rod results in the pin movement of ¼”.

NoteAlignment cylinder rod extension should be 2 3/8” +/ -1/8”Gland to rod threads when aligned properly.

d) Secure the jam nut and lock the tab when alignment is set.

Training Manual

Alignment

For units with a separate alignment cylinder accumulator

Check you have a pre-charge of 900 psi in the accumulator

The counterbalance system must be properly adjusted beforeattempting to adjust the alignment cylinder.

The pressure setting is adjusted by screwing the pressurereducingvalve in or out with a hex wrench (Figure 13). Screwing in thevalve increases pressure and moves the saver sub toward therails.Backing out the pressure reducing valve reduces pressure andmoves the saver sub away from the rails (see additional notes atthe end of this procedure).

1. Verify the correct pressure setting using the following procedure:

a. With the power unit on, back down the pressure using the pressure reducing valve (PRV) until the saver sub begins to pivot away from the rails. Record this pressure.

b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a “dead band” area.

c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs.

d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by

two. The resulting pressure “dead band” provides equal pre-load in each direction – both toward and away from the rails.

e. Record the pressure setting for future reference.

2. Set a joint of drill pipe in the slips.

3. Bring the top drive down as if stabbing the saver sub into the box. The pin and the box should be in alignment so that the O.D. of the pin clears the shoulder of the box. If adjustment is necessary, use the following procedure:

Training Manual

Alignment

a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box.

b. Turn off the hydraulic power unit and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame.

c. Loosen the lock tab and jam nut on the cylinder clevis.

d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4" of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2-3/8" ± 1/8" gland to rod threads when the system is properly aligned.

e. Secure the jam nut and lock tab.

f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2" of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats.

g. Tighten the lock nuts and replace the caps on all valvestems.

If the alignment cylinder is removed for service, install thealignment cylinder replacement brace to support the motorhousing assembly while continuing to operate the TDS.After reinstalling the alignment cylinder, use the threebleed holes(located along top of cylinder barrel) to removeair trapped in the cylinder.Rail spacing and setback from the centerline of the wellmust be held within recommended tolerances in order tomaintain vertical alignment of the TDS.

Alignment CylinderLug (ref)

Pressure ReducingValve

Needle Valve

Motor Frame (ref)

AlignmentCylinderManifold

Accumulator

BracketGas Valve

Motor alignment cylinder manifold

MotorAlignmentCylinder

MotorFrame Dolly (Ref)

Split Shipping

Brace

Alignment cylinder

Troubleshooting the MotorAlignment Cylinder


Alignment cylinderfails to movetransmission attrunnion pivot pointswith recommendedpressure setting.

Transmission trunnion pinswill not pivot in dollysupport brackets, from lackof lubrication.

Free trunnion pins as needed andlubricate area regularly.

Counterbalancesystem workserratically or does notwork at all.

Possible problem withsystem hydrauliccomponents.

Chec k Troubleshooting theCounterbalance section of this book.

Loss of nitrogen precharge inaccumulators located inmotor dolly upright frame.

Recharge accumulators as per theprocedure in th e Counterbalancesection of this book.

System does not holdpressure.

Needle valve is not closed. Se e Adjustment procedure.

Cylinder rod seals leak. Replace seals.

Fittings or hoses leak. Tighten or replace as required.

Dirty or defective PRV valve . Clean or replace.

Saver sub on TDSdoes not align withdrill pipe.

Alignment cylinder pressuretoo high or too low.

Se e Adjustment procedure.

Alignment cylinder rodadjustment too long or short.

Adjust according to procedure.

Rails not properly alignedwith centerline of well.

Check to make sure that rotary is incenter of floor and then checkalignment of rails in relation torotary.

Excessive motormovement.

Alignment cylinder fluidflow not adequatelythrottled.

Se e Adjustment procedure. Normaladjustment is 1 1/2 turns from fullclosed position on flow controlvalves. If there is excessive movementclose to 3/4 turn from full closedposition.

Pilot Operated Check Valves

The pilot operated check valve positively locks apressure load, but releases the load upon applicationof a pressure signal at the pilot port. This valve isnormally used to lock an actuator in position when thedirectional control valve is centered. It it used inapplications where overrunning load control and or arelief function is not needed or is provided by othermeans.

Theory of Operation

A pilot operated check valve consists of a valve bodywith inlet and outlet ports and a poppet held against aseat by a spring. Directly opposite the check valvepoppet are a plunger and a plunger piston that arebiased by a light spring. Pilot pressure is sensed at theplunger piston through the pilot port. The valve allowsfree flow from its inlet port to its outlet port. Fluid flowattempting to pass through the valve from the outletport to the inlet forces the poppet to its seat, blockingflow through the valve. When enough pilot pressure issensed at the plunger piston, the plunger moves andunseats the check valve allowing fluid to pass. Theratio of the load pressure to the pilot presure requiredto release the load is called the pilot ratio.

Needle Valve

Needle valves are commonly used to meter accurateand precise flow of the fluid within a hydraulicsystem. It can also be used to as a positive shut off forthe hydraulic system.

Reducing /Relieving Valve

These valves are dual purpose valves the Reducingpart of the valve maintains pressure at steady flow ratewhile ensuring that the hydraulic system does notbecome over pressurised

Pressure relief valves are used in hydraulic systems tolimit the system pressure to a specific set level. If thisset level is reached the pressure relief valve isactivated and feeds the excess flow from system totank.

The pressure reducing valves are used to influence theoutput pressure.The reduction of input pressure or the maintenance ofoutput pressure is achieved at set value, which isbelow the charging pressure available in the maincircuit. It is thus possible to reduce the pressure in onepart of the system to a level lower than systempressure.

Theory of Operation

The basic principle of all pressure Reducing /Relievingvalve is not to let the output pressure rise above acertain level, the relief valve monitors the pressure onthe system, when the system pressure rises above aset pressure it returns the fluid back to tank. Thispressure can be influenced by the relief port .(See hyd schematic)



Cooling Motor

Cooling SystemsVarco has four types of cooling systems thecustomer can choose from to cool the VarcoTop Drive Drilling Motor.

1. Closed Loop Cooling2. Local Blower3. Local blower with extended air intake4. Remote blower

Q Why have so many different systems.

A The main reason is that countries aroundthe world have their own underlyingcertifying authorities how govern theirpolicies on certification. Many of theseauthorities have different rules governingspecifications on electrical motors.Depending on where the drilling rig is goingto operate will depend on what coolingsystem will be used.A Rig working in the North Sea may onlyhave 2 systems to choose from, a RemoteBlower system or a Closed Loop coolingSystem.A rig working in the Gulf of Mexico can haveall 4 systems to choose from.Before a Top drive is sold a survey shouldbe carried out on the installation to check theTop Drive System components conforms tothe particular area where it is going to work.

Q What is the best system

A Each system has its own uniqueadvantages and disadvantages, thefollowing pages describe all four systems.

Varco Technical Education Centre

Closed Loop

Closed Loop System

The Close Loop Cooling System can use EXD OR ULcomponents to meet all world underlying Authorities, by usingEXD or UL components the Top Drive with closed loop coolingcan have classification to work any where in the world. Thesystem should be capable of producing a CFM of 3200.

The closed Loop system consists of the following main parts :-

20 HP Blower motorHeat exchangersAir Flow DuctsWater detectorsDifferential pressure switchPressure switchTemperature switchExpo purge systemWater pumpsFlow indicatorService loop containing water hoses

Blower Motors

The blower motor is a dual shaft 20 HP AC, that is attached tothe blower mount brake cover. The motors are EXD or Ul rated itis always best to check the name plate before installing.

The impellers are attached to each shaft end and are fixed by ataper lock mechanism.

The Blower impellers are then incased in the ducting assembly.A 8 “ flex connects to the ducts on the GE 752 or EMD DrillingMotor. The Blower inlets are connected to the heat exchangers

.

.

Heat Exchangers

The closed loop cooling system consists of two tube fin type heatexchangers cooled by twin blowers driven by a double ended ACMotor. Ducting passes air out the motor exhausts port to the heatexchangers and back to the blower inlets. The heat exchangersare built from Cupro Nickel tubes and the headers are pressuretested to 250 psi.The system requires a supply of liquid coolant (Sea Water,Chilled fresh water or Glycol) at 50 gpm ( in the case of a TSD6S each motor requires 50gpm) at a maximum inlet temperatureOF 90°F.

As the drilling motor rotates carbon dust is being produced by thewear of the brushes inside the drilling motor. As the air flows roundthe system the carbon dust can then build up on the commutatorand can cause a flash over inside the drilling motor resulting in amotor change There are Carbon dust filters that can be installed.These filters are an aid in stopping build up of the carbon but theymust be replaced at regular intervals

Water Detectors

System operation

The sensor is mounted in the scroll of the blower housing ofdrilling motor at such a position that the air circulation patternfrom the blower,s impeller will cause leaking coolant waterparticles to strike the sensitive sensor element. If water ispresent the sensors resistance lowers causing the water detectoramplifier to conduct a 24 Vdc to the Programmable LogicController (PLC). The PLC then sounds the warning horn andilluminates the Drillers console water detection indicator lamp.

Pressure/ Temperature Switches

Differential pressure switch

The reason for having a differential pressure switch is to monitorthe flow of pressure in the system.A line is connected to a fitting on the duct at the commutator endof the main drilling motor and attached to the high port fitting ofthe switch, and another line is connected to a fitting in theopposite air duct at the pinion end of the drilling Motor andconnected to the fitting on the low pressure of the switch.

Dureing normal operation the blower differential pressure switchon the TDS is in the open position. Upon Blower failure thepressure switch senses low or zero output pressure and theswitch closes to supply a 24Vdc signal to the ProgrammableLogic Controller (PLC) Module. In addition another 24Vdc signalis sent to the auxiliary contacts of the Blower Starter Relay to thePLC. When the PLC receives the pressure switch signal and theauxiliary signal from the blower motor starter it sends no signalto the Drillers Console. If either signal is lost the PLC sends apulse 24Vdc signal to the Blower Fail Indicator on the DrillersConsole for a a flashing “ON” indication and sounds the warningalarm. If The operator depresses the alarm silence button tosilence the alarm , the flashing indicator changes to a steadyindication . After 5 minutes if the malfunction still exists then theindicator will revert back to flashing indicator and the warning hornwill sound

A clogged carbon filter can restrict the airflow and can cause thedifferential alarm.

Cooling Air Temperature switch

The cooling Air Over-temperature switch monitors the DrillingMotor outlet air temperature to alert the operator of dangerouslyhigh temperature. It is a normally open pressure switch with aliquid filled temperature bulb connected to the pressure inlet of theswitch with a capillary tube. The temperature bulb is mounted inthe exhaust air outlet in the TDS Main Drilling Motor duct Whenair temperature exceeds 170° the switch closes sending a 24VDCsignal to the PLC. The PLC activates the warning horn andilluminates the TDS OVERTEMP Indicator Lamp.If the water pumps are not producing 50 GPM or the flow isrestricted this would cause an alarm situation.

A flow switch is installed on the return pipe work which is usuallyplaced near the water reservoir, (except in the case of the TDS6Sits switch is usually placed up at the diving board level )

When the blower is running the system is in a negative state andrequires a purge air rate of 70 scfm per motor at 1.0 psig toprovide a positive system. A purge control system is required tomonitor system pressure for safe operations.


Local Blower

Local Blower System

The Local Blower System can be use UL or EX components to meetall world underlying authorities, by using EX or UL components theTop Drive with the Local blower can have classification to work inmost areas where drilling operations are required. There are differentclassifications within the European Nations, (British Sector,Norwegian Sector, Danish Sector, Dutch Sector to name but a few.The Hazardous area zones differ in shape and sizes for mostsectors,There is a hazardous area course that covers all these zones alongwith other important issues.

(It would be beneficial to all Engineers if they attend one ofthese courses)

The Local Blower Components consists of the following main Parts:-

20HP Blower MotorSpark ArrestorsAir flow ductsDifferential Pressure SwitchTemperature SwitchPressure SwitchFlex cooling Duct ( For extended intake system)

Local Blower

The basic local blower system is designed to provide local cooling airto the drilling motor. It receives air from approx 20 feet above the rigfloor at the lowest point of the motors travel.A heavy constructed pressure blower is mounted to the motor. Themotor is directly driven by an explosion proof 20 HP, 3450 rpm ACelectrical motor.( older versions may have an 15 HP Motor) Themotor is connected to the blower with a rigid duct.The design provides highly reliable service with positive ventilationthrough its normal inlet and spark arrestor protected outlets. Itprovides a safe, visibly verifiable system that will prevent explosion offlammable gasses or vapors coming from the well bore.The system should be capable of producing a CFM of 3200.The system is monitored in the same way as the closed loop system,and gives the operator the same alarms.

Local Blower with Extended Intake

To comply with certain Authorities requirements, the minimum intakeheight must be raised. In order to accomplish this is to fit an extendedintake. This system consist of the standard type local blower withducting to allow the intake to be mounted on the hook or travelingblock with a flexible hose running down to the motor. This raises theair intake height to approximately 30 feet above the rig floor.

MountingBrackets (2)

Mounting Plate

Oil Fittings (2)

TransmissionCooler

Axial Fan20 hp

Blower Motor

Locking Key

Gasket

Blower Housing

Blower Impeller

Taper LockBushing

Gasket

Blower Duct toAC Drilling Motor

FLL-X DuctConnection

Point

Spark Arrestor

Typical local blower cooling system

Typical local blower cooling system(Shown with optional extended intake)

Lubricating the cooling system

Lubricate AC blower motors every three months .

.

Transmission Cooler

Explosion Proof AC Blower Motor

Grease Fitting

Grease Fitting

Motor Cooling Blower

. Lubricating the local cooling system

Use the following procedure to install a new motor in the localcooling system:

1. Install wear sleeves on the blower motor shaft.

2. Bolt the blower motor onto the blower motor mount andsafetywire the bolts.

3. Install the blower housing and inner plate assemblies on bothsides of the blower motor frame as follows:

a. Use two 3/8 in. bolts in the threaded alignment bolt holeson both sides to line up the blower housing and innerplate assemblies with the blower motor frame on bothsides.

b. Gradually insert and tighten the bolts that connect theblower housing and inner plate assemblies on both sidesto the blower motor frame. Check the alignment holes asyou tighten the bolts to make sure both assemblies line upproperly on the blower motor frame.

4. Install shaft seal assemblies inside both blower housingassemblies. Make sure the seals are centered.

5. Tighten and safetywire the retainer plates in place on bothsides.

6. Install the impellers and taper lock bushings on both sidesand safetywire the bolts.

7. Install the blower inlet duct assemblies to the blower housingon both sides using the same alignment holes used in Step 3a.

8. Hoist the entire cooling system assembly onto the TDS. If thealignment holes were properly used, the cooling systemassembly should line up perfectly on the TDS.

9. Install and safetywire the four bolts connecting the blowermount to the brake cover.

10. Install and safetywire the four bolts on each side connectingthe heat exchange duct housing assemblies to the blower inletduct assemblies.

11. Install and safetywire the six bolts on each side connecting thetransmission ducts to the blower housing ducts.

12. Connect the electrical wires to the blower motor.


Remote Blower

Remote Blower System

The Local Blower System can be use UL or EX components tomeet all world underlying authorities, by using EX or ULcomponents the Top Drive with the Local blower can haveclassification to work in anywhere drilling operations are required.

The remote Blower cooling system consists of the followingcomponents:-

40 HP Blower MotorSkid for Blower to mount onSpark Arrestors8” flexible hoseDifferential Pressure switchTemperature switchWater detector (optional extra)

The remote blower system is normally used when the rig cannotbe assured of good safe cooling air. The system works the sameas the Local system except that a 40HP motor is placed in theDerrick at diving board level and receives air from out side thederrick walls. The extra horse power is required to force the airdown through the hose and through the motor, keeping it in apositive state. The system is monitored the same as the closedloop cooling system, and the Local Blower system, giving theoperator the same alarms.The system should be capable of producing a CFM of 3200.The impeller is fitted the same way as the Closed Loop Systemand there is a mist filter to stop moisture getting into the system.

40 hp Explosion ProofElectric Motor (AC)

and CentrifugalPressure Blower

Air Inlet

Racking Platformat Racking Board Level

Rigid Cooling Duct

Spark Arrestor

86' Flex Air DuctMotor Dolly Assembly

Wind Wall

Typical remote blower cooling system


Trouble-Shooting

Troubleshooting the cooling system


Mechanical noise inblower.

Loose impeller. Reinstall impeller and hub andlocktite screws.

Faulty motor bearings. Repair or replace as needed.

Blower runsintermittently.

Faulty or loose wiring. Locate and repair as needed.

Faulty motor starter. Check for dirt or trash betweenstarter coil. Repair or replace asneeded.

Excessive air loss inblower motor shaftarea.

Worn or defective seal orwear sleeve.

Replace as needed.

Loose or vibrating blowermotor, wearing sealsexcessively.

Correct blower mounting problemor faulty motor bearing and replaceblower shaft seals.

DC MOTOROVERHEATING,OVERTEMP alarmstays on with blowerrunning.

Incorrect blower rotation. Verify blower rotation. Correct asneeded.

Dirty or clogged sparkarrestors (local or remotecooling systems).

Remove spark arrestors from motorand clean screens if screens aredamaged with holes. Replace asneeded.

Clogged water or air passagesin water cooled exchangers(closed loop cooling).

Remove and clean passages asneeded.

Troubleshooting the cooling system (cont.)


DC MOTOROVERHEATING,OVERTEMP alarmstays on with blowerrunning.

Continuous drilling Ampsover recommended levels.

Check service manual for continuousAmp motor rating and adjustdrilling program accordingly.

Motor being stalled for overrecommended periods oftime.

DC motor should never be stalledfor more than 5 seconds with over300 Amps applied.

e Serious damage could occur to themotor if this is done.

Faulty temperature switch orprobe.

Repair or replace as needed.

z Do not readjust or raise heat rangesetting.

Improper cooling water flowor incoming water temp toohigh (closed loop cooling).

See the Installation andCommissioning book forrecommended or required flow ratesand water temp.

Restricted air flow (local orremote cooling).

Check and clean spark arrestors asneeded.

Check air intake on blower to ensurethere are no restrictions.

Verify proper blower rotation.

WATERDETECTOR alarm is on (closed loop system).

Moisture in air inside DCmotor.

Check for leaks in heat exchanger. Check air purge line filters. Ensuredry air is going into motor.

Dirty or faulty waterdetector.

Clean or replace as needed.


COOLING SYSTEMS TEST


Name Position

1) Name the different cooling systems Varco uses_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

2) Explain why Varco uses different systems?

________________________________________________________________________________________________________________________________________________

3) What size of Blower Motor is used on the Closed Loop System?

______________________________________________________________________________

4) What GPM is required for the cooling of the TDS 6S Model?

____________________________________

5) Why does the Local Cooling System require a Differential PressureSwitch ?

________________________________________________________________________

6) What is the Air Temperature switch set at ?

________________________________________________________________________

7) What Cooling System requires a CFM OF 3200?

____________________________________

8) What keeps the impeller in place on the Remote Cooling System?

________________________________________________________________________

9) What causes excessive air loss in the Remote Blower Cooling system?

________________________________________________________________________10) What Direction Should the Local blower motor run ?

______________________________________________________________________________________

______________________________________________________________________________________



Motor Brake

Item ComponentDescription

1 Rim

2 Tube(withvalvestemsnapringswhererequired)

3 ElbowAssembly

3A Optional - QuickReleaseValveAssembly

4 CompressionRing(includedwithitems 3 & 3A)

5 Air ConnectionTube

6 Air ConnectionGasket

7 FrictionShoeAssembly

8 Air TubeGroup(DualMounted)

9 SpacerGroup(DualMounted)

10 ReplacementFrictionLining & FastenerKit

11 Side Plate(2 required)

12 TorqueBar

13 ReleaseSpring

7, 12, & 13 FrictionShoe, TorqueBar & SpringKit

1

2

11

1312

10

7

43

5

6

3ANote:OptionalQuickReleaseValve. Notavailable for11.5VC500.

Top Drive BrakeTraining Manual

Ventilated ConstructionFriction shoe backing plates have large air passagesthrough the entire length. This constuction coupled withscallop side plates allow cooling air to flow through the elementIn addition the large exposed inside diameter assures thecoolest possible operation. None of the heat is generated deep in the element's internal parts where it can be trapped. The open construction assures rapid heat dissipation.



Motor Housing



Washpipe Assay

Washpipe assembly

1. With the packing box upside down, assemble thepacking seals and spacers into the packing boxusing care to line up the upper spacer slot with thedowel pin.

2. Hand pack all seals with multipurpose lithium-basedoutside diameter of the spacers.

3. Install the socket head dog nose screw, ensuringthat the screw nose is fully engaged in the grooveof the lower spacer.

4. Install the grease fitting and turn the packing boxupright.

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

6. Install the wash pipe nut onto the wash pipe.7. Grease the packing seal and install into the holding

ring using care not to grease the outside diameterof the holding ring.

8. Install the packing seal and holding ring over theslotted endof the wash pipe.

9. Install the snap ring.10. Install the upper and lower o-rings using grease to

hold them in place.11. Compress the assembly to the length of the wash

pipe.Disassemble the washpipe packing in the reverseorder of theabove procedure. Refer to the Washpipe AssemblyGuide, P/N 128844.



Drilling Motor

D.C. Motor Identification

3

Section 1 - IntroductionVarco has used two different types of Electrical DC motors on their DC Top Driverange they are from EMD (Electro Motive Diesel) and from GE (General Electric).The fist ever Top Drive built, TDS-1 utilized an EMD M89VTS series motor, and thismotor had been previously used on a Locomotive. This Top Drive went to work onboard the Sedco 201 rig in the Arabian Gulf on 1st April 1982. Initially the EMDmotor was preferred, but as to production demands etc. Varco decided to utilize asecond company (GE) in 1983, this then gave the option of utilizing either a Shunt orSeries type motor as opposed to EMD who only supplied a Series type motor.

The main operating difference between the Series and the Shunt type motorsis the output Torque and Speed control. Where the Series motor has a slightlygreater Output Torque, the Shunt motor gives greater speed control with the abilityto also alter the Field current with an Active Field Supply and thus get greater speedcontrol. This is one of the main reasons why a Shunt motor is more commonlyspecified as opposed to a Series motor on Top Drive applications.

In 1989 GE introduced their new High Torque motors, this motor was able toincrease the Top Drive torque output, this is now used as standard when a newmotor is obtained from GE.

The charts below show examples of the differences between Shunt and Seriesmotors, and between Standard Torque and High Torque motors for continuousdrilling maximum Top Drive output Torque’s.

Shunt @ 57A Standard Torque motor High Torque motorTDS-3 26,400 Ft/Lbs. @195 RPM 31,000 Ft/Lbs. @165 RPMTDS-4(Low gear) 38,700 Ft/Lbs. @130 RPM 45,000 Ft/Lbs. @130 RPMTDS-4(High gear) 24,800 Ft/Lbs. @200 RPM 29,100 Ft/Lbs. @200 RPMTDS-5 33,000 Ft/Lbs. @155 RPM 38,700 Ft/Lbs. @130 RPM

Series Standard Torque motor High Torque motorTDS-3 27,800 Ft/Lbs. @185 RPM 34,700 Ft/Lbs. @150 RPMTDS-4(Low gear) 40,900 Ft/Lbs. @125 RPM 50,900 Ft/Lbs. @100 RPMTDS-4(High gear) 26,100 Ft/Lbs. @195 RPM 32,500 Ft/Lbs. @160 RPMTDS-5 34,800 Ft/Lbs. @150 RPM 43,300 Ft/Lbs. @125 RPM

4

The above picture shows the EMD Series motor that was used in the construction ofthe First Top Drive. The commutator and shaft were removed and machined to fitthe requirements of the Top Drive gearbox.

7

Section 3 – DC Motor Types

General Electric

TDS – 3,4,5+6GE 752 AUP 1,2,3. Series wound standard torque motor P/N 75989-1Cable size 535 MCM

GE 752 UP 1,2,3. Shunt wound standard torque motor P/N 75989-2Cable size 646 MCM

GE 752 AUT 1,2,3. Series wound high torque motor P/N 86542-1Cable size 535 MCM

GE 752 US 1,2, Shunt wound high torque motor P/N 87966Cable size 646 MCM

IDSGE752IDS Shunt wound high torque motor PN 103609Cable size 646 MCM

EMD

TDS - 3M89VTS Series wound standard torque motor P/N 77029Cable size 444 MCM

DC Motor ConnectorsGE Motor connectors (TDS 3,4,5 +6) P/N 79826GE Motor Connectors (IDS Integrated J/B) P/N 79826 * 1

P/N 99580 * 2EMD Motor connectors (TDS 3) P/N 79835

8

Section 4 - Cooling Ducts IdentificationTo identify the motor type visually by the cooling ducts in the pinion end cover, 4cooling holes is a standard Torque and 10 cooling holes high Torque, this isillustrated in the pictures below.

Above is a standard torque motor, with 4 cooling ports on the lower face with bolt oncooling ducting as used on TDS 3 and TDS 5 applications.

Above is a high torque motor with 4 cooling ports on lower face plus 6circumferential slots in the main end cover.

9

Section 5 - Gearcase Identification

The gearcase application for a standard torque and high torque motor is alsodifferent, details of these is shown below.

Above is a standard torque motor gearcase application where the gearcase isseparate from the cooling system and the ducting bolts directly to the motor.

Above is a high torque gearcase application where the gearcase is an interregnalpart of the cooling system and the motor seals against the gearcase.

10

Section 6 - Testing the GE752 Motor

1. Remove commutator covers on motor to inspect and ensure allbrushes are fully seated and their retaining springs are in place.

2. Check armature and field cables for signs of wear or damage andensure all tails are sitting clear of both the motor and the shop floor.

3. Select the 1000V range on the Megger and check that the batteryis O.K

4. Connect one lead from the Megger to the motor frame ensuring agood connection. Connect the other lead to one of the armaturecables. Press the test pushbutton on the Megger and note downvalue below.

5. Repeat step 4 but this time move lead from the armature cable tothe armature cable screen and note down value below.

6. Repeat steps 4 & 5 but this time use one of the field cables andnote values below.

7. Connect one lead from the armature cable and the other from thefield cable. Press test button on Megger and note down value below.

Armature to Ground / Screen Megger ReadingThis should give a reading somewhere in the region from 500M Ohms to 50MOhms. When new this should be expected to be reasonably high. The lowestreading that the motor should be operated at is 0.5M Ohms, once the motor iselectrically energized, this should rise. If the megger reading is lower than 0.5MOhms, the motor should be heated up before use, as most SCR systems will faultbelow this level and there is also a possibility of damage to the motor.

Field to Ground / Screen Megger ReadingThis reading should be about 500M Ohms, if this reading is lower, the motor shouldalso be heated to bring the value a higher.

PINION GEARINSTALLATION

Training Manual

PINION GEAR INSTALLATION

SUBJECT: Pinion Gear and Drive Train Life.

PURPOSE: To notify users of proper assemblyprocedures for Pinion Gears and Hubs to Top Drivedrilling motors.

EFFECTIVITY: All Varco BJ Top Drive DrillingSystems.

Assembly of the Pinion Gear or Pinion Gear Hub to theTop Drive drilling motor shaft is extremely critical to thelife expectancy to the drive train. The Pinion Gear andHub used on the Varco Top Drive is unique to thisapplication and the fit to the motor shaft is notnecessarily the same as other gears, hubs, sprockets, etc,which may be used on other types of machinery.Improper assembly may lead to premature failurethrough material fractures and/or separation of the gearor hub from the shaft.

Training Manual

PINION GEAR INSTALLATION

Proper fit requires hand fitting and polishing of themating surfaces while maintaining precise tolerances inrelation to other dimensions of the pinion. Successfulassembly depends a great deal on skill, knowledge, andtraining of the personnel performing the work. Finalverification of correct installation dimensions isessential.

Here is an example of the Pinion Gear being heatedusing the Induction Heater.

Training Manual

Current date

4-70 TDS-3H Maintenance and Troubleshooting

Installing the top drive motor pinion

n Installing a pinion gear can be dangerous to personnelinstalling it as well as anyone witnessing the procedure.Exercise caution at all times.

Use the following procedure to install a TDS motor pinion:

1. Clean the motor shaft by hand and cover with a thin layer of“Engineer’s Blue.”

2. Firmly install the pinion on the motor shaft by hand. Markreference lines on the pinion and the shaft to ensure identicalangular orientation each time.

3. There must be a minimum of 75% surface contact betweenthe pinion and motor shaft. Dress the motor shaft/pinionvery lightly with a fine emery cloth and repeat the blueingprocedure if necessary until there is at least 75% surfacecontact between the pinion and motor shaft.

4. After thoroughly cleaning all blueing, oil, and/or grease fromthe pinion bore and shaft, trial mount the cold pinion gear onthe motor shaft, lining up the reference marks.

5. Make sure the fixture is clean and the “horse shoe” face andbar are parallel.

6. Place the fixture on the motor shaft with the “horse shoe” endagainst the inner face of the gear and the bar against the outerface of the gear, sandwiching the pinion gear in the fixture.

7. Adjust the adjusting screw to butt against the end of themotor shaft.

8. Attach a calibrated dial indicator gauge to the fixture and setto zero.

9. Back off the adjusting screw until the gauge reads 0.072 to0.074 in. Then lock the screw in place with a locknut.

10. Remove the fixture from the pinion gear assembly.

e Do not put the fixture in the oven.

TDS-3H Maintenance and Troubleshooting 4-71

11. Heat the pinion gear to 360 - 385°F (182 - 196°C) for threehours in an oven. After heating for three hours, remove thepinion gear assembly and immediately attach the fixture.

12. Place the pinion gear assembly and fixture on the motor shaft,lining up the reference marks.

13. Gently tap the pinion gear assembly and fixture into placeuntil the adjusting screw butts against the motor shaft.

14. Wait 2-3 minutes and back off the nuts holding the fixture inplace. There may be some noise as the pinion gear cools.

15. The pinion creeps up the shaft as it cools to the requiredposition of 0.085 ± 0.005 in. advancement.

16. When the pinion is fully cooled, fit the fixture and check finaladvancement.

17. Complete the required documentation recording pinionadvancement.



Gearbox



Motor Removal

TDS-3H Maintenance

Removing the motor assembly from theguide dolly

You can perform some service procedures on top drives (i.e. upperquill shaft bearing and seal, air brake or locally mounted coolingsystem) without removing the drilling motor assembly from thedolly. If service is required on the lower end (i.e. gear set, lowerbearings or seals), you must remove the drilling motor from the dolly.

1 Set the TDS down horizontally on a good flat surface. Makesure that none of the components protrude past the guidedolly roller brackets before setting down. If so, block dolly upaccordingly.

2. Disconnect all wiring and hoses between the transmission andguide dolly frame.

3. Remove any cooling ducts (heat exchanger, spark arrestor,etc.) that interfere with removing the transmission from theguide dolly frame.

4. Run a suitable sling through the quill shaft to support theweight of the motor and housing assembly (approximately10,000 lb).

5. Attach the sling to the crane, take up slack and remove thetrunnion blocks that hold the transmission to the guide dollyframe.

6. Hoist the transmission out of the guide dolly frame.

7. Set the motor and housing assembly down on woodenchocks, being careful not to damage the components.

8. Disconnect the wiring between the motor and the housing.Make sure the transmission is in neutral.

9. Remove the dowel pins in the motor feet.

10. Remove the four large motor bolts.

11. Lift the transmission off of the motor, angling the upper endslightly to clear the motor frame, and sliding the housing offof the motor towards the gearcase end.

12. Remove the blower and brake assemblies.

13. Reverse this procedure for reassembly.

Training Manual

TDS-3H Maintenance

Removing the drilling motor fromthe housing assembly1. Remove the upper bearing cover and grease seal.

2. Pressurize the air brake to hold the drive mechanism in placeand remove the quill shaft locknut.

3. Remove the cotter pins, slotted nuts and rotating head.

4. Remove the lower gear case. The lower gear case is locatedwith dowel pins.

5. Carefully remove the quill shaft with bull gear so as to avoiddamaging the bearing surfaces or wear sleeves. Do not removethe gear from the shaft unless replacing it.

6. Remove the large quill shaft bearings.

7. Remove the pinion seal and retaining ring.

8. Remove the upper gear case.

9. On the opposite end of the motor, remove the magneticpickup and brake cover.

10. The brake may now be removed for service.

Refer to the electric motor sections to remove the pinion or hubon the armature shaft or to service the motor itself.

z Once the unit has been disassembled, inspect the assemblies forany wear or damage that may be critical, as follows:

1. Gear set: Check the teeth and splines for chips or heavyspalling. The wear pattern should be even and symmetrical.If not, replace it. Some small surface pitting is to be expectedand is not cause for replacing the gear set.

2. Bearings: Clean thoroughly in solvent, then rotate and listenfor any roughness during rotation.

3. Main shaft: Check splines and tool joints for wear.Replace the shaft if spline wear exceeds 0.090 in.

4. Main shaft: Check fit to bull gear, wear sleeve surfaces andretaining threads.

5. Seals: Always replace seals and gaskets when removed.

TDS-3H Maintenance

6. Main shaft housing: The bore for the upper bearing and thepilot diameter for the lower gear case are critical. Any nicks orgouges must be cleaned up prior to re-assembly.

7. Air brake: Check the brake for air leakage and the pads forwear.

8. Wear sleeves: These should be free of any imperfections onthe sealing surface.

9. Blower: Clean any accumulation of dust from the ducting,then operate the unit and correct any interference betweenthe impeller and housing.

10. Air valve assembly: If any air-operated systems have beenmalfunctioning, remove the appropriate valve and repair orreplace.

Reassemble the drilling motor and housing assembly by reversingthe steps in the above disassembly procedure. Replace all greaseseals and O-rings. Refer to the following torque chart for bolttightening guidelines.

Torque chart

Motor housing to motor 1750 ft lb. (2373 N.m)

Upper gear case to housing assembly 1100 ft lb (1492 N.m)

Bull gear to hub 580 ft lb (786 N.m)

Lower gear case to main body 250 ft lb (339 N.m)

Rotating head to lower gear case 250 ft lb (339 N.m)

Brake adapter ring to motor 250 ft lb (339 N.m)

Brake to brake adapter plate 50 ft lb (68 N.m)

Brake drum to hub 250 ft lb (339 N.m)

Brake cover to brake 50 ft lb (68 N.m)

Upper seal retainer to motor housing 75 ft lb (102 N.m)

Training Manual

TDS-3S Maintenance

BullGear

LowerGearCase

MotorAlignmentCylinder(Ref.)

MainBody

PinionGear

D.C.DrillingMotor

AirBrake

DriveStem

MotorSupportBonnet

Gooseneck

Figure 19. Drilling motor and motor support bonnet assembly/disassembly

Training Manual

TDS3 Maintenance


You can perform some service procedures on top drives (i.e. upperdrive stem bearing and seal, air brake or locally mounted coolingsystem) without removing the drilling motor assembly from thedolly. If service is required on the lower end (i.e. gear set, lowerbearings or seals), you must remove the drilling motor from thedolly.1. Set TDS down horizontally on a good flat surface.2. Make sure that none of the components protrude past theguide dolly roller brackets before setting the TDS down. If so,block the guide dolly up accordingly.3. Disconnect all wiring and hoses between transmission andguide dolly frame.4. Remove any cooling ducts (heat exchanger, spark arrestor,etc.) that interfere with removing the transmission from guidedolly frame.5. Use a suitable sling to support the weight of the TDS andmotor support bonnet (approximately 10,000 lb).6. Take up the slack and remove the trunnion blocks that holdthe transmission to the guide dolly frame.7. Hoist the transmission out of the guide dolly frame.8. Set the TDS and motor support bonnet down on wooden chocks,being careful not to damage components.9. Disconnect the wiring between the motor and motor supportbonnet.10. Make sure the transmission is in neutral.11. Remove the dowel pins in the motor feet.12. Remove the four large motor bolts.13. Lift the transmission off of the motor, angling the upper endslightly to clear the motor support bonnet, and sliding thehousing off of the motor toward the gearcase end.14. Remove the blower and brake assemblies.15. Reverse this procedure for reassembly.

Training Manual

TDS3 Maintenance

Disassembly/assembly of drillingmotor and motor support bonnet

1. Remove the upper bearing cover and grease seal (Figure 19).2. Pressurize the air brake to hold the drive mechanism in place.3. Remove cotter pins, slotted nuts and the rotating head.4. Remove the lower gearcase, carefully avoiding damage to thelower gearcase locator dowel pins.5. Carefully remove the bull gear, avoiding damage to thebearing surfaces or wear sleeves. Do not remove the gear fromthe shaft unless you are replacing it.6. Remove the pinion seal and retaining ring.7. Remove the main body.8. On the opposite end of the motor, remove the magneticpickup and brake cover.9. Remove the brake for service.

Refer to the GE Electric Motor Manual included as a separate bookin this manual for procedures to remove the pinion or hub on thearmature shaft, or to service the motor itself.Once the unit has been disassembled, inspect the followingassemblies for any wear or damage that may be critical:1. Gear set: Check the teeth and splines for chips or heavy spalling.The wear pattern should be even and symmetrical. If not, replace it.Expect some small surface pitting. It is not cause for replacing thegear set.2. Bearings: Clean thoroughly in solvent, then rotate and listenfor any roughness during rotation.3. Main shaft: Check splines and tool joints for wear. Replacethe shaft if spline wear exceeds 0.090".4. Main shaft: Check fit to bull gear, wear sleeve surfaces andretaining threads.5. Seals: Always replace seals and gaskets when removed.6. Main shaft housing: The bore for the upper bearing and the pilotdiameter for the lower gearcase are critical. Clean up any nicks orgouges prior to reassembly.7. Air brake: Check the brake for air leakage and the pads for wear.8. Wear sleeves: These should be free of any imperfections on thesealing surface.

Training Manual

TDS3 Maintenance

9. Blower: Clean any accumulation of dust from the ducting, thenoperate the unit and correct any interference between the impellerand housing.10. Air valve assembly: If any air-operated systems aremalfunctioning, remove the appropriate valve and repair or replace.

Reassemble the drilling motor and motor support bonnet byreversing steps in the disassembly procedure. Replace all greaseseals and O-rings, and refer to the following torque chart for bolttightening guidelines.

Torque ChartMotor support /bonnet to main body 7850 ft lbMain body to motor bonnet 1100 ft lbBull gear to hub 580 ft lbLower gear case to main body 250 ft lbRotating head to lower gearcase 250 ft lbBrake adapter ring to motor 250 ft lbBrake to brake adapter plate 50 ft lbBrake drum to hub 250 ft lbBrake cover to brake 50 ft lb

Training Manual

TDS-3S Maintenance

BullGear

LowerGearCase

MotorAlignmentCylinder(Ref.)

MainBody

PinionGear

D.C.DrillingMotor

AirBrake

DriveStem

MotorSupportBonnet

Gooseneck


Training Manual

TDS-4H Maintenance


You can perform some service procedures on top drives (i.e. upperquill shaft bearing and seal, air brake or locally mounted coolingsystem) without removing the drilling motor assembly from thedolly. If service is required on the lower end (i.e. gear set, lowerbearings or seals), you must remove the drilling motor from thedolly.

1 Set TDS down horizontally on a flat surface. Make sure thatnone of the components protrude past guide dolly rollerbrackets before setting down. If so, block dolly upaccordingly.

2. Disconnect all wiring and hoses between transmission andguide dolly frame.

3. Remove any cooling ducts (heat exchanger, spark arrestor,etc.) that interfere with removing the transmission from guidedolly frame.

4. Run a suitable sling through quill shaft to support weight ofmotor and housing assembly (approximately 10,000 lb).

5. Attach sling to crane, take up slack and remove trunnionblocks that hold the transmission to the guide dolly frame.


7. Set motor and housing assembly down on wooden chocks,being careful not to damage components.

8. Disconnect the wiring between the motor and the housing.Make sure the transmission is in neutral.

9. Remove the dowel pins in motor feet.


11. Lift transmission off of motor by slightly angling upper endto clear the motor frame, and slide the housing off of themotor towards the gear case end.



Training Manual

TDS-4H Maintenance

Removing the drilling motor fromthe housing assembly1. Remove upper bearing cover and grease seal.

2. Pressurize air brake to hold drive mechanism in place andremove quill shaft locknut.

3. Remove cotter pins, slotted nuts and rotating head.

4. Remove the lower gear case. Lower gear case is located withdowel pins (Figure 20).

5. Carefully remove quill shaft with bull gear so as to avoiddamaging bearing surfaces or wear sleeves. Do not remove thegear from the shaft except to replace it.

6. Remove large quill shaft bearings.

7. Remove pinion seal and retaining ring.

8. Remove upper gear case.

9. On opposite end of motor, remove magnetic pickup andbrake cover.

10. Brake may now be removed for service.

Refer to electric motor sections to remove the pinion or hub onarmature shaft or to service the motor.

Training Manual

TDS-4H Maintenance

Figure 20. Gear case assembly/disassembly

Training Manual

TDS-4H Maintenance

z Once the unit has been disassembled, inspect the assemblies forany wear or damage that may be critical, as follows:

1. Gear set: Check the teeth and splines for chips or heavyspalling. The wear pattern should be even and symmetrical. Ifnot, replace it. Some small surface pitting is to be expectedand is not cause for replacing the gear set.


3. Main shaft: Check splines and tool joints for wear. Replacethe shaft if spline wear exceeds 0.090".

4. Main shaft: Check fit to bull gear, wear sleeve surfaces andretaining threads.


6. Main shaft housing: The bore for the upper bearing and thepilot diameter for the lower gear case are critical. Any nicks orgouges must be cleaned up prior to reassembly.




10. Air valve assembly: If any air-operated systems have beenmalfunctioning, remove the appropriate valve and repair orreplace.

September 16, 199676 TDS-4H Maintenance and troubleshootingRe-assemble the drilling motor and housing assembly by reversingthe steps in the preceding disassembly procedure. Replace allgrease seals and O-rings, and refer to the following torque chartfor bolt tightening guidelines.Torque chartMotor housing to motor 1750 ft lbUpper gear case to housing assembly 1100 ft lbBull gear to hub 580 ft lbLower gear case to main body 250 ft lbRotating head to lower gear case 250 ft lbBrake adapter ring to motor 250 ft lbBrake to brake adapter plate 50 ft lbBrake drum to hub 250 ft lbBrake cover to brake 50 ft lbUpper seal retainer to motor housing 75 ft lb

Training Manual

TDS-4S Maintenance


You can perform some service procedures on top drives (i.e. upperdrive stem bearing and seal, air brake or locally mounted coolingsystem) without removing the drilling motor assembly from thedolly. If service is required on the lower end (i.e. gear set, lowerbearings or seals), the drilling motor must be removed from the dolly.

1. Set TDS down horizontally on a good flat surface.

2. Make sure that none of the components protrude past theguide dolly roller brackets before setting the TDS down. If so,block up the guide dolly accordingly.

3. Disconnect all wiring and hoses between transmission andguide dolly frame.

4. Remove any cooling ducts (heat exchanger, spark arrestor,etc.) that interfere with removing the transmission from guidedolly frame.

5. Use a suitable sling to support the weight of the TDS andmotor support bonnet (approximately 10,000 lb).

6. Take up the slack and remove the trunnion blocks that holdthe transmission to the guide dolly frame.


8. Set the TDS and motor support bonnet down on woodenchocks, being careful not to damage components.

9. Disconnect the wiring between the motor and motor supportbonnet.

10. Make sure the transmission is in neutral.

11. Remove the dowel pins in the motor feet.


13. Lift the transmission off of the motor, angling the upper endslightly to clear the motor support bonnet, and sliding hous-ing off of the motor toward the gearcase



Training Manual

TDS-4S Maintenance

Disassembly/assembly of drillingmotor and motor support bonnet1. Remove the upper bearing cover and grease seal (Figure 20).

2. Pressurize the air brake to hold the drive mechanism inplace.

3. Remove cotter pins, slotted nuts and the rotating head.

4. Remove the lower gearcase, carefully avoiding damage to thelower gearcase locator dowel pins.

5. Carefully remove the bull gear, avoiding damage to the bear-ing surfaces or wear sleeves. Do not remove the gear fromthe shaft unless you are replacing it.

6. Remove the pinion seal and retaining ring.

7. Remove the main body.

8. On the opposite end of the motor, remove the magneticpickup and brake cover.

9. Remove the brake for service.

Training Manual

TDS-4S Maintenance

HI

LO

BullGear

LowerGearCase

MotorAlignment

Cylinder

MainBody

D.C.DrillingMotor

AirBrake

MotorPinionSeal

Shaft

HighGearAssembly

PinionGearManual

ShifterInput Geneva

Mechanism

LowGearAssembly

GearSelectionIndicator

OilLevelSight Glass


Training Manual

TDS-4S Maintenance

Refer to the GE Electric Motor Manual for procedures to removethe pinion or hub on the armature shaft, or to service the motoritself.

Once the unit has been disassembled, inspect the following as-semblies for any wear or damage that may be critical:

1. Gear set: Check the teeth and splines for chips or heavy wear.The wear pattern should be even and symmetrical. If not, re-place it. Expect some small surface pitting. It is not cause forreplacing the gear set.


3. Main shaft: Check splines and tool joints for wear. Replacethe shaft if spline wear exceeds 0.090".

4. Main shaft: Check fit to bull gear, wear sleeve surfaces and re-taining threads.


6. Main shaft housing: The bore for the upper bearing and thepilot diameter for the lower gearcase are critical. Clean up anynicks or gouges prior to reassembly.




10. Air valve assembly: If any air-operated systems are malfunc-tioning, remove the appropriate valve and repair or replace.

Training Manual

TDS-4S Maintenance

Reassemble the drilling motor and motor support bonnet by re-versing the steps in the disassembly procedure. Replace all greaseseals and O-rings, and refer to the following torque chart for bolttightening guidelines.

Torque Chart

Motor support/bonnet to main body 1100 ft lb

Main body to motor bonnet 1100 ft lb

Bull gear to hub 580 ft lb

Lower gearcase to main body 250 ft lb

Rotating head to lower gearcase 250 ft lb

Brake adapter ring to motor 250 ft lb

Brake to brake adapter plate 50 ft lb

Brake drum to hub 250 ft lb

Brake cover to brake 50 ft lb



Gearbox Lubrication



Rotating Head

Training Manual

TDS-Rotating Head

Rotating headThe rotating head allows transferring pneumatic and hydraulicpressure from stationary ports on the TDS drilling motor housingto rotating ports on the rotating head (Figure 9). It features twohydraulic passages, three pneumatic passages, and two spare pas-sages capable of transferring either pneumatic or hydraulic fluid(all are rated at 2000 psi).

The rotating head assembly consists of:

❏ A stationary flange

❏ Eight rotary glyd rings

❏ A swivel block

❏ A cam

❏ A return cylinder

❏ A cam follower

❏ Swivel block locking mechanism

The hydraulic and air lines for the various pipehandler functions(link tilt, torque wrench, etc.) run from their respective solenoidvalves to the stationary flange. The fluids travel from the flange tothe swivel block via sealed rotating passages.

Additional hoses connect the ports in the swivel block to the cor-responding devices (link tilt, etc.). The swivel block rotatesrelative to the flange without twisting or damaging any hoses.There is also a lug for mounting the torque wrench hanger andholes for attaching the torque arrestors on the swivel block.

The rotating head stationary flange bolts directly to the bottom ofthe gearcase with the drive stem running through the center.There is also a return cylinder mounted on the stationary flange.The return cylinder is hydraulically connected to the counterbal-ance manifold. The rod end of the cylinder connects to a camfollower assembly that tracks the cam mounted to the swivelblock.

Training Manual

TDS-Rotating Head

Stationary Flange

LockingLever

Auto-ReturnCylinder

Swivel Block

CamCamFollower

Figure 9. Rotating head assembly

Integrated swivel and swivelwashpipeThe integrated swivel is a bearing assembly that allows transfer ofthe rotating load to the lifting components (Figure 2). The swivelwashpipe is a rotating seal that allows mud to flow to the rotatingdrill string.

Training Manuale

TDS-500 Ton Rotating Head

Replacing the rotating head glyd ring

z Rotary glyd ring replacement is indicated when hydraulic oil isdetected in the pipehandler air supply. An indication of oilcontaminating the air supply would be an accumulation of oil inthe link tilt air actuator (bag).

The following disassembly and assembly procedures assume thatthe TDS is swung out for maintenance in accordance with theTDS Swing Out procedures. Refer to Figures 4-16 and 4-17,when performing the following procedures:

Disassembly

1. Order eight replacement glyd rings, two gearcase seals, oneflange gasket, and one excluder cap gasket from Varco.Contact the nearest Varco Service Center for details aboutbuilding an appropriate stand for working on the rotatinghead when removed from the TDS for service ormaintenance.

2. Disconnect the hydraulic and air hoses from the rotating headrotating block to the various pipehandler components.

3. Support the torque wrench.

4. Disconnect the IBOP actuator arms and hoses.

5. Remove the pin attaching the hanger to the rotating blockclevis, and remove the torque wrench.

6. Support the link tilt and link adapter assembly whileremoving the pins attaching the torque arrestors to therotating block.

7. Remove the torque arrestors, link tilt and link adapter.

8. Place the rotating head stand, built prior to disassembly,under the TDS and lower the TDS until the rotating headrests on the stand.

9. Remove the flange nuts and lift the block, leaving the rotatinghead on the stand.

10. Remove the quick disconnect fittings from the rotating blockhydraulic lines and drain the hydraulic fluid from the system.

11. Remove the cotter pin from the return cylinder clevis pin.

12. Remove the hex-slotted nut and remove the clevis pin.


13. Push the cam follower away from the rotating block cam.

14. Remove the safety wire from the ten hex-head screwsattaching the rotating block to the stationary flange.

15. Support the rotating block and remove the ten screws.

16. Remove the rotating block and glyd rings.

17. Remove the excluder cap and gasket.

18. Remove the glyd rings from the rotating block and discard.

19. Remove excluder cap gasket and replace with new gasket.

Stationary Flange

Cam

LockingLever Swivel Block

Auto-ReturnCylinder

CamFollower

Figure 4-16. Rotating head assembly

Training Manual


Assembly

1. Lubricate the eight new glyd rings with hydraulic fluid andinsert them into the glyd ring grooves inside the rotatingblock.

2. Place the excluder cap and gasket on the bottom of therotating block.

3. Using a tugger or other support, carefully mate the rotatingblock to the stationary flange.

4. Reinstall the ten hex-head screws and torque to 250 ft lb.

5. Safety wire the screws per standard safety wire procedures.

6. Reinstall the quick disconnect hydraulic fittings on therotating block.

7. Attach the return cylinder rod to the clevis with the clevis pinand install the slotted hex-head nut and cotter pin.

8. Reinstall the pipehandler components per the proceduresdetailed in the Installation and Commissioning book of thismanual.

TDS-500 ton Rotating Head1

Stationary Flange

ReturnCylinder

Return CylinderClevis (2)

Return CylinderClevis Pin (2)

Hex Nut (2)

CotterPin (2)

Cam Follower

Cam Follower

Glyd Rings (8)

GearcaseSeals

Retainer Ring

Figure 4-17. Rotating head assembly/disassembly

Training Manual


Replacing the rotating head glyd ring

z Rotary glyd ring replacement is indicated when hydraulic oil isdetected in the pipehandler air supply. An indication of oil con-taminating the air supply would be an accumulation of oil in thelink tilt air actuator (bag).

The following disassembly and assembly procedures assume thatthe TDS is swung out for maintenance in accordance with theTDS Swing Out procedures. Refer to Figures 17 and 18, whenperforming the following procedures.

Stationary Flange

LockingLever

Auto-ReturnCylinder

Swivel Block

CamCamFollower

Figure 17. Rotating head assembly

Training Manual


Disassembly

1. Order eight replacement glyd rings, two gearcase seals, oneflange gasket, and one excluder cap gasket from Varco. Con-tact the nearest Varco Service Center for details aboutbuilding an appropriate stand for working on the rotatinghead when removed from the TDS for service or mainte-nance.

2. Disconnect the hydraulic and air hoses from the rotating headrotating block to the various pipehandler components.

3. Support the torque wrench.

4. Disconnect the IBOP actuator arms and hoses.

5. Remove the pin attaching the hanger to the rotating blockclevis, and remove the torque wrench.

Training Manual


��

��

��Cotter Pin

Hex Nut

ReturnCylinder

Rod End Detail

Cylinder Clevis

ExcluderCap

Excluder CapGasket

Retainer Ring

Glyd Ring (8)

Detail C

Cam

Ball Bearing

Stationary Flange

Bull GearLip Seal

Cam Assembly

Return Cylinder

CAM

Locking Handle

ReturnCylinder

Clevis Pin

Ball Bearing

C

Figure 18. Rotating head glyd ring replacement

Training Manual


6. Support the link tilt and link adapter assembly while remov-ing the pins attaching the torque arrestors to the rotatingblock.

7. Remove the torque arrestors, link tilt and link adapter.

8. Place the rotating head stand, built prior to disassembly, un-der the TDS and lower the TDS until the rotating head restson the stand.

9. Remove the flange nuts and lift the block, leaving the rotatinghead on the stand.

10. Remove the quick disconnect fittings from the rotating blockhydraulic lines and drain the hydraulic fluid from the system.

11. Remove the cotter pin from the return cylinder clevis pin.

12. Remove the hex-slotted nut and remove the clevis pin.

13. Push the cam follower away from the rotating block cam.

14. Remove the safety wire from the ten hex-head screws attach-ing the rotating block to the stationary flange.

15. Support the rotating block and remove the ten screws.

16. Remove the rotating block and glyd rings.

17. Remove the excluder cap and gasket.

18. Remove the glyd rings from the rotating block and discard.

19. Remove excluder cap gasket and replace with new gasket.

Assembly

1. Lubricate the eight new glyd rings with hydraulic fluid andinsert them into the glyd ring grooves inside the rotatingblock.

2. Place the excluder cap and gasket on the bottom of the rotat-ing block.

3. Using a tugger or other support, carefully mate the rotatingblock to the stationary flange.

4. Reinstall the ten hex-head screws and torque to 250 ft lb.

5. Safety wire the screws per standard safety wire procedures.

6. Reinstall the quick disconnect hydraulic fittings on the rotat-ing block.



Link Tilt

Current date


Replacing the link tilt air actuatorThere is an air actuator on the link tilt mechanism (Figure 4-18).The following procedure details the replacement of the actuators:

Parts required: 1 Air actuator (P/N 82353)

18 Button head cap screws (P/N 50186-10-01)

Disassembly

1. Disconnect the air hose from the rotating head rotating blockto the link tilt assembly.

2. Support the link tilt and remove the two upper and two lowerscrews attaching the link tilt to the link adapter.

3. Lower the link tilt to the floor with the air actuator to bereplaced facing up.

4. Remove the cotter key and pin from one end of chainconnecting the two sealing plates.

5. Remove the safety wire from the four hex-head cap screwsholding the air actuator sealing plate to the link tilt base orlever and remove the screws.

6. Lift the lever or base off the air actuator sealing plate, androtate it 180° on the link tilt pivot pin and lay down.

7. Remove the 18 nuts and washers holding the sealing plate tothe air actuator and remove the plate.

8. Using a pry bar or screwdriver, pry the air actuator away fromthe screws attaching the actuator to the hanger plate andremove the screws using a hex wrench.

9. Remove and discard the air actuator.

10. Remove any burrs or gouges on sealing surfaces of the hangerand sealing plates.


Lever Weldment

Sealing Plate (2)

Sealing PlateBolt (4)

Lever

Elevator Link (Ref)

Stop ReleaseLoop

IntermediateStop (2)

Pivot Pin

Nuts, LockWashers (18)

Air Actuator

Hanger Plate

Base

PressureRegulator

QuickExhaustValve

ButtonheadCapscrew (18)

Stop Pivot Arm

Connecting Chain

Figure 4-18. Link tilt assembly/disassembly

Current date


Assembly

1. Place a new actuator on the hanger plate.

2. Attach the air actuator to the hanger plate with the (18)button head cap screws. Coat the screw threads with locktitebefore installation.

e The air actuator has aluminum neck bead rings on both sealingsurfaces. These beads must be compressed equally to ensure a good airseal. This requires more than one tightening pass. Over-torquing maycause hex sockets to strip.

3. Torque the cap screws to the hanger plate at 80 ft lb.

4. Insert the 18 bolts into the neck ring of the air actuator.

5. Reinstall the air actuator sealing plate, coat the bolt threadswith locktite and fasten with the lockwashers and nutsprovided.

6. Torque the nuts to the sealing plate at 80 ft lb (see cautionabove).

7. Lift and rotate the link tilt lever or base to line up with the airactuator sealing plate. Attach with the four hex-head capscrews and torque to 250 ft lb.

8. Safety wire the four screws.

9. Reconnect the chain between the two sealing plates.

10. Reinstall and adjust the link tilt per the procedure outlined inthe Installation and Commissioning book.



Torque Arrestors

Torque Arrestors

The Link Adapter (Solid body Elevator), link tilt, LinkBails and Pipe elevators are supported on componentscalled Torque Arrestors. They are pinned to the rotatingHead mounted on the bottom of the gear case. The torquearrestors contain compression springs that keeps the Solidbody Elevator, link adapter, Link Bails and Pipe elevatorsabove the load collar on the main shaft. The springs doprovide a pre-load sufficient to support a stand of drillpipe in the full full up position. When hoisting thesetorque arrestor springs will be compressed by thehoisting load allowing the link adapter ( solid bodyelevator) to be pulled down onto the load collartransferring the load to the main shaft. Two torquearrestors are used in the 500 ton version TDS and fourtorque arrestors are used in the 650/750 ton version TDS

Caution:Under No circumstances should TorqueArrestors be disassembled in the field as thecontain powerful springs under compressionand could cause serious injury and damage ifreleased inadvertently.



IBOP

IBOP Control Circuit

Q Why is there 30 psi on the actuator shell at all times.

A, During rough drilling conditions especially surface hole, Vertical vibration of the drillstring can cause the upper ibop actuator shell to hammer on the the ibop crankassembly damaging the crank arms and the bearings

The IBOP Control circuit prevents excessive damage to the actuator and bearingsby holding the shell down with a force of 500 lbs in the open position. There is anreducing valve on the circuit which is set to 30 psi. The control circuit has a 30second timer,( controlled by the PLC) when the open solenoid is operated it staysfully open for 30 seconds then shuts of and the pressure is reduced to 30psi from aprv on the close circuit.

Schematic showing circuit after timer operation

Open solenoid

Close solenoidTo manifoldvent

PRV set at 30psi

Actuator Cylinders

30 PSI oncylinders

Shuttle Valve

Rig air 90 psi


Schematic showing circuit in close operation

Open solenoid


PRV set at 30psi

Actuator Cylinders

30 PSI oncylinders

Shuttle Valve

Rig air 90 psi


Schematic showing circuit before end of timer operation

Open solenoid


PRV set at 30psi

Actuator Cylinders

90 PSI oncylinders

Shuttle Valve

Rig air 90 psi

Sa fe ty Va lveSa fe ty Va lve( I B O P )( I B O P )

Serv ice Manua lServ ice Manua l

® ™DRILLING SYSTEMS

Feb. 2, 1994

Feb. 2, 1994

i

Feb. 2, 1994

Contents

GENERAL DESCRIPTION.............................................................................. 1PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5

Introduction .................................................................................................. 5Principle Features ................................................................................... 5

Remote IBOP Actuator Improvements ........................................................ 7Internal Valve Mechanism Improvements.................................................... 8

INSTALLATION ............................................................................................ 9OPERATION.............................................................................................. 16

Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17LUBRICATION ........................................................................................... 18INSPECTION ............................................................................................ 21

Magnetic Particle Inspection...................................................................... 21Safety Valve Inspection Procedures .......................................................... 21

Visual Inspection ................................................................................... 22ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23MAINTENANCE ......................................................................................... 25

Seal Replacement ..................................................................................... 25Shop Assembly and Disassembly ............................................................. 27

Disassembly.......................................................................................... 28Assembly .............................................................................................. 32IBOP Valve Testing in the Shop ............................................................ 39

APPENDIX ................................................................................................ 40

ii

Feb. 2, 1994

1

Feb. 2, 1994

Varco/BJSafety Valves

(IBOPs)

GENERAL DESCRIPTION

The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internalopenings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psiworking pressure.

If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lowerIBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and leftin the string if required.

The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operatedat any height in the derrick from the driller’s console. The upper IBOP can also be operatedmanually using a 7/8" hex wrench.

There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushingfor purging any debris that may get in the wave spring area.

2

Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)

3

Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

Var co

Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)

4

Feb. 2, 1994

CLSDOPEN

Retaining Ring

Upper Seat

Back-up Rings

O-Ring

StabilizerRing

Ball

Back-upRings

O-Ring

Sleeve

Seal Ring

Crank

Seat

Grease/Mud Seal

Back-up Ring

O-Ring

WaveSpring

Body

ThreadProtector

Plug

ThreadProtector

Figure 3. Typical Upper Safety Valve (IBOP)

5

Feb. 2, 1994

PH-60 IBOP/Actuator Upgrade Kit

Introduction

Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existingPH-60 pipe handler will dramatically improve the reliability of the remote-operated system, bothas a primary safety valve and as a mud saver while drilling ahead.

Maintenance and operating costs will be greatly reduced, allowing a minimum plannedmaintenance interval of six months for the upper IBOP.

PRINCIPLE FEATURES

❏ The upper IBOP valves (2 ea.) are equipped with:• PH-85 style dual-path operating systems• New low-stress inside body contours• Completely redesigned long-life internals

❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides.

❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and theyeliminate the need for periodic adjustment.

❏ The dual external crank assemblies share the operating loads. Each is reinforced, withimproved sealing and retention.

❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, grease-packed, and completely isolated from mud caking and corrosion to ensure full bore opening.

6

Feb. 2, 1994

ACTUATOR CYLINDERMOUNTING BRACKETREQUIRES NO ADJUSTMENT

LARGE BORE,LONG STROKE IBOPACTUATOR CYLINDERS (2)

REINFORCED DUALEXTERNAL CRANKS ANDHOUSINGS WITH IMPROVEDBALL ROTATION STOPS

SOLID, ONE-PIECE,JOURNAL-GUIDEDIBOP ACTUATOR SHELL

IMPROVED DESIGNDUAL-CRANKUPPER IBOP VALVE

Aug. 9, 1993. A.N.

Figure 4. PH-60 Upgrade Kit

7

Feb. 2, 1994

Remote IBOP Actuator Improvements

(Refer to Drawing 99261 in the Appendix)

1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%larger piston area ensures positive, complete ball rotation under the most arduous conditions.A 60% increase in available cylinder stroke eliminates the need for sensitive positionadjustments, both at initial rig-up as well as over the life of the system.

2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the currentmulti-piece actuator shell assembly, eliminating the separately attached (and vulnerable)guide roller assemblies. The bronze-lined internal diameter of the new actuator shell ridesdirectly on the IBOP outer diameter. The new design is very robust, requires no adjustments,and is able to withstand punishing environments without damage.

3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. Thischange reduces the operating and environmental forces on the internal and external componentsby 50%. It also provides a balanced reaction force to the actuating levers. This force balanceallows elimination of the bolt-on guide roller assemblies.

Each of the two external crank housings is anchored to the IBOP body with 1/2" screwsinstead of the 3/8" screws used in the previous design. The crank housings are also securedto react the ball stop torque using a close-tolerance fit between the base of the housing andthe machined recess in the IBOP valve body. When required, jacking screws make removingthe housings easier.

8

Feb. 2, 1994

Internal Valve Mechanism Improvements

1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They arereplaced with a smooth bore through the ball and seat region. This significantly lowers themaximum stress in the valve body and effectively eliminates the possibility of leaks causedby cracking at the crank bores under corrosive mud conditions.

2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ballrotation stop in the previous design. The crank was easily replaced, but the body was notrepairable after stop shoulder wear. The wear-induced loss of ball stop accuracy overextended use could eventually allow the ball to over-travel, leading to washouts.

In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internalcranks (2) and external crank housings (2) need replacement should they ever become worn.The external crank housings in the new design serve as the ball rotation stops. Each externalcrank housing has two struts which contact the internal crank to stop the ball precisely at theopen or closed position. The torque required to stop the ball is then shared by four surfacesrather than the previous design’s single surface.

The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricatedregions beneath the external cranks. This eliminates the presence of caked drilling fluidaround the stop mechanism and is more reliable.

3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,the PH-85. This effectively cuts the operating forces in half on the critical ball actuating andlocating components, decreasing wear and eliminating mechanical failure.

9

Feb. 2, 1994

INSTALLATION

The following installation procedure assumes that all other rig components are already installed.

1. Use slips to install a joint of drill pipe into the rotary table.

2. Install the saver sub hand tight onto the drill pipe.

3. Install the lower IBOP hand tight onto the saver sub.

4. Install the upper IBOP hand tight onto the lower IBOP.

5. Screw the stem/main shaft and upper IBOP together.

CAUTIONThe same care should be taken with these valves as would be anyother threaded valve. Be sure to use a thread compound with 60%lead by weight or Kopper Kote. Varco does not recommend usinga zinc thread compound. If making up new threads for the firsttime, use the following procedure:

a. Torque up to the recommended torque value (Table 1).b. Back off the connection and inspect the threads and face.c. Torque up to the recommended torque value (Table 1).

10

Feb. 2, 1994

Table 1. Make-Up Torque Values

Torque (ft-lb)Components I.D. Connection O.D. (min.) (max.)

Mainshaft to UpperIBOP Safety Valve*

3" 6-5/8 API Reg. 7-3/4 60,000 70,000

Upper IBOP SafetyValve to LowerIBOP Valve

3" 6-5/8 API Reg. 7-3/4 50,000 70,000

Lower IBOP Valveto Saver Sub

3" 6-5/8 API Reg. 7-3/8 46,000 64,000

Crossover Sub toLower IBOP SafetyValve

3" 6-5/8 API Reg. 7-3/8 46,000 60,000

Mainshaft to UpperIBOP SafetyValve**

3" 7-5/8 API Reg. 9 83,000 91,000

Upper IBOP SafetyValve to LowerIBOP

3" 7-5/8 API Reg. 9 75,000 91,000

Lower IBOP Valveto Saver Sub

3" 7-5/8 API Reg. 8-5/8 66,000 85,000

Crossover Sub toLower IBOP Valve

3" 7-5/8 API Reg. 9 75,000 91,000

* 500 Ton** 650 Ton

6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows(Figures 5 & 6):

a. Carefully grind off any raised tong marks on the O.D. of the safety valves.b. Open the valve exactly halfway (45 degree rotation of the actuator).c. Orient the levers on the crank assemblies horizontally as shown.d. Slide the shell up onto the valve with the actuator arm groove on the bottom.e. Hold the shell in position relative to the valve operating sockets.f. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through

and the cam follower into the horizontal slot. Use the lock tabs on the retaining screwsand locktite on the bolt threads to secure the assemblies.

g. Manually operate the actuator to ensure free movement though a full 90° of crank travel.

11

Feb. 2, 1994

Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):

a. Carefully grind off any raised tong marks on O.D. of the safety valves.b. Open the valve exactly halfway (45 degree rotation of actuator).c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire

groove on side of crank body is to the right and the safety tab is on the left).d. Slide the shell up onto the valve with the roller groove at the bottom.e. Hold the shell in position relative to the valve operating socket.f. Using the two bolts provided, install the crank assembly, sliding the safety tab through

and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wirethe bolt heads, routing lock wire around the right side of the crank body through the safetywire groove.

g. Install the two roller assemblies nearest the crank slot, and then using shims provided,install the third roller assembly, maintaining .005" to .010" clearance between the thirdroller assembly and the safety valve body with the shell vertically centered on the valve.

h. Manually operate the actuator to ensure free movement through full 90° of crank travel.

NOTEWhen the actuator is in the lowest position, the valve should beopen.

7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manualfor the installation and adjustment procedures).

8. Use the torque wrench to make up the saver sub to the lower IBOP.

9. Use the torque wrench to make up the lower IBOP to the upper IBOP.

12

Feb. 2, 1994

Safety WireGroove

7/8" Allen Crank

Cam Follower

CrankAssembly

Lock Tabs

Crank AssemblyRetaining ScrewAnd Lock Tabs

Slot

Crank Arm*

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

CrankAssembly

*Note Orientation

Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d

13

Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions

14

Feb. 2, 1994

RollerAssembly (3)

RollerAssembly (3)

CrankAssembly

Safety WireGroove Shim

ActuatorArmGroove

Crank*

ActuatorShell

Slot

Crank AssemblyRetaining Screw

CrankAssembly

RollerAssembly(3)

SafetyValve

*Note Orientation

Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for thePH-60

15

Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions

16

Feb. 2, 1994

OPERATIONOperating the switch on the driller’s console to the IBOP Close position causes the two (2)actuator air cylinder rods to extend moving the arms and the actuator shell body upward. Thisupward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve.

Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.

17

Feb. 2, 1994

Erosion Prevention of the Ball and Seats in the Lower IBOP Valve

To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fullyclosed at least one time each shift change. The valves can partially open without being externallyactuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball andseats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommendsremoving the lip seal from the spring loaded (floating) seat to correct this problem.

Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):

1. Breakout and remove the lower IBOP.

2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.

3. Replace the O-rings and back-up rings on the fixed and floating seats.

4. Re-assemble the valves.

5. Reinstall and torque the lower valve.

Figure 9. Lower IBOP Seal Removal

18

Feb. 2, 1994

LUBRICATION

Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crankin the recessed counter bore. There are three reasons for lubricating the valve:

1. To verify the integrity of the grease seal.

2. To lubricate the floating seat.

3. To flush mud and debris from the spring cavity.

Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):

1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release ofpressure. A release of pressure indicates the mud/grease seal is not functioning properly —the valve should be serviced.

2. Install a suitable grease fitting.

3. Open the valve.

4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or anequivalent amount from an air powered grease injector. The grease pressure should notexceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude intothe clearance between the floating seat and the valve body.

5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,tightening securely.

CAUTIONThe plug must be replaced in the valve prior to use to maintainpressure integrity.

19

Feb. 2, 1994

SEAL RING STABILIZER

MUD/ GREASE SEAL

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLL

CFigure 10. Lubricating a T

ypical Upper IB

OP

20

Feb

. 2, 1

994

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLL

C

Fig

ure

11.

Lubr

icat

ing

a T

ypic

al L

ower

IBO

P

21

Feb. 2, 1994

INSPECTION

Magnetic Particle Inspection

After approximately three to six months (depending on the severity of operating conditions)Varco recommends performing a Magnetic Particle Inspection of all load bearing components– including IBOPs – over their entire surface and internal bores to reveal any fatigue or crackindications (Figure 11). Any indications found are a potential cause for the replacement of thesuspect component.

Details on Magnetic Particle Inspection procedures are in the following publications:

I.A.D.C. Drilling Manual, 9th EditionASTM A-275 Std. Method for Magnetic Particle Inspection of Steel ForgingsASTM E-709 Std. Recommended Practice for Magnetic Particle

Safety Valve Inspection Procedures

Upper and lower safety valves, because of their internal grooves and shoulders, are particularlysusceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers forbending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crackmay begin at the root of the pit.

Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PHlevels below 9.0. Inspect safety valves operated under such exposures for internal, transversecracks every three to six months, depending on the severity of the exposure.

Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can behidden under corrosion products. Use the magnetic particle inspection procedure.

Concentrate attention on (Figure 12):

❏ The area inside the operating crank window❏ The fillet radii of internal grooves and shoulders❏ The last engaged threads of box connections❏ The IBOP actuator shell

22

Feb. 2, 1994

RecommendedInspection Areas

Figure 12. IBOP Inspection Points

NOTERepairing valve body cracks is not practical because of the closetolerances of internal components and the metallurgy of the valvematerial. Remove from service and scrap any safety valve bodyshowing positive crack indications.

VISUAL INSPECTION

Whenever connections are broken, clean and check them for the following:

1. Thread and shoulder condition. Threads should be inspected for galling, stretching or otherabnormal conditions. Check shoulders for any marks, gouges or other damage.

2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on uppersafety valve for wear.

NOTERemove any surface imperfections on upper (splined) safetyvalves after the valve is made up into string to prevent remoteactuator malfunctions, causing the valve to wash out.

23

Feb. 2, 1994

ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of themechanism and to minimize mechanical component wear. The actuator shell installs over theupper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend thesafety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13)adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuatorshell as follows:

1. After removing the crank assemblies, make sure the actuator shell easily moves up and downover the upper IBOP.

NOTEThere is only one crank on upper IBOPs for the PH-60 pipehandler.There are also three roller assemblies.

2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.

3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab.

4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and checkfor signs of binding. Make sure the shell travels freely throughout its full range of travel. Ifbinding exists, troubleshoot to eliminate any problems before returning to service.

5. Actuate the control switch on the driller's console to the open the safety valve. The cylindersshould retract and the actuator ring should be down.

6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between thecylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distanceis not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch.

7. Actuate the valve to make sure it opens and closes fully.

24

Feb. 2, 1994

Upper IBOP Valve Actuator Shell

Crank Assy(Shown with Valve OPEN. Note Crank Assy Position

Upper IBOP ValveActuator Air Cylinders (2)

Upper IBOP

ActuatorArm

Torque Tube

Lower IBOP

Saver Sub

DriveStem(Ref.)

Landing Collar

LinkAdapter

*1 Inch

RodEnd

CylinderGland

Cylinderin OPENPosition

OP E N

C L OS E

*IMPORTANT

Eye Bolts (2)

Cylinder Adjustment Bolts (4)

F igure 13. A djus ting the S afety V alve A c tuator S ys tem for the P H-85, P H-60d &S ingle C rank P H-60

5/8 max 3/8 min

25

Feb. 2, 1994

MAINTENANCE

Seal Replacement

Replace seals at six month intervals under normal operating conditions (Figure 14). If there aresigns of wear, replace the ball and seat every six months. If the valve is used with oil-based orhigh salt content drilling fluids, shorter intervals may be necessary.

2 14517 6 1 10 18

13

12

12

9

3

4

208

7 16

19

15

2X

11

7/8" Hex

Note: Dual Crank Remote IBOP ShownSingle Crank Remote and Lower IBOPhave similar construction.

Figure 14. IBOP Safety Valve Illustrated Parts List

26

Feb. 2, 1994

BALL/SEAT SET

SEAL RING STABILIZER

1

17

16

20

19

18

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

PLUG

CRANK, LEFT HAND

NYLON PLUG

O'RING

BODY

WAVE SPRING

CRANK, RIGHT HAND

BACKING RING

O'RING

SLEEVE

CROWN SEAL

BACK-UP RING

POLYSEAL

UPPER SEAT (SET)

LOWER SEAT (SET)

BACK-UP RING

O'RING

RETAINING RING

BALL, DUAL CRANK (SET)

ITEM QYT. / KITDESCRIPTION

Parts List

1 -

1 1 -

1 1 1

1 1 1

1 1 -

1 1 -

1 1 1

2 2 2

1 2 2

1 2 -

1 2 2

2 4 4

1 1 -

1 1 -

- - -

1 1 1

2 2 2

- 1 -

1 1 -

1 1 1

REPAIR KIT - SINGLE CRANK

REPAIR KIT - DUAL CRANK

REPAIR KIT - SOFT SEAL ONLY

Refer to the Appendix for Part Numbers




(For either Single or Dual Crank)

1

1

1

2

PART NUMBERS

90939-5

89141-1

90441-9

90441-10

90939-5

90939-5

96439

89141-13

89141-8

90441-7 (93806-12 for Dual Crank)

89141-11

89141-12

89141-7 (93806-10 for Dual Crank)

89141-9

89141-3

93806-11

96438

Figure 14. IBOP Illustrated Parts List (Cont.)

27

Feb. 2, 1994

Shop Assembly and Disassembly

The following tools are required (Figure 15):Crank wrench Varco Part No. 77408Seat puller Varco Part No. 79489-14Nut wrench (for internal nut) Varco Part No. 89141-18Bushing installation toolOpen end or adjustable wrenchesTwo large flat screwdrivers or light pry bars1/4" and 3/4" allen wrenchesPipe vise or suitable holding device to hold valve secure

Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner ormild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,but also serves to loosen internal components. Follow these general rules while working on thevalve:

1. Take proper precautions while working with the components of the valve to make sureprecision matched surfaces and seal contact surfaces are not damaged.

2. After removing each part, thoroughly clean the exposed area to prevent damage to other partsas they are removed.

7.5"

Load Bar

3"Maximum

22"

Seat Puller For All ModelsVarco Part No. 79489-14

Nut Wrench for DSV ModelsVarco Part No. 89141-18

7/8" Hex Wrench For All ModelsVarco Part No. 89141-18

15.25"

3"

Figure 15. IBOP Tools

28

Feb. 2, 1994

1. Place the valve in a vise orclamp to hold the valvesecurely (Figure 16).

Figure 16

2. Engage the seat puller inthe inside groove of thelower seat (Figure 17).

3. Using the load bar acrossthe face of the connection,tighten the nut against theload bar to compress thewave spring approximately0.030" (Figure 17).

Figure 17

DISASSEMBLY

Starting with the valve in the closed position, disassemble the IBOP as follows:

29

Feb. 2, 1994

4. At the other end of thevalve, insert the upper seatwrench, P/N 89141-18, intothe upper seat engaging thewrench lugs into the matingslots (Figure 18).

5. Using the crank wrench,P/N 77408, as a lever in thehole provided in the upperseat wrench, rotate theupper seat clockwise untilit stops (Figure 18).

Figure 18

6. Remove the wrench.

7. Remove the retainer ringfrom the groove in the valvebody by using a screwdriverto pry one end of the retainerring out of the groove. Thering can then be removedby hand (Figure 19).

8. Re-insert the upper seatwrench into the upper seat.

9. Rotate the upper seatcounterclockwise until itdisengages from the bodythreads.

10. Remove the wrench and theupper seat (Figure 20).

Figure 20

Figure 19

30

Feb. 2, 1994

11. Remove the ball valve(Figure 21).

Figure 21

12. From the outside of thevalve, push the crank intothe valve body and removethem (Figure 22).

Figure 22

13. Remove the pulling toolfrom the lower seat.

14. Insert the pulling tool fromthe opposite end of thevalve and engage thegroove on the I.D. of thelower seat (Figure 23).

Figure 23

31

Feb. 2, 1994

15. Using the load bar acrossthe face of the connection,tighten the nut against it toremove the lower seat andthe wave spring (Figures24 and 25).

16. Remove and discard theseals from all IBOPcomponents.

17. Thoroughly clean andinspect each item.

Figure 24

Figure 25

32

Feb. 2, 1994

ASSEMBLY

1. Inspect the lower seat.Look carefully for signs ofcorrosion, pitting andgaulling – especially in thesealing areas (Figure 26).

2. Make sure the wave springis not broken or damaged(Figure 26).

3. Inspect the steel stabilizerring, making sure it is notworn, pitted or damaged(Figure 26).

4. Replace all O-rings, backuprings and seals (Figure 26).

Figure 26

5. Install the steel stabilizerand seal on the lower seat(floating seat), by placingthe steel stabilizer in thegroove of the U-cup sealand, starting on one side ofthe seat, work the stabilizerand seal around the seatusing a screw driver (Figure27).

NOTEThe steel stabilizer ringshould be inside the sealwhen properly installed.

Figure 27

33

Feb. 2, 1994

6. Install the wave spring onthe lower seat (Figure 28).

Figure 28

7. Inspect the ball valve forcorrosion, pitting andgaulling (Figure 29).

Figure 29

34

Feb. 2, 1994

8. Install new nylon plugs onthe upper stationary seat(Figure 30).

Figure 30

9. Make sure the snap ring isnot broken or damaged(Figure 31).

Figure 31

35

Feb. 2, 1994

10. Make sure the crankassembly notches are notworn and there is no pittingon the outside (Figure 32).Check for a sliding fit withthe slots in the ball.

11. Install the seals on the crankassembly.

12. Inspect the crank sleeve forwear and washouts.Replace as necessary.

Figure 32

13. Thoroughly lubricate thevalve bore with a thin filmof multipurpose grease ofNLGI Grade 2.

14. Insert the pulling tool intothe O-ring end of the lowerseat engaging the I.D.groove (Figure 33).

15. Apply a generous coat ofgrease to the O.D. of thelower seat.

16. Slide the wave spring downthe threaded rod of thepulling tool until it seats onthe spring surface of thelower seat (Figure 33).

17. Insert the threaded rod ofthe pulling tool first intothe box opposite the splinedend of the upper valve,pulling the lower seat intoplace in the valve body(Figure 33).

Figure 33

36

Feb. 2, 1994

18. Using the load bar againstthe face of the connection,tighten the nut to firmlyseat the lower seat in thevalve body (Figure 34).

Figure 34

19. Apply a generous coat ofgrease to the outside of thesleeve and crank.

20. From the inside of the valvebody, install the cranksleeve in the body. Insertthe crank into the sleeve(Figure 35).

Figure 35

21. Make sure the crank moves90° to the Open and Closedposition (the flat sides ofthe crank are parallel to thevalve body).

22. Position the crank in theClosed position.

23. Apply a generous coat ofgrease to the entire outsideof the ball, but make surethe holes are clear (Figure 36).

Figure 36

37

Feb. 2, 1994

24. Slide the ball onto the crankinside the valve body. Thekeyway must be in theClosed position, or parallelto the key of the crank.

25. Apply a generous coat ofgrease to the outside threadsand seal of the upper seat.

26. Insert the upper seat intothe valve body, engagingthe threads (Figure 37). Figure 37

Figure 38

30. Insert the upper seat wrenchinto the mating slots of theupper seat.

31. Rotate the upper seatcounterclockwise until theseat is firmly against theretainer ring.

32. Remove the puller and usean allen wrench to makesure the valve functionsproperly.

33. Leave the valve in the Openposition.

34. Remove the wrench.

27. Insert the upper seat wrenchinto the mating slots of theupper seat.

28. Rotate the wrenchclockwise until the upperseat sets firmly against theball.

29. Remove the upper seatwrench and install theretainer ring firmly into thegroove of the body (Figure38).

38

Feb. 2, 1994

35. Grease the valve throughthe pressure plug untilgrease extrudes from insidethe valve (Figure 39).

NOTEThe grease pressure should not exceed300 psi. Excess pressure can cause themud/grease seal to extrude.

Figure 39

36. Install the 1/4" N.P.T. pluginto the lubrication port ofthe body. Torque this plugto approximately 15 to 20ft.-lbs.

Assembly is now complete. With the 7/8" hex wrench, open and close the valve several timesto assure smooth operation. Test the valve according to the procedure in the followingsection.

39

Feb. 2, 1994

IBOP VALVE TESTING IN THE SHOP

Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic testpump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use thefollowing procedure to test IBOPs:

1. Rotate the valve crank to the Open position.

2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plugin the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valveto the plug in the opposite end.

3. Place the valve in the vertical position (splined end down for upper IBOP, box end down forlower IBOP) with the ball and the bleed valve in the Open position.

4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,but using water increases the liklihood of corrosion in the valve body—especially when thevalve is not in use for a prolonged period of time.

NOTEOpen and close the valve five times to release trapped air andoverflow through the bleed valve for approximately 30 seconds toassure complete filling of the valve cavity.

5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closedposition.

6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.

7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatictest pump and the bleed valve. Reverse the orientation of the valve (splined end up for upperIBOP, box end up for lower IBOP).

8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP(pin end of the lower IBOP).

9. Fill the valve cavity with water while rotating the ball full open to closed five times to releasetrapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold workingpressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over theduration of the test.

10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve toinsure smooth operation.

11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. isacceptable.

12. Drain the valve cavity and remove the test plugs. Open and close the ball several times torelease trapped fluid. When testing with water, coat the valve internals with a preservativeto prevent oxidation and install thread protectors.

40

Feb. 2, 1994

APPENDIX

IBOP Part Numbers

IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.

94769-500 STD Upper Valve-PH60 90939-2 90939-1 90939-594769-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594769-501 NAM Load Collar Design 90939-2 90939-1 90939-5

94770-500 STD Upper Valve-PH60 90939-2 90939-1 90939-594770-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594770-501 NAM Load Collar Design 90939-2 90939-1 90939-5

94099-500 STD Upper Valve - PH60 90939-2 90939-1 90939-594099-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594099-501 NAM Landing Collar Design 90939-2 90939-1 90939-5

94100-500 STD Upper Valve - PH60 90939-2 90939-1 90939-594100-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594100-501 NAM Landing Collar Design 90939-2 90939-1 90939-5

90815 STD Upper Valve - PH85 93806 93806-1 90939-5- H2S 6 5/8 Box X 6 5/8 Box (Spl End) - - -- NAM Land Collar Design - - -

90814 STD Upper Valve - PH85 93806 93806-1 90939-5- H2S 6 5/8 Box X 7 5/8 Box (Spl End) - - -- NAM Load Collar Design - - -



94206-500 STD Upper Valve - PH85 93806 93806-1 90939-594206-501 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594206-502 NAM Landing Collar Design 93806 93806-1 90939-5



41

Feb. 2, 1994

IBOP Part Numbers (Cont.)

IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.


91138 STD Upper Valve - PH85 - Big Bore 95384 91137-SP 91137-1- H2S 7 5/8 Box X 7 5/8 Box (Spl End) - - -- NAM Load Collar Design - - -

89451-501 STD Lower Valve 90939-2 90939-1 90939-589491-503 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-1586434 NAM

89452-501 STD Lower Valve-Stepped 90939-2 90939-1 90939-589492-502 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15- NAM 90939-2 90939-1 90939-5

90811 STD Lower Valve 93807 93807-1 90939-5- H2S 7 5/8 Pin X 7 5/8 Box - - -- NAM - - -

91138 STD Lower Valve - Big Bore 94385 91137-SP 91137-1- H2S 7 5/8 Pin X 7 5/8 Box - - -- NAM - - -

105629 STD Upper Valve - Type "E" - - 90939-5- H2S 6 5/8 Pin X 6 5/8 Box - - - -- NAM For Ids Only - - -

103220 STD Upper Valve - Type "E" 90939-2 90939-1 90939-5- H2S 6 5/8 Pin X 6 5/8 Box - - -- NAM For TDS and SDS - - -

98977-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 6517001498977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 9896698977-501 NAM Landing Collar Design 99468-2 99468-1 65170014

99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966NAM Landing Collar Design 99468-2 99468-1 65170014

42

Feb. 2, 1994

Identifying Varco Safety Valves

43

Feb. 2, 1994

44

Feb. 2, 1994

45

Feb. 2, 1994

46

Feb. 2, 1994



Pipe Handler

Adjusting the Torque Wrench

Use the following procedure to adjust the pipe handlertorque wrench.

ø The pipe handler torque wrench is properly adjusted in thefactory before it is shipped. Perform the adjustmentprocedure after performing maintenance on the torquewrench or if the torque wrench does not function correctly.

1. Connect a pup joint or a joint of drill pipe to the saver sub andmake up hand tight. Be sure to use the correct threadcompound when making up.

K When adjusting torque wrench manifold valves loosen the locknut with a 9/16 wrench and use a 5/32 allen key to adjust thevalve. After obtaining the correct setting tighten locknutaround valve stem.

K For PH85 ONLY Close one of the rotation speed valves 3turns and adjust the second valve approximately 4 turnsuntil the tube stays centered when operated.

K The above operation should only be carried out if thetorque tube is out of center when operating

2 With the hydraulic unit switched off, fully screw in allsequence valves including lift lower valve. The PRV valveshould be set at a minimum pressure of 750 psi,

3 Turn the hydraulic power unit on.

4 If the torque cylinders are in there full clockwise position, setthe make/break valve to MAKE. If the torque cylinders are inthe full counterclockwise position the set the make/break valveto BREAK.

NOTE The torque cylinders should not move if the recycle valve is fully in.

5 Set make/break valve to MAKE/BRAKE

6 Back out the recycle valve until you have the cylindersrecycling at 7-9 second speed then tighten the lock nut.

7 Set Make Brake Valve to MAKE

8 Depress and hold the torque wrench operating button on thedrillers console. Back out the lift/lower sequence valve until itstarts to lift then adjust an additional half turn.

9 Back out the clamp sequence valve until the clamp cylinderstarts to move then an additional ¾ of a turn.

10 Back out the torque valve until the torque cylinders start tomove the an additional ¾ of a turn.

11 Release the torque wrench operating button on the drillersconsole and observe the toque wrench function it should startto unclamp then drop and recycle. If the torque wrench dropsbefore unclamping adjust the lift/lower valve in a ¼ of a turnand back out the clamp sequence valve an additional ¼ turn.

TDS-TW Operation

Supply FlowReturn FlowAir - Piloted

Hydraulic Valve

Lift Lift

1200 PSISequence

1200 PSISequence

1500 PSISequence

1500 PSISequence

Clamp

Torque

PressureAdjust

PressureAdjust

Clamp

Torque

1

2

33

1

2

Torque wrench hydraulic operation schematic

Trouble Shooting Pipe Handler

The Driller presses the TW Button but nothing functions :-

Check Quick DisconnectsCheck Hydraulic SupplyCheck Air SupplyCheck Drill/Spin /Torque switch is in Drill positionCheck Throttle is in the off positionCheck Electrical Supply, (Solenoids, Wiring, VDC Switches)

Training Maual June 99

Assemb ly and disassemb ly

Pipehandler (PH-60d)

Torque wren ch disassemb ly(Figure 4-15)

1. Remove the guard.

2. Disconnect the hard plumbing from the quick disconnectsnear the left torque cylinder.

3. Remove the bolts holding the frame onto the cast body andlift off.

4. Remove the pins holding the torque tube in place.

5. Disconnect and label the hoses from the torque cylinders andremove the cylinders.

6. Disconnect and label the remaining plumbing, and removethe Make/Break manifold assembly.

7. Remove the jaws.

8. Remove the stabbing guide.

9. Remove the retaining bolts, hinge pins and outer body.

10. Remove the cylinder ring from the clamping piston bore.

11. Pressurize the blind end of the clamping cylinder to removethe gland and piston.

e Use care in this operation. High pressure air can be explosive.


MountingShaft

Guard

TorqueCylinder (2)

Clamp Cylinder Body

Control Manifold

ClampingCylinderPiston

ClampingJaws (2)

StabbingGuide

Body

Stop Tube

TorqueTube

Safety ValveActuatingArm (2)

Frame

VerticalPositingCylinder

Safety ValveActuating

Cylinders (2)

Hanging HeightAdjustment Shim

TorqueTube

Stabilizer

Figure 4-15. Torque wrench assembly/disassembly


Reassembly is accomplished in the reverse order of the aboveprocedure. Pay close attention to the following points:

1. Replace all seals.

2. Take great care when installing the clamping piston andgland. If they are not closely aligned with the bore, they maybecome jammed and could be extremely difficult to remove.

3. Use the following torque values:

Cylinder rod end to cylinder rod * 944 ft lb (1275 N.m)

Frame to clamp cylinder body 250 ft lb (339 N.m)

Stabbing guide to body 250 ft lb (339 N.m)

Die retainer screws 380 ft lb (515 N.m)

Body hinge pin retainer screws 150 ft lb (203 N.m)

Stabbing guide spring retainer screws 75 ft lb (102 N.m)

Jaw retaining screws 110 ft lb (149 N.m)

* The torque cylinder rod ends are threaded into the rods withlock-tite and cross pinned.

Replacing the torque wrench clamping piston seal

The following procedures require removing the torque wrenchfrom the pipehandler.

Parts required for replacing the front and rear piston seal

Qty. P/N Description

3 72219 Piston seal

2 72220 Rod seal

2 72221 Rod wiper

Disassembly

1. Remove the pins from the torque wrench guard and removethe guard.

2. Remove the slotted hex nut and cotter pin attaching the twohalves of the stabbing guide together at the front and swingthe guides out to each side.

3. Vent the clamping cylinder as follows: disconnect thehydraulic lines to the clamp port and front unclamp port onthe clamp body cylinder at the torque wrench manifold clampand unclamp ports.


4. Remove the jaw pins from the rear clamping jaw and removethe jaw.

5. Remove the two screws holding the jaw spacer to the frontclamp cylinder piston and remove the spacer and jaw spacer.

6. Remove the two screws holding the clamp clevis to the rearclamp cylinder piston.

7. Remove the pins holding the clamp body to the clamp clevisand remove the clamp clevis. Be sure to remove the spacerfrom the piston rod slot.

8. Push in the cylinder gland from the rear cylinder headretainer ring and remove the ring with a screwdriver.

9. Attach the sliding hammer to the rear piston rod and carefullypull the piston until the cylinder gland can be removed.

10. Continue to pull until the piston comes out.

11. Using a piece of wood or brass bar, tap the front clamp pistonfrom the front and remove it from the rear.

12. Remove and discard the piston seals, rod seals and rod wipers.

13. Remove the front piston rod seal and rod wiper from theclamp cylinder body and discard.

14. Inspect the clamp cylinder bore thoroughly for dirt, burrs,nicks, gouges and pitting. Repair and clean as necessary.

Assembly

1. Insert a new front rod seal and rod wiper in the clampcylinder body and lubricate with clean hydraulic fluid.

2. Install a new piston seal in the front piston groove andlubricate with hydraulic fluid.

3. Insert the front piston into the clamp cylinder body with thetwo jaw spacer screws holes orientated vertically.

4. Gently and evenly tap the piston into place until the rodappears beyond the front cylinder bore.

5. Install new piston seal in rear piston groove and lubricate withhydraulic fluid.

6. Insert rear piston into the clamp cylinder body with the twoscrews holes on the rod oriented to the horizontal position.


7. Gently tap piston into place until there is enough spacebetween the piston face and retaining ring groove to insertcylinder gland and retainer ring.

8. Install rod seal and rod wiper in inside grooves of the cylindergland.

9. Install piston seal in outside groove.

10. Lubricate all seals with hydraulic fluid.

11. Insert cylinder gland into bore rod and piston seals first.Push gland past retainer groove and install retainer ring.

12. Insert the spacer and attach the clamp clevis to the rearcylinder rod with the two hex head cap screws and flatwashers. Tighten firmly and lockwire.

13. Adjust orientation of the clamp clevis and attach to the clampbody using the two clevis pins and cotter pins.

14. Attach the rear clamping jaw spacer to the front piston rodusing the spacer and two hex head cap screws and flatwashers. Tighten firmly and lockwire.

15. Attach the clamping jaw with the two jaw pins.

16 Swing the stabbing guide back into position and attach withthe slotted nut and cotter pin.

17. Reconnect the hydraulic lines from the clamp body cylinderclamp port and front unclamp port at the torque wrenchmanifold clamp and unclamp ports.

18. Reinstall and perform the Torque wrench adjustment procedure.

May 22, 1996

TDS-4S Maintenance and troubleshooting 57

Assembly and disassembly

Pipehandler (PH-85)

Torque wrench disassembly(Figures 16a, 16b, 16c and 16d)

1. Remove the guard.

2. Disconnect the hard plumbing from the quick disconnectsnear the left torque cylinder.

3. Remove the bolts holding the frame onto the cast body andlift off.

4. Remove the pins holding the torque tube in place and remove.

5. Disconnect and label the hoses from the torque cylinders andremove the cylinders.

6. Disconnect and label the remaining plumbing, and removethe Make/Break manifold assembly.

7. Remove the jaws.

8. Remove the stabbing guide.

9. Remove the retaining bolts, hinge pins and outer body.

10. Remove the cylinder ring from the clamping piston bore.

11. Pressurize the blind end of the clamping cylinder to removethe gland and piston.

e Use care in this operation. High pressure air can be explosive!

May 22, 1996

58 TDS-4S Maintenance and troubleshooting

TORQUECYLINDERS (2)

TORQUETUBE

Var co

Figure 16a. Torque wrench assembly/disassembly

May 22, 1996


CLAMPCYLINDERPISTON

BODY

CLAMPINGJAWS (2)

STABBINGGUIDE

CLAMP CYLINDERBODY

Figure 16b. Torque wrench assembly/disassembly

May 22, 1996


HANGINGHEIGHT ADJUSTMENT

GUARD

FRAME

SAFETYVALVEACTUATINGCYLINDERS (2)

MOUNTINGSHAFT

VERTICALPOSITIONGCYLINDER

Figure 16c. Torque wrench assembly/disassembly

May 22, 1996


Figure 16d. Torque wrench assembly/disassembly(optional link retractor)

May 22, 1996


Reassembly is accomplished in the reverse order of the above pro-cedure. Pay close attention to the following points:

1. Replace all seals.

2. Take great care when installing the clamping piston andgland. If they are not closely aligned with the bore, they maybecome jammed and could be extremely difficult to remove.

3. Use the following torque values:

Cylinder rod end to cylinder rod* 944 ft lb

Frame to clamp cylinder body 250 ft lb

Stabbing guide to body 250 ft lb

Die retainer screws 380 ft lb

Body hinge pin retainer screws 150 ft lb

Stabbing guide spring retainer screws 75 ft lb

Jaw retaining screws 110 ft lb

*The torque cylinder rod ends are threaded into the rods withlocktite and cross pinned.

Replacing the torque wrench clamping piston seal

The following procedures require that the torque wrench be re-moved from the pipehandler.

Replacing the front and rear piston seal

Parts required front and rear piston seal replacement:

Qty. P/N Description

3 72219 Piston seal

2 72220 Rod seal

2 72221 Rod wiper

Disassembly

1. Remove the slotted hex nut and cotter pin attaching the twohalves of the stabbing guide together at the front and swingthe guides out to each side.

2. Vent the clamping cylinder as follows: disconnect the hydrau-lic lines to the clamp port and front unclamp port on theclamp body cylinder at the torque wrench manifold clampand unclamp ports.

3. Remove the jaw pins from the rear clamping jaw and removethe jaw.

May 22, 1996


4. Remove the two screws holding the jaw spacer to the frontclamp cylinder piston and remove the spacer and jaw spacer.

5. Remove the two screws holding the clamp clevis to the rearclamp cylinder piston.

6. Remove the pins holding the clamp body to the clamp clevisand remove the clamp clevis. Be sure to remove the spacerfrom the piston rod slot.

7. Push in the cylinder gland from the rear cylinder head re-tainer ring and remove the ring with a screwdriver.

8. Attach the sliding hammer to the rear piston rod and carefullypull the piston until the cylinder gland can be removed.

9. Continue to pull until the piston comes out.

10. Using a piece of wood or brass bar, tap the front clamp pistonfrom the front and remove it from the rear.

11. Remove and discard the piston seals, rod seals and rod wipers.

12. Remove the front piston rod seal and rod wiper from theclamp cylinder body and discard.

13. Inspect the clamp cylinder bore thoroughly for dirt, burrs,nicks, gouges and pitting. Repair and clean as necessary.

Assembly

1. Insert a new front rod seal and rod wiper in the clamp cylin-der body and lubricate with clean hydraulic fluid.

2. Install a new piston seal in the front piston groove and lubri-cate with hydraulic fluid.

3. Insert the front piston into the clamp cylinder body with thetwo jaw spacer screws holes orientated vertically.

4. Gently and evenly tap the piston into place until the rod ap-pears beyond the front cylinder bore.

5. Install new piston seal in rear piston groove and lubricate withhydraulic fluid.

6. Insert rear piston into the clamp cylinder body with the twoscrews holes on the rod oriented to the horizontal position.

7. Gently tap piston into place until there is enough space be-tween the piston face and retaining ring groove to insertcylinder gland and retainer ring.

May 22, 1996


8. Install rod seal and rod wiper in inside grooves of the cylindergland.

9. Install piston seal in outside groove.

10. Lubricate all seals with hydraulic fluid.

11. Insert cylinder gland into bore rod and piston seals first. Pushgland past retainer groove and install retainer ring.

12. Insert the spacer and attach the clamp clevis to the rear cylin-der rod with the two hex head cap screws and flat washers.Tighten firmly and lockwire.

13. Adjust orientation of the clamp clevis and attach to the clampbody using the two clevis pins and cotter pins.

14. Attach the rear clamping jaw spacer to the front piston rodusing the spacer and two hex head cap screws and flat wash-ers. Tighten firmly and lockwire.

15. Attach the clamping jaw with the two jaw pins.

16 Swing the stabbing guide back into position and attach withthe slotted nut and cotter pin.

17. Reconnect the hydraulic lines from the clamp body cylinderclamp port and front unclamp port at the torque wrenchmanifold clamp and unclamp ports.

18. Reinstall and perform Torque Wrench Adjustment Procedure.



Lubrication

September 16, 1996

TDS-4H Maintenance and troubleshooting 23

Chapter 2

Lubrication

Lubricating the motor and motor housingassembly

Lubricating the main shaft splineThere is a lube point on the quill shaft located behind the largeplug on the side of the motor housing just below the trunnion.Lubricate it weekly.

GearboxCheck the oil daily. With the motor off, check to see that the oillevel is at the middle of the sight glass located on the side of themain body. Drain and refill the gearbox every 1,500 operatinghours or three months, whichever occurs first (Refer to Oilcapacities below).

September 16, 1996

24 TDS-4H Maintenance and troubleshooting

Properly maintaining the TDS gear shifting mechanism increasesthe operational life of the top drive. Use the following procedureto maintain proper gear lubrication:

1. Shift all top drive two speed gearboxes from one gear to theother and back again at least once a week. This helps todistribute lubricant and prevents contaminant buildup.

2. Remove the gear indicator lever assembly and the indicatorgear case cover.

3. Repack the inside area with grease every six months.

4. Inspect the gears for corrosion or damage. Clean, lubricate orreplace components as required. There is a “timing mark” onthe gears to ensure correct orientation. If these marks are notvisible when removing the gears, mark the gears beforeremoval to ensure correct orientation when reinstalling them.

If there are problems shifting from one gear to the other, use thefollowing procedure to shift the gears:

1. Turn the drive stem with chain tongs to make sure the gearmesh aligns properly. Do not turn the DC motor whileshifting gears.

2. Insert two 3/8" bolts in the threaded holes on the bottom ofthe shafts while shifting the gears and use a bar to turn theshaft in the proper direction. Do not shear the bolts.Eccentric shaft rotation direction is the same as the shifterinput shaft when shifting into gear.

3. If the shift input mechanism slips when attempting to shiftgears, use a torque wrench to check the torque of the shifterwhen the clutch begins to slip. If the torque is less than 65 ftlb, use the torque setting procedure on the following page toadjust the clutch.

e Gearbox oil must be drained before removing clutch.

The factory setting of the clutch is 45 ft lb. Increase the torque ifproblems persist.

4. Remove the 3" inspection plugs on the rear of the gear caseand make sure the compound gears are free to turn with theunit in neutral. If the gears cannot turn, it is an indication ofa larger problem (i.e., contaminants in gears, damagedbearings, etc.).

September 16, 1996


Torque setting procedureUse the following procedure to set the torque limit clutch to 45-50 ft lb:

1. Attach any torque indicator to the output stub (Figure 4).

2. Hold the body and determine the current torque setting.

3. Remove the snap ring and locking plate.

4. Use a 5/8" open end wrench to turn the nut clockwise toincrease torque, or to turn the nut counterclockwise todecrease the torque.

5. Check the resulting torque and repeat the above steps if moreadjustment is necessary.

6. Replace the locking plate and snap ring.

Other gearbox lubrication and maintenanceconsiderations

❏ Keep the bottom of the eccentric gear shafts clean and free ofcorrosion, paint or other contaminants. Keep this area lightlylubricated with oil.

❏ Contaminant build up or corrosion around the upper end ofthe eccentric shafts can cause persistent shifting problems.Install sealed caps on the top of the shaft to correct theproblem. There are two ways to install sealed caps. One wayrequires shop installation during top drive overhaul.

There is a kit for field installation (P/N 97926). It consists of arubber gasket, a sealing cap and a stud which threads into anexisting tapped hole in the top of the eccentric shaft. The studholds the cap on top of the gear case and keeps contaminantsaway from the shaft. It also adds a secondary seal between the oilin the gearbox and the DC motor cooling air path.

Initial oil change periodDrain and refill the gearbox after the first 500 operating hours orfour weeks, whichever occurs first.

Remove and clean the oil pump suction strainer (or oil filter–depending on the model and configuration) when changing theoil.

September 16, 1996


Figure 4. Torque setting procedure

September 16, 1996


Oil capacityThe TDS holds approximately 10-20 gallons of oil, but oilcapacities vary according to the type of cooling systems, etc.installed. Always fill the transmission to the middle of the sightglass. Use the following procedure to fill the transmission for thefirst time on a new top drive:

1. Fill the gearbox to the top of the sight glass (approximately 10-20 gallons).

2. Operate the top drive 10-15 minutes and check the sightglass.

3. The oil level should be near the middle of the sight glass. Ifthe oil level is below the middle of the sight glass, add moreoil until the level reaches the middle of the sight glass. If theoil level is at, or above the middle of the sight glass, do not addany additional oil to the gear case.

After installation and initial operation of the top drive, always fillthe transmission to the middle of the sight glass.

When draining oil from the drain plug at the bottom of the gearcase, only 5-6 gallons of oil at the bottom of the gear case actuallydrains. Oil remains in the rotating head cavity (approximately 1-2gallons), the oil lube/pump/cooler system (approximately 1-2gallons), and the wetted surfaces inside the motor housingassembly (approximately 2-3 gallons). Removing the suction hosefrom the cover plate below the pinion shaft allows more oil todrain and also removes sediment that collects there.

September 16, 1996


Lubricating the DC motorThe upper motor armature bearings have grease points located onthe brake adapter plate attached to the top of the motor. Thelower armature bearing grease point on the GE motor is at theend of a small diameter tube projecting toward the back of thetool.

The grease points all have plugs or relief fittings installed duringoperation. Install grease fittings to lubricate and then remove thefittings and replace the plugs for operation. Lubricate the pinion(transmission) end bearing every 750 hours, or 90 days, with twoounce by weight Shell Cyprina RA™. Lubricate the commutator(brake) end bearing every 1,500 hours, or six months, with twoounce by weight Shell Cyprina RA™.

e Excessive lubrication of electric motors can cause motor failure due toshorting or heat buildup from grease coming in contact with the fieldwindings.

September 16, 1996


Lubricating the rotating head

Apply grease daily at the five fittings. Inspect for seal leakagearound the lower bearing retainer weekly.

GreaseFittings

GreaseFittings Grease

Fitting

Figure 5. Lubricating the rotating head

September 16, 1996


Lubricating the link adapter

Apply grease to the four fittings weekly.

650 TonSolid Body Elevator

2 Grease Fittings on front,2 Grease Fittings opposite.

(4 places total)

Figure 6. Lubricating the Link Adapter

September 16, 1996


Lubricating the torque wrench

Apply grease to the six fittings daily. Inspect the stabbing forexcessive wear or cracks. Replace as necessary.

Lubricating the elevator support and masterbushing wear guide

Apply grease to the seven fittings on the elevator support weekly.The master bushing wear guide has four fittings (Figure 5).Lubricate weekly. Inspect the guide ring periodically for wear ordamage and replace as necessary.

Grease Fittings2 places as shownand 2 placesopposite side.(4 Total)

Figure 5. Lubricating the master bushing wear guide

September 16, 1996


Lubricating the Varco BNC drill pipeelevator

Apply grease to the seven grease fittings on the BNC elevator eachtrip, and inspect the tool for wear on the bore, the link ears andto make sure that the latch mechanism operates correctly.

Grease Fittings as Shown

Figure 8. Lubricating the BNC drill pipe elevator

September 16, 1996


Lubricating the RBS

Grease the 17 fittings each trip. Also check for worn tong dies inthe clap jaws and replace as necessary. RBS units with stabbingheads have an additional 10 fittings–lubricate all 10 each trip.

Lubricating the safety valve actuator

Apply grease to the six fittings on the actuator arms daily. Checkfor worn components and operate the valve to verify correctadjustment weekly.

September 16, 1996


Lubricating the upper IBOP safety valve

Lubricate the upper IBOP daily at the lubrication fittings locateddirectly below the actuator cranks in the recessed counter bores.Refer to the IBOP Service Manual included in this manual forcomplete IBOP lubrication instructions.

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

Figure 9. Lubricating the IBOP actuator

September 16, 1996


Lubricating the guide dolly assembly

Lubricate the 20 guide rollers weekly at the four manifolds (5fittings each) located on each corner of the guide dolly (Figure10). Check guide rollers weekly for cracks or excessive axial orradial play and replace as necessary. Lubricate the hinges (oneplace on each hinge) once each trip.

It is possible to over-grease (too much pressure, not volume) theguide rollers. This can push the plugs out. Visually inspect all ofthe guide rollers for evidence of grease extruding from the end(s)of the shaft. If you discover over-greasing, perform the followingprocedure:

1. Remove and disassemble the roller assembly.

2. Thoroughly clean and inspect all parts.

3. If the component parts are still serviceable, drill and tap theshaft end(s) for 1/8" NPT threads and install internalwrenching pipe plugs after thoroughly cleaning metal chipsfrom the grease ports in the roller shaft.

4. Pre-grease roller bearings before reassembling and installingthe rollers and shaft.

5. Re-grease roller bearings through grease lines to make surelubricant is pumping through the roller bearings. Some greaseshould extrude between the rollers and roller shaft.

6. Replace unserviceable assemblies.

7. Improve plug retention on roller assemblies with intact sheetmetal plugs by staking the edges of the port(s). To do this:

a. Remove the roller or roller bracket assembly to improveaccessibility.

b. Use a hammer and chisel to stake the port edges.

A preferred method is to rework the roller assembly for drill andtap operation, but the staking method is also effective.

There are two grease points for the motor trunnions, one at eachbottom corner of the motor frame (Figure 11). Lubricate theseweekly.

September 16, 1996


Lubricate the wash pipe packing daily with the mud pump off.

Check the filter gauge on the pressure filter daily with thehydraulic power on to determine the condition of the filterelement. Replace the element when a bypass condition isindicated.

e Do not weld or torch cut on or near the motor frame withoutremoving hydraulic accumulators.

1

2

5

LubricationManifold (4)

3

4

6

Figure 10. Guide dolly assembly (with hinges – rear half)

September 16, 1996


1

2

3

4

5

Figure 11. Motor frame/guide dolly assembly (with hinges – front)

September 16, 1996


Lubricating the bail pins

Lubricate the bail pins weekly, at the same time the dolly rollersare lubricated, at the two fittings, one on each bail pin.

Lubricating the cooling system

Lubricate AC blower motors every three months. On rigs withclosed loop cooling systems also check the heat exchangers forwater leakage weekly, and remove the access covers and operatethe blower to remove dust buildup every 500 operating hours.

September 16, 1996


Lubrication scheduleLubricant Number

Frequency Location code* of pointsDaily Torque wrench 1 6Daily Gearbox oil (check level) 2 1Daily Rotating head 1 5Daily Safety valve actuator cranks 1 2Daily Hydraulic pressure filter† 4 -Daily Upper quill shaft bearings 1 1Each trip BNC drill pipe elevator 1 7Each trip PS-16 power slip 1 8Each trip RBS 1 17Each trip RBS stabbing head 1 10Each trip Guide dolly rollers 1 20Weekly Gearbox (shift gears) - -Weekly Dolly motor trunnions 1 2Weekly Air filter/regulator/lubricator† - -Weekly IBOP actuator arms 1 6Weekly Link adapter 1 4Weekly Elevator support 1 7Weekly Master bushing wear guide 1 4Weekly Link tilt (check condition) - -Weekly Main shaft spline 1 1750 hrs/90 days GE motor pinion bearing 3 -1500 hrs/6 mos. GE motor commutator bearing 3 -Monthly Motor frame/dolly hinges 1 4Monthly Cooling system cleaning - -3 months AC blower motor 1 23 months Change gearbox oil 2 13 months Gear oil filter/suction strainer† - 1

*See lubricant specification table †Check condition and replace as necessary

e Use only 10-wt. hydraulic oil or non-detergent motor oil as alubricant in the air control system. Using any other type of oil orsynthetic additive causes the seals in the air valves to swell and ceaseto function.

September 16, 1996


Lubricant specifications

TDS transmissions operate under a combination of heavy andshock loads. Under these conditions oil tends to extrude out ofthe gear mesh. Keeping an effective film of oil on the gear meshrequires oil with an AGMA “extra pressure” rating, and aminimum viscosity of 100 SUS at operating temperature.

Varco top drives also operate under a wide variety oftemperatures. Select lubrication for the TDS based on theminimum ambient temperature to be expected before the next oilchange. Under all but the most severe operating conditions, Varcorecommends changing the oil every three months. Introducing anoil viscosity greater than required by the ambient temperaturecan:

❏ Damage the gearbox due to reduced oil flow

❏ Damage the oil pump because of excessive load

All oils change viscosity with temperature and “EP” oil is noexception. The TDS transmission lubrication system is limited topumping oils of a maximum of 9,000 SUS viscosity.

Varco recommends measuring the oil temperature with a contactthermometer. Measure on the pump discharge fitting on theTDS.

The following tables will aid in your lubricant selection and keepyour TDS-S transmission operating properly:

September 16, 1996


Minimum AmbientTemperature

Oil Type Required Varco Part Number

°F (°C)Below 20° (-6°) See Note Below* See Note Below*20°-60° (-6°–16°) 2EP, ISO 68 56004-145°-85° (7°–30°) 4EP, ISO 150 56004-BSCAbove 70° (21°) 6EP, ISO 320 56004-2

z For minimum temperatures below 20°F, the TDS must bewarmed up by rotating at a very light load (less than 200 amps)and at very slow speeds (less than 50 RPM) until the oiltemperature climbs above 20°F.

If the oil temperature falls below 20°F, Varco recommendsrunning the TDS at very light loads (less than 100 amps) untilthe oil is above 20°F. If drilling conditions dictate oiltemperatures below 20°F, consult Varco engineering.

If the oil temperature rises above 200°F, Varco recommendsshutting down or reducing drilling loads to stabilize the oiltemperature below 200°F. If drilling conditions dictate oiltemperatures above 200°F, consult Varco engineering.

September 16, 1996


Gen

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Pur

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Gre

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Abo

ve -

20˚

Bel

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Abo

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1˚C

7˚ to

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C-6

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C-1

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C-1

5˚ to

75˚

CA

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34

Weekly

500 TonLink Adapter

Apply two pumps per grease fitting(2 places)

Weekly

Weekly

Rotating HeadPositioning Roller

Apply two pumps

Support ShaftApply general purpose greaseat the contact point between

the shaft and frame

Varco P/N126732

PH-60 Lubrication andMaintenance Guide

See the other side for thePH-60 650/750 Ton Capacity

500 Ton Capacity

IBOP Actuator ArmsApply two pumps per grease fitting

(4 places, 2 each side)

Weekly

PneumaticLink Tilt

Check condition of the airbladder, the pivot pin and the stops

Link AdapterWear Shoe

Apply two pumps per grease fitting(4 places)

Weekly

Weekly

Upper IBOP ValveRemove 1/4" NPT plug,

install grease fittingApply ten pumps Weekly

IBOP ActuatorCam Followers

Apply two pumps per grease fitting(2 places, one each side)

Weekly

Elevator Link Eyes

IBOPActuator Cranks

Apply one pump per grease fitting(2 places, 1 each side)

Daily

Daily

Weekly

Clamp BodyApply two pumps per grease fitting


Weekly

Clamp BodyCylinder Trunnion

Apply two pumpsper grease fitting


Torque Tube Clevis PinsApply two pumps per grease fitting


Weekly

Link Spreader (if equipped)Apply two pumps per grease fitting


Pipe Dope

Grease Lubrication Schedule

Hydraulic Link Tilt

Daily

Weekly

500 Ton Rotating HeadApply two pumps per grease fitting

(4 places)Weekly

Applytwo pumps pergrease fitting

(8 places)

Frequency

Rotating Head Positioning Roller

500 Ton Rotating Head

500 Ton Link Adapter

Hydraulic Link Tilt

Link Adapter Wear Shoe

IBOP Actuator Cranks

Upper IBOP Valve

IBOP Actuator Arms

IBOP Actuator Cam Followers

Link Spreader (if equipped)

Torque Tube Clevis Pins

Clamp Body Cylinder Trunnion

Clamp Body

Support Shaft

Elevator Link Eyes

1

4

2

8

4

2

1

4

2

6

2

4

6

1

4

Description

FrequencyDescription

Points

Daily

Daily

Daily

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

See the Service Manual for more detail

!Replace plug

before operating

Manufacturer

Viscosity Index

General Purpose Grease

Above -20˚C(Above -4˚F)

Below -20˚C(Below -4˚F)

Ambient Temperature Range

CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion

NGLIAGMA

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R

Recommended Lubricants

Daily

Daily

Daily

Daily

Daily

Daily

Weekly

Weekly

General Condition Checks

Check for missing lockwire

Check for loose or broken parts

Check for missing cotter pins

Check for hydraulic and air leaks

Check for wear on tong dies and guide flippers

Test IBOPs for leakage (in place)

Check for proper rotation ofthe IBOP actuator cam followers

Check condition of the air bladder, stops,and pivot pin on the pneumatic link tilt

Daily


650/750 Ton Capacity


Weekly

Weekly

Weekly

650/750 Ton Powered Rotating Head Hydraulic Link Tilt

650/750 Ton Powered Rotating HeadApply two pumps per grease fitting

(5 places)

Rotating Head Bull GearBrush with grease

Weekly

Weekly

650/750 TonRotating HeadApply two pumpsper grease fitting

(5 places)

PH-60Support Shaft

Apply general purposegrease at the contact

point betweenthe shaft and frame

650/750 TonLink AdapterApply two pumpsper grease fitting

(4 places)



Weekly

Pneumatic Link TiltCheck condition of the air bladder,

the pivot pin and the stops

Link Adapter Wear ShoeApply two pumps per grease fitting

(4 places)

Weekly

Weekly

Weekly

Upper IBOPActuator

Cam FollowersApply two pumpsper grease fitting


Weekly

Clamp BodyCylinderTrunnion



Weekly

Link Spreader(if equipped)Apply two pumpsper grease fitting


Weekly

Elevator Link Eyes

IBOP Actuator CranksApply one pump per grease fitting


Daily

Daily

Weekly





Pipe Dope

Upper IBOP ValveRemove 1/4" NPT plug, install grease fitting

Apply ten pumps

!Replace plug

before operating


650/750 Ton Rotating Head

650/750 Ton Powered Rotating Head

Powered Rotating Head Bull Gear

650/750 Ton Link Adapter

Hydraulic Link Tilt



Upper IBOP Valve

IBOP Actuator Arms





Clamp Body

Support Shaft

Elevator Link Eyes

5

5

1

4

8

4

2

1

4

2

6

2

4

6

1

4

Daily

Daily

Daily

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Varco P/N126732

See the other side for thePH-60 500 Ton Capacity

Weekly


(8 places)

FrequencyDescription Points


Manufacturer

Viscosity Index






NGLIAGMA

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R


Daily

Daily

Daily

Daily

Daily

Daily

Weekly

Weekly












Weekly

Weekly

Weekly

Elevator Link Eyes

Daily

Weekly



Weekly

Clamp BodyCylinder Trunnion





Weekly



500 Ton Rotating HeadApply two pumps per grease fitting

(4 places)

Varco P/N126731

Pipe Dope


500 Ton Capacity

Weekly

IBOP ActuatorCam Followers


(2 places, one each side)

Weekly

Rotating HeadPositioning Roller

Apply two pumps

Weekly

PH-85 Support ShaftApply general purpose greaseat the contact point between

the shaft and frame

Weekly

500 TonLink AdapterApply two pumpsper grease fitting

(2 places)

Weekly

PneumaticLink Tilt

Check condition of the airbladder, the pivot pin and the stops

Link AdapterWear Shoe


(4 places)

Daily

IBOPActuator Cranks

Apply one pump per grease fitting(2 places, 1 each side)

Daily

Weekly

Upper IBOP ValveRemove 1/4" NPT plug,

install grease fittingApply ten pumps

!Replace plug

before operating

See the other side for thePH-85 650/750 Ton Capacity



Hydraulic Link Tilt

Weekly


(8 places)

Frequency

Rotating Head Positioning Roller

500 Ton Rotating Head

500 Ton Link Adapter

Hydraulic Link Tilt



Upper IBOP Valve

IBOP Actuator Arms





Clamp Body

Support Shaft

Elevator Link Eyes

1

4

2

8

4

2

1

4

2

6

2

4

8

1

4

Description


Points

Daily

Daily

Daily

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Manufacturer

Viscosity Index






NGLIAGMA

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R


Daily

Daily

Daily

Daily

Daily

Daily

Weekly

Weekly










Daily


Varco P/N126731

650/750 Ton Capacity

Weekly

Weekly

Weekly

650/750 TonRotating HeadApply two pumpsper grease fitting

(5 places)

PH-85Support Shaft

Apply general purposegrease at the contact

point betweenthe shaft and frame

650/750 TonLink AdapterApply two pumpsper grease fitting

(4 places)



Weekly

Pneumatic Link TiltCheck condition of the air bladder,

the pivot pin and the stops

Link Adapter Wear ShoeApply two pumps per grease fitting

(4 places)

Weekly

Weekly

Weekly

Upper IBOPActuator

Cam FollowersApply two pumps


Weekly



Weekly

Clamp BodyCylinderTrunnion



Weekly

Elevator Link Eyes

IBOP Actuator CranksApply one pump per grease fitting


Daily

Daily

Weekly





Pipe Dope

Upper IBOP ValveRemove 1/4" NPT plug, install grease fitting

Apply ten pumps

!Replace plug

before operating


See the other side for thePH-85 500 Ton Capacity


650/750 Ton Powered Rotating Head Hydraulic Link Tilt

650/750 Ton Powered Rotating HeadApply two pumps per grease fitting

(5 places)

Rotating Head Bull GearBrush with grease

Weekly

Weekly

650/750 Ton Rotating Head

650/750 Ton Powered Rotating Head

Powered Rotating Head Bull Gear

650/750 Ton Link Adapter

Hydraulic Link Tilt



Upper IBOP Valve

IBOP Actuator Arms





Clamp Body

Support Shaft

Elevator Link Eyes

5

5

1

4

8

4

2

1

4

2

6

2

4

8

1

4

Daily

Daily

Daily

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly


(8 places)

FrequencyDescription Points


Manufacturer

Viscosity Index






NGLIAGMA

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R


Daily

Daily

Daily

Daily

Daily

Daily

Weekly

Weekly










LO

Gear Oil Sight GageCheck with Top Drive

“OFF”

Gear Oil Fill

Varco P/N127052

Weekly

Retract Guide DollyApply two pumps per grease fitting

(28 places, 7 each manifold)

Weekly

Bail PinsApply two pumps per grease fitting


Daily

Gear Oil Lubrication Schedule


Frequency

Replace the Gearbox Oil and Perform an Oil Analysis

Replace the Gearbox Oil Filter

Description

3 Months

3 Months

Frequency

Bail Pins

Upper Bearing

Motor Trunnions

Swing Guide Dolly Hinges

Swing Guide Dolly (Grease Fittings on Manifolds)

Non-Swing Guide Dolly (Grease Fittings on Manifolds)

Retract Guide Dolly (Grease Fittings on Manifolds)

See lubrication section of the TDS-4H service manual for lubrication of electric motors

2

1

2

4

20

20

28

Description Points

Monthly

Monthly

Weekly

Weekly

Weekly

Weekly

Weekly

Mfr.

Viscosity Index

Grease Gear Oil





NGLIAGMAISOViscosityGrade

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R

N/R


Daily

Daily

Daily

Daily

Daily

Daily






Check condition of the oil and hydraulic filter gauges

Check the gear oil levels

Check for cracks and excessive axial or radial playon the guide dolly rollers and replace as necessary

Above 21˚C(Above 70˚F)Alpha LS-320

NL Gear 320

Spartan EP320

EP Lube HD320

MobilGear 632

Omala 320

Loadway EP320

Meropa 320

Carter EP 320

Extra Duty NL6EP

N/R

6EP

320

7˚ to 30˚C(45˚ to 85˚F)Alpha LS-150

NL Gear 150

Spartan EP150

EP Lube HD150

MobilGear 629

Omala 150

Loadway EP150

Meropa 150

Carter EP 150

Extra Duty NL4EP

N/R

4EP

150

-6˚ to 16˚C(20˚ to 60˚F)Alpha LS-68

NL Gear 68

Spartan EP68

EP Lube HD68

MobilGear 626

Omala 68

Loadway EP68

Meropa 68

Carter EP 68

Extra Duty NL2EP

N/R

2EP

68


Oil viscosity should be adjusted based on expected ambient conditions for next three months

Gear OilFilter

(Actual locationmay vary)

HydraulicFilter


Monthly

Motor TrunnionsApply two pumpsper grease fitting


TDS-4H Lubricationand Maintenance Guide

For more detail see theTDS-4H Service Manual

See the other side of this chart for theTDS-4S Lubrication and Maintenance Guide

Refer to theTDS-4H Service Manual

or thePipehandler Lubricationand Maintenance Guide

for maintenance andlubrication of theRotating Head

See the manufacturer’sdocumentation for Swivel

lubrication information

Swing Guide Dolly

Weekly

Monthly

Swing Guide Dolly HingesApply two pumps per grease fitting

(4 places, 2 each hinge)

Swing Guide DollyApply two pumpsper grease fitting

(20 places, 5 each manifold,if equipped)

Weekly

Upper BearingApply two pumpsper grease fitting

Monthly



Gear Oil Drainand Sample Valve

LO

Daily

Daily

Weekly

Upper Bonnet SealsApply one pump of

general purpose greaseUsing hand pump only

Gear Oil Fill

Gear Oil Drainand Sample Valve

Daily

Washpipe AssemblyApply three pumps of

general purpose greaseat beginning of tour

Mud pumps “OFF”

Gear OilFilter


HydraulicFilter


Weekly

Weekly

Bail PinsApply two pumpsper grease fitting


Gear OilSight Gage

Check with Top Drive“OFF”

Retract Guide DollyApply two pumps per grease fitting

(28 places, 7 each manifold)

Varco P/N127052

TDS-4S Lubricationand Maintenance Guide

Gear Oil Lubrication Schedule

Swing Guide Dolly

Frequency

Replace the Gearbox Oil and Perform an Oil Analysis

Replace the Gearbox Oil Filter

Description

3 Months

3 Months

Grease Lubrication ScheduleFrequency

Washpipe Assembly

Upper Bonnet Seal

Bail Pins

Motor Trunnions

Swing Guide Dolly Hinges

Swing Guide Dolly (Grease Fittings on Manifolds)

Non-Swing Guide Dolly (Grease Fittings on Manifolds)

Retract Guide Dolly (Grease Fittings on Manifolds)

See lubrication section of the TDS-4S service manual for lubrication of electric motors

1

1

2

2

4

20

20

28

Description Points

Weekly

Monthly

Monthly

Weekly

Weekly

Weekly

Weekly

For more detail see theTDS-4S Service Manual

See the other side of this chart for theTDS-4H Lubrication and Maintenance Guide

Mfr.

Viscosity Index

Grease Gear Oil





NGLIAGMAISOViscosityGrade

MP Grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

N/R

N/R

N/R

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

N/R

N/R


Daily

Daily

Daily

Daily

Daily

Daily






Check the washpipe assembly for leaks

Check condition of the oil and hydraulic filter gauges

Check the gear oil levels

Check for cracks and excessive axial or radial playon the guide dolly rollers and replace as necessary

Above 21˚C(Above 70˚F)Alpha LS-320

NL Gear 320

Spartan EP320

EP Lube HD320

MobilGear 632

Omala 320

Loadway EP320

Meropa 320

Carter EP 320

Extra Duty NL6EP

N/R

6EP

320

7˚ to 30˚C(45˚ to 85˚F)Alpha LS-150

NL Gear 150

Spartan EP150

EP Lube HD150

MobilGear 629

Omala 150

Loadway EP150

Meropa 150

Carter EP 150

Extra Duty NL4EP

N/R

4EP

150

-6˚ to 16˚C(20˚ to 60˚F)Alpha LS-68

NL Gear 68

Spartan EP68

EP Lube HD68

MobilGear 626

Omala 68

Loadway EP68

Meropa 68

Carter EP 68

Extra Duty NL2EP

N/R

2EP

68


Oil viscosity should be adjusted based on expected ambient conditions for next three months

Weekly

Monthly

Swing GuideDolly HingesApply two pumpsper grease fitting

(4 places, 2 each hinge)

Swing Guide DollyApply two pumpsper grease fitting

(20 places, 5 each manifold,if equipped)

Monthly



Monthly



Daily

Refer to theTDS-4S Service Manual

or thePipehandler Lubricationand Maintenance Guide

for maintenance andlubrication of theRotating Head

!

!

!

Varco Wash Pipe Assembly Guide

128844

O-Ring51300-348-F

O-Ring51300-348-F

Snap Ring123562

Holding Ring123288

Wash PipeNut

123284

Wash Pipe123289

*123289-TC

* Tungsten Coated

Packing Box123563

GreaseFitting53219-1

Socket HeadDog Nose Screw

123564

Long-ArmAllen Wrench

53303-14

Packing Seal(5 per Set)123292-2 or

123292-3

Upper Spacer123285

Hand pack all sealswith multipurposelithium-based orhigh temperature

moly-based greasecompletely filling

the void

Slide thewash pipe nut

and the packing boxtogether for installation

The wash pipe nut andthe packing box haveleft-handed threads

Ensure that the nose of thesocket head dog nose screw

is fully engaged in the groove ofthe lower spacer

Recommended for propertightening of the wash pipe

nut and packing box

Middle Spacer123286

DowelPin

Middle Spacer123286

Lower Spacer123287

O-Ring51300-359-F

O-Ring51300-359-F

Snap Ring123634

Holding Ring123437

Wash PipeNut

123431

Wash Pipe123438

*123438-TC

* Tungsten Coated

Packing Box123626

GreaseFitting53219-1

Socket HeadDog Nose Screw

123564

Long-ArmAllen Wrench

53303-14

Packing Seal(5 per Set)123584-2 or

123584-3

Upper Spacer123434

Middle Spacer123435

Middle Spacer123435

Lower Spacer123436

See the Top Drive Service Manual for more detail

3" BoreWash Pipe Wrench

30150084

4" BoreWash Pipe Wrench

141481

Lubrication ScheduleFrequencyLubricant

Packing Box Apply 3 pumps of multipurposelithium-based or high temperaturemoly-based grease (do not mixlubricants)

Rotate the mainshaft at approximately 50 rpm for 1 to 2 minutesbefore turning on the mud pumps

Regular greasing will increase packing seal and wash pipe life

or

Description

Special ToolsWash Pipe Wrench

Installation Procedure

Install the wash pipe assembly on the Top Drive and hand tightenthe wash pipe nut and packing box (apply pipe dope to the threads)

Manually rotate the mainshaft 1 or 2 revolutions to seatand align the pipe in the packing box

Set the Top Drive brake

Tighten the packing box first with the wash pipe wrench or byhammering a few blows on every other lug, releasing the brake,turning the mainshaft and reseting the brake with each blow(the packing box should tighten at approximately 3/4 turn oradvance 1/4 inch from the hand tightened position)

Tighten the wash pipe nut next with the wash pipe wrench or byhammering gently on a lug (the wash pipe nut should tighten atapproximately 1/4 turn or advance 1/10 inch from the handtightened position)

Apply 6 to 8 pumps of multipurpose lithium-based or hightemperature moly-based grease to the grease fitting

Rotate the Top Drive at approximately 50 rpm for 1 minutewithout mud pumps

Turn on the mud pumps and check for leaks (if leaks occur,disassemble and repeat all previous steps)

If leaks continue, see the Top Drive service manual for inspectionof alignment and runout of mating parts.

Checklist

Reassembly Procedure

With the packing box upside down, assemble the packing seals andspacers into the packing box using care to line-up the upper spacerslot with the dowel pin

Hand pack all seals with multipurpose lithium-based or hightemperature moly-based grease using care not to grease theoutside diameter of the spacers

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

Install the grease fitting and turn the packing box upright

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

Install the wash pipe nut onto the wash pipe

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

Install the packing seal and holding ring over the slotted endof the wash pipe

Install the snap ring

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

Compress the assembly to the length of the wash pipe

Checklist

3" Bore Packing Kits 4" Bore Packing KitsComments

123290-PK(Standard)

123290-PK-1(High Pressure)

(1) Packing Set 123292-2(2) O-Rings 51300-348-F(1) Grease Fitting 53219-1


Nitrile/Cotton, Pressurerated at 5,000 psi(Use with Wash Pipe123289 or 123289-TC)

Nitrile/Armide, Pressurerated at 10,000 psi(Use with Wash Pipe123289-TC only)

Part #'s Contents Comments

123440-PK(Standard)

123440-PK-1(High Pressure)



Nitrile/Cotton, Pressurerated at 5,000 psi(Use with Wash Pipe123438 or 123438-TC)

Nitrile/Armide, Pressurerated at 7,500 psi(Use with Wash Pipe123438-TC only)

Part #'s

Typical Assembly View

Contents

Twice Daily

Each Tour

3" Bore123290 &

123290-1000

4" Bore123440 &

123440-750

If the packing box is properly tightened, and a leak is still present, do

not attempt to eliminate the leak with additional hammering (See Installation Procedure)

The wash pipe should be replaced when any measurable

wear or grooving is present

Varco P/N

275275

1010

0300300

175175150150125125

100

100

75752525

225225

250250

200200

20002000

12501250

0

500

500

250

250

1000

1000

750

750

30003000

27502750

25002500

22502250

15001500 17501750

Varco P/N30150095

Upper IBOPBreak-out Procedure

For more detail see thePH-85 Pipehandler Service Manual

PH-85

SaverSub

LowerIBOP

Step 2 Step 3 Step 4Step 1

Step 6 Step 7 Step 8Step 5

Top of RotaryTable and Deck

Top of RotaryTable and Deck

OldUpperIBOP

Upper IBOPValve

Lock Rotary Table

Torque Tube

RTBS (RotaryTable Back-up

Structure)

Tie-upCable

Tie-upCable

NewUpperIBOP

Step7D

Secure ToPad Eye OnGE Motor

Drive Ring

LiftingPlug

LiftingPlug

EngagedOn Square

Boss

RTBSIntensifierAssembly

RTBSIntensifier Assembly

RTBSIntensifierAssembly

HandleShown inHorizontal

Lock Position

Adjust AirPressure

To 175 Psi

To Release BrakeMove Handle ToVertical Position

YellowArea

YellowArea

IntensifierAdjustment

A. Breakout saver sub and lower IBOP the normal way using PH-85 pipe handler.

B. Tilt links with elevator to mouse hole or remove.C. Tie up links with cable to Top Drive (safety).D. Hang the RTBS intensifier assembly on guard of

PH-85. Connect (2) 1/4" hoses to line body onPH-85 manifold, connect the 1/2" hose to theTDS brake by disconnecting the existing brake hose at the brake drum, and hook up rig air to(A1) location on the intensifier assembly.

A. Swing PH-85 back with tugger line.B. Install thread protector in IBOP valve and lower

TDS/PH-85 so splines are engaged.C. Tie up PH-85 with cable and leave tugger line

slack (safety).D. Unlock TDS main shaft and spin out upper IBOP

until it is separated from main shaftE. Raise TDS/PH-85.F. Screw in lifting plug

to upper IBOP.G. Remove upper IBOP

with shell.

A. Install thread protector in replacementupper IBOP.

B. Position replacement upper IBOP with shell over RTBS and drive ring.

C. Lower TDS/main shaft slowly into new upper IBOP, (PH-85 swung out) while spinning main shaft until upper IBOP connection is shouldered.

D. Lock main shaft again.

A. Raise TDS/PH-85 above RTBS, remove thread protector. Remove drive ring.

B. Release tie-up cable (Ref 5B), stab PH-85 over RTBS and lower it to yellow area as shown

C. Switch PH-85 valve to "BREAK OUT" mode (reverse from normal).

D. Push "TORQUE WRENCH" button on VDC, PH-85 will rise, clamp on RTBSand make-upupper IBOPto desired torqueindicated by pressuregauge on RTBSintensifier assy paneland stroke back down.Note: make up torque91,000 lb-ft = 2,150 psi)

A. Remove RTBS from rotary table.B. Unlock main shaft and rotary table.C. Disconnect rig air to intensifier assy, disconnect

(2) 1/4" hoses and the 1/2" hose from the TDSbrake drum. Reconnect the brake hose fromTDS manifold.

D. Readjust the PRV valve to its original setting.E. Remove the RTBS intensifier assembly

and store away.F. Reinstall lower IBOP and saver sub

in the normal way usingthe PH-85.

G. Release the links (Ref 1C).

A. Hoist RTBS with the shackle on the end of the stem and place and secure RTBS on rotary table, remove shackle.

B. Lock rotary table. C. Lock main shaft with

TDS brake, switch valvehandle to horizontalposition and adjust airpressure to 175 psi.

A. Stab PH-85 over RTBS & lower it to line up withtop of yellow area.

B. Select "MAKE-UP" mode (reverse from normal).C. Screw the PRV valve on PH-85 manifold all

the way inD. Push "TORQUE WRENCH" button

on VDC. PH-85 will rise, clamp onRTBS, and break out upper IBOP.It will stroke back downwhen the button isreleased. Repeat untilIBOP is loose.(Note: IBOP valveshould breakout @approximately 2500 psi)

A. Raise TDS/PH-85 until stabbing guide clears the top of RTBS.

B. Place drive ring over RTBSshoulder with square bossengaged with drive ring.



Inspection


Maintenance

Inspection

Swinging out th e TDS formaintenanceVarco top drives with swing-out guide dollies can be quicklyswung aside on its own dolly frame for inspection, maintenance,running casing, or to allow drilling operations requiring a kellyand rotary table. Electrical, hydraulic and air supplies do not haveto be disconnected. Use the following procedure to swing out theTDS only if your rig has a guide dolly with hinge pins (refer tothe engineering drawings for information specific to your rigconfiguration):

1. If you have a retract system, operate the switch on the driller’sconsole to retract the TDS.

2. Slowly lower the TDS until the elevator nears the rig floor.

3. Remove the elevator and elevator links.

4. Lower the TDS guide dolly to the stop.

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z On some rigs, it may be necessary to secure the traveling blockframe to the guide dolly frame using chain and/or rope.

5. Turn off the hydraulic power unit and bleed down hydraulicpressure by opening the needle valve (NV) on thecounterbalance manifold. (The counterbalance manifold islocated on the upper motor frame.)

6. Detach the counterbalance system cylinders from the hook orblock by unhooking the pear links from the ears on the hookor block.

7. Disconnect the air intake hose.

8. Disconnect the mud hose from the TDS S-tube.

n Unlatching the hook from the swivel bail may cause the TDSmotor assembly and/or the hook to lurch suddenly. Alwayskeep adequate tension on the tailing lines to prevent suddenmovement of these assemblies.

9. Unlatch the hook.

10. Attach tugger lines to the TDS motor frame, opposite theframe hinges, to assist in swinging out the TDS motorassembly. Use tailing lines on the motor frame to controlswing out.

11. Unfasten the two swing-out bolts, opposite the hinges,holding the motor frame to the guide dolly.

12. Operate the air tuggers to slowly pull on the motor framewhile unhooking the traveling block from the swivel bail.

13. When the traveling block is disconnected, continue swingingout the TDS 180° and secure the motor assembly to thederrick with chain and/or rope.


To swing the TDS back in for operation after inspection ormaintenance, perform the following procedure:

1. Lower the traveling block guide dolly far enough to allowswinging the TDS back into place.

n While latching the hook to the swivel bail, the swivel and/orthe TDS motor assembly may suddenly lurch. Always keepadequate tension on tailing lines to prevent sudden movementof these assemblies.

2. Attach tugger lines to the TDS motor assembly, opposite thehinges, to aid in swinging back the TDS assembly. Use tailinglines on the motor frame to control swing back.

3. Release the chain and/or rope securing the TDS motorassembly to the derrick and slowly swing back the TDS motorassembly to the guide dolly. While swinging it back, latch thehook onto the swivel.

4. Secure the motor frame to the guide dolly with the twoswing-out bolts opposite the hinges.

5. Connect the mud hose to the S-tube.

6. Connect the air intake hose.

7. Hook the counterbalance system pear links onto the ears ofthe hook or block.

8. Turn on the hydraulic power unit and bleed air out of thesystem.

9. Adjust the hydraulics as outlined later in this section.

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DC drilling motorThoroughly inspect the TDS, motor support bonnet, and guidedolly assembly for loose bolts and fittings daily. If any safety wireor cotter pins were removed to facilitate repairs, replace themimmediately.

z The DC motor has a complete manufacturer’s instruction manualfor your reference provided as a separate book in this manual.

Air exhaust mufflerVarco installs air exhaust mufflers on the exhaust ports of themulti-gang solenoid valve manifold for noise abatement. All suchmufflers reduce noise and collect contaminants that caneventually restrict the air passage. Air passage constriction resultsin back pressure on all of the solenoid valves and erratic valveoperation. It also holds pressure on the air brake.

Periodically remove the mufflers and clean or replace them.

If noise abatement is not an issue on the rig, replace the mufflerswith simple pipe elbows.


Derrick termination kit air filter/regulator/lubricatorsTop drives that rely on rig air to power link tilt, upper IBOP,brake and torque wrench makeup/breakout sequence pilot signalfunctions require regular inspection. The air valves, cylinders andactuators for these functions require proper lubrication andmoisture-free and particle contaminant-free air. Moisture in theair can cause corrosion on internal cylinder surfaces. Particlecontamination can damage the seals in moving parts and causesolenoid valves to stick. Oil, injected by the lubricator and carriedby the air, reduces friction between moving parts and increasesthe life of seals in valves and actuators.

e Varco supplies a filter/regulator/lubricator in the derrick installationkit and recommends installing it at the fingerboard level in thederrick. Improperly adjusted regulators can cause poor deviceperformance at reduced pressures, or valve and cylinder seals and O-ring extrusion at excessive pressures.

Inspect the entire filter/regulator/lubricator monthly for damageto the filter bowl, overall body, or inlet and outlet fittings.Replace any damaged, corroded, or improperly functioningcomponents.

Adjust the pressure regulator outlet pressure to 100-120 psigmonthly. Clean and drain the filter weekly. Fill the lubricatorwith petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU at 100°F (ISO 32/34).

e Do not use fluids such as “Marvel Mystery Oil,” motor oil, orDextron II in the lubricator. Swollen seals may result.

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PipehandlerThoroughly inspect the pipehandler for loose bolts and fittingsdaily. If any safety wire or cotter pins were removed duringrepairs, replace them immediately.

Inspect the hinge bolts daily to make sure they are not separatingfrom the pipehandler. Make sure the hinge pins are not looseeither because of excessive wear in the bore of the clamp clevis ora broken retaining bolt.

n Inspect the link tilt intermediate stop and adjustment devicefor overall integrity weekly. Replace the components if there isexcessive looseness of the threaded rod in the threaded hole ofthe pivot arm (refer to the figure in the Air ActuatorReplacement procedure later in this book). An indication of apossible problem is if the two intermediate stops are notadjusted “equally” (i.e., if the thread engagement differsbetween the two stops). Failure to perform this inspection and/or component replacement can result in injury to rigpersonnel.

Drill stem load-carryingcomponentsBecause the drill stem load carrying components are critical,Varco recommends performing the following procedures andinspections on a regular basis.

Visual inspectionUse calipers on a regular basis to measure the amount of wear onthe elevator link eyes (Figure 4-1). Compare the measurementswith the Wear Chart (Figure 4-1) to determine the currentstrength of the elevator links. The capacity of the links equals thecapacity of the weakest link.


��

��

��

5 in.4 13/16 in.

4 5/8 in.4 7/16 in.

2 3/4 in.2 9/16 in.2 3/8 in.

2 3/16 in.

350300225175

B = 3 1/2 in., 350-Ton

Wear Chart - Forged Links

6 in.5 3/4 in.5 1/2 in.5 1/4 in.

3 1/2 in.3 1/4 in.

3 in.2 3/4 in.

500420325250

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

7 1/2 in.7 1/4 in.

7 in.6 3/4 in.

350300225175

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

UpperEye

DimensionC

LowerEye

DimensionA

Capacity(per set)in Tons

7 1/2 in.7 1/4 in.

7 in.6 3/4 in.

UpperEye

(Hook)

LowerEye

(Elevator)

To determine the strength of worn links,measure (with calipers) the amount of eyewear and compare the measurementswith the above Wear Chart to find thecurrent capacity. The capacity of the set oflinks is determined by the weakest link.

CC

B

B

A

A

Figure 4-1. Visual inspection of elevator links

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Landing collar

Disassemble and inspect the landing collar every six months.Use the following procedure to disassemble the landing collar(Figure 2-4 in the Installation and Commissioning book) forinspection:

1. Disconnect the top drive from the drill string.

2. Remove the IBOPs and pipehandler.

3. Raise the solid body elevator to expose the landing collarretainer.

4. Straighten the retainer tabs.

5. Slide the retainer ring above the split landing collar halves.

6. Drive out one roll pin.

7. Remove the landing collar halves.

8. Slide the retainer off the drive stem.

After disassembly, inspect all landing collar parts for wear,damage, or corrosion. Check for:

❏ Grooves or other radial wear marks indicating that the bore ofthe solid body elevator is rubbing on the outside diameter ofthe landing collar retainer shell

❏ Radial grooves on the inside diameter of the retainer shell

❏ Missing tabs from the retainer shell

❏ Wear or corrosion induced pitting on the retainer shellshoulder

❏ Wear, corrosion, or fatigue cracks on the inside or outsidediameter of the landing collar halves

❏ Evidence of drive stem contact with the solid body elevator

❏ Evidence of inside bore wear on the solid body elevatorindicating contact with the drive stem or landing collarretainer. Wear on the inside shoulder of the elevator shouldnot exceed 1/8 in.

❏ Evidence of wear, corrosion or fatigue cracks on the safetylinks


Replace the appropriate part(s) if any of the above conditionsexist. Use the following procedure to reassemble the landingcollar:

1. Replace the existing O-ring in the retainer shell.

2. Grease the inside diameter of the retainer shell.

3. Slide the retainer onto the drive stem above the landing collargrooves.

4. Install one new roll pin and safety links on the split landingcollar halves.

5. Coat the landing collar halves with a generous amount ofwater resistant grease.

6. Place the landing collar halves on the drive stem with 15°taper closest to the top drive.

7. Drive in the remaining roll pin.

8. Slide the retainer shell over the landing collar halves.

9. Use a hammer and drift to bend all 32 retainer tabs to securethe retainer shell.

10. Coat the retainer shell and drive stem with a generousamount of water resistant grease to prevent corrosion.

11. Reinstall the IBOPs and pipehandler.

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Drive stem

Regularly inspect and measure the drive stem/mainshaft for wear.Remove the drive stem/mainshaft from service if bore wear isgreater than the dimensions shown in Figure 4-2.

Determine inspection frequency according to API RecommendedPractice 8B, Section 2 for power swivels and power subs.

Varco recommends the use of API RP 7G and API RP 8B asguidelines for interpreting and performing inspections.Measurement techniques are specified in API RP 7G, Section 10.Use API Bulletin 5T1 to identify and define imperfections foundduring inspections.

Figure 4-2. 500-ton drive stem minimum bore wear dimensions


Use the following API recommended guidelines (Figure 4-3) todetermine the tensile load bearing capacities of the drive stemlanding collar.

Figure 4-3. 500-ton drive stem landing collar tensile dimensions

September 16, 1996


Main shaft

Regularly inspect and measure the drive stem/main shaft for wear.Remove the main shaft from service if bore wear is greater thanthe dimensions shown in Figure 2.

Determine inspection frequency according to API RecommendedPractice 8B, Section 2 for power swivels and power subs.

Varco recommends the use of API RP 7G and API RP 8B asguidelines for interpreting and performing inspections.Measurement techniques are specified in API RP 7G, Section 10.Use API Bulletin 5T1 to identify and define imperfections foundduring inspections.

* See Figure 3

Figure 2. TDS-4H 650-ton minimum bore wear dimensions

September 16, 1996


Use the following API recommended guidelines (Figure 3) todetermine the tensile load bearing capacities of the drive stem/main shaft landing collar.

Figure 3. 650-Ton drive stem /main shaft landing collar, tensile dimensions

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Magnetic particle inspectionAfter approximately three to six months, depending on theseverity of operating conditions, or 1,500 operating hours, Varcorecommends performing a magnetic particle inspection of theexposed surfaces of all load bearing components and load collargrooves to reveal any fatigue or crack indications. Any indicationsfound are a potential cause for the replacement of the suspectcomponent. Round bottom pits and erosion are acceptable aslong as the defect is less than 1/8 in. deep. Larger defects or anycrack indications are cause for replacing the suspect component.

After approximately five years or 15,000 operating hours,depending on the severity of operating conditions, Varcorecommends performing a magnetic particle inspection of all loadbearing components over their entire surface (including internalbores) to reveal any fatigue or crack indications. Any indicationsfound are a potential cause for the replacement of the suspectcomponent. Round bottom pits and erosion are acceptable aslong as the defect is less than 1/8 in. deep. Larger defects or anycrack indications are cause for replacing the suspect component.These components are:

❏ Drive stem/main shaft (lower portion)

❏ Landing collar

❏ Upper and lower IBOP

❏ 350-ton BNC drill pipe elevator

❏ Link adapter

❏ Saver and spacer subs

❏ Power subs

❏ Power swivels

❏ Elevator links


Ultrasonic inspectionIn addition to the magnetic particle inspection, Varco alsorecommends performing an ultrasonic inspection of the abovecomponents to detect any erosion of the inside diameter. Anyerosion reduces the load-carrying capability of the part. Anysubsurface irregularity can also compromise a component’sintegrity.

Details on magnetic particle and ultrasonic inspection proceduresare in the following publications:

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

ASTM A-275 Std. Method for Magnetic Particle Inspection ofSteel Forgings

ASTM E-709 Std. Recommended Practice for Magnetic Particle

ASTM A-388 Std. Practice for Ultrasonic Examination ofHeavy Steel Forgings

Safety valves inspection procedures (IBOP)

z Upper and lower safety valves, because of their internal groovesand shoulders, are particularly susceptible to corrosion fatiguecracking. These internal diameter changes act as stress risers forbending and tensile loads. It is especially important to properlyinspect the safety valves on a frequent basis. Be sure to read anduse the safety valve inspection procedures described in the IBOPService Manual included as a separate book in this manual.

Training Manual

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