Training Manual PDF
Training Manual PDF
Training Manual PDF
Training Manual
Company
Owner
TOP DRIVE
Training Manual
Description
Training Manual
TOP DRIVE
Training Manual
Installation
Chapter 1
Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up
has been accomplished prior to installation of the TDS. This
includes:
1. Guide rails and bracing are installed and inspected to
conform 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 with
closed 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 that
they will not foul with the TDS and other rig equipment.
Chapter 2
Installation
1/4"
OVER FULL LENGTH
3/8
1/8"
C
L RAIL
C
L RAIL
OVER FULL LENGTH
WITHIN 25' OF FLOOR
C
L RAIL
C
L RAIL
CL WELL
TDS BACK
OPERATIONAL CLEARANCE BETWEEN TOP DRIVE
& NEAREST GIRT OR FASTLINE SHOULD BE 3 MINIMUM
GUIDE RAILS
NEAREST GIRT
SPLICE
CLEARANCE
SPLICE PLATES
OR BOLTS ARE
NOT PERMISSABLE
ON INSIDE
SURFACES OF
BEAM
DOLLY
OVERHANG
MAXIMUM RAIL
SUPPORT SPACING
16 FT FOR W12x53 RAILS
25 FT FOR W14x74 RAILS
6" RAIL
STOP
GUIDE
DOLLY
CONFIG
39 X 66
48 X 62
30 X 72
30 X 72
RAIL
SIZE
W14X74
W14X74
W12X53
W14X74
DRILL FLOOR
C
L WELL
SPLICE DOLLY
CLEAR OVERHANG
INCHES
3.3
3.3
3.3
2.3
0
0
1.6
0.5
16.0
DERRICK J-BOX PLATE
CLEARANCE HOLE
FOR .75 DIA BOLT
4 PLACES
INSTRUMENT J-BOX **
MOTOR J-BOX **
BRACES *
16.0
CONVENIENT
WORKING HEIGHT
ABOVE WALKAROUND
16.0
B
MUST SUPPORT
4000 LBS
16.00
AIR
STANDPIPES
TO BE
1-1/2
SCHED 40 PIPE*
WATER
STANDPIPES
TO BE 2 SCHED 40 PIPE*
VIEW A-A
TYPICAL SERVICE LOOP TERMINATION
A
86 FT.
SERVICE
LOOPS
A
GUSSETS *
75 FT.
MUD
HOSE
REF
SERVICE
LOOP
BRACKET**
EXISTING GIRT *
VIEW B-B
7 FT REF
Motor Frame
Setback
Rails
L
9'3" TDS-3S
10'3" TDS-4S
7'0" TDS-3S
8'0"TDS-4S,
TDS-6S
Rail Stops
L
42,600 LBS for a typical TDS-3S
48,000 LBS for a typical TDS-4S
52,000 LBS for a typical TDS-7S
TDS-3S
TDS-4S
39 x 66
18,600
18,900
48 x 62
18,600
18,900
30 x 72
17,500
17,800
TDS-3S
TDS-4S
TDS-6S
TDS-7S
39 x 66
3450
5450
--
3090
48 x 62
3680
5800
--
3290
30 x 72
3170
5000
--
2840
91/101 x 108
--
3330
3780
--
Motor Frame
Setback
Rails
L
L
10'3" TDS-4H
7'0"TDS-4H,
L
Rail Stops
L
48,000 LBS for a typical TDS-4H
TDS-4H
39 x 66
18,900
48 x 62
18,900
30 x 72
17,800
Load L - LBS
Rail Spacing
TDS-4H
39 x 66
5450
48 x 62
5800
30 x 72
5000
91/101 x 108
3330
Wiring
The electrical installation requires routing power to the transfer
panel 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 drillers console, the SCRs
drillers console, the hydraulic and water pumps and the drilling
recorder.
Derrick
Power
J Box
Transfer Panel
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#6AWG/2C*
Shunt Field
Derrick
A.C.
J Box
(4)646MCM*
Top
Drive
System
AC
Power
HYD
Pump
#2
#16AWG/10C
#16AWG/10C
Existing
Driller's Console
#16AWG/10C
#10AWG/4C
#10AWG/4C
#6AWG/4C
#6AWG/4C
TDS
Driller's Console
HYD
Pump
#1
Rotary
Table
RBS
Controls
#12AWG/3C
E/P
RPM
Existing
Power
Cables
#16AWG/10C
E/P
Torq
#14AWG/2 Pr Shld
#12AWG/3C
#14AWG/37C
#12AWG/20C
#12AWG/20C
#16AWG/10C
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#12AWG/3C
SCR
Room
Service Loop
#6AWG/2C*
Shunt Field
#16AWG/10C
Water
Pump
#1
Water
Pump
#2
Runs
646MCM (4 Shunt)
(8 Series)
#6AWG/4C
#10AWG/4C
#12AWG/20C
#12AWG/3C
#14AWG/37C
#14AWG/2PR SHLD
#16AWG/10C
#16AWG/10C
#14AWG/2PR SHLD
Plumbing
The plumbing connections should terminate near the service loop
bracket. The mating halves are preassembled on the service loop.
Specifications for specific lines are described in the following
sections.
Hydraulic
Hydraulic 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. The
derrick connections are reduced to 1" NPT female pressure and
fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1" or 1 1/2" pipe in the case of
the purge supply for the TDS. Install a shut-off valve at drill floor
or racking board level. The air lines connect to the filtered and
lubricated supply. The derrick connections are reduced to 1"
NPT female for the purge line (if required) and 1/2" for the air
line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean,
dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2" pipe. Install
shut-off valves at the drill floor or racking board level. See the
cooling system specifications for water supply requirements. The
derrick connections are reduced to 1 1/4" NPT female pressure
and return for connection to the fluids service loop.
Rig-up procedure
z
16
5. Use the four lift slings from the crane, one attached at each
corner of the guide dolly, to lift the top drive motor and dolly
assembly onto the rig floor. If possible, set it on the rig floor
with the crane - do not drag it up the V-door. Position it on the
rotary table with the swivel end under the guide rails. The
slings must be a minimum of 15' long (equal length) and
capable of lifting 40,000 lb combined. (BOP lift slings are
usually adequate.)
17
6. Attach lifting slings to the pad eyes located at the swivel end
of the motor frame and lift the TDS into the guide rails.
18
Landing
Collar
Retainer
Landing Collar
Retainer Tabs
O-Ring
Drive
Stem
Roll Pin (4)
Split Landing
Collar (2)
19
13. Pull up on the release handle and unlock the rotating head.
Rotate the link adapter and the rotating head so that the
mounting point for the torque wrench is at the front of the
tool. Raise the torque wrench with the air winch and pin into
place. Adjust hanging position per the procedure described in
Book 4. Rotate the pipehandler assembly to the rear and
connect the two air hoses and two hydraulic hoses. Quick
disconnects on the hoses allow connection in only one way so
that the hoses cannot be interchanged.
14. Connect the hose to the back of the link tilt actuator. Use the
four bolts, lockwashers and safety wire provided to install the
link tilt acutator to the link adapter. Connect the opposite
end of the hose to the quick disconnect on the rotating head
assembly.
15. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). Allow for
1/2" 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 distance
from bottom of pear link to top of mounting lug on
swivel link (Dimension A).
c. Subtract 37 1/4" from dimension A.
d. Cut chain to the length obtained in step c (measure inside
chain links per illustration). The tolerance is: +3 1/4"/-0".
e. Assemble remaining components and install per the
illustration.
20
21
17. Attach the service loops to the bracket on the top drive frame.
Use the cable clamps provided on the motor frame to route
the electrical cables over the gear box and into the junction
boxes. The front guard swings aside for access to the junction
boxes by removing the attachment bolts on one side.
Use the electrical schematic (refer to the engineering
drawings) to make the connections. Be certain that the cables
are securely tied or clamped to the structure along their
length. Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type and identify spares.
18. Attach the S-tube to the swivel gooseneck and the side of the
motor frame as follows (Figure 6):
a. Makeup the upper union just before clamping S-tube to
side of motor frame.
b. Install the drill pipe rubber onto the S-tube aligned with
mounting 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 adjust
the hanging direction of mud hose.
22
23
Rig-up procedure
z
16
TDS-4S Installation
Landing
Collar
Retainer
O-Ring
Landing Collar
Retainer Tabs
Drive
Stem
Split Landing
Collar (2)
TDS-4S Installation
17
8. Connect the hose to the back of the link tilt actuator. Use the
four bolts, lock washers and safety wire provided to install this
assembly to the link adapter. Connect the opposite end of the
hose to the quick disconnect on the rotating head assembly.
9. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). There
should 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 determine
the chain length required:
a. Install pear links to ears on hook-block.
b. With the hook supporting the TDS, measure the distance
from the point of contact inside the pear link to the top
of 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. The
tolerance is: +3-1/4" or -0".
e. Assemble remaining components and install per Figure 6.
Pear Link
Connecting
Link
Hydraulic
Accumulator
(Inside Motor Frame)
Counterbalance
Manifold
(On Guide Dolly)
Integrated
Swivel
Bail
TDS-4S Installation
11. Attach the service loops to the bracket on the TDS dolly
frame. Using the cable clamps provided on the motor support
bonnet, route the electrical cables over the gear box and into
the junction boxes. The front guard folds down for access to
the junction boxes.
Use the electrical schematic (refer to the engineering
drawings) to make the connections. Be certain that the cables
are securely tied or clamped to the structure along their
length. Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type, and identify spares.
12. Attach the S-tube to the swivel gooseneck and the side of the
motor frame as follows:
a. Make up the upper union just before clamping the
S-tube to the side of the motor frame.
b. Install the drill pipe rubber onto the S-tube aligned with
the mounting saddle on the frame.
c. Attach the mud hose to the bottom connection of the
S-tube.
d. Position the 20 S-tube elbow on the bottom of the
S-tube to adjust the hanging direction of mud hose.
13. Remove the exhaust duct shipping cover from the spark
arrestors on the air exhaust duct at each side of the DC
motor. Save the covers for use during future shipping or
storage.
Never operate the top drive with the exhaust duct covers
attached to the spark arrestors on the air exhaust ducts. Doing
so severely restricts air flow through the motor, causing
overheating and potential damage. They can also fall off
during operation and injure personnel working below. Attach
the covers only during shipping and storage.
TDS-4S Installation
19
Counterbalance system
Figure 6 illustrates the installation arrangement for this system.
Please see the Maintenance and troubleshooting book for the
adjustment procedures.
This assembly is pre-charged when it is shipped by land or water
transport. When this assembly is shipped by air freight, it must be
pre-charged according to the instructions inthe Maintenance and
troubleshooting book.
20
TDS-4S Installation
Split
Shipping
Brace
Motor
Alignment
Cylinder
Motor
Frame Dolly (Ref)
TDS-4S Installation
21
Drillers console
Mount the drillers console within easy reach and in plain view of
the driller while he is operating the drawworks brake and
clutches. The gauges must be easily seen by the driller during
drilling operations. Provide appropriate cable glands for the
electric cables.
Wiring
Refer to the electrical schematics in the engineering drawings.
Service loops
Installation
Install the service loops as follows:
1. Fabricate the appropriate brackets and clamps to attach the
service loop mounting bracket to the derrick structure.
2. Place the service loop derrick mounting bracket at the height
specified on the derrick interface drawing provided in the
engineering drawings. Locate the bracket on the side of the
derrick adjacent to the hinges on the TDS and as far as
practical toward the corner where the guide rail bracing is
attached. The bracket must be located far enough from the
corner to insure the loops do not catch under the guide rails
during operations, but far enough back to provide clearance
for tong lines, the stabbing board, tugger lines, etc.
3. Do not unpack the service loops from the shipping protective
crate until they are ready to hang in the derrick. Lift the
service loops onto the rig floor (still in the crates) and then
remove them from the crates with the lifting eyes provided.
7. Pick up the TDS end of the loops and attach them to the
service loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in the
following sections.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematic
provided to ensure proper terminal block assignments.
2
Fluids loop
1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of any
contamination.
The hoses in the fluid loop only extend 11' from the mounting
bracket. It may be necessary to make jumper hoses to reach the
standpipes.
Air loop
Chapter 3
Commissioning
Checkout procedure
1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (drillers controls only).
3. Check the function of switches and solenoids. There is an
audible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and the
elevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears the
monkey-board when actuated. Refer to the Maintenance and
troubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the air
escapes when the brake releases.
7. Move the make/break valve located on the manifold at the back
of the pipehandler torque wrench to the BREAK position.
8. Turn on the hydraulic power supply and adjust the pressure
reducing valve (also located on the torque wrench manifold)
to the appropriate pressure for the lower IBOP connection.
25. Bring the TDS down as if stabbing the saver sub into box.
The pin and box should be in alignment. If adjustment is
necessary, use the following procedure:
a. Measure how far and in what direction (toward or away
from the rails) the pin must move to line up with the drill
pipe box.
b. Turn off the hydraulic power unit and bleed down the
cylinder accumulator (open the needle valve on the back
of the manifold). This allows the motor alignment
cylinder to relax and the motor to rotate on its trunnions
until the integrated swivel bail contacts the motor support
bonnet.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. With a wrench located on the cylinder rod flats, screw the
rod into or out of the clevis, in the same direction the
saver sub pin is to be moved.
e. Secure the jam nut and lock tab.
f. The nominal position of the two cylinder flow control
valves is 1-1/2 turn off their seats. If you experience heavy
drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface.
If motor movement becomes excessive due to continued
vibration, (more than 1/2" of total cylinder stroke) close
the flow controls to 3/4 turn off their seats.
TOP DRIVE
Training Manual
Counterbalance
Counterbalance System
---------------------------------------------------------------------------------------------------------------------------------------------------
TOP DRIVE
Installation
TOP DRIVE
Training Manual
Hydraulic Components
Accumulators
The main task of an accumulator is to take a specific
amount of fluid under pressure from the hydraulic
system and store it until it is required within the
system.
As the fluid is under pressure, accumulators are treated
as pressure vessels and must be designed taking into
account the max operating pressure. How ever they
must also pass the acceptance standards in the
country in which they are being used.
In order to store energy in accumulators, the fluid in an
accumulator is weight or spring loaded or pressurised
by gas. Therefore a balance is maintained between the
pressure in a fluid and opposing pressure produced by
the weight, spring or pressure created by gas.
In most hydraulic systems hydro-pneumatic (gas
pressurised) accumulators with a separating element
are used. Depending on the type of separating element
used, accumulators are categorised into Bladder,
Piston and membrane accumulators.
Function
Accumulators have to carry out various functions in a
hydraulic system:Energy storage
Fluid reserve
Emergency operation
Balance in forces
Damping of mechanical shocks
Damping of pressure shocks
Compensation of oil leakage
Damping of shocks and vibrations
Damping suspension
Reclaiming of deceleration energy
Maintaining constant pressure
Compensation of flow (expansion tank)
Theory of Operation
The basic principle of all pressure relief valves is that
the inlet pressure is fed to a measuring surface which
is acted on by force. The inlet pressure loads the
poppet or lower side of the control spool with hydraulic
force. The force of the pre-tensioned spring acts in the
direction of the closure. The spring chamber is
unloaded to tank. As long as the spring force is larger
than the pressure force, the seating element stays on
its seat. If the pressure force exceeds the spring force
the element pushes against the spring and opens the
connection. The excess fluid returns to tank. As the
fluid flows away via the pressure control valve,
hydraulic energy is converted into heat
Theory of Operation
A pilot operated check valve consists of a valve body
with inlet and outlet ports and a poppet held against a
seat by a spring. Directly opposite the check valve
poppet are a plunger and a plunger piston that are
biased by a light spring. Pilot pressure is sensed at the
plunger piston through the pilot port. The valve allows
free flow from its inlet port to its outlet port. Fluid flow
attempting to pass through the valve from the outlet
port to the inlet forces the poppet to its seat, blocking
flow through the valve. When enough pilot pressure is
sensed at the plunger piston, the plunger moves and
unseats the check valve allowing fluid to pass. The
ratio of the load pressure to the pilot presure required
to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate
and precise flow of the fluid within a hydraulic
system. It can also be used to as a positive shut off for
the hydraulic system.
Theory of Operation
The basic principle of all pressure Reducing /Relieving
valve is not to let the output pressure rise above a
certain level, the relief valve monitors the pressure on
the system, when the system pressure rises above a
set pressure it returns the fluid back to tank. This
pressure can be influenced by the relief port .
(See hyd schematic)
TOP DRIVE
Set Up Procedure
Set up Procedures
TDS 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
Drawing
VM 2126 SHEETS 1 T0 5
Drawing
92114
Drawing
75420
Drawing
107530
Drawing
110407
Check the following valves are correctly installed:Pilot to open check valve
Needle Valve
Pressure Reducing Valve
Pressure Relief Valve
e
e
e
e
e
P/N
P/N
P/N
P/N
77616
76419
77615
94522-21N
Check all connecting liks are secure and all bolts are
safety wired.
Check TDS is not sitting on the guide stops .
Check the Hydraulic reservoir is full and all quick
disconnects are installed properly.
Check all hose connections are tight.
Check the 2 accumulators are pre-charged with 900
psi of Nitrogen.
Check hydraulic power supply is set to 2000 psi.
Adjustment Procedure
Screw needle valve counterclockwise until fully open.
Screw pressure reducing valve counterclockwise until
fully open.
Start hydraulic power unit and let hydraulic oil flow for
2 minutes.
Bleed system cylinders.
Screw needle vale clockwise until fully closed.
Screw pressure reducing valve clockwise until
cylinders start to retract raising the TDS.
Slowly screw the pressure reducing valve
counterclockwise reducing the pressure to the
cylinders.
When the swivel bail just contacts the hook note the
pressure and decrease it by 25psi tighten lock nut.
Probable cause
Remedy
Replace seals.
Tighten or replace as required.
. See adjustment procedure.
Clean or replace.
Clean or replace.
____________________________________
____________________________________
____________________________________
____________________________________
_______________________________________
_______________________________________
_______________________________________
3) What stops the counterbalance system from being over pressurized?
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
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.
___________________________________________________________
___________________________________________________________
___________________________________________________________
TOP DRIVE
Training Manual
Alignment
Training Manual
Alignment
Training Manual
Alignment
Training Manual
Alignment
Training Manual
Alignment
Alignment Cylinder
Lug (ref)
Pressure Reducing
Valve
Needle Valve
Alignment
Cylinder
Manifold
Accumulator
Bracket
Gas Valve
Split
Shipping
Brace
Motor
Alignment
Cylinder
Motor
Frame Dolly (Ref)
Alignment cylinder
Probable cause
Remedy
Alignment cylinder
fails to move
transmission at
trunnion pivot points
with recommended
pressure setting.
Adjustment
Se e
procedure.
Replace seals.
. Clean or replace.
Se eAdjustment procedure.
Excessive motor
movement.
Theory of Operation
A pilot operated check valve consists of a valve body
with inlet and outlet ports and a poppet held against a
seat by a spring. Directly opposite the check valve
poppet are a plunger and a plunger piston that are
biased by a light spring. Pilot pressure is sensed at the
plunger piston through the pilot port. The valve allows
free flow from its inlet port to its outlet port. Fluid flow
attempting to pass through the valve from the outlet
port to the inlet forces the poppet to its seat, blocking
flow through the valve. When enough pilot pressure is
sensed at the plunger piston, the plunger moves and
unseats the check valve allowing fluid to pass. The
ratio of the load pressure to the pilot presure required
to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate
and precise flow of the fluid within a hydraulic
system. It can also be used to as a positive shut off for
the hydraulic system.
Theory of Operation
The basic principle of all pressure Reducing /Relieving
valve is not to let the output pressure rise above a
certain level, the relief valve monitors the pressure on
the system, when the system pressure rises above a
set pressure it returns the fluid back to tank. This
pressure can be influenced by the relief port .
(See hyd schematic)
TOP DRIVE
Training Manual
Cooling Motor
Cooling Systems
Varco has four types of cooling systems the
customer can choose from to cool the Varco
Top Drive Drilling Motor.
1.
2.
3.
4.
Closed Loop
Blower Motors
The blower motor is a dual shaft 20 HP AC, that is attached to
the blower mount brake cover. The motors are EXD or Ul rated it
is always best to check the name plate before installing.
The impellers are attached to each shaft end and are fixed by a
taper lock mechanism.
.
.
Heat Exchangers
The closed loop cooling system consists of two tube fin type heat
exchangers cooled by twin blowers driven by a double ended AC
Motor. Ducting passes air out the motor exhausts port to the heat
exchangers and back to the blower inlets. The heat exchangers
are built from Cupro Nickel tubes and the headers are pressure
tested 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 TSD
6S each motor requires 50gpm) at a maximum inlet temperature
OF 90F.
Water Detectors
System operation
The sensor is mounted in the scroll of the blower housing of
drilling motor at such a position that the air circulation pattern
from the blower,s impeller will cause leaking coolant water
particles to strike the sensitive sensor element. If water is
present the sensors resistance lowers causing the water detector
amplifier to conduct a 24 Vdc to the Programmable Logic
Controller (PLC). The PLC then sounds the warning horn and
illuminates the Drillers console water detection indicator lamp.
Local Blower
Local Blower
The basic local blower system is designed to provide local cooling air
to the drilling motor. It receives air from approx 20 feet above the rig
floor at the lowest point of the motors travel.
A heavy constructed pressure blower is mounted to the motor. The
motor is directly driven by an explosion proof 20 HP, 3450 rpm AC
electrical motor.( older versions may have an 15 HP Motor) The
motor is connected to the blower with a rigid duct.
The design provides highly reliable service with positive ventilation
through its normal inlet and spark arrestor protected outlets. It
provides a safe, visibly verifiable system that will prevent explosion of
flammable 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.
Axial Fan
20 hp
Blower Motor
Transmission
Cooler
Locking Key
Oil Fittings (2)
Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
FLL-X Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
Transmission Cooler
Remote Blower
Air Inlet
40 hp Explosion Proof
Electric Motor (AC)
and Centrifugal
Pressure Blower
Wind Wall
Racking Platform
at Racking Board Level
Spark Arrestor
Trouble-Shooting
Probable cause
Remedy
Mechanical noise in
blower.
Loose impeller.
Replace as needed.
Blower runs
intermittently.
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
Symptom
Probable cause
Remedy
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
WATER
DETECTOR
alarm is on
(closed loop system).
Position
____________________________________
____________________________________
____________________________________
____________________________________
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?
____________________________________
____________________________________
____________________________________
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 ?
______________________________________________________________________________________
______________________________________________________________________________________
TOP DRIVE
Training Manual
Motor Brake
Training Manual
10
5
6
3A
Note:
OptionalQuickRelease
Valve. Notavailable for
11.5VC500.
2
12
11
Ventilated Construction
Item
ComponentDescription
Rim
Tube(withvalvestemsnapringswhererequired)
ElbowAssembly
3A
Optiona
l - QuickReleaseValveAssembly
Air ConnectionTube
Air ConnectionGasket
FrictionShoeAssembly
Air TubeGroup(DualMounted)
SpacerGroup(DualMounted)
10
11
12
TorqueBar
13
ReleaseSpring
7, 12, & 13
13
TOP DRIVE
Training Manual
Motor Housing
TOP DRIVE
Training Manual
Washpipe Assay
Washpipe assembly
1. With the packing box upside down, assemble the
packing seals and spacers into the packing box
using care to line up the upper spacer slot with the
dowel pin.
2. Hand pack all seals with multipurpose lithium-based
outside diameter of the spacers.
3. Install the socket head dog nose screw, ensuring
that the screw nose is fully engaged in the groove
of the lower spacer.
4. Install the grease fitting and turn the packing box
upright.
5. Install the wash pipe into the packing box assembly
(slotted end up).
6. Install the wash pipe nut onto the wash pipe.
7. Grease the packing seal and install into the holding
ring using care not to grease the outside diameter
of the holding ring.
8. Install the packing seal and holding ring over the
slotted 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 reverse
order of the
above procedure. Refer to the Washpipe Assembly
Guide, P/N 128844.
TOP DRIVE
Training Manual
Drilling Motor
Section 1 - Introduction
Varco has used two different types of Electrical DC motors on their DC Top Drive
range 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 this
motor had been previously used on a Locomotive. This Top Drive went to work on
board the Sedco 201 rig in the Arabian Gulf on 1st April 1982. Initially the EMD
motor was preferred, but as to production demands etc. Varco decided to utilize a
second company (GE) in 1983, this then gave the option of utilizing either a Shunt or
Series type motor as opposed to EMD who only supplied a Series type motor.
The main operating difference between the Series and the Shunt type motors
is the output Torque and Speed control. Where the Series motor has a slightly
greater Output Torque, the Shunt motor gives greater speed control with the ability
to also alter the Field current with an Active Field Supply and thus get greater speed
control. This is one of the main reasons why a Shunt motor is more commonly
specified as opposed to a Series motor on Top Drive applications.
In 1989 GE introduced their new High Torque motors, this motor was able to
increase the Top Drive torque output, this is now used as standard when a new
motor is obtained from GE.
The charts below show examples of the differences between Shunt and Series
motors, and between Standard Torque and High Torque motors for continuous
drilling maximum Top Drive output Torques.
Shunt @ 57A
TDS-3
TDS-4(Low gear)
TDS-4(High gear)
TDS-5
Series
TDS-3
TDS-4(Low gear)
TDS-4(High gear)
TDS-5
The above picture shows the EMD Series motor that was used in the construction of
the First Top Drive. The commutator and shaft were removed and machined to fit
the requirements of the Top Drive gearbox.
P/N
75989-1
75989-2
P/N
P/N
IDS
GE752IDS Shunt wound high torque motor
Cable size 646 MCM
86542-1
87966
PN
103609
P/N
77029
EMD
TDS - 3
M89VTS Series wound standard torque motor
Cable size 444 MCM
DC Motor Connectors
GE Motor connectors (TDS 3,4,5 +6)
GE Motor Connectors (IDS Integrated J/B)
EMD Motor connectors (TDS 3)
P/N 79826
P/N 79826 * 1
P/N 99580 * 2
P/N 79835
Above is a standard torque motor, with 4 cooling ports on the lower face with bolt on
cooling ducting as used on TDS 3 and TDS 5 applications.
Above is a high torque motor with 4 cooling ports on lower face plus 6
circumferential slots in the main end cover.
Megger Reading
This should give a reading somewhere in the region from 500M Ohms to 50M
Ohms. When new this should be expected to be reasonably high. The lowest
reading that the motor should be operated at is 0.5M Ohms, once the motor is
electrically energized, this should rise. If the megger reading is lower than 0.5M
Ohms, the motor should be heated up before use, as most SCR systems will fault
below this level and there is also a possibility of damage to the motor.
10
Training Manual
PINION GEAR
INSTALLATION
Training Manual
Training Manual
Current date
e
4-70
11. Heat the pinion gear to 360 - 385F (182 - 196C) for three
hours in an oven. After heating for three hours, remove the
pinion 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 place
until the adjusting screw butts against the motor shaft.
14. Wait 2-3 minutes and back off the nuts holding the fixture in
place. There may be some noise as the pinion gear cools.
15. The pinion creeps up the shaft as it cools to the required
position of 0.085 0.005 in. advancement.
16. When the pinion is fully cooled, fit the fixture and check final
advancement.
17. Complete the required documentation recording pinion
advancement.
4-71
TOP DRIVE
Training Manual
Gearbox
TOP DRIVE
Training Manual
Motor Removal
Training Manual
Once the unit has been disassembled, inspect the assemblies for
any wear or damage that may be critical, as follows:
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. Some small surface pitting is to be expected
and is not cause for replacing the gear set.
2. Bearings: Clean thoroughly in solvent, then rotate and listen
for 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 and
retaining threads.
5. Seals: Always replace seals and gaskets when removed.
TDS-3H Maintenance
6. Main shaft housing: The bore for the upper bearing and the
pilot diameter for the lower gear case are critical. Any nicks or
gouges must be cleaned up prior to re-assembly.
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
the sealing surface.
9. Blower: Clean any accumulation of dust from the ducting,
then operate the unit and correct any interference between
the impeller and housing.
10. Air valve assembly: If any air-operated systems have been
malfunctioning, remove the appropriate valve and repair or
replace.
Reassemble the drilling motor and housing assembly by reversing
the steps in the above disassembly procedure. Replace all grease
seals and O-rings. Refer to the following torque chart for bolt
tightening guidelines.
Torque chart
Motor housing to motor
Upper gear case to housing assembly
Bull gear to hub
Lower gear case to main body
Rotating head to lower gear case
Brake adapter ring to motor
Brake to brake adapter plate
Brake drum to hub
Brake cover to brake
Upper seal retainer to motor housing
1750 ft lb.
1100 ft lb
580 ft lb
250 ft lb
250 ft lb
250 ft lb
50 ft lb
250 ft lb
50 ft lb
75 ft lb
(2373 N.m)
(1492 N.m)
(786 N.m)
(339 N.m)
(339 N.m)
(339 N.m)
(68 N.m)
(339 N.m)
(68 N.m)
(102 N.m)
TDS-3H Maintenance
Training Manual
Gooseneck
Main
Body
Air
Brake
Motor
Support
Bonnet
Bull
Gear
D.C.
Drilling
Motor
Pinion
Gear
Drive
Stem
Motor
Alignment
Cylinder
(Ref.)
Lower
Gear
Case
TDS-3S Maintenance
Training Manual
TDS3 Maintenance
Training Manual
Disassembly/assembly of drilling
motor 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 the
lower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to the
bearing surfaces or wear sleeves. Do not remove the gear from
the 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 magnetic
pickup and brake cover.
9. Remove the brake for service.
Refer to the GE Electric Motor Manual included as a separate book
in this manual for procedures to remove the pinion or hub on the
armature shaft, or to service the motor itself.
Once the unit has been disassembled, inspect the following
assemblies 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 the
gear set.
2. Bearings: Clean thoroughly in solvent, then rotate and listen
for any roughness during rotation.
3. Main shaft: Check splines and tool joints for wear. Replace
the shaft if spline wear exceeds 0.090".
4. Main shaft: Check fit to bull gear, wear sleeve surfaces and
retaining threads.
5. Seals: Always replace seals and gaskets when removed.
6. Main shaft housing: The bore for the upper bearing and the pilot
diameter for the lower gearcase are critical. Clean up any nicks or
gouges 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 the
sealing surface.
TDS3 Maintenance
Training Manual
TDS3 Maintenance
Training Manual
Gooseneck
Main
Body
Air
Brake
Motor
Support
Bonnet
Bull
Gear
D.C.
Drilling
Motor
Pinion
Gear
Drive
Stem
Motor
Alignment
Cylinder
(Ref.)
Lower
Gear
Case
TDS-3S Maintenance
Training Manual
TDS-4H Maintenance
Training Manual
TDS-4H Maintenance
Training Manual
TDS-4H Maintenance
Training Manual
Once the unit has been disassembled, inspect the assemblies for
any wear or damage that may be critical, as follows:
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. Some small surface pitting is to be expected
and is not cause for replacing the gear set.
2. Bearings: Clean thoroughly in solvent, then rotate and listen
for any roughness during rotation.
3. Main shaft: Check splines and tool joints for wear. Replace
the shaft if spline wear exceeds 0.090".
4. Main shaft: Check fit to bull gear, wear sleeve surfaces and
retaining threads.
5. Seals: Always replace seals and gaskets when removed.
6. Main shaft housing: The bore for the upper bearing and the
pilot diameter for the lower gear case are critical. Any nicks or
gouges must be cleaned up 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
the sealing surface.
9. Blower: Clean any accumulation of dust from the ducting,
then operate the unit and correct any interference between
the impeller and housing.
10. Air valve assembly: If any air-operated systems have been
malfunctioning, remove the appropriate valve and repair or
replace.
TDS-4H Maintenance
Training Manual
Training Manual
Disassembly/assembly of drilling
motor and motor support bonnet
1. Remove the upper bearing cover and grease seal (Figure 20).
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 the
lower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear sleeves. Do not remove the gear from
the 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 magnetic
pickup and brake cover.
9. Remove the brake for service.
TDS-4S Maintenance
Training Manual
Main
Body
Air
Brake
Low
Gear
Assembly
D.C.
Drilling
Motor
Bull
Gear
High
Gear
Assembly
Pinion
Gear
Manual
Shifter
Input
Geneva
Mechanism
Shaft
HI
LO
Oil
Level
Sight Glass
Motor
Pinion
Seal
Lower
Gear
Case
Motor
Alignment
Cylinder
Gear
Selection
Indicator
TDS-4S Maintenance
Training Manual
TDS-4S Maintenance
Training Manual
Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. Replace all grease
seals and O-rings, and refer to the following torque chart for bolt
tightening guidelines.
Torque Chart
Motor support/bonnet to main body
Main body to motor bonnet
Bull gear to hub
Lower gearcase to main body
Rotating head to lower gearcase
Brake adapter ring to motor
Brake to brake adapter plate
Brake drum to hub
Brake cover to brake
TDS-4S Maintenance
1100 ft lb
1100 ft lb
580 ft lb
250 ft lb
250 ft lb
250 ft lb
50 ft lb
250 ft lb
50 ft lb
TOP DRIVE
Training Manual
Gearbox Lubrication
TOP DRIVE
Training Manual
Rotating Head
Training Manual
Rotating head
The rotating head allows transferring pneumatic and hydraulic
pressure from stationary ports on the TDS drilling motor housing
to rotating ports on the rotating head (Figure 9). It features two
hydraulic passages, three pneumatic passages, and two spare passages 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 solenoid
valves to the stationary flange. The fluids travel from the flange to
the swivel block via sealed rotating passages.
Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the 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 counterbalance manifold. The rod end of the cylinder connects to a cam
follower assembly that tracks the cam mounted to the swivel
block.
TDS-Rotating Head
Training Manual
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
TDS-Rotating Head
Training Manuale
13. Push the cam follower away from the rotating block cam.
14. Remove the safety wire from the ten hex-head screws
attaching 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
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
Training Manual
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block 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
rotating block.
7. Attach the return cylinder rod to the clevis with the clevis pin
and install the slotted hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book of this
manual.
Gearcase
Seals
Stationary Flange
Cam Follower
Return Cylinder
Clevis (2)
Hex Nut (2)
Cotter
Pin (2)
Cam Follower
Return
Cylinder
Return Cylinder
Clevis Pin (2)
Retainer Ring
Training Manual
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
Training Manual
Disassembly
Training Manual
Cam Assembly
Locking Handle
Return Cylinder
Return
Cylinder
Clevis Pin
Return
Cylinder
Rod End Detail
Hex Nut
CAM
Cotter Pin
,,
Cylinder Clevis
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
Excluder
Cap
Detail C
Retainer Ring
Glyd Ring (8)
Ball Bearing
Excluder Cap
Gasket
Cam
Ball Bearing
C
Stationary Flange
Bull Gear
Lip Seal
Training Manual
6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating
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 head rests
on the stand.
9. Remove the flange nuts and lift the block, leaving the rotating
head on the stand.
10. Remove the quick disconnect fittings from the rotating block
hydraulic 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 attaching 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 and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the rotating block.
3. Using a tugger or other support, carefully mate the rotating
block 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 rotating block.
TDS-650 Ton Rotating Head
TOP DRIVE
Training Manual
Link Tilt
Current date
1. Disconnect the air hose from the rotating head rotating block
to the link tilt assembly.
2. Support the link tilt and remove the two upper and two lower
screws attaching the link tilt to the link adapter.
3. Lower the link tilt to the floor with the air actuator to be
replaced facing up.
4. Remove the cotter key and pin from one end of chain
connecting the two sealing plates.
5. Remove the safety wire from the four hex-head cap screws
holding the air actuator sealing plate to the link tilt base or
lever and remove the screws.
6. Lift the lever or base off the air actuator sealing plate, and
rotate it 180 on the link tilt pivot pin and lay down.
7. Remove the 18 nuts and washers holding the sealing plate to
the air actuator and remove the plate.
8. Using a pry bar or screwdriver, pry the air actuator away from
the screws attaching the actuator to the hanger plate and
remove the screws using a hex wrench.
9. Remove and discard the air actuator.
10. Remove any burrs or gouges on sealing surfaces of the hanger
and sealing plates.
4-62
Lever Weldment
Pivot Pin
Sealing Plate (2)
Nuts, Lock
Washers (18)
Pressure
Regulator
Air Actuator
Base
Hanger Plate
Sealing Plate
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Buttonhead
Capscrew (18)
4-63
Current date
Assembly
The air actuator has aluminum neck bead rings on both sealing
surfaces. These beads must be compressed equally to ensure a good air
seal. This requires more than one tightening pass. Over-torquing may
cause 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 threads
with locktite and fasten with the lockwashers and nuts
provided.
6. Torque the nuts to the sealing plate at 80 ft lb (see caution
above).
7. Lift and rotate the link tilt lever or base to line up with the air
actuator sealing plate. Attach with the four hex-head cap
screws 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 in
the Installation and Commissioning book.
4-64
TOP DRIVE
Training Manual
Torque Arrestors
Torque Arrestors
The Link Adapter (Solid body Elevator), link tilt, Link
Bails and Pipe elevators are supported on components
called Torque Arrestors. They are pinned to the rotating
Head mounted on the bottom of the gear case. The torque
arrestors contain compression springs that keeps the Solid
body Elevator, link adapter, Link Bails and Pipe elevators
above the load collar on the main shaft. The springs do
provide a pre-load sufficient to support a stand of drill
pipe in the full full up position. When hoisting these
torque arrestor springs will be compressed by the
hoisting load allowing the link adapter ( solid body
elevator) to be pulled down onto the load collar
transferring the load to the main shaft. Two torque
arrestors are used in the 500 ton version TDS and four
torque arrestors are used in the 650/750 ton version TDS
Caution:
Under No circumstances should Torque
Arrestors be disassembled in the field as the
contain powerful springs under compression
and could cause serious injury and damage if
released inadvertently.
TOP DRIVE
Training Manual
IBOP
A,
During rough drilling conditions especially surface hole, Vertical vibration of the drill
string can cause the upper ibop actuator shell to hammer on the the ibop crank
assembly damaging the crank arms and the bearings
The IBOP Control circuit prevents excessive damage to the actuator and bearings
by holding the shell down with a force of 500 lbs in the open position. There is an
reducing valve on the circuit which is set to 30 psi. The control circuit has a 30
second timer,( controlled by the PLC) when the open solenoid is operated it stays
fully open for 30 seconds then shuts of and the pressure is reduced to 30psi from a
prv on the close circuit.
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
Actuator Cylinders
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
Actuator Cylinders
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
Actuator Cylinders
Safety Valve
(IBOP)
Service Manual
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in 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 operated
at any height in the derrick from the drillers console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
V
a
r
c
o
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
OPE
CL SD
Back-up
Rings
O-Ring
O-Ring
Ball
Sleeve
Seal Ring
Stabilizer
Ring
Crank
Grease/
Mud Seal
Seat
Wave
Spring
Back-up Ring
O-Ring
Thread
Protector
Feb. 2, 1994
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 linedeliminating bolted-on external guides.
The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Feb. 2, 1994
Feb. 2, 1994
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.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, 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).
Feb. 2, 1994
I.D.
Connection
O.D.
Torque (ft-lb)
(min.)
(max.)
Mainshaft to Upper
IBOP Safety Valve*
3"
7-3/4
60,000
70,000
3"
7-3/4
50,000
70,000
3"
7-3/8
46,000
64,000
Crossover Sub to
Lower IBOP Safety
Valve
3"
7-3/8
46,000
60,000
Mainshaft to Upper
IBOP Safety
Valve**
3"
83,000
91,000
3"
75,000
91,000
3"
8-5/8
66,000
85,000
Crossover Sub to
Lower IBOP Valve
3"
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.
b.
c.
d.
e.
f.
Carefully grind off any raised tong marks on the O.D. of the safety valves.
Open the valve exactly halfway (45 degree rotation of the actuator).
Orient the levers on the crank assemblies horizontally as shown.
Slide the shell up onto the valve with the actuator arm groove on the bottom.
Hold the shell in position relative to the valve operating sockets.
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 screws
and 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.
10
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 wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire 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 third
roller 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.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for 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.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Groove
Lock Tabs
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open
Position
Closed
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Roller
Assembly (3)
Crank Assembly
Retaining Screw
Crank
Assembly
Slot
Roller
Assembly
(3)
Actuator
Shell
Crank*
Roller
Assembly (3)
Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove
Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Closed
Position
Open
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the drillers 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. This
upward 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.
16
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 fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing 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.
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in 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 of
pressure. 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 an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the 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.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT
19
C
L
BALL
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
GREASE PORT
Feb. 2, 1994
PRESSURE PLUG
WAVE SPRING
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
Feb. 2, 1994
VALVE
BODY
PRESSURE PLUG
GREASE PORT
20
C
L
BALL
Figure 11. Lubricating a Typical Lower IBOP
FIXED SEAT
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 crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C.
ASTM A-275
ASTM E-709
21
Feb. 2, 1994
Recommended
Inspection Areas
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing 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 other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Adapter
Cylinder
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2)
*1 Inch
Cylinder
in OPEN
Position
Rod
End
Actuator
Arm
5/8 max 3/8 min
Cylinder
Gland
Upper IBOP
Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
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
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13
17
19
10
18
14
15
20
16
8
2X 4
3
9
12
11
12
7/8" Hex
25
Feb. 2, 1994
Parts List
ITEM
QYT. / KIT
DESCRIPTION
PART NUMBERS
90939-5
RETAINING RING
89141-1
O'RING
90441-9
BACK-UP RING
90441-10
90939-5
90939-5
POLYSEAL
96439
BACK-UP RING
89141-13
CROWN SEAL
89141-8
10
SLEEVE
11
O'RING
89141-11
12
BACKING RING
89141-12
13
14
WAVE SPRING
89141-9
15
BODY
16
O'RING
17
NYLON PLUG
18
19
PLUG
20
89141-3
93806-11
96438
Feb. 2, 1994
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Nut Wrench for DSV Models
Varco Part No. 89141-18
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or
clamp to hold the valve
securely (Figure 16).
Figure 16
2. Engage the seat puller in
the inside groove of the
lower seat (Figure 17).
3. Using the load bar across
the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).
Figure 17
28
Feb. 2, 1994
Figure 18
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat
counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the
upper seat (Figure 20).
Figure 20
29
Feb. 2, 1994
Figure 21
12. From the outside of the
valve, push the crank into
the valve body and remove
them (Figure 22).
Figure 22
13. Remove the pulling tool
from the lower seat.
14. Insert the pulling tool from
the opposite end of the
valve and engage the
groove on the I.D. of the
lower seat (Figure 23).
Figure 23
30
Feb. 2, 1994
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
Figure 26
Figure 27
32
Feb. 2, 1994
Figure 28
7. Inspect the ball valve for
corrosion, pitting and
gaulling (Figure 29).
Figure 29
33
Feb. 2, 1994
Figure 30
9. Make sure the snap ring is
not broken or damaged
(Figure 31).
Figure 31
34
Feb. 2, 1994
Figure 32
13. Thoroughly lubricate the
valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the
pulling tool until it seats on
the spring surface of the
lower seat (Figure 33).
Figure 33
Feb. 2, 1994
Figure 34
19. Apply a generous coat of
grease to the outside of the
sleeve and crank.
20. From the inside of the valve
body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).
Figure 35
21. Make sure the crank moves
90 to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the
Closed position.
23. Apply a generous coat of
grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).
Figure 36
36
Feb. 2, 1994
Figure 37
Figure 38
37
Feb. 2, 1994
Figure 39
36. Install the 1/4" N.P.T. plug
into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.
38
Feb. 2, 1994
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP
PART NO.
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
94769-500
94769-502
94769-501
STD
H2S
NAM
Upper Valve-PH60
6 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94770-500
94770-502
94770-501
STD
H2S
NAM
Upper Valve-PH60
7 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94099-500
94099-502
94099-501
STD
H2S
NAM
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94100-500
94100-502
94100-501
STD
H2S
NAM
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90815
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90814
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90813
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90812
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
94206-500
94206-501
94206-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94205-500
94205-501
94205-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94204-500
94204-501
94204-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
40
Feb. 2, 1994
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
94203-500
94203-501
94203-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
91138
-
STD
H2S
NAM
95384
-
91137-SP
-
91137-1
-
89451-501
89491-503
86434
STD
H2S
NAM
Lower Valve
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-1
-
90939-5
89453-15
89452-501
89492-502
-
STD
H2S
NAM
Lower Valve-Stepped
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90811
-
STD
H2S
NAM
Lower Valve
7 5/8 Pin X 7 5/8 Box
93807
-
93807-1
-
90939-5
-
91138
-
STD
H2S
NAM
94385
-
91137-SP
-
91137-1
-
105629
-
STD
H2S
NAM
90939-5
-
103220
-
STD
H2S
NAM
90939-2
-
90939-1
-
90939-5
-
98977-500
98977-502
98977-501
STD
H2S
NAM
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
99461-500
STD
H2S
NAM
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
41
Feb. 2, 1994
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46
TOP DRIVE
Training Manual
Pipe Handler
1.
Connect a pup joint or a joint of drill pipe to the saver sub and
make up hand tight. Be sure to use the correct thread
compound when making up.
Back out the recycle valve until you have the cylinders
recycling at 7-9 second speed then tighten the lock nut.
Back out the clamp sequence valve until the clamp cylinder
starts to move then an additional of a turn.
10 Back out the torque valve until the torque cylinders start to
move the an additional of a turn.
11 Release the torque wrench operating button on the drillers
console and observe the toque wrench function it should start
to unclamp then drop and recycle. If the torque wrench drops
before unclamping adjust the lift/lower valve in a of a turn
and back out the clamp sequence valve an additional turn.
Supply Flow
Return Flow
Air - Piloted
Hydraulic Valve
1
Lift
Lift
1200 PSI
Sequence
1500 PSI
Sequence
1200 PSI
Sequence
Clamp
1500 PSI
Sequence
Torque
Clamp
Torque
3
Pressure
Adjust
Pressure
Adjust
TDS-TW Operation
Quick Disconnects
Hydraulic Supply
Air Supply
Drill/Spin /Torque switch is in Drill position
Throttle is in the off position
Electrical Supply, (Solenoids, Wiring, VDC Switches)
Frame
Mounting
Shaft
Safety Valve
Actuating
Cylinders (2)
Vertical
Positing
Cylinder
Safety Valve
Actuating
Arm (2)
Torque
Tube
Stabilizer
Stop Tube
Hanging Height
Adjustment Shim
Torque
Tube
Guard
Body
Torque
Cylinder (2)
Stabbing
Guide
Clamping
Jaws (2)
Clamping
Cylinder
Piston
Control
Manifold
The torque cylinder rod ends are threaded into the rods with
lock-tite and cross pinned.
Qty.
3
2
2
P/N
72219
72220
72221
Description
Piston seal
Rod seal
Rod wiper
Disassembly
1. Remove the pins from the torque wrench guard and remove
the guard.
2. Remove the slotted hex nut and cotter pin attaching the two
halves of the stabbing guide together at the front and swing
the guides out to each side.
3. Vent the clamping cylinder as follows: disconnect the
hydraulic lines to the clamp port and front unclamp port on
the clamp body cylinder at the torque wrench manifold clamp
and unclamp ports.
4. Remove the jaw pins from the rear clamping jaw and remove
the jaw.
5. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
6. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
7. Remove the pins holding the clamp body to the clamp clevis
and remove the clamp clevis. Be sure to remove the spacer
from the piston rod slot.
8. Push in the cylinder gland from the rear cylinder head
retainer ring and remove the ring with a screwdriver.
9. Attach the sliding hammer to the rear piston rod and carefully
pull 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 piston
from 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 the
clamp 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 clamp
cylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and
lubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with the
two jaw spacer screws holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod
appears beyond the front cylinder bore.
5. Install new piston seal in rear piston groove and lubricate with
hydraulic fluid.
6. Insert rear piston into the clamp cylinder body with the two
screws holes on the rod oriented to the horizontal position.
57
TORQUE
TUBE
V
a
r
c
o
TORQUE
CYLINDERS (2)
58
BODY
CLAMPING
JAWS (2)
CLAMP CYLINDER
BODY
STABBING
GUIDE
CLAMP
CYLINDER
PISTON
59
MOUNTING
SHAFT
FRAME
SAFETY
VALVE
ACTUATING
CYLINDERS (2)
VERTICAL
POSITIONG
CYLINDER
HANGING
HEIGHT
ADJUSTMENT
GUARD
60
61
Reassembly is accomplished in the reverse order of the above procedure. Pay close attention to the following points:
1. Replace all seals.
2. Take great care when installing the clamping piston and
gland. If they are not closely aligned with the bore, they may
become 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 with
locktite and cross pinned.
Replacing the torque wrench clamping piston seal
The following procedures require that the torque wrench be removed from the pipehandler.
Replacing the front and rear piston seal
P/N
72219
72220
72221
Description
Piston seal
Rod seal
Rod wiper
Disassembly
1. Remove the slotted hex nut and cotter pin attaching the two
halves of the stabbing guide together at the front and swing
the guides out to each side.
2. Vent the clamping cylinder as follows: disconnect the hydraulic lines to the clamp port and front unclamp port on the
clamp body cylinder at the torque wrench manifold clamp
and unclamp ports.
3. Remove the jaw pins from the rear clamping jaw and remove
the jaw.
62
4. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
5. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
6. Remove the pins holding the clamp body to the clamp clevis
and remove the clamp clevis. Be sure to remove the spacer
from the piston rod slot.
7. Push in the cylinder gland from the rear cylinder head retainer ring and remove the ring with a screwdriver.
8. Attach the sliding hammer to the rear piston rod and carefully
pull 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 piston
from 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 the
clamp 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 cylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and lubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with the
two jaw spacer screws holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod appears beyond the front cylinder bore.
5. Install new piston seal in rear piston groove and lubricate with
hydraulic fluid.
6. Insert rear piston into the clamp cylinder body with the two
screws holes on the rod oriented to the horizontal position.
7. Gently tap piston into place until there is enough space between the piston face and retaining ring groove to insert
cylinder gland and retainer ring.
TDS-4S Maintenance and troubleshooting
63
8. Install rod seal and rod wiper in inside grooves of the cylinder
gland.
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 rear cylinder 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 clamp
body using the two clevis pins and cotter pins.
14. Attach the rear clamping jaw spacer to the front piston rod
using the spacer and two hex head cap screws and flat washers. Tighten firmly and lockwire.
15. Attach the clamping jaw with the two jaw pins.
16 Swing the stabbing guide back into position and attach with
the slotted nut and cotter pin.
17. Reconnect the hydraulic lines from the clamp body cylinder
clamp port and front unclamp port at the torque wrench
manifold clamp and unclamp ports.
18. Reinstall and perform Torque Wrench Adjustment Procedure.
64
TOP DRIVE
Training Manual
Lubrication
Chapter 2
Lubrication
Gearbox
Check the oil daily. With the motor off, check to see that the oil
level is at the middle of the sight glass located on the side of the
main body. Drain and refill the gearbox every 1,500 operating
hours or three months, whichever occurs first (Refer to Oil
capacities below).
23
24
25
Oil capacity
The TDS holds approximately 10-20 gallons of oil, but oil
capacities vary according to the type of cooling systems, etc.
installed. Always fill the transmission to the middle of the sight
glass. Use the following procedure to fill the transmission for the
first time on a new top drive:
1. Fill the gearbox to the top of the sight glass (approximately 1020 gallons).
2. Operate the top drive 10-15 minutes and check the sight
glass.
3. The oil level should be near the middle of the sight glass. If
the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass. If the
oil level is at, or above the middle of the sight glass, do not add
any additional oil to the gear case.
After installation and initial operation of the top drive, always fill
the transmission to the middle of the sight glass.
When draining oil from the drain plug at the bottom of the gear
case, only 5-6 gallons of oil at the bottom of the gear case actually
drains. Oil remains in the rotating head cavity (approximately 1-2
gallons), the oil lube/pump/cooler system (approximately 1-2
gallons), and the wetted surfaces inside the motor housing
assembly (approximately 2-3 gallons). Removing the suction hose
from the cover plate below the pinion shaft allows more oil to
drain and also removes sediment that collects there.
27
28
Grease
Fittings
Grease
Fitting
Grease
Fittings
29
650 Ton
Solid Body Elevator
2 Grease Fittings on front,
2 Grease Fittings opposite.
(4 places total)
30
Grease Fittings
2 places as shown
and 2 places
opposite side.
(4 Total)
31
32
33
Open
Position
Closed
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
34
35
Lubricate the wash pipe packing daily with the mud pump off.
Check the filter gauge on the pressure filter daily with the
hydraulic power on to determine the condition of the filter
element. Replace the element when a bypass condition is
indicated.
5
2
1
Lubrication
Manifold (4)
4
3
37
38
Lubrication schedule
Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Each trip
Each trip
Each trip
Each trip
Each trip
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
750 hrs/90 days
1500 hrs/6 mos.
Monthly
Monthly
3 months
3 months
3 months
Lubricant Number
Location
code*
of points
Torque wrench
1
6
Gearbox oil (check level)
2
1
Rotating head
1
5
Safety valve actuator cranks
1
2
Hydraulic pressure filter
4
Upper quill shaft bearings
1
1
BNC drill pipe elevator
1
7
PS-16 power slip
1
8
RBS
1
17
RBS stabbing head
1
10
Guide dolly rollers
1
20
Gearbox (shift gears)
Dolly motor trunnions
1
2
Air filter/regulator/lubricator
IBOP actuator arms
1
6
Link adapter
1
4
Elevator support
1
7
Master bushing wear guide
1
4
Link tilt (check condition)
Main shaft spline
1
1
GE motor pinion bearing
3
GE motor commutator bearing
3
Motor frame/dolly hinges
1
4
Cooling system cleaning
AC blower motor
1
2
Change gearbox oil
2
1
Gear oil filter/suction strainer
1
39
Lubricant specifications
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of
the gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA extra pressure rating, and a
minimum viscosity of 100 SUS at operating temperature.
Varco top drives also operate under a wide variety of
temperatures. Select lubrication for the TDS based on the
minimum ambient temperature to be expected before the next oil
change. Under all but the most severe operating conditions, Varco
recommends changing the oil every three months. Introducing an
oil viscosity greater than required by the ambient temperature
can:
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 no
exception. The TDS transmission lubrication system is limited to
pumping oils of a maximum of 9,000 SUS viscosity.
Varco recommends measuring the oil temperature with a contact
thermometer. Measure on the pump discharge fitting on the
TDS.
The following tables will aid in your lubricant selection and keep
your TDS-S transmission operating properly:
40
Minimum Ambient
Temperature
F
(C)
Below 20
(-6)
20-60
(-616)
45-85
(730)
Above 70
(21)
41
42
Chevron
Exxon
Lidok EP1
Avi-Motive W
Below -20C
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
2
-
Mobil
Shell
Statoil
Texaco
Total
Union
NGL1
AGMA
ISO Viscosity
Grade
-
Unoba EP1
Multis EP1
Multifak EP1
Uniway EP1N
Alvania EP1
Mobilux EP1
MP grease
Castrol
Gulf
Above -20
Ambient
temperature
range
Above 21C
Carter EP 150
Meropa 150
Loadway EP150
Omala 150
MobilGear 629
EP Lube HD150
Spartan EP150
NL Gear 150
Alpha -150
Carter EP 68
Meropa 68
Statoil
Omala 68
MobilGear 626
EP Lube HD68
Spartan EP68
NL Gear 68
Alpha LS-68
-6 to 16C
320
6EP
150
4EP
I66
2EP
Carter EP 320
Meropa 320
Loadway EP320
Omala 320
MobilGear 632
EP Lube HD320
Alpha LS-320
Alpha LS-320
Alpha LS-320
7 to 30C
Gear Oil
Cyprina RA
All
temperatures
Motor Grease
Tellus 32
DTE 24
Harmony 32AW
Nuto H32
AW Hyd oil 32
Hyspin AWS-32
-15 to 75C
45
Unax AW46
Azolla ZS 46
32
Unax AW32
Azolla ZS 32
Tellus 46
DTE 25
Harmony 46AW
Nuto H46
AW Hyd oil 46
Hyspin AWS-46
-10 to 85C
Hydraulic Oil
Weekly
Rotating Head
Positioning Roller
Apply two pumps
Weekly
Weekly
500 Ton Rotating Head
Apply two pumps per grease fitting
(4 places)
Weekly
Support Shaft
Apply general purpose grease
at the contact point between
the shaft and frame
Weekly
Weekly
Pneumatic
Link Tilt
Check condition of the air
bladder, the pivot pin and the stops
Points Frequency
Weekly
Weekly
Weekly
Weekly
Daily
Daily
Weekly
Weekly
Weekly
Weekly
Weekly
Daily
Weekly
Clamp Body
Weekly
Support Shaft
Weekly
Weekly
Recommended Lubricants
Manufacturer
Daily
IBOP
Actuator Cranks
Apply one pump per grease fitting
(2 places, 1 each side)
Replace plug
before operating
Above -20 C
(Above -4F)
Weekly
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Mobil
Mobilux EP1
Mobilux EP2
Daily
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
Weekly
Clamp Body
Apply two pumps per grease fitting
(6 places, 3 each side)
N/R
N/R
Gulf
Viscosity Index
NGLI
AGMA
Weekly
IBOP Actuator
Cam Followers
Apply two pumps per grease fitting
(2 places, one each side)
Weekly
(Below -4F)
Exxon
Link Adapter
Wear Shoe
Apply two pumps per grease fitting
(4 places)
Below -20 C
Chevron
Daily
Weekly
Castrol
500 Ton
Link Adapter
Apply two pumps per grease fitting
(2 places)
Clamp Body
Cylinder Trunnion
Apply two pumps
per grease fitting
(4 places, 2 each side)
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly
Elevator Link Eyes
Pipe Dope
Weekly
Daily
Weekly
Varco P/N
126732
Weekly
Weekly
Weekly
650/750 Ton
Rotating Head
Apply two pumps
per grease fitting
(5 places)
Weekly
PH-60
Support Shaft
Apply general purpose
grease at the contact
point between
the shaft and frame
Weekly
Weekly
650/750 Ton
Link Adapter
Apply two pumps
per grease fitting
(4 places)
Points Frequency
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Daily
Daily
Weekly
Weekly
Daily
Weekly
Weekly
Daily
Weekly
Clamp Body
Weekly
Daily
Link Adapter Wear Shoe
Apply two pumps per grease fitting
(4 places)
Weekly
Weekly
Weekly
Replace plug
before operating
Recommended Lubricants
Below -20 C
Above -20 C
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Daily
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
Weekly
N/R
N/R
Clamp Body
Apply two pumps per grease fitting
(6 places, 3 each side)
Exxon
Gulf
Weekly
Clamp Body
Cylinder
Trunnion
Apply two pumps
per grease fitting
(4 places, 2 each side)
Weekly
(Below -4F)
Chevron
Link Spreader
(if equipped)
Apply two pumps
per grease fitting
(6 places, 3 each side)
Castrol
Upper IBOP
Actuator
Cam Followers
Apply two pumps
per grease fitting
(2 places, 1 each side)
Weekly
Support Shaft
Manufacturer
Weekly
(Above -4F)
Viscosity Index
NGLI
AGMA
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly
Daily
Weekly
Weekly
Varco P/N
126732
Weekly
Hydraulic Link Tilt
Apply
two pumps per
grease fitting
(8 places)
Weekly
Rotating Head
Positioning Roller
Apply two pumps
Weekly
Weekly
PH-85 Support Shaft
Apply general purpose grease
at the contact point between
the shaft and frame
Weekly
Weekly
Pneumatic
Link Tilt
Check condition of the air
bladder, the pivot pin and the stops
500 Ton
Link Adapter
Apply two pumps
per grease fitting
(2 places)
Points Frequency
Weekly
Weekly
Daily
Daily
Weekly
IBOP
Actuator Cranks
Apply one pump per grease fitting
(2 places, 1 each side)
Link Adapter
Wear Shoe
Apply two pumps
per grease fitting
(4 places)
Weekly
Daily
Daily
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Daily
IBOP Actuator
Cam Followers
Apply two pumps
per grease fitting
(2 places, one each side)
Weekly
Clamp Body
Weekly
Support Shaft
Weekly
Weekly
Replace plug
before operating
Weekly
Weekly
Recommended Lubricants
Manufacturer
Link Spreader
(if equipped)
Apply two pumps
per grease fitting
(4 places, 2 each side)
Above -20 C
(Below -4F)
(Above -4F)
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Daily
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
N/R
N/R
Castrol
Chevron
Exxon
Gulf
Weekly
Clamp Body
Cylinder Trunnion
Apply two pumps
per grease fitting
(4 places, 2 each side)
Viscosity Index
NGLI
AGMA
Weekly
Frequency
Clamp Body
Apply two pumps per grease fitting
(8 places, 4 each side)
Daily
Daily
Daily
Daily
Daily
Weekly
Weekly
Daily
Pipe Dope
Weekly
Varco P/N
126731
Weekly
Weekly
Weekly
650/750 Ton
Rotating Head
Apply two pumps
per grease fitting
(5 places)
Weekly
PH-85
Support Shaft
Apply general purpose
grease at the contact
point between
the shaft and frame
Weekly
Weekly
650/750 Ton
Link Adapter
Apply two pumps
per grease fitting
(4 places)
Points Frequency
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Daily
Daily
Weekly
Weekly
Weekly
Daily
Weekly
Daily
Weekly
Clamp Body
Weekly
Weekly
Weekly
Recommended Lubricants
Manufacturer
Upper IBOP
Actuator
Cam Followers
Apply two pumps
(2 places, 1 each side)
Daily
Link Adapter Wear Shoe
Apply two pumps per grease fitting
(4 places)
Weekly
Support Shaft
Weekly
Replace plug
before operating
Weekly
Link Spreader
(if equipped)
Apply two pumps
per grease fitting
(6 places, 3 each side)
Weekly
Clamp Body
Cylinder
Trunnion
Apply two pumps
per grease fitting
(4 places, 2 each side)
Above -20 C
(Below -4F)
(Above -4F)
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
Weekly
N/R
N/R
Clamp Body
Apply two pumps per grease fitting
(8 places, 4 each side)
Castrol
Chevron
Exxon
Gulf
Weekly
IBOP Actuator Arms
Apply two pumps per grease fitting
(4 places, 2 each side)
Daily
Torque Tube Clevis Pins
Apply two pumps per grease fitting
(2 places, 1 each side)
Viscosity Index
NGLI
AGMA
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly
Daily
Weekly
Weekly
Varco P/N
126731
TDS-4H Lubrication
and Maintenance Guide
For more detail see the
TDS-4H Service Manual
See the other side of this chart for the
TDS-4S Lubrication and Maintenance Guide
Monthly
Swing Guide Dolly Hinges
Apply two pumps per grease fitting
(4 places, 2 each hinge)
Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Weekly
Bail Pins
Apply two pumps per grease fitting
(2 places, 1 each side)
Weekly
Monthly
Motor Trunnions
Apply two pumps
per grease fitting
(2 places, 1 each side)
Weekly
Swing Guide Dolly
Apply two pumps
per grease fitting
(20 places, 5 each manifold,
if equipped)
Hydraulic
Filter
(Actual location
may vary)
Points Frequency
Bail Pins
Weekly
Upper Bearing
Weekly
Motor Trunnions
Monthly
Monthly
20
Weekly
20
Weekly
28
Weekly
Gear Oil
Filter
(Actual location
may vary)
See lubrication section of the TDS-4H service manual for lubrication of electric motors
Frequency
3 Months
3 Months
LO
Oil viscosity should be adjusted based on expected ambient conditions for next three months
Recommended Lubricants
Mfr.
Grease
Gear Oil
Monthly
Above -20C
N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
MP Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
(Below -4F)
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
(Above -4F)
-6 to 16C
(20 to 60F)
7 to 30C
(45 to 85F)
Above 21C
Viscosity Index
NGLI
AGMA
ISO
Viscosity
Grade
1
N/R
N/R
2
N/R
N/R
N/R
2EP
68
N/R
4EP
150
Motor Trunnions
Apply two pumps
per grease fitting
(2 places, 1 each side)
(Above 70F)
Alpha LS-68
Alpha LS-150
Alpha LS-320
NL Gear 68
NL Gear 150
NL Gear 320
Spartan EP68
Spartan EP150
Spartan EP320
EP Lube HD68
EP Lube HD150
EP Lube HD320
MobilGear 626
MobilGear 629
MobilGear 632
Omala 68
Omala 150
Omala 320
Loadway EP68
Loadway EP150
Loadway EP320
Meropa 68
Meropa 150
Meropa 320
Carter EP 68
Carter EP 150
Carter EP 320
Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
N/R
6EP
320
Weekly
Upper Bearing
Apply two pumps
per grease fitting
Refer to the
TDS-4H Service Manual
or the
Pipehandler Lubrication
and Maintenance Guide
for maintenance and
lubrication of the
Rotating Head
127052
TDS-4S Lubrication
and Maintenance Guide
For more detail see the
TDS-4S Service Manual
See the other side of this chart for the
TDS-4H Lubrication and Maintenance Guide
Description
Monthly
Swing Guide
Dolly Hinges
Apply two pumps
per grease fitting
(4 places, 2 each hinge)
Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Weekly
Upper Bonnet Seals
Apply one pump of
general purpose grease
Using hand pump only
Washpipe Assembly
Apply three pumps of
general purpose grease
at beginning of tour
Mud pumps OFF
Weekly
Daily
Monthly
Motor Trunnions
Apply two pumps
per grease fitting
(2 places, 1 each side)
Weekly
Swing Guide Dolly
Apply two pumps
per grease fitting
(20 places, 5 each manifold,
if equipped)
Hydraulic
Filter
(Actual location
may vary)
Points Frequency
Washpipe Assembly
Daily
Weekly
Bail Pins
Weekly
Motor Trunnions
Monthly
Monthly
20
Weekly
20
Weekly
28
Weekly
Gear Oil
Filter
(Actual location
may vary)
See lubrication section of the TDS-4S service manual for lubrication of electric motors
Frequency
3 Months
3 Months
LO
Oil viscosity should be adjusted based on expected ambient conditions for next three months
Recommended Lubricants
Mfr.
Grease
Gear Oil
Above -20C
N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
MP Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
(Below -4F)
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
(Above -4F)
-6 to 16C
(20 to 60F)
(45 to 85F)
Above 21C
(Above 70F)
Alpha LS-68
Alpha LS-150
Alpha LS-320
NL Gear 68
NL Gear 150
NL Gear 320
Spartan EP68
Spartan EP150
Spartan EP320
EP Lube HD68
EP Lube HD150
EP Lube HD320
MobilGear 626
MobilGear 629
MobilGear 632
Omala 68
Omala 150
Omala 320
Loadway EP68
Loadway EP150
Loadway EP320
Meropa 68
Meropa 150
Meropa 320
Carter EP 68
Carter EP 150
Carter EP 320
Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Viscosity Index
NGLI
AGMA
ISO
Viscosity
Grade
1
N/R
N/R
2
N/R
N/R
N/R
2EP
68
N/R
4EP
150
N/R
6EP
320
Weekly
Bail Pins
Apply two pumps
per grease fitting
(2 places, 1 each side)
Monthly
Refer to the
TDS-4S Service Manual
or the
Pipehandler Lubrication
and Maintenance Guide
for maintenance and
lubrication of the
Rotating Head
Gear Oil
Sight Gage
Check with Top Drive
OFF
Gear Oil Drain
and Sample Valve
Motor Trunnions
Apply two pumps
per grease fitting
(2 places, 1 each side)
Varco P/N
127052
Lubrication Schedule
Description
Lubricant
Packing Box
3" Bore
4" Bore
123290 &
123290-1000
123440 &
123440-750
Frequency
Each Tour
or
Twice Daily
Contents
Comments
123290-PK
(Standard)
Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123289 or 123289-TC)
123290-PK-1
(High Pressure)
Nitrile/Armide, Pressure
rated at 10,000 psi
(Use with Wash Pipe
123289-TC only)
Special Tools
Wash Pipe Wrench
O-Ring
51300-348-F
O-Ring
51300-359-F
Snap Ring
123562
Snap Ring
123634
Holding Ring
123288
Holding Ring
123437
Packing Seal
(5 per Set)
123292-2 or
123292-3
Packing Seal
(5 per Set)
123584-2 or
123584-3
Wash Pipe
Nut
123284
Wash Pipe
Nut
123431
Wash Pipe
123289
*123289-TC
Wash Pipe
123438
*123438-TC
* Tungsten Coated
* Tungsten Coated
3" Bore
Wash Pipe Wrench
30150084
Recommended for proper
tightening of the wash pipe
nut and packing box
Contents
Comments
123440-PK
(Standard)
Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123438 or 123438-TC)
123440-PK-1
(High Pressure)
Nitrile/Armide, Pressure
rated at 7,500 psi
(Use with Wash Pipe
123438-TC only)
Reassembly Procedure
Checklist
With the packing box upside down, assemble the packing seals and
spacers into the packing box using care to line-up the upper spacer
slot with the dowel pin
Hand pack all seals with multipurpose lithium-based or high
temperature moly-based grease using care not to grease the
outside diameter of the spacers
Install the socket head dog nose screw, ensuring that the screw nose
is fully engaged in the groove of the lower spacer
Packing Box
123563
Packing Box
123626
Install the grease fitting and turn the packing box upright
Install the wash pipe into the packing box assembly (slotted end up)
4" Bore
Wash Pipe Wrench
141481
Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564
Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564
Install the upper and lower o-rings using grease to hold them in place
Compress the assembly to the length of the wash pipe
Installation Procedure
Checklist
Install the wash pipe assembly on the Top Drive and hand tighten
the wash pipe nut and packing box (apply pipe dope to the threads)
Long-Arm
Allen Wrench
53303-14
Long-Arm
Allen Wrench
53303-14
Upper Spacer
123285
Upper Spacer
123434
Middle Spacer
123286
Middle Spacer
123435
Middle Spacer
123286
Middle Spacer
123435
Lower Spacer
123287
Lower Spacer
123436
O-Ring
51300-348-F
O-Ring
51300-359-F
Dowel
Pin
Slide the
wash pipe nut
and the packing box
together for installation
128844
Upper IBOP
Break-out Procedure
For more detail see the
PH-85 Pipehandler Service Manual
Step 1
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 on
PH-85 manifold, connect the 1/2" hose to the
TDS brake by disconnecting the existing brake
hose at the brake drum, and hook up rig air to
(A1) location on the intensifier assembly.
Step 2
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 valve
handle to horizontal
position and adjust air
pressure to 175 psi.
Step 3
A. Stab PH-85 over RTBS & lower it to line up with
top of yellow area.
B. Select "MAKE-UP" mode (reverse from normal).
C. Screw the PRV valve on PH-85 manifold all
the way in
D. Push "TORQUE WRENCH" button
on VDC. PH-85 will rise, clamp on
RTBS, and break out upper IBOP.
It will stroke back down
when the button is
released. Repeat until
IBOP is loose.
(Note: IBOP valve
should breakout @
approximately
2500 psi)
Step 4
A. Raise TDS/PH-85 until stabbing guide clears the
top of RTBS.
B. Place drive ring over RTBS
shoulder with square boss
engaged with drive ring.
RTBS
Intensifier
Assembly
Tie-up
Cable
Upper IBOP
Valve
PH-85
Lower
IBOP
Adjust Air
Pressure
To 175 Psi
Intensifier
Adjustment
Torque Tube
Saver
Sub
Drive Ring
Yellow
Area
RTBS
Intensifier
Assembly
RTBS (Rotary
Table Back-up
Structure)
Step 5
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 shaft
E. Raise TDS/PH-85.
F. Screw in lifting plug
to upper IBOP.
G. Remove upper IBOP
with shell.
150
125
Handle
Shown in
Horizontal
Lock Position
Top of Rotary
Table and Deck
RTBS
Intensifier Assembly
Step 6
A. Install thread protector in replacement
upper 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.
Secure To
Pad Eye On
GE Motor
Step 7
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 RTBS
and make-upupper IBOP
to desired torque
indicated by pressure
gauge on RTBS
intensifier assy panel
and stroke back down.
Note: make up torque
91,000 lb-ft = 2,150 psi)
175
200
75
225
25
250
10
275
1500
1750
300
1000
2000
0
750
2250
500
2500
250
2750
3000
To Release Brake
Move Handle To
Vertical Position
Tie-up
Cable
New
Upper
IBOP
Lifting
Plug
Lifting
Plug
Old
Upper
IBOP
Yellow
Area
Step
7D
Top of Rotary
Table and Deck
Varco P/N
30150095
Step 8
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 TDS
brake drum. Reconnect the brake hose from
TDS 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 using
the PH-85.
G. Release the links (Ref 1C).
100
1250
Engaged
On Square
Boss
TOP DRIVE
Training Manual
Inspection
Maintenance
Inspection
Swinging out the TDS for
maintenance
Varco top drives with swing-out guide dollies can be quickly
swung aside on its own dolly frame for inspection, maintenance,
running casing, or to allow drilling operations requiring a kelly
and rotary table. Electrical, hydraulic and air supplies do not have
to be disconnected. Use the following procedure to swing out the
TDS only if your rig has a guide dolly with hinge pins (refer to
the engineering drawings for information specific to your rig
configuration):
1. If you have a retract system, operate the switch on the drillers
console 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.
4-9
Current date
Unlatching the hook from the swivel bail may cause the TDS
motor assembly and/or the hook to lurch suddenly. Always
keep adequate tension on the tailing lines to prevent sudden
movement of these assemblies.
9. Unlatch the hook.
10. Attach tugger lines to the TDS motor frame, opposite the
frame hinges, to assist in swinging out the TDS motor
assembly. Use tailing lines on the motor frame to control
swing 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 frame
while unhooking the traveling block from the swivel bail.
13. When the traveling block is disconnected, continue swinging
out the TDS 180 and secure the motor assembly to the
derrick with chain and/or rope.
4-10
While latching the hook to the swivel bail, the swivel and/or
the TDS motor assembly may suddenly lurch. Always keep
adequate tension on tailing lines to prevent sudden movement
of these assemblies.
2. Attach tugger lines to the TDS motor assembly, opposite the
hinges, to aid in swinging back the TDS assembly. Use tailing
lines on the motor frame to control swing back.
3. Release the chain and/or rope securing the TDS motor
assembly to the derrick and slowly swing back the TDS motor
assembly to the guide dolly. While swinging it back, latch the
hook onto the swivel.
4. Secure the motor frame to the guide dolly with the two
swing-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 of
the hook or block.
8. Turn on the hydraulic power unit and bleed air out of the
system.
9. Adjust the hydraulics as outlined later in this section.
4-11
Current date
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide
dolly assembly for loose bolts and fittings daily. If any safety wire
or cotter pins were removed to facilitate repairs, replace them
immediately.
4-12
4-13
Current date
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings
daily. If any safety wire or cotter pins were removed during
repairs, replace them immediately.
Inspect the hinge bolts daily to make sure they are not separating
from the pipehandler. Make sure the hinge pins are not loose
either because of excessive wear in the bore of the clamp clevis or
a broken retaining bolt.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes (Figure 4-1). Compare the measurements
with the Wear Chart (Figure 4-1) to determine the current
strength of the elevator links. The capacity of the links equals the
capacity of the weakest link.
4-14
Upper
Eye
(Hook)
,,,,
,,,,
,,,,
,,,,
Capacity
(per set)
in Tons
2 3/4 in.
2 9/16 in.
2 3/8 in.
2 3/16 in.
350
300
225
175
,,,
,,,
,,,
,,,
3 1/2 in.
3 1/4 in.
3 in.
2 3/4 in.
500
420
325
250
7 1/2 in.
7 1/4 in.
7 in.
6 3/4 in.
350
300
225
175
,,,,
,,,,
,,,,
A
Lower
Eye
(Elevator)
4-15
Current date
Landing collar
4-16
4-17
Current date
Drive stem
4-18
4-19
Main shaft
Regularly inspect and measure the drive stem/main shaft for wear.
Remove the main shaft from service if bore wear is greater than
the dimensions shown in Figure 2.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B as
guidelines for interpreting and performing inspections.
Measurement techniques are specified in API RP 7G, Section 10.
Use API Bulletin 5T1 to identify and define imperfections found
during inspections.
* See Figure 3
18
Figure 3. 650-Ton drive stem /main shaft landing collar, tensile dimensions
19
Current date
4-20
Ultrasonic inspection
In addition to the magnetic particle inspection, Varco also
recommends performing an ultrasonic inspection of the above
components to detect any erosion of the inside diameter. Any
erosion reduces the load-carrying capability of the part. Any
subsurface irregularity can also compromise a components
integrity.
Details on magnetic particle and ultrasonic inspection procedures
are in the following publications:
I.A.D.C.
4-21