Link tilt mechanisms ................................................ 1-45Standard and extended reach pneumaticlink tilt mechanisms ........................................... 1-45Hydraulic link tilt mechanism ........................... 1-48
Link tilt controls .......................................... 1-48Elevator links ................................................................. 1-50Counterbalance system .................................................. 1-51TDS Control System (TDCS) ....................................... 1-53
Varco Driller’s control and instrumentationConsole (VDC) ....................................................... 1-53Transfer control panel .............................................. 1-54Purge control system ................................................ 1-54
Chapter 3 SpecificationsDrilling motor ......................................................... 1-65Main gearbox lube system ........................................ 1-65Cooling systems ....................................................... 1-66
Electrical equipment accessories ............................... 1-70API Class I, Division II -N.E.C. ........................ 1-70European standard zone 2 area-EExd ................. 1-70
TDS-4S Contents v
Book 2 – Installation and Commissioning
Preface/Manual conventionsSafety information ........................................................... 2-5Directional references ...................................................... 2-6Manual layout.................................................................. 2-6
Air loop ....................................................... 2-26Retract loop ....................................................... 2-27
Chapter 3 CommissioningCheckout procedures ..................................................... 2-29Long term TDS storage procedures................................ 2-32Returning the TDS to service after storage ..................... 2-33
Drilling ahead with triples ....................................... 3-21Drilling ahead with singles ....................................... 3-24Drilling ahead on a semi .......................................... 3-26
Initial oil change period ........................................... 4-27Oil capacity.............................................................. 4-28Lubricating the DC motor ....................................... 4-29Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31Lubricating the link adapter ........................................... 4-32Lubricating the torque wrench ....................................... 4-33Lubricating the master bushing ID wear guide ............... 4-34
March 8, 2001
viii TDS-4S Contents
Lubricating the safety valve actuator .............................. 4-34Lubricating the upper safety valve (IBOP) ..................... 4-35Lubricating the guide dolly assembly ............................. 4-36Lubricating the bail pins ................................................ 4-41Lubricating the cooling system....................................... 4-42Lubrication schedule ...................................................... 4-44Lubricant specifications ................................................. 4-45
Adjusting the torque wrench .................................... 4-49Adjusting the upper safety valve (IBOP)and safety valve actuator system ............................... 4-52Adjusting the counterbalance system ........................ 4-52Adjusting the motor alignment cylinder system ....... 4-54Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62Replacing the torque wrenchclamping piston seal ..................................... 4-68
Replacing the standard rotating headglyd rings ........................................................... 4-71Replacing the powered rotating headglyd rings ........................................................... 4-75Replacing the standard or extended reachlink tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81Front jaw ........................................................... 4-81Rear jaw ............................................................. 4-81
Removing the motor assemblyfrom the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motorand motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87Local blower cooling system assembly/disassembly ... 4-89Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95Safety wiring tips ..................................................... 4-97
TDS-4S Contents ix
Chapter 4 TroubleshootingTroubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101Troubleshooting the retract guide dolly ................. 4-101Troubleshooting the transmission .......................... 4-102Troubleshooting the oil pump ............................... 4-103Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106Troubleshooting the torque wrench ....................... 4-106Troubleshooting the safety valve actuator............... 4-108Troubleshooting the link tilt .................................. 4-108Troubleshooting the pipehandler at thecounterbalance manifold ........................................ 4-109Troubleshooting the crown height indicator .......... 4-110Six-gang air valve assembly illustration ................... 4-111
Book 4 – TDS-4S Control System
General description .......................................................... 5-5Maintenance and troubleshooting/checkout procedures ........................................................ 5-7
March 8, 2001
x TDS-4S Contents
TDS-4S
Top DriveDrillingSystem
DescriptionSM00620-1
Rev. B
March 8, 2001
1-2 TDS-4S Description
TDS-4S Description 1-3
Contents
Preface/Manual conventionsSafety information ........................................................... 1-5Directional references ...................................................... 1-6Manual layout.................................................................. 1-6
Standard and extended reach pneumaticlink tilt mechanisms ........................................... 1-45Hydraulic link tilt mechanism ........................... 1-48
Link tilt controls .......................................... 1-48Elevator links ................................................................. 1-50Counterbalance system .................................................. 1-51
March 8, 2001
1-4 TDS-4S Description
TDS Control System (TDCS) ....................................... 1-53Varco Driller’s control and instrumentationConsole (VDC) ....................................................... 1-53Transfer control panel .............................................. 1-54Purge control system ................................................ 1-54
Chapter 3 SpecificationsDrilling motor ......................................................... 1-65Main gearbox lube system ........................................ 1-65Cooling systems ....................................................... 1-66
Electrical equipment accessories ............................... 1-70API Class I, Division II -N.E.C. ........................ 1-70European standard zone 2 area-EExd ................. 1-70
TDS-4S Description 1-5
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the examplesbelow and pay close attention to these important advisories.
z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personnel injury or equipmentdamage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rigpersonnel.
Avoid personnel injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.
March 8, 2001
1-6 TDS-4S Description
Directional references
References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the Top DriveDrilling System (TDS-4S), standing behind the TDS-4S as itfaces well center.
Manual layout
This binder contains several separate books that you can removeindividually for convenience.
TDS-4S Description 1-7
Chapter 1
Introduction
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45ft. kelly was the industry standard for years. For decades, drillersextended the drill string with the “making-a-single-connection”process using the rotary table, kelly, pipe tongs, drawworkscathead, master bushing, bowls, and slips. This method ofhandling pipe and joint makeup remained unchanged, apart fromminor improvements such as kelly spinners, until the advent oftop drive drilling systems.
Varco produces several Top Drive Drilling Systems (TDS) torotate the drill string and allow adding entire 93 ft. stands of pipe,eliminating two thirds of the conventional single-pipe drillingconnections. This manual describes the function andmaintenance of the TDS-4S, which integrates the drill pipeconnection handling and drive systems with the drilling swivel.
The TDS (Figures 1-1 and 1-2) provides the rotating power of aconventional rotary table drive while eliminating the need to“pick up” the cumbersome swivel/kelly combination. The TDSdoes not interfere with the existing conventional equipment. Itallows tripping, circulation, rotation, and the running of casing aswell as providing 90 ft. back reaming capabilities to reduce thechance of stuck pipe.
March 8, 2001
1-8 TDS-4S Description
LO
Guide DollyAssembly
Pipehandler Assembly
Motor HousingAssembly
Figure 1-1. Typical TDS-4S overall view
TDS-4S Description 1-9
The TDS integrated swivel bail connects directly to a drillinghook. Connecting the TDS integrated swivel bail directly to thetraveling block or motion compensator frame can eliminate thedrilling hook and shorten the TDS working height further.
Figure 1-2. TDS-4S motor and swivel housing assembly
March 8, 2001
1-10 TDS-4S Description
The integrated drive stem functions as the main output shaftdriving the drill string. The electric drilling motor andtransmission, located next to the stem, rotates the stem.The DC motor bolts to an upper assembly of the gearcase,called the motor support bonnet.
The motor frame/guide dolly attaches to the motor housingassembly. The entire assembly moves vertically on two railsinstalled in the derrick. The vertical rails react the motor torqueduring drilling operations and keeps the TDS positioned overwellcenter.
The pipehandler assembly (Figures 1-3 and 1-4) can make orbreak drill pipe at any height in the derrick.
TDS-4S Description 1-11
Rotating Head(Part of the Motor Housing Assembly)
Hydraulic/Pneumatic Link Tilt
Splined UpperIBOP Valve
Torque Wrench
350-Ton 108 in. Link (2)(Optional Varco Equipment)
Manually or Remotely Operated Drill Pipe Elevator(Optional Varco Equipment)
Figure 1-4. 650-Ton, PH-60d pipehandler assembly
TDS-4S Description 1-13
Internal Blow Out Preventor (IBOP) valves connect to the end ofthe drive stem (Figure 1-5). The driller can close the upper IBOPat any position in the derrick from the driller’s control console. Asecond, lower IBOP can be manually closed and sent downholewhile controlling a kick.
Safety Valve Actuator Shell
Crank Assembly (2)
Upper IBOP
Actuator Arm (2)
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Landing Collar
Link Adapter(Also known as
Solid Body Elevator)
Upper IBOPValve ActuatorAir Cylinder (2)
Main Shaft/Drive Stem
Figure 1-5. Safety valves (IBOPs) and actuator assembly
March 8, 2001
1-14 TDS-4S Description
The drive stem passes through the link adapter. The torquearrestors keep the link adapter above the landing collar on thedrive stem when drilling (Figures 1-6, 1-7 and 1-8). Whenhoisting, the link adapter is pulled down onto the landing collardue to the added weight of the drill string. This directs thehoisting load through the drive stem, motor housing assembly,and swivel bail.
The fluid service loop provides the hydraulic, pneumatic power,and optional cooling water services to the TDS. The electricservice loops provide DC power and AC power/control.
A drill pipe elevator hangs from a pair of conventional links thatattach to the link adapter. Actuating the link tilt swings theelevator out to facilitate picking up pipe.
The Major component description chapter of this book describeseach of these assemblies. Subsequent books provide moreinformation on the equipment specific to your rig configuration.
TDS-4S Description 1-15
Link Adapter(Also known as
Solid Body Elevator)
Rotating Head(Part of Motor Housing Assembly)
TorqueArrestors (4)
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors
March 8, 2001
1-16 TDS-4S Description
650/500-TonRotating Head
(Part ofMotor Housing
Assembly)
TorqueArrestor
650-Ton: (4)500-Ton: (2)
Link AdapterSupport Plate
Safety ValveActuator
LowerIBOP Valve
Saver Sub
108 in.350-Ton
Links(Optional
Varco Equipment)
Manually or Remotely OperatedDrill Pipe Elevator
(Optional Varco Equipment)
UpperIBOP Valve
Hydraulic/Pneumatic Link Tilt
Torque Wrench
650/500-TonLink Adapter
(Also known asSolid BodyElevator)
Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies
TDS-4S Description 1-17
TorqueArrestor (4)
Link AdapterSupport Plate
Safety ValveActuator
LowerIBOP Valve
Saver Sub
UpperIBOP Valve
Pneumatic Link Tilt
Torque Wrench
650-TonRotating Head(Part of Motor
HousingAssembly)
650-TonLink Adapter
(Also known asSolid BodyElevator)
108 in.350-Ton
Links(Optional
VarcoEquipment)
Manually or Remotely OperatedDrill Pipe Elevator
(Optional Varco Equipment)
Figure 1-8. 650-Ton, PH-60d pipehandler in relation to other TDS assemblies
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1-18 TDS-4S Description
TDS-4S Description 1-19
Chapter 2
Major componentdescription
Motor housing assembly
The motor housing assembly is composed of the following:
❏ Drilling motor and brake
❏ Two speed transmission
❏ Rotating head
❏ Integrated swivel and washpipe
March 8, 2001
1-20 TDS-4S Description
Drilling motorThe drilling motor on the TDS is a 1,100 hp DC drilling motor.Mechanically, the motor features a double-ended armature shaftand thrust bearings for vertical operation.
There is an air brake on the motor to hold torque in the drillstring to assist in directional work. It is remotely operated by asolenoid valve. Please refer to the specifications included later inthis book for additional details.
Two speed transmissionThe two speed transmission consists of the following majorcomponents:
❏ Bull gears – 96 tooth, 2.0 diametral pitch
❏ High range compound gears – 27 tooth and 30 tooth
❏ Low range compound gears – 23 tooth and 40 tooth
The compound gears mount to their eccentric shafts with a two-row, full complement roller bearing on one end and a sphericalroller bearing on the other end.
TDS-4S Description 1-21
HI LO
High GearEccentric Shaft
(Engaged)
Low GearEccentric Shaft(Disengaged)
GenevaMechanism
Shifter Input
ExternalHI / LO
Indicator
CompoundGear Shafts
ShifterInput Shaft
Rotating HeadAssembly
Bottom View
Top View
Figure 1-9. Transmission/geneva mechanism
March 8, 2001
1-22 TDS-4S Description
Lubrication to the bearings and gear meshes is force fed by anelectrically driven gear pump externally mounted on the gearcase(Figure 1-10). The lower gearcase is a heavy duty steel casting,fully ribbed for added heat dissipation.
The transmission shifts gears by rotating two vertical compoundgear eccentric shafts. The two compound shafts (high and low)are supported on heavy trunnions between the main body andlower gearcase halves. As the shafts rotate (less than one-halfturn), the compound gears go into or out of mesh with both themotor pinion gear and the bull gear because the support shaftcenter axes are offset or eccentric.
Each compound shaft carries a large, internally splined genevaslave. A common geneva master sequentially unlocks, rotates, andlocks both gears. The master rotates using a reduction gear setwith a vertical manual input shaft. It carries its own latchingmechanism and provides the security of a double lock on thecompound shafts.
A 1 in. male hex at the bottom of the transmission case (Figure1-9), rotates the input shaft. After pushing inward on the malehex, it takes five turns of the input shaft to unlock both gear sets,rotate the engaged gear set to full disengagement, rotate thedisengaged gear set into full engagement, and lock both gear setsin their proper positions with positive stops in the lockedposition. An external indicator shows the gear range selection.
Integrated swivel bail and swivelwashpipeThe integrated swivel bail is a bearing assembly that allowstransfer of the rotating load to the lifting components(Figure 1-2).
The swivel washpipe is a rotating seal that allows mud to flow tothe rotating drill string.
TDS-4S Description 1-23
LEGEND
FabricatedDrilled
Pressure Tap
Compound Shafts (Not Visible)Inlet
BullGears
Motor PinionGears
Lower RadialShaft Bearing
Bottom View
Side View
Bull Gears
Motor PinionGears
Figure 1-10. Transmission lubrication system
March 8, 2001
1-24 TDS-4S Description
Standard rotating headThe standard rotating head allows transferring pneumatic andhydraulic pressure from stationary ports on the drilling motorhousing to rotating ports on the rotating head (Figure 1-11). Itfeatures two hydraulic passages, three pneumatic passages, andtwo spare passages capable of transferring either pneumatic orhydraulic fluid (all are rated at 2,500 psi).
The rotating head assembly consists of:
❏ Stationary flange
❏ Eight rotary glyd rings
❏ Swivel block
❏ Cam
❏ Auto-return cylinder
❏ Cam follower
❏ Swivel block locking mechanism
The hydraulic and air lines for the various pipehandler functions(air link tilt, torque wrench, etc.) run from their respectivesolenoid valves to the stationary flange. The fluids travel from theflange to the swivel block via sealed rotating passages. The glydrings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to thecorresponding devices (link tilt, etc.). The swivel block rotatesrelative to the flange without twisting or damaging any hoses.There is also a lug for mounting the torque wrench hanger andholes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom ofthe gearcase with the drive stem running through the center.There is also an auto-return cylinder mounted on the stationaryflange. The auto-return cylinder is hydraulically connected to thecounterbalance manifold. The rod end of the cylinder connects toa cam follower assembly that tracks the cam mounted to theswivel block.
TDS-4S Description 1-25
Stationary Flange
Locking Lever
Glyd Ring (8)
Auto-ReturnCylinder
Swivel Block
Cam
Cam Follower
Torque ArrestorLocation
Torque Wrench Hanger(Lug not shown)
Figure 1-11. Standard 650-Ton rotating head assembly
March 8, 2001
1-26 TDS-4S Description
Powered rotating headThe 10-port powered rotating head (Figure 1-12) allowstransferring pneumatic and hydraulic pressure from stationaryports on the drilling motor housing to rotating ports on therotating head. It features three hydraulic passages, five pneumaticpassages, and two spare passages capable of transferring eitherpneumatic or hydraulic fluid (all are rated at 2,000 psi).
The rotating head assembly consists of the following components:
❏ Stationary flange
❏ Eleven rotary glyd rings
❏ Swivel block
❏ Bull gear
❏ Hydraulic motor assembly
❏ Proximity sensor and adjustable targets
The hydraulic and air lines for the various pipehandler functions(hydraulic link tilt, torque wrench, etc.) run from their respectivesolenoid valves to the stationary flange. The fluids travel from theflange to the swivel block via sealed rotating passages. The glydrings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to thecorresponding devices (link tilt, etc.). The swivel block rotatesrelative to the flange without twisting or damaging any hoses.There is also a lug for mounting the torque wrench hanger andholes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom ofthe gearcase with the drive stem running through the center.
The hydraulic motor assembly mounts to the swivel flange whichengages a compound gear, driven by a pinion gear on thehydraulic motor shaft. Two switches on the driller’s control panelcontrol the hydraulic motor.
Rotating head controlsThe powered rotating head has two switches. The ROTATINGHEAD LEFT/RIGHT switch rotates the rotating head, pipehandler, and link tilt to the right or left (same direction as thedrill string). The AUTO STOP/FREE ROTATE switch controlsthe powered rotating head operating mode.
TDS-4S Description 1-27
A4
A5
H3
S2
H2
A2
A3
H1
S1
A1
A1
A3
A5
A4
H2 S1
A2
S2
H3
PR
ES
SU
RE
H1
StationaryFlange
Bull Gear
Torque ArrestorHanger
Hydraulic MotorAssembly
Rotary GlydRing (11)
Swivel Block
Figure 1-12. Powered rotating head assembly
March 8, 2001
1-28 TDS-4S Description
Cooling systems
Local blowerThe local blower cooling system with an optional extended intakeprovides local cooling air to the drilling motor (Figure 1-13). Itreceives air approximately 27 ft. above the rig floor at the lowestpoint of the motor’s travel.
An explosion-proof 20 hp, 3,450 rpm AC electrical motordirectly drives the impeller in the blower housing. An optionalflexible duct connects the blower housing to the extended intakemounted on the traveling equipment.
Two spark arrestor assemblies are mounted on the exhaust portsof the upper gearcase. These components hinder the egress of anyair born sparks from the DC motor.
TDS-4S Description 1-29
MountingBrackets (2)
Mounting Plate
Oil Fittings (2)
TransmissionCooler
Axial Fan20 hp
Blower Motor
Locking Key
Gasket
Blower Housing
Blower Impeller
Taper LockBushing
Gasket
Blower Duct toAC Drilling Motor
Flex DuctConnection
Point
Spark Arrestor
Figure 1-13. Typical local blower cooling system
March 8, 2001
1-30 TDS-4S Description
Closed loopThe closed loop cooling system (Figure 1-14) consists of two air/water heat exchangers cooled by twin blowers driven by a doubleended AC motor. Ducting directs air out the motor exhaust portto the heat exchangers and back to the blower inlets. The heatexchangers are built from Cupro-Nickel tubes and the headers arepressure tested to 250 psi.
The system requires a supply of liquid coolant (sea water, chilledfresh water or glycol) at 100 gpm at a maximum inlettemperature of 90°F.
Purge air at a rate of 70 scfm per motor at 1.0 psig is also requiredto provide positive system pressure, and a purge control system(refer to TDS Control System information provided later in thischapter) monitors system pressure to insure safe operation.
TDS-4S Description 1-31
Impeller (2)
WaterConnections
Blower Mount/Brake Cover
BlowerHousing (2)
Heat Exchanger (2)
GEDrilling Motor
InspectionCover
8 in. FlexConnection (2)
Dual Shaft20 hp AC
Blower Motor
Blower Inlet (2)
DC to MotorExhaust Port on
Upper Gear Case
Figure 1-14. Typical closed loop cooling system
March 8, 2001
1-32 TDS-4S Description
Remote blowerThe remote blower motor cooling system consists of a motor andpressure blower mounted in the derrick at racking board level(Figure 1-15). Air is drawn in from outside the wind wall,through a flexible duct into the top of the drilling motor, andexits through spark arrestors attached to the air outlets of themotor.
A pressure switch monitors the motor air inlet pressure to verifyblower operation. The contacts of the pressure switch are usuallywired into the SCR assignment logic for the drilling motor.
A moisture separator is attached to the blower inlet duct toprevent water from entering the motor.
TDS-4S Description 1-33
40 hp Explosion ProofElectric Motor (AC)
and CentrifugalPressure Blower
Air Inlet
Racking Platformat Racking Board Level
Rigid Cooling Duct
Spark Arrestor
86' Flex Air DuctMotor Dolly Assembly
Wind Wall
Figure 1-15. Typical remote blower cooling system
March 8, 2001
1-34 TDS-4S Description
Guide dolly assemblies
The guide dolly assembly transmits the drilling torque reaction tothe guide rails keep the TDS positioned over wellcenter and canprovide a method for setting the entire unit aside for maintenanceor to allow rig operation without the TDS if necessary.
The standard guide dolly assembly consists of two framesconnected by hinges on the pivot side and hold-down bolts onthe other (Figure 1-16).
Non-swing retract guide dollies use hold-down bolts (swing bolts)on both sides (Figure 1-17). One frame attaches to the motorhousing assembly and includes attachment points for the serviceloops and rotary hose. The other frame includes the guide rollersand remains in the guide rails during all normal operations.Centralized lubrication manifolds provide roller lubrication.
TDS-4S Description 1-35
Motor Frame
Guide Dolly Frame
Hinge Pin (2)
Hold-down Bolt(Swing Bolt) (2)
Figure 1-16. Typical swing guide dolly assembly
March 8, 2001
1-36 TDS-4S Description
LEGEND
Extended Mode
Retracted ModeIntermediate
Frame
LowerExtend/Retract
Arm
RetractCylinder
Guide DollyFrame
Upper Stabilizer ArmMotor Frame
45.0"
Figure 1-17. Typical retract guide dolly assembly
TDS-4S Description 1-37
Motor alignment system
The motor alignment system consists of a duplex cylinder,hydraulic accumulator, pressure reducing valve manifold, andrelated hardware.
The duplex cylinder attaches between the bottom of the lowergearcase and the motor frame. It connects to an accumulatorcircuit located on the guide dolly. The accumulator is chargedwith nitrogen and maintained at a predetermined pressure settingby the alignment cylinder manifold. Figure 1-18 shows the motoralignment cylinder installed in a typical motor frame.
The duplex cylinder maintains a wellcenter orientation for theswivel stem when disconnected from the drill sting, whileallowing the motor housing assembly to float slightly about itstrunnions.
Motor AlignmentCylinder
MotorFrame Dolly (Ref)
ShippingBrace
Figure 1-18. Motor alignment cylinder
March 8, 2001
1-38 TDS-4S Description
Pipehandler
The main components of the pipehandler include the following(Figures 1-3 and 1-4):
❏ Link adapter
❏ Safety valves (Upper and Lower IBOPs)
❏ IBOP valve actuator
❏ Torque wrench
❏ Link tilt mechanism
The pipehandler provides two basic functions for the TDS:
❏ Tripping 93 ft. drilling pipe stands
❏ Providing up to 85,000 ft lb torque for makeup andbreak-out of connections at any height in the derrick(the PH-60d provides up to 60,000 ft lb torque)
The pipehandler can be configured for various tool jointconnections. It includes a link adapter and a special-purposeVarco torque wrench assembly. It also incorporates a remoteIBOP valve actuator and link tilt mechanism.
When not in use, the pipehandler remains stationary and freefrom the drill string passing through it. When tripping orperforming bottom hole operations, the pipehandler is free torotate 360°, emulating the action of a standard hook.
TDS-4S Description 1-39
Link adapterThe link adapter (solid body elevator) and the elevator links(Figures 1-7 and 1-8), working in conjunction with the torquearrestors, transfer the hoisting loads to the drive stem.
The drive stem is free to rotate inside the link adapter whiledrilling. The link adapter does not rotate with the drive stembecause torque arrestors raise the link adapter up off the loadsupporting landing collar located on the drive stem.
When hoisting loads, springs inside the torque arrestors compessto transfer the load to the drive stem by pulling the link adapterdown onto the landing collar. The link adapter rotates with therotating head–which is required for tripping operations.
The torque arrestors contain compression springs capable ofsupporting any stand of drill pipe in the full up position.
March 8, 2001
1-40 TDS-4S Description
Safety valves (IBOP)The Varco pipehandler includes two Internal Blowout Preventorsafety valves (IBOPs) to provide blowout prevention. For detaileddescriptions, installation, operation, maintenance, and partsinformation, refer to the IBOP Service Manual.
Saver and crossover subsEach pipehandler ships with two saver subs and one crossoversub. Saver subs (Figures 1-7 and 1-8) are dual pin subs used topreserve the threads on the lower IBOP and provide a pin for thebox end of the drill string. Saver sub threads can be recut to aminimum shoulder-to-shoulder length of 5 in. before the submust be discarded.
The crossover sub converts the lower IBOP pin to a boxconnection for well control procedures with standard pipe.
e Saver subs are load bearing components in the TDS and must beinspected periodically along with other load bearing components.Refer to the Maintenance and Troubleshooting book for moreinformation.
Safety valve actuatorThe remotely operated upper IBOP valve actuator allows upperIBOP actuation at any height in the derrick.
The upper IBOP actuator system consists of the following:
❏ Two pneumatic air cylinders
❏ Two actuator arms
❏ Actuator shell
❏ Two crank assemblies
❏ Two pneumatic solenoid valves
Double-acting air cylinders move the actuator arm. The actuatorarm connects to the valve actuator shell and moves the actuatorshell up or down (Figure 1-19). A slot in the actuator shellengages the crank assemblies, which opens or closes the IBOP.The air cylinders are operated remotely by a solenoid valvecontrolled by an electrical switch at the VDC.
TDS-4S Description 1-41
Safety Valve Actuator Shell
Crank Assembly (2)
Upper IBOP
Actuator Arm (2)
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Landing Collar
Link Adapter(Also known as
Solid Body Elevator)
Upper IBOPValve ActuatorAir Cylinder (2)
Main Shaft/Drive Stem
Figure 1-19. Safety valve actuator system
March 8, 2001
1-42 TDS-4S Description
Torque wrenchThe torque wrench provides a means for making and breakingout connections with the drive stem.
The torque wrench assembly consists of the followingcomponents (Figures 1-20 and 1-21):
❏ Hanger
❏ Torque tube
❏ Torque tube guide ring
❏ Two torque cylinders
❏ Two clamping jaws
❏ Two clamping pistons
❏ Control manifold
❏ Lift cylinder
❏ Two stop tubes
❏ Stabbing guide
❏ IBOP actuator cylinders and arms
A hanger attached to the rotating head supports the torquewrench. The torque wrench has two torque cylinders connectedto the torque tube.
The clamping jaw contains a 10 in. diameter clamping piston forgripping the box end of the drill pipe. On the lower section of theupper IBOP, a female spline engages the mating male spline onthe lower IBOP contained inside the torque tube.
When actuated, the torque wrench rises and engages the splineson the upper IBOP. It then receives sequenced pressure to clampthe clamping piston on the box connection. After the clampingpressure develops, another sequence valve automatically opensand directs pressure to the torque cylinders. The torque cylinderscan rotate up to 25° while developing a maximum torque of85,000 ft lb (60,000 ft lb for PH-60d).
One electrical push button on the VDC controls the entire torquewrench operation. The driller simply holds the button down untilthe connection is made or broken. The driller then releases thebutton to allow the unit to automatically recycle to the readyposition. A two-position, air piloted hydraulic valve located onthe counterbalance manifold controls the cycle.
The torque wrench can also make up or break out the saver subor the lower IBOP. A manually operated valve on the rear of thepipehandler selects either the make up or break out function.
TDS-4S Description 1-43
Var co
Hanger
IBOP ActuatorAir Cylinders
Lift Cylinder
IBOPActuator Arms
Torque Tube
Clamping Jaw(Inside Clamp Body)
Stabbing Guide
Guide Ring(Not Visible)
Clamping Piston(Inside Clamp Body Cylinder)
Torque Cylinder (2)
Control Manifold(Hidden)
Stop Tube (2)
Torque Wrench Hoses (Hydraulic)
IBOP ActuatorHoses (Air)
Figure 1-20. PH-85 torque wrench assembly
March 8, 2001
1-44 TDS-4S Description
Clamping Piston(Inside Clamp Body Cylinder)
Torque Cylinder (2)
Control Manifold(Hidden)
Stop Tube (2)
Hanger
IBOP ActuatorAir Cylinders
Lift Cylinder
IBOPActuator Arms
Torque Tube
Clamping Jaws(Inside Clamp Body)
Stabbing Guide
Torque Wrench Hoses (Hydraulic)
IBOP ActuatorHoses (Air)
Guide Ring(Not Visible)
Figure 1-21. PH-60d torque wrench assembly
TDS-4S Description 1-45
Link tilt mechanisms
Standard and extended reach pneumaticlink tilt mechanismsThe standard (Figure 1-22) and extended reach (Figure 1-23) linktilt assembly allows:
❏ The elevators to move off of well center to pick up a stand inthe mousehole.
❏ The derrickman to handle pipe more easily.
The link tilt assembly mounts on the front of the solid bodyelevator (link adapter). This assembly consists of a pivoting liftingframe connected to the drilling elevator links with chains andclamps. A switch on the VDC controls a pneumatic solenoidvalve that inflates an air spring within the lifting frame. Inflatingthe air spring pivots the frame upward, tilting the links outward.
Extended reach link tilt mechanisms have two air springs andextend 76 in. A standard reach link tilt will extend links 52 in.Both reaches are based on 108 in. elevator links.
An adjustable intermediate stop mechanism provides clearancebetween the drill pipe elevator and the monkey board to assist thederrickman in racking operations.
March 8, 2001
1-46 TDS-4S Description
AirActuator
IntermediateStop
IntermediateStop Release
D/P ElevatorLink Clamp
Lifting Frame
Figure 1-22. Standard pneumatic link tilt mechanism
TDS-4S Description 1-47
Double AirActuator
IntermediateStop
IntermediateStop Release
D/P ElevatorLink Clamp
LiftingFrame
Figure 1-23. Extended reach pneumatic link tilt mechanism
March 8, 2001
1-48 TDS-4S Description
Hydraulic link tilt mechanismThe hydraulic link tilt assembly (Figure 1-24) provides lateralmovement of the drill pipe elevator to a position above themousehole or toward the monkeyboard.
The link tilt assembly mounts on the front of the link adapter(solid body elevator). The link tilt uses dual hydraulic cylinders.Full link tilt extension moves drill pipe approximately 78 in. fromwell center, based on 108 in. links. During operation, theoperator can stop link tilt movement at any position and hold thesupported load in place.
The link tilt also enables retracting the open drill pipe elevatorfrom the drill pipe while drilling, tripping, and adding stands(available only on PH-85 models).
Link tilt controls
The link tilt is controlled by a four-position switch. The positionsare RETRACT, FLOAT, HOLD, and EXTEND.
RETRACT
In the RETRACT position, the elevator backs away from wellcenter.
FLOAT
FLOAT returns the elevators to well center from the retracted orextended position. A 1/2-second delay is programmed into theFLOAT function to allow the control switch to travel from theRETRACT position to the HOLD position without activatingthe FLOAT.
HOLD
This setting holds the position of the elevators extended orretracted.
EXTEND
This setting extends the elevator forward to the mouseholethrough wellcenter.
TDS-4S Description 1-49
LinkTilt Arm
IntermediateStop
StopAdjuster
CylinderAssembly
(2)
PassiveStop
Assembly(2)
HydraulicLink Tilt withPassive Stop
HydraulicLink Tilt with
Intermediate Stop
Figure 1-24. Hydraulic link tilt
March 8, 2001
1-50 TDS-4S Description
Elevator links
Varco elevator links attach to the link adapter and support thedrill pipe elevator. Elevator link options include:
❏ 108 in., 350-Ton elevator links
❏ 132 in., 350-Ton elevator links
❏ 180 in., 500-Ton elevator links (special long links for runningcasing, providing 120 in. of clearance for cementing heads)
TDS-4S Description 1-51
Counterbalance system
The counterbalance system prevents damage to tool joint threadswhile making or breaking connections with the TDS. It providescushioned stroke similar to that provided by the hook.
The counterbalance system prevents damage to the threads of thesaver sub and drill pipe by offsetting the weight of the top drivewhile stabbing into a connection. The system (Figure 1-27)consists primarily of two hydraulic cylinders, a counterbalancemanifold, and two hydraulic accumulators. The hydrauliccylinder assemblies connect the integrated swivel bail and thetraveling equipment (hook, block, becket, hook adapter, etc.).
When properly adjusted, the counterbalance system supports allbut about 800 lb of the weight of the top drive over a full 8 to10 in. of travel.
The system also incorporates a complete backup. The twoaccumulators, constantly maintained at system pressure, arealways able to provide pressure to the counterbalance cylinders ifthe HPU is “off” or non-operational for any reason. For normaloperation, however, the HPU is “on” when using the torquewrench for breaking out the top drive at the floor and is left onwhile making up the next stand.
When adding a stand to the string during drilling operations, thedriller takes a stand in the elevators and stabs it into the box inthe rotary table. The driller continues to lower the TDS until thesaver sub touches the box of the new stand. At this point, onlyabout 800 lb load is on the saver sub/drill pipe connection. Thecounterbalance cylinders support the remainder of the TDSweight. The driller then spins in and torques up the connectionwith the pipehandler assembly and is ready to drill ahead.
Note that the driller does not have to do anything extra to get thecounterbalance system to function properly. It is a pre-adjustedsystem. Once drilling resumes, the HPU can be turned off andrestarted again for breaking out the connection at the floor afterdrilling the stand down.
March 8, 2001
1-52 TDS-4S Description
810 lbWeight on Threads
18,970 lb
38,750 lbTypical System Weight
HydraulicCylinders (2)
HydraulicAccumulators (2)
Guide DollyAssembly
HydraulicPower Supply
Stabbing Mode:Top Drive Lowered Past Thread Contact
CounterbalanceManifold
18,970 lb
Rig Floor
FluidsService Loop
Figure 1-27. Counterbalance system
TDS-4S Description 1-53
TDS Control System (TDCS)
The TDS Control System (TDCS) provides the driller with acontrol console that operates all of the TDS functions. Thecomponents of the TDCS include:
❏ Varco Driller’s control and instrumentation Console (VDC)
❏ Transfer control panel (TP)
❏ Purge control system for closed loop cooling systems
Varco Driller’s control andinstrumentation Console (VDC)The Varco driller’s control and instrumentation Console (VDC)consists of a torque meter, an RPM meter and various switchesand indicator lights. The basic TDS control functions are:
❏ Link tilt
❏ Remotely controlled upper IBOP valve
❏ Motor brake
❏ Motor spin-torque control
❏ Makeup torque limit
❏ Transfer switch (TDS/ROT)
The existing rotary table controls adjust motor speed, torque anddirection while drilling. A typical VDC also contains indicatorlights for determining the status of:
❏ The brake
❏ The remotely controlled upper IBOP valve
❏ The oil pump
❏ Blower pressure loss
❏ Cooling air temperature
❏ The purge system(s)
Optional controls and status indicator lights are available. Referto Engineering Drawing 98952 for VDC configurations.
March 8, 2001
1-54 TDS-4S Description
Transfer control panelThe TDS operates from the same SCR as the rotary table.The Transfer control panel switches power between them.This electrical enclosure contains the DC contacts, theprogrammable controller, the auxiliary AC componentsand the rig instrumentation interfaces for recording torqueand speed of the TDS.
The DC power cables running from the SCR to the rotary tablemotor are disconnected from the rotary table and connect to thetransfer panel. New cables run from the TP to the rotary tablemotor and to the racking board junction boxes for the TDS.
The transfer panel has a purge control system for use in ahazardous area (Zone 2 or Class 1, Div. 2). If the panel is in theSCR room, a purge system is not required.
The panel is compatible with all currently installed SCR systemsand is configured at installation for the SCR it will control. Logicand alarm functions are connected to the TDS by programmingthe transfer panel’s Programmable Logic Controller (PLC) tooperate the rig’s existing systems. Similarly, TDS interlocks andlimits, such as spin-up and makeup speeds, are programmed intothe PLC and are the same for all installations.
Purge control systemThe transfer panel, VDC, and TDS closed loop cooling systemhave separate purge systems. All systems provide positive internalpressure to prevent hazardous gases from entering areas ofpotential ignition in Zone 2 or Class 1, Div. 2 hazardous areas.
Pressure switches in the protection units monitor the pressure andprovide an alarm signal in the event of purge pressure loss.
Prior to starting an unpurged system, the purge control unitpurges the system for a specific time interval sufficient to removeany trapped hazardous gas. Status lights on the VDC indicate tothe driller correct purge pressure, loss of purge and systempurging. If purge pressure loss alarms and indicators are ignoredfor a preset time interval, the isolation unit can be set to shutdown the TDS.
TDS-4S Description 1-55
Service loops
The service loops transfer the required electric and fluid servicesbetween the derrick service standpipes and junction boxes, andthe corresponding junction boxes and fluid connections locatedon the TDS. There are two kinds of loops: one containing theelectric cables, and one containing air, hydraulic and water lines(water lines included only on units with a closed loop coolingsystem).
The power electrical loop contains four 646 MCM DC powercables, one 2/0 AWG drilling motor ground cable. The otherelectrical service loop contains a composite cable consisting of:
❏ 26 14 AWG conductors for auxiliary features
❏ 4 8 AWG conductors for blower motor
❏ 2 5 AWG conductors for series motor field supply
❏ 2 14 AWG shielded pairs for the RPM pickup signal
The power and ground cables are spiral wound and potted insidea protective cover with 7 1/2 in. mounting flanges at each end.
The composit cable is pathed in its own smaller service loop. Thisallows for easy changeout of either the power loop or thecomposit loop in the event of a failure.
The TDS can use optional dual electrical service loops in order tomeet certain regulatory agency requirements for power cablecurrent carrying capacity.
The fluids loop can consists of any combination of the following:
❏ 3 3/4 in. diameter hoses for hydraulic supplies(one is a spare)
❏ 2 1/2 in. diameter hoses for air supply (one is a spare)
❏ 1 1 in. diameter hoses for purge supply
❏ 2 1 1/4 in. diameter hoses for cooling water(closed loop cooling systems only)
❏ 2 1 in. diameter hoses for retract cylinder supply and return
❏ Additional 7-conductor, 20 AWG cables as required
March 8, 2001
1-56 TDS-4S Description
Derrick electrical termination kit
This kit consists of all the necessary electrical junction boxesattached to a bulkhead mounting plate, which is then mounted inthe derrick to connect the rig electric supplies to the service loop.
There are several J-box configurations, depending upon whichelectrical system is ordered. Each configuration complies withspecific electrical codes and regulatory agency requirementsthroughout the world.
TDS-4S Description 1-57
Auxiliary equipment
Auxiliary equipment is compatible with all TDS models. All ofthe equipment is selected or adapted for your specific rig. Below isa list of auxiliary equipment available:
❏ Master bushing ID wear guide
❏ Swiveling drill collar dolly
❏ Wireline adapter
❏ Crown height indicator
❏ Driller’s recorder tranducer kit
March 8, 2001
1-58 TDS-4S Description
Master bushing ID wear guideThe master bushing ID wear guide centers the rotating drillstring and protects the master bushing while drilling ahead(Figure 1-26). It hinges open for removal or when settingmanual slips. The bushings can be changed out to accomodatedifferent size drill pipe.
Figure 1-26. Master bushing ID wear guide
TDS-4S Description 1-59
Swiveling drill collar dollyThe swiveling drill collar dolly (Figure 1-27) allows the drill collarelevators to turn freely when handling bottom hole assemblies.The drill collar dolly’s upset, which latches in the standard drillpipe elevator, mounts on a bearing which allows it to swivel evenunder load. A shoulder elevator is suspended from the“perfection” links (or a second drill pipe elevator if lifting subs areused). The collars can be walked in or out with the elevatorturning on the drill collar dolly.
100 TONVARCO ��
������ ��
������
A
A
Drill PipeElevator
Drill CollarDolly
PerfectionLinks (36")
SquareShoulderElevator
LiftingSub
DrillCollar8 in.
View A - A
91 in.
37 in.
Figure 1-27. Swiveling drill collar dolly
March 8, 2001
1-60 TDS-4S Description
Wireline adapterThe wireline adapter (Figures 1-28 and 1-29) attaches to thepipehandler and prevents wireline from interfering and damagingpipe and TDS components. It can be used with a lubricator heldin the elevators by using 180 in. casing elevator links.
Typical Section through Sheave
42.52 in.
23.1 in.
26.0 in.
Figure 1-28. Typical PH-85 wireline adapter
TDS-4S Description 1-61
View A-A
View A-ATop Drive
Torque Wrench
Torque Wrench Guard(remove for installation)
20 in. Dia.Sheave
To Mud Manifold
Elevator Links(180 in. or longer-
Customer furnished)
Wireline Adapter installs inplace of Torque Wrench
Guard using existing Pins
9/16 in. Max.Wire Rope Dia.
Elevator Links(180 in. long-
Customer furnished)
Lubricator
Figure 1-29. Typical PH-60d wireline adapter
March 8, 2001
1-62 TDS-4S Description
Crown height indicatorThe crown height position indicator is a self-contained electronicinstrument which determines the position of the travelingequipment with respect to the derrick crown. The system containsfour major subassemblies:
❏ A metal target typically located on the Varco block dollyassembly
❏ Two hinged sensor bracket assemblies located on the rear ofthe guide track
❏ A sensor junction box located in the derrick near the abovebracket assemblies
❏ A crown height indicator control box, or an integral controlin the driller’s control and instrumentation console
The Crown Height Indicator Control (CHIC) control box(Figure 1-30) contains three indicator lights and an electronicprinted circuit board. Two of the indicators display the positionof the top of the traveling equipment relative to the crown. Thethird indicator displays system power status.
The yellow indicator on the CHIC control box illuminates whenthe top of the traveling equipment is within ten feet of the crown.The red indicator illuminates when the traveling equipment iswithin five feet of the crown. When the traveling equipment iswithin two feet of the crown both indicators flash alternately. Thegreen indicator illuminates when correct DC system power isavailable. This indicator also contains a push-to-test button whichsimulates the 2 ft. position.
The integral crown height indicator controls on the VDC areidentical to the separate control box.
TDS-4S Description 1-63
IBOPCLOSE
BRAKEON
BRAKEOFF ON
IBOPCLOSE OPEN
TORQ. WRENCHPUSH & PULL
LINK TILTOFF ON
CROWN CLEARANCE2 FEET WHEN FLASHING
5 FEET
10 FEET
ACTIVE/TEST
IBOPCLOSE
BRAKEON
BRAKEOFF ON
IBOPCLOSE OPEN
TORQ. WRENCHPUSH & PULL
LINK TILTOFF ON
CROWN CLEARANCE2 FEET
WHEN FLASHING
5 FEET
10 FEET
R
Y
G
ACTIVE/TEST
G
Y
R
Integrated Controls
Purge Air outto Protection Unit
VDCIndependent
Controls
Purge Air in
Figure 1-30. Typical CHIC control box
March 8, 2001
1-64 TDS-4S Description
TDS-4S Description 1-65
Chapter 3
Specifications
Drilling motorHorsepower: 1,100
Maximum stall time at full power is generally about 10 seconds.Refer to the Operation book for details.
Main gearbox lube systemProvides lubrication to both the primary gear set and swivelbearing. It includes explosion proof 5 hp AC motor/pumpcombination, filter/strainer, pressure loss sensor, and oil level sightglass. The TDS-4S main gearbox lube system holds approximately20 gallons (refer to the Maintenance and Troubleshooting book fordetails on oil capacity and adding oil to the gearbox).
March 8, 2001
1-66 TDS-4S Description
Cooling systems
Local blower *Flow 3,200 cfm
Blower motor 20 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Spark arrestors Standard style, BASEEFAapproved type available
Derrick mounted remote blower *Flow 3,200 cfm
Blower motor 40 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Spark arrestors Standard style, BASEEFAapproved type available
* These systems include an additional oil cooler/heat exchangermounted on top of the gearcase on the TDS.
Closed loopFlow 3,200 cfm
Blower motor 20 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Heat exchanger 220,000 BTU/Hr.for GE motor
Cooling water supply 50 gpm at 250 foot head,measured at rig floor
Oil cooler 6 gpm
Max. inlet temp 90°F
TDS-4S Description 1-67
Guide dolliesStandard rail setback 30, 39 or 48 in.(Wellcenter to centerline of rails)
Standard rail spacing 62, 66 or 72 in.(Centerline of rails)
Air loop ....................................................... 2-26Retract loop ....................................................... 2-27
Chapter 3 CommissioningCheckout procedures ..................................................... 2-29Long term TDS storage procedures................................ 2-32Returning the TDS to service after storage ..................... 2-33
October 20, 1998
2-4 TDS-4S Installation and Commissioning
TDS-4S Installation and Commissioning 2-5
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the examplesbelow and pay close attention to these important advisories.
z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personnel injury or equipmentdamage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rigpersonnel.
Avoid personnel injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.
October 20, 1998
2-6 TDS-4S Installation and Commissioning
Directional references
References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the Top DriveDrilling System (TDS-4S), standing behind the TDS-4S as itfaces well center.
Manual layout
This binder contains several separate books that you can removeindividually for convenience.
TDS-4S Installation and Commissioning 2-7
Chapter 1
Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-uphas been accomplished prior to installation of the TDS. Thisincludes:
1. Guide rails and bracing are installed and inspected toconform to Varco specification and installation tolerances(Figures 2-1, 2-2, and 2-3).
2. Stops are ready for installation at the bottom of the rails.
3. Hydraulic and air standpipes are installed in the derrick,flushed clean, and pressure tested. Water piping is installed,flushed, and pressure tested as well for configurations withclosed loop cooling systems.
4. All electronics are installed up to the derrick junction box:DC power leads, AC leads for blower motor, and control/alarm signals.
5. The transfer panel is installed.
6. Rigging of the tong lines, etc. are inspected to ensure thatthey will not foul with the TDS and other rig equipment.
October 20, 1998
2-8 TDS-4S Installation and Commissioning
TDS-4S Installation and Commissioning 2-9
Chapter 2
Installation
Derrick electrical termination kit
InstallationRefer to Figures 2-1, 2-2, and 2-3 for typical mountingdimensions of the plate assembly. Mount it at racking boardheight within 15 ft. of the service loop support bracket.Remember to provide convenient access for wiring andmaintenance.
Usually, mounting the plate so that the J-box is four to five feetabove the walk-around and near the service loop support bracketis adequate. If a walk-around does not exist, then construct awork platform to allow access to the J-boxes. Manufactureappropriate brackets and clamps to attach the plate to the derrickstructure.
October 20, 1998
2-10 TDS-4S Installation and Commissioning
39 x 66 W14 x 9048 x 62 W14 x 9030 x 72 W12 x 9030 x 72 W14 x 90
3.33.33.32.3
001.60.5
RailSize
SpliceClear
DollyOverhang
Inches
GuideDolly
Config.
± 1/4 in.Over Full Length
± 3/8 in. Over Full Length± 1/8 in. Within 25 ft. of Floor
± 3/8 in. Over Full Length± 1/8 in. Within 25 ft. of Floor
C Well CenterL
LC Rail C Rail
LC Well Center
LC Rail LC Rail
Splice Plates or Bolts Are
Not Permissibleon InsideSurfaces of Beam
10 ft. 6 in. +0/-4 in.
Maximum Rail Support Spacing16 ft. for W12x53 Rails25 ft. for W14x74 Rails
Nearest Girt
Guide Rails
C Well Center
Drill Floor
6" Rail Stop
TDS Back
L
SpliceClearance
Operational Clearance Between Top DriveAnd Nearest Girt or Fastline Should Be 3 in. Minimum
Dolly Overhang
L
Figure 2-1. General rail installation data
TDS-4S Installation and Commissioning 2-11
10 ft. 6 in.+0/-4 in. 7 ft. Ref
73 ft. Mud HoseConnection
Typical Equipment Stack-Up
* Customer Supplied** Varco Supplied
InstrumentJ-Box **
Motor J-Box **36.0 in.
36.0 in.
Control Service Loop**
Electrical Service Loop**
Fluids Service Loop**
48.0 in.
800 lb Load
5500 lb Load
18.0 in.
Ele
ctric
al S
uppl
y*
Must Support4,000 lb
View A-A
Typical ServiceLoop Termination
Gussets *
Existing Girt *
View B-B
HydraulicStandpipesTo Be 1 1/2 in.Sch 80 Pipe*
Air StandpipesTo Be 1 1/2 in.Sch 40 Pipe*
Water StandpipesTo Be 2 in. Sch 40 Pipe*
Clearance Hole For.75 in. Dia. Bolt (4 Places)
Filter/RegulatorLubrication Assembly**
Service LoopBracket**
75 ft.MudHoseRef
B
B
86 ft.ServiceLoops
83 ft. Hydraulic, Air and WaterStandpipe Height and
Service Loop Bracket Location
A
A
Figure 2-2. Derrick services/general installation data
October 20, 1998
2-12 TDS-4S Installation and Commissioning
L
L
L
L
Rail Loading while Drilling - 38,000 ft lb for TDS-3S, 60,000 ft lb for TDS-4S, 68,000 ft lb for TDS-6S,34,000 ft lb for TDS-7S and 62,250 ft lb for TDS-8S.
Rail Spacing TDS-3S TDS-4S, TDS-8S
Load L - lb
39 in. x 66 in. 3450
TDS-6S
--
48 in. x 62 in. 3680 --
30 in. x 72 in. 3170 --
--91/101 in. x 108 in. --
5450
5800
5000
3330
3090
3290
2840
3780
TDS-7S
P
P
Rail Loading with TDS in Setback position
Rail Spacing
39 in. x 66 in.
48 in. x 62 in.
30 in. x 72 in.
TDS-3S TDS-4S, TDS-8S
Load P - lb
18,600
18,600
17,500
18,900
18,900
17,800
Rail Stops
42,600 lb for a typical TDS-3S48,000 lb for a typical TDS-4S52,000 lb for a typical TDS-7S48,000 lb for a typical TDS-8S
Motor FrameSetback
Rails
9 ft. 3 in. TDS-3S10 ft. 3 in. TDS-4S,
TDS-8S 7 ft. TDS-3S8 ft. TDS-4S,
TDS-6S, TDS-8S
Figure 2-3. General installation data
TDS-4S Installation and Commissioning 2-13
WiringThe electrical installation requires routing power to the transferpanel and then to the TDS through the service loops (Figure 2-4).In addition, control cables are required between the service loop,the transfer panel, the SCR, the TDS Varco Driller’s Console(VDC), the SCR’s driller’s console, the hydraulic and waterpumps and the drilling recorder.
Transfer Panel
#12AWG/20C#10AWG/4C#14AWG/2 Pr Shld#6AWG/2C*Shunt Field
TopDrive
System
DerrickAC
J-Box
DerrickPowerJ-Box
Ser
vice
Loo
p
RotaryTable
#6AWG/2C*ExistingPowerCables
#14A
WG
/2 P
r S
hld
#12A
WG
/3C
#14A
WG
/37C
#12A
WG
/20C
#16A
WG
/10C
#12A
WG
/20C
#12A
WG
/20C
#10A
WG
/4C
#10A
WG
/4C
#6A
WG
/4C
#6A
WG
/4C
#12A
WG
/3C
#14A
WG
/2 P
r S
hld
#10AWG/4C
#16AWG/10C#16AWG/10C
#16A
WG
/10C
#16A
WG
/10C
#6AWG/2C*Shunt Field
#16AWG/10C
SCRRoom
ACPower
E/PTorq
E/PRPM
RBSControls
#12A
WG
/3C
TDSDriller’s Console
ExistingDriller’s Console
HYDPump
#1
HYDPump
#2WaterPump
#1
WaterPump
#2
(4)646MCM*
Figure 2-4. Typical cabling diagram
October 20, 1998
2-14 TDS-4S Installation and Commissioning
The cable requirements, depending on options selected are:
Cable Runs
646MCM (4 Shunt) SCR room to transfer panel
(8 Series) Transfer panel to derrick J-boxTransfer panel to rotary
#6AWG/2C (Shunt only) SCR Room to transfer panelTransfer panel to derrick J-boxTransfer panel to rotary
#6AWG/4C AC Power to hydraulic pumps
#10AWG/4C AC Power to water pumpsAC Power to transfer panelTransfer panel to derrick J-box
#12AWG/20C Transfer panel to existing driller’s consoleTransfer panel to derrick J-boxTransfer panel to hydraulic pumpsTransfer panel to water pumps
#12AWG/3C Transfer panel to RBS unitTransfer panel to VDCRBS unit to VDC
#14AWG/37C Transfer panel to VDC
#14AWG/2PR SHLD Transfer panel to derrick J-boxTransfer panel to VDCTransfer panel to drilling recorder
#16AWG/10C Transfer panel to SCR consoleTransfer panel to SCR roomHydraulic pumps to transfer panelWater pumps to transfer panel
Purge control system (not shown)
#12AWG/3C Purge control unit to transfer panelIsolation unit to floor air control unitTransfer panel protection unit to isolation unit
#16AWG/10C Purge control unit to transfer panelVDC protection unit to isolation unit
#14AWG/2PR SHLD Transfer panel to derrick J-box
Terminate the J-boxes per the electrical schematic. Followapplicable electrical codes during installation. Cable glands areprovided for the service loop cables. Cable glands for theincoming power, control and signal cables are not provided.
TDS-4S Installation and Commissioning 2-15
Plumbing
The plumbing connections should terminate near the service loopbracket. The mating halves are preassembled on the service loop.Specifications for specific lines are described in the followingsections.
HydraulicHydraulic lines should be cleaned and pickled, black pipe lines(one pressure and one return) 1 1/2 or 2 in. schedule 80 pipe.Install shut-off valves at the drill floor or racking board level. Thederrick connections are reduced to 1 in. NPT female pressure andfluid return for connection to the service loop.
AirAir lines should be schedule 40, 1 or 1 1/2 in. pipe in the case ofthe purge supply for the TDS. Install a shut-off valve at drill flooror racking board level. The air lines connect to the filtered andlubricated supply. The derrick connections are reduced to 1 in.NPT female for the purge line (if required) and 1/2 in. for the airline in order for the fluids service loop to match.
z Do not connect purge air lines to the lubricator. Only use clean,dry air in the purge air system.
WaterThe two cooling lines should be schedule 40, 2 in. pipe. Installshut-off valves at the drill floor or racking board level. See thecooling system specifications for water supply requirements. Thederrick connections are reduced to 1 1/4 in. NPT female pressureand return for connection to the fluids service loop.
October 20, 1998
2-16 TDS-4S Installation and Commissioning
Rig-up procedure
z Refer to the engineering drawings to install the TDS.
1. Using four lift slings from the crane, one attached at eachcorner of the guide dolly, lift the TDS motor and dollyassembly to the V-door.
2. Attach the lifting slings from the hook or block to the padeyes located at the swivel end of the motor support bonnetand lift the TDS into the guide rails. The slings must be aminimum of 15 ft. long (equal length) and capable of lifting40,000 lb combined. (BOP stack lift slings are usuallyadequate.)
z On some configurations it may be necessary to remove the upperroller brackets from the dolly to allow the unit to engage theguide rails.
3. Once the TDS is fully engaged on the guide rails, install thestops at the bottom of the guide rails and lower the TDS ontothe stops.
4. Slide the link adapter onto the drive stem and support it upagainst the rotating head with adequate rigging and an airwinch. Be certain that the link tilt mounting bosses areopposite from the torque wrench mounting clevis on therotating head.
5. Slide the landing collar retainer onto the drive stem as shownin Figure 2-5. Install the O-ring in the uppermost groove onthe stem. Load the O-ring and remaining grooves with awaterproof grease. Place the split landing collar around thegrooves of the drive stem, and drive in the remaining roll pin.Grease the OD liberally. Wipe off excess grease.
6. Use the installation procedure in the IBOP Service Manual toinstall the pipehandler assembly.
7. Use the pipehandler to tighten the connection between thelower IBOP/saver sub assembly to the upper IBOP.
TDS-4S Installation and Commissioning 2-17
Drive Stem
Safety Link (4)
Roll Pin (4)
Split LandingCollar (2)
O-Ring
Figure 2-5. Installing the landing collar
8. Use the four bolts, lock washers and safety wire provided toinstall this assembly to the link adapter. Connect the oppositeend of the hose to the quick disconnect on the rotating headassembly.
9. Install the elevator links and drill pipe elevator. Attach thelink tilt clamps to the bails (U-bolts on the inside). Thereshould be about 1/2 in. slack in the chains.
October 20, 1998
2-18 TDS-4S Installation and Commissioning
10. Install the counterbalance system as illustrated in Figure 2-6.When using chain, use the following procedure to determinethe chain length required:
a. Install pear links to ears on hook-block.
b. With the hook supporting the TDS, measure the distancefrom the point of contact inside the pear link to the topof the mounting lug on the integrated swivel bail.
c. Subtract 37 1/4 in. from the measurement in step b.
d. Cut the chain to the length obtained in step c.The tolerance is: +3 1/4 in. or -0 in.
e. Assemble remaining components and install perFigures 2-6 and 2-7.
11. Attach the service loops to the bracket on the TDS dollyframe. Using the cable clamps provided on the motor supportbonnet, route the electrical cables over the gear box and intothe J-boxes. The front guard folds down for access to the J-boxes.
Use the electrical schematic (refer to the engineeringdrawings) to make the connections. Be certain that the cablesare securely tied or clamped to the structure along theirlength. Route the hoses to the bulkhead and plug in the quickdisconnects. Follow the stamped code numbers to confirmeach type, and identify spares.
12. Attach the S-tube to the swivel gooseneck and the side of themotor frame as follows:
a. Make up the upper union just before clamping theS-tube to the side of the motor frame.
b. Install the drill pipe rubber onto the S-tube aligned withthe mounting saddle on the frame.
c. Attach the mud hose to the bottom connection of theS-tube.
d. Position the 20° S-tube elbow on the bottom of theS-tube to adjust the hanging direction of mud hose.
13. Remove the exhaust duct shipping covers from the sparkarrestors on the air exhaust duct at each side of the DCmotor. Save the covers for use during future shipping orstorage.
TDS-4S Installation and Commissioning 2-19
ConnectingLink
CounterbalanceManifold
(On Guide Dolly)
Pear Link
HydraulicAccumulator
(Inside Motor Frame)
CounterbalanceCylinder Assembly
(2)
Motor Frameand Guide Dolly
Assembly
IntegratedSwivel Bail
Counterbalance Lug(Bolted to Bail)
Figure 2-6. Typical counterbalance assembly
October 20, 1998
2-20 TDS-4S Installation and Commissioning
Guide Assembly
Hose Assemblies
Swivel BailCounterbalanceOperation Switch
Hydraulic Accumulator(Inside Dolly Tube)
Cylinder Assembly
Loop Assembly
Figure 2-7. Optional counterbalance assembly with parking system
n Never operate the top drive with the exhaust duct coversattached to the spark arrestors on the air exhaust ducts.Doing so severely restricts air flow through the motor, causingoverheating and potential damage. They can also fall offduring operation and injure personnel working below.Attach the covers only during shipping and storage.
TDS-4S Installation and Commissioning 2-21
Counterbalance system
Figures 2-6 and 2-7 illustrates the installation arrangement forthis system. Please see the Maintenance and Troubleshooting bookfor the adjustment procedures.
This assembly is pre-charged when it is shipped by land or watertransport. When this assembly is shipped by air freight, it must bepre-charged according to the instructions in the Maintenance andTroubleshooting book.
October 20, 1998
2-22 TDS-4S Installation and Commissioning
Motor alignment cylinder system
Figure 2-8 shows the motor alignment cylinder installed on atypical motor frame.
The split shipping brace, shown exploded from the cylinder rod,is only removed after unit is fully installed. If the brace is removedbefore the hydraulic system is powered, the motor will tend torotate on its trunnions.
If the cylinder is removed for service, use the three bleed holes(located along the top of the cylinder barrel) to remove trappedair from the cylinder before operating the unit. Refer to theMaintenance and Troubleshooting book for the adjustmentprocedure.
Motor AlignmentCylinder
MotorFrame Dolly (Ref)
ShippingBrace
Figure 2-8. Motor alignment cylinder
TDS-4S Installation and Commissioning 2-23
Driller’s controls and instrumentation
The controls and instrumentation described in the followingsections are, or must be, supplied for operation of the TDSsystem.
Varco Driller’s Console (VDC)Mount the VDC within easy reach and in plain view of the drillerwhile he is operating the drawworks brake and clutches. Thegauges must be easily seen by the driller during drillingoperations. Provide appropriate cable glands for the electriccables.
Throttle and torque limit controlsThe throttle and torque limit controls are the standard controlsused for the independent rotary drive table. If not using anindependent rotary drive, then these controls must be added bythe SCR manufacturer.
WiringRefer to the electrical schematics in the engineering drawings.
n Customers who choose to use control systems not manufacturedby Varco should be aware that Varco systems are specificallydesigned with operational interlocks and safety devices toprevent possible injury to personnel or damage to the system.Other systems must meet Varco requirements. Varco highlyrecommends the use of its system as it is specifically made foruse with the TDS.
October 20, 1998
2-24 TDS-4S Installation and Commissioning
Service loops
InstallationInstall the service loops as follows:
1. Fabricate the appropriate brackets and clamps to attach theservice loop mounting bracket to the derrick structure.
2. Place the service loop derrick mounting bracket at the heightspecified on the derrick interface drawing provided in theengineering drawings. Locate the bracket on the side of thederrick adjacent to the hinges on the TDS and as far aspractical toward the corner where the guide rail bracing isattached. The bracket must be located far enough from thecorner to insure the loops do not catch under the guide railsduring operations, but far enough back to provide clearancefor tong lines, the stabbing board, tugger lines, etc.
3. Do not unpack the service loops from the shipping protectivecrate until they are ready to hang in the derrick. Lift theservice loops onto the rig floor (still in the crates) and thenremove them from the crates with the lifting eyes provided.
e Use care in lifting gear rigging so as not to damage electricalconductors. Use lifting eyes only. Do not bend the service loops tighterthan a three foot bend radius. Tighter bends damage the loops.
4. Attach a sling to the TDS end of the service loop and liftusing the lifting eyes only. Allow enough room for the 86 ft.service loop to hang and untwist.
5. Use the lifting eyes to pull the derrick end of the loopthrough the V-door and attach it to the air tugger. Hoist thisend of the loop into the derrick while slacking off at the craneend. Do not drag the loop on any sharp areas on the derrick.Disconnect the crane from the sling and continue hoisting theloop into the derrick.
6. Check that the derrick end of the loop is hanging toward thecrown. Attach the derrick end to the derrick service loop bracketand hold in place with flange clamps (Figures 2-2).
TDS-4S Installation and Commissioning 2-25
7. Pick up the TDS end of the loops and attach them to theservice loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in thefollowing sections.
Electrical loop1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematicprovided to ensure proper terminal block assignments.
2 Cut wires and cables to length and terminate them at thederrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assemblyequipment (crimping pliers, wire strippers, and hydraulic crimperfor the DC power lugs with the correct dies for the cable) must beprovided by the installer. Installation practices should complywith applicable electrical codes (i.e., NEC, etc.).
Fluids loop1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of anycontamination.
z Use only 10 wt. hydraulic oil or non-detergent motor oil as alubricant in the air system. Use of any other type of oil (i.e., MarvelMystery Oil, etc.) or synthetic additive will cause the seals in the airvalves to swell and cease to function.
2. Plug the quick disconnects into the appropriate mating endon the TDS. The quick disconnects are arranged to connectonly one way so that the hoses cannot be mixed up. Thehydraulic and air lines are identification stamped at both endsso they can be verified and connected properly.
An assortment of pipe fittings are supplied with thetermination kit to attach the fluid service loop hoses to thetop of the standpipes in the derrick (Figure 2-2).
October 20, 1998
2-26 TDS-4S Installation and Commissioning
3. Connect the service loop to the standpipes, noting the codes(i.e., A for air, H for hydraulic, etc.) to separate the hoses.
z The hoses in the fluids loop only extend 11 ft. from themounting bracket. It may be necessary to make jumper hoses toreach the standpipes.
Air loop
e To reduce the possibility of accidental opening of the air-operatedelevator, attach the airlines from the air-operated elevators to thespare port S1 on the rotating head whenever possible. Port S1 islocated next to the hydraulic return port in the rotating head.Port S2 is next to the hydraulic press port.
Install a pressure relief valve on the elevator and set at 200 psi.
TDS-4S Installation and Commissioning 2-27
Retract loopIf your rig is equipped with a retract guide dolly, attach the retractloop to the derrick mounting brackets as follows:
z There are four separate service loops needed for a TDS withretractable dollies: two electrical loops, a fluids loop, and a retractsystem loop. The electrical and fluids service loops attach to thederrick service loop mounting bracket, the retract loop attaches tothe retract system service loop bracket.
1. Lift the crate containing the retract system service loop ontothe rig floor.
2. Uncrate the service loop.
3. Attach an air winch to the lifting eyes on the derrick end(derrick end has 8 ft. of hose extending beyond the flange)and hoist to the retract system mounting bracket.
4. Attach the service loop flange to the mounting bracket withthe hardware provided. Ensure that the service loop hangsstraight in the derrick without any twists or kinks.
e Use only 10 wt. hydraulic oil or non-detergent motor oil as alubricant in the air system. Use of any other type of oil (i.e. MarvelMystery Oil, etc.) or synthetic additive will cause the seals in the airvalves to swell and cease to function.
5. Connect the retract service loop hydraulic and pneumatichoses to the derrick standpipes.
e Before connecting the hoses from the service loop, be certain that thestandpipes have been flushed free of any contamination.
October 20, 1998
2-28 TDS-4S Installation and Commissioning
TDS-4S Installation and Commissioning 2-29
Chapter 3
Commissioning
Checkout procedures1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (driller’s controls only).
3. Check the function of switches and solenoids. There is anaudible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and theelevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears themonkeyboard when actuated. Refer to the Maintenance andTroubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the airescapes when the brake releases.
7. Move the Make/Break valve located on the manifold at the backof the pipehandler torque wrench to the BREAK position.
8. Turn on the hydraulic power supply and adjust the pressurereducing valve (also located on the torque wrench manifold)to the appropriate pressure for the lower IBOP connection.
October 20, 1998
2-30 TDS-4S Installation and Commissioning
9. Return the Make/Break valve to the MAKE position.
10. Torque the connection between the upper and lower IBOPvalves. The torque wrench automatic sequence is adjusted atthe factory, but be sure that it follows the proper sequence. Ifnecessary, refer to the Maintenance and Troubleshooting bookfor the adjustment procedure.
11. Push and hold the makeup button on the VDC a sufficientnumber of times to make up the connection.
12. Make up the lower IBOP to the saver sub.
13. Reset pressure to the appropriate setting for drill pipeconnections (you can preset the pressure with the Make/Breakvalve in the MAKE position).
14. Use the procedure outlined in the Maintenance andTroubleshooting book to adjust the safety valve actuatormechanism.
15. Actuate the IBOP valve. Verify that the stroke adjustment iscorrect and that no binding occurs.
e It is extremely important to verify that the stroke adjustment is correctand that no binding occurs as the valve will fail prematurely (washout) if it does not open and close fully.
16. Verify that the indicator light on the VDC lights up when theIBOP valve is closed.
17. Assign the TDS at the driller’s console and check that theblower operates.
18. Advance the throttle and be sure that the motor is operatingproperly in both directions.
19. Calibrate the Torque meter and RPM meter.
20. With the Hydraulic Power Unit (HPU) off, bleed down theTDS accumulators (HYD SIDE, not gas side).
21. Remove the split shipping brace (Figure 2-7) from the motoralignment cylinder.
22. Open the two flow control valves 1-1/2 turns off their seats.
23. Set a joint of drill pipe in the slips.
TDS-4S Installation and Commissioning 2-31
24. Bring the TDS down as if stabbing the saver sub into the box.The pin and box should be in alignment. If adjustment isnecessary, use the following procedure:
a. Measure how far and in what direction (toward or awayfrom the rails) the pin must move to line up with the drillpipe box.
b. Turn off the HPU and bleed down the cylinderaccumulator (open the needle valve on the back of themanifold). This allows the motor alignment cylinder torelax and the motor to rotate on its trunnions until theintegrated swivel bail contacts the motor support bonnet.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. With a wrench tightened on the cylinder rod flats, screwthe rod into or out of the clevis, in the same direction thesaver sub pin is to be moved.
e. Secure the jam nut and lock tab.
f. The nominal position of the two cylinder flow controlvalves is 1-1/2 turn off their seats. If you experience heavydrill pipe vibration, first attempt to control it with non-rotating stabilizers if the casing shoe is close to the surface.If motor movement becomes excessive due to continuedvibration, (more than 1/2 in. of total cylinder stroke)close the flow controls to 3/4 turn off their seats.
October 20, 1998
2-32 TDS-4S Installation and Commissioning
Long term TDS storage procedures
1. Palletize the main unit for indoor storage. A cargo container isappropriate for indoor/outdoor storage.
2. Avoid wide variations in temperature and high humidity. Thepreferred environment is clean and dry at 60°F ambient. Ifhigh humidity is unavoidable, 70°F is recommended.
3. All exposed unpainted metal surfaces are coated with a rustpreventive at the factory prior to shipment, however, checkthese surfaces periodically to be sure that no corrosion istaking place. The recommended rust preventive (slushingcompound) for bare metal surfaces is Kendall Grade 5(GE-D6C6A1) or equivalent.
4. Cover all openings to prevent water or dust from entering. Leaveenough space around the drilling motor to allow the machine tobreathe. Do not use silica gel or a dehydrating agent.
5. During storage, lubricant drains from the top half of the rollerbearings in the motor, allowing corrosion to take place on theexposed areas. In order to counteract this, rotate the motorand gear train periodically to distribute lubricant over the topof the bearings. Perform this at three month intervals if storedindoors, and at one month intervals if stored outdoors.
6. The drilling motor is equipped with AC space heaters inorder to keep the internal motor temperature above ambient,preventing condensation. Connect power to the space heatersat terminals 1 and 2 in the AC motor J-box (see electricalschematic in the back of this section for proper voltage).Be sure to reseal the protective covering after connection.
7. Megger the drilling motor armature and field (static voltage of1,000 VAC and 2 MOhm minimum) when placed intostorage and at three month intervals thereafter (one month ifstored outside). Keep a record of the readings, as a dropbetween readings indicates an increase in moisture in thewindings created by inadequate storage protection. If meggerreadings drop, bake the motor as soon as possible to restoreproper resistance and avoid further damage.
8. Varco recommends adding one gallon of Mobilarma 524 RustPreventive prior to shutdown. Or drain the oil and mix with arust preventive, then replace the oil, run the oil pump androtate motor to insure 100% coverage.
TDS-4S Installation and Commissioning 2-33
Returning the TDS to service after storage
Before placing the TDS back into service, verify the followingitems:
1. Remove all rust preventive and any corrosion that may havetaken place, taking special care with all load carryingcomponents.
2. Follow the procedure in the drilling motor service manual.To verify the condition of the motor, take note of thefollowing:
a. Blow out all dust and dirt that may have accumulated inthe windings with clean, dry air.
b. Visually inspect for spring corrosion, sticking brushes andgeneral defects.
c. Remove the brushes from holders, inspect and replacethem as necessary prior to operation.
d. Check the winding insulation continuity to ground witha 1,000 volt megger. If the reading is less than twoMOhms, bake the winding until the moisture content issufficiently reduced to produce an acceptable reading.
3. Perform a complete system test and adjustment as detailed inthe next section.
October 20, 1998
2-34 TDS-4S Installation and Commissioning
TDS-4S
Top DriveDrillingSystem
OperationSM00620-3
October 20, 1998
3-2 TDS-4S Operation
TDS-4S Operation 3-3
Contents
Preface/Manual conventionsSafety information ........................................................... 3-5Directional references ...................................................... 3-6Manual layout.................................................................. 3-6
Chapter 1 Operating proceduresStart-up procedure ........................................................... 3-7Stalling the DC motor ..................................................... 3-8Changing transmission speeds .......................................... 3-9Pipehandler operation .................................................... 3-11
Standard rotating head ............................................. 3-11Powered rotating head ............................................. 3-12
Drilling ahead with triples ....................................... 3-21Drilling ahead with singles ....................................... 3-24Drilling ahead on a semi .......................................... 3-26
Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the examplesbelow and pay close attention to these important advisories.
z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personnel injury or equipmentdamage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rigpersonnel.
Avoid personnel injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.
October 20, 1998
3-6 TDS-4S Operation
Directional references
References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the Top DriveDrilling System (TDS-4S), standing behind the TDS-4S as itfaces well center.
Manual layout
This binder contains several separate books that you can removeindividually for convenience.
TDS-4S Operation 3-7
Chapter 1
Operating procedures
Start-up procedure
Use the following procedure to start up the TDS:
1. Place the blower/oil pump switch in the AUTO position.
2. Place the hydraulic power unit (HPU) switch in the PLCposition.
3. Place the water pumps switch in the PLC position.
4. Place the motor space heater switch in the ON position.
5. Place the top drive/rotary table (TDS/ROT) lockout switchin the TDS position.
6. Assign a SCR.
October 20, 1998
3-8 TDS-4S Operation
Stalling the DC motor
e The brake on the top end of the TDS drilling motor armature shaft isa static, or parking brake. It is not a running or dynamic brake. It isnot intended to, nor is it capable of, slip-releasing the wind-up torquein the drill string. Using the brake to slip-release the drill stringwind-up torque causes the brake to heat up and can destroy the brakelining.
When the TDS motor brake holds the down-hole torque, Varcorecommends using the following procedure to safely release thetorque in the string:
1. Use the hand throttle to develop motor torque equal to thewind-up torque held by the parking brake.
2. Release the parking brake.
3. Reduce the drill current, reducing motor torque, as the drillstring slowly releases the wind-up torque.
4. Turn the hand throttle off and reset the drill current to thenormal operating position after the pipe unwinds completely.
e Do not leave the top drive DC motor stalled in a high torquecondition generally for more than 10 seconds (refer to the followingtable):
Amps Stall time (sec) Amps Stall time (sec)
280 240 900 25
470 90 1000 20
670 45 1200 15
820 30 1400 10
TDS-4S Operation 3-9
Changing transmission speeds
The transmission shifts gears by rotating two vertical compoundgear eccentric shafts (Figure 3-1). The two compound shafts (highand low) are supported between the main body and lower gearcase halves on heavy trunnions. As the shafts rotate (less than one-half turn), the compound gears go into or out of mesh with boththe motor pinion gear and the bull gear because the support shaftcenter axes are offset or eccentric.
To change transmission speeds, use a 1 in. wrench to turn the1 in. male hex, located on the well side of the guide dolly lowercross members at the bottom of the transmission case, to rotatethe input shaft. It takes five turns of the input shaft to unlockboth gear sets, rotate the engaged gear set to full disengagement,rotate the disengaged gear set into full engagement and lock bothgear sets in their proper positions with positive stops in the lockedposition. An external indicator shows the gear range selection.
An optional remote gear shifter is available. It allows the operatorto change gears simply by turning a switch to select the desiredgear. Refer to the Remote Gear Shifter Supplement for moreinformation.
October 20, 1998
3-10 TDS-4S Operation
HI LO
High GearEccentric Shaft
(Engaged)
Low GearEccentric Shaft(Disengaged)
GenevaMechanism
Shifter Input
ExternalHI / LO
Indicator
CompoundGear Shafts
ShifterInput Shaft
Rotating HeadAssembly
Bottom View
Top View
Figure 3-1. Transmission/geneva mechanism
TDS-4S Operation 3-11
Pipehandler operation
Standard rotating headThe perimeter of the rotating head cam (Figure 3-2) has anindented area where the cam follower normally rests. When thecam follower is in this indented area, the return cylinder rod isfully retracted and hydraulic pressure inside the cylinder is atequilibrium. When the swivel block and cam rotates to anotherposition along with the drill string, the ramp of the cam extendsthe return cylinder rod, unbalancing hydraulic pressure in thecylinder. When the elevator is released, the system automaticallyreturns to its pre-selected (indented) position (equilibrium).
To operate the swivel block locking mechanism, pull down thelocking lever, pulling the locking pin out of one of 24 lockingslots in the cam. With the locking lever in the vertical position,manually rotate the swivel block to the desired position andrelease the locking lever, setting the pin.
Stationary Flange
Locking Lever
Glyd Ring (8)
Auto-ReturnCylinder
Swivel Block
Cam
Cam Follower
Torque ArrestorLocation
Torque Wrench Hanger(Lug not shown)
Figure 3-2. Standard 650-Ton rotating head assembly
October 20, 1998
3-12 TDS-4S Operation
Powered rotating headThe 10-port powered rotating head (Figure 3-3) functions as ahydraulic slip ring. It provides ten hydraulic and pneumaticpassages between the stationary swivel flange and the rotatingswivel block and attached pipe handling equipment.
The powered rotating head is operated by controls on the driller’sconsole. The driller can rotate the swivel block and attached pipehandling equipment freely, or to a predesignated AUTO STOPposition. The position can be set by locating a target in the bullgear on the rotating head, to align with the proximity sensormounted on the flange of the rotating head.
ControlsThe powered rotating head is controlled by two switches.
ROTATING HEAD LEFT/RIGHT switch
This switch rotates the powered rotating head, pipe handler, andlink tilt to the right or left (same direction as the drill string).Rotation only occurs when the switch is held in the RIGHT orLEFT position. Rotation stops when the switch returns to thecenter position.
z The ROTATING HEAD function is only active when the LINKTILT switch is in the FLOAT position.
AUTO STOP/FREE ROTATE switch
This switch is in the AUTO STOP mode when the light isilluminated (on). In the AUTO STOP mode, a proximity sensorautomatically stops rotating head rotation. The AUTO STOPfunction is independent of the direction of rotation. Rotationcontinues when the ROTATE switch returns to the centerposition, then activated again. When the AUTO STOP/FREEROTATE light is off, the FREE ROTATE mode is active. In thismode, the rotating head rotates as described in the ROTATINGLEFT/RIGHT section above.
TDS-4S Operation 3-13
A4
A5
H3
S2
H2
A2
A3
H1
S1
A1
A1
A3
A5
A4
H2 S1
A2
S2
H3
PR
ES
SU
RE
H1
StationaryFlange
Bull Gear
Torque ArrestorHanger
Hydraulic MotorAssembly
Rotary GlydRing (11)
Swivel Block
Figure 3-3. Powered rotating head assembly
October 20, 1998
3-14 TDS-4S Operation
Safety valves (IBOP)Operating the switch on the VDC to the IBOP CLOSEDposition causes the two actuator air cylinder rods to extend,moving the arms and the actuator shell body upward (Figure 3-4).This upward movement causes the crank assemblies to rotate 90°,closing the upper IBOP.
Operating the switch to the OPEN position retracts the cylinderrods, drawing the IBOP actuator shell downward-opening theupper IBOP.
z Closing the manually operated lower IBOP requires an Allenwrench.
TDS-4S Operation 3-15
Safety Valve Actuator Shell
Crank Assembly (2)
Upper IBOP
Actuator Arm (2)
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Landing Collar
Link Adapter(Also known as
Solid Body Elevator)
Upper IBOPValve ActuatorAir Cylinder (2)
Main Shaft/Drive Stem
Figure 3-4. Safety valve actuator system
October 20, 1998
3-16 TDS-4S Operation
Torque wrenchThe primary function of the TDS torque wrench is to breakoutthe drill string from the saver sub before making a connection.The torque wench can also make connections if necessary (i.e.,when replacing the lower IBOP or saver sub, or while back-reaming, or when adding a pup joint to the drill stem).
The torque wrench has a control manifold with the followingcomponents (Figure 3-5):
❏ Hydraulic pressure gauge
❏ Control and sequencing valves
❏ Hydraulic hose inlet and outlet Quick Disconnects (QDs)
❏ Manual Make/Break directional valve
The Make/Break valve controls the torque wrench operatingdirection (makeup/breakout) during operation.
A pressure reducing valve (PRV) on the control manifold allowspresetting the makeup torque (this valve is bypassed when thetorque wrench is in breakout mode).
When the driller actuates the torque wrench from the VDC, thelifting cylinder rod retracts, raising the torque tube to engage thesplines on the upper IBOP. A sequenced signal from the controlmanifold then operates the clamping piston, clamping the jawsonto the drill string box connection. Then another sequencedsignal from the control manifold automaticallydirects pressure to the torque cylinders, rotating the torque tubeup to 25° while developing a maximum torque of 85,000 ft lb(65,000 ft lb on the PH-60d Pipehandler). The position of theMake/Break valve on the control manifold determines thedirection that the torque tube rotates.
A two-position, air-piloted, hydraulic valve located on thecounterbalance manifold located on top of the TDS guide dollycontrols the entire sequenced cycle described above. A pushbutton switch on the VDC operates the hydraulic valve. Thedriller holds the button down to makeup or breakout aconnection, and then releases the button to allow the torquewrench to automatically recycle to the ready position. If thetorque developed on the first pass is insufficient, the driller simplyoperates the button again.
TDS-4S Operation 3-17
Manually switch the Make/Break valve on the torque wrench tothe MAKE position to use the top drive torque wrench to makeconnections. This allows the driller to initiate automatic torquewrench sequences and repeat them until reaching the presetmakeup torque.
BREAK MAKE
PRVTORQUECLAMPRECYCLE
LIFT LOWER
PSI
Ft.Lbs. x1000
0
1020
30
4050 60
70
8090
1000
500
1000 1500
2000
2500®
Make/BreakValve
Torque WrenchManifold
TorqueSequence
Valve
ClampSequence
Valve
RecycleSequence
Valve
HydraulicPressureReturn
HydraulicPressure
Inlet
Lift/LowerFlow Control
Valve
Torque Gauge0 - 2500 PSI
Figure 3-5. Typical torque wrench control manifold
October 20, 1998
3-18 TDS-4S Operation
n Failing to apply the correct amount of torque when using thetorque wrench to makeup connections can result in equipmentdamage and injury to rig personnel.
Do not switch the Make/Break valve to BREAK until completingthe makeup sequence, which may require repeating the makeupsequence several times.
Verify the torque pressure regulating valve setting after everymakeup sequence before releasing the makeup valve. Repeat themakeup sequence until the torque cylinders do not stroke morethan one inch during the final sequence, repeat the sequence ifuncertain. Varco recommends that the driller operating thepipehandler verify that the torque cylinders do not stroke morethan one inch on the last makeup cycle.
Varco also recommends checking the torque gauge on thepipehandler while making connections to make sure the torquewrench applies the correct amount of torque to the connection.
Stop and verify correct operation whenever the operator observesunsteady or inconsistent hydraulic pressure readings, or finds itdifficult to adjust set points.
Varco recommends that a second individual assist the driller whenmaking connections with the torque wrench. The second personcan verify that the torque wrench applies the correct torque toconnections.
TDS-4S Operation 3-19
Changing drill string sizes
PH-85To operate the torque wrench using drill string sizes that are differentfrom the size specified on your rig’s original configuration, install aseparate drill string handling kit. Refer to the following tables whenordering a drill string handling kit for a PH-85:
Drill String Change-Over Kits750/650 Ton PH-85
Desired Tool Joint ConnectionPipehandlingOriginal Part Number NC 38
PH-60dTo operate the torque wrench with a 3 1/2 in. drill string, install aseparate drill string handling kit. The following lists available kitsfor a PH-60d:
❏ Part No. 78652-1 – Includes stabbing guide assembly, jawassemblies, saver subs, installation drawing.
❏ Part No. 78652-2 – Includes stabbing guide assembly, jawassemblies, installation drawing.
z Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No.78652-2 does not. By purchasing the latter, the user assumesresponsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saversubs separately. Specifications for these are available from thefactory or any Varco service center.
October 20, 1998
3-20 TDS-4S Operation
Torque values for load carryingcomponentsProper makeup torque is critical to the function of drill stemcomponents. Table 3-3 only includes components within theTDS. Refer to the API charts for other components.
Table 3-3. Torque values for load carrying components
Components ID Connection OD Min. torque Max. torque
Upper IBOP tomain stem/main shaft 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 63,000 ft lb
Lower IBOP valveto upper safety valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 60,000 ft lb
Saver sub tolower IBOP valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft lb 60,000 ft lb
Crossover sub tolower IBOP valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft lb 60,000 ft lb
Upper IBOP valve tomain stem/main shaft 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 83,000 ft lb 91,000 ft lb
Lower IBOP valveto upper IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 84,000 ft lb
Saver sub tolower IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 7 5/8 in. 66,000 ft lb 85,000 ft lb
Crossover sub tolower IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 91,000 ft lb
TDS-4S Operation 3-21
Drilling ahead
Drilling ahead with triplesDrilling ahead with triples is the common drilling mode for theTDS. There are various sources for triples. On skidding rigsdrilling multiple well platforms, drill pipe can be left racked andused to drill the next well.
If triples do not currently exist, there are two recommendedmethods of obtaining them. One is to leave some triples racked inthe derrick when tripping back in the hole and finish the tripwith singles. Leave enough triples racked to handle anticipated bitlife.
The second method for obtaining triples is to make up triples inthe mousehole while drilling ahead or during idle rig time. Forsafety reasons a pivoting mousehole is best because it can pivot toa vertical plane to simplify making connections.
Use the following procedure to drill ahead with triples(Figure 3-6):
1. Drill down until the saver sub is within three feet of therotary table.
2. Circulate bottoms up as necessary.
3. Stop the string rotation.
4. Pick up the string and set slips for a connection four feet offthe rig floor.
5. Switch the TDS motor from FORWARD to REVERSE.
6. Stop the mud pumps.
7. Close the IBOP.
8. Break out the drill pipe connection using the torque wrenchon the pipehandler.
9. Using the TDS motor, spin out of the box while hoisting theTDS with the drawworks (follow with the drawworks, do notlead).
October 20, 1998
3-22 TDS-4S Operation
Set slips onstring
Stop circulation
Breakoutconnectionusing pipehandler and drilling motor(in reverse)
Raise block
Tilt link tiltto derrickman
Pickup stand withelevator
Stab bottom ofstand onto string
Lower block tostab motor intotop of stand
Spin in motorand stand
Makeup bothconnections withmotor
Pull slips
Start circulation
Begin drilling
1 2 3 4 5
Stab Makeup
Makeup
StopCirculation
StartCirculation
LinkTilt
Figure 3-6. Drilling ahead with triples
TDS-4S Operation 3-23
10. Stop the spin out mode.
11. Open the drill pipe elevators.
12. Retract the TDS away from the hole.
13. Hoist the TDS to the racking board level to get the nextstand.
14. Latch the backup tong on the box connection.
15. Thoroughly dope the box connection in the rotary table.
16. When the TDS is fully raised, extend the TDS.
17. Tilt the links.
18. Switch the TDS motor from REVERSE to FORWARD.
19. Derrickman latches the elevator on the next stand.
20. Hoist the pin off setback area and clear the box with thestand.
21. Release the link tilt.
22. Stab the connection at the floor.
23. Switch the TDS to SPIN IN mode.
24. Continue to slack off approximately two feet to stab theupper connection of the stand with the TDS.
25. Slack off to allow connection to shoulder up (lead with thedrawworks, do not follow).
26. Switch to TORQUE and hold for approximately six seconds.The makeup torque is preset.
27. Verify full makeup to the correct value on the torque meter.
28. Switch to DRILL mode.
29. Unlatch the backup tong.
30. Open the IBOP.
31. Start the mud pumps.
32. Pick up to pull the slips.
33. Drill ahead.
October 20, 1998
3-24 TDS-4S Operation
Drilling ahead with singlesTypically there are two situations requiring drilling ahead withsingles. One is beginning operations on a new well where thereare no triples made up and racked. The other is when makingsurveys every 30 ft. (i.e., when kicking off using a downhole mudmotor). The link tilt feature makes drilling with singles safe andefficient by moving the elevators to the mousehole to pick up thesingles.
Use the following procedure to drill ahead with singles(Figure 3-7):
1. Drill down the existing single, pull up to the 4 ft. level(approximately), close the IBOP, stop mud circulation, andset the slips.
2. Break the connection between the saver sub and the drill pipeusing the torque wrench in the pipehandler.
3. Spin out the connection using the drilling motor.
4. Lift the TDS, opening the drill pipe elevators to allow themto pass over the box setting in the rotary table.
5. Actuate the link tilt to bring the elevator over to the single inthe mousehole and latch the elevator around the single.
6. Pull the single out of the mousehole and as the pin clears thefloor, deactivate the link tilt to allow the single to come towell center.
7. Stab the connection at the floor and lower the TDS, allowingthe added single to enter the stabbing guide until the saversub pin stabs into the box of the new joint.
8. Using a backup tong to react the torque, spin up and torquethe connection using the TDS motors in the TORQUEmode.
9. Pull the slips, start the mud pumps and drill ahead.
TDS-4S Operation 3-25
Set slips onstring
Stop circulation
Close IBOP
Breakoutconnectionusing pipehandler and drilling motor(in reverse)
Tilt links tomousehole
Latch drill pipeelevator aroundsingle
Pickup single withelevator
Release link tilt
Stab bottom ofsingle onto string
Lower block tostab motor intotop of single
Spin in motorand single
Makeup bothconnections with motor intorque mode
Pull slips
Open IBOP
Start circulation
Begin drilling
Stab Makeup
OpenIBOP
LinkTilt
1 2 3 4 5
Makeup
CloseIBOP
Figure 3-7. Drilling ahead with singles
October 20, 1998
3-26 TDS-4S Operation
Drilling ahead on a semiDerrick clearances are critical for drilling operations with theTDS on a floater. When making a connection, kelly drilling pullsthe bit off bottom far enough to account for vessel heave. The54 ft. kelly must be pulled all the way up to add the next joint.
With the TDS, there is no kelly to pull up. Therefore, you mustbe able to pull the bit off bottom enough to allow for vessel heavewhen making a connection. The practical method for doing thisis to pull up the pipe string until the bit is sufficiently off bottom,and then set the slips. The distance should equal the maximumexpected heave.
The TDS pipehandler can break out the drive shaft, and the TDSmotor can spin out the connection. Then hoist the TDS into thederrick and add a new 90 ft. stand from the pipe rack in the samemanner as on a fixed rig.
Because the pin connection of the new stand is about 15 ft. abovethe floor, a torque backup device is required, as well as a means toassist stabbing. Varco provides a simple, remotely-operated RaisedBackup System (RBS) which retracts out of the way when not inuse.
Use the following procedure to drill ahead with triples on a semi(Figure 3-8):
1. Drill the stand down until the elevator is to the floor.
2. Pull the string up sufficiently off bottom.
3. Set the slips.
4. Breakout the TDS and spinout shaft using the drilling motor.
5. Raise the TDS to the racking platform and latch the elevatoron a new stand.
6. Extend the RBS and adjust the height. Clamp the RBS tongon the elevated box of the drill string.
7. Stab the pin of the new stand into the string using the RBSstabbing head if so equipped, or use the lower racking arm.
8. Stab the TDS into the upper end of the stand, spin in, andmake up both connections.
9. Retract the RBS.
10. Pull the slips and drill ahead.
TDS-4S Operation 3-27
1 2 3 4 5
Drill down stand
Stop circulation
Unlatch elevator
Pickup string10 to 20 ft.
Set slips
Breakout/spinoutwith pipehandlerand motor
Raise block
Extend RBSand adjust height
Pickup stand
Stab stand usingRBS to assist
Spin in stand
Makeup bothconnectionswith motor
Pull slips
Retract RBS
Start circulation
Begin drilling90 ft.
Makeup
StopCirculation
Makeup
StartCirculation
Figure 3-8. Drilling ahead with triples (floaters)
October 20, 1998
3-28 TDS-4S Operation
Tripping
Perform tripping operations in the conventional manner. Use thelink tilt feature to tilt the elevator to the derrickman so thederrickman can quickly latch it around the pipe.
The hydraulic link tilt allows the elevator to also reach themousehole.
The air actuated link tilt has an intermediate stop which isadjustable to set the elevator at a convenient working distancefrom the monkeyboard. The intermediate stop tilts out of the wayto allow the elevator to reach the mousehole.
If a tight spot or key seat is encountered while tripping out of thehole, spin the drilling motor into the stand at any height in thederrick. Establish circulation and rotation immediately to workthe pipe through the tight spot.
TDS-4S Operation 3-29
Reaming out
The TDS permits reaming out of an open hole to prevent pipesticking and to reduce key seat formation, without affectingracking functions associated with normal tripping (i.e., there areno singles to contend with). The pipehandler torque wrench canbreak out 90 ft. stands in the derrick.
Use the following procedure to ream out of the hole (Figure 3-9):
1. Hoist the block while circulating and rotating the drillingmotor until the third connection appears.
2. Stop circulation and rotation and set the slips.
3. Break out the drilling motor from the top of the stand usingthe pipehandler torque wrench. Hold a backup at the floorand spin out the drilling motor.
4. Break out the stand at floor level, and spin out using pipespinners.
5. Pick up the stand with the drill pipe elevator.
6. Rack the stand back.
7. Lower the block and TDS to the floor.
8. Stab the drilling motor into the box, spin up and torque itwith the drilling motor. With light slip loads, the pipehandlertorque wrench can be used to torque the connection.
9. Resume circulation and continue reaming out of the hole.
October 20, 1998
3-30 TDS-4S Operation
Hoist whilecirculating androtating
When 3rdconnectionsurfaces, stoprotation andcirculation
Set slips onstring
Breakout connec-tion using pipehandlerand drilling motor (reverse)
Breakout andspinout standat floor
Hoist free standwith elevator
Setback standusing link tilt
Setback
Lower block,stab motor intostring
Spin in motorand makeupconnection withmotor
Start circulation,pull slips,hoist and rotate
1 2 3 4 5
Breakout
Breakout Hoist
Hoist andRotate
Figure 3-9. Reaming out
TDS-4S Operation 3-31
Well control procedures
The TDS can stab into the string in any position in the derrick.While drilling, the remotely controlled IBOP valve is always inthe string for immediate use as needed.
Use the following TDS well control procedure in conjunctionwith standard IBOP well control procedures:
1. On indication of a kick, set the slips at the nearest connectionand stab the TDS into the string.
2. Spin up and torque the connection using the Spin/Torquecontrol, after setting the backup tong.
3. Remotely close the upper IBOP valve.*
4. Lower the string to the floor and reset the slips.
5. Manually close the lower IBOP valve.
6. Remove the torque wrench vertical travel stops.
7. Breakout the lower IBOP from the upper IBOP.
8. Engage the top drive motor in reverse to spin out theconnection.
9. Install the appropriate crossover sub, check valve orcirculation sub on top of the lower IBOP valve.
10. Proceed with normal well control procedures.
* Operation of the IBOP valves is the same as any standard valve.A 7/8 in. hex wrench is included with the system to operate theupper valves if the remote actuator should fail, or for checkingthat the valve is functioning correctly.
October 20, 1998
3-32 TDS-4S Operation
Running casing
For casing operations, longer elevator links (180 in.) must be usedto allow clearance for the cementing head under the torquewrench in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler tofill the casing while lowering. Use the remotely controlled upperIBOP valve to start and stop the fluid flow.
If desired, run casing conventionally using the block and hookand swinging the TDS aside. Use longer bails (180 in.) to preventthe block dolly (if used) from contacting the TDS dolly.
Handling bottom hole assemblies
For handling bottom hole assemblies, use the swiveling drill collardolly (Figure 3-10) to allow the elevators to turn freely. The drillcollar dolly’s upset, which latches in the standard drill pipeelevator, is mounted on a bearing allowing it to swivel even whileit is under load. A shoulder elevator is suspended from the“perfection” links (or a second drill pipe elevator if lifting subs areused.) The collars can be walked in or out with the elevatorturning on the drill collar dolly.
TDS-4S Operation 3-33
100 TONVARCO ��
������ ��
������
A
A
Drill PipeElevator
Drill CollarDolly
PerfectionLinks (36")
SquareShoulderElevator
LiftingSub
DrillCollar8 in.
View A - A
91 in.
37 in.
Figure 3-10. Swiveling drill collar dolly
October 20, 1998
3-34 TDS-4S Operation
Post jarring operations
e Jarring occurs on all drilling rigs. It is not practical to recommendremoving the top drive from the drill string during all jarringoperations. But the possibility of damage to a top drive during ajarring operation is considerable. Consider removing the top drivefrom the drill string before performing prolonged jarring. It isimperative to exercise caution when using a top drive after a jarringoperation.
Safe operation of the TDS is the responsibility of the user and rigcrew. Use the Post Jarring Checklist (PI 93-1) and DesignSpecification, Design Torque Standard (DS00008) to help ensuresafe top drive operation. Note that the checklist includesrecommended procedures. Do not limit inspections to items on thechecklist.
The checklist draws attention to specific parts on major subassemblies.Inspection should be rigorous, looking for any wear that could cause asafety or operational risk.
Use the Post Jarring Checklist (PI 93-1) and Design Specification,Design Torque Standard (DS00008) after performing any jarringoperation while the top drive is in the drill string.
TDS-4S
Top DriveDrillingSystem
MaintenanceandTroubleshooting
SM00620-4Rev. B
March 8, 2001
4-2 TDS-4S Maintenance and Troubleshooting
TDS-4S Maintenance and Troubleshooting 4-3
Contents
Preface/Manual conventionsSafety information ........................................................... 4-7Directional references ...................................................... 4-8Manual layout.................................................................. 4-8
Initial oil change period ........................................... 4-27Oil capacity.............................................................. 4-28Lubricating the DC motor ....................................... 4-29Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31Lubricating the link adapter ........................................... 4-32Lubricating the torque wrench ....................................... 4-33Lubricating the master bushing ID wear guide ............... 4-34
March 8, 2001
4-4 TDS-4S Maintenance and Troubleshooting
Lubricating the safety valve actuator .............................. 4-34Lubricating the upper safety valve (IBOP) ..................... 4-35Lubricating the guide dolly assembly ............................. 4-36Lubricating the bail pins ................................................ 4-41Lubricating the cooling system....................................... 4-42Lubrication schedule ...................................................... 4-44Lubricant specifications ................................................. 4-45
Adjusting the torque wrench .................................... 4-49Adjusting the upper safety valve (IBOP)and safety valve actuator system ............................... 4-52Adjusting the counterbalance system ........................ 4-52Adjusting the motor alignment cylinder system ....... 4-54Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62Replacing the torque wrenchclamping piston seal ..................................... 4-68
Replacing the standard rotating headglyd rings ........................................................... 4-71Replacing the powered rotating headglyd rings ........................................................... 4-75Replacing the standard or extended reachlink tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81Front jaw ........................................................... 4-81Rear jaw ............................................................. 4-81
Removing the motor assemblyfrom the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motorand motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87Local blower cooling system assembly/disassembly ... 4-89Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95Safety wiring tips ..................................................... 4-97
TDS-4S Maintenance and Troubleshooting 4-5
z This section contains some information regarding the GE motor.Refer to the GE Motor Service Manual, VDR00023 (included inVDP0001) for specific details such as:
❏ Inspection and maintenance schedule
❏ Recommended storage instructions -drilling motors and generators
❏ Removing motors or generators from storage
Chapter 4 TroubleshootingTroubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101Troubleshooting the retract guide dolly ................. 4-101Troubleshooting the transmission .......................... 4-102Troubleshooting the oil pump ............................... 4-103Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106Troubleshooting the torque wrench ....................... 4-106Troubleshooting the safety valve actuator............... 4-108Troubleshooting the link tilt .................................. 4-108Troubleshooting the pipehandler at thecounterbalance manifold ........................................ 4-109Troubleshooting the crown height indicator .......... 4-110Six-gang air valve assembly illustration ................... 4-111
March 8, 2001
4-6 TDS-4S Maintenance and Troubleshooting
TDS-4S Maintenance and Troubleshooting 4-7
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the examplesbelow and pay close attention to these important advisories.
z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personnel injury or equipmentdamage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rigpersonnel.
Avoid personnel injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.
March 8, 2001
4-8 TDS-4S Maintenance and Troubleshooting
Directional references
References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the Top DriveDrilling System (TDS-4S), standing behind the TDS-4S as itfaces well center.
Manual layout
This binder contains several separate books that you can removeindividually for convenience.
TDS-4S Maintenance and Troubleshooting 4-9
Chapter 1
Maintenance
Inspection
TDS swing out procedureVarco top drives with swing-out guide dollies can be quicklyswung aside on their own dolly frames for inspection,maintenance, running casing, or to allow drilling operationsrequiring a kelly and rotary table. Electrical, hydraulic, and airsupplies do not have to be disconnected. Use the followingprocedure to swing out the TDS only if your rig has a guide dollywith hinge pins (refer to the engineering drawings forinformation specific to your rig configuration):
1. If you have a retract system, operate the switch on the VDCto 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.
March 8, 2001
4-10 TDS-4S Maintenance and Troubleshooting
z On some rigs, it may be necessary to secure the traveling blockframe to the guide dolly frame using chain and/or rope.
5. Turn off the Hydraulic Power Unit (HPU) and bleed downhydraulic pressure by opening the needle valve on thecounterbalance manifold. (The counterbalance manifold islocated on the upper motor frame.)
6. Detach the counterbalance system cylinders from the hook orblock by unhooking the pear links from the ears on the hookor block.
7. Disconnect the air intake hose.
8. Disconnect the mud hose from the TDS S-tube.
n Unlatching the hook from the integrated swivel bail may cause theTDS motor assembly and/or the hook to lurch suddenly. Alwayskeep adequate tension on the tailing lines to prevent suddenmovement of these assemblies.
9. Unlatch the hook.
10. Attach tugger lines to the TDS motor frame, opposite theframe hinges, to assist in swinging out the TDS motorassembly. Use tailing lines on the motor frame to controlswing out.
11. Unfasten the two swing-out bolts, opposite the hinges,holding the motor frame to the guide dolly.
12. Operate the air tuggers to slowly pull on the motor framewhile unhooking the traveling block from the swivel bail.
13. When the traveling block is disconnected, continue swingingout the TDS 180° and secure the motor assembly to thederrick with chain and/or rope.
TDS-4S Maintenance and Troubleshooting 4-11
To swing the TDS back in for operation after inspection ormaintenance, perform the following procedure:
1. Lower the guide dolly far enough to allow swinging theTDS back into place.
2. Retract the TDS and secure it.
n While latching the hook to the integrated swivel bail, the swiveland/or the TDS motor assembly may suddenly lurch. Always keepadequate tension on tailing lines to prevent sudden movement ofthese assemblies.
3. Attach tugger lines to the TDS motor assembly, opposite thehinges, to aid in swinging back the TDS assembly. Use tailinglines on the motor frame to control swing back.
4. Release the chain and/or rope securing the TDS motorassembly to the derrick and slowly swing back the TDS motorassembly to the guide dolly. While swinging it back, latch thehook onto the swivel.
5. Secure the motor frame to the guide dolly with the twoswing-out bolts opposite the hinges.
6. Connect the mud hose to the S-tube.
7. Connect the air intake hose.
8. Hook the counterbalance system pear links onto the ears ofthe hook or block.
9. Turn the HPU on and bleed air out of the system.
March 8, 2001
4-12 TDS-4S Maintenance and Troubleshooting
DC drilling motorThoroughly inspect the TDS, motor support bonnet, and guidedolly assembly for loose bolts and fittings daily. If any safety wireor cotter pins were removed to facilitate repairs, replace themimmediately.
z The DC motor has a complete manufacturer’s service manual foryour reference provided in the Vendor Documentation Package.
Motor alignment cylinder
e The alignment cylinder is not intended to be used to align the pinwith the box at the well bore. It is a device to counterbalance theoffset weight of the DC motor and allow the system to accommodateexternal forces. It is adjustable to ensure that the mainshaft is straightat well center–to compensate for design tolerances in the guide railsand dolly. To work properly, the guide rails must be properly located,and the dolly must fit within design tolerances.
Check alignment cylinder operation weekly. Also, inspect allmoving parts and check accumulator pressures on a weekly basis.
Air exhaust mufflerVarco installs air exhaust mufflers on the exhaust ports of themulti-gang solenoid valve manifold for noise abatement. All suchmufflers reduce noise and collect contaminants that caneventually restrict the air passage. Air passage constriction resultsin back pressure on all of the solenoid valves and erratic valveoperation. It also holds pressure on the air brake.
Periodically remove the mufflers and clean or replace them.
If noise abatement is not an issue on the rig, replace the mufflerswith simple pipe elbows.
TDS-4S Maintenance and Troubleshooting 4-13
Derrick termination kit air filter/regulator/lubricatorsTop drives that rely on rig air to power link tilt, upper IBOP,brake, and torque wrench makeup/breakout sequence pilot signalfunctions require regular inspection. The air valves, cylinders andactuators for these functions require proper lubrication andmoisture-free and particle contaminant-free air. Moisture in theair can cause corrosion on internal cylinder surfaces. Particlecontamination can damage the seals in moving parts and causesolenoid valves to stick. Oil, injected by the lubricator and carriedby the air, reduces friction between moving parts and increasesthe life of seals in valves and actuators.
z Varco supplies a filter/regulator/lubricator in the derrickinstallation kit and recommends installing it at the fingerboardlevel in the derrick. Improperly adjusted regulators can cause poordevice performance at reduced pressures, or valve and cylinderseals and O-ring extrusion at excessive pressures.
Inspect the entire filter/regulator/lubricator monthly for damageto the filter bowl, overall body, or inlet and outlet fittings.Replace any damaged, corroded, or improperly functioningcomponents.
Adjust the pressure regulator outlet pressure to 100-120 psigmonthly. Clean and drain the filter weekly. Fill the lubricatorwith petroleum-based hydraulic oil with a fluid viscosity of100-200 SSU at 100°F (ISO 32/34).
e Do not use fluids such as Marvel Mystery Oil, motor oil, orDextron II in the lubricator. Swollen seals may result.
March 8, 2001
4-14 TDS-4S Maintenance and Troubleshooting
PipehandlerThoroughly inspect the pipehandler for loose bolts and fittingsdaily. If any safety wire or cotter pins were removed duringrepairs, replace them immediately.
Inspect the hinge bolts daily to make sure they are not separatingfrom the pipehandler. Make sure the hinge pins are not loose dueto excessive wear in the bore of the clamp clevis or a brokenretaining bolt.
n Inspect the link tilt intermediate stop and adjustment device foroverall integrity weekly. Replace the components if there isexcessive looseness of the threaded rod in the threaded hole of thepivot arm (Figures 4-24 and 4-25). An indication of a possibleproblem is if the two intermediate stops are not adjusted equally(i.e., if the thread engagement differs between the two stops).Failure to perform this inspection and/or component replacementcan result in injury to rig personnel.
Nondestructive Examination (NDE)Yearly (or after approximately 3,000 operating hours), perform aNondestructive Examination (NDE) of all critical load pathitems.
z NDE inspection includes visual examination, dye penetrantexamination, magnetic particle inspection, ultrasonic inspection,x-ray examination, and other methods of nondestructive testingfor metallurgical integrity.
Visual inspectionUse calipers on a regular basis to measure the amount of wear onthe elevator link eyes (Figure 4-1). Compare the measurementswith the Wear Chart (Figure 4-1) to determine the currentstrength of the elevator links. The capacity of the links equals thecapacity of the weakest link.
TDS-4S Maintenance and Troubleshooting 4-15
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5 in.4 13/16 in.
4 5/8 in.4 7/16 in.
2 3/4 in.2 9/16 in.2 3/8 in.2 3/16 in.
350300225175
B = 3 1/2 in., 350-Ton
Wear Chart - Forged Links
6 in.5 3/4 in.5 1/2 in.5 1/4 in.
3 1/2 in.3 1/4 in.
3 in.2 3/4 in.
500420325250
B = 4 1/2 in., 500-Ton
7 1/2 in.7 1/4 in.
7 in.6 3/4 in.
350300225175
B = 6 1/4 in., 750-Ton
UpperEye
DimensionC
LowerEye
DimensionA
Capacity(per set)in Tons
7 1/2 in.7 1/4 in.
7 in.6 3/4 in.
UpperEye
(Hook)
LowerEye
(Elevator)
To determine the strength of worn links,measure (with calipers) the amount of eyewear and compare the measurementswith the above Wear Chart to find thecurrent capacity. The capacity of the set oflinks is determined by the weakest link.
CC
B
B
A
A
Figure 4-1. Visual inspection of elevator links
March 8, 2001
4-16 TDS-4S Maintenance and Troubleshooting
Landing collar
Disassemble and inspect the landing collar every six months.Use the following procedure to disassemble the landing collar(Figure 2-5) for inspection:
1. Disconnect the top drive from the drill string.
2. Remove the IBOPs and pipehandler.
3. Raise the solid body elevator to expose the landing collarretainer.
4. Straighten the retainer tabs.
5. Slide the retainer ring above the split landing collar halves.
6. Drive out one roll pin.
7. Remove the landing collar halves.
8. Slide the retainer off the drive stem.
After disassembly, inspect all landing collar parts for wear,damage, or corrosion. Check for:
❏ Grooves or other radial wear marks indicating that the bore ofthe solid body elevator is rubbing on the outside diameter ofthe landing collar retainer shell
❏ Radial grooves on the inside diameter of the retainer shell
❏ Missing tabs from the retainer shell
❏ Wear or corrosion induced pitting on the retainer shell shoulder
❏ Wear, corrosion, or fatigue cracks on the inside or outsidediameter of the landing collar halves
❏ Evidence of drive stem contact with the solid body elevator
❏ Evidence of inside bore wear on the solid body elevator indicatingcontact with the drive stem or landing collar retainer. Wear onthe inside shoulder of the elevator should not exceed 1/8 in.
❏ Evidence of wear, corrosion, or fatigue cracks on the safetylinks
TDS-4S Maintenance and Troubleshooting 4-17
Replace the appropriate part(s) if any of the above conditionsexist. Use the following procedure to reassemble the landingcollar:
1. Replace the existing O-ring in the retainer shell.
2. Grease the inside diameter of the retainer shell.
3. Slide the retainer onto the drive stem above the landing collargrooves.
4. Install one new roll pin and safety links on the split landingcollar halves.
5. Coat the landing collar halves with a generous amount ofwater resistant grease.
6. Place the landing collar halves on the drive stem with15° taper closest to the top drive.
7. Drive in the remaining roll pin.
8. Slide the retainer shell over the landing collar halves.
9. Use a hammer and drift to bend all 32 retainer tabs to securethe retainer shell.
10. Coat the retainer shell and drive stem with a generousamount of water resistant grease to prevent corrosion.
11. Reinstall the IBOPs and pipehandler.
March 8, 2001
4-18 TDS-4S Maintenance and Troubleshooting
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear.Remove the drive stem/mainshaft from service if bore wear isgreater than the dimensions shown in Figure 4-2.
Determine inspection frequency according to API RecommendedPractice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B asguidelines for interpreting and performing inspections.Measurement techniques are specified in API RP 7G, Section 10.Use API Bulletin 5T1 to identify and define imperfections foundduring inspections.
7 5/8 API REG R.N. Pin
7.500-3 ACME-3GLeft-hand Thread
9.000Diameter
3.75Diameter (New)
1.30 Minimum @ LandingCollar Grooves (2.45 New)
(1.70 New)
7 5/8 API REG R.N. Pin
6.250-3 ACME-2GLeft-hand Thread
9.000Diameter
3.00Diameter (New)
1.30 Minimum @ LandingCollar Grooves (2.45 New)
(1.70 New)
Large Bore
Small Bore
Figure 4-2. Typical minimum bore wear dimensions(Refer to engineering drawings for exact dimensions)
TDS-4S Maintenance and Troubleshooting 4-19
Use the following API recommended guidelines (Figures 4-3) todetermine the tensile load bearing capacities of the drive stem/main shaft landing collar.
3800000
3700000
3600000
3500000
3400000
3300000
3200000
Remaining Wall Thickness Under Pin Thread Relief Groove(Inches)
Magnetic Particle Inspection (MPI)Once a year, or every 3,000 operating hours, Varco recommendsperforming a Magnetic Particle Inspection (MPI) of the exposedsurfaces of all load carrying components and load collar groovesto reveal any fatigue or crack indications. Any indications foundare a potential cause for replacing the suspect component. Roundbottom pits and erosion are acceptable as long as the defect is lessthan 1/16 in. deep. Larger defects or any crack indications arecause for replacing the suspect component.
After approximately five years, or 15,000 operating hours,depending on the severity of operating conditions, Varcorecommends performing a MPI of all load carrying componentsover their entire surface (including internal bores) to reveal anyfatigue or crack indications. Any indications found are a potentialcause for replacing the suspect component. Round bottom pitsand erosion are acceptable as long as the defect is less than 1/16in. deep. Larger defects or any crack indications are cause forreplacing the suspect component. The load carrying componentsare:
❏ Drive stem/main shaft (lower portion)
❏ Landing collar
❏ Upper and lower IBOP
❏ 350-Ton BNC drill pipe elevator
❏ Link adapter
❏ Saver, crossover, and spacer subs
❏ Power subs
❏ Power swivels
❏ Elevator links
Details on MPI procedures are in the following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspectionof Steel Forgings
ASTM E-709 Std. Recommended Practice forMagnetic Particle Inspection
TDS-4S Maintenance and Troubleshooting 4-21
Ultrasonic InspectionIn addition to the MPI, Varco also recommends performing anUltrasonic Inspection of the above components to detect anyerosion of the inside diameter. Any erosion reduces the load-carrying capability of the part. Any subsurface irregularity canalso compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in thepublication: ASTM A-388 Std. Practice for Ultrasonic Examinationof Heavy Steel Forgings.
Safety valve inspection procedures (IBOP)
z Upper and lower IBOP valves, because of their internal groovesand shoulders, are particularly susceptible to corrosion fatiguecracking. These internal diameter changes act as stress risers forbending and tensile loads. It is especially important to properlyinspect the IBOP valves on a frequent basis. Read and use theIBOP valve inspection procedures described in the IBOP ServiceManual (SM00611).
March 8, 2001
4-22 TDS-4S Maintenance and Troubleshooting
TDS-4S Maintenance and Troubleshooting 4-23
Chapter 2
Lubrication
Lubricating the motor and motor supportbonnet assembly
GearboxCheck oil daily. With the motor off, check to see that the oil levelis at the middle of the sight glass located on the side of the mainbody. Drain and refill the gearbox every 1,500 operating hours orthree months, whichever occurs first. (Refer to Oil capacity laterin this chapter.)
Properly maintaining the TDS gear shifting mechanism increasesthe operational life of the top drive. Use the following procedureto maintain proper gear lubrication:
1. Shift all top drive two speed gearboxes from one gear to theother and back again at least once a week. This helps todistribute lubricant and prevents contaminant buildup.
2. Remove the gear indicator lever assembly and the indicatorgearcase cover.
March 8, 2001
4-24 TDS-4S Maintenance and Troubleshooting
3. Repack the inside area with grease every six months (refer toFigures 1-9 and 1-10 in the Description book).
4. Inspect the gears for corrosion or damage. Clean, lubricate orreplace components as required. There is a “timing mark” onthe gears to ensure correct orientation. If these marks are notvisible when removing the gears, mark the gears beforeremoval to ensure correct orientation when reinstalling them.
If there are problems shifting from one gear to the other, use thefollowing procedure to shift the gears:
1. Turn the drive stem with chain tongs to make sure the gearmesh aligns properly. Do not turn the DC motor whileshifting gears.
2. Insert two 3/8 in. bolts in the threaded holes on the bottomof the shafts while shifting the gears and use a bar to turn theshaft in the proper direction. Do not shear the bolts.Eccentric shaft rotation direction is the same as the shifterinput shaft when shifting into gear.
3. If the shift input mechanism slips when attempting to shiftgears, use a torque wrench to check the torque of the shifterwhen the clutch begins to slip. If the torque is less than65 ft lb, then use the Torque setting procedure to adjust theclutch
e Gearbox oil must be drained before removing clutch.
The factory setting of the clutch is 45 ft lb. However, increase thetorque if there are persistent problems.
4. Remove the 3 in. inspection plugs on the rear of the gearcaseand make sure the compound gears are free to turn with theunit in neutral. If the gears cannot turn, it indicates a largerproblem (i.e., contaminants in gears, damaged bearings, etc.).
TDS-4S Maintenance and Troubleshooting 4-25
Torque setting procedureUse the following procedure to set the torque limit clutch to45-50 ft lb:
1. Attach any torque indicator to the output stub (Figure 4-4).
2. Hold the body and determine the current torque setting.
3. Remove the snap ring and locking plate.
4. Use a 5/8 in. open end wrench to turn the nut clockwise toincrease torque, or to turn the nut counterclockwise todecrease the torque.
5. Check the resulting torque and repeat the above steps if moreadjustment is necessary.
6. Replace the locking plate and snap ring.
March 8, 2001
4-26 TDS-4S Maintenance and Troubleshooting
Gear Subplate
Gear Shaft Changer
Housing Gear Changer
Lower Gearcase
Torque Limiter (Clutch)
Torque Limit Clutch
A
Detail A
Figure 4-4. Torque setting procedure
TDS-4S Maintenance and Troubleshooting 4-27
Other gearbox lubrication and maintenanceconsiderations
❏ Keep the bottom of the eccentric gear shafts clean and free ofcorrosion, paint or other contaminants. Keep this area lightlylubricated with oil.
❏ Contaminant build up or corrosion around the upper end ofthe eccentric shafts can cause persistent shifting problems.Install sealed caps on the top of the shaft to correct theproblem. There are two ways to install sealed caps. One wayto install sealed caps requires shop installation during topdrive overhaul.
There is a kit for field installation (P/N 97926). It consists of arubber gasket, a sealing cap and a stud which threads into anexisting tapped hole in the top of the eccentric shaft. The studholds the cap on top of the gearcase and keeps contaminants awayfrom the shaft. It also adds a secondary seal between the oil in thegearbox and the DC motor cooling air path.
Initial oil change periodDrain and refill the gearbox after the first 500 operating hours orfour weeks, whichever occurs first.
Remove and clean the oil pump suction strainer (or oil filter,depending on the model and configuration) when changingthe oil.
March 8, 2001
4-28 TDS-4S Maintenance and Troubleshooting
Oil capacityThe TDS-4S holds approximately 10-20 gallons of oil, but oilcapacities vary according to the type of cooling systems, etc.installed. Always fill the transmission to the middle of the sightglass. Use the following procedure to fill the transmission for thefirst time on a new top drive:
1. Fill the gearbox to the top of the sight glass(approximately 10-20 gallons).
2. Operate the top drive 10-15 minutes and check thesight 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 moreoil until the level reaches the middle of the sight glass. If theoil level is at, or above the middle of the sight glass, do not addany additional oil to the gearcase.
After installation and initial operation of the top drive, always fillthe transmission to the middle of the sight glass.
When draining oil from the drain plug at the bottom of thegearcase, only the 5-6 gallons of oil at the bottom of the gearcaseactually drains. Oil still 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 themotor housing assembly (approximately 2-3 gallons). Removingthe suction hose from the cover plate below the pinion shaftallows more oil to drain and also removes sediment that collectsthere. Removing the oil drain plug from the rotating head allowsmore oil to drain.
TDS-4S Maintenance and Troubleshooting 4-29
Lubricating the DC motorThe upper motor armature bearings have grease points located onthe brake adapter plate attached to the top of the motor. Thelower armature bearing grease point on the G.E. motor is at theend of a small diameter tube projecting toward the back of thetool.
The grease points all have plugs or relief fittings installed duringoperation. Install grease fittings to lubricate and then remove thefittings and replace the plugs for operation. Lubricate the pinion(transmission) end bearing every 750 operating hours, or threemonths, with two ounce by weight Shell Cyprina RA™.Lubricate the commutator (brake) end bearing every 1,500operating hours, or six months, with two ounce by weight ShellCyprina RA™.
e Excessive lubrication of electric motors can cause motor failure due toshorting or heat buildup from grease coming in contact with the fieldwindings.
March 8, 2001
4-30 TDS-4S Maintenance and Troubleshooting
Lubricating the washpipe andbonnet sealApply grease daily to the washpipe grease fitting and the twobonnet seal fittings (located below the washpipe grease fitting)(Figure 4-5).
GreaseFittings
Wash PipeAssembly
Bonnet
Figure 4-5. Lubricating the washpipe and bonnet seal
TDS-4S Maintenance and Troubleshooting 4-31
Lubricating the rotating head
Apply grease daily at the fittings (Figures 4-6 and 4-7). Inspect forseal leakage weekly around the lower bearing retainer.
GreaseFittings
GreaseFittings
GreaseFitting
Figure 4-6. Lubricating the standard rotating head
Grease Fittings
Grease Fitting
Figure 4-7. Lubricating the powered rotating head
March 8, 2001
4-32 TDS-4S Maintenance and Troubleshooting
Lubricating the link adapter
Apply grease to the link adapter fittings weekly as shownin Figure 4-8.
2 Grease Fittings on front,2 Grease Fittings opposite.
(4 places total)
Figure 4-8. Lubricating the link adapter
TDS-4S Maintenance and Troubleshooting 4-33
Lubricating the torque wrench
Apply grease daily to the torque wrench fittings (Figure 4-9).Inspect the stabbing guide for excessive wear or cracks. Replace asnecessary.
Grease Fitting(8 on Bottom of Clamp)
Grease Fitting(1 each side of Torque
Tube on Clevis Pin)
Grease Fitting(6 on Optional Link Stopand Cylinder Assembly)
Grease Fitting(6 on IBOP Actuator
Rollers, Cylinder Pinsand Arm Pins)
Figure 4-9. Lubricating the PH-85 torque wrench
March 8, 2001
4-34 TDS-4S Maintenance and Troubleshooting
Lubricating the master bushingID wear guide
The master bushing ID wear guide has four fittings (Figure 4-10).Lubricate weekly. Inspect the guide ring periodically for wear ordamage and replace it as necessary.
Master BushingWear Guide
Grease Fittings (4)
Figure 4-10. Lubricating the master ID bushing wear guide
Lubricating the safety valve actuator
Apply grease daily to the fitting in the crank assemblies (Figure 4-11). Check for worn components and operate the valve to verifycorrect adjustment weekly.
TDS-4S Maintenance and Troubleshooting 4-35
Lubricating the upper safety valve (IBOP)
Lubricate the upper IBOP valve weekly at the lubrication fittingslocated directly below the actuator cranks in the recessed counterbores (Figure 4-11). Refer to the IBOP Service Manual forcomplete IBOP lubrication instructions.
Crank Arm
Actuator ArmGroove
Actuator Shell Grease Fitting
Upper IBOPValve
Grease Port
OpenPosition
Figure 4-11. Lubricating the IBOP
March 8, 2001
4-36 TDS-4S Maintenance and Troubleshooting
Lubricating the guide dolly assembly
Lubricate the 20 guide rollers every trip at the four manifolds(5 fittings each) located on each corner of the guide dolly (Figure4-12). If your rig has a retract system, refer to the Retract GuideDolly supplement. Check guide rollers weekly for cracks orexcessive axial or radial play and replace as necessary. Lubricatethe hinges (one place on each hinge) monthly.
It is possible to over-grease (too much pressure, not volume) theguide rollers. This can push the plugs out. Visually inspect all ofthe guide rollers for evidence of grease extruding from the end(s)of the shaft. If you discover over-greasing, perform the followingprocedure:
1. Remove and disassemble the roller assembly.
2. Thoroughly clean and inspect all parts.
3. If the component parts are still serviceable, drill and tap theshaft end(s) for 1/8 in. NPT threads and install internalwrenching pipe plugs after thoroughly cleaning metal chipsfrom the grease ports in the roller shaft.
4. Pre-grease roller bearings before reassembling and installingthe rollers and shaft.
5. Re-grease roller bearings through grease lines to make surelubricant is pumping through the roller bearings. Some greaseshould extrude between the rollers and roller shaft.
6. Replace unserviceable assemblies.
7. Improve plug retention on roller assemblies with intact sheetmetal plugs by staking the edges of the port(s). To do this:
a. Remove the roller or roller bracket assembly to improveaccessibility.
b. Use a hammer and chisel to stake the port edges.
TDS-4S Maintenance and Troubleshooting 4-37
A preferred method is to rework the roller assembly for drill andtap operation, but the staking method is also effective.
At each bottom corner of the motor frame are the two greasepoints for the motor trunnions (Figure 4-13). Lubricate theseweekly.
Lubricate the washpipe packing daily with the mud pump off.
Daily, with the hydraulic power on, check the filter gauge on thepressure filter to determine the condition of the filter element.Replace the element when a bypass condition is indicated.
e Do not weld or torch cut on or near the motor frame withoutremoving hydraulic accumulators.
March 8, 2001
4-38 TDS-4S Maintenance and Troubleshooting
Non-SwingGuide Dolly
(TDS Removed for clarity)
Grease Fittings
Grease Fittings
GreaseFitting(20)
Figure 4-12. Lubricating the non-swing guide dolly assembly
TDS-4S Maintenance and Troubleshooting 4-39
GreaseFitting(20)
GreaseFitting
Grease Fittings
Grease Fittings
SwingGuide Dolly
GreaseFitting
Figure 4-13. Lubricating the swing guide dolly assembly
March 8, 2001
4-40 TDS-4S Maintenance and Troubleshooting
Retract Guide Dolly
Grease Fittings
Grease Fittings
GreaseFitting(28)
(TDS Removed for clarity)
Figure 4-14. Lubricating the retract guide dolly assembly
TDS-4S Maintenance and Troubleshooting 4-41
Lubricating the bail pins
Lubricate the bail pins weekly, at the same time the dollyrollers are lubricated, at the two fittings, one on each bail pin(Figure 4-15).
Bail
Bail Pin Bail Pin
Grease Fitting Grease Fitting
Figure 4-15. Lubricating the bail pins
March 8, 2001
4-42 TDS-4S Maintenance and Troubleshooting
Lubricating the cooling system
Lubricate AC blower motors every three months (Figure 4-16).On rigs with closed loop cooling systems (Figure 4-17) also checkthe heat exchangers for water leakage weekly, and remove theaccess covers and operate the blower to remove dust buildup every500 operating hours.
Transmission Cooler
Explosion Proof AC Blower Motor
Grease Fitting
Grease Fitting
Motor Cooling Blower
Figure 4-16. Lubricating the local cooling system
TDS-4S Maintenance and Troubleshooting 4-43
Heat ExchangerHeat Exchanger
Motor Cooling BlowerMotor Cooling Blower
Grease Fitting Grease Fitting
Explosion Proof AC Blower Motor
Figure 4-17. Lubricating the closed loop cooling system
March 8, 2001
4-44 TDS-4S Maintenance and Troubleshooting
Lubrication schedule
Frequency Location Lubricant code* Number of points
* See Table 4-1, Recommended lubricants† Check condition and replace as necessary‡ Refer to Retract Guide Dolly supplement
e Use only 10-wt. hydraulic oil or non-detergent motor oil as alubricant in the air control system. Using any other type of oil orsynthetic additive causes the seals in the air valves to swell and ceaseto function.
TDS-4S Maintenance and Troubleshooting 4-45
Lubricant specifications
TDS-4S transmissions operate under a combination of heavy andshock loads. Under these conditions oil tends to extrude out ofthe gear mesh. Keeping an effective film of oil on the gear meshrequires oil with an AGMA “extra pressure” rating, and aminimum viscosity of 100 SUS at operating temperature.
Varco top drives also operate under a wide variety oftemperatures. Select lubrication for the TDS based on theminimum ambient temperature to be expected before the next oilchange. Under all but the most severe operating conditions,Varco recommends changing the oil every three months.Introducing an oil viscosity greater than required by the ambienttemperature 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 noexception. The TDS transmission lubrication system is limited topumping oils of a maximum of 9,000 SUS viscosity.
Varco recommends measuring the oil temperature with a contactthermometer. Measure on the pump discharge fitting on the TDS.
The following tables will aid in your lubricant selection and keepyour TDS-4S transmission operating properly:
Minimum ambient temperature°F °C Oil type required Varco P/N
Below 20° -6° See note below See note below
20° to 60° -6 to 16° 2EP, ISO 68 56004-1
45° to 85° 7° to 30° 4EP, ISO 150 56004-BSC
Above 70° 21° 6EP, ISO 320 56004-2
z For minimum temperatures below 20°F, the TDS must bewarmed up by rotating at a very light load (less than 200 Amps)and at very slow speeds (less than 50 rpm) until the oiltemperature climbs above 20°F.
March 8, 2001
4-46 TDS-4S Maintenance and Troubleshooting
If the oil temperature falls below 20°F, Varco recommendsrunning the TDS at very light loads (less than 100 Amps) untilthe oil is above 20°F. If drilling conditions dictate oiltemperatures below 20°F, consult Varco engineering.
If the oil temperature rises above 200°F, Varco recommendsshutting down or reducing drilling loads to stabilize the oiltemperature below 200°F If drilling conditions dictate oiltemperatures above 200°F, consult Varco engineering.
Table 4-1. Recommended lubricants
General Purpose Grease
Above-4°F
(-20°C)
Below-4°F
(-20°C)
Above70°F
(21°C)
45° to 85°F(7° to 30°C)
20° to 60°F(-6° to 16°C)
Ambienttemperaturerange
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
NGLI
AGMA
ISO ViscosityGrade
MP grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
2
-
-
-
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
1
-
-
Alpha LS-320
NL Gear 320
Spartan EP320
EP Lube HD320
MobilGear 632
Omala 320
Loadway EP320
Meropa 320
Carter EP 320
Extra Duty NL6EP
-
6EP
320
Alpha -150
NL Gear 150
Spartan EP150
EP Lube HD150
MobilGear 629
Omala 150
Loadway EP150
Meropa 150
Carter EP 150
Extra Duty NL4EP
-
4EP
150
Alpha LS-68
NL Gear 68
Spartan EP68
EP Lube HD68
MobilGear 626
Omala 68
Statoil
Meropa 68
Carter EP 68
Extra Duty NL2EP
-
2EP
68
Lube Code and Description
Gear Oil
1 2
TDS-4S Maintenance and Troubleshooting 4-47
Table 4-1. Recommended lubricants (continued)
14° to 185°F(-10° to 85°C)
5° to 167°F(-15° to 75°C)
Alltemperatures
Ambienttemperaturerange
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
NGLI
AGMA
ISO ViscosityGrade
N/R
Black Pearl
N/R
N/R
N/R
N/R
N/R
N/R
N/R
N/R
2
-
-
Hyspin AWS-46
AW Hyd oil 46
Nuto H46
Harmony 46AW
DTE 25
Tellus 46
Hydraway HMA 46
Rando oil HD46
Azolla ZS 46
Unax AW46
-
-
46
Hyspin AWS-32
AW Hyd oil 32
Nuto H32
Harmony 32AW
DTE 24
Tellus 32
Hydraway HMA 32
Rando oil HD32
Azolla ZS 32
Unax AW32
-
-
32
Lube Code and Description
Motor Grease Hydraulic Oil
3 4
Bio-degradable
5
March 8, 2001
4-48 TDS-4S Maintenance and Troubleshooting
TDS-4S Maintenance and Troubleshooting 4-49
Chapter 3
Maintenance
Adjustment procedures
Adjusting the torque wrenchUse the following procedure to adjust the pipehandler torquewrench:
e The pipehandler torque wrench is properly adjusted and tested in thefactory before it is shipped. Perform the adjustment procedure afterperforming maintenance on the torque wrench or if the torquewrench does not function correctly.
1. Connect a pup joint or joint of drill pipe to the saver sub andmakeup hand tight. Be sure to use the correct threadcompound when making up.
z When adjusting torque wrench manifold needle valves, loosen thelocknut around the valve stem and use a 5/32 in. hex wrench toadjust the valve. After obtaining desired setting tighten locknutaround valve stem.
March 8, 2001
4-50 TDS-4S Maintenance and Troubleshooting
2. With the HPU off, screw the RECYCLE, CLAMP, andTORQUE sequence valves on the torque wrench manifoldfully in (Figure 4-18).
3. Fully back out the Pressure Reducing Valve (PRV), then screwin one turn.
4. Turn the LIFT/LOWER flow control valve fully in, and thenback it out three turns.
5. Turn on the HPU.
6. If the torque cylinders are in their full clockwise position, setthe Make/Break valve to MAKE. If they are in their fullcounterclockwise position, set Make/Break valve to BREAK.Note that torque cylinders should not move if the recyclesequence valve is fully in.
7. Slowly back out the RECYCLE sequence valve until torquecylinders just start to move, then screw out an additionalfull turn.
BREAK MAKE
PRVTORQUECLAMPRECYCLE
LIFT LOWER
PSI
Ft.Lbs. x1000
0
1020
30
4050 60
70
8090
1000
500
1000 1500
2000
2500®
Make/BreakValve
Torque WrenchManifold
TorqueSequence
Valve
ClampSequence
Valve
RecycleSequence
Valve
HydraulicPressureReturn
HydraulicPressure
Inlet
Lift/LowerFlow Control
Valve
Torque Gauge0 - 2500 PSI
Figure 4-18. Torque wrench control manifold
TDS-4S Maintenance and Troubleshooting 4-51
8. Move the Make/Break valve to BREAK. Set the PRVto 750 psi.
9. Switch the lever between MAKE and BREAK to adjust theRECYCLE sequence valve until full rotation in each directiontakes six to eight seconds. Tighten the locknut around theRECYCLE sequence valve adjustment screw.
10. Set the Make/Break valve to MAKE.
11. Depress and hold the torque wrench operating button on theVDC. The torque wrench should lift and the clamp jawsshould remain retracted.
12. Slowly back out the CLAMP sequence valve until the clampjaws just begin to clamp onto the tool joint. Screw out anadditional half turn. Lock the CLAMP sequence valveadjustment screw in position by tightening the locknut.
13. Back out the TORQUE sequence valve until the torquecylinders just begin to stroke, then back out an additional halfturn. Tighten the locknut around the TORQUE sequencevalve adjustment screw.
14. Release the torque wrench operating button on the VDC.The torque wrench should start to unclamp and drop, thenthe torque cylinders should recycle.
15. If the torque cylinders recycle before the clamp cylindersretract, screw in the RECYCLE sequence valve until thetorque cylinders do not move before clamp cylinders havefully retracted. Tighten the RECYCLE sequence valveadjustment screw locknut.
16. Cycle the torque wrench as many times as required to makeupthe connection.
17. Set the Make/Break valve to BREAK.
18. Verify that the torque wrench correctly breaks out the drillpipe from the saver sub, without breaking out the saver sub orlower IBOP.
19. The torque wrench is ready for operation.
March 8, 2001
4-52 TDS-4S Maintenance and Troubleshooting
Adjusting the upper safety valve(IBOP) and safety valve actuatorsystemRefer to the IBOP Service Manual for upper IBOP and safetyvalve actuator system adjustment procedures.
Adjusting the counterbalancesystemLeave the HPU on during the entire adjustment procedure, anddisconnect the TDS from the drill string near the bottom of therails, but well off the stops.
1. Remove the caps and loosen the lock nuts on the needle valveand PRV located on the counterbalance manifold (Figure 4-19). It is not necessary to remove the front guard for access tothe manifold. A small amount of oil will leak around theadjusting stems after removing the caps.
2. Open the needle valve and let the stem circulate for twominutes. Crack both upper cylinder fittings and bleed airfrom system. Tighten the fittings. Close the needle valve.
3. Using a hex wrench, screw in the PRV until the cylinderretracts, raising the TDS.
4. Slowly back out the PRV. The pressure decreases and thecylinder rods begin extending. When the integrated swivelbail contacts the hook, note the pressure on the gauge. Allowthe pressure to decrease an additional 25 psi and tighten thelocknut. Replace the caps on the valve adjustment stem.
TDS-4S Maintenance and Troubleshooting 4-53
Upper Motor FrameCrossmember
Pressure ReducingValve
PressureGauge
Needle Valve(on opposite side)
Figure 4-19. Counterbalance manifold
March 8, 2001
4-54 TDS-4S Maintenance and Troubleshooting
Adjusting the motor alignmentcylinder systemOnce the alignment cylinder is installed, use the followingprocedure to properly adjust the motor alignment beforeoperating TDS systems that have a separate alignment cylinderaccumulator and valve manifold.
1. With the HPU turned off, bleed down the alignment cylinderaccumulator by opening the needle valve located at thealignment cylinder valve manifold (Figures 4-20 and 4-21).
2. Remove the split shipping brace from the motor alignmentcylinder (Figure 4-22).
3. Turn on the HPU and allow the system to circulate forapproximately two minutes.
4. Close the needle valve.
5. Open the two flow control valves located at the alignmentcylinder supply return lines 1-1/2 turns off their seats.
TDS-4S Maintenance and Troubleshooting 4-55
Alignment CylinderLug (ref)
Pressure ReducingValve
Needle Valve
Motor Frame (ref)
AlignmentCylinderManifold
Accumulator
BracketGas Valve
Figure 4-20. Typical motor alignment cylinder valve manifold
March 8, 2001
4-56 TDS-4S Maintenance and Troubleshooting
Pressure Reducing Valve(PRV)
Directional Control Valve(Operation Switch)
Prefill Valve Assembly
Needle Valve
Motor Frame (ref)
Alignment CylinderValve Manifold
Accumulator
Bracket
Gas Valve
Figure 4-21. Motor alignment cylinder valve manifold
TDS-4S Maintenance and Troubleshooting 4-57
Motor AlignmentCylinder
MotorFrame Dolly (Ref)
ShippingBrace
Figure 4-22. Motor alignment cylinder
March 8, 2001
4-58 TDS-4S Maintenance and Troubleshooting
z The pressure setting is adjusted by screwing the PRV in or outwith a hex wrench (Figure 4-19). Screwing in the valve increasespressure and moves the saver sub toward the rails. Backing out thePRV reduces pressure and moves the saver sub away from the rails(see additional notes at the end of this procedure).
6. Verify the correct pressure setting using the followingprocedure:
a. With the HPU on, back down the pressure using the PRVuntil the saver sub begins to pivot away from the rails.Record this pressure.
b. Slowly increase the pressure until the saver sub no longermoves closer to the rails as pressure increases. At this time,the cylinder should be in a “dead band” area.
c. Slowly increase the pressure until the saver sub begins tomove toward the rails again. Record the pressure readingwhen this occurs.
d. To determine the correct pressure setting, add the averagepressure readings from steps a and c above and divide by two.The resulting pressure “dead band” provides equal pre-loadin each direction – both toward and away from the rails.
e. Record the pressure setting for future reference.
7. Set a joint of drill pipe in the slips.
8. Bring the top drive down as if stabbing the saver sub into thebox. The pin and the box should be in alignment so that theOD of the pin clears the shoulder of the box. If adjustment isnecessary, use the following procedure:
a. Measure how far and in what direction (toward or awayfrom the rails) the pin must move to line up with drillpipe box.
b. Turn off the HPU and bleed down the alignment cylinderaccumulator. This allows the motor alignment cylinder torelax and the motor to rotate on its trunnions, until theswivel contacts the motor frame.
c. Loosen the lock tab and jam nut on the cylinder clevis.
TDS-4S Maintenance and Troubleshooting 4-59
d. Use a wrench on the cylinder rod flats to screw the rodinto or out of the clevis, in the same direction the saversub pin is to be moved. A 1/4 in. of pin movement resultsfrom a 3/4 turn of the rod. The alignment cylinder rodextension should be 2 3/8 ± 1/8 in. gland to rod threadswhen the system is properly aligned.
e. Secure the jam nut and lock tab.
f. The nominal position of the two flow control valves is1-1/2 turns off their seats. Should heavy drill pipevibration be encountered, first attempt to control it withnon-rotating stabilizers in the casing close to the surface.If motor movement becomes excessive due to continuedvibration (more than 1/2 in. of cylinder stroke), the flowcontrol valves may be closed to 3/4 turn off their seats.
g. Tighten the lock nuts and replace the caps on all valve stems.
z If the alignment cylinder is removed for service, install thealignment cylinder replacement brace to support the motorhousing assembly while continuing to operate the TDS. Afterreinstalling the alignment cylinder, use the three bleed holes(located along top of cylinder barrel) to remove air trapped in thecylinder.
Rail spacing and setback from the centerline of the well must beheld within recommended tolerances in order to maintain verticalalignment of the TDS.
March 8, 2001
4-60 TDS-4S Maintenance and Troubleshooting
Precharging thecounterbalance systemPlease read these instructions completely before precharging,making note of the special cautions at the end of the section.
1. Use an inert gas such as nitrogen for prechargingaccumulators. If oil-pumped is not available, use dry, water-pumped nitrogen gas.
2. Before precharging, make certain:
a. The accumulator end caps are screwed flush into theaccumulator body.
b. The gas valve is screwed in tight.
c. No oil remains trapped in the top end of the accumulator.
3. Remove the gas valve protector and the gas valve cap.
4. Attach the charging hose to the nitrogen bottle and to the gasvalve using the following procedure:
a. Use thread sealing and lubricating compound on the pipethreads of the gauge.
b. Back the gas chuck stem completely out of the way beforeattaching the assembly to the accumulator gas valve.
c. Use a wrench to tighten the gas chuck swivel nut onto thegas valve. Close the bleeder valve.
d. Turn the gas chuck stem all of the way down, depressingthe core in the accumulator gas valve.
e. Only crack open the nitrogen bottle valve to slowly fill theaccumulator. Shut it off when the gauge indicates 900 psi.
f. If the 900 psi precharge pressure is exceeded, make surethe nitrogen bottle valve is closed, then open the bleedervalve (opposite the gas valve below the gauge) slightly, butonly momentarily, to reduce pressure.
g. Before loosening the swivel nut, turn the gas chuck stemout all of the way, then open the bleeder valve.
h. Prevent the gas valve from turning, loosen swivel nut, andremove the assembly.
5. When precharging is complete, replace the cap on the gasvalve and install the gas valve protector.
TDS-4S Maintenance and Troubleshooting 4-61
e Do not loop or twist hose as it stiffens when gas pressure is releasedfrom nitrogen bottles.
Never loosen the swivel nut attached to the gas valve in theaccumulator without first backing the gas chuck stem all of the wayout.
Do not reduce accumulator precharge by depressing valve core (highpressure may rupture rubber valve seat). Instead, slowly turn gas valveout until gas begins to escape through bleed hole drilled throughthreads of valve. This hole is a safety feature, it warns of storedpressure whenever gas valve is being removed. Install new gas valveO-ring each time gas valve is removed.
March 8, 2001
4-62 TDS-4S Maintenance and Troubleshooting
Assembly and disassembly
Pipehandler
Torque wrench disassemblyFor PH-85, see Figures 4-23, 4-24, 4-25, and 4-26.For PH-60d, see Figure 4-27.
1. Remove the guard.
2. Disconnect the hard plumbing from the quick disconnectsnear the left torque cylinder.
3. Remove the bolts holding the frame onto the cast body andlift off.
4. Remove the pins holding the torque tube in place and remove.
5. Disconnect and label the hoses from the torque cylinders andremove the cylinders.
6. Disconnect and label the remaining plumbing, and removethe Make/Break manifold assembly.
7. Remove the jaws.
8. Remove the stabbing guide.
9. Remove the retaining bolts, hinge pins and outer body.
10. Remove the cylinder ring from the clamping piston bore.
11. Pressurize the blind end of the clamping cylinder to removethe gland and piston.
e Use care in this operation. High pressure air can be explosive.
Reassembly is accomplished in the reverse order of the aboveprocedure. Pay close attention to the following points:
1. Replace all seals.
2. Take great care when installing the clamping piston andgland. If they are not closely aligned with the bore, they maybecome jammed and could be extremely difficult to remove.
3. Use the following torque values:
Cylinder rod end to cylinder rod* 944 ft lb
Frame to clamp cylinder body 250 ft lb
Stabbing guide to body 250 ft lb
Die retainer screws 380 ft lb
Body hinge pin retainer screws 150 ft lb
Stabbing guide spring retainer screws 75 ft lb
Jaw retaining screws 110 ft lb
*The torque cylinder rod ends are threaded into the rods withlocktite and cross pinned.
Replacing the torque wrench clamping piston seal
The following procedures require that the torque wrench beremoved from the pipehandler.
Replacing the front and rear piston seals
Parts required front and rear piston seal replacement:
Qty. P/N Description
3 72219 Piston seal
2 72220 Rod seal
2 72221 Rod wiper
Disassembly
1. Remove the slotted hex nut and cotter pin attaching the twohalves of the stabbing guide together at the front and swingthe guides out to each side.
2. Vent the clamping cylinder as follows: disconnect thehydraulic lines to the clamp port and front unclamp port onthe clamp body cylinder at the torque wrench manifold clampand unclamp ports.
TDS-4S Maintenance and Troubleshooting 4-69
3. Remove the jaw pins from the rear clamping jaw and removethe jaw.
4. Remove the two screws holding the jaw spacer to the frontclamp cylinder piston and remove the spacer and jaw spacer.
5. Remove the two screws holding the clamp clevis to the rearclamp cylinder piston.
6. Remove the pins holding the clamp body to the clamp clevisand remove the clamp clevis. Be sure to remove the spacerfrom the piston rod slot.
7. Push in the cylinder gland from the rear cylinder headretainer ring and remove the ring with a screwdriver.
8. Attach the sliding hammer to the rear piston rod and carefullypull the piston until the cylinder gland can be removed.
9. Continue to pull until the piston comes out.
10. Using a piece of wood or brass bar, tap the front clamp pistonfrom the front and remove it from the rear.
11. Remove and discard the piston seals, rod seals, and rodwipers.
12. Remove the front piston rod seal and rod wiper from theclamp cylinder body and discard.
13. Inspect the clamp cylinder bore thoroughly for dirt, burrs,nicks, gouges, and pitting. Repair and clean as necessary.
Assembly
1. Insert a new front rod seal and rod wiper in the clampcylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove andlubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with thetwo jaw spacer screw holes orientated vertically.
4. Gently and evenly tap the piston into place until the rodappears beyond the front cylinder bore.
March 8, 2001
4-70 TDS-4S Maintenance and Troubleshooting
5. Install a new piston seal in the rear piston groove andlubricate with hydraulic fluid.
6. Insert the rear piston into the clamp cylinder body with thetwo screws holes on the rod oriented to the horizontalposition.
7. Gently tap piston into place until there is enough spacebetween the piston face and retaining ring groove to insertcylinder gland and retainer ring.
8. Install the rod seal and rod wiper in the inside grooves of thecylinder gland.
9. Install the piston seal in the outside groove.
10. Lubricate all seals with hydraulic fluid.
11. Insert cylinder gland into the bore rod and piston seals first.Push the gland past retainer groove and install the retainerring.
12. Insert the spacer and attach the clamp clevis to the rearcylinder rod with the two hex head cap screws and flatwashers. Tighten firmly and lockwire.
13. Adjust orientation of the clamp clevis and attach to the clampbody using the two clevis pins and cotter pins.
14. Attach the rear clamping jaw spacer to the front piston rodusing the spacer and two hex head cap screws and flatwashers. Tighten firmly and lockwire.
15. Attach the clamping jaw with the two jaw pins.
16 Swing the stabbing guide back into position and attach withthe slotted nut and cotter pin.
17. Reconnect the hydraulic lines from the clamp body cylinderclamp port and front unclamp port at the torque wrenchmanifold clamp and unclamp ports.
18. Reinstall and adjust the torque wrench(refer to Adjusting the torque wrench earlier in this chapter).
TDS-4S Maintenance and Troubleshooting 4-71
Replacing the standard rotating headglyd rings
z Rotary glyd ring replacement is indicated when hydraulic oil isdetected in the pipehandler air supply. An indication of oilcontaminating the air supply would be an accumulation of oil inthe link tilt air actuator (bag).
The following disassembly and assembly procedures assume thatthe TDS is swung out for maintenance in accordance with theTDS swing out procedures (refer to TDS swing out procedure inChapter 1 of this book). Refer to Figures 4-28 and 4-29, whenperforming the following procedures.
Stationary Flange
Locking Lever
Glyd Ring (8)
Auto-ReturnCylinder
Swivel Block
Cam
Cam Follower
Torque ArrestorLocation
Torque Wrench Hanger(Lug not shown)
Figure 4-28. 650-Ton rotating head assembly
March 8, 2001
4-72 TDS-4S Maintenance and Troubleshooting
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, oneflange gasket, and one excluder cap gasket from Varco.Contact the nearest Varco Service Center for details aboutbuilding an appropriate stand for working on the rotatinghead when removed from the TDS for service ormaintenance.
2. Disconnect the hydraulic and air hoses from the rotating headrotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating blockclevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly whileremoving the pins attaching the torque arrestors to therotating block.
7. Remove the torque arrestors, link tilt and link adapter.
8. Place the rotating head stand, built prior to disassembly,under the TDS and lower the TDS until the rotating headrests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotatinghead on the stand.
10. Remove the quick disconnect fittings from the rotating blockhydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Push the cam follower away from the rotating block cam.
14. Remove the safety wire from the ten hex-head screwsattaching the rotating block to the stationary flange.
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.
TDS-4S Maintenance and Troubleshooting 4-73
������������������������������������
������������
����
C
Hex Nut
ReturnCylinder
Rod End Detail
ExcluderCap
Excluder CapGasket
Retainer Ring
Glyd Ring (8)
Cam
Ball Bearing
Stationary Flange
Bull GearLip Seal
Cam Assembly
Return Cylinder
Cam
Locking Handle
ReturnCylinder
Clevis Pin
Ball Bearing
Cotter Pin
Cylinder Clevis
Detail C
Figure 4-29. Replacing the 650-Ton rotating head glyd rings
March 8, 2001
4-74 TDS-4S Maintenance and Troubleshooting
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid andinsert them into the glyd ring grooves inside the rotatingblock.
2. Place the excluder cap and gasket on the bottom of therotating block.
3. Using a tugger or other support, carefully mate the rotatingblock to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the quick disconnect hydraulic fittings on therotating block.
7. Attach the return cylinder rod to the clevis with the clevis pinand install the slotted hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the proceduresdetailed in the Installation and Commissioning book.
TDS-4S Maintenance and Troubleshooting 4-75
Replacing the powered rotating headglyd ringsRefer to the assembly drawings when performing the followingprocedures.
Disassembly
1. Order eleven replacement glyd rings, two gearcase seals, oneflange gasket, and one excluder cap gasket from Varco.Contact the nearest Varco Service Center for details aboutbuilding an appropriate stand for working on the rotatinghead when removed from the TDS for service ormaintenance.
2. Disconnect the hydraulic and air hoses from the rotating headrotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating blockclevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly whileremoving the pins attaching the torque arrestors to therotating block.
7. Remove the torque arrestors, link tilt, and link adapter.
8. Place the rotating head stand, built prior to disassembly,under the TDS and lower the TDS until the rotating headrests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotatinghead on the stand.
10. Remove the quick disconnect fittings from the rotating blockhydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Remove the hydraulic motor assembly.
14. Remove the safety wire from the ten hex-head screwsattaching the rotating block to the stationary flange.
March 8, 2001
4-76 TDS-4S Maintenance and Troubleshooting
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 eleven new glyd rings with hydraulic fluid andinsert them into the glyd ring grooves inside the rotatingblock.
2. Place the excluder cap and gasket on the bottom of therotating block.
3. Using a tugger or other support, carefully mate the rotatingblock to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the QD hydraulic fittings on the rotating block.
7. Reinstall the hydraulic motor assembly.
8. Reinstall the pipehandler components per the proceduresdetailed in the Installation and Commissioning book.
TDS-4S Maintenance and Troubleshooting 4-77
Replacing the standard or extended reachlink tilt air actuatorThe link tilt mechanism has two air actuators. Use the followingprocedure to replace one air actuator (Figures 4-30 and 4-31).
Parts required: One air actuator (P/N 82353)
18 Button head cap screws (P/N 50186-10-01)
Disassembly
1. Disconnect the air hose from the rotating head rotating blockto the link tilt assembly.
2. Support the link tilt and remove the two upper and two lowerscrews attaching the link tilt to the link adapter.
3. Lower the link tilt to the floor with the air actuator to bereplaced facing up.
4. Remove the cotter key and pin from one end of chainconnecting the two sealing plates.
5. Remove the safety wire from the four hex-head cap screwsholding the air actuator sealing plate to the link tilt base orlever and remove the screws.
6. Lift the lever or base off the air actuator sealing plate, androtate it 180° on the link tilt pivot pin and lay down.
7. Remove the nuts and washers holding the sealing plate to theair actuator and remove the plate.
8. Using a pry bar or screwdriver, pry the air actuator away fromthe screws, attach the actuator to the hanger plate and removethe screws using a hex wrench.
9. Remove and discard the air actuator.
10. Remove any burrs or gouges on sealing surfaces of the hangerand sealing plates.
March 8, 2001
4-78 TDS-4S Maintenance and Troubleshooting
Lever Weldment
Sealing Plate (2)
Sealing PlateBolt (4)
Lever
Elevator Link (Ref)
Stop ReleaseLoop
IntermediateStop (2)
Pivot Pin
Nuts, LockWashers (18)
Air Actuator
Base
PressureRegulator
QuickExhaustValve
ButtonheadCapscrew (18)
Stop Pivot Arm
Connecting Chain
Figure 4-30. Standard reach link tilt assembly/disassembly
TDS-4S Maintenance and Troubleshooting 4-79
Lever Weldment
Sealing Plate (2)
SealingPlate
Bolt (4)
Lever
Elevator Link (Ref) Stop ReleaseLoop
IntermediateStop (2)
Pivot Pin
Nuts, LockWashers (18)
Air Actuator (2)
Hanger Plate
Base
PressureRegulator
QuickExhaust
Valve
Stop Pivot Arm
Connecting Chain
Figure 4-31. Extended reach link tilt assembly/disassembly
March 8, 2001
4-80 TDS-4S Maintenance and Troubleshooting
Assembly
1. Place a new actuator on the hanger plate.
2. Attach the air actuator to the hanger plate with the 18buttonhead cap screws. Coat the screw threads with locktitebefore installation.
e The air actuator has aluminum neck bead rings on both sealingsurfaces. These beads must be compressed equally to ensure a good airseal. This requires more than one tightening pass to accomplish.Over-torquing may cause hex sockets to strip.
4. Torque the cap screws to the hanger plate at 80 ft lb.
5. Insert the 18 bolts into the neck ring of the air actuator.
6. Reinstall the air actuator sealing plate, coat the bolt threadswith locktite and fasten with the lockwashers and nutsprovided.
7. Torque the nuts to the sealing plate at 80 ft lb.(See Caution above.)
8. Lift and rotate the link tilt lever or base to line up with the airactuator sealing plate. Attach with the four hex-head capscrews and torque to 250 ft lb.
9. Safety wire the four screws.
10. Reconnect the chain between the two sealing plates.
11. Reinstall and adjust the link tilt per the Installation andCommissioning book.
TDS-4S Maintenance and Troubleshooting 4-81
Removing the tong dies
Front jaw1. Remove the cotter pin from the retaining bolts
and slotted nut.
2. Remove the nuts securing the die retainer to the jaw.
3. Remove the die retainer from the jaw.
4. Remove the tong dies from the jaw.
Rear jaw1. On the rear jaw, remove the cotter pins from the retaining
bolts and slotted nuts.
2. Support the retaining bolt while removing the slotted nut.
3. Remove the retaining bolt from the piston jaw.
4. Support the remaining retaining bolt while removing theslotted nut and upper die retainer.
5. Remove the retaining bolt and lower die retainer.
6. Remove the tong dies from the jaw.
March 8, 2001
4-82 TDS-4S Maintenance and Troubleshooting
Removing the jaws
Front jaw1. Loosen the socket head cap screws securing the jaw assembly
to the torque wrench body.
2. Support the jaw and remove the socket-head cap screws andwashers from the jaw assembly and the torque wrench body.
3. Remove the front jaw assembly from the torque wrench body.
Rear jaw1. Loosen the socket head cap screws securing the jaw assembly
to the piston.
2. Support the jaw assembly and remove the socket-head capscrews and washers from the jaw assembly and piston.
3. Remove the rear jaw assembly from the piston.
Upper safety valve (IBOP)Refer to the IBOP Service Manual for IBOP valve assembly anddisassembly procedures.
Lower safety valve (IBOP)Refer to the IBOP Service Manual for IBOP valve assembly anddisassembly procedures.
TDS-4S Maintenance and Troubleshooting 4-83
Removing the motor assemblyfrom the guide dolly
You can perform some service procedures on top drives (i.e. upperdrive stem bearing and seal, air brake or locally mounted coolingsystem) without removing the drilling motor assembly from thedolly. If service is required on the lower end (i.e. gear set, lowerbearings or seals), the drilling motor must be removed from the dolly.
1. Set the TDS down horizontally on a good flat surface.
2. Make sure none of the components protrude past the guidedolly roller brackets before setting the TDS down. If so, blockup the guide dolly accordingly.
3. Disconnect all wiring and hoses between transmission andguide dolly frame.
4. Remove any cooling ducts (heat exchanger, spark arrestor,etc.) that interfere with removing the transmission from guidedolly frame.
5. Use a suitable sling to support the weight of the TDS andmotor support bonnet (approximately 10,000 lb).
6. Take up the slack and remove the trunnion blocks that holdthe transmission to the guide dolly frame.
7. Hoist the transmission out of the guide dolly frame.
8. Set the TDS and motor support bonnet down on woodenchocks, being careful not to damage components.
9. Disconnect the wiring between the motor and motor supportbonnet.
10. Make sure the transmission is in neutral.
11. Remove the dowel pins in the motor feet.
12. Remove the four large motor bolts.
13. Lift the transmission off of the motor, angling the upper endslightly to clear the motor support bonnet, and sliding thehousing off of the motor toward the gearcase
14. Remove the blower and brake assemblies.
15. Reverse this procedure for reassembly.
March 8, 2001
4-84 TDS-4S Maintenance and Troubleshooting
Disassembly/assembly of thedrilling motor and motor supportbonnet1. Remove the upper bearing cover and grease seal
(Figure 4-32).
2. Pressurize the air brake to hold the drive mechanism in place.
3. Remove cotter pins, slotted nuts and the rotating head.
4. Remove the lower gearcase, carefully avoiding damage to thelower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to thebearing surfaces or wear sleeves. Do not remove the gear fromthe shaft unless you are replacing it.
6. Remove the pinion seal and retaining ring.
7. Remove the main body.
8. On the opposite end of the motor, remove the magneticpickup and brake cover.
9. Remove the brake for service.
TDS-4S Maintenance and Troubleshooting 4-85
HI
LO
Bull Gear
Lower GearCase
MotorAlignmentCylinder
Main Body
DCDrillingMotor
Air Brake
MotorPinion Seal
Shaft
HighGear
Assembly
Pinion GearManualShifterInput Geneva
Mechanism
LowGear
Assembly
GearSelectionIndicator
Oil LevelSight Glass
Figure 4-32. Drilling motor and motor support bonnet assembly/disassembly
March 8, 2001
4-86 TDS-4S Maintenance and Troubleshooting
Refer to the GE Electric Motor Manual for procedures to removethe pinion or hub on the armature shaft, or to service the motoritself.
Once the unit has been disassembled, inspect the followingassemblies for any wear or damage that may be critical:
1. Gear set: Check the teeth and splines for chips or heavy wear.The wear pattern should be even and symmetrical. If not,replace it. Expect some small surface pitting. It is not causefor replacing the gear set.
2. Bearings: Clean thoroughly in solvent, then rotate and listenfor any roughness during rotation.
3. Main shaft: Check splines and tool joints for wear. Replacethe shaft if spline wear exceeds 0.090 in.
4. Main shaft: Check fit to bull gear, wear sleeve surfaces, andretaining threads.
5. Seals: Always replace seals and gaskets when removed.
6. Main shaft housing: The bore for the upper bearing and thepilot diameter for the lower gearcase are critical. Clean up anynicks or gouges prior to reassembly.
7. Air brake: Check the brake for air leakage and the pads forwear.
8. Wear sleeves: These should be free of any imperfections onthe sealing surface.
9. Blower: Clean any accumulation of dust from the ducting,then operate the unit and correct any interference betweenthe impeller and housing.
10. Air valve assembly: If any air-operated systems aremalfunctioning, remove the appropriate valve and repair orreplace.
Reassemble the drilling motor and motor support bonnet byreversing the steps in the disassembly procedure. Replace allgrease seals and O-rings, and refer to the following torque chartfor bolt tightening guidelines.
TDS-4S Maintenance and Troubleshooting 4-87
Torque Chart
Motor support/bonnet to main body 1100 ft lb
Main body to motor support/bonnet 1100 ft lb
Bull gear to hub 580 ft lb
Lower gearcase to main body 250 ft lb
Rotating head to lower gearcase 250 ft lb
Brake adapter ring to motor 250 ft lb
Brake to brake adapter plate 50 ft lb
Brake drum to hub 250 ft lb
Brake cover to brake 50 ft lb
Installing the TDS motor pinion
n Installing a pinion gear can be dangerous to personnel installingit as well as anyone witnessing the procedure. Exercise caution atall times.
Use the following procedure to install a TDS motor pinion:
1. Clean the motor shaft by hand and cover with a thin layer ofEngineer’s Blue.
2. Firmly install the pinion on the motor shaft by hand. Markreference lines on the pinion and the shaft to ensure identicalangular orientation each time.
3. There must be a minimum of 75% surface contact betweenthe pinion and motor shaft. Dress the motor shaft/pinionvery lightly with a fine emery cloth and repeat the “blueing”procedure if necessary until there is at least 75% surfacecontact between the pinion and motor shaft.
4. After thoroughly cleaning all blueing, oil, and/or grease fromthe pinion bore and shaft, trial mount the cold pinion gear onthe motor shaft, lining up the reference marks.
March 8, 2001
4-88 TDS-4S Maintenance and Troubleshooting
5. Make sure the fixture is clean and the “horse shoe” face andbar are parallel.
6. Place the fixture on the motor shaft with the “horse shoe” endagainst the inner face of the gear and the bar against the outerface of the gear, sandwiching the pinion gear in the fixture.
7. Adjust the adjusting screw to butt against the end of themotor shaft.
8. Attach a calibrated dial indicator gauge to the fixture and setto zero.
9. Back off the adjusting screw until the gauge reads 0.072-0.074 in. Then lock the screw in place with a locknut.
10. Remove the fixture from the pinion gear assembly.
e Do not put the fixture in the oven.
11. Heat the pinion gear to 360-385°F (182-196°C) for threehours in an oven. After heating for three hours, remove thepinion gear assembly and immediately attach the fixture.
12. Place the pinion gear assembly and fixture on the motor shaft,lining up the reference marks.
13. Gently tap the pinion gear assembly and fixture into placeuntil the adjusting screw butts against the motor shaft.
14. Wait 2-3 minutes and back off the nuts holding the fixture inplace. There may be some noise as the pinion gear cools.
15. The pinion creeps up the shaft as it cools to the requiredposition of 0.085 ± 0.005 in. advancement.
16. When the pinion is fully cooled, fit the fixture and check finaladvancement.
17. Complete the required documentation recording pinionadvancement.
TDS-4S Maintenance and Troubleshooting 4-89
Local blower cooling systemassembly/disassemblyUse the following procedure to remove the blower motor in thelocal blower cooling system (Figure 4-33):
1. Remove the electrical wires from the blower motor.
2. Remove the eight bolts on each side connecting the ducts tothe blower housing ducts.
3. Remove the four bolts on each side connecting the ducthousing to the blower inlet ducts.
4. Remove the four bolts connecting the blower mount to thebrake cover.
5. Hoist the blower assembly off of the TDS and place on aclean work space on the derrick floor.
6. Remove the blower inlet ducts on both sides of the blowermotor.
7. Remove the taper lock bushings from both blower impellers.
8. Remove both blower impellers.
9. Remove the bolts connecting the blower housing assemblieson both sides to the blower mount.
10. Remove the shaft seal assemblies from both sides.
11. Remove the blower housing and inner plate assemblies asunits from both sides. Do not separate the blower housingassemblies from the inner plates.
12. Unbolt the four bolts connecting the blower motor feet to theblower mount.
13. Lift the motor out.
March 8, 2001
4-90 TDS-4S Maintenance and Troubleshooting
MountingBrackets (2)
Mounting Plate
Oil Fittings (2)
TransmissionCooler
Axial Fan20 hp
Blower Motor
Locking Key
Gasket
Blower Housing
Blower Impeller
Taper LockBushing
Gasket
Blower Duct toAC Drilling Motor
Flex DuctConnection
Point
Spark Arrestor
Figure 4-33. Typical local blower cooling system assembly/disassembly
TDS-4S Maintenance and Troubleshooting 4-91
Use the following procedure to install a new motor in the localcooling system:
1. Install wear sleeves on the blower motor shaft.
2. Bolt the blower motor onto the blower motor mount andsafetywire the bolts.
3. Install the blower housing and inner plate assemblies on bothsides of the blower motor frame as follows:
a. Use two 3/8 in. bolts in the threaded alignment bolt holeson both sides to line up the blower housing and innerplate assemblies with the blower motor frame on bothsides.
b. Gradually insert and tighten the bolts that connect theblower housing and inner plate assemblies on both sidesto the blower motor frame. Check the alignment holes asyou tighten the bolts to make sure both assemblies line upproperly on the blower motor frame.
4. Install shaft seal assemblies inside both blower housingassemblies. Make sure the seals are centered.
5. Tighten and safetywire the retainer plates in place on bothsides.
6. Install the impellers and taper lock bushings on both sidesand safetywire the bolts.
7. Install the blower inlet duct assemblies to the blower housingon both sides using the same alignment holes used in Step 3a.
8. Hoist the entire cooling system assembly onto the TDS. If thealignment holes were properly used, the cooling systemassembly should line up perfectly on the TDS.
9. Install and safetywire the four bolts connecting the blowermount to the brake cover.
10. Install and safetywire the four bolts on each side connectingthe heat exchange duct housing assemblies to the blower inletduct assemblies.
11. Install and safetywire the six bolts on each side connecting thetransmission ducts to the blower housing ducts.
12. Connect the electrical wires to the blower motor.
March 8, 2001
4-92 TDS-4S Maintenance and Troubleshooting
Closed loop cooling systemassembly/disassemblyUse the following procedure to remove the blower motor in thelocal blower cooling system (Figure 4-34):
1. Remove the electrical wires from the blower motor.
2. Remove the eight bolts on each side connecting the ducts tothe blower housing ducts.
3. Remove the four bolts on each side connecting the ducthousing to the blower inlet ducts.
4. Remove the four bolts connecting the blower mount to thebrake cover.
5. Hoist the blower assembly off of the TDS and place on aclean work space on the derrick floor.
6. Remove the blower inlet ducts on both sides of the blowermotor.
7. Remove the taper lock bushings from both blower impellers.
8. Remove both blower impellers.
9. Remove the bolts connecting the blower housing assemblieson both sides to the blower mount.
10. Remove the shaft seal assemblies from both sides.
11. Remove the blower housing and inner plate assemblies asunits from both sides. Do not separate the blower housingassemblies from the inner plates.
12. Unbolt the four bolts connecting the blower motor feet to theblower mount.
13. Lift the motor out.
TDS-4S Maintenance and Troubleshooting 4-93
Impeller (2)
WaterConnections
Blower Mount/Brake Cover
BlowerHousing (2)
Heat Exchanger (2)
GEDrilling Motor
InspectionCover
8 in. FlexConnection (2)
Dual Shaft20 hp AC
Blower Motor
Blower Inlet (2)
DC to MotorExhaust Port on
Upper Gear Case
Figure 4-34. Typical closed loop cooling system assembly/disassembly
March 8, 2001
4-94 TDS-4S Maintenance and Troubleshooting
Use the following procedure to install a new motor in the localcooling system:
1. Install wear sleeves on the blower motor shaft.
2. Bolt the blower motor onto the blower motor mount andsafetywire the bolts.
3. Install the blower housing and inner plate assemblies on bothsides of the blower motor frame as follows:
a. Use two 3/8 in. bolts in the threaded alignment bolt holeson both sides to line up the blower housing and innerplate assemblies with the blower motor frame on bothsides.
b. Gradually insert and tighten the bolts that connect theblower housing and inner plate assemblies on both sidesto the blower motor frame. Check the alignment holes asyou tighten the bolts to make sure both assemblies line upproperly on the blower motor frame.
4. Install shaft seal assemblies inside both blower housingassemblies. Make sure the seals are centered.
5. Tighten and safetywire the retainer plates in place on bothsides.
6. Install the impellers and taper lock bushings on both sidesand safetywire the bolts.
7. Install the blower inlet duct assemblies to the blower housingon both sides using the same alignment holes used in Step 3a.
8. Hoist the entire cooling system assembly onto the TDS. If thealignment holes were properly used, the cooling systemassembly should line up perfectly on the TDS.
9. Install and safetywire the four bolts connecting the blowermount to the brake cover.
10. Install and safetywire the four bolts on each side connectingthe heat exchange duct housing assemblies to the blower inletduct assemblies.
11. Install and safetywire the six bolts on each side connecting thetransmission ducts to the blower housing ducts.
12. Connect the electrical wires to the blower motor.
TDS-4S Maintenance and Troubleshooting 4-95
Replacing the safety wiring
Use the following procedures to safety wire screws, nuts, bolts, orother fasteners where applicable.
n Torque fasteners before safety wiring any screw, nut, plug, orother fastener. Never overtorque or loosen a torqued fastener toalign safety wire holes.
Use the size and type of safety wire required in the applicablespecifications and drawings. Whenever possible, use double-twistsafety wiring.
n Limit single-twist wiring to the following: small screws located inclosely spaced, closed geometrical patterns (e.g., triangles, squares,rectangles, or circles), parts in electrical systems, or parts that aredifficult to reach.
n Do not reuse safety wire.
To install safety wire:
1. Open the jaws of the safety twist pliers.
2. Squeeze the handles of the pliers together and unlock theround, perforated slider in the center of the pliers from thehook lock.
3. Grip both safety wires in the jaw. Squeeze the handlestogether with one hand and pull the slider toward the rear ofthe pliers with the other hand to lock the pliers.
4. Twist the safety wire by pulling the aluminum knob and twistthe rod out from the pliers. Let the pliers spin free.
5. Return the knob and twist the rod by holding the plierssteady with one hand and pushing against the end of theknob the with other hand (step 4 in Figure 4-35).
6. Repeat the previous twisting cycle.
March 8, 2001
4-96 TDS-4S Maintenance and Troubleshooting
7. After threading the safety wire through the hole in thefastener, pull the wire straight through without nicking thewire. Twist four to five complete revolutions per inch of wire.
8. Make a pigtail of approximately 1 in. (25 mm) length (fourtwists minimum) at the end of the wiring and bend back orunder to prevent it from becoming a snag.
12
3 4
5
Figure 4-35. Safety wiring procedures
TDS-4S Maintenance and Troubleshooting 4-97
Safety wiring tips
❏ Pull the safety wire firmly, but do not stretch it or let kinksdevelop. Make twists tight, even, and as taut as possiblewithout weakening the wire by overtwisting (Figure 4-36).
n Do not nick the wire with the edge of the hole in the fastener.Position the safety wire so the pull exerted by the wire tightens thenut. For best results, let the wire leave the fastener in a clockwisedirection
❏ Twist the safety wire so the loop around the bolt or head hassufficient tension to keep it from slipping up and over thebolt head, with resulting slack in the safety wiring.
n When securing castellated nuts with safety wire, tighten the nut tothe low side of the selected torque range, unless otherwise specified.If necessary, continue tightening within specified torque limitsuntil a slot aligns with the hole.
❏ The number of nuts, bolts or screws that can be safety-wiredtogether depends on the application. As a guide, when safety-wiring widely spaced bolts by the double-twist method, agroup of three, or a 24 in. (610 mm) length of safety wire isusually the maximum.
Figure 4-36. Safety wiring examples
March 8, 2001
4-98 TDS-4S Maintenance and Troubleshooting
TDS-4S Maintenance and Troubleshooting 4-99
Chapter 4
Troubleshooting
Troubleshooting the counterbalance
Symptom Probable cause Remedy
System does not holdpressure.
Needle valve is not closed. See adjustment procedure and checkneedle valve.
Cylinder rod seals leak. Replace seals.
Fittings or hoses leak. Tighten or replace as required.
Dirty or defective PRV valve. See adjustment procedure. Clean or replace.
Dirty or stuck check valve. Clean or replace.
Counterbalance control valvein rig down position.
Return valve to drilling position.
Cylinder rods remainretracted (closed).
Pressure setting too high. Adjust per adjustment procedure.
e When activating or reactivating the counterbalance system, never startan empty system with the needle valve closed. Always start the HydraulicPower Unit (HPU) first, run for 3-5 minutes, then slowly close needlevalve with HPU running. If an empty system is started up with needlevalve closed there is a good potential for damaging counterbalancecylinder seals.
March 8, 2001
4-100 TDS-4S Maintenance and Troubleshooting
Troubleshooting the motoralignment cylinder
Symptom Probable cause Remedy
Alignment cylinderfails to movetransmission attrunnion pivot pointswith recommendedpressure setting.
Transmission trunnion pinswill not pivot in dollysupport brackets, from lackof lubrication.
Free trunnion pins as needed andlubricate area regularly.
Counterbalancesystem workserratically or does notwork at all.
Possible problem withsystem hydrauliccomponents.
Check Troubleshooting thecounterbalance section of this book.
Loss of nitrogen precharge inaccumulators located inmotor dolly upright frame.
Recharge accumulators as per theprocedure in the Troubleshooting thecounterbalance section of this book.
System does not holdpressure.
Needle valve is not closed. See the adjustment procedure.
Cylinder rod seals leak. Replace seals.
Fittings or hoses leak. Tighten or replace as required.
Dirty or defective PRV valve. Clean or replace.
Saver sub on TDSdoes not align withdrill pipe.
Alignment cylinder pressuretoo high or too low.
See the adjustment procedure.
Alignment cylinder rodadjustment too long or short.
Adjust according to procedure.
Rails not properly alignedwith centerline of well.
Check to make sure that rotary is incenter of floor and then checkalignment of rails in relation torotary.
Excessive motormovement.
Alignment cylinder fluidflow not adequatelythrottled.
See the adjustment procedure.Normal adjustment is 1 1/2 turnsfrom full closed position on flowcontrol valves. If there is excessivemovement close to 3/4 turn fromfull closed position.
TDS-4S Maintenance and Troubleshooting 4-101
Troubleshooting the drilling motorand guide dolly
Troubleshooting the motor air brake
Symptom Probable cause Remedy
Brake does not hold. Insufficient air supply. Check air supply pressure, 90 psi minimum required.
Solenoid valve not shifting. Check electrical continuity.
Check lubricator on air supply.
Check mechanical operation ofsolenoid valve.
Brake drum contaminatedwith grease or pads worn orburnt.
Inspect and replace if necessary.
Brake does notrelease.
Solenoid valve sticking. Lubricate, repair with repair kit orreplace valve.
Check air supply lubricator.
Quick exhaust valve notfunctioning properly.
Clean or replace.
Troubleshooting theretract guide dolly
Symptom Probable cause Remedy
Guide dolly retractstoo slow or too fast.
Flow control valves on theguide dolly are not properlyset.
Set the flow controls to attaindesired retract speed.
March 8, 2001
4-102 TDS-4S Maintenance and Troubleshooting
Troubleshooting the transmission
Symptom Probable cause Remedy
Oil leaking fromlower seal.
Lower gear case seals are dryor damaged.
Apply grease to seal. Grease fitting daily.
If problem persists replace gearcaseseals and bearing.
Oil leaking from shafthousing breather.
Oil level too high. Adjust oil level per recommendedspecification.
Incorrect lubricant used. Check recommended lubricantschart and replace as needed.
Oil is foaming. Replace oil.
Gearbox temperatureis excessive.
Oil level too low or too high. Adjust oil level to recommendedlevel in sight glass.
Incorrect lubricant used. Check recommended lubricantschart and replace as needed.
Clogged oil suction screen. Remove suction screen from oilpump. Check discharge or pressurehoses at outlets to confirmcirculation.
Clogged or dirty heatexchangers on unit equippedwith such.
Check heat exchangers for air flowor water flow to ensure adequateheat transfer and dissipation.
TDS-4S Maintenance and Troubleshooting 4-103
Troubleshooting the oil pump
Symptom Probable cause Remedy
OIL PUMP LOSSalarm is on.
Motor is not running. Check electrical components toensure power is available to motor.Repair or replace as needed.
Incorrect motor rotation. Verify proper rotation and correct if necessary.
Dirty or clogged oil pumpsuction screen.
Remove and clean suction screenmaking sure to properly seal screencover when installing.
Oil pump cavitating-evidence of air bubbles indischarge lines.
Check all connections and suctionscreen cover plate to ensure there areno air leaks on suction side of oilpump. Repair as needed.
Defective or improperlyadjusted pressure switch.
Check switch operation. Repair or replace as needed.
Failure of oil pump drivecoupling.
Inspect, repair or replace as needed.
Faulty or worn oil pump. Check relief valve on back of pump.Install test gauge in discharge lineand adjust to 10 psi.
If unable to make oil pump workafter checking all of the above, repairor replace as needed.
Incorrect lubricant used. Check recommended lubricantschart to make sure proper viscosityof oil is used. Replace as needed.
March 8, 2001
4-104 TDS-4S Maintenance and Troubleshooting
Troubleshooting the cooling system
Symptom Probable cause Remedy
Mechanical noise inblower.
Loose impeller. Reinstall impeller and hub andlocktite screws.
Faulty motor bearings. Repair or replace as needed.
Blower runsintermittently.
Faulty or loose wiring. Locate and repair as needed.
Faulty motor starter. Check for dirt or trash betweenstarter coil. Repair or replace asneeded.
Excessive air loss inblower motor shaftarea.
Worn or defective seal orwear sleeve.
Replace as needed.
Loose or vibrating blowermotor, wearing sealsexcessively.
Correct blower mounting problemor faulty motor bearing and replaceblower shaft seals.
DC MOTOROVERHEATING,OVERTEMP alarmstays on with blowerrunning.
Air pilot valve on counter-balance manifold stuck orinoperative.
Remove air supply line to verify airsupply when solenoid valve isactivated.
Pilot valve dirty. If air supply is available remove endcap on pilot valve, clean andlubricate.
Improperly connected quickdisconnects.
If air pilot valve is operable, hookboth pipehandler hoses together andverify flow in both directions byactivating switch with hydraulics on.
If there is flow in only one direction,check QDs.
If QDs are properly connected,check hydraulic pilot valve for stuckspool.
Hydraulic valve not shifting. Repair or replace.
Saver sub breaks outinstead of tool joint.
Saver sub not made upproperly.
Make up saver sub per proceduredescribed in the IBOP ServiceManual, increase previous torquemakeup by 10% to maximumtorque recommended in the IBOPService Manual (for original VarcoOEM subs).
Tong dies break orscore drill pipe.
Valves in manifold out ofadjustment.
Readjust per procedure.
Tong dies worn. Replace tong dies.
Connection overtorqued. If saver sub is made up torecommended torque and continuesto break out instead of drill pipeconnection, break out using rigtongs.
If saver sub or drill pipe will notbreak out using pipehandler, removepipehandler and break out with rigtongs at floor.
March 8, 2001
4-108 TDS-4S Maintenance and Troubleshooting
Troubleshooting thesafety valve actuator
Symptom Probable cause Remedy
Safety valve leaks. Internal parts worn out. Check for washouts or defectiveparts. Repair as needed.
Actuator out of adjustment. Check electrical continuity.
Check spool mechanical operation.Lubricate if needed.
Retracts slowly, doesnot make it back towell center.
Pressure setting on floatvalve too low.
Adjust pressure setting.
Passive stop not in rightspot.
Adjust jam not on passive stop toposition elevators over well center.
Retracts past wellcenter in float mode.
Pressure setting on floatvalve too high.
Adjust pressure setting.
Passive stop not in rightspot.
Adjust jam not on passive stop toposition elevators over well center.
TDS-4S Maintenance and Troubleshooting 4-109
Troubleshooting the pipehandler atthe counterbalance manifold
Symptom Probable cause Remedy
Pipehandler goes up andclamps when the HPU isturned on withoutpressing switch.
Improperly connectedQDs.
Check all QDs to make sure that they areproperly connected, also making sure thateach half is intact and not coming apart andrestricting fluid.
Solenoid valve stuck orinoperative.
Disconnect air line from solenoid to air pilotvalve. If there is a constant air flow, thesolenoid valve is stuck in the open position.Remove the solenoid and valve. Clean asneeded. Repair or replace valve as needed.
Check oil lubricator to make sure valves arebeing lubricated.
Air pilot valve sticking. If there is no constant air flow from air line,remove end cover on air pilot valve andcheck spool to see if it is operating freely.Clean as needed and lubricate. Repair orreplace valve as needed.
IBOP valve actuatorremains either in closed oropen position.
Faulty or loose wiring. Check electrical continuity to switches andsolenoids.
No air supply or airsupply incorrect.
Check air supply. There must be 90 psiminimum pressure.
Crank assembly, actuatorarms or cylinderssticking.
Check crank assembly, actuator arms andcylinders. Repair as needed.
Solenoid valves stuck inthe open position or incenter position.
Check solenoid valves to see if they are notstuck in the open position or in centerposition. Repair or replace valve as needed.
IBOP valve does not fullyopen or close.
Actuator cylinder out ofadjustment.
Check actuator cylinder adjustment andadjust as needed.
Cam follower rollerssticking.
Check cam follower rollers on crankassembly and arms.
Yellow and red indicatorconstantly flash whiletraveling assembly is belowten feet.
Misadjusted lower sensorproximity switch.
Check proximity switch alignment.
Defective sensor cablebetween the sensor junctionbox and control electronics.
Perform cable continuity tests.
Defective upper sensorbracket assemblies.
Check the mechanical operation of the uppersensor bracket assembly.
Defective upper proximityswitches.
Check voltages from upper proximity switchby measuring voltage between TB3 and TB2for upper sensor at the sensor junction box. A measurement of less than 2.0 VDC indicatesa working sensor when metal is detected.Replace proximity switches as required.
Malfunction of electronicscontrol module.
Replace electronic control module.
TDS-4S Maintenance and Troubleshooting 4-111
Six-gang air valve assemblyillustration
Link Tilt
IBOP Open
Brake
Torque Wrench
Air Elevator
IBOP Close
March 8, 2001
4-112 TDS-4S Maintenance and Troubleshooting
TDS-4S
Top DriveDrillingSystem
Control SystemSM00620-5
March 8, 2001
5-2 TDS-4S Control System
TDS-4S Control System 5-3
ContentsTDS-4S Control System
General description .......................................................... 5-5Maintenance and troubleshooting/checkout procedures ........................................................ 5-7
March 8, 2001
5-4 TDS-4S Control System
TDS-4S Control System 5-5
TDS-4SControl System
General description
The Top Drive Drilling System (TDS) typically operates from thesame SCR as the rotary table. A panel, located in a CentralElectronics Enclosure (CEE), switches power from one to theother. The CEE typically contains the following components:
❏ DC contactors
❏ A programmable logic controller (PLC)
❏ Auxiliary AC components
❏ Rig instrumentation interfaces for recordingTDS torque and speed
March 8, 2001
5-6 TDS-4S Control System
In dedicated top drive SCR configurations, the SCR runs the topdrive only.
The panel can feature a purge control system so it can be locatedin hazardous areas. If the panel is located in the SCR room, apurge system is not required.
The panel is designed to be compatible with all presently installedSCR systems and is configured at installation for the specific SCRused on a rig. Logic and alarm functions are connected to theTDS via PLC programming so the TDS can operate existing rigsystems. Also, TDS interlocks and limits, such as spin-up andmakeup speeds, are programmed into the PLC and are the samefor all installations.
TDS-4S Control System 5-7
Maintenance and troubleshooting/checkout procedures
The Varco Top Drive Drilling Control System (TDCS) isstraightforward in its operation and relatively easy to service.Refer to the following documentation for maintenance,troubleshooting and checkout information:
❏ Periodic control system maintenance schedule(See Table 1 below.)
❏ Rig checklist
❏ PLC manual
❏ Card rack terminal specifications
Table 1. Periodic control system maintenance schedule
Location Procedure Frequency
Indicator lamps Test using the lamp test switch Each time theon the driller’s console. TDS is assigned.
Heater Check operation with an Ohm meter. Monthly
High voltage connections Check for discolored or brittle insulation. Monthly
Check retaining bolt torque Monthly(needs to be 25 ft lb).
Component mounting Check fastener tightness, especially in Monthlyvibration-prone areas.
Blower mounting current Check and record current. Monthly(A drop in the current may indicaterestriction or blockage of the air intake.)
Drilling motor field current Verify and record. Weekly
Seals and gaskets Check for integrity. Monthly
Apply a light film of silicone lubricant Every 3 monthsto the transfer panel door.
Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This publication is the property of, and contains information proprietary to, Varco International, Inc. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Varco International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. Information in this manual is subject to change without notice.
General InformationIntended Audience and UseThis manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Varco International, Inc., will not be held liable for errors in this material, or for consequences arising from misuse of this material.
This manual is intended as a supplement to the service manuals supplied with the Varco Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).
ConventionsNotes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage.
Please pay close attention to these advisories.
IllustrationsFigures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale.
For more specific component information pertinent to your rig configuration, see the technical drawings included with your Varco documentation.
Note: iThe note symbol indicates that additional information isprovided about the current topics.
Caution:
!The caution symbol indicates that potential damage toequipment or injury to personnel exists. Followinstructions explicitly. Extreme care should be taken whenperforming operations or procedures preceded by thiscaution symbol.
Warning:
The warning symbol indicates a definite risk ofequipment damage or danger to personnel. Failure toobserve and follow proper procedures could result inserious or fatal injury to personnel, significantproperty loss, or significant equipment damage.
6 Varco
Safety RequirementsVarco equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by Varco manuals are the recommended methods of performing those operations.
Personnel TrainingAll personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.
Contact the Varco training department for more information about equipment operation and maintenance training.
Recommended ToolsService operations may require the use of tools designed specifically for the purpose being described. Varco recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when using service procedures or tools not specifically recommended by Varco.
!To avoid injury to personnel or equipment damage,carefully observe the following safety requirements.
!During installation, maintenance, or repair of equipment,personnel should wear protective gear. Protective gearmust be worn during certain operation.
Washpipe 7
Safety RequirementsGeneral System Safety PracticesThe equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water.
Isolate all energy sources before beginning work.
Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing ComponentsVerify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment to ensure correct installment.
Replace failed or damaged components with Varco certified parts. Failure to do so could result in equipment damage, or personal injury.
Routine MaintenanceEquipment must be maintained on a regular and routine basis. See the service manual for maintenance recommendations.
Proper Use of EquipmentVarco equipment is designed for specific functions and applications, and should be used only for their intended purpose.
!Before installing or performing maintenance or repairs onequipment, read the following instructions to avoidendangering exposed persons or damaging equipment.
!Failure to conduct routine maintenance could result inequipment damage or injury to personnel.
8 Varco
General DescriptionWashpipe AssemblyThe washpipe assembly is located between the main shaft and the gooseneck (S-pipe) on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard and hammerless.
Washpipe 9
General DescriptionSpecial ToolsThe standard washpipe assembly has hammer nuts on its washpipe nut and packing box. The hammer nuts are provided so that a special wrench and a hammer can be used to tighten to washpipe nut and packing box during installation.
The hammerless washpipe assembly uses gear nuts which are tightened more precisely without a hammer but with a special torque wrench kit. This feature makes the unit easier to install by allowing the unit to swing in and out of its support bonnet before being torqued and does not require the use of a hammer.
Standard Washpipe Wrench
Strike here
Standard Washpipe
Hammerless WashpipeTorque Wrench
30-250 ft lb
Hammerless WashpipeTorque Multiplier
3200 ft lbRemovable extension
not shown
Socket Adapter
10 Varco
SpecificationsWashpipe Assembly Pressure Ratings
iAssembly descriptions are repeated for similar units. Usethe assembly part number when referencing pressureratings.
Standard Washpipe Assembly
Description Part No. Pressure Rating (psi)
Small Bore (3-inch) 30123290 7,500
Large Bore (4-inch) 30123440 7,500
Large-to-Small Bore 30153491-50 7,500
Hammerless Washpipe Assembly
Description Part No. Pressure Rating (psi)
Large Bore (4-inch) 30156883 7,500
Large-to-Small Bore 30173058-50 7,500
Washpipe 11
General Maintenance PracticesEquipment Maintenance RecordsKeep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.
Maintenance Schedules
Maintenance schedules list preventive maintenance tasks.
Inspection schedules assume normal operating conditions. Some conditions (excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent inspection intervals. Perform the procedures indicated, as warranted by the inspection.
Safety PrecautionsAvoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following Warnings before performing maintenance or troubleshooting procedures:
iProcedures in this chapter relate to Varco onlycomponents. See the vendor manuals for maintenanceprocedures and schedules for the vendor equipment.
Unless instructed otherwise, properly lock out themain power source before performing anymaintenance procedure.
Wear protective glasses to prevent eye injuries.
Do not attempt any adjustments while the machine ismoving.
Read and understand all safety precautions andwarnings before performing maintenance procedures.
12 Varco
Standard Washpipe AssemblyInitial Installation
1. Install the washpipe assembly on the TDS/IDS and hand-tighten the washpipe nut and packing box, then back off the packing box and washpipe nut by 1/4 turn.
the packing box.
securely tighten.)
Procedure
Nut
i
Washpipe 13
Standard Washpipe AssemblyInitial Installation
14 Varco
Standard Washpipe AssemblyInitial Installation
PackingBox
DialIndicator
Washpipe
11. Check washpipe alignment. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box.
12. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.
Procedure
Washpipe 15
Standard Washpipe AssemblyMaintenance Schedules Inspection Schedule
Item Inspect for Interval
Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck
• Surface should be smooth and free of flaws or burrs• ID of stem liners
When washpipe assembly is to be removed from TDS/IDS
TDS/IDS main shaft bearing endplay Endplay is within specification (refer to TDS/IDS Service Manual)
Once every six months and immediately after jarring
Washpipe Assembly grease fitting Proper operation Replace every six months
Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/IDS main shaft
Proper alignment between pilots
After TDS/IDS main shaft bearing endplay has been checked and is within specification
Washpipe Assembly grease fitting Apply 3 to 4 pumps of grease (refer to Lubrication Procedure)
Twice daily or every 10 rotating hours
16 Varco
Standard Washpipe AssemblyInspection ProceduresWhen Washpipe is to be Removed from TDS/IDS
Service Limit(inches)
3.090
3.840
3.120
Washpipe 17
Standard Washpipe AssemblyInspection ProceduresEvery Six Months
DialIndicator
WashpipeGrease Fitting
Replace
1. Remove the washpipe assembly and replace the grease fitting.
2. Check the main shaft axial movement by applying an upward force to the main shaft and measuring the amount of axial movement with a dial indicator.
3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).
Procedure
18 Varco
Standard Washpipe AssemblyInspection ProceduresEvery Six Months
DialIndicator
0.002 TIR betweenthese two surfaces
GooseneckPilot
Main ShaftPilot
Bonnet removedfor clarity.
Washpipe 19
Standard Washpipe AssemblyLubrication ProceduresDaily Lubrication
grease fitting.2.
Description
Cyprina
20 Varco
Standard Washpipe AssemblyTroubleshooting
iThe troubleshooting table does not necessarily cover allpossible symptoms. The table provides an insight to typicalsymptoms, their possible causes, and what components tocheck.
Symptom Probable cause Remedy
Leakage at threads between packing box and TDS/IDS main shaft
Poly Pak seal failure in main shaft stem liner
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.
Lower O-ring failure 1. Remove washpipe assembly.2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
Stem liner not smooth and does not allow O-ring to seal properly
Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.
Stem liner not flat and does not allow O-ring to seal properly
Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.
Spacers not flat and prevents packing seals from sealing between spacers proper
Follow inspection procedures as outlined in step 8 of the Disassembly Procedure.
Leakage at grease fitting access hole
Poly Pak seal failure in main shaft stem liner
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.
Lower O-ring failure 1. Remove washpipe assembly.2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
Washpipe 21
Standard Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Leakage through grease fitting access hole (cont)
Spacers not flat and prevents packing seals from sealing between spacers proper
Follow inspection procedures as outlined the Inspection Procedure.
Leakage at grease fitting Grease fitting failure Follow inspection procedures as outlined in step 12 of the Disassembly Procedure.
Leakage between the washpipe and the packing box
Packing failure Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Leakage between the washpipe and the washpipe nut
Packing failure or packing is improperly seated
Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Upper O-ring failure 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.
Leakage at threads between washpipe nut and gooseneck
Upper O-ring failure 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
Packing failure or packing is improperly seated
Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Premature failure after greasing
Improper greasing procedure
Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.
22 Varco
Standard Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Premature failure accompanied by occasional spurts of mud from packing box
Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay
If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page):1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box.2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.3. If out of specification, check gooseneck alignment.
Premature failure accompanied by occasional spurts of mud from packing box
Misalignment of gooseneck- to-washpipe pilot
Inspect main shaft and mainshaft-to- gooseneck alignment as described in the Every Six Months Inspection procedure.
Installation problems The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).
Premature failure due to flanged packing
Nut not torqued Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.
Too mush grease during assembly of the unit
Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.
During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).
Washpipe 23
Standard Washpipe AssemblyTroubleshooting
PackingBox
DialIndicator
Washpipe
24 Varco
Standard Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Packing is worn out Poor greasing schedule or improper grease.
Follow proper lubrication procedures.
RPM, pressure and mud temperature too high
Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.
Packing extruding between spacers
Spacers too flat If the spaces are not flat, then metal-to-metal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.
Nut not torqued Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.
Blue spacers Improper torque or grease on the OD of the spacers
Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.
Unable to maintain torque on packing box
Improper assembly or installation
1. Remove washpipe assembly from TDS/IDS.2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers.3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.
Washpipe 25
Standard Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Unable to maintain torque on packing box (cont)
4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken.
NOTETo ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.
26 Varco
Standard Washpipe AssemblyDisassembly
1. Remove washpipe assembly from the TDS/IDS.2. Completely disassemble the washpipe assembly.
Take care to prevent damage to the sharp edge of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.
Procedure
O-Ring
O-Ring
Snap Ring
Holding Ring
Washpipe Nut
WashpipeDiscard and replace
these non-serviceableparts from the
washpipe assembly.
Packing Box
GreaseFitting
Socket HeadDog Nose
Screw
Packing Set(5 per Set)
Upper Spacer
Middle Spacer
Middle Spacer
i
Washpipe 27
Standard Washpipe AssemblyDisassembly
4. Thoroughly clean and inspect remainder of parts.5. Check that the ID of each spacer is within specification.6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer.
Procedure
Upper Spacer
Middle Spacer
Middle Spacer
This surface to besmooth and flat
This surface to besmooth and flat
This edge to besharp
ID
ServiceLimit ID(inches)
WashpipeAssembly Spacer
VarcoPartNo.
ProperID
(inches)
Small Bore Upper 123585 3.635 to 3.640 3.645 Middle 30123286 3.635 to 3.640 3.645 Lower 123287 3.635 to 3.640 3.645
Large Bore Upper 30123434 4.895 to 4.900 4.905 Middle 30123435 4.895 to 4.900 4.905 Lower 30123436 4.895 to 4.900 4.905
Large to Small Bore Upper 123585 3.635 to 3.640 3.645 Middle 30123286 3.635 to 3.640 3.645 Lower 123287 3.635 to 3.640 3.645
28 Varco
Standard Washpipe AssemblyDisassembly
8. Check that the ID of the washpipe nut where the washpipe passes through.
9. Check that the ID of the packing box where the washpipe passes through.
Procedure
PackingBox
WashpipeNut
ID
Service Limit ID(inches)
WashpipeAssembly
Washpipe NutPart No.
Proper ID(inches)
Service Limit ID(inches)
Proper ID(inches)
Small Bore 123284 3.655 to 3.660 3.665
Large Bore 30123431 4.905 to 4.910 4.915
Large to 30153493 3.655 to 3.660 3.665Small Bore
WashpipeAssembly
Packing BoxPart No.
Small Bore 30123563 3.637 to 3.644
Large Bore 30123626 4.900 to 4.905
Large to 30153494 3.637 to 3.644Small Bore
Washpipe 29
Standard Washpipe AssemblyDisassembly
10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.
11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly.
13. Reassemble the washpipe assembly as described in the Reassembly Procedure.
Procedure
HoldingRing
Undercut
reasei
This surface to besmooth and flat
This surface to besmooth and flat
30 Varco
Standard Washpipe AssemblyReassembly
1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing.
2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers.
Procedure
Upper Spacer
PackingSeal
Spacer
Middle Spacer
Middle Spacer
Fill with greaseto level shown
Sharp edgeof spacer Wipe grease
from area shown,all the way aroundon each spacer.Sharp edge
of spacer
Sharp edgeof spacer
Washpipe 31
Standard Washpipe AssemblyReassembly
i
3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box.
4. Install the socket head cap screws. The heads of the screwsshould bottom out in the nut casing. The dog head should notbottom out on the spaceer. The screw prevents the spacers from
not otherwise constrain them.5.
packing box.6.
NOT OVER GREASE.
Procedure
GreaseFitting
DowelPin
PackingBox
Socket HeadDog Nose
Screw
In the following step, an Arbor press may be required to compress the packing enough to in stall the screws.
Ensure that the nose of thesocket head dog nose screw
is fully engaged in the groove ofthe lower spacer (screw should
not push spacer off center)
.010" Min
32 Varco
Standard Washpipe AssemblyReassembly
7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the non-slotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Procedure
PackingBox
Washpipe
WashpipeNut
Washpipe 33
Standard Washpipe AssemblyReassembly
9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.
10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe.
11. Install the snap ring.12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
13.approximately the length of the washpippe.
14.Initial Installation Procedure.
Procedure
HoldingRing
SnapRing
O-ring
PackingSeal
PackingSeal
HoldingRing
Fill with greaseto level shown.
Wipe greasefrom area shown,all the way aroundthe holding ring.
34 Varco
Standard Washpipe AssemblyIllustrated Parts List
O-Ring
Snap Ring
Holding Ring
WashpipeNut
Washpipe
Packing Box
Grease Fitting
Socket HeadDog Nose Screw
Long-ArmAllen Wrench
Packing Set5 per set
O-Ring
Upper Spacer
Middle Spacer
Middle Spacer
Lower Spacer
Washpipe 35
Standard Washpipe AssemblyIllustrated Parts List
Description Small Bore(3-inch)
Large Bore(4-inch)
Large-to-Small Bore
Washpipe Assembly 30123290 30123440 30153491
O-Ring 51300-348-F 51300-359-F 51300-348-F
Snap Ring 30123562 123634 30123562
Holding Ring 30123288 30123437 30123288
Washpipe Nut 123284 30123431 30153493
Washpipe 30123289 (7,500 psi)
30123438 (7,500 psi)
30123289(7,500 psi)
Packing Box 30123563 30123626 30153494
Grease Fitting 53219-1 53219-1 53219-1
Socket Head Screw 30123564 30123564 30123564
Upper Spacer 123585 30123434 123585
Middle Spacer 30123286 30123435 30123286
Lower Spacer 123287 30123436 123287
Pressure Seal Kit (Packing Set)
30123290-PK 30123440-PK 30123290-PK
Stem Liners 98290 112871 30153492
Poly Pak Seal 98291 112895 112895
Grease 56005-1 56005-1 56005-1
36 Varco
Hammerless Washpipe AssemblyInitial Installation
i
i
Nut
Yoke 2 places
During installation the washpipe assembly is brought into place as one unit and handled by a tugger line. Ensure that the washpipe assembly is strapped together securely before lifting.
1. Unlock the TDS/IDS handling yoke from its stored position and swing it out to accept the washpipe assembly.
Procedure
Makes the washpipe assembly easier to install by allowing it to swing in and out of the motor-support bonnet.
Washpipe 37
Hammerless Washpipe AssemblyInitial Installation
Torque WrenchTorque MultiplierRatio – 18.5 to 1
Removable extension
the TDS/IDS main shaft.4.
it until it makes contact with the top of the main shaft.5.
packing box and the washpipe nuts.6. Apply pipe dope to the threads and hand-tighten the
washpipe nut and packing box.7.
align the pipe in the packing box.8. Set the TDS/IDS brake.
Procedure
9. Loosen the thumb screw on the pinion gear and raise the pinion gear from its stored position and lock the thumb screw in place when it aligns with the gear on the packing box. It may be necessary to rotate the square drive shaft to engage the gears.
10. Install the torque kit assembly over the square shaft. Set the torque wrench to 100 ft-lb and begin applying torque to the packing box gradually until the torque wrench clicks.
11. Disengage the pinion gear from the packing box gear and engage it with the washpipe nut gear and secure it in place. Similarly, apply torque to the washpipe nut, completing the installation of the washpipe assembly.
12. Apply 6 to 8 pumps of grease to the grease fittings.13. Return the pinion gear to its stored position and secure it
with the thumb screw. Secure the handling yoke to its stored position by pinning it with the two pins.
14. Release the TDS/IDS brake and rotate the TDS/IDS at approximately 50 rpm for one minute.
Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck
• Surface should be smooth and free of flaws or burrs• ID of stem liners
When washpipe assembly is to be removed from TDS/IDS
TDS/IDS main shaft bearing endplay Endplay is within specification (refer to TDS/IDS Service Manual)
Once every six months and immediately after jarring
Washpipe Assembly grease fitting Proper operation Replace every six months
Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/IDS main shaft
Proper alignment between pilots
After TDS/IDS main shaft bearing endplay has been checked and is within specification
All parts Refer to Disassembly Procedure
Upon disassembly of washpipe assembly
Cleaning Schedule
Item Procedure Interval
TDS bonnet (inside) Remove residual mud Weekly
Lubrication Schedule
Item Procedure Interval
Washpipe Assembly grease fitting Apply 3 to 4 pumps of grease
Twice daily or every 10 rotating hours
!To prevent rust from damaging parts, properly clean andgrease the following parts before storage:
1. Jacking nut and shaft threads 2. Square shaft from top to bottom 3. Gear teeth on all three gears
Washpipe 39
Hammerless Washpipe AssemblyInspection ProceduresEvery Six Months
Washpipe Assembly Alignment
Satisfactory packing life depends on good washpipe alignment. Use the following procedure to check sleeve-to-gooseneck support alignment:
1. Attach an indicator base to the gooseneck support and place the indicator at the top of the sleeve.
2. Raise and lower the sleeve and record the total indicator reading.
3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or packing box.
4. Rotate the sleeve 360° and record the TIR.
Washpipe Assembly Tolerances
Use the following procedure to check washpipe assembly tolerances:
1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to 0.003 inch.
2. Check the clearance by raising and lowering the sleeve. The maximum allowable misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum allowable misalignment after complete assembly of the washpipe assembly is 0.010 inch TIR.
iInspection may indicate misalignment exceedingrecommended limits. The packing box assemblies aredesigned to accommodate misalignment of the sleeve tothe gooseneck and can operate with some excessivemisalignment. However, to achieve maximum packing life,maintain the misalignment at the washpipe within therecommended limits.
40 Varco
Hammerless Washpipe AssemblyInspection ProceduresEvery Six Months
DialIndicator
WashpipeGrease Fitting
Replace
1. Remove the washpipe assembly and replace the grease fitting.
2. Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator.
3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).
Procedure
Washpipe 41
Hammerless Washpipe AssemblyInspection ProceduresEvery Six Months
1. Twice daily or once every 10 hours of rotation, apply 3 to 4 pumps of grease to the washpipe grease fitting.
2. Rotate the TDS/IDS at 50 rpm for one minute with 0 psi standpipe pressure.
3. Turn on the mud pumps and check for leaks.
Manufacturer Description
Shell Cyprina
ProcedureRecommended Grease
Washpipe 43
Hammerless Washpipe AssemblyTroubleshooting
iThe troubleshooting table does not necessarily cover allpossible symptoms. The table provides an insight to typicalsymptoms, their possible causes, and what components tocheck.
Symptom Probable cause Remedy
Leakage at threads between packing box and TDS/IDS main shaft
Poly Pak seal failure in main shaft stem liner
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.
Lower O-ring failure 1. Remove washpipe assembly.2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
Stem liner not smooth and does not allow O-ring to seal properly
Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.
Stem liner not flat and does not allow O-ring to seal properly
Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.
Spacers not flat and prevents packing seals from sealing between spacers proper
Follow inspection procedures as outlined in step 8 of the Disassembly Procedure.
Leakage at grease fitting access hole
Poly Pak seal failure in main shaft stem liner
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.
Lower O-ring failure 1. Remove washpipe assembly.2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
44 Varco
Hammerless Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Leakage through grease fitting access hole (cont)
Spacers not flat and prevents packing seals from sealing between spacers proper
Follow inspection procedures as outlined the Inspection Procedure.
Leakage at grease fitting Grease fitting failure Follow inspection procedures as outlined in step 12 of the Disassembly Procedure.
Leakage between the washpipe and the packing box
Packing failure Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Leakage between the washpipe and the washpipe nut
Packing failure or packing is improperly seated
Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Upper O-ring failure 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.
Leakage at threads between washpipe nut and gooseneck
Upper O-ring failure 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner.3. Replace the O-ring and reinstall the washpipe assembly.
Packing failure or packing is improperly seated
Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.
Premature failure after greasing
Improper greasing procedure
Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.
Washpipe 45
Hammerless Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Premature failure accompanied by occasional spurts of mud from packing box
Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay
If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page):1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box.2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.3. If out of specification, check gooseneck alignment.
Premature failure accompanied by occasional spurts of mud from packing box
Misalignment of gooseneck- to-washpipe pilot
Inspect main shaft and mainshaft-to- gooseneck alignment as described in the Every Six Months Inspection procedure.
Installation problems The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).
Premature failure due to flanged packing
Nut not torqued Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.
Too mush grease during assembly of the unit
Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.
During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).
46 Varco
Hammerless Washpipe AssemblyTroubleshooting
PackingBox
DialIndicator
Washpipe
Washpipe 47
Hammerless Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Packing is worn out Poor greasing schedule or improper grease.
Follow proper lubrication procedures.
RPM, pressure and mud temperature too high
Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.
Packing extruding between spacers
Spacers too flat If the spaces are not flat, then metal-to-metal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.
Nut not torqued Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.
Blue spacers Improper torque or grease on the OD of the spacers
Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.
Unable to maintain torque on packing box
Improper assembly or installation
1. Remove washpipe assembly from TDS/IDS.2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers.3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.
48 Varco
Hammerless Washpipe AssemblyTroubleshooting
Symptom Probable cause Remedy
Unable to maintain torque on packing box (cont)
4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken.
NOTETo ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.
Washpipe 49
Hammerless Washpipe AssemblyRemoving the Washpipe AssemblyRemove the washpipe assembly by reversing the Installation Procedure.
!Once the packing box and washpipe nuts are unscrewed,the assembly must be strapped together as one unit beforeit is picked up by the handling yoke.
iThe hammerless washpipe assembly must always behandled as one unit. Avoid disassembly unless yoususpect faulty parts (refer to Troubleshooting).
50 Varco
Hammerless Washpipe AssemblyDisassembly
1. Remove washpipe assembly from the TDS/IDS.2. Completely disassemble the washpipe assembly.
Take care to prevent damage to the sharp edge of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.
Procedure
O-Ring
O-Ring
Snap Ring
Holding Ring
WashpipeNut
WashpipeDiscard and replace
these non-serviceableparts from the
washpipe assembly.
PackingBox
GreaseFitting
Socket HeadDog Nose Screw
Packing Set(5 per Set)
Upper Spacer
Middle Spacer
Middle Spacer
i
Washpipe 51
Hammerless Washpipe AssemblyDisassembly
Upper Spacer
Middle Spacer
4. Thoroughly clean and inspect remainder of parts.5. Check that the ID of each spacer is within specification.6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer.
Procedure
This surface to besmooth and flat
This surface to besmooth and flat
This edge to besharp
ID
ServiceLimit ID(inches)
WashpipeAssembly Spacer
VarcoPartNo.
ProperID
(inches)
Large Bore Upper 30123434 4.895 to 4.900 4.905 Middle 30123435 4.895 to 4.900 4.905 Lower 30123436 4.895 to 4.900 4.905
Large to Small Bore Upper 123585 3.635 to 3.640 3.645 Middle 30123286 3.635 to 3.640 3.645 Lower 123287 3.635 to 3.640 3.645
52 Varco
Hammerless Washpipe AssemblyDisassembly
8. Check that the ID of the washpipe nut where the washpipe passes through.
9. Check that the ID of the packing box where the washpipe passes through.
Procedure
PackingBox
hpipeut
ID
Service Limit ID(inches)
WashpipeAssembly
Washpipe NutPart No.
Proper ID(inches)
Service Limit ID(inches)
Proper ID(inches)
Large Bore 30123431 4.905 to 4.910 4.915
Large to 30153493 3.655 to 3.660 3.665Small Bore
WashpipeAssembly
Packing BoxPart No.
Large Bore 30123626 4.900 to 4.905
Large to 30153494 3.637 to 3.644 3 650Small Bore
Washpipe 53
Hammerless Washpipe AssemblyDisassembly
GreaFitti
HoldingRing
10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.
11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly.
13. Reassemble the washpipe assembly as described in the Reassembly Procedure.
Procedure
Undercut
This surface to besmooth and flat
This surface to besmooth and flat
54 Varco
Hammerless Washpipe AssemblyReassembly
1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing.
2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers.
Procedure
Upper Spacer
PackingSeal
Spacer
Middle Spacer
Fill with greaseto level shown
Sharp edgeof spacer Wipe grease
from area shown,all the way aroundon each spacer.Sharp edge
of spacer
Sharp edgeof spacer
Washpipe 55
Hammerless Washpipe AssemblyReassembly
i
3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box.
4. Install the socket head cap screws. The heads of the screwsshould bottom out in the nut casing. The dog head should notbottom out on the spaceer. The screw prevents the spacers from
not otherwise constrain them.5.
packing box.6.
NOT OVER GREASE.
Procedure
PackingBox
DowelPinGrease
Fitting
Socket HeadDog Nose
Screw
In the following step, an Arbor press may be required to compress the packing enough to in stall the screws.
Ensure that the nose of thesocket head dog nose screw
is fully engaged in the groove ofthe lower spacer (screw should
not push spacer off center)
.010" Min
56 Varco
Hammerless Washpipe AssemblyReassembly
7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the non-slotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Procedure
Washpipe
WashpipeNut
PackingBox
Washpipe 57
Hammerless Washpipe AssemblyReassembly
9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.
10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe.
11. Install the snap ring.12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
13.approximately the length of the washpippe.
14.Initial Installation Procedure.
Procedure
HoldingRing
SnapRing
O-ring
PackingSeal
PackingSeal
HoldingRing
Fill with greaseto level shown.
Wipe greasefrom area shown,all the way aroundthe holding ring.
58 Varco
Hammerless Washpipe AssemblyIllustrated Parts List
O-Ring
Snap Ring
Holding Ring
WashpipeNut
Washpipe
Packing Box
Grease Fitting
Socket HeadDog Nose Screw
Long-ArmAllen Wrench
Packing Set5 per set
O-Ring
Upper Spacer
Middle Spacer
Middle Spacer
Lower Spacer
Washpipe 59
Hammerless Washpipe AssemblyIllustrated Parts List
Kit, Link Tilt Clamp……………………………………….……………………...M614000290-50
Control System Control Panel……………………........................................................................... 30184445
Service Loops, Derrick Terminations, and Miscellaneous Kits Service Loop Kit, Electrical…. ........................................................................ 117933-86-10
Service Loop, Fluids…………....................................................................109179-86-19-10
Motor Electrical Installation Kit…………………… ..............................M614000217-SE-U24
Kit, Link Tilt Clamp……………………………………….……………………...M614000290-50
Retrofit Kit, Rotating Head Motor Assembly………………………………..M614000418-500
Hose Kit, CRT to PH-85…………………. ........................................ M614000509-ASM-001
This page left blank intentionally.
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
Local Cooling System (109412-2A1) 109412-DWG Drawing, Motor Cooling System 1 1 1 109412-2A1 Local Cooling Assembly 109411 Heat Exchanger - - 1 109412-2A1 Local Cooling Assembly 88229 Motor Blower, 20HP, UL - - 1 109412-2A1 Local Cooling Assembly
-1 -2 -3 Commission Operational Insurance Where Description
Part Number Description Spare Spare Spare Used Where Used
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
CURRENT INITIAL DRAWN T. GONZALEZ
TITLE
CONTROL SPARES LIST, TDS-4S, PETROBRAS P-14
CHECKED T. JORDANAPPVD T. JORDAN
SIZE
ADWG NO
30184734 REV
-DATE 11/07/07 SCALE NONE WT LBS SHEET 1 OF 3 DCF0045 (REV B)
Part No. Description Spare Spare Spare Used Where Used
92119-6 Barrier, Potentiometer Converter
1 - 1 30184445 Control System Assy.
141611 Power Supply 15VDC, 1A 1 - 1 30184445 Control System Assy. 122627-02 Power Supply 24VDC, 10A 1 - 1 30184445 &
P804000014-ASM-001
Control System Assy.
122627-36 Digital Input Module, 16x24VDC
1 - 1 30184445 Control System Assy.
112627-101 Digital Relay Output Module, SM322
1 - 1 30184445 Control System Assy.
122627-142 Analog Input, SM331, 8Ch 2 - 2 30184445& P804000014-ASM-001
Control System Assy.
122627-19 Analog Output 1 - 1 30184445 Control System Assy. 122627-76 Frequency Counter 1 - 1 30184445 Control System Assy.
112627-101 Digital Relay Output Module, SM322
2 - 2 30184445 & P804000014-ASM-001
Control System Assy.
122627-14 Digital Output 2 - 2 30184445 & P804000014-ASM-001
Control System Assy.
122627-27 Front Connector, Screw Terminal, 20 Pins
- - 1 30184445 Control System Assy.
122627-75 Front Connector, Screw Terminal, 40 Pins
- - 1 30184445 Control System Assy.
122627-34 Profibus Connector w/PG Socket .
- - 1 30184445 Control System Assy.
122627-143 CPU 315-2DP 1 - 1 30184445 Control System Assy. 30123233-10E Isolator, Analog Signal 1 - 1 30184445 Control System Assy.
3071075 Isolator, Analog Signal 1 - 1 30184445 Control System Assy. 30087708-59 Light, Indicator, Clear 24V
DC - 1 1 30184445 Control System Assy.
30087708-39 Light, Indicator, Green 24V DC
- 1 1 30184445 Control System Assy.
30087708-44 Lamp, Bayonet 24V DC - 10 1 30184445 Control System Assy. 30087708-37 Switch, 3 Position - - 1 30184445 Control System Assy. 30087708-27 Switch, 2 Position - - 1 30184445 Control System Assy.
81736-2 Potentiometer, 2W, 10K - - 1 30184445 Control System Assy. 118910-7 Relay,DPDT, 2NO, 24V 1 - 2 30184445 &
P804000014-ASM-001
Control System Assy.
118910-17 Relay,DPDT, 2NO, 120V 1 - 2 30184445 Control System Assy. 30171978 Barrier, .I.S. 1 - 1 P804000014-
ASM-001 Remote I/O J-Box
92119-8 Barrier, I.S. 1 - 1 P804000014-ASM-001
Remote I/O J-Box
98263 Barrier, I.S. 1 - 1 P804000014-
ASM-001 Remote I/O J-Box
111070 Barrier, I.S. 1 - 1 P804000014-ASM-001
Remote I/O J-Box
122627-01 Power Supply 24VDC, 5A 1 - 1 P804000014-ASM-001
Remote I/O J-Box
122627-127 ET200S POWER MODULE 1 - 1 P804000014-ASM-001
