varco tds 10

TDS-10S

Top DriveDrillingSystem

Service ManualSM00400

March 2, 1998

ii TDS-10S Contents

Manual conventions

This manual uses conventions that make it easy for the reader tolocate key information and detailed descriptions. Graphicsillustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and its components.

Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention. Note the examples belowand pay close attention to these important advisories.

z Note: Indicates advisories for operational or servicing proceduresinvolving no risk of personal injury or equipment damage.

e Caution: Indicates advisories involving a risk of equipment damage.

n Warning: Indicates advisories involving a definite risk of injuryto rig personnel.

Avoid personal injury and equipment damage by reading thismanual and related documents prior to operating or maintainingthe equipment.

About this manual

TDS-10S Contents iii

Contents

Book 1 – Description, Installation and Operation

PrefaceManual conventions............................................................ 5Safety information .............................................................. 5Directional references ......................................................... 6Illustrations ......................................................................... 6Manual layout..................................................................... 6Varco service centers ........................................................... 6

Chapter 1 IntroductionIntroduction to the TDS-10S ............................................. 7

Chapter 2 DescriptionTDS-10S major components .............................................. 9

Motor housing and swivel assembly ............................ 10Transmission and swivel housing .......................... 10Integrated swivel assembly .................................... 11Drilling motor and brakes ..................................... 11

Motor cooling system ................................................. 12Carriage and guide beam............................................. 14PH-55 pipehandler ..................................................... 14

Powered rotating link adapter ............................... 14Torque backup clamp cylinder .............................. 15Bidirectional link tilt ............................................. 16Internal blowout prevention ................................. 18

Hydraulic control system ............................................ 20Counterbalance system ......................................... 22

STAND JUMP feature (optional) ................... 23AC motor and control system ..................................... 24

March 2, 1998

iv TDS-10S Contents

Chapter 3 InstallationInstalling the TDS-10S ..................................................... 27

Chapter 4 OperationDriller’s interface and driller’s console ............................... 33

Throttle control .......................................................... 33Torque control............................................................ 34Switches ...................................................................... 34Indicators .................................................................... 36Varco control system................................................... 37

Variable frequency inverter ............................................... 38Rectifier and DC link filter ......................................... 38Power modules ........................................................... 38Control section ........................................................... 38

Service loop ...................................................................... 39Drilling ahead ................................................................... 40

Drilling ahead with triples .......................................... 40Drilling ahead with singles .......................................... 42Tripping in and tripping out ....................................... 44Back reaming .............................................................. 44Well control procedures .............................................. 46Running casing ........................................................... 48

Chapter 5 SpecificationsGeneral ............................................................................. 49

Drilling parameters ..................................................... 50Rated capacities ..................................................... 50Drilling motor ...................................................... 50Pipehandler (PH-55) ............................................ 50

Chapter 6 Appendix............................... 51

TDS-10S Contents v

Book 2 – Maintenance and Troubleshooting


Chapter 1 IntroductionPrecautions ......................................................................... 9

Chapter 2 Maintenance schedulesInspection schedules ......................................................... 11Lubrication schedule ......................................................... 13Lubricant specifications .................................................... 14

Selecting a lubricating/hydraulic oil ............................ 14Selecting a lubricant .................................................... 15

Chapter 3 InspectionInspecting hardware and fittings ....................................... 17Inspecting the AC drilling motor brakes ........................... 18Inspecting the AC drilling motor louvers .......................... 18Inspecting the wash pipe assembly .................................... 18Inspecting the upper stem liner ......................................... 19Inspecting main shaft end play .......................................... 21Inspecting the gearbox oil level ......................................... 22Inspecting the guide beam ................................................ 22Inspecting the IBOPs ........................................................ 22Inspecting the pipehandler ................................................ 23Nondestructive Examination (NDE) ................................ 24

Inspecting the elevator link eyes .................................. 24Inspecting the drive stem ............................................ 26Magnetic particle inspection (MPI) ............................ 27Ultrasonic inspection .................................................. 28

Inspecting the hydraulic system ........................................ 29Inspecting the electrical system ......................................... 29

March 2, 1998

vi TDS-10S Contents

Chapter 4 LubricationIntroduction ..................................................................... 31Lubricating the AC blower motor bearings ....................... 32Lubricating the hydraulic pump AC motor ....................... 32Lubricating the AC drilling motor bearings ...................... 32Lubricating the wash pipe assembly .................................. 34Lubricating the upper main body oil seals ......................... 35Replacing the gearbox oil .................................................. 35

Initial oil change ......................................................... 35Oil capacity ................................................................. 35

Replacing the gearbox oil filter .......................................... 36Lubricating the carriage and guide beam ........................... 36Lubricating the rotating link adapter ................................. 36Lubricating the link tilt and PH-55 stabilizer bushing ...... 38Lubricating the elevator support andmaster bushing wear guide ................................................ 38Lubricating the wireline adapter ........................................ 38Lubricating the IBOP actuator yoke ................................. 39Lubricating the IBOP actuator crank ................................ 40Lubricating the torque arrestor tubes andclamp cylinder gate ........................................................... 41

Chapter 5 MaintenanceGeneral hydraulic system maintenance.............................. 43

Start-up procedure ...................................................... 44Accumulator maintenance ................................................ 44

Chapter 6 TroubleshootingTroubleshooting the AC drilling motor ............................ 45Troubleshooting the AC blower motor ............................. 46Troubleshooting the hydraulic system ............................... 47Troubleshooting the ACdrilling motor brakes ......................................................... 51Troubleshooting the rotating link adapter(rotating head) motor ....................................................... 52

Operation ................................................................... 52System test .................................................................. 52

Troubleshooting the IBOP actuator cylinder .................... 54Operation ................................................................... 54System test .................................................................. 55

TDS-10S Contents vii

Troubleshooting the shot pin cylinderand clamp cylinder ............................................................ 57


Troubleshooting the counterbalance system ...................... 60Counterbalance testing ............................................... 61Stand jump testing ...................................................... 62

Troubleshooting the hydraulic power unit (HPU)and reservoir ..................................................................... 64


Chapter 7 Disassembly and assemblyPrecautions ....................................................................... 67PH-55 Pipehandler ........................................................... 69

Disassembling the PH-55 Pipehandler ........................ 69Assembling the PH-55 Pipehandler ............................ 71

Rotating link adapter ........................................................ 72Disassembling the rotating link adapter assembly ........ 72Assembling the rotating link adapter assembly ............ 73

Transmission/motor housing ............................................ 75Removing the transmission/motor housing ................. 75Installing the transmission/motor housing .................. 75Disassembling the transmission/motor housing .......... 76

Removing the bonnet and wash pipe .................... 76Removing the upper bearing retainer plate .................. 77

Removing the AC drilling motor .......................... 77Removing transmission components ..................... 78

Assembling the transmission/motor housing ............................................................ 81

Assembling the main body .................................... 81Assembling the main shaft .................................... 82Assembling the gears to the main body ................. 84Installing the AC drilling motor ............................ 87Installing the upper bearing retainer plate ............. 89Installing the wash pipe......................................... 91Checking the gear train backlash ........................... 91

AC drilling motor disassembly/assembly ........................... 92AC drilling motor disassembly .................................... 92AC drilling motor assembly ........................................ 94

Replacing the safety wiring ............................................... 96Safety wiring tips ........................................................ 98

March 2, 1998

viii TDS-10S Contents

Book 3 – Control System

Chapter 1 DescriptionGeneral description ............................................................. 5Major component descriptions ........................................... 7

Varco Driller’s Console (VDC)..................................... 7Programmable logic controller (PLC) ..................... 9Variable Frequency Drive (VFD) .......................... 10

Electrical service loops ................................................. 12

Chapter 2 OperationPreoperational checklists ................................................... 13VDC controls ................................................................... 17Correcting a drive fault ..................................................... 20

Drive fault while drilling ............................................. 20Drive fault while making up ....................................... 21

Chapter 3 MaintenanceMaintaining the control system......................................... 23Troubleshooting ............................................................... 25

VFD ........................................................................... 28

Book 4 – Supplemental Material

TDS-10S


Description,Installation andOperation

2 TDS-10S Service Manual

March 10, 1998

TDS-10S Service Manual 3

Contents


Chapter 1 IntroductionIntroduction to the TDS-10S ............................................. 7

Chapter 2 DescriptionTDS-10S major components .............................................. 9

Motor housing and swivel assembly ............................ 10Transmission and swivel housing .......................... 10Integrated swivel assembly .................................... 11Drilling motor and brakes ..................................... 11

Motor cooling system ................................................. 12Carriage and guide beam............................................. 14PH-55 pipehandler ..................................................... 14

Powered rotating link adapter ............................... 14Torque backup clamp cylinder .............................. 15Bidirectional link tilt ............................................. 16Internal blowout prevention ................................. 18

Hydraulic control system ............................................ 20Counterbalance system ......................................... 22

STAND JUMP feature (optional) ................... 23AC motor and control system ..................................... 24

Chapter 3 InstallationInstalling the TDS-10S ..................................................... 27


March 10, 1998

Chapter 4 OperationDriller’s interface and driller’s console ............................... 33

Throttle control .......................................................... 33Torque control............................................................ 34Switches ...................................................................... 34Indicators .................................................................... 36Varco control system................................................... 37

Variable frequency inverter ............................................... 38Rectifier and DC link filter ......................................... 38Power modules ........................................................... 38Control section ........................................................... 38

Service loop ...................................................................... 39Drilling ahead ................................................................... 40

Drilling ahead with triples .......................................... 40Drilling ahead with singles .......................................... 42Tripping in and tripping out ....................................... 44Back reaming .............................................................. 44Well control procedures .............................................. 46Running casing ........................................................... 48

Chapter 5 SpecificationsGeneral ............................................................................. 49

Drilling parameters ..................................................... 50Rated capacities ..................................................... 50Drilling motor ...................................................... 50Pipehandler (PH-55) ............................................ 50

Chapter 6 Appendix ............................... 51


Preface

Manual conventions

This manual contains conventions that make it easy for the readerto locate key information and detailed descriptions. Graphicsillustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and assemblies to providea better understanding of the equipment’s functionality.

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 symbols belowand pay close attention to these important advisories throughoutthe text.

z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personal injury and equipmentdamage.

e Indicates advisories involving a risk of equipment damage.

n Indicates advisories involving a definite risk of injury to rigpersonnel.


March 10, 1998

Avoid personal injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.

Directional references

References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the toolassembly–standing behind the tool as it faces well center.

Illustrations

Figures present a graphical representation of tool components foruse in identifying parts or establishing nomenclature.

Illustrations show measurements with inches (in.), followed bymillimeters (mm).

For more specific component information pertinent to your rigconfiguration, see the drawing index in the Drawings chapter toobtain the engineering drawing number.

Manual layout

This binder contains several separate chapters that you canremove individually for convenience.

Varco service centers

If you need technical assistance, see the back cover of this manualfor a complete list of Varco’s Worldwide Service Centers.


Chapter 1

Introduction

Introduction to the TDS-10S

Varco Drilling Systems developed the TDS-10S Top DriveDrilling System primarily for smaller land rigs.

Varco made use of the recent advancements in AC technology,designing the TDS-10S to use one 350-hp AC drilling motor.This 350-hp system produces 20,000 ft lb of continuous drillingtorque and 36,500 ft lb of makeup/break out torque. The TDS-10S is compact enough to be safely operated in a standard 136 ft.mast while providing 250 tons of hoisting capacity. Its highlyportable design allows for simple rig-up and rig-down in just afew hours. It easily integrates into existing rigs at minimalinstallation cost and rig modification.


March 10, 1998


Chapter 2

Description

TDS-10S major components

The TDS-10S drilling system includes the following assembliesand subassemblies:

❏ Motor housing and swivel assembly

❏ Motor cooling system

❏ Guide beam

❏ PH-55 pipehandler

❏ Hydraulic control system

❏ Counterbalance system

❏ AC drilling motor

❏ Electrical control system


March 10, 1998

Motor housing and swivel assemblyThis assembly is comprised of the following subassemblies:

❏ Transmission and swivel housing

❏ Integrated swivel assembly

❏ Drilling motor and brakes

Transmission and swivel housingThe assembly consists of the following components:

❏ Bonnet/cover

❏ Main body

❏ Motor pinion

❏ Compound gear

❏ Bull gear

❏ Main shaft

❏ Lubrication system

The single-speed helical gear transmission with double reductionprovides a 13.1:1 ratio from the motor to the main shaft. Themain body and gear case cover house the transmission, the mainthrust and radial bearings. The gear case cover houses the uppertake-up bearing and supports the AC motor. The bull gearattaches to the load shoulder on the main shaft. All lubrication ofthe gears and bearing is via a pressurized system integrated intothe main body and cover.


Integrated swivel assemblyAn industry-standard washpipe packing assembly is locatedbetween the main shaft and gooseneck, and allows for therotation of the drill string. The bonnet/gear case cover supportsthe assembly and attaches to the gear case to provide lateralsupport.

An alloy steel swivel bail attaches to the main body. The swivelbail can stroke vertically relative to the swivel housing to providean integral counterbalance system. An extended length is availableto allow operator clearance between the gooseneck and hook forwireline packing assemblies.

Drilling motor and brakesA 350 hp AC drilling motor supplies power to the TDS-10S.The motor mounts vertically on top of the transmission gear casecover with a modified “D-face” to avoid shimming or specialalignment during installation.

The motor has a double-ended shaft with a drive hub mountedon the lower end and a disc brake rotor mounted on the upperend. Two hydraulic caliper disc brakes mount to the top end ofthe motor, where they can be easily inspected and serviced via theaccess covers around the brake covers. The caliper disc brakes alsoassist in drill string positioning when performing directionalwork. They are remotely operated from the driller’s console.


March 10, 1998

Motor cooling systemThe motor cooling system (Figure 1) on the TDS-10S is a localintake centrifugal blower consisting of a cooling fan motormounted on top of the AC drilling motor. The system draws airacross the brake and delivers it through rigid ducting to anopening at the top of the motor. The cooling air then passesthrough the inside of the open-frame type AC drilling motor andexits through the louvered openings near the bottom of themotor. This rugged, simple design provides highly reliable servicewith positive ventilation.


Blower Motor

Louvers

Air Flow

Duct

Centrifugal Blower

Disk Brake Housing

AC Drilling Motor

Intake Air Flow(Between Motor and

Brake Housing)

Exhaust Air Flow

Figure 1. TDS-10S motor cooling system


March 10, 1998

Carriage and guide beamThe TDS-10S drilling system travels on a hanging guide beam bymeans of a carriage attached to the gear case. The guide beamhangs from the crown and extends to within seven feet of the drillfloor. There, it attaches to either a lower mast girt or a torquereaction beam mounted across the lower section of the mast orderrick.

The drilling torque is reacted through the carriage and into theguide beam. The guide beam is available in 18-ft. sections(63 lb/ft) and hangs from a pad eye at the crown. The guide beamsections are pinned together making installation easy. Guide beamsections can be assembled one section at a time, at the drill floor,while raising the guide beam to the crown attachment using thedrawworks.

The carriage consists of an angle structure and low friction guidepads. This arrangement maintains alignment of the main shaftwith the drill string while moving up and down on the guidebeam.

PH-55 pipehandlerThe PH-55 pipehandler consists of the following majorcomponents:

❏ Powered rotating link adapter

❏ Torque backup clamp cylinder

❏ Bidirectional link tilt

❏ Remote upper IBOP actuator

❏ Elevator links and drill pipe elevator

Powered rotating link adapterThe powered rotating link adapter hangs from the stem.Hydraulic pressure applied to an annulus between the stem andthe rotating link adapter supports the weight of the pipe handlerwith links and drill pipe elevator during drilling. During tripping,when the drill pipe elevator supports the weight of the drill string,the rotating link adapter strokes down to the landing collar seatand, in turn, transfers the load to the main shaft.


The powered rotating link adapter allows the hydraulic lines toremain connected as the pipehandler rotates with the drill stemcomponents while tripping or when positioning the link tilt.During this operation, the pressurized annulus acts as a hydraulicthrust bearing.

The powered rotating link adapter has a hydraulic drive motor torotate it in either direction. An electric solenoid valve operates thehydraulic motor. A pinion gear on the hydraulic drive motorrotates the positioning gear that is attached to the top of therotating link adapter.

During make or brake operations the rotating link adapter can belocked into any of 24 index positions by selecting the pipehandlerclamp mode which actuates a hydraulically operated shot pin.When the hydraulic drive motor is not powered the link adaptercan rotate freely.

The link tilt mechanism is integrated into the rotating link adapter.The torque arrestor frame hangs from the rotating link adapter.

Two bushings located toward the top and bottom ends of therotating link adapter and sandwiched radially against the stem,support the radial loads. The internal hydraulic fluid passages inthe stem connect to the respective fluid passages in the rotatinglink adapter.

Fluid is fed from the main manifold into the stem through the radialpassages at the upper end. This fluid is routed from the verticalpassages in the stem to grooves in the rotating link adapter, and outto all actuators on the pipe handler. While rotating or in anystationary position, fluid flows between the two components.

Torque backup clamp cylinderThe torque backup clamp cylinder assembly is located below thelower shoulder of the saver sub. It includes two gripping jawswith die inserts and a clamping cylinder for gripping the box endof the drill string when connecting to a saver sub. A torquearrestor frame hanging from the rotating link adapter supportsthe torque backup clamp cylinder and allows the clamp cylinderto float up or down to allow for thread engagement anddisengagement. With the torque backup clamp cylinderpressurized to clamp on a tool joint, torque is reacted through thetorque arrestor frame while making and breaking connections.

The torque backup clamp cylinder position is adjustable. Itsposition is adjusted so that the top of the dies are 3/8 to 1/2 in.below the top of the box end of the tool joint.


March 10, 1998

Bidirectional link tiltThe link tilt mechanism consists of two hydraulic cylinders and acrank mounted with a pivot arrangement on the rotating linkadapter (Figure 2). The top end of the crank is connected to therod end clevises of the two hydraulic cylinders. The bottom endof the crank is connected to the elevator links through two levers,attached to the links with U-bolts and link clamps.

The stop mechanism limits the travel of the elevator to thederrickman position which is adjustable. Releasing the stop (bypulling a cable) allows the elevator to travel to the mouseholeposition.

The elevator is fully extended in the opposite direction byextending the two hydraulic cylinders. This gives the tool overdrillcapability.

The link tilt operates from a three-position switch located on thedriller’s console. The TILT position moves the links toward themousehole or derrickman by retracting the two hydrauliccylinders. The DRILL position tilts the links back to clear thedrill pipe and raise the elevator to allow drilling down to the floor.The spring centered position holds the link at any intermediateposition. There is a separate float switch which is used to allowthe links to hang free. The DRILL position changes the tiltdirection, which also keeps the elevator off the drill pipe whendrilling or moves it away from the well center to clear the drillfloor when drilling down to the floor. The links may be stoppedat any intermediate position. The links float back to the wellcenter when the FLOAT position button on the driller’s console isoperated.


108"

76"

Drill Floor

56"

28"

Link Tilt Cylinder (2)

Mou

seho

le

Der

rickm

an *

Overdrill

Dril

l

34"

36"Typ.

14"

4"

WellCL

All dimensions are true for108" long Elevator Links and

FOR REFERENCE ONLY

* At Monkey Board level (80')and placed into view

FOR CLARITY ONLY

Figure 2. Bidirectional link tilt positions


March 10, 1998

Internal blowout preventionThe two ball-type internal blowout prevention (IBOP) valves arefull size, internal opening safety valves (Figure 3). The remotelyoperated upper valve and the manually operated lower valve formthe well control system. Both valves have 6 5/8 in. regular RHconnections and 15,000 psi pressure ratings.

A two-position switch at the driller’s console operates the OPENand CLOSE functions of the upper IBOP valve. When the switchis operated, a hydraulic cylinder through a non-rotating leverarrangement attached to the torque arrestor slides an actuatorshell up and down. This lever arrangement drives a small crankarm on each side of the valve which opens and closes the upperIBOP valve.

Both upper and lower IBOP valves can be broken out and sentdown hole.


Main Shaft

Tool Joint Lock

Tool Joint Lock

Tool Joint Lock

Upper IBOP and Actuator(Remote)

Manual Lower IBOP(Optional)

Back-up Clamp Cylinder Assembly Stabbing Guide

Torque Arrestor Frame

Upper IBOP Actuator Cylinder

Saver Sub

Figure 3. TDS-10S drill stem assembly


March 10, 1998

Hydraulic control systemThe hydraulic control system (Figure 4) is completely self-contained (on board) and supplies all hydraulic power. Iteliminates the need for an additional service loop. The systemconsists of components that operate the following assemblies:

❏ Counterbalance system

❏ AC motor brakes

❏ Gear/main bearings lubrication system

❏ Powered rotating head

❏ Remotely actuated IBOP

❏ Torque backup clamp cylinder

❏ Link tilt

The hydraulic control system is powered by a 10 hp, 1,200 rpmAC motor that is direct coupled to drive a hydraulic pump.

An integral hydraulic manifold mounts to the carriage andcontains all solenoid, pressure, and flow control valves.

There is also a manifold mounted to the shot pin housing forcontrolling the hydraulic rotating link adapter motor.

Hydro-pneumatic accumulators operate the IBOP, pressurecontrol valves, and counterbalance system.


M

Reservoir

HydraulicPump

10 HP A.C.Motor

Rotating LinkAdapter Motor

Shot PinCylinder

CounterbalanceAccumulator

DrillingMotor Brake

Upper IBOPActuatorCylinder

Link TiltCylinders

Torque BackupClamp

Cylinder

CounterbalanceCylinders

Lube Oil

Distribution

SystemAccumulator

Pipehandler Rotating Link Adapter

(D.P. Elevator Positioner)

System Control Manifold

Upper IBOPTime DelayAccumulator

Figure 4. TDS-10S hydraulic system


March 10, 1998

Counterbalance systemThe integral counterbalance system prevents damage to tool jointthreads while making or breaking connections with the TDS-10S.It replaces the function of the hook compensator spring.

The system consists of two hydraulic cylinders attached betweenthe transmission cover and bail, a hydraulic accumulator, and ahydraulic manifold. The system is integral to the TDS-10S andtherefore does not require any external attachment to the hook.The cylinders are connected to a hydraulic accumulator. Theaccumulator is charged with hydraulic fluid and maintained at apredetermined pressure setting by the counterbalance circuit inthe main hydraulic control system manifold.


STAND JUMP feature (optional)

The stand jump feature developed for the TDS-9S is available asan option for the TDS-10S. It consists of a switch at the driller’sconsole allowing the operator to change the mode of operation ofthe counterbalance cylinders from DRILL, which is a standardcounterbalance condition, to STAND JUMP. The STANDJUMP feature allows the cylinders to lift the weight of the topdrive off the drill string while breaking out a connection. Thiseases the stress on the threads and avoids damage.


March 10, 1998

AC motor and control systemThe TDS-10S uses one 350 hp AC motor (Figure 5). It is locatedon top of the gear case, which minimizes the distance from thewell centerline to the rear of the guide beam.

Varco selected an AC drilling motor for use on the TDS-10Sbecause it provides the following benefits:

❏ Reliability

❏ Low maintenance

❏ Nonpolluting

❏ Wide operational range

❏ May be stalled indefinitely at full torque

❏ 180% overload capability for up to one minute

❏ Brushless

❏ Nonsparking

One AC induction motor powers the TDS-10S at 550 VACmaximum, 3-phase. The TDS-10S includes an air cooling system.

The motor is fed from a PWM inverter that provides variablevoltage at variable frequency for speed and torque control.

The motor is rated at 350 hp with a maximum constant outputtorque of 1,550 ft lb. Maximum constant torque is available from0 to 1,200 motor rpm, with constant power of 350-hp from1,200 rpm up to the maximum rated motor speed of 2,400 rpm.(See the TDS-10S output curve figures in the Appendix chapter.)


Thrust Ball Bearing

Air Inlet(1100 CFM)

Air Exhaust

Upper Grease Fitting

Lower Grease Fitting

End Coil

End Coil

Guide Roller Bearing

Stator Assembly(Laminated)

Rotor Assembly(Laminated)

Hub (Ref)

Mounting Base

Motor Frame(Laminated)

Motor Shaft(Vertical Type)

Hydraulic Motor Brake (Ref)

Figure 5. AC drilling motor


March 10, 1998

The AC motor (350 hp) and the gear ratios (13.1:1 high torque,standard speed, or optional 4.8:1 low torque, high speed) provide20,000 ft lb of torque at a drill stem operating speed range of 0 to87 rpm. Maintaining constant 350-hp output, the top driveprovides 8,081 ft lb of torque at a maximum drill stem speed of182 rpm.

The open-frame design of the AC drilling motor allows thecooling air to pass through the inside of the motor, whichprovides more efficient transfer of rotor and winding heat to thecooling air. The motor is manufactured specifically for top driveapplications. They include:

❏ Internal temperature sensors

❏ Double varnish impregnated glass-served windings

❏ Upgraded bearing/shaft seals

❏ High-capacity bearings

❏ Tapered output shafts

❏ High strength tie bolts

❏ Improved material castings


Chapter 3

Installation

Installing the TDS-10S

Electrical, mechanical and structural modifications are necessaryto install a TDS-10S on an existing rig. Dependent upon thespecific rig characteristics, possible modifications can include:

❏ Extending the standpipe to 73 ft.

❏ Replacing the rotary hose (75 ft.)

❏ Installing an AC drive electrical generator (new or upgrade)

❏ Tie-back for the guide beam

❏ Crown pad eye for the guide beam

❏ Attachment pad eye for service loop/bundle saddleinstallation at the 80 ft. level

❏ Location of tongs, pipe spinner, mud bucket and trigger lines

❏ Guide beam clearance to girts and fastline

❏ Location of the casing stabbing board


March 10, 1998

All of the above modifications may not be necessary, but all mustbe considered as well as the overall rig floor layout in order toensure that proper installation, time utilization and accurate costinformation is made.

The functional operation of a TDS-10S has many considerations;a primary consideration is the mast/derrick height. The workingheight and crown clearance are two primary factors to finalizeprior to ordering and installing your TDS-10S. Working heightand Crown clearance can both vary dependent upon hook, block,bail, elevator links, and coupling chosen. Figure 6 shows a typicalTDS-10S mast interface. A mast/derrick interface requirementsand worksheet is provided in the Appendix chapter.


3X50 ft(3X15,2 m)

A.C. Cables

Existing Traveling Equipment(250 ton Hook/Block Combo-Typ.)

Varco Portable TopDrive System TDS-10S

Crown

Block Top

Bail Rest

Tool Joint

Tool Joint

*

**

Dimensions are Subject forVerificationStandard TDS Configuration-One IBOP with 96" elev.LinksOptional TDS Configuration-Two IBOP’s with 108" elev. Links

Beam

Service Loop

CL

Sectional Guide Beam10 X 10" Square Tube

75 ft(22,9 m) Mud Hose* Connectedto Standpipe at 73 ft (22,3 m) Level

200 ft(61 m)* Unitized Service Loop

Service Loop Saddle at ~80 Ft(24,4 M) Level*

Portable Torque Reaction Beam(Varco Universal Clamp on System, or Custormer Supplied)

Varco Driller's Control

150 ft (45,7 m) ControlCable with Connectors

"Local Power Supply"(Diesel/Alternator Set)

Unitized Variable FrequencyInverter & Varco Control Panel

Drill Floor

93 ft(28,4 m)Drill StandMade-up at4 ft(1,2 m)

Level

12.6 ft(3,8 m)-Std.11.6 ft(3,5 m)-Opt.

Clearance**

15.0 ft(4,6 m)-Std.16.0 ft(4,9 m)-Opt.TDS Work Height**

11.4 ft(3,5 m)*Stroked-Typ.

4.0 ft(1,2 m)

10.0

ft(3

,0 m

)-M

in*

7.0

ft(2,

1 m

)-M

in

136

ft(41

,5 m

) -

Cle

ar W

orki

ng H

eigh

t

Figure 6. Typical TDS-10S mast interface


March 10, 1998

Another key consideration in selecting and successfully operatinga top drive is how well the top drive fits inside of the mast/derrick. Given the specific dimensions within the mast/derricklegs, the top drive and its guidance system need to utilize thecomplete working height. Figure 7 shows a detailed top view ofthe TDS-10S.

The TDS-10S is shipped on a transportation skid with the PH-55pipehandler connected. In the skid, the top drive is attached tothe upper section of the guide beam. Using the hook or a crane,the TDS-10S and skid is moved to the rig floor.

Following the directions provided will allow for easy connectionand locking-in of the remainder of the guide beam section andthe attachment to the upper support brackets.

Once the guide beam is secured at the top, the lower end of theguide beam is attached to the spreader beam and tied back to themast/derrick. Proper attachment and tieback is vital to thetransmission of the system torque to the rig structure.

Additional unit subsystem checkouts and precautions areprovided, all of which must be followed to ensure properfunctionality of the TDS-10S unit.


Carriage Assemblywith Guide Pads

Guide Beam10 X 10 (250 X 250)

Square Tube

20.5 (521)

25.6(650)Ref.

44.0(1118)Ref.

19.5(495)

26.0(660)

28.0 (711)

48.0 (1219) Ref.

Motor Housing Gooseneck Service Loop Bracket

Well CLCL

CL

CL

Reliance ElectricAC Induction

350 HP Drilling Motor

18.0(457)

24.0 (610)

Dimensions are in inches(millimeters)

Figure 7. TDS-10S envelope/plan view


March 10, 1998


Chapter 4

Operation

Driller’s interface and driller’s console

The driller’s console is manufactured from 300-series stainlesssteel and it uses full-size, oil-tight switches and indicators. It isdesigned for purging to meet hazardous area requirements. Byrequest, Varco can supply the console with Pyle-Nationalconnectors.

Throttle controlThe throttle uses a design similar to the standard throttle controlused with SCR systems. The handle is robust and includesintegral stops to prevent damage.


March 10, 1998

Torque controlTwo torque limit potentiometers are provided for setting drill andmakeup torque limits.

The drill limit control allows the driller to set the maximumtorque output of the top drive to match the drill pipe size beingused.

The makeup control sets the torque when making up connectionsusing the TDS-10S drilling motor.

SwitchesVarious switches control the following functions:

❏ Drill/Spin/Torque mode select

❏ Link tilt

❏ Brake

❏ Backup clamp cylinder

❏ Powered rotating link adapter

❏ IBOP valve

❏ Forward and reverse selection for the drill pipe rotation

❏ Emergency stop

❏ Stand jump (optional)


VarcoDriller'sConsole

Jumper Cable Assembliescould be used betweenMast Termination Plateand Skid (Control House).

*

+

-

VarcoDriller's

Interface

VariableFrequency

Drive /

AC PowerHighline

orDiesel/Alternator

Set

+-

*

*

Top Drive

Solenoids

SystemElectrical PanelElectrical

ServiceLoop

MastSaddle

Sensors

Skid

J-Box

Motor1

Enc

oder

*

DC Generator(Alternate)

Figure 8. Electrical interface


March 10, 1998

IndicatorsVarious indicators report status/faults to the driller:

❏ Oil pressure loss

❏ Drill motor over temp

❏ Blower loss

❏ Rotating link adapter

❏ IBOP closed

❏ Brake

❏ Drive fault

R

R

R A

RPMTORQUE

R

MAX0

0 MAX

STOPEMERGENCY

THROTTLE

REVERSE FORWARD

ONBRAKEOFF

ONAUTO

HYDRAULIC POWER

CLOSEOPENIBOPAUTO

BRAKE

ONBRAKE

CLOSEDIBOP

SILENCE CHECKALARM LAMP

OVERTEMPDRILL MOTOR

BLOWER LOSS

MAX0

CURRENT LIMITMAKE-UP

TORQUEDRILL

SPIN

OFFDRIVEFAULT

OILPRESS LOSS

DRILL TORQUE

OFF

LINK TILT FLOAT

PUSH & HOLDTORQUE WRENCH

ROTATE

DRILL TILT

PIPEHANDLER IBOPBRAKE

LEFT RIGHT

LINK TILT

R

Figure 9. Typical TDS-10S Varco driller’s console (VDC)


Varco control systemThe driller’s interface is integrated with the Variable FrequencyDrive (VFD). The VFD is located in an environmentallycontrolled house.

The driller’s interface integrated with the VFD includes thefollowing components:

❏ Control logic for system interlocks

❏ Blower and oil pump motor starters

❏ Control circuitry for pipehandler functions

❏ Power supply for TDS-10S solenoids and VDC indicators

❏ AC inverter

❏ Programmable Logic Controller (PLC)

The driller’s interface to the VFD is via a common data bus.Function changes are implemented with programming toolsstandard for Varco top drive systems.

The driller’s interface receives input from the operator controls onthe driller’s console and processes this information through theprogrammable logic controller (PLC). It controls the responses ofthe cooling system motor, the solenoid valves, the brakes, IBOPfunctions, and sensors. The PLC reads the status of the sensorsand acts as an interlock to prevent inadvertent tool operations. Itnotifies the driller of the operational status of the TDS-10S andprovides a diagnosis of any inadvertent operational conditions.


March 10, 1998

Variable frequency inverter

The frequency inverter consists of the following three majorsections:

Rectifier and DC link filterIn this section, the incoming 3-phase AC voltage is converted toDC voltage and filtered by the DC link capacitors. This providesa ripple-free 740 VDC voltage as input for the inverter.Alternately, by bypassing the rectifier section, the inverter can bepowered from a 740 VDC source.

Power modulesAC motor speed control requires variable frequency voltage. Todo this, the DC voltage is converted to an output waveform thatconsists of a series of pulses. The duration of each pulse iscontrolled so that the fundamental voltage applied to the ACmotor has the desired frequency and amplitude. The technique ofusing pulses to develop a waveform that appears to the motor as asine wave is called pulse width modulation or PWM.

Control sectionThe control section monitors the performance of the drillingmotor, accepts throttle and torque limit signals from theTDS-10S control system, and controls the firing circuits of thepower modules.

To vary motor speed, the driller uses a hand throttle. The throttlevaries the frequency and voltage to the motor. Because the drillingmotor is frequency synchronous, the motor speed is proportionalto the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200motor rpm).

One of the greatest advantages of an AC variable frequency driveis the quality of the speed and torque control. It allows precisecontrol of the drill pipe speed over the full operational range.


+

-

Variable Frequency Drive

TD

S-1

0S A

C M

otor

s

0-57

5VA

C, 0

to 8

0 H

z, 3

-Pha

se

Inverter Controller

Data Bus

Resultant Pulse DC

AC Inverter(AC Frequency Drive)

810 VDC20 Hz=600 RPM @ Mtr.

40 Hz=1200 RPM @ Mtr.

0

0

0

ACPowerSource

PLC

Insulated gate Bi-polarTransistors (IGBT)

00

600 VAC, 42 to 62 Hz3-Phase (350 AMPS)

Figure 9. AC power conversion to variable frequency

Service loop

The TDS-10S has an on board hydraulic system and, therefore,does not need a fluids service loop. This adds to the cost-effectiveness of the TDS-10S drilling system and provides a saferwork area.

The TDS-10S has three electrical service loops. One loop consistsof four 313 MCM cables (three for drilling motor power, one forground). One loop is a composite cable that contains conductorsfor the sensors and actuator (solenoid) control. The third loopcontains power for the smaller AC motors and space heater forthe drive motor.


March 10, 1998

Drilling ahead

Drilling ahead with triplesThis is the common drilling mode for the TDS-10S. There arevarious sources for triples to drill with. On skidding rigs drillingmultiple wells, or rigs that can move with racked pipe, the drillpipe can be left racked and used to drill the next well. If triples donot currently exist to drill with, 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. Enough triples should be left racked to handleanticipated bit life. The second is to make up triples in themousehole while drilling ahead or during rig idle time. For safetyreasons it is best to have a pivoting mousehole so it can be put ina vertical plane to simplify making connections. Note that theconnections just need to be spun up as they will be torqued whenthe Top drive motor applies the makeup torque.

Use the following procedure for drilling ahead with triples(Figure 11):

1. Drill down the existing stand and set slips.

2. Break out the saver sub from the drill pipe using the top drivemotor and backup clamp in the pipehandler.

3 Spin out the connection using the drilling motor.

4. Lift the top drive.

5. The derrickman latches the triple in the elevator and the floorcrew stabs it in the box.

6. Lower the top drive stabbing the pipe into the stabbing guideuntil the pin of the saver sub enters the box.

7. Spin-up and torque the connection using the drilling motor(makeup torque must be preset). Use a backup tong to reactthe torque.

8. Pull the slips, start the mud pumps and drill ahead.


Set slips onstring

Stop circulation

Close IBOP

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

Open IBOP

Begin drilling

1 2 3 4 5

Stab Makeup

Makeup

CloseIBOP

OpenIBOP

LinkTilt

Figure 11. Drilling ahead with triples


March 10, 1998

Drilling ahead with singlesTypically there are two situations when it is desirable to drillahead with singles. One is beginning operations on a new welland there are no triples made-up and racked back. The other iswhen surveys must be made every 30 feet (kicking off using adownhole mud motor). The link tilt feature makes drilling withsingles safe and efficient by moving the elevators to themousehole to pick up the singles.

Use the following procedure for drilling ahead with singles(Figure 12):

1. Drill down existing joint and set the slips.

2. Break out the saver sub from the using the top drive motorand the backup clamp in the pipehandler.

3. Spin out the connection using the drilling motor.

4. Lift the top drive until elevators clear box.

5. Actuate the link tilt to bring the elevator over to the single inthe mousehole, lower the top drive and latch the elevatoraround the single in the mousehole.

6. Pull the single out of the mousehole and as the pin clears thefloor, release the link tilt to allow the single to come to wellcenter.

7. Stab the connection at the floor and lower the top driveallowing the added single to enter the stabbing guide.

8. Spin-up and torque the connection using the drilling motor(torque mode). Set a backup tong to react the torque.

9. Pull the slips, start the mud pumps and drill ahead.


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 12. Drilling ahead with singles


March 10, 1998

Tripping in and tripping outTripping is handled in the conventional manner. The link tilt featurecan be used to tilt the elevator to the derrickman, enhancing hisability to latch it around the pipe thus improving trip times.

The link tilt has an intermediate stop which is adjustable to setthe elevator at a convenient working distance from the monkeyboard. The intermediate stop is tilted out of the way to allow theelevator to reach the mousehole.

If a tight spot or key seat is encountered while tripping out of thehole, the drilling motor may be spun into the stand at any heightin the derrick and circulation and rotation establishedimmediately to work the pipe through the tight spot.

Back reamingThe TDS-10S permits reaming out of open hole to prevent pipesticking and reducing keyseat formation, without affectingracking functions associated with normal tripping; i.e., no singlesto contend with. This is provided by the ability of the top driveand backup clamp to break out 93 ft. stands in the derrick/mast.

Use the following procedures for reaming out of the hole(Figure 13):

1. Hoist the block while circulating and rotating the drill motoruntil the third connection appears.

2. Stop circulation and rotation, and set the slips.

3. Break out the stand at floor level, and spin out using thedrilling motor.

4. Break out the drilling motor from the top of the stand usingthe top drive motor and backup clamp, then spin out withthe drilling motor.

5. Pick up the stand with the drill pipe elevator.

6. Rack stand back.

7. Lower the top drive to the floor.

8. Stab drilling motor into box, spin-up and torque with thedrilling motor and backup clamp.

9. Resume circulation and continue reaming out of the hole.


Hoist whilecirculating androtating

When 3-rd connectionsurfaces, 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 13. Back reaming


March 10, 1998

Well control proceduresThe TDS-10S can stab into the string at any point in the derrick.While drilling, the remotely controlled upper IBOP valve isalways in the string for immediate use as needed.

The lower IBOP valve is the same type as the upper IBOP valveexcept it must be operated manually with a wrench. Both valvesalways remain in the string and are therefore always readilyavailable by connecting the TDS-10S to the drill string.

To attach well control equipment to the drill string the torquearrestor frame assembly can be pulled away from the drill stringby opening the clamp cylinder.

After removing the lower valve from the upper valve, the lowervalve remains connected to the drill string for well controlpurposes. The TDS-10S includes crossover subs for connectingthe drill stem to the lower valve.

Use the following procedure for well control during trippingoperations (Figure 14):

1. On indication of a kick, set the slips and stab the top driveinto the string.

2. Spin-up and torque the connection.

3. Close the remote upper IBOP.

Internal pipe pressure of up to 15,000 psi is now held by theupper IBOP valve. If it becomes necessary to continuetripping in with a dart valve, or another well controlaccessory, the lower IBOP valve can be used to assist theoperation. In this case, the following steps may be followed:

4. Lower string to the floor and reset the slips.

5. Manually close the lower IBOP valve.

6. With the tugger line attached to the back of the unit, swingout the torque arrestor clamp cylinder assembly.

7. Remove the lower and intermediate tool joint locks.

8. Break out lower IBOP and saver sub from upper IBOP usingtongs.

9. Install appropriate crossover sub, check valve or circulationsub on top of lower IBOP valve.

10. Proceed with normal well control procedures.


Remote IBOPActuator Cylinder

Upper IBOP Valve

Lower IBOPValve

Insert NewSaver Sub

Add X-Over Sub(Check Valve etc.)

Saver Sub

Drill Pipe

Figure 14. PH-55 pipehandler well control procedures


March 10, 1998

Running casingUse longer elevator links (180 in.) to allow clearance forcementing head under the backup clamp 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.


Chapter 5

Specifications

General

Transmission 13.1:1 high torque/lowspeed, or optional 4.8:1low torque/high speeddouble reduction helicalgear

Transmission lube Pressure fed, filtered

Powered rotating head Infinitely positionable

System weight 18,000 lb


March 10, 1998

Drilling parametersDrilling speed range 0 to 182 rpm continuous

Drilling torque 20,000 ft lb maximumcontinuous (27115 Nm)

Breakout torque 36,500 ft lb max. int.

Drilling horsepower 350 maximum continuous

Static locking brake 35,000 ft lb (47455 Nm)

Rated capacitiesHoisting 250 Tons, API-8C, PSL-1

Drilling (rotating) 250 Tons

Water course (main shaft bore) 5,000 psi CWP (3 in.)

Drilling motorType AC induction, forced air

cooled.

Rating 350 hp

Rated speed 1,200 rpm

Maximum speed 2,400 rpm

Maximum continuous torque 1,550 ft lb

Maximum intermittent torque 2,790 ft lb

Pipehandler (PH-55)Torque capacity 50,000 ft lb @ 2,000 psi

Drill pipe range (OD) 2 7/8 in. through 5 in.(4 in. through 6 5/8 in.OD tool joint)

Upper IBOP (remote) 6 5/8 in. API Reg. RH,Box

Lower IBOP (manual) 6 5/8 in. API Reg . RH,Box and Pin (optional)

IBOP pressure rating 15,000 psi CWP

Elevator links 175 tons, 250 tons, or 350tons, API, 96 in. long(108 in. links optional)


Chapter 6

Appendix


March 10, 1998

Bail Rest

TDS-10S250 Ton System350 HP AC Motor

Output Torque20,000 ft-lbs

Drill Floor

Tool Joint

20.8 ft(6,3 m)TDS-4SWorkingHeight

Bail Rest

TDS-4S650 Ton System

1,100 HP DC Motor

Output Torque29,100(HI)/45,000(LO) ft-lbs

IDS-1500 Ton System

1,000 HP DC Motor

Output Torque34,000 ft-lbs

Bail Rest

Tool Joint Tool Joint

23.0 ft(7,0 m)IDS-1

WorkingHeight

15.0 ft(4,6 m)

TDS-10SWorkingHeight

Varco’s Top Drive Drilling Systems comparison


50 100 150 20000

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

Drill Pipe RPM

Dri

ll P

ipe

Torq

ue

(Ft-

Lb

s)

350 HP AC Motor - 13.1:1 Tranmission (Standard)

Max. Stall @36,500 ft lb

TDS-10S output curve (13.1:1)


March 10, 1998

100 200 300 400 50000

2,500

5,000

7,500

10,000

12,500

15,000

Drill Pipe RPM

Dri

ll P

ipe

Torq

ue

(Ft-

Lb

s)

350 HP AC Motor - 4.8:1 Tranmission (Optional)

Max. Stall @13,390 ft lb

TDS-10S output curve (4.8:1)


TRAVELINGEQUIPMENT MAKE MODEL

WORKING HEIGHT WEIGHT (EST)

in ft mm lbs kg

660B-500 92 7.6 2324 18500 8391DRECO 760B-650 105 8.7 2654 23800 10795

760B-750 109 9.0 2756 27500 12474650H500 91 7.5 2299 13500 6266

NATIONAL 660H500 109 9.0 2756 18750 8509760H650 112 9.3 2832 21800 9888

B500 100 8.3 2543 17900 8119OILWELL650 104 8.6 2629 20240 9181

A750 120 10.4 3210 34016 15429TRAVELINGTB525-6-60 105 8.8 2670 18200 8255BLOCKS

IDECO TB650-6-60 110 9.2 2794 20500 9299TB750-7-60 113 9.4 2873 22100 10024RA52-6-500 92 7.7 2337 13250 6010

CECO RA60-6-650 103 8.6 2621 19158 8690RA60-7-750 110 9.2 2794 22871 10374

McKISSICK500 91 7.6 2315 21500 9752650 109 9.1 2769 22590 10246

MH500-1195 92 7.7 2340 21546 10000650-1090 105 8.7 2664 26932 12500

PYRAMID 500 104 8.7 2648 22000 9979650/750 103 8.5 2604 27000 12247

HOOK-BLOCK 650G500 169 14.1 4293 21250 9639 COMBOS

NATIONAL660G500 184 15.3 4674 26500 12020

(stroked 8") 760G650 192 16.0 4883 31780 14415IDECO UTB 525-6-60 181 15.1 4607 9000 4082

545G350 152 12.6 3861 15260 6922540G250 137 11.4 3480 11600 5262

5500 117 9.8 2981 9950 4513VARCO BJ5750 138 11.5 3493 18090 8205

51000 158 13.2 4035 32076 14550HOOKS 500 97 8.1 2457 6920 3138

NATIONAL 650 103 8.6 2623 8550 3872750 113 9.4 2873 9750 4423

WEB WILS. 500 120 10.0 3048 8500 3856

MH500 112 9.3 2845 11850 5500

650/750 138 11.5 3508 18745 8700P500 92 7.7 2343 5700 2585

NATIONAL P650 94 7.8 2375 6900 3130P750 116 9.6 2937 11500 5216

OILWELLPC500 94 7.8 2388 5708 2589PC650 96 8.0 2438 7350 3334TL-500 91 7.6 2311 5200 2359

IDECO TL-650 101 8.4 2562 6900 3130TL-750 114 9.5 2899 8200 3719SWIVELS

CECOLB500 91 7.6 2311 5947 2698LB650 99 8.2 2505 6646 3015SW550 94 7.8 2381 5700 2585

G.-DENVER S500 98 8.1 2486 5800 2631S650 101 8.4 2570 6850 3107500 102 8.5 2578 6100 2767

DRECO 650 109 9.1 2769 7000 3175750 119 9.9 3001 9100 4128

TDS-3H 214 17.8 5436 32600 14800TDS-3S 250 20.8 6350 36750 16685TDS-4H 221 18.4 5613 37000 16798

VARCOTOP DRIVES

TDS-4S 250 20.8 6350 38750 17593TDS-5H 214 17.8 5436 35200 15981TDS-6S* 276 23.0 7010 43750 19826

IDS-11S 216 18.0 5486 26500 12020

(stroked 8")

TDS-7S 250 20.8 6350 49000 22742TDS-9S 214 17.8 5425 24000 10886

5350 106 8.8 2692 6340 28765250 104 8.7 2642 5050 2291

TDS-10S 192 16.0 4877 18000 8164

H350 77 6.4 1956 9380 4255

IDS-1** 346 28.8 8788 49000 22742

Block Top

Block

Hook(If Used)

Swivel

DrillingSystem

Hook-BlockCombination

S-TypeDrillingSystem

(IntegratedSwivel)

Tool Joint

IntegratedDrilling System

(IDS)(Integrated Block

and Swivel)

Saddle

Saddle

StemShoulder

Saddle

To short-couple a Swivel Bail/Top Driveto a Traveling Block VARCO offers specialAdapters with a 3 to 4 ft working height.

** With 500 Ton 60-in SheaveVarco Integrated Taveling Block

* Includes 750 Ton Hook Adapter

Top drive worksheet


March 10, 1998

VFD / Varco Driller's Interface

Drill Floor

4 ft

Beam

.............ft

.............ftMast

Bundle

.............ftMud Hose,[email protected]

ServiceLoop/Mast

BundleSaddle

@..........ft

..................Clearance

Customer:

..........................................

..........................................

ExistingTraveling Equipment:

...........................................

...........................................

Traveling EquipmentShort-Coupling usingVarco Adapter/Becket

(if applicable):

............................................

............................................

............................................

..................(Stroked)

15.0 or 16.0 ftTDS Working Height

SectionalGuide Beam

Tool Joint

Tool Joint

Bail Rest

Block Top

Crown

CL...

......

...ft

Mas

t Ope

ratin

g H

eigh

t

93 ft

Dril

l Sta

nd

TDS-10S Mast interface worksheet (generic)

TDS-10S


MaintenanceandTroubleshooting

March 2, 1998

2 TDS-10S Maintenance and Troubleshooting

TDS-10S Maintenance and Troubleshooting 3

Contents

PrefaceManual conventions............................................................ 7Safety information .............................................................. 7Directional references ......................................................... 8Illustrations ......................................................................... 8Manual layout ..................................................................... 8Varco service centers ........................................................... 8

Chapter 1 IntroductionPrecautions ......................................................................... 9

Chapter 2 Maintenance schedulesInspection schedules ......................................................... 11Lubrication schedule ......................................................... 13Lubricant specifications .................................................... 14

Selecting a lubricating/hydraulic oil ............................ 14Selecting a lubricant .................................................... 15

Chapter 3 InspectionInspecting hardware and fittings ....................................... 17Inspecting the AC drilling motor brakes ........................... 18Inspecting the AC drilling motor louvers .......................... 18Inspecting the wash pipe assembly .................................... 18Inspecting the upper stem liner ......................................... 19Inspecting main shaft end play .......................................... 21Inspecting the gearbox oil level ......................................... 22Inspecting the guide beam ................................................ 22Inspecting the IBOPs ........................................................ 22Inspecting the pipehandler ................................................ 23Nondestructive Examination (NDE) ................................ 24

Inspecting the elevator link eyes .................................. 24Inspecting the drive stem ............................................ 26Magnetic particle inspection (MPI) ............................ 27Ultrasonic inspection .................................................. 28

Inspecting the hydraulic system ........................................ 29Inspecting the electrical system ......................................... 29

March 2, 1998


Chapter 4 LubricationIntroduction ..................................................................... 31Lubricating the AC blower motor bearings ....................... 32Lubricating the hydraulic pump AC motor ....................... 32Lubricating the AC drilling motor bearings ...................... 32Lubricating the wash pipe assembly .................................. 34Lubricating the upper main body oil seals ......................... 35Replacing the gearbox oil .................................................. 35

Initial oil change ......................................................... 35Oil capacity................................................................. 35

Replacing the gearbox oil filter .......................................... 36Lubricating the carriage and guide beam ........................... 36Lubricating the rotating link adapter ................................. 36Lubricating the link tilt and PH-55 stabilizer bushing ...... 38Lubricating the elevator support andmaster bushing wear guide ................................................ 38Lubricating the wireline adapter ........................................ 38Lubricating the IBOP actuator yoke ................................. 39Lubricating the IBOP actuator crank ................................ 40Lubricating the torque arrestor tubes andclamp cylinder gate ........................................................... 41

Chapter 5 MaintenanceGeneral hydraulic system maintenance.............................. 43

Start-up procedure ...................................................... 44Accumulator maintenance ................................................ 44

Chapter 6 TroubleshootingTroubleshooting the AC drilling motor ............................ 45Troubleshooting the AC blower motor ............................. 46Troubleshooting the hydraulic system............................... 47Troubleshooting the ACdrilling motor brakes ......................................................... 51Troubleshooting the rotating link adapter(rotating head) motor ....................................................... 52


Troubleshooting the IBOP actuator cylinder .................... 54Operation ................................................................... 54System test .................................................................. 55


Troubleshooting the shot pin cylinderand clamp cylinder ............................................................ 57


Troubleshooting the counterbalance system ...................... 60Counterbalance testing ............................................... 61Stand jump testing ...................................................... 62

Troubleshooting the hydraulic power unit (HPU)and reservoir ..................................................................... 64


Chapter 7 Disassembly and assemblyPrecautions ....................................................................... 67PH-55 Pipehandler ........................................................... 69

Disassembling the PH-55 Pipehandler ........................ 69Assembling the PH-55 Pipehandler ............................ 71

Rotating link adapter ........................................................ 72Disassembling the rotating link adapter assembly ........ 72Assembling the rotating link adapter assembly ............ 73

Transmission/motor housing ............................................ 75Removing the transmission/motor housing ................. 75Installing the transmission/motor housing .................. 75Disassembling the transmission/motor housing .......... 76

Removing the bonnet and wash pipe .................... 76Removing the upper bearing retainer plate .................. 77

Removing the AC drilling motor .......................... 77Removing transmission components ..................... 78

Assembling the transmission/motor housing ............................................................ 81

Assembling the main body .................................... 81Assembling the main shaft .................................... 82Assembling the gears to the main body ................. 84Installing the AC drilling motor ............................ 87Installing the upper bearing retainer plate ............. 89Installing the wash pipe......................................... 91Checking the gear train backlash ........................... 91

AC drilling motor disassembly/assembly ........................... 92AC drilling motor disassembly .................................... 92AC drilling motor assembly ........................................ 94

Replacing the safety wiring ............................................... 96Safety wiring tips ........................................................ 98

March 2, 1998



Preface

Manual conventions

This manual contains conventions that make it easy for the readerto locate key information and detailed descriptions. Graphicsillustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and assemblies to providea better understanding of the equipment’s functionality.

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 symbols belowand pay close attention to these important advisories throughoutthe text.

z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personal injury and equipmentdamage.

e Indicates advisories involving a risk of equipment damage.

n Indicates advisories involving a definite risk of injury to rigpersonnel.

March 2, 1998


Avoid personal injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.

Directional references

References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the toolassembly–standing behind the tool as it faces well center.

Illustrations

Figures present a graphical representation of tool components foruse in identifying parts or establishing nomenclature.

Illustrations show measurements with inches (in.), followed bymillimeters (mm).

For more specific component information pertinent to your rigconfiguration, see the drawing index in the Drawings chapter toobtain the engineering drawing number.

Manual layout

This binder contains several separate chapters that you canremove individually for convenience.

Varco service centers

If you need technical assistance, see the back cover of this manualfor a complete list of Varco’s Worldwide Service Centers.


Chapter 1

Introduction

Precautions

To avoid serious injury or death, read and understand thefollowing warnings before performing maintenance procedures:

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

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

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

March 2, 1998


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

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

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

n Do not attempt repairs you do not understand.

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


Chapter 2

Maintenanceschedules

Inspection schedules

z The service intervals listed in Table 1 on the following page arebased on average operating conditions. Use the schedule as aguide. Some conditions (excessive loadings, dusty or corrosiveatmosphere, temperature extremes, etc.) may warrant morefrequent service intervals.

March 2, 1998


Table 1. Inspection schedule

Component Check for Frequency

Gearbox/Hydraulic reservoir Oil level Daily

Hardware and fittings Looseness Daily

Wash pipe assembly Leaks Daily

Main body Lubrication oil spray/flow Weekly

AC drilling motor Louvers/screens Weekly

Guide beam Hinge pin retainers WeeklyGuide beam wear

Upper stem liner Corrosion Monthly, or whenever thewash pipe packing is serviced

Elevator link Eye diameter Monthly

AC drilling motor brakes Wear and hydraulic leaks Monthly

Main shaft Axial movement (end play) Every three months

Accumulators (3) Charge Every three months

Gooseneck Wear Every six months

IBOPs Damage Whenever connectionsare broken

Load bearing components Magnetic Particle Inspection At three months or 1,500(MPI) hours on exposed surfaces

At five years overentire surface

Ultrasonic Inspection to beperformed along with MPI


Lubrication schedule

Table 2. Lubrication schedule

Component Fittings Type Frequency

Wash pipe assembly 1 General purpose grease Daily

Upper main body oil seal grease fittings 2 General purpose grease Daily

IBOP actuator yoke and pins General purpose grease Daily

IBOP actuator cranks 2 General purpose grease Daily

Stabilizer bushing General purpose grease Daily

Rotating link adapter grease fittings 3 General purpose grease Weekly

Clamp cylinder gate General purpose grease Weekly

Torque arrestor tubes–at clamp cylinder area 2 General purpose grease Weekly–at clamp cylinder gate 4 General purpose grease Weekly

Link tilt General purpose grease Weekly

Elevator support General purpose grease Weekly

Master bushing wear guide General purpose grease Weekly

Wireline adapter General purpose grease Weekly

AC drilling motor bearings 2 Chevron Black Pearl EP2 Three months

AC blower motor 2 Chevron Black Pearl EP2 Three months

Hydraulic pump motor 2 Chevron Black Pearl EP2 Three months

Replace oil Gear oil Three months

Replace oil filter Three months

March 2, 1998


Lubricant specifications

Selecting a lubricating/hydraulic oilVarco Top Drives operate under a wide variety of temperaturesand conditions. The oil viscosity varies from quite thick at start-up in cold climates to very thin in hot climates during difficultdrilling conditions.

Select gearbox lubrication based on the minimum ambienttemperature to be expected before the next oil change.Introducing an oil viscosity greater than required by the ambienttemperature could damage the gearbox due to reduced oil flow, ordamage the oil pump with an excessive load.

Use the following table to select the proper lubricant:

e The TDS-10S uses the same lubricant for both the transmission andhydraulic reservoir.

Table 3. Selecting a lubricating/hydraulic oil

Minimum ambient temp Oil type required Varco P/N

Below -15°F (-26°C) See note below See note below

-15 to 35°F (-26 to 2°C) ISO 32 56008-1

20 to 65°F (-7 to 18°C) ISO 68 56008-2

40 to 85°F (4 to 29°C) ISO 100 56008-3

65 to 100° (18 to 38°C) ISO 150 56008-4

z For minimum temperatures below -15°F, warm the TDS-10S upby rotating at a very light load and very slow speeds until the oiltemperature is above -15°F. Contact your local Varco ServiceCenter for specific instructions.


Selecting a lubricantUse Table 4 to select the appropriate lubricant for your specificapplication.

Table 4. Recommended lubricants

General Purpose Grease

Above -20˚ Below -20˚CAmbienttemperaturerange

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

NGL1

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

-

-

Lube Code and Description

1

Use Chevron Black Pearl EP2 grease for all temperatures whereapplicable.

March 2, 1998



Chapter 3

Inspection

Inspecting hardware and fittings

Visually inspect the TDS-10S for loose or missing hardware andfittings daily. Make sure all lockwire is undamaged.

March 2, 1998


Inspecting the AC drilling motor brakes

Remove the brake housing covers to access the drilling motorbrakes.

Inspect the brake shoes for wear, and replace the shoes if wornbelow the allowable lining wear limit given by the manufacturer(approximately 3/32 in.). See the brake manual included in theVendor Documentation Package for additional information. If thebrake shoes are wearing unevenly, adjust the brake pads byadjusting the bolts on the brake calipers.

Inspect the brake hydraulic lines for leaks.

n Never check for hydraulic leaks with your hands. Oil under pressureescaping from a hole can be nearly invisible and can penetrate skincausing serious injury. Always check for leaks with a piece of wood orcardboard.

Inspecting the AC drilling motor louvers

Make sure that no AC drill motor louvers are missing ordamaged.

Make sure that the screens inside the louvers are clean and free ofcontaminates and allow for adequate ventilation.

Inspecting the wash pipe assembly

Visually inspect the wash pipe assembly daily for leaks.


Inspecting the upper stem liner

Use the following procedure to inspect the upper stem liner whenreplacing the washpipe assembly.

1. Remove the wash pipe packing (Figure 1).

2. Check the upper stem liner for erosion cause by leaking washpipe packing and replace the liner if erosion is found.

z The 3.875 in. OD polypack seal must also be replaced wheneverthe upper stem liner is replaced. Make sure the O-ring of the sealis facing down when the seal is installed on the liner.

March 2, 1998


Wash Pipe Assembly

Main Shaft

Polypack Seal

Upper StemLiner

Polypack Seal

Upper Stem Liner

Figure 1. Inspecting the upper stem liner


Inspecting main shaft end play

Use the following procedure to check for main shaft end play:

1. Remove the wash pipe packing.

2. Check the main shaft axial movement by applying an upwardforce to the main shaft and measuring the amount of axialmovement with a dial indicator.

3. If axial shaft movement is not .001 to .002 in., remove theupper bearing retainer plate and adjust the number of shimsunder the bearing retainer plate as required to allow .001 to.002 in. of axial shaft movement (end play) with the retainerplate cap screws tightened to 250-270 ft lb.

z Align the shims so that the upper bearing lube tube bore is notblocked.

z Refer to Installing the upper bearing retainer plate in theDisassembly and assembly section of this book for further detailson this adjustment.

March 2, 1998


Inspecting the gearbox oil level

With the drive motor and hydraulic system off, check to see thatthe oil level is at the middle of the sight glass located on the lubepump adapter plate mounted on the side of the gearbox.

z Oil level is identified by three sight glasses. Oil level should be atthe top of the upper sight glass.

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

Inspecting the guide beam

Inspect the guide beam components weekly. Verify that the hingepins and retainer pins are in place. Re-torque tieback clamp nuts.

Inspecting the IBOPs

z Upper and lower safety valves, because of their internal groovesand shoulders, are particularly susceptible to corrosion fatiguecracking. These internal diameter changes act as stress risers forbending and tensile loads. It is especially important to properlyinspect the safety valves on a frequent basis. Read and use thesafety valve inspection procedures described in the IBOP ServiceManual included in this manual.


Inspecting the pipehandler

Thoroughly inspect the pipehandler for loose bolts and fittingsdaily. If any safety wire or cotter pins were removed duringrepairs, replace them immediately.

Inspect the hinge pins and retainer bolts daily to make sure theyare not separating from the pipehandler. Make sure the hinge pinsare not loose because of excessive wear in either the bore of thegate or clamp body.

March 2, 1998


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 (MPI), ultrasonicinspection, x-ray examination, and other methods ofnondestructive testing for metallurgical integrity.

Inspecting the elevator link eyesUse calipers on a regular basis to measure the amount of wear onthe elevator link eyes. Compare the measurements with the WearChart (Figure 2) to determine the current strength of the elevatorlinks. The capacity of the links equals the capacity of the weakestlink.


�

�

� C

A

A

B

UpperEye

(Hook)

LowerEye

(Elevator)

B

C

UpperEye

Dimen-sion C

LowerEye

Dimen-sion A

Capacity(Per Set)

InTons

54-7/84-5/84-3/8

2-1/42-1/82-1/161-3/4

250210188137

54-13/16

4-5/84-7/16

2-3/42-9/162-3/82-3/16

350300225175

Wear Chart - Forged Links

B = 2-7/8 in., 250 Ton

B = 3-1/2 in., 350 Ton

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.

Figure 2. Visual inspection of elevator links

March 2, 1998


Inspecting the drive stemRegularly inspect and measure the drive stem/main shaft for wear.

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.


Magnetic particle inspection (MPI)Once a year, or every 3,000 operating hours, Varco recommendsperforming a MPI of the exposed surfaces of all load bearingcomponents and load collar grooves to reveal any fatigue or crackindications. Any indications found are a potential cause forreplacing the suspect component. Round bottom pits and erosionare acceptable as long as the defect is less than 1/16 in. deep.Larger defects or any crack indications are a cause for replacingthe 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 bearing componentsover the entire surface (including internal bores) to reveal anyfatigue or crack indications. Any indications found are apotential 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 are acause for replacing the suspect component. The load bearingcomponents are:

❏ Bail


❏ Main body casting

❏ Landing collar

❏ Main shaft

❏ Upper and lower IBOPs

❏ Saver sub

❏ Elevator

❏ Elevator links

Details on MPI Inspection procedures are in the followingpublications:

❏ ASTM A-275, Standard Method for Magnetic ParticleInspection of Steel Forgings

❏ ASTM E-709, Standard Recommended Practice for MagneticParticle Inspection

❏ I.A.D.C., Drilling Manual, 9th Edition

March 2, 1998


Ultrasonic inspectionIn addition to MPI, Varco also recommends performing anUltrasonic Inspection of the above components to detect anyerosion of the inside diameter. Any erosion reduces the load-carrying capacity of the part. Any subsurface irregularity can alsocompromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the followingpublications:

❏ I.A.D.C., Drilling Manual, 9th Edition

❏ ASTM A-388, Standard Practice for Ultrasonic Examination ofHeavy Steel Forgings

z Upper and lower safety valves, because of their internal groovesand shoulders, are particularly susceptible to corrosion fatiguecracking. These internal diameter changes act as stress risers forbending and tensile loads. It is especially important to properlyinspect the safety valves on a frequent basis. Read and use thesafety valve inspection procedures described in the IBOP ServiceManual included in this manual.


Inspecting the hydraulic system

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

Inspect the hydraulic system weekly for leaks at fittings, damagedhose covers, kinked or crushed hoses, hard or stiff hoses, anddamaged or corroded fittings. In addition, during the inspection,tighten or replace any leaking port connections, and clean anydirt buildup from hydraulic components.

e Keep in mind that a loss of hydraulic oil is also a loss of gearlubrication

Inspecting the electrical system

Periodically, depending on severity of service, check all electricallines, connectors, and related electrical hardware for looseconnections and damage, and replace components and tightenconnections as necessary.

Also, inspect electrical sensors for exterior damage and replacecomponents as required.

March 2, 1998



Chapter 4

Lubrication

Introduction

The lubrication intervals described in this manual are based onlubricant supplier recommendations. Severe conditions such asextreme loads or temperature, corrosive atmosphere, etc., mayrequire more frequent lubrication.

Worn bushings, binding parts, rust accumulations, and otherabnormal conditions indicate more frequent lubrication isnecessary. Be careful not to over lubricate parts. For example, toomuch grease forced into a fitting can pop out a bearing seal. Overlubrication can also affect safety since over lubricated parts candrip, creating a potential slipping hazard for personnel.

March 2, 1998


Lubricating the AC blower motor bearings

Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings.Apply grease every three months to the grease fittings for thebearings in the AC blower motor located on top of the ACdrilling motor, and to the grease fittings for the bearings in theAC motor that powers the hydraulic system. All fittings arelocated on the ends of the motor. After greasing, remove thefittings and reinstall the plugs.

Lubricating the hydraulic pump AC motor

Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings.Apply grease every three months to the grease fittings for thebearings in the hydraulic pump AC motor located on top of theAC drilling motor, and to the grease fittings for the bearings inthe AC motor that powers the hydraulic system. All fittings arelocated on the ends of the motor. After greasing, remove thefittings and reinstall the plugs.

Lubricating the AC drilling motor bearings

Use the following procedure to lubricate the AC drilling motorbearings at the locations indicated every three months with theshaft stationary and the motor warm.

1. Locate the grease inlet at the top of the motor frame(Figure 3).

2. Clean the area and replace the 1/8 in. pipe plug with a greasefitting and remove the grease drain plug located opposite thegrease inlet.

3. Repeat steps 1 and 2 for the bottom of the motor frame


4. Add grease to the bearing with a manual grease gun. Themotor manufacturer’s manual located in the VendorDocumentation Package, contains information on the properamount and type of grease to use.

5. Clean any excess grease from the grease drain and replace thepipe plugs at the inlet and the drain.

0.375" Drain Hole

AC Drilling Motor

0.375" Drain HoleGrease Inlet For

.125-27 NPT Grease Fitting

Grease Inlet For.125-27 NPT Grease Fitting

Figure 3. Lubricating the AC drilling motor

March 2, 1998


Lubricating the wash pipe assembly

Apply grease daily to the wash pipe assembly grease fitting withthe mud pump shut off (Figure 4).

Grease Fitting

Upper Main Body Oil SealGrease Fittings

Washpipe Assembly

Figure 4. Lubricating the wash pipe assembly


Lubricating the upper main body oil seals

Apply grease daily to the two grease fittings for the main bodyupper oil seals located inside the bonnet.

z Grease the main body oil seals daily to prevent abrasive drillingmud from leaking into the main body.

Replacing the gearbox oil

Initial oil changeDrain and refill the gearbox after the first four weeks, or 500hours of operation, whichever comes first. Replace the oil filterwhen changing the oil.

z After every oil change, check for proper lubrication oil flow.

Oil capacityThe TDS-10S main body holds approximately 17-19 gallons ofoil. Always fill the transmission to the middle of the upper sightglass. Use the following procedure to fill the transmission for thefirst time:

1. Use a hand pump to fill the gearbox to the top of the sightglass (approximately 17-19 gallons).

2. Operate the TDS and hydraulic systems 10-15 minutes andthen check the sight glass.

3. If the oil level is below the middle of the sight glass, add moreoil until the level reaches the middle of the sight glass.

March 2, 1998


Replacing the gearbox oil filter

Replace the gearbox oil filter at the same time the oil is changed. Thefilter is located on a bracket attached to the carriage.

Lubricating the carriage and guide beam

Apply a thin film of grease to the running surfaces of the guidebeam once a week.

Lubricating the rotating link adapter

Apply grease weekly to the three grease fittings on the rotatinglink adapter (Figure 5).


B4L H J A4 E5

HE5

G5

G6

E6

J

B8

B4

A4

G6

E6

250 TON

Back

Front

GreaseFitting

GreaseFitting

Rotating Link Adapter

Rotating Link Adapter

Grease Fittings

Figure 5. Lubricating the rotating link adapter

March 2, 1998


Lubricating the link tilt and PH-55 stabilizerbushing

Apply grease to the four link tilt grease fittings weekly. Lubricatethe stabilizer bushing daily.

Lubricating the elevator support and masterbushing wear guide

Apply grease to the seven fittings on the elevator support weekly.The master bushing wear guide has four fittings. Lubricateweekly. Inspect the guide ring periodically for wear or damageand replace it as necessary.

Lubricating the wireline adapter

Apply grease to the wireline adapter weekly. The wireline adapterhas one fitting. Inspect the sheaves periodically for wear ordamage and replace as necessary.


Lubricating the IBOP actuator yoke

Apply grease to the five grease fittings on the IBOP actuator daily(Figure 6).

IBOP ActuatorYoke

Grease Fitting (2)

Upper IBOPActuator Shell

IBOP Actuator Cylinder

Figure 6. Lubricating the IBOP actuator yoke

March 2, 1998


Lubricating the IBOP actuator crank

Apply grease daily to the two IBOP actuator crank grease fittings(Figure 7).

Crank Arm

Actuator Arm Groove

Actuator Shell

Upper IBOPValve

ClosedPosition

OpenPosition

Grease Fitting

Figure 7. Lubricating the IBOP actuator crank


Lubricating the torque arrestor tubes andclamp cylinder gate

Apply grease with a brush to the torque arrestor tubes and applygrease to the four clamp cylinder gate fittings weekly (Figure 8).

Clamp Cylinder Gate

Torque Arrestor

Grease Locations(Each side)

Grease Fittings(Each side)

Grease Fitting (2)

Figure 8. Lubricating the torque arrestor tubes and clamp cylinder gate

March 2, 1998



Chapter 5

Maintenance

General hydraulic system maintenance

n Release all hydraulic oil pressure by bleeding accumulators beforedisconnecting hydraulic lines. Allow several minutes after thehydraulic system is turned off prior to attempting any servicewhich would involve opening hydraulic lines. Hydraulic oil underpressure can penetrate skin and cause serious injury.

n Before opening hydraulic system, thoroughly clean work area, andmaintain system cleanliness by promptly capping all disconnectedlines. Dirt is extremely harmful to hydraulic system componentsand can cause equipment failure and subsequent injury topersonnel.

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

March 2, 1998


Start-up procedure

e Only operate the hydraulic system when the TDS-10S is in thevertical position.

Perform the following start-up procedure whenever restarting ahydraulic system in which a motor or pump has been removedand reinstalled:

1. Inspect all hydraulic system components (reservoir, hoses,valves, fittings, etc.) to make sure they are clean prior to fillingwith fluid.

2. Fill the gear case oil reservoir with the recommendedlubricating oil passed through a 10 micron (nominal, nobypass) filter.

3. Check the oil level and add filtered fluid if necessary.

4. Jog start the AC drilling motor to verify correct rotationdirection.

Accumulator maintenance

The Vendor Documentation Package contains the accumulatormanufacturer’s instructions for the TDS-10S hydraulicaccumulators (Bulletin SB1630-M1). This bulletin contains allnecessary maintenance, removal and replacement, and pre-charging instructions for the TDS-10S accumulators.


Chapter 6

Troubleshooting

Troubleshooting the AC drilling motor

Refer to the AC motor manufacturer service manual in the VendorDocumentation Package.

March 2, 1998


Troubleshooting the AC blower motor

The AC blower motor is located on top of the AC drilling motor.The Table 5 describes problems, probable causes and remedies.

Table 5. Troubleshooting the AC blower motor

Problem Probable cause Remedy

Mechanical noise in blower. Loose impeller. Reinstall impeller and hubwith threadlockingcompound on screws.

Faulty motor bearings. Repair or replace as needed.

Blower runs intermittently. Faulty or loose wiring. Locate and repair as needed.

Faulty motor starter. Check for dirt or trashbetween starter coil. Repairor replace as needed.

Broken service loopconductor.

Use spare service loopconductor.

Motor overheating, overtempalarm stays on with blowerrunning.

Incorrect blower rotation. Verify blower rotationcorrect.

Broken service loopconductor.

Use spare service loopconductor.


Troubleshooting the hydraulic system

The following hydraulic troubleshooting section provides aschematic diagram and description for each TDS-10S hydrauliccircuit. Following each schematic is a group of troubleshootingcharts to help you quickly locate and correct hydraulic systemproblems.

When performing hydraulic troubleshooting, be aware that:

❏ The electrical control system can be bypassed fortroubleshooting by manually overriding the solenoid valve foreach operational system.

n Alert all personnel near the top drive before overriding a solenoidvalve. When you override a solenoid valve, you bypass the safetyinterlock and top drive components will move possibly causingserious injury or death.

❏ Test points shown in the hydraulic schematic with a box(e.g., A4) can be found on the manifold under the main body.There are also test points on the rotating link adapter motor.

❏ The system is preadjusted. Hydraulic problems are usuallyrelated to faulty valves, contamination, or other damage tothe system rather than misadjustments. Changes toadjustments should be made only after all other possiblecauses have been eliminated.

❏ Table 6 identifies the schematic symbols used in this section.

March 2, 1998


Table 6. Hydraulic schematic symbols

Description Symbol Schematic Reference

SolenoidOperatedValves

ManualValve(Rotary)

Pump

PressureReliefValves

PressureReducingValve

PressureReducing/RelievingVavle

CheckValve

2 Position 4 way Valves (Single Solenoid)

3 Position 4 way Valves (Double Solenoid)

3 Position 4 way Valve

Fixed Displacement

Standard Valve

Differential Unloading Valve

Ventable Relief Valve

SV1, SV4, SV5, SV8, SV9

SV2, SV6

MV

RV2, A2R, B2R, SJR

RV1

UV1

PC1, PC4

PCC

CDF, CTF, CV2, CTR, CDR, CXCDPrefill valve assemblyCV1, CV2

1

1 2

3

2

A B

P T

A B

P T

A B

P T


Table 6. Hydraulic schematic symbols (continued)

31

2


Pilot-To-Open Check Valve

Pilot-To-Close Check Valve

Cavity Plug

Internal Plug

Non Adjustable Flow Control Valves

Non Adjustable Orifice

CounterbalanceValves

Logic Cartridges

Logic Cartridge With Metering

Quick Disconnect Coupling

3 Port (Internal Drain)

4 Port (Internal Drain)

CKCB (Link Tilt)

CA6, CB6, CV3, CV4(Clamp Body)

PC5

CV1

Diameter in Inches

CBCA (Link Tilt Circuit)

CWCK (Link Tilt Circuit)

LA6, LB6, LC5, LODC

See Prefill Assembly

March 2, 1998


Table 6. Hydraulic schematic symbols (continued)


Non Bypass Filter

Filter With Bypass

Manual Shutoff Valve

Thermostat

Pressure Switch

Heat Exchanger

Pressure Compensator Control

Hydro-Pneumatic Accumulator

Hydraulic Motor (Bi-Directional)

Hydraulic Cylinder

Tank (Reservoir)

Test Point

See Lube Oil Circuit

See Return Circuit

Lube Oil Circuit

Lube Oil Circuit

Hydraulic Circuit(Inside Brake Housing)

Part of the Pump


Troubleshooting the ACdrilling motor brakes

The AC drilling motor brakes are spring released and hydraulicpressure applied at 2,000 psi. The solenoid valve operates to applypressure, setting the brakes, or stop pressure to release the brakes.

Table 7. Troubleshooting the AC drilling motor brakes


Brake does not release. Directional valve is stuck. Test the valve and replace ifnecessary.

Brakes release but still drags. Check valve is blocked or thetube is pinched.

Replace the check valve ortube as required.

Mechanical problems withbrakes.

Repair the brake mechanism.

Brakes do not engage or slip. There is hydraulic oil on thebrake pads.

Check for hydraulic leaksand repair.

Delay in the brakes actuatingafter the console switch isturned on.

The hydraulic oil iscontaminated.

Replace the hydraulic oil.

The pressure reducing valve is faulty.

Replace the valve.

To test the system, turn the AUTO BRAKES switch on thedriller’s console to the ON position. Attach a pressure gauge toB1 in the manifold. The pressure reading should be 2,000 psi.Turn the AUTO BRAKES switch to the OFF position. Thepressure reading should be very low. If the pressure is high, thesolenoid valve could be sticking.

March 2, 1998


Troubleshooting the rotating link adapter(rotating head) motor

OperationThe three position directional valve controls the direction of therotating head to the left or right. The pressure is applied to the Aor B port of the hydraulic motor, depending on the selecteddirection. The auto return function is controlled by the processorand returns the tool to the home position.

System testTo test the system, operate the rotating head switch on thecontrol panel. Verify both directions of rotation. The rotationspeed is limited by the nonadjustable orifice. The torque islimited by the two relief valves.

z The 1,600 psi test pressure at ports A and B is maximum loadpressure. If the rotating link adapter is free to rotate, the loadpressure will be less than maximum. The shot pin must beengaged to achieve full load pressure.


Table 8. Troubleshooting the rotating link adapter (rotating head) motor


Tool does not rotate. Direct control valve or relief valve is sticking.

Inspect, repair or replace the valve.Look for pressure changes whensolenoid is energized. If there is nopressure change, try the manualoveride on the valve.

nWhen you overide a directionalvalve, you bypass the safetyinterlock and top drivecomponents move, possiblycausing serious injury or death.

Solenoid valve is notelectrically operating.

Check the electrical connections andvalve functions.

Motor is worn out or gearteeth are broken.

Replace the motor.

Shot pin is engaged. Adjust the relief valve.

Mechanical interference. Inspect and repair.

Directional valve does notshift.

Test pressure the left and right.Replace the valve.

Fixed valve orifice isplugged.

Clear the orifice or replace the valve.

Hydraulic lines are damaged.

Replace the hydraulic lines.

March 2, 1998


Troubleshooting the IBOP actuator cylinder

OperationThe IBOP is in the open position under low hydraulic pressure,A4 = 500 psi, B4 and C4 = less than 100 psi. When you closethe IBOP, high pressure is applied to the cylinder. A4 is less than100 psi; B4 and C4 are 2000 psi. When the solenoid is de-energized, for opening the IBOP, A4 goes to 500 psi after a smalltime delay. B4 is less than 100 psi and C4 reaches 2,000 psi aftera small time delay. The time delay is operated by the time delayaccumulator.

Table 9. Troubleshooting the IBOP actuator cylinder


Safety valve leaks. Internal parts are worn out. Check for washouts ordefective parts and repair orreplace as needed.

Actuator is not functioningproperly.

Check the mechanicaloperation of actuator. Check the reducing valves.

Excessive vibration or wobblewhile rotating.

Yoke bushings or actuatorbushings are worn out.

Replace the bushings.

Worn cam rollers. Repair or replace the rollersand roller brackets.

Cylinder does not actuate. Pressure reducing valveplugged orifice.

Test pressures and adjust orreplace the pressure reducingvalve.

Accumulator is not charged. Test the accumulatorpressure and charge asrequired.

No system pressure. Check the hydraulic systemoperation.


System testRefer to the hydraulic circuit schematic in the Technical Drawingbook for the IBOP actuator cylinder. The IBOP is normallyopen.

n Alert all personnel near the shot pin, clamp, and rotating headbefore overriding a directional valve. When you override adirectional valve, you bypass the safety interlock and top drivecomponents move, possibly causing serious injury or death.

To test the system, engage the IBOP and measure the pressure atB4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open theIBOP and test the pressure at A4, which increases to 2,000 psi.The pressure at B4 and C4 drops to 500 psi.

March 2, 1998


IBOP ACTUATOR CYLINDER2.500 DIA. BORE X 2.00 STROKE

1.375 DIA. DOUBLE ROD

OPENCLOSE

400

4

2

T-21A

1

3

12

3

N12

T-11A

2

D03

500

b

1

.055Ø

.016Ø

30 PSI

T-13A

PRECHARGE

11.5 IN^ 3500 PSI

N07

A4

A4

B4

B4

PSI

A4 SQ4

P T

BA

A4 SV4

PC4

PSI

FC4

IBOP CLOSE

B4

B4 C4

Hydraulic Cylinder

Figure 9. Hydraulic circuit for the IBOP actuator cylinder


Troubleshooting the shot pin cylinderand clamp cylinder

OperationThe shot pin cylinder and clamp cylinder operation areinterrelated and complex. The shot pin cylinder is different inthat it has an extra port called the barrel port. The barrel port isback from the end of stroke which creates a valving effect. Whenthe shot pin and clamp cylinders are not activated, the shot pin isfully retracted with full pressure and the clamp cylinder isretracted with 500 psi.

When you energize the clamp cylinder, the shot pin cylinder isactuated against the rotating gear and it may miss one of the 24holes. The control system starts pulsing the rotating head to moveslowly until the shot pin engages a hole on the rotating gear. Theshot pin cylinder pressure is limited by the relief valve until thecylinder passes through one of the holes. Once the pin engagesthe hole, full system pressure is applied to C5 which opens valveCV5, applying full pressure to the clamp cylinder to close.

When the clamp cylinder is de-energized, the clamp releases andthe shot pin pulls out.

March 2, 1998


System testAt rest, the pressure at C5 is 2,000 psi, B5 is less than 100 psi,CP is less than 100 psi, and CR is 500 psi.

n Alert all personnel near the shot pin, clamp, and rotating headbefore overriding a directional valve. When you override adirectional valve, you bypass the safety interlock and top drivecomponents move, possibly causing serious injury or death.

When you energize solenoid valve SV5, using the manualoverride, pressure increases to the barrel of the shot pin cylinder.The pressure is controlled by a .031 pressure reducing valve thatprevents the shot pin from putting full force on the rotating headsurface until the pin engages in one of the holes.

Pressure at B5 is 200 psi (limited by the relief valve), C5 is lessthan 100 psi, G5 is less than 100 psi, CP is less than 100 psi, andCR is less than 100 psi.

Once the shot pin engages the hole, full pressure is applied in C5to control valve CV5 open for clamp. Pressure at B5 is 2000 psi,C5 is 2000 psi (forces valve CV5 open for clamp), G5 is less than100 psi, CP is 2,000 psi, and CR is less than 100 psi.

When solenoid valve SV5 is de-energized, the shot pin cylinderwithdraws the shot pin, and the clamp disengages at the sametime. The circuit returns to rest conditions.


Table 10. Troubleshooting the shot pin cylinder and clamp cylinder


Shot pin does not engage. Solenoid valve is not operating orrelief valve is not adjusted.

Check the electrical actuationand test pressure. Adjust asrequired.

Abnormal pressure change at B5and C5 indicates valve problem.

Replace the directional controlvalve.

Normal pressure changeindicates plumbing or shot pincylinder are faulty.

Repair the plumbing or shot pincylinder.

Shot pin applies excessiveforce to rotating headgear.

Relief valve is not operating orout of adjustment.

Test pressures and adjust asrequired.

Clamp cylinder does notactuate.

No pressure or reduced pressureat the cylinder.

Test pressures and adjust andrepair as required.

Cylinder is damaged. Inspect the cylinder and repair orreplace.

z To provide high pressure to theclamp circuit, pressure at C5must be 2,000 psi and G5 mustbe less than 100 psi. If thiscondition is met, pressure at CPshould increase from less than100 psi to higher than 2,000 psi.If not, check the plumbing,rotating head, and clampcylinder.

Repair plumbing, rotating head,or clamp cylinder.

While clamping, pressure at CRshould be 2.7 times the pressureat CP. When the dies contact thepipe, pressure at CR should beless than 100 psi. If the pressuredoes not fade, check valveCNEC for contamination.

Clean or repair the CNEC valve.

Shot pin engages butclamp cylinder does notactivate.

Control valve not operating. Check the pressure at C5.Replace valve CV5 if required orthe regenerate manifold.

March 2, 1998


Troubleshooting the counterbalance system

The accumulator, with precharge pressure of 900 psi, along withcheck valve CV3, maintains a hydraulic pressure. Refer to themanufacturer's documentation in the Vendor DocumentationPackage for the gas charging procedure for the accumulator.

A three-position manually operated valve controls counterbalanceoperation for rig-up, run, and shut down modes. In the rig-upmode, system pressure is applied to XC and the prefill valve,causing both cylinders to extend. When the cylinders extend, youmake up the mechanical connection to the bail. In the run mode,for counterbalance operation, approximately 1,600 psi is neededat the counterbalance cylinders to lift the TDS-10S off the hook.

Stand jump operation is controlled by solenoid valve SV9. Withthe counterbalance in the run mode and the stand jump switchon, additional pressure of approximately 300 psi is applied to overthe normal counterbalance pressure to lift the TDS-10S and drillstring off the hook.

In the shutdown mode, the hydraulic system bleeds down thesystem accumulator and the counterbalance accumulator pressure.


Counterbalance testingFor the counterbalance operation, a lift of approximately30,000 lb is achieved with a pressure of 1,600 psi at CB.Perform the following steps to adjust the force:

1. Set the COUNTERBALANCE MODE switch to the RUNmode. Set the pressure control valve PCC to the minimumsetting (fully counterclockwise).

2. Test the pressure at port B9. There should be a 0 psi reading.

3. Test the pressure at port CB. Observe the position of the topdrive on the hook.

4. Adjust the pressure at pressure control valve PCC clockwise,observing pressure at CB, until the top drive just lifts off thehook. Back off the pressure 25 psi, as the top drive rests onthe hook.

March 2, 1998


Stand jump testingFor the stand jump operation, a lift of about 33,000 lb is achievedwith a pressure of approximately 1,800 psi at CB. The additional300 psi pressure over the normal counterbalance pressure isprovided by energizing the stand jump solenoid valve SV9.Perform the following steps to adjust the pressure:

1. Set the counterbalance mode switch to Run and engage thestand jump switch. Test the pressure at port CB and B9.Adjust relief valve SJR fully counterclockwise to theminimum setting.

2. Slowly increase the pressure at CB by adjusting relief valveSJR clockwise until the bail lifts off the hook with a stand ofpipe in the elevator.

z Adjust relief valve SJR slowly to allow pressure at CB to stabilize.


Table 11. Troubleshooting the counterbalance system


Counterbalance doesnot function.

Cylinder damaged. Seal leaks. Inspect the cylinder and repair orreplace the seal.

No hydraulic pressure. Test the pressure and adjust thepressure reducing valve.

Solenoid valve SV9 is not operating.

Test the electrical and hydraulicoperation. Replace or repair asapplicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on accumulator is low.

Charge the accumulator.

Stand jump does notfunction.

Cylinder damaged. Seal leaks. Inspect the cylinder and repair orreplace the seal.

No hydraulic pressure. Test the pressure and adjust thepressure reducing valve.

Solenoid valve SV9 is not operating.

Test the electrical and hydraulicoperation. Replace or repair asapplicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on accumulator is low.

Charge the accumulator.

March 2, 1998


Troubleshooting the hydraulic power unit(HPU) and reservoir

OperationFigure 10 shows the onboard HPU schematic. A 10 hp electricmotor drives the fixed displacement pump.

The fixed displacement pump provides hydraulic power tooperate the lubrication pump motor. Pressure can be tested atport PF. Relief valve RV2 limits the driving pressure of the lubeoil circuit.

System testTest the circuit pressure at port PV. Relief valves RV1 and UV1are a part of the circuit. UV1 is a differential unloading valve,which can be pressure checked at port Z1.

RV2 is set at 400 psi and can be tested at PF. Test the pressure atPV to confirm the relief valve RV1 is set at 800 psi. Thedifferential unloading valve UV1 is tested at Z1 to confirm thepressure is 2,000 psi.


10 HP1200 RPM

1.40 in3/rev

1.5GPMGPM

1.0

30

N08

.062Ø .205Ø

No Bypass Out10 Micron

IN

.059Ø .047ØPF Y1 D

PSI

M

Lower Compound Bearing

Lower Radial/Main Thrust Bearings

Upper Compound Bearing

Upper Mainshaft Bearing

Upper CompoundGear

Lower Compound Gear

Figure 10. Hydraulic circuit for the HPU and reservoir

March 2, 1998


Table 12. Troubleshooting the hydraulic power unit (HPU) and reservoir


Hydraulic systemoverheating.

Relief valves out ofadjustment.

Test the pressures and adjustthe relief valves.

Unloading valve is notworking.

Test and adjust the UV1 orreplace the unloading valve.

Counterbalance mode valve left in shut downposition too long andpressure bleeds down.

Check the system pressure.

No precharge in systemaccumulator.

Charge the systemaccumulator.

Hydraulic components do not operate.

System pressure is down. Test the pump and motor.Test the relief valve pressures.Adjust as required. Check forleaks, loose fittings, loosecylinders, worn hoses, fluidlevels and seals.

Flexible coupling isdamaged.

Replace the flexible coupling.

Pressure at UV1 is too low. Adjust the pressure at UV1.

Pump is rotating in thewrong direction.

Inspect the hydraulicconnections and correctrotation.

Low oil level in reservoir. Fill the hydraulic reservoir.


Chapter 7

Disassembly andassembly

Precautions

e Only authorized Varco repair technicians should perform thefollowing major disassembly and assembly procedures.

e Transport hydraulic components to a clean, dust-free service areabefore disassembling for service.

March 2, 1998


z Disassembly procedures are usually performed when replacingdamaged components that are causing a tool function to fail.Whenever performing a disassembly, practice preventivemaintenance by:

❏ Cleaning and inspecting all disassembled parts.

❏ Replacing all worn and damaged parts before they can causeanother failure.

❏ Installing thread protectors on exposed threads.

e Torque all fasteners to the limits given in DS00008 (DesignSpecification Design Torque Standard), located in the SupplementalMaterials book, unless an alternative torque value is given in theprocedure.


PH-55 Pipehandler

Disassembling the PH-55PipehandlerRemove the PH-55 Pipehandler to service the followingcomponents:

❏ Stem

❏ Stem seals

❏ Rotating link adapter upper and lower wear bushings

❏ Rotating link adapter rotary seals

n Release all hydraulic oil pressure before disconnecting hydrauliclines. Hydraulic oil under pressure can penetrate skin and causeserious injury.

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

z To protect the rotating link adapter seals and inner surfaces,remove the stem along with the rotating link adapter.

z Contact the nearest Varco Service Center for details aboutbuilding an appropriate stand for removing the rotating linkadapter.

March 2, 1998


Use the following procedures to disassemble the pipehandler:

1. Remove the elevator links and the elevator.

2. Disengage and remove the shot pin.

3. Disconnect the hydraulic lines and cap all connections.

4. Remove one of the backup clamp cylinder gate hinge pins andopen the gate.

z The link tilt brackets remain attached to the links.

5. Remove the two pins that attach the link tilt crank to the linktilt lever.

6. Remove the pin attaching the torque arrestor to the rotatinglink adapter and remove the torque arrestor with the clampcylinder assembly.

7. Remove the upper IBOP crank assembly.

8. Remove the lower tool joint lock.

9. Remove the intermediate joint lock.

10. Remove the IBOP actuator shell.

11. Remove the upper tool joint lock.

12. Remove the saver sub, lower IBOP, and upper IBOP.

13. Remove the pipe plug from the stem flange and drain thetransmission oil from the housing.

14. Lower the top drive until the bottom of the rotating linkadapter just rests on a stand or blocks.

15. Remove the landing collar assembly from the main shaft.

16. Remove the screws holding the rotating link adapter to themain housing.

17. Raise the top drive slowly, leaving the rotating link adapter onthe stand or blocks.


Assembling the PH-55 PipehandlerUse the following procedures to assemble the pipehandler:

1. Install the new main shaft seals inside the stem bore.

e Always install new main shaft seals and use care not to damage seallips or case.

2. Install the new O-rings on the stem flange.

3. Grease the walls of the bore in the main body, the stem mainshaft seals, and the O-rings on the rotating link adapterassembly.

4. Position the rotating link adapter assembly, supporting it withthe same stand or block used in the disassembly procedure.

5. Using three 5/8-11 UNC bolts, pull the rotating link adapterto the main body and completely seat the rotating linkadapter into the bore.

6. Install screws to secure the rotating link adapter to the mainbody.

7. Replace the drain plug.

8. Install the upper IBOP, lower IBOP, and saver sub.

9. Install the upper tool joint lock and tighten the bolts to180 to 190 ft lb.

10. Install the IBOP actuator shell.

11. Install the intermediate tool joint lock and tighten the bolts to180 to 190 ft lb.

12. Install the lower tool joint lock.

13. Install the upper IBOP crank assembly.

14. Pin the torque arrestor to the rotating link adapter.

z The link clamp assembly remains attached to the torque arrestor.

15. Position the drill pipe elevator and links, and pin the link tiltlevers to the link clamp assemblies.

16. Close and pin the torque backup clamp cylinder gate.

17. Connect all hydraulic lines.

March 2, 1998


Rotating link adapter

Disassembling the rotating linkadapter assemblyUse the following procedures to disassemble the rotating linkadapter assembly:

1. Remove the pipehandler as described above and transport therotating link adapter assembly to a suitable work area.

2. Support the rotating link adapter assembly on a work table sothat the link tilt crank hangs down.

3. Remove the hose assemblies, link tilt crank and the twocylinders.

4. Remove the lock wire and screws that hold the gear and stemassembly to the rotating link adapter body.

5. Attach three lifting slings symmetrically to the top of the stemflange and slowly raise the stem and gear assembly to separateit from the rotating link adapter body.

6. Set the stem and gear assembly on a suitably protectedsurface.

e Protect the internal surfaces of the rotating link adapter body and thesurfaces of the stem when separating the two components. Whenremoving the rotating link adapter from the stem, carefully tap with amallet to remove the rotating link adapter from the stem. There canbe resistance from misalignment between the two bores when rasingthe stem and gear assembly.

7. Prepare a work area to stand up the stem and gear assemblyon the bottom surface of the stem.

8. Remove the retainer ring under the piston ring from the stemand gear assembly.

9. Remove the piston ring and the gear. This may require lighttapping on top of the gear with the gear sitting on the pistonring.


e The piston ring is assembled with a light press fit. Provide a supportunder the gear so that it does not drop when it breaks loose.

10. Remove and discard all rotary seals, o-rings, the thrust ring,and two wear bushings from inside the rotating link adapterand gear inside dimension.

11. Remove and discard the stem flange O-rings and stem boreshaft seals.

Assembling the rotating link adapterassemblyUse the following procedures to assemble the rotating linkadapter assembly:

1. Orient the stem so the stem flange (top of the stem) is downon a suitably protected surface.

2. Install the gear with it's rotating seal and wiper in place. Notethe orientation.

3. Install the o-ring for the piston ring.

4. Install the piston ring. It requires light tapping to press it intoplace.

5. Install the retainer ring.

6. Install all of the rotary seals on the rotating link adapter (nineof one size and one larger), and an o-ring on the top surface.

7. Install the two wear bushings and the thrust ring in therotating link adapter.

8. Rest the rotating link adapter on its bottom surface.

9. Clean and then lubricate (with hydraulic oil) the sealingsurface of the stem and the inside diameter of the rotatinglink adapter.

March 2, 1998


10. Attach three lifting slings symmetrically through the holes onthe top of the stem flange and slowly lower the assembly intothe rotating link adapter body.

e Make sure the seals do not twist in the grooves.

11. Line up the dowel pin holes and replace all of the screws andsafety wire.

12. Install the link tilt cylinders; pin and secure in place.

13. Install the link tilt crank; pin and secure in place.

14. Install all hose assemblies.

15. Invert the rotating link adapter assembly so that the stemflange is up.

19. Install a new main shaft seal inside the stem bore with the seallip facing up.

e Always install a new mainshaft seal and use care not to damage theseal or the case.

20. Install new stem flange O-ring.

z A light coating of grease applied to the O-ring helps in installingthe rotating link adapter assembly into the TDS main body.

e Always install new stem O-ring and use care not to damage theO-ring or the case.


Transmission/motor housing

Removing the transmission/motorhousingRemove the transmission/motor housing to service the followingcomponents:

❏ Compound gear and bearings

❏ Main shaft

❏ Main thrust bearing

❏ Bull gear

The AC drive motor can be removed with the TDS-10S left inplace. To remove this component, skip to the applicable removalsection below.

To remove the transmission/motor housing:

1. Remove the PH-55 pipehandler components as describedabove.

2. Remove the saver sub and the lower and upper IBOPs. Seethe IBOP Service Manual, included in the SupplementalMaterials book for the procedure.

3. Disconnect the service loop, rig down the tool, and transportthe transmission/motor housing to a suitable work area.

Installing the transmission/motorhousingPerform the rig up procedures in the Installation chapter.

March 2, 1998


Disassembling the transmission/motor housing

z Drain the oil from the transmission/motor housing beforedisassembling components.

Removing the bonnet and wash pipeUse the following procedures to disassemble the transmission/motor housing assembly upper component:

1. Remove the bail (see steps a through g).

e An installation tool is required to safely remove the bail from theTDS-10S.

a. Remove the bail retainers from the main body.

b. Disconnect the counterbalance cylinders from the bailand main body cover.

c. Attach two swivel lifting eyes (rated for 10,000 lbminimum), one on each side, 2 in. up from the bottom ofthe bail.

d. Using shackles rated for 10,000 lb minimum, attach theswivel eyes to the installation tool.

e. Tighten the nut on the turnbuckle shaft until the distancebetween the tips of the bail have increased byapproximately 3.5 in. over the beginning position.

f. The bail can be removed by leaving one end engaged inthe pocket and rocking the other end around the pocketin the main body until it is fully clear.

g. Move the bail until it is clear of the main body and thenremove the installation tool.

2. Remove the wash pipe packing box assembly.

3. Remove the upper stem liner on top of the main shaft usingthe two pry points, and remove and discard the liner seal.

4. Remove the bearing shield from the top of the main shaft.


Removing the upper bearingretainer plateUse the following procedures to remove the upper bearingretainer plate:

1. Remove the six cap screws and lockwashers that attach thebearing retainer plate to the main body cover and remove theplate.

z Use the two jacking holes in the upper bearing retainer plate asrequired to help remove the plate.

2. Remove the lube tube from the lube tube bore of the cover,and remove the lube tube O-rings.

3. Remove and discard the two lip seals in the bearing retainerplate.

4. Remove the bearing retainer plate shims.

5. Remove the taper roller bearing outer race from the coverbore.

Removing the AC drilling motorUse the following procedures to remove the AC drilling motor:

1. Remove the four nuts and tie rods between the brake adapterplate at the top of the motor, and the top of the main bodycover.

2. Remove the four cap screws and lockwashers that attach theAC drilling motor to the main body cover. Attach handlinggear to the brake end of the motor and lift the motor off themain body cover. The pinion hub separates from the pinionshaft as the motor rises.

3. Remove the O-ring that seals the AC drilling motor to themain body cover.

March 2, 1998


Removing transmission components

e Heat the bearings with an induction heater to facilitate bearingremoval. Because this method heats quickly and could possiblydamage bearings, always use a Tempilstik or pyrometer to monitorbearing temperature.

Use the following procedures to disassemble the transmission/motor housing:

1. Remove the oil reservoir by removing all but four attachmentscrews. Leave four screws (one on each edge) loosenedapproximately 1/8 in. Using screws to jack the reservoir apart,thread the screws into the threaded holes located around thereservoir flange. Tighten the screws until the sealant separates.Remove the last four screws after providing suitable supportfor the weight of the reservoir.

2. Mark, disconnect and plug all hoses attached to the hydraulicpump/motor assembly. Remove the hydraulic pump/motorassembly. Disconnect the electrical cable attached to theelectric motor.

3. Remove the screws that attach the pump assembly to themain body cover. Use jack screws around the perimeter of theflange to remove the pump assembly.

4. Remove the cap screws that attach the cover to the mainbody. Use jack screws around the perimeter of the main bodycover to separate the cover from the main body and removethe cover.

5. Remove the oil gallery O-rings.

6. Carefully lift the main shaft/bull gear assembly straight up.

e When raising the main shaft, the main thrust bearing separates.Lift the main shaft slowly.

7. Use the lifting eye on the end of the compound shaft to liftout the compound gear.


8. Install a lifting eye in the bottom of the internal splined areaand apply tension to remove the pinion gear. Remove allhoses that attach to the pinion shaft retainer. Remove theattachment screws and use jack screws, if necessary, to removethe pinion shaft retainer from the bottom side of the mainbody. Lower the pinion and bearing assembly out of thebottom of the main body.

9. Remove and inspect the main body orifices and the pipeplugs.

e Do not use a steel hammer when removing the gears. It can damagecomponents.

10. Remove the mainshaft upper wear sleeve by heating the sleeveto 250°F (121°C). Check the sleeve for wear after removingit.

11. Remove and discard the upper taper bearing inner race byheating the race to 250°F (121°C).

z If replacing the bull gear, perform steps 12, 13, and 14. If not,proceed to step 15 and remove the bull gear along with the mainshaft.

12. Remove the 10 lockwired cap screws that hold the bull gear inplace.

13. Install two 5/8-11 UNC forged eyebolts in the bull gearpickup holes and heat the bull gear to between 150°F (66°C)and 200°F (93°C), then remove the bull gear by lifting thegear straight up off the alignment pin.

14. Inspect the bull gear alignment dowel pin, and remove anddiscard the pin if damaged.

15. Remove the main shaft wear sleeve by heating the sleeve to250°F (121°C), then pulling the sleeve off shaft. Check thesleeve for wear grooves after it is removed.

16. Remove the lower radial bearing inner race by heating therace to 250°F (121°C), then pulling the race off the mainshaft.

March 2, 1998


17. Remove the main shaft sleeve by heating the sleeve to between200°F (93°C) and 250°F (121°C) and pulling the sleeve offthe shaft.

18. Remove half of the thrust bearing race, the bearings, and thecage of the thrust bearing.

19. Remove the other half of the thrust bearing race by heatingthe race to 200°F (93°C) and pulling the race off the mainshaft.

20. Remove the four lockwired cap screws that hold the lowerradial bearing ring retainers in place and remove the retainers.

21. Remove the outer race of the lower radial bearing from thebore in the housing with a bearing puller.

22. Remove the retainer nut and washer from the pinion shaft toseparate the bearing from the pinion gear. Heat the bearing to200°F (93°C) and pull the bearing from the shaft.

23. Heat the inner bearing races to 200°F (93°C) and pull it offthe journals to remove the inner bearing races (cones) fromthe compound gear journals.

24. When replacing the thrust bearing or radial bearing innerrace, turn the main shaft assembly upside down with the6 5/8 in. pin connection pointed up. In order to turn theassembly upside down, raise the lower race of the thrustbearing until the rollers contact the upper race. Use two largeC-clamps and clamp the lower race and rollers to the mainshaft shoulder. Once the shaft is inverted, remove the clamps.

e Do not drop the races or rollers during this tipping over process.


Assembling the transmission/motor housing

e Keep the transmission bearings, shafts, and housing free of chips,burrs, and dirt during the following assembly process to preventdamage to transmission parts.

z Varco strongly recommends replacing any bearing or gear whereeven the slightest wear is indicated. It is usually less expensive toreplace any questionable parts found during disassembly than riskhaving to rebuilt the gearbox later.

Assembling the main bodyUse the following procedures to assemble the main body:

1. Steam clean the main body, blowing out all passages (makesure all the plugs and spray nozzles are removed). Apply aprotective coating, such as WD-40, to all unpainted internalsurfaces.

z Do not apply any thread sealant to the orifice.

2. Chill the outer race of the lower radial bearing to at least 0°F(-18°C), but no lower than -60°F (-51°C), then install thebearing into the bore of the main body. Immediately afterinstalling the bearing, spray the bearing with WD-40 toprevent corrosion.

e Do not use liquid nitrogen to cool parts. Temperatures below -60°F(-51°C) can affect the composition of certain metals and lead to theweakening of parts.

3. Install the two lower radial bearing ring retainers.

4. Apply an anti-seize compound to the threads of the four1/2 in. hex-head cap screws that hold the bearing ringretainers in place, and install the cap screws and lockwashersin place. Tighten the cap screws in a star pattern to 71-79ft lb.

5. Safety wire the cap screws with .047 in. diameter lockwire.

6. Turn the main body over.

March 2, 1998


Assembling the main shaft1. Remove any burrs, steam clean, and coat the main shaft with

a protective coating such as WD-40.

e C-clamps must be used when the main shaft assembly is inverted.

2. Restrain the main shaft in a vertical position with the bottomfacing up (Figure 11).

3. Heat the upper race of the main thrust bearing to 200°F(93°C) and install the race on top of the 18 in. diameter loadplate machined into the shaft. Rotate the race until it seats flaton the plate.

4. Install the thrust bearing’s roller bearings and cage andliberally apply oil to the bearing rollers.

5. Install the other half of the thrust bearing race.

6. Heat the lower radial bearing inner race to between 225°F(107°C) and 250°F (121°C) and install the race onto themain shaft sleeve by rotating the race until it seats.

7. Inspect the lower wear sleeve. If the sleeve shows signs of wearor damage, replace it.

8. Heat the wear sleeve to 250°F (121°C) and install the sleeve.


Lower Race

Upper RaceHeat to 200°F (93°C)

Rollers and Cage

Main ShaftStem

Shaft Shoulder

18" DiameterLoad Plate

Rest

Bottom End of Shaft

Tapered RollerThrust Bearing

Top End of Shaft

Figure 11. Assembling transmission/motor housing

March 2, 1998


Assembling the gears to the main body1. Reinstall the pipe plugs, orifices, and nozzles. Apply thread

sealant (not Teflon tape) to the plugs and Loctite 232Threadlocker (blue) to orifices and nozzles.

2. Ensure that the lower radial bearings and bearing ringretainers are installed before proceeding (see Assembling themain body).

3. Heat the inner races of compound (cones) bearings to 200°F(93°C) and install on each end of the compound gear.

4. Heat the pinion shaft bearing to 200°F (93°C) and install onthe pinion shaft until the inner race shoulders against thepinion shaft.

5. Install the lockwasher and nut. Tighten the nut to 200 ft lband continue tightening until the tab from the washer alignswith the slot. Bend the tab up into the slot.

6. Using a lifting eye installed in the bottom of the internalsplined area, raise the pinion/bearing assembly from thebottom into the main housing.

7. Install the pinion shaft retainer using the six bolts.

e Support the pinion shaft in a vertical attitude–do not allow it to tilt.Otherwise the bearing will bind when attempting to return thepinion shaft to vertical.

8. Loosely install the compound bearing retainer into the mainbody, leaving 3/16 in. gap between the mating surfaces of theretainer and the main body.

9. Install cups of compound bearings in the bores of the mainbody and main body cover. Chill 30°F if needed.

10. Position the compound gear in the main body using thelifting hole in the end of the compound gear to aid inhandling.


11. Liberally apply oil to the lower radial bearing and inner raceof same bearing. Before lowering the main shaft, slowly loosenthe C-clamps until the lower race of the thrust bearing restson the inner race of the main radial bearing. Remove the C-clamps.

e Loosen the C-clamps slowly to prevent the rollers from fallong out.

Lower the main shaft assembly through the main bore of themain body until both the main thrust bearing races contactthe rollers and the main shaft rotates easily.

12. Heat the bull gear to between 150°F (66°C) and 200°F(93°C). Install two 5/8-11 UNC forged eyebolts in the gearpickup holes, making sure the stamping “TOP SIDE” is up.

13. Carefully lower the bull gear into position until it seats. If theold dowel pin has been removed, rotate the gear until the1 in. dowel pin hole is aligned.

z If the bull gear dowel pin has been removed, chill the new dowelpin to at least 0°F (-18°C), but no lower than -60°F(-51°C) as the bull gear is being placed into position. Then drivethe dowel pin into the alignment hole using a bronze hammer.The pin will sit flush to 1/4 in. high.

14. Apply an anti-seize compound to the threads of the ten 1 in.hex-head cap screws that hold the bull gear in place, andinstall the cap screws and lockwashers in place. Tighten thecap screws in a star pattern to 610-670 ft lb.

15. Safety wire the cap screws with .051 in. diameter lockwire.

16. Heat the upper taper bearing inner race to between 225°F(107°C) and 250°F (121°C). Install the bearing rotating therace until it seats.

17. Inspect the upper wear sleeve. If the sleeve shows signs of wearor damage, replace it.

18. Heat the upper wear sleeve to between 200°F (93°C) and250°F (121°C). Install the sleeve and rotate the sleeve until itseats.

March 2, 1998


19. Install dowel pins in the main body cover and keys in themain body.

20. Apply a thin layer of sealant to the mating surfaces of themain body and main body cover.

21. Install O-rings around the oil galleys in the back wall of themain body.

22. Liberally apply oil to the upper cone of compound gear andcup in cover. Lower the cover onto the main body, makingcertain the compound gear bearing halves are aligned.

23. Install and tighten the cover bolts.

24. Lightly tighten the screws to the compound retainer andmeasure the gap between the retainer and the main body.

25. Install a stack of shims between the retainer and the mainbody that exceeds the gap by approximately .002 in.

26. Tighten the screws to 75 ft lb. Check the end play byinserting a dial indicator through the hole in the bearingretainer and moving the compound up and down using a prybar.

27. Disassemble the retainer and remove or add shims to obtainan end play of .001 to .002 in.

28. Clean the mating faces, then apply a thin layer of sealant tothe mating faces. Install the reservoir.

29. Place the O-ring in the groove on the top face of the mainbody cover where the hydraulic pump assembly attaches.

30. Install the hydraulic pump assembly.

e Take care to not damage the inlet filter when lowering the pumpinto place.


Installing the AC drilling motor

z This procedure assumes the brake and cooling system isinstalled on the AC drilling motor as well as the pinion hub.See AC drilling motor assembly for instructions on installing thebrake hub and pinion hub to the AC motor shaft.

Use the following procedures to assemble the transmission/motorhousing upper component:

1. Inspect the O-ring that seals the AC drilling motor to themain body joint and replace any O-ring that has flat spots,nicks, or other damage. Place the O-ring on the pilot borediameters and apply grease (Figure 12).

2. Pick up the AC motor by the brake end (using lifting strapsplaced under the brake adapter) and lower it into position onthe pilot bore being careful not to move or crush the O-ring.

z Make sure the brake end with mounting feet faces the rear, andthe blower duct faces the hydraulic pump when installing the ACdrilling motor.

3. Install the four cap screws and lockwashers that hold the ACdrilling motor to the main body.

4. Apply an anti-seize compound to the threads of the four mainbody cover bolts for the motor. Tighten the four main bodycover bolts to 250-270 ft lb.

5. Install the tie rods by first inserting the end of the rod withthe greatest length of thread into the holes in the brakeadapter plate.

a. Raise the tie rod until the lower end clears the top of themain body cover.

b. Install the tie rod into the threaded holes.

c. Tighten the tie rods until the lower end shoulders againstthe main body cover.

d. Install the flat washer and locknut onto the remaining endof the tie rod and torque to 325 ft lb.

March 2, 1998


O-Ring

AC Motor

Pilot Bore

Figure 12. Installing the AC drilling motor


Installing the upper bearing retainer plate1. Oil the taper roller bearing on top of the main shaft. Chill the

taper roller bearing outer race to at least 0°F (-18°C), theninstall the race into the cover bore.

2. Clean the retainer plate pipe plugs, apply thread sealer (notTeflon tape) to the pipe plug threads, and install the plugsinto the retainer plate.

3. Determine the proper number of shims required under thebearing retainer plate by installing shims, installing theretainer plate, and checking the main shaft axial movement.Check main shaft axial movement by applying a force to theend of the main shaft and measuring the amount of axialmovement at the other end with a dial indicator. Add ordelete shims as necessary to obtain .001 to .002 in. of axialshaft movement (end play) with the retainer plate cap screwstightened to 250-270 ft lb.

z Align the shims so that the upper bearing lube tube bore is notblocked.

4. Remove the bearing retainer plate cap screws and the bearingretainer plate.

5. Install the two new upper bonnet oil seals in the bearingretainer plate with the lips facing up.

e Use care not to damage the seals. Be careful to install the seals withthe lips facing up since these seals function to keep mud from enteringthe main body.

6. Using a center punch, stake the last seal in place on eightpoints.

7. Install the O-ring on the bearing retainer plate and coat theO-ring with grease.

8. Install two O-rings on the upper bearing lube tube and coatthe O-rings with grease.

9. Install the lube tube into the lube tube bore in the cover withthe .060 in. diameter hole facing up.

March 2, 1998


10. Install the bearing retainer plate, being careful to align thelube tube bore in the retainer with the lube tube protrudingfrom the cover.

11. Carefully tap the bearing retainer plate to seat the plate ontop of the cover.

12. Apply an anti-seize compound to the threads of the sixbearing retainer plate cap screws, install the six cap screws andlockwashers, and tighten to 250-270 ft lb. Safety wire the capscrews.

13. Recheck the main shaft axial movement by applying a force tothe main shaft and measuring the amount of axial movementwith a dial indicator. The main shaft movement must bebetween .001 and .002 in. If the movement falls outside ofthis specification, readjust the number of shims under thebearing retainer plate.

14. Install two new grease fittings into the bearing retainer plate.


Installing the wash pipe1. Install the new bearing shield on top of the main shaft. Hold

the shield in place with the worm clamp.

2. Install the 3.875 in. OD polypack seal onto the upper stemliner with the O-ring facing away from the flange of the stemliner.

3. Lubricate the upper stem liner with grease and tap the liner inplace on top of the main shaft.

4. Using a dial indicator, measure the main shaft to adapterwash pipe pilot on the gooseneck. The TIR should not exceed.006 in.

5. Install the wash pipe packing and tighten.

6. Grease the wash pipe packing and the bearing retainer plateseals.

Checking the gear train backlashUsing feeler gauges, check the backlash of the primary andsecondary gears through the access covers on the right side andleft side of the main body (you can also use 3 in. NPT ports foraccess).

z Backlash for the primary gears should be .010 to .020 in.(.024 in. maximum). Backlash for the secondary gears should be.010 to .024 in. (.030 in. maximum).

March 2, 1998


AC drilling motor disassembly/assembly

AC drilling motor disassemblyEach AC drilling motor has a brake hub on the top of the motorshaft, and a pinion hub at the bottom of the motor shaft asshown in Figure 13. When disassembling the brake hub andpinion hub from the motor shaft:

1. Obtain special tool 110026, a hydraulic hand pump with agauge and high pressure hose, and connect as shown inFigure 13.

2. Increase the pressure to 35,000 psi and remove the brake hub.

3. Use the same procedure described in steps one and two, toremove the pinion hub.


��

��

��

Hub

Pressure Gauge

Hydraulic Hand PumpTool # 110026

Brake Hub

AC Motor

High Pressure Hose

Figure 13. AC drilling motor disassembly

March 2, 1998


AC drilling motor assemblyEach AC drilling motor has a brake hub installed on the top ofthe motor shaft, and a pinion hub installed at the bottom of themotor shaft as shown in Figure 14. When assembling the brakehub and pinion hub to the motor shaft:

1. Lap the brake hub and pinion hub to their respective ends ofthe motor shaft until the contact area between them is at least85%.

2. Lightly install the brake hub and pinion hub onto the motorshaft and measure the gap to the motor (dimension A).

3. Remove the brake hub and pinion hub and heat them in anoven to between 400°F and 425°F.

4. Reinstall the brake hub and pinion hub onto the motor shaftadvancing the pinion hub .068 ± .005 in. and the brake hub.054 ± .005 in. past the original dimension A. This ensuresthey remain securely fastened to the motor shaft.


��

��

��

Lap to 85% Contact

Lap to 85% Contact

5.029Ref

5.975Ref

A

A

Brake Hub

Pinion Hub

AC Motor

Figure 14. AC drilling motor assembly

March 2, 1998


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., triangle, square,rectangle, circle), 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 15).

6. Repeat the previous twisting cycle.


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 15. Safety wiring procedures

March 2, 1998


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 16).

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 16. Safety wiring examples

TDS-10S


Control System

2 TDS-10S Control System

March 2, 1998

TDS-10S Control System 3

Contents

Chapter 1 DescriptionGeneral description ............................................................. 5Major component descriptions ........................................... 7

Varco Driller’s Console (VDC)..................................... 7Programmable logic controller (PLC) ..................... 9Variable Frequency Drive (VFD) .......................... 10

Electrical service loops................................................. 12

Chapter 2 OperationPreoperational checklists ................................................... 13VDC controls ................................................................... 17Correcting a drive fault ..................................................... 20

Drive fault while drilling ............................................. 20Drive fault while making up ....................................... 21

Chapter 3 MaintenanceMaintaining the control system......................................... 23Troubleshooting ............................................................... 25

VFD ........................................................................... 28


March 2, 1998


Chapter 1

Description

The following chapter describes the TDS-10S Control System ingeneral and its major components in detail.

General description

The TDS-10S control system consists of the following threemajor components:

❏ Varco Driller’s Console (VDC)

❏ Varco Electrical House (VEH)

❏ Electrical Service Loops

These components directly interface to control and provide safetyinterlocks for the TDS-10S (Figure 1).


March 2, 1998

Remote I/O

TDS-10S

VariableFrequency Drive

(VFD)

PLC

ControlSignals

ControlSignals

DataBus

3-Phase Power

Varco Electrical House (VEH)

VarcoDriller's Console

(VDC)

Figure 1. TDS-10S control system interface


Major component descriptions

Varco Driller’s Console (VDC)The VDC, made from 300-series stainless steel, uses full size oiltight switches and indicators, and is designed for purging to meethazardous area requirements (Figure 2).

R

RAGR

STOPEMERGENCY

THROTTLE

IBOP BRAKE

MAX0

0 MAX

REVERSE FORWARD

ONBRAKEOFF

AUTO ON

HYDRAULIC POWER

CLOSEOPENIBOP AUTO

BRAKE

ONBRAKE

CLOSEDIBOP

SILENCE CHECKALARM LAMP

PUSH & HOLDTORQUE WRENCH

OVERTEMPDRILL MOTOR

R

PRESS LOSSVDC

BLOWER LOSS

MAX0

CURRENT LIMITMAKE-UP

TORQUEDRILLSPIN

OFFDRIVEFAULT

OILPRESS LOSS

DRILL TORQUE

LINK TILT FLOATROTATE

OFFLINK TILT

DRILL TILT

LEFT RIGHT

RRRPMTORQUE

PIPEHANDLER

Figure 2. Varco Driller’s Console (VDC)


March 2, 1998

It is equipped with the following items to directly interface withthe programmable logic controller (PLC):

❏ Throttle

❏ Torque limit potentiometer

❏ Makeup limit potentiometer

❏ Switches and buttons

❏ Indicator lights

The throttle uses a design similar to a standard throttle controlsupplied with Silicone Controlled Rectifier (SCR) systems. Thehandle includes integral stops to prevent damage.

The torque limit potentiometer is also similar to the design usedon SCR systems. The maximum torque output of the drive islimited to the continuous torque rating of the drive and motors.

The makeup limit potentiometer controls the makeup torquewhen using the drilling motor to makeup connections.

Switches and buttons control the following:

❏ Drill, Spin, Torque mode select

❏ Link tilt

❏ AC drilling motor brakes

❏ Backup clamp


❏ Remote IBOP valve

❏ Drill pipe forward/reverse select

❏ Emergency stop

Indicator lights show the following conditions:

❏ Oil pressure loss

❏ Drill motor overtemperature

❏ Blower loss

❏ IBOP closed

❏ Brake

❏ Drive fault


Programmable logic controller (PLC)The Variable Frequency Drive (VFD) cabinet encloses thefollowing electrical components:

❏ Master programmable logic controller (PLC)

❏ Circuit breakers

❏ 24 Volt DC power supply for solenoids and VDC

❏ Motor starters for blower and oil pump

With the PLC functioning as the central control unit for theTDS-10S, interface to the variable frequency drive (VFD) islimited to a digital communication buss. Input signals from thePLC to the drive include the following:

❏ Control word 1 (On/Off, fwd/rev)

❏ Control word 2 (set point data set selection)

❏ Speed

❏ Torque forward

❏ Torque reverse

Communication from the drive to the PLC includes rpm, torqueand status word (fault).

Any changes to alarm or interlock functions have no effect on theVFD.

The remote I/O receives input from the operator controls on theVDC and processes this information through the PLC. The PLCcontrols the responses of the cooling system motor, solenoidvalves, brakes, IBOP functions, and sensors. It reads the status ofthe sensors and creates interlock conditions to prevent inadvertenttool operations. The PLC also notifies the operator of theoperational status of the TDS-10S using alarm indicators whichprovide diagnosis of inadvertent operational conditions.


March 2, 1998

Variable Frequency Drive (VFD)The VFD, used to operate the TDS-10S AC drilling motors,consists of three major parts:

❏ Rectifier section

❏ Control section

❏ Power inverter section

The rectifier section converts incoming 3-phase AC power to DCfor use by the power devices.

The control section monitors the performance of the drillingmotor, accepts throttle and torque limit signals from the driller,and controls the firing circuits of the power modules.

The power inverter section converts DC power into a simulatedAC signal using pulse-width-modulation (PWM) field vectorcontrol techniques.

The driller controls the speed of the AC drilling motors with ahand throttle. The throttle varies the frequency and voltage to themotor. The speed of the drilling motor is proportional to thefrequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1200 motorrpm).


+

-

TD

S-1

0S A

C M

otor

s

0-57

5VA

C, 0

to 8

0 H

z, 3

-Pha

se

Inverter Controller

Data Bus

VFD

Resultant Pulse DC

AC Inverter(AC Frequency Drive)

810 VDC20 Hz=600 RPM @ Mtr.

40 Hz=1200 RPM @ Mtr.

0

0

0

ACPowerSource

PLC

Insulated gate Bi-polarTransistors (IGBT)

00

600 VAC, 42 to 62 Hz3-Phase (350 AMPS)

Figure 3. Variable Frequency Drive (VFD)


March 2, 1998

Electrical service loopsThe TDS-10S requires three electrical service loops. The mainloop consists of four 313 MCM power conductors (three fordrilling motor power, one for ground); and a composite cable thatcontains all of the conductors for sensors and actuator (solenoid)control. This encoder signal is contained in three of four twistedpair shielded wire in the composit cable. An auxiliary power loopprovides power for the auxiliary AC motors and heater.


Chapter 2

Operation

The following chapter contains the TDS-10S Control Systempreoperational checklists and detailed descriptions of the VDCcontrols.

Preoperational checklists

The tables on the subsequent pages provide the followingpreoperational checklists:

❏ Drive control system function checks (Table 1)

❏ Top Drive control system function checks (Table 2)

❏ Top Drive control system interlock checks (Table 3)

❏ Top Drive control system alarm checks (Table 4)


March 2, 1998

Table 1. Drive control system function checks

FunctionSwitch

PositionIndicator

Display LampPhysicalCheck Check OK

Blowers Forward

Reverse

Off

N/A

N/A

N/A

Blower on

Blower on

Blower off

Oil pump Forward

Reverse

Off

N/A

N/A

N/A

Oil pump on

Oil pump on

Oil pump off

IBOP Closed

Open

On

Off

Actuator shell up

Actuator shelldown

Link tilt Drill

Off

Tilt

N/A

N/A

N/A

Links to drilldown position

No movement

Links extendedto mousehole

Link tilt float Push N/A Links float tow/c

Rotating head (manual)

Left

Right

N/A

N/A

Rotates left

Rotates right

Counterbalance Drill

Stand Jump(opt.)

N/A

N/A

Balance TDSweight

Lifts TDSweight


Table 2. Top Drive control system function checks

FunctionSwitch

PositionIndicator

Display LampPhysicalCheck Check OK

Brake Off

On

Auto/throttle on

Auto/throttle off

Off

On

Off

On

Brake released

Brake set

Brake released

Brake set

Torque wrench Off

Clamp

N/A

N/A

Jaws unclamped

Jaws clamped

Alarm silence

Lamp check

Push

Push

On

On (after 2 seconds)

Horn silenced

All lamps on(after 2 seconds)

Table 3. Top Drive control system interlock checks

FunctionControl

Sequence Action Check OK

Rotating head With links in tilt ordrill position,actuate rotateleft/right.

With links in tilt ordrill position,actuate float pushbutton.

After 5 secondsactuate rotateleft/right.

No rotation

Links float towardwrench clamp.

After 5 seconds,rotating headrotates.

Torque wrenchclamp

Withdrill/spin/torqueswitch in drill modeand throttle on,actuate torquewrench clamp.

No torque wrenchclamp


March 2, 1998

Table 4. Top Drive control system alarm checks

Alarm Function Action to Initiate Display Indication Check OK

Oil pressure loss Remove/cap oil Press line to oil Press switch

Disconnect aux.power loop

“Oil Pressure Alarm”flashes and hornsounds

“Oil Pressure Alarm”flashes and hornsounds

Blower differentialpress

Remove line to leftdifferential pressswitch

Disconnect aux.power loop

“Blower PressAlarm” flashes andhorn sounds

“Blower PressAlarm” flashes andhorn sounds


VDC controls

Table 5 describes each of the VDC controls in detail (Figure 4).

EMERGENCYSTOP

THROTTLE

BRAKE ON

BLOWER LOSS

BRAKEAUTO

MAX0

STANDJUMP

DRILL

BRAKEON

OFF

COUNTERBALANCETILTDRILL

LINK TILTOFF

ONOFF

HYDRAULICPOWER

TORQUEDRILLSPIN

ALARM/LAMP TEST(PRESS TO SILENCE)

TORQUE WRENCHPUSH & HOLD

LINK TILT FLOAT

RIGHTLEFT

ROTATE

FORWARDREVERSE

OFF

0 MAX

DRILL TORQUE

0 MAX

MAKE-UPCURRENT LMIT

RPMTORQUE

BRAKEIBOP

CLOSED IBOP

CLOSEOPEN

IBOP

PIPE HANDLER

DRILL MOTOROVERTEMP

OILPRESS LOSS

PURGELOSS

DRIVEFAULT

24

12

13

5

10

16

19

11 15 7 14 18 17 22

9

23

8

3

21

202461

Figure 4. VDC controls


March 2, 1998

Table 5. VDC controls

Control/IndicatorName Description and Function

1 DRIVE FAULT Red indicator light flashes and horn sounds when a VFD faultis detected. Pressing the alarm silence button stops the horn.The alarm indicator light stays on while the switch is timedfor 5 minutes. The alarm returns if the fault is not fixed,otherwise, the alarm light turns off.

2 BLOWER LOSS Red indicator light illuminates in case of a failure in aircooling motor.

3 BRAKE ON Red indicator light illuminates when the brake solenoid valveis energized.

4 DRILL MOTOROVERTEMP

Red indicator light illuminates in case of an overtemperaturecondition in the 350 hp AC drilling motor.

5 IBOP CLOSED Amber indicator light illuminates when there is hydraulicpressure to the cylinder that closes the IBOP valve.

6 OIL PRESS LOSS Red indicator light illuminates when there is an oil pressureloss in the gearcase lubrication system.

7 ALARM /LAMP TESTswitch

When the alarm indicator light illuminates and the hornsounds, press the switch to silence the horn. The alarm lightstays on until the fault is corrected. If it is not corrected in 5minutes, the alarm repeats. The switch is also a lamp check forall lights on the VDC. The switch must be pushed and heldfor two seconds to obtain a lamp check.

8 BRAKE switch There are three brake switch positions: OFF, AUTO, andON. Turning the switch to the ON position turns the brakeon and lights the indicator light above the switch. In theAUTO position, the brake automatically turns on when thethrottle is turned off. Turning the switch to the OFF positionturns the brake off. After a DRIVE FAULT or emergencystop, the BRAKE SWITCH must be turned ON and thenOFF to reset the brake.

9 DRILL TORQUELimit Potentiometer

A potentiometer sets the current limit in the VFD duringdrilling operations. This sets the torque for normal drillingoperations in the drill position. Torque and rpm are displayedand can be adjusted. Adjust the torque by setting the brakeand turning the potentiometer to increase or decrease thetorque.

10 ROTATE There are three switch positions: OFF, LEFT, and RIGHT.Turn the spring-loaded switch to the left to rotate the head tothe left, and turn the switch to the right to rotate the head tothe right.

NOTE: Works only after the link tilt float switch is pressed.


Table 5. VDC controls (continued)

Control/IndicatorName Description and Function

11 DRILL/SPIN,/TORQUE switch

There are three switch positions: DRILL, SPIN, andTORQUE. The switch is in the DRILL mode during normaldrilling. SPIN mode is a fixed speed of the AC drillingmotors. TORQUE mode is a slower fixed speed of the ACdrilling motors. It generates a gradual increase in torque to themake-up limit.

12 EMERGENCY STOPswitch

Emergency stop shuts down all operations. Emergency stopswitch is hardwired to the VFD. Pressing the stop buttondeselects the drive and sets the brake, causing the top driverotation to stop regardless of throttle position. Auxiliarycooling motors remain on.

13 IBOP switch Activates the upper IBOP valve. Turning the switch to the leftretracts the IBOP actuator cylinder to close the valve. Turningthe switch to the right extends the cylinder to open the valve.

14 LINK TILT FLOAT The links “float” to the center (NEUTRAL) position when thepushbutton is depressed.

15 LINK TILT switch Activates the link tilt cylinder. The center position is OFF;turning the switch to the left extends the cylinder to themousehole; and turning the switch to the right retracts thecylinder for drill down. This is a maintained switch that holdsthe position of the cylinder when returned to OFF.

16 MAKE-UP CURRENTLIMIT Potentiometer

A potentiometer sets the torque limit in the VFD when usingthe top drive to makeup connections. Torque is displayed onthe torque meter. Adjust the torque by setting the brake andturning the potentiometer to increase or decrease the torque.

17 REVERSE /OFF/FORWARD switch

There are three switch positions: OFF, FORWARD, andREVERSE. In the OFF position, the top drive cannotoperate. FORWARD and REVERSE are used when drillingor making/breaking connections. This switch acts as the driveassignment.

18 TORQUE WRENCHPUSH & HOLDswitch

Pushing this button engages the pipe clamp and shot pin lock.The rotating head rotates until the shop pin engages. The pipeclamp operates after the shot pin is engaged.

19 HYDRAULIC POWER Turns the tool hydraulics on or off.

20 PURGE LOSS Indicates that the VDC has lost purge pressure.

21 RPM meter Displays the rpm of drill pipe.

23 THROTTLE Controls the speed of the AC drilling motors. Motor rpm isdisplayed on the rpm meter.

24 TORQUE meter Displays the drill pipe torque in ft lb.


March 2, 1998

Correcting a drive fault

When a drive fault occurs, the brake automatically sets regardlessof the brake switch position. The brake sets at less than 5 rpm.

Use the following procedure to release the brakes and unwind thedrill string torque in a controlled operation.

Drive fault while drilling1. Turn the brake switch on, if it is not already there. This sets

the top drive brakes and keeps the drill string from rotating.

2. Rest the drive. If there is torque build up on the string, openthe throttle. The torque meter indicates the preset drill torquelimit. If the torque meter reading is different from the drilltorque limit prior to the drive fault, readjust the drill torquelimit before releasing the brake.

3. Turn the brake control switch off to release the brakes.

4. Rotate the drill torque limit control slowly to unwind the drillstring torque.

5. If the drive does not reset and there is torque build up in thedrill string, toggle the brake switch from on to off repeatedly.This releases a little torque each time, until it is safe tocompletely release the brakes.

e The top drive must not be deassigned (hydraulic pump and blowermotors running) for more than 10 minutes to maintain maximumbraking. Brakes are applied by hydraulic caliper pressure actuated byaccumulator pressure. When the hydraulic pump is off, theaccumulator pressure drops due to normal system leakage, resulting ina decrease in braking. The decrease in braking is gradual until theaccumulator precharge pressure is reached. If the drill string torque islow, there may be noticeable rotation due to a gradual decrease inbraking since the required brake holding pressure is low. In thissituation, the brakes release once hydraulic pressure reaches theaccumulator precharge pressure.


Drive fault while making up1. Turn the brake switch on, if it not already there. This sets the

top drive brakes and keeps the drive stem from rotating.

2. Toggle the brake switch from on to off repeatedly. Thisreleases a little torque in the drive stem each time until thereis slack in the back-up tong line and it is safe to completelyrelease the brakes.

n Floor hands should stay clear of back-up tong and long lineduring this operation due to the possibility that a sudden releaseof torque might cause the tong to recoil and fall to the floor.


March 2, 1998


Chapter 3

Maintenance

The following chapter contains the TDS-10S Control Systemmaintenance guide.

Maintaining the control system

Refer to the following documentation for maintenanceinformation:

❏ Periodic control system maintenance schedule (Table 6)

❏ Preoperational checklists (Chapter 2)

❏ PLC manufacturer’s manual

❏ VFD manufacturer’s manual


March 2, 1998

Table 6. Periodic control system maintenance schedule

Location Procedure Interval

Indicator lamps Test using the lamp test switch on theVDC.

Daily

Heater Check operation with an ohmmeter. Monthly

High voltageconnections

Check for discolored or brittleinsulation.

Check retaining bolt torque (25 ft lb).

Monthly

Monthly

Componentmounting

Check fastener tightness, especially invibration-prone areas.

Monthly

Seals and gaskets Check for integrity. Monthly


Troubleshooting

The figures in the subsequent pages show the following PLCmodules during normal operations:

❏ S7-300 CPU (Figure 5)

❏ Input module (Figure 6)

❏ Output module (Figure 7)

❏ Remote I/O (Figure 8)

RUN-P

RUN

SF

STOP

RUN

FRCE

DC5V

BATF

CPU315-2 DP

BUSF

STOP

MRES

M

L+

M

X1 MPI X2 DP

DC24V

Status and fault LEDs

(Cover removed for clarity)

Mode Selector

Battery Compartment

Jumper (removable)

Terminals forpower supply andfunctional ground

PROFIBUS-DPinterface

MPI port

Memory cardreceptacle

Figure 5. S7-300 CPU during normal operations


March 2, 1998

0 1

RUN

RUN STOP

BFDIA

-4AIET 200B

Figure 6. Input module during normal operations

0 4

RUN

RUN STOP

BFDIA

-4AOET 200B

Figure 7. Output modules during normal operations


RUN

BF

DIA

0 5

RUN STOP

Figure 8. Remote I/O during normal operations


March 2, 1998

VFDThe VFD has an LCD panel that can be used for troubleshooting(Figure 9).

7Jog 8 9

4 5 6

P

1 2 3

0 +/- Reset

Run

Fault

Output voltage 15,2A 120V

# 14.00Hz

* 14.00Hz

°014=Operation Mode name

Output current

Mode number

Setpoint

Actual value

Figure 9. LCD panel

TDS-10S


SupplementalMaterial

March 2, 1998

2 TDS-10S Supplemental Material

TDS-10S Supplemental Material 3

Contents

Supplemental MaterialSupplement list ................................................................ 8-5

March 2, 1998


TDS-10S Supplemental Material 5

SupplementalMaterial

Supplement list

This chapter contains the following supplements:

❏ Design Specification, Design Torque Standard (DS00008)

❏ IBOP Service Manual

March 2, 1998


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

Serv ice Manua lServ ice Manua l

® ™DRILLING SYSTEMS

Feb. 2, 1994

Feb. 2, 1994

i

Feb. 2, 1994

Contents

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

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

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

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

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

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

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

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

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

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

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Feb. 2, 1994

1

Feb. 2, 1994

Varco/BJSafety Valves

(IBOPs)

GENERAL DESCRIPTION

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

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

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

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

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Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

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

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Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

Var co

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

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Feb. 2, 1994

CLSDOPEN

Retaining Ring

Upper Seat

Back-up Rings

O-Ring

StabilizerRing

Ball

Back-upRings

O-Ring

Sleeve

Seal Ring

Crank

Seat

Grease/Mud Seal

Back-up Ring

O-Ring

WaveSpring

Body

ThreadProtector

Plug

ThreadProtector

Figure 3. Typical Upper Safety Valve (IBOP)

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Feb. 2, 1994

PH-60 IBOP/Actuator Upgrade Kit

Introduction

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

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

PRINCIPLE FEATURES

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

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

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

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

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

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Feb. 2, 1994

ACTUATOR CYLINDERMOUNTING BRACKETREQUIRES NO ADJUSTMENT

LARGE BORE,LONG STROKE IBOPACTUATOR CYLINDERS (2)

REINFORCED DUALEXTERNAL CRANKS ANDHOUSINGS WITH IMPROVEDBALL ROTATION STOPS

SOLID, ONE-PIECE,JOURNAL-GUIDEDIBOP ACTUATOR SHELL

IMPROVED DESIGNDUAL-CRANKUPPER IBOP VALVE

Aug. 9, 1993. A.N.

Figure 4. PH-60 Upgrade Kit

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Feb. 2, 1994

Remote IBOP Actuator Improvements

(Refer to Drawing 99261 in the Appendix)

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

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

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

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

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Feb. 2, 1994

Internal Valve Mechanism Improvements

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

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

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

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

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

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Feb. 2, 1994

INSTALLATION

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

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

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

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

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

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

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

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

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Feb. 2, 1994

Table 1. Make-Up Torque Values

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

Mainshaft to UpperIBOP Safety Valve*

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

Upper IBOP SafetyValve to LowerIBOP Valve

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

Lower IBOP Valveto Saver Sub

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

Crossover Sub toLower IBOP SafetyValve

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

Mainshaft to UpperIBOP SafetyValve**

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

Upper IBOP SafetyValve to LowerIBOP

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

Lower IBOP Valveto Saver Sub

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

Crossover Sub toLower IBOP Valve

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

* 500 Ton** 650 Ton

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

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

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

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

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Feb. 2, 1994

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

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

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

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

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

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

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

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

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

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

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Feb. 2, 1994

Safety WireGroove

7/8" Allen Crank

Cam Follower

CrankAssembly

Lock Tabs

Crank AssemblyRetaining ScrewAnd Lock Tabs

Slot

Crank Arm*

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

CrankAssembly

*Note Orientation

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

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Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

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

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Feb. 2, 1994

RollerAssembly (3)

RollerAssembly (3)

CrankAssembly

Safety WireGroove Shim

ActuatorArmGroove

Crank*

ActuatorShell

Slot

Crank AssemblyRetaining Screw

CrankAssembly

RollerAssembly(3)

SafetyValve

*Note Orientation

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

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Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

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

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Feb. 2, 1994

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

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

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Feb. 2, 1994

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

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

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

1. Breakout and remove the lower IBOP.

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

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

4. Re-assemble the valves.

5. Reinstall and torque the lower valve.

Figure 9. Lower IBOP Seal Removal

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Feb. 2, 1994

LUBRICATION

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

1. To verify the integrity of the grease seal.

2. To lubricate the floating seat.

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

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

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

2. Install a suitable grease fitting.

3. Open the valve.

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

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

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

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Feb. 2, 1994

SEAL RING STABILIZER

MUD/ GREASE SEAL

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLL

CFigure 10. Lubricating a T

ypical Upper IB

OP

20

Feb

. 2, 1

994

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLL

C

Fig

ure

11.

Lubr

icat

ing

a T

ypic

al L

ower

IBO

P

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Feb. 2, 1994

INSPECTION

Magnetic Particle Inspection

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

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

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

Safety Valve Inspection Procedures

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

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

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

Concentrate attention on (Figure 12):

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

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Feb. 2, 1994

RecommendedInspection Areas

Figure 12. IBOP Inspection Points

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

VISUAL INSPECTION

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

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

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

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

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Feb. 2, 1994

ADJUSTING THE SAFETY VALVE ACTUATOR

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

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

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

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

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

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

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

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

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

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Feb. 2, 1994

Upper IBOP Valve Actuator Shell

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

Upper IBOP ValveActuator Air Cylinders (2)

Upper IBOP

ActuatorArm

Torque Tube

Lower IBOP

Saver Sub

DriveStem(Ref.)

Landing Collar

LinkAdapter

*1 Inch

RodEnd

CylinderGland

Cylinderin OPENPosition

OPEN

CLOSE

*IMPORTANT

Eye Bolts (2)

Cylinder Adjustment Bolts (4)

Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &Single Crank PH-60

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Feb. 2, 1994

MAINTENANCE

Seal Replacement

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

2 14517 6 1 10 18

13

12

12

9

3

4

208

7 16

19

15

2X

11

7/8" Hex

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

Figure 14. IBOP Safety Valve Illustrated Parts List

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Feb. 2, 1994

BALL/SEAT SET

SEAL RING STABILIZER

1

17

16

20

19

18

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

PLUG

CRANK, LEFT HAND

NYLON PLUG

O'RING

BODY

WAVE SPRING

CRANK, RIGHT HAND

BACKING RING

O'RING

SLEEVE

CROWN SEAL

BACK-UP RING

POLYSEAL

UPPER SEAT (SET)

LOWER SEAT (SET)

BACK-UP RING

O'RING

RETAINING RING

BALL, DUAL CRANK (SET)

ITEM QYT. / KITDESCRIPTION

Parts List

1 -

1 1 -

1 1 1

1 1 1

1 1 -

1 1 -

1 1 1

2 2 2

1 2 2

1 2 -

1 2 2

2 4 4

1 1 -

1 1 -

- - -

1 1 1

2 2 2

- 1 -

1 1 -

1 1 1

REPAIR KIT - SINGLE CRANK

REPAIR KIT - DUAL CRANK

REPAIR KIT - SOFT SEAL ONLY

Refer to the Appendix for Part Numbers




(For either Single or Dual Crank)

1

1

1

2

PART NUMBERS

90939-5

89141-1

90441-9

90441-10

90939-5

90939-5

96439

89141-13

89141-8

90441-7 (93806-12 for Dual Crank)

89141-11

89141-12

89141-7 (93806-10 for Dual Crank)

89141-9

89141-3

93806-11

96438

Figure 14. IBOP Illustrated Parts List (Cont.)

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Feb. 2, 1994

Shop Assembly and Disassembly

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

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

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

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

7.5"

Load Bar

3"Maximum

22"

Seat Puller For All ModelsVarco Part No. 79489-14

Nut Wrench for DSV ModelsVarco Part No. 89141-18

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

15.25"

3"

Figure 15. IBOP Tools

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Feb. 2, 1994

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

Figure 16

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

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

Figure 17

DISASSEMBLY

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

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Feb. 2, 1994

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

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

Figure 18

6. Remove the wrench.

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

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

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

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

Figure 20

Figure 19

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Feb. 2, 1994

11. Remove the ball valve(Figure 21).

Figure 21

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

Figure 22

13. Remove the pulling toolfrom the lower seat.

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

Figure 23

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Feb. 2, 1994

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

16. Remove and discard theseals from all IBOPcomponents.

17. Thoroughly clean andinspect each item.

Figure 24

Figure 25

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Feb. 2, 1994

ASSEMBLY

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

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

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

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

Figure 26

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

NOTEThe steel stabilizer ringshould be inside the sealwhen properly installed.

Figure 27

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Feb. 2, 1994

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

Figure 28

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

Figure 29

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Feb. 2, 1994

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

Figure 30

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

Figure 31

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Feb. 2, 1994

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

11. Install the seals on the crankassembly.

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

Figure 32

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

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

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

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

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

Figure 33

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Feb. 2, 1994

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

Figure 34

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

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

Figure 35

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

22. Position the crank in theClosed position.

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

Figure 36

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Feb. 2, 1994

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

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

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

Figure 38

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

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

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

33. Leave the valve in the Openposition.

34. Remove the wrench.

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

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

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

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Feb. 2, 1994

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

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

Figure 39

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

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

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Feb. 2, 1994

IBOP VALVE TESTING IN THE SHOP

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

1. Rotate the valve crank to the Open position.

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

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

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

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

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

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

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

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

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

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

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

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

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Feb. 2, 1994

APPENDIX

IBOP Part Numbers

IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.

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

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

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

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

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

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



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



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Feb. 2, 1994

IBOP Part Numbers (Cont.)

IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.


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

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

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

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

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

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

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

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

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

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Feb. 2, 1994

Identifying Varco Safety Valves

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44

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45

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46

Feb. 2, 1994

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