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Service Manual
SM00620-TOC
Rev. A
ii
TDS-4S Contents
Contents
Book 1 Description
Preface/Manual conventions
Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
TDS-4S Contents
iii
Link tilt mechanisms ................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51 TDS Control System (TDCS) ....................................... 1-53 Varco Drillers control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62
Chapter 3 Specifications
Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower * .................................................... 1-66 Derrick mounted remote blower * ..................... 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70
iv
TDS-4S Contents
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Drillers controls and instrumentation ........................... 2-23 Varco Drillers Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33
TDS-4S Contents
Book 3 Operation
Preface/Manual conventions
Safety information ........................................................... 3-5 Directional references ...................................................... 3-6 Manual layout .................................................................. 3-6
vi
TDS-4S Contents
Chapter 1 Maintenance
Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Contents vii
Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97
viii TDS-4S Contents
Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111
TDS-4S Contents
ix
TDS-4S Contents
Description
SM00620-1
1-2
TDS-4S Description
Contents
Preface/Manual conventions
Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
TDS-4S Description
1-3
TDS Control System (TDCS) ....................................... 1-53 Varco Drillers control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62
Chapter 3 Specifications
Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower * .................................................... 1-66 Derrick mounted remote blower * ..................... 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70
1-4
TDS-4S Description
Safety information
Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the readers attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.
z e
Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.
Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
TDS-4S Description
1-5
Directional references
References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.
Manual layout
This binder contains several separate books that you can remove individually for convenience.
1-6
TDS-4S Description
Chapter 1 Introduction
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45 ft. kelly was the industry standard for years. For decades, drillers extended the drill string with the making-a-single-connection process using the rotary table, kelly, pipe tongs, drawworks cathead, master bushing, bowls, and slips. This method of handling pipe and joint makeup remained unchanged, apart from minor improvements such as kelly spinners, until the advent of top drive drilling systems. Varco produces several Top Drive Drilling Systems (TDS) to rotate the drill string and allow adding entire 93 ft. stands of pipe, eliminating two thirds of the conventional single-pipe drilling connections. This manual describes the function and maintenance of the TDS-4S, which integrates the drill pipe connection handling and drive systems with the drilling swivel. The TDS (Figures 1-1 and 1-2) provides the rotating power of a conventional rotary table drive while eliminating the need to pick up the cumbersome swivel/kelly combination. The TDS does not interfere with the existing conventional equipment. It allows tripping, circulation, rotation, and the running of casing as well as providing 90 ft. back reaming capabilities to reduce the chance of stuck pipe.
TDS-4S Description 1-7
LO
Pipehandler Assembly
1-8
TDS-4S Description
The TDS integrated swivel bail connects directly to a drilling hook. Connecting the TDS integrated swivel bail directly to the traveling block or motion compensator frame can eliminate the drilling hook and shorten the TDS working height further.
Swivel Bearing
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Bull Gear
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DC Drilling Motor
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Upper Gearcase
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High Gear (Disengaged) Rotating Head Main Shaft/Drive Stem Lower Gearcase
TDS-4S Description
1-9
The integrated drive stem functions as the main output shaft driving the drill string. The electric drilling motor and transmission, located next to the stem, rotates the stem. The DC motor bolts to an upper assembly of the gearcase, called the motor support bonnet. The motor frame/guide dolly attaches to the motor housing assembly. The entire assembly moves vertically on two rails installed in the derrick. The vertical rails react the motor torque during drilling operations and keeps the TDS positioned over wellcenter. The pipehandler assembly (Figures 1-3 and 1-4) can make or break drill pipe at any height in the derrick.
1-10
TDS-4S Description
Link Adapter (Also know as: Solid Body Elevator) (Landing Collar Inside on Main Shaft/Drive Stem)
Splined Upper IBOP Valve Lower IBOP Valve (Inside Torque Tube)
Torque Wrench
TDS-4S Description
1-11
Link Adapter (Also known as Solid Body Elevator) (Landing Collar Inside On Main Shaft/Drive Stem)
Lower IBOP Valve (Inside Torque Tube) Splined Upper IBOP Valve
Torque Wrench
1-12
TDS-4S Description
Internal Blow Out Preventor (IBOP) valves connect to the end of the drive stem (Figure 1-5). The driller can close the upper IBOP at any position in the derrick from the drillers control console. A second, lower IBOP can be manually closed and sent downhole while controlling a kick.
Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
The drive stem passes through the link adapter. The torque arrestors keep the link adapter above the landing collar on the drive stem when drilling (Figures 1-6, 1-7 and 1-8). When hoisting, the link adapter is pulled down onto the landing collar due to the added weight of the drill string. This directs the hoisting load through the drive stem, motor housing assembly, and swivel bail. The fluid service loop provides the hydraulic, pneumatic power, and optional cooling water services to the TDS. The electric service loops provide DC power and AC power/control. A drill pipe elevator hangs from a pair of conventional links that attach to the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up pipe. The Major component description chapter of this book describes each of these assemblies. Subsequent books provide more information on the equipment specific to your rig configuration.
1-14
TDS-4S Description
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors
TDS-4S Description
1-15
Saver Sub
1-16
TDS-4S Description
Saver Sub
TDS-4S Description
1-17
1-18
TDS-4S Description
TDS-4S Description
1-19
Drilling motor
The drilling motor on the TDS is a 1,100 hp DC drilling motor. Mechanically, the motor features a double-ended armature shaft and thrust bearings for vertical operation. There is an air brake on the motor to hold torque in the drill string to assist in directional work. It is remotely operated by a solenoid valve. Please refer to the specifications included later in this book for additional details.
1-20
TDS-4S Description
External HI / LO Indicator
Bottom View
Low Gear Eccentric Shaft (Disengaged)
Geneva Mechanism
Top View
LO
Shifter Input
HI
TDS-4S Description
1-21
Lubrication to the bearings and gear meshes is force fed by an electrically driven gear pump externally mounted on the gearcase (Figure 1-10). The lower gearcase is a heavy duty steel casting, fully ribbed for added heat dissipation. The transmission shifts gears by rotating two vertical compound gear eccentric shafts. The two compound shafts (high and low) are supported on heavy trunnions between the main body and lower gearcase halves. As the shafts rotate (less than one-half turn), the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. Each compound shaft carries a large, internally splined geneva slave. A common geneva master sequentially unlocks, rotates, and locks both gears. The master rotates using a reduction gear set with a vertical manual input shaft. It carries its own latching mechanism and provides the security of a double lock on the compound shafts. A 1 in. male hex at the bottom of the transmission case (Figure 1-9), rotates the input shaft. After pushing inward on the male hex, it takes five turns of the input shaft to unlock both gear sets, rotate the engaged gear set to full disengagement, rotate the disengaged gear set into full engagement, and lock both gear sets in their proper positions with positive stops in the locked position. An external indicator shows the gear range selection.
1-22
TDS-4S Description
Side View
Bull Gears
Inlet
Bull Gears
LEGEND
Pressure Tap
Bottom View
Fabricated Drilled
1-24
TDS-4S Description
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return Cylinder
Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown)
TDS-4S Description
1-25
Stationary Flange
Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly
Bull Gear
S1
A1
H1
PRESSU
A1
S2
RE
A5
H2
S2
A2
H3
A3
H2
S1
TDS-4S Description
A2
H1
A3 H3 A5 A4
A4
1-27
Cooling systems
Local blower
The local blower cooling system with an optional extended intake provides local cooling air to the drilling motor (Figure 1-13). It receives air approximately 27 ft. above the rig floor at the lowest point of the motors travel. An explosion-proof 20 hp, 3,450 rpm AC electrical motor directly drives the impeller in the blower housing. An optional flexible duct connects the blower housing to the extended intake mounted on the traveling equipment. Two spark arrestor assemblies are mounted on the exhaust ports of the upper gearcase. These components hinder the egress of any air born sparks from the DC motor.
1-28
TDS-4S Description
Transmission Cooler
Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket FLL-X Duct Connection Point Mounting Plate
Spark Arrestor
TDS-4S Description
1-29
Closed loop
The closed loop cooling system (Figure 1-14) consists of two air/ water heat exchangers cooled by twin blowers driven by a double ended AC motor. Ducting directs air out the motor exhaust port to the heat exchangers and back to the blower inlets. The heat exchangers are built from Cupro-Nickel tubes and the headers are pressure tested to 250 psi. The system requires a supply of liquid coolant (sea water, chilled fresh water or glycol) at 100 gpm at a maximum inlet temperature of 90F. Purge air at a rate of 70 scfm per motor at 1.0 psig is also required to provide positive system pressure, and a purge control system (refer to TDS Control System information provided later in this chapter) monitors system pressure to insure safe operation.
1-30
TDS-4S Description
Impeller (2)
Water Connections
TDS-4S Description
1-31
Remote blower
The remote blower motor cooling system consists of a motor and pressure blower mounted in the derrick at racking board level (Figure 1-15). Air is drawn in from outside the wind wall, through a flexible duct into the top of the drilling motor, and exits through spark arrestors attached to the air outlets of the motor. A pressure switch monitors the motor air inlet pressure to verify blower operation. The contacts of the pressure switch are usually wired into the SCR assignment logic for the drilling motor. A moisture separator is attached to the blower inlet duct to prevent water from entering the motor.
1-32
TDS-4S Description
Air Inlet
Wind Wall
Spark Arrestor
TDS-4S Description
1-33
1-34
TDS-4S Description
Motor Frame
TDS-4S Description
1-35
Retract Cylinder
LEGEND
Intermediate Frame
45.0"
1-36
TDS-4S Description
Shipping Brace
TDS-4S Description
1-37
Pipehandler
The main components of the pipehandler include the following (Figures 1-3 and 1-4): t Link adapter t Safety valves (Upper and Lower IBOPs) t IBOP valve actuator t Torque wrench t Link tilt mechanism The pipehandler provides two basic functions for the TDS: t Tripping 93 ft. drilling pipe stands t Providing up to 85,000 ft lb torque for makeup and break-out of connections at any height in the derrick (the PH-60d provides up to 60,000 ft lb torque) The pipehandler can be configured for various tool joint connections. It includes a link adapter and a special-purpose Varco torque wrench assembly. It also incorporates a remote IBOP valve actuator and link tilt mechanism. When not in use, the pipehandler remains stationary and free from the drill string passing through it. When tripping or performing bottom hole operations, the pipehandler is free to rotate 360, emulating the action of a standard hook.
1-38
TDS-4S Description
Link adapter
The link adapter (solid body elevator) and the elevator links (Figures 1-7 and 1-8), working in conjunction with the torque arrestors, transfer the hoisting loads to the drive stem. The drive stem is free to rotate inside the link adapter while drilling. The link adapter does not rotate with the drive stem because torque arrestors raise the link adapter up off the load supporting landing collar located on the drive stem. When hoisting loads, springs inside the torque arrestors compess to transfer the load to the drive stem by pulling the link adapter down onto the landing collar. The link adapter rotates with the rotating headwhich is required for tripping operations. The torque arrestors contain compression springs capable of supporting any stand of drill pipe in the full up position.
TDS-4S Description
1-39
Saver subs are load bearing components in the TDS and must be inspected periodically along with other load bearing components. Refer to the Maintenance and Troubleshooting book for more information.
Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
TDS-4S Description
1-41
Torque wrench
The torque wrench provides a means for making and breaking out connections with the drive stem. The torque wrench assembly consists of the following components (Figures 1-20 and 1-21): t t t t t t t t t t t Hanger Torque tube Torque tube guide ring Two torque cylinders Two clamping jaws Two clamping pistons Control manifold Lift cylinder Two stop tubes Stabbing guide IBOP actuator cylinders and arms
A hanger attached to the rotating head supports the torque wrench. The torque wrench has two torque cylinders connected to the torque tube. The clamping jaw contains a 10 in. diameter clamping piston for gripping the box end of the drill pipe. On the lower section of the upper IBOP, a female spline engages the mating male spline on the lower IBOP contained inside the torque tube. When actuated, the torque wrench rises and engages the splines on the upper IBOP. It then receives sequenced pressure to clamp the clamping piston on the box connection. After the clamping pressure develops, another sequence valve automatically opens and directs pressure to the torque cylinders. The torque cylinders can rotate up to 25 while developing a maximum torque of 85,000 ft lb (60,000 ft lb for PH-60d). One electrical push button on the VDC controls the entire torque wrench operation. The driller simply holds the button down until the connection is made or broken. The driller then releases the button to allow the unit to automatically recycle to the ready position. A two-position, air piloted hydraulic valve located on the counterbalance manifold controls the cycle. The torque wrench can also make up or break out the saver sub or the lower IBOP. A manually operated valve on the rear of the pipehandler selects either the make up or break out function.
1-42 TDS-4S Description
Torque Tube
V a r c o
Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)
TDS-4S Description
1-43
Hanger
Lift Cylinder
Torque Tube Stop Tube (2) Clamping Jaws (Inside Clamp Body)
Stabbing Guide
Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)
1-44
TDS-4S Description
TDS-4S Description
1-45
Lifting Frame
Intermediate Stop
1-46
TDS-4S Description
Lifting Frame
TDS-4S Description
1-47
The link tilt is controlled by a four-position switch. The positions are RETRACT, FLOAT, HOLD, and EXTEND.
RETRACT
In the RETRACT position, the elevator backs away from well center.
FLOAT
FLOAT returns the elevators to well center from the retracted or extended position. A 1/2-second delay is programmed into the FLOAT function to allow the control switch to travel from the RETRACT position to the HOLD position without activating the FLOAT.
HOLD
This setting extends the elevator forward to the mousehole through wellcenter.
1-48
TDS-4S Description
TDS-4S Description
1-49
Elevator links
Varco elevator links attach to the link adapter and support the drill pipe elevator. Elevator link options include: t 108 in., 350-Ton elevator links t 132 in., 350-Ton elevator links t 180 in., 500-Ton elevator links (special long links for running casing, providing 120 in. of clearance for cementing heads)
1-50
TDS-4S Description
Counterbalance system
The counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS. It provides cushioned stroke similar to that provided by the hook. The counterbalance system prevents damage to the threads of the saver sub and drill pipe by offsetting the weight of the top drive while stabbing into a connection. The system (Figure 1-27) consists primarily of two hydraulic cylinders, a counterbalance manifold, and two hydraulic accumulators. The hydraulic cylinder assemblies connect the integrated swivel bail and the traveling equipment (hook, block, becket, hook adapter, etc.). When properly adjusted, the counterbalance system supports all but about 800 lb of the weight of the top drive over a full 8 to 10 in. of travel. The system also incorporates a complete backup. The two accumulators, constantly maintained at system pressure, are always able to provide pressure to the counterbalance cylinders if the HPU is off or non-operational for any reason. For normal operation, however, the HPU is on when using the torque wrench for breaking out the top drive at the floor and is left on while making up the next stand. When adding a stand to the string during drilling operations, the driller takes a stand in the elevators and stabs it into the box in the rotary table. The driller continues to lower the TDS until the saver sub touches the box of the new stand. At this point, only about 800 lb load is on the saver sub/drill pipe connection. The counterbalance cylinders support the remainder of the TDS weight. The driller then spins in and torques up the connection with the pipehandler assembly and is ready to drill ahead. Note that the driller does not have to do anything extra to get the counterbalance system to function properly. It is a pre-adjusted system. Once drilling resumes, the HPU can be turned off and restarted again for breaking out the connection at the floor after drilling the stand down.
TDS-4S Description
1-51
1-52
TDS-4S Description
TDS-4S Description
1-53
1-54
TDS-4S Description
Service loops
The service loops transfer the required electric and fluid services between the derrick service standpipes and junction boxes, and the corresponding junction boxes and fluid connections located on the TDS. There are two kinds of loops: one containing the electric cables, and one containing air, hydraulic and water lines (water lines included only on units with a closed loop cooling system). The power electrical loop contains four 646 MCM DC power cables, one 2/0 AWG drilling motor ground cable. The other electrical service loop contains a composite cable consisting of: t 26 14 AWG conductors for auxiliary features t 4 t 2 t 2 8 AWG conductors for blower motor 5 AWG conductors for series motor field supply 14 AWG shielded pairs for the RPM pickup signal
The power and ground cables are spiral wound and potted inside a protective cover with 7 1/2 in. mounting flanges at each end. The composit cable is pathed in its own smaller service loop. This allows for easy changeout of either the power loop or the composit loop in the event of a failure. The TDS can use optional dual electrical service loops in order to meet certain regulatory agency requirements for power cable current carrying capacity. The fluids loop can consists of any combination of the following: t 3 t 2 t 1 t 2 t 2 t 3/4 in. diameter hoses for hydraulic supplies (one is a spare) 1/2 in. diameter hoses for air supply (one is a spare) 1 in. diameter hoses for purge supply 1 1/4 in. diameter hoses for cooling water (closed loop cooling systems only) 1 in. diameter hoses for retract cylinder supply and return Additional 7-conductor, 20 AWG cables as required
TDS-4S Description
1-55
1-56
TDS-4S Description
Auxiliary equipment
Auxiliary equipment is compatible with all TDS models. All of the equipment is selected or adapted for your specific rig. Below is a list of auxiliary equipment available: t Master bushing ID wear guide t Swiveling drill collar dolly t Wireline adapter t Crown height indicator t Drillers recorder tranducer kit
TDS-4S Description
1-57
1-58
TDS-4S Description
A
100 TON VARCO
8 in.
A-A
TDS-4S Description
1-59
Wireline adapter
The wireline adapter (Figures 1-28 and 1-29) attaches to the pipehandler and prevents wireline from interfering and damaging pipe and TDS components. It can be used with a lubricator held in the elevators by using 180 in. casing elevator links.
42.52 in.
26.0 in.
23.1 in.
1-60
TDS-4S Description
View A-A
Top Drive Torque Wrench
Lubricator Wireline Adapter installs in place of Torque Wrench Guard using existing Pins
To Mud Manifold
View A-A
TDS-4S Description
1-61
1-62
TDS-4S Description
IBOP CLOSE
BRAKE ON
R
5 FEET IBOP CLOSE OPEN BRAKE OFF ON
Y
10 FEET
ACTIVE/TEST
Integrated Controls
IBOP CLOSE
BRAKE ON
Purge Air in
IBOP CLOSE OPEN BRAKE OFF ON
R
5 FEET
Y
10 FEET
G
ACTIVE/TEST
VDC
Independent Controls
TDS-4S Description
1-63
1-64
TDS-4S Description
Chapter 3 Specifications
Drilling motor
Horsepower: 1,100 Maximum stall time at full power is generally about 10 seconds. Refer to the Operation book for details.
TDS-4S Description
1-65
Cooling systems
Local blower *
Flow Blower motor Typical voltage Speed Spark arrestors 3,200 cfm 20 hp 220/460 VAC, 3-phase, 60 Hz 3,450 rpm Standard style, BASEEFA approved type available
* These systems include an additional oil cooler/heat exchanger mounted on top of the gearcase on the TDS.
Closed loop
Flow Blower motor Typical voltage Speed Heat exchanger Cooling water supply Oil cooler Max. inlet temp 3,200 cfm 20 hp 220/460 VAC, 3-phase, 60 Hz 3,450 rpm 220,000 BTU/Hr. for GE motor 50 gpm at 250 foot head, measured at rig floor 6 gpm 90F
1-66
TDS-4S Description
Guide dollies
Standard rail setback 30, 39 or 48 in. (Wellcenter to centerline of rails) Standard rail spacing (Centerline of rails) Recommended rail sizes Roller size Frame material 62, 66 or 72 in. W12x53 (land masts), or W14x74, W14x90 6 in. flange and 6 in. side ASTM A-500/A-36 steel or equivalent
Pipehandler
Break-out torque Hydraulic pressure Hydraulic flow Air pressure PH-85 and PH-85H = 85,000 ft lb PH-60d = 60,000 ft lb 2,000 psi maximum 30 to 35 gpm 90 psi minimum
TDS-4S Description
1-67
1-68
TDS-4S Description
Fluid loop
Not all hoses are required for all configurations. Overall length of assembly Size Maximum working pressure
Air supply hose (2 each)
86 ft. (flange to flange) 3/4 in. ID, SAE 100-R9 3,000 psi 1/2 in. ID, SAE 100-R2 150 psi 3,500 psi 1 in. ID, SAE 100-R2 150 psi 2,000 psi 1 1/4 in. ID, SAE 100-R2 150 psi 1,625 psi 1 in. ID, SAE 100-R2 3,000 psi
TDS-4S Description
1-69
Motor space heaters (2 each) 2 - 200 watt, 110 volt VDC/instrument kit Torque meter RPM meter Various switches (0 - 1,500 Amps) (0 - 350 rpm)
1-70
TDS-4S Description
LOW GEAR
45,000
40,000
25,000
HIGH GEAR
20,000
15,000 12,000 ft lb 10,000 5,000 ft lb 5,000 120 0 0 50 100 150 200 250 300 190
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC. MAX. DURATION JUNE 3, 1991 A.N.
TDS-4S Description
1-71
LOW GEAR
HIGH GEAR
20,000 15,000
10,000 5,000 130 RPM 0 0 50 100 150 200 250 300 205 RPM
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC. MAX. DURATION REDUCED FIELD AREA IS BASED ON A 30 AMPS FIELD. FEBRUARY 19,1991 A.N.
1-72
TDS-4S Description
2-2
Contents
Preface/Manual conventions
Safety information ........................................................... 2-5 Directional references ...................................................... 2-6 Manual layout.................................................................. 2-6
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Drillers controls and instrumentation ........................... 2-23 Varco Drillers Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33
2-3
2-4
Safety information
Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the readers attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.
z e
Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.
Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
2-5
Directional references
References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.
Manual layout
This binder contains several separate books that you can remove individually for convenience.
2-6
Chapter 1 Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up has been accomplished prior to installation of the TDS. This includes: 1. Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances (Figures 2-1, 2-2, and 2-3). 2. Stops are ready for installation at the bottom of the rails. 3. Hydraulic and air standpipes are installed in the derrick, flushed clean, and pressure tested. Water piping is installed, flushed, and pressure tested as well for configurations with closed loop cooling systems. 4. All electronics are installed up to the derrick junction box: DC power leads, AC leads for blower motor, and control/ alarm signals. 5. The transfer panel is installed. 6. Rigging of the tong lines, etc. are inspected to ensure that they will not foul with the TDS and other rig equipment.
2-7
2-8
Chapter 2 Installation
2-9
1/4 in.
C Rail L
C Rail L 3/8 in. Over Full Length 1/8 in. Within 25 ft. of Floor C Rail L
3/8 in. Over Full Length 1/8 in. Within 25 ft. of Floor
C Well Center L
TDS Back Guide Rails Operational Clearance Between Top Drive And Nearest Girt or Fastline Should Be 3 in. Minimum Nearest Girt
Splice Clearance
Dolly Overhang
Maximum Rail Support Spacing 16 ft. for W12x53 Rails 25 ft. for W14x74 Rails
Rail Size
39 x 66 48 x 62 30 x 72 30 x 72
0 0 1.6 0.5
2-10
Clearance Hole For .75 in. Dia. Bolt (4 Places) 36.0 in. Motor J-Box **
Instrument J-Box **
Electrical Supply*
Filter/Regulator Lubrication Assembly**
48.0 in.
800 lb Load
B
18.0 in. Must Support 4,000 lb
Hydraulic Air Standpipes Standpipes To Be 1 1/2 in. To Be 1 1/2 in. Sch 40 Pipe* Sch 80 Pipe* Water Standpipes A To Be 2 in. Sch 40 Pipe* 86 ft. Service Loops 75 ft. Mud Hose Ref
36.0 in.
Gussets *
View B-B
83 ft. Hydraulic, Air and Water Standpipe Height and Service Loop Bracket Location
10 ft. 6 in. +0/-4 in.
7 ft. Ref
2-11
L P
9 ft. 3 in. TDS-3S 10 ft. 3 in. TDS-4S, TDS-8S 7 ft. TDS-3S 8 ft. TDS-4S, TDS-6S, TDS-8S
P L
Rail Stops
L
42,600 lb for a typical TDS-3S 48,000 lb for a typical TDS-4S 52,000 lb for a typical TDS-7S 48,000 lb for a typical TDS-8S
Rail Loading with TDS in Setback position Load P - lb Rail Spacing 39 in. x 66 in. 48 in. x 62 in. 30 in. x 72 in. TDS-3S 18,600 18,600 17,500 TDS-4S, TDS-8S 18,900 18,900 17,800
Rail Loading while Drilling - 38,000 ft lb for TDS-3S, 60,000 ft lb for TDS-4S, 68,000 ft lb for TDS-6S, 34,000 ft lb for TDS-7S and 62,250 ft lb for TDS-8S. Load L - lb Rail Spacing 39 in. x 66 in. 48 in. x 62 in. 30 in. x 72 in. 91/101 in. x 108 in. TDS-3S 3450 3680 3170 -TDS-4S, TDS-8S 5450 5800 5000 3330 TDS-6S ---3780 TDS-7S 3090 3290 2840 --
2-12
Wiring
The electrical installation requires routing power to the transfer panel and then to the TDS through the service loops (Figure 2-4). In addition, control cables are required between the service loop, the transfer panel, the SCR, the TDS Varco Drillers Console (VDC), the SCRs drillers console, the hydraulic and water pumps and the drilling recorder.
Derrick Power J-Box #6AWG/2C* Shunt Field #16AWG/10C #12AWG/20C #10AWG/4C #14AWG/2 Pr Shld #6AWG/2C* Shunt Field Derrick AC J-Box
Service Loop
Transfer Panel
Rotary Table
RBS Controls
#12AWG/3C
#16AWG/10C
Water Pump #1
Water Pump #2
#16AWG/10C
The cable requirements, depending on options selected are: Cable 646MCM (4 Shunt) (8 Series) #6AWG/2C (Shunt only) Runs SCR room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary SCR Room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary AC Power to hydraulic pumps AC Power to water pumps AC Power to transfer panel Transfer panel to derrick J-box Transfer panel to existing drillers console Transfer panel to derrick J-box Transfer panel to hydraulic pumps Transfer panel to water pumps Transfer panel to RBS unit Transfer panel to VDC RBS unit to VDC Transfer panel to VDC Transfer panel to derrick J-box Transfer panel to VDC Transfer panel to drilling recorder Transfer panel to SCR console Transfer panel to SCR room Hydraulic pumps to transfer panel Water pumps to transfer panel
#6AWG/4C #10AWG/4C
#12AWG/20C
#12AWG/3C
#16AWG/10C
Purge control system (not shown) #12AWG/3C Purge control unit to transfer panel Isolation unit to floor air control unit Transfer panel protection unit to isolation unit Purge control unit to transfer panel VDC protection unit to isolation unit Transfer panel to derrick J-box
Terminate the J-boxes per the electrical schematic. Follow applicable electrical codes during installation. Cable glands are provided for the service loop cables. Cable glands for the incoming power, control and signal cables are not provided.
2-14 TDS-4S Installation and Commissioning
Plumbing
The plumbing connections should terminate near the service loop bracket. The mating halves are preassembled on the service loop. Specifications for specific lines are described in the following sections.
Hydraulic
Hydraulic lines should be cleaned and pickled, black pipe lines (one pressure and one return) 1 1/2 or 2 in. schedule 80 pipe. Install shut-off valves at the drill floor or racking board level. The derrick connections are reduced to 1 in. NPT female pressure and fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of the purge supply for the TDS. Install a shut-off valve at drill floor or racking board level. The air lines connect to the filtered and lubricated supply. The derrick connections are reduced to 1 in. NPT female for the purge line (if required) and 1/2 in. for the air line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean, dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2 in. pipe. Install shut-off valves at the drill floor or racking board level. See the cooling system specifications for water supply requirements. The derrick connections are reduced to 1 1/4 in. NPT female pressure and return for connection to the fluids service loop.
2-15
Rig-up procedure z
Refer to the engineering drawings to install the TDS. 1. Using four lift slings from the crane, one attached at each corner of the guide dolly, lift the TDS motor and dolly assembly to the V-door. 2. Attach the lifting slings from the hook or block to the pad eyes located at the swivel end of the motor support bonnet and lift the TDS into the guide rails. The slings must be a minimum of 15 ft. long (equal length) and capable of lifting 40,000 lb combined. (BOP stack lift slings are usually adequate.)
On some configurations it may be necessary to remove the upper roller brackets from the dolly to allow the unit to engage the guide rails. 3. Once the TDS is fully engaged on the guide rails, install the stops at the bottom of the guide rails and lower the TDS onto the stops. 4. Slide the link adapter onto the drive stem and support it up against the rotating head with adequate rigging and an air winch. Be certain that the link tilt mounting bosses are opposite from the torque wrench mounting clevis on the rotating head. 5. Slide the landing collar retainer onto the drive stem as shown in Figure 2-5. Install the O-ring in the uppermost groove on the stem. Load the O-ring and remaining grooves with a waterproof grease. Place the split landing collar around the grooves of the drive stem, and drive in the remaining roll pin. Grease the OD liberally. Wipe off excess grease. 6. Use the installation procedure in the IBOP Service Manual to install the pipehandler assembly. 7. Use the pipehandler to tighten the connection between the lower IBOP/saver sub assembly to the upper IBOP.
2-16
O-Ring
Drive Stem
2-17
10. Install the counterbalance system as illustrated in Figure 2-6. When using chain, use the following procedure to determine the chain length required: a. Install pear links to ears on hook-block. b. With the hook supporting the TDS, measure the distance from the point of contact inside the pear link to the top of the mounting lug on the integrated swivel bail. c. Subtract 37 1/4 in. from the measurement in step b. d. Cut the chain to the length obtained in step c. The tolerance is: +3 1/4 in. or -0 in. e. Assemble remaining components and install per Figures 2-6 and 2-7. 11. Attach the service loops to the bracket on the TDS dolly frame. Using the cable clamps provided on the motor support bonnet, route the electrical cables over the gear box and into the J-boxes. The front guard folds down for access to the Jboxes. Use the electrical schematic (refer to the engineering drawings) to make the connections. Be certain that the cables are securely tied or clamped to the structure along their length. Route the hoses to the bulkhead and plug in the quick disconnects. Follow the stamped code numbers to confirm each type, and identify spares. 12. Attach the S-tube to the swivel gooseneck and the side of the motor frame as follows: a. Make up the upper union just before clamping the S-tube to the side of the motor frame. b. Install the drill pipe rubber onto the S-tube aligned with the mounting saddle on the frame. c. Attach the mud hose to the bottom connection of the S-tube. d. Position the 20 S-tube elbow on the bottom of the S-tube to adjust the hanging direction of mud hose. 13. Remove the exhaust duct shipping covers from the spark arrestors on the air exhaust duct at each side of the DC motor. Save the covers for use during future shipping or storage.
2-18
2-19
Loop Assembly
Guide Assembly
Cylinder Assembly
Hose Assemblies
Never operate the top drive with the exhaust duct covers attached to the spark arrestors on the air exhaust ducts. Doing so severely restricts air flow through the motor, causing overheating and potential damage. They can also fall off during operation and injure personnel working below. Attach the covers only during shipping and storage.
2-20
Counterbalance system
Figures 2-6 and 2-7 illustrates the installation arrangement for this system. Please see the Maintenance and Troubleshooting book for the adjustment procedures. This assembly is pre-charged when it is shipped by land or water transport. When this assembly is shipped by air freight, it must be pre-charged according to the instructions in the Maintenance and Troubleshooting book.
2-21
Shipping Brace
2-22
Wiring
Refer to the electrical schematics in the engineering drawings.
Customers who choose to use control systems not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel or damage to the system. Other systems must meet Varco requirements. Varco highly recommends the use of its system as it is specifically made for use with the TDS.
2-23
Service loops
Installation
Install the service loops as follows: 1. Fabricate the appropriate brackets and clamps to attach the service loop mounting bracket to the derrick structure. 2. Place the service loop derrick mounting bracket at the height specified on the derrick interface drawing provided in the engineering drawings. Locate the bracket on the side of the derrick adjacent to the hinges on the TDS and as far as practical toward the corner where the guide rail bracing is attached. The bracket must be located far enough from the corner to insure the loops do not catch under the guide rails during operations, but far enough back to provide clearance for tong lines, the stabbing board, tugger lines, etc. 3. Do not unpack the service loops from the shipping protective crate until they are ready to hang in the derrick. Lift the service loops onto the rig floor (still in the crates) and then remove them from the crates with the lifting eyes provided.
Use care in lifting gear rigging so as not to damage electrical conductors. Use lifting eyes only. Do not bend the service loops tighter than a three foot bend radius. Tighter bends damage the loops. 4. Attach a sling to the TDS end of the service loop and lift using the lifting eyes only. Allow enough room for the 86 ft. service loop to hang and untwist. 5. Use the lifting eyes to pull the derrick end of the loop through the V-door and attach it to the air tugger. Hoist this end of the loop into the derrick while slacking off at the crane end. Do not drag the loop on any sharp areas on the derrick. Disconnect the crane from the sling and continue hoisting the loop into the derrick. 6. Check that the derrick end of the loop is hanging toward the crown. Attach the derrick end to the derrick service loop bracket and hold in place with flange clamps (Figures 2-2).
2-24
7. Pick up the TDS end of the loops and attach them to the service loop bracket at the bottom of the motor frame. 8. Complete the terminations of the two loops as outlined in the following sections.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes using the appropriate glands. Refer to the electrical schematic provided to ensure proper terminal block assignments. 2 Cut wires and cables to length and terminate them at the derrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assembly equipment (crimping pliers, wire strippers, and hydraulic crimper for the DC power lugs with the correct dies for the cable) must be provided by the installer. Installation practices should comply with applicable electrical codes (i.e., NEC, etc.).
Fluids loop
1. Before connecting the hoses from the service loop, be certain that the service stand pipes have been flushed free of any contamination.
Use only 10 wt. hydraulic oil or non-detergent motor oil as a lubricant in the air system. Use of any other type of oil (i.e., Marvel Mystery Oil, etc.) or synthetic additive will cause the seals in the air valves to swell and cease to function. 2. Plug the quick disconnects into the appropriate mating end on the TDS. The quick disconnects are arranged to connect only one way so that the hoses cannot be mixed up. The hydraulic and air lines are identification stamped at both ends so they can be verified and connected properly. An assortment of pipe fittings are supplied with the termination kit to attach the fluid service loop hoses to the top of the standpipes in the derrick (Figure 2-2).
2-25
3. Connect the service loop to the standpipes, noting the codes (i.e., A for air, H for hydraulic, etc.) to separate the hoses.
z e
The hoses in the fluids loop only extend 11 ft. from the mounting bracket. It may be necessary to make jumper hoses to reach the standpipes.
Air loop
To reduce the possibility of accidental opening of the air-operated elevator, attach the airlines from the air-operated elevators to the spare port S1 on the rotating head whenever possible. Port S1 is located next to the hydraulic return port in the rotating head. Port S2 is next to the hydraulic press port. Install a pressure relief valve on the elevator and set at 200 psi.
2-26
Retract loop
If your rig is equipped with a retract guide dolly, attach the retract loop to the derrick mounting brackets as follows:
There are four separate service loops needed for a TDS with retractable dollies: two electrical loops, a fluids loop, and a retract system loop. The electrical and fluids service loops attach to the derrick service loop mounting bracket, the retract loop attaches to the retract system service loop bracket. 1. Lift the crate containing the retract system service loop onto the rig floor. 2. Uncrate the service loop. 3. Attach an air winch to the lifting eyes on the derrick end (derrick end has 8 ft. of hose extending beyond the flange) and hoist to the retract system mounting bracket. 4. Attach the service loop flange to the mounting bracket with the hardware provided. Ensure that the service loop hangs straight in the derrick without any twists or kinks.
Use only 10 wt. hydraulic oil or non-detergent motor oil as a lubricant in the air system. Use of any other type of oil (i.e. Marvel Mystery Oil, etc.) or synthetic additive will cause the seals in the air valves to swell and cease to function. 5. Connect the retract service loop hydraulic and pneumatic hoses to the derrick standpipes.
Before connecting the hoses from the service loop, be certain that the standpipes have been flushed free of any contamination.
2-27
2-28
Chapter 3 Commissioning
Checkout procedures
1. Turn on the hydraulic and air power and check for leaks. Repair as required. 2. Turn on the electric power (drillers controls only). 3. Check the function of switches and solenoids. There is an audible click when each solenoid is actuated. 4. Actuate the link tilt. Be sure that it operates smoothly and the elevator reaches a joint in the mousehole. 5. Adjust the intermediate stop so that the elevator clears the monkeyboard when actuated. Refer to the Maintenance and Troubleshooting book if a problem occurs. 6. Actuate the motor brake. There is a loud sound as the air escapes when the brake releases. 7. Move the Make/Break valve located on the manifold at the back of the pipehandler torque wrench to the BREAK position. 8. Turn on the hydraulic power supply and adjust the pressure reducing valve (also located on the torque wrench manifold) to the appropriate pressure for the lower IBOP connection.
2-29
9. Return the Make/Break valve to the MAKE position. 10. Torque the connection between the upper and lower IBOP valves. The torque wrench automatic sequence is adjusted at the factory, but be sure that it follows the proper sequence. If necessary, refer to the Maintenance and Troubleshooting book for the adjustment procedure. 11. Push and hold the makeup button on the VDC a sufficient number of times to make up the connection. 12. Make up the lower IBOP to the saver sub. 13. Reset pressure to the appropriate setting for drill pipe connections (you can preset the pressure with the Make/Break valve in the MAKE position). 14. Use the procedure outlined in the Maintenance and Troubleshooting book to adjust the safety valve actuator mechanism. 15. Actuate the IBOP valve. Verify that the stroke adjustment is correct and that no binding occurs.
It is extremely important to verify that the stroke adjustment is correct and that no binding occurs as the valve will fail prematurely (wash out) if it does not open and close fully. 16. Verify that the indicator light on the VDC lights up when the IBOP valve is closed. 17. Assign the TDS at the drillers console and check that the blower operates. 18. Advance the throttle and be sure that the motor is operating properly in both directions. 19. Calibrate the Torque meter and RPM meter. 20. With the Hydraulic Power Unit (HPU) off, bleed down the TDS accumulators (HYD SIDE, not gas side). 21. Remove the split shipping brace (Figure 2-7) from the motor alignment cylinder. 22. Open the two flow control valves 1-1/2 turns off their seats. 23. Set a joint of drill pipe in the slips.
2-30
24. Bring the TDS down as if stabbing the saver sub into the box. The pin and box should be in alignment. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with the drill pipe box. b. Turn off the HPU and bleed down the cylinder accumulator (open the needle valve on the back of the manifold). This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions until the integrated swivel bail contacts the motor support bonnet. c. Loosen the lock tab and jam nut on the cylinder clevis. d. With a wrench tightened on the cylinder rod flats, screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. e. Secure the jam nut and lock tab. f. The nominal position of the two cylinder flow control valves is 1-1/2 turn off their seats. If you experience heavy drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface. If motor movement becomes excessive due to continued vibration, (more than 1/2 in. of total cylinder stroke) close the flow controls to 3/4 turn off their seats.
2-31
2-33
2-34
Operation
SM00620-3
3-2
TDS-4S Operation
Contents
Preface/Manual conventions
Safety information ........................................................... 3-5 Directional references ...................................................... 3-6 Manual layout.................................................................. 3-6
TDS-4S Operation
3-3
3-4
TDS-4S Operation
Safety information
Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the readers attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.
z e
Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.
Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
TDS-4S Operation
3-5
Directional references
References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.
Manual layout
This binder contains several separate books that you can remove individually for convenience.
3-6
TDS-4S Operation
Start-up procedure
Use the following procedure to start up the TDS: 1. Place the blower/oil pump switch in the AUTO position. 2. Place the hydraulic power unit (HPU) switch in the PLC position. 3. Place the water pumps switch in the PLC position. 4. Place the motor space heater switch in the ON position. 5. Place the top drive/rotary table (TDS/ROT) lockout switch in the TDS position. 6. Assign a SCR.
TDS-4S Operation
3-7
Do not leave the top drive DC motor stalled in a high torque condition generally for more than 10 seconds (refer to the following table): Amps 280 470 670 820 Stall time (sec) 240 90 45 30 Amps 900 1000 1200 1400 Stall time (sec) 25 20 15 10
3-8
TDS-4S Operation
TDS-4S Operation
3-9
External HI / LO Indicator
Bottom View
Low Gear Eccentric Shaft (Disengaged)
Geneva Mechanism
Top View
3-10
TDS-4S Operation
LO
Shifter Input
HI
Pipehandler operation
Standard rotating head
The perimeter of the rotating head cam (Figure 3-2) has an indented area where the cam follower normally rests. When the cam follower is in this indented area, the return cylinder rod is fully retracted and hydraulic pressure inside the cylinder is at equilibrium. When the swivel block and cam rotates to another position along with the drill string, the ramp of the cam extends the return cylinder rod, unbalancing hydraulic pressure in the cylinder. When the elevator is released, the system automatically returns to its pre-selected (indented) position (equilibrium). To operate the swivel block locking mechanism, pull down the locking lever, pulling the locking pin out of one of 24 locking slots in the cam. With the locking lever in the vertical position, manually rotate the swivel block to the desired position and release the locking lever, setting the pin.
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return Cylinder
Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown)
TDS-4S Operation
3-11
Controls
The powered rotating head is controlled by two switches.
ROTATING HEAD LEFT/RIGHT switch
This switch rotates the powered rotating head, pipe handler, and link tilt to the right or left (same direction as the drill string). Rotation only occurs when the switch is held in the RIGHT or LEFT position. Rotation stops when the switch returns to the center position.
The ROTATING HEAD function is only active when the LINK TILT switch is in the FLOAT position.
AUTO STOP/FREE ROTATE switch
This switch is in the AUTO STOP mode when the light is illuminated (on). In the AUTO STOP mode, a proximity sensor automatically stops rotating head rotation. The AUTO STOP function is independent of the direction of rotation. Rotation continues when the ROTATE switch returns to the center position, then activated again. When the AUTO STOP/FREE ROTATE light is off, the FREE ROTATE mode is active. In this mode, the rotating head rotates as described in the ROTATING LEFT/RIGHT section above.
3-12
TDS-4S Operation
Stationary Flange
Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly
Bull Gear
S1
A1
H1
PRESSU
A1
S2
RE
A5
H2
S2
A2
H3
A3
H2
S1
A2
TDS-4S Operation
H1
A3 H3 A5 A4
A4
3-13
3-14
TDS-4S Operation
Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
TDS-4S Operation
3-15
Torque wrench
The primary function of the TDS torque wrench is to breakout the drill string from the saver sub before making a connection. The torque wench can also make connections if necessary (i.e., when replacing the lower IBOP or saver sub, or while backreaming, or when adding a pup joint to the drill stem). The torque wrench has a control manifold with the following components (Figure 3-5): t Hydraulic pressure gauge t Control and sequencing valves t Hydraulic hose inlet and outlet Quick Disconnects (QDs) t Manual Make/Break directional valve The Make/Break valve controls the torque wrench operating direction (makeup/breakout) during operation. A pressure reducing valve (PRV) on the control manifold allows presetting the makeup torque (this valve is bypassed when the torque wrench is in breakout mode). When the driller actuates the torque wrench from the VDC, the lifting cylinder rod retracts, raising the torque tube to engage the splines on the upper IBOP. A sequenced signal from the control manifold then operates the clamping piston, clamping the jaws onto the drill string box connection. Then another sequenced signal from the control manifold automatically directs pressure to the torque cylinders, rotating the torque tube up to 25 while developing a maximum torque of 85,000 ft lb (65,000 ft lb on the PH-60d Pipehandler). The position of the Make/Break valve on the control manifold determines the direction that the torque tube rotates. A two-position, air-piloted, hydraulic valve located on the counterbalance manifold located on top of the TDS guide dolly controls the entire sequenced cycle described above. A push button switch on the VDC operates the hydraulic valve. The driller holds the button down to makeup or breakout a connection, and then releases the button to allow the torque wrench to automatically recycle to the ready position. If the torque developed on the first pass is insufficient, the driller simply operates the button again.
3-16
TDS-4S Operation
Manually switch the Make/Break valve on the torque wrench to the MAKE position to use the top drive torque wrench to make connections. This allows the driller to initiate automatic torque wrench sequences and repeat them until reaching the preset makeup torque.
Make/Break Valve
BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE
MAKE
PRV
40
50
60
70
30
1000
1500
80
LIFT LOWER
20
500
2000
90
10
2500
10
PSI Ft.Lbs.
x1000
TDS-4S Operation
3-17
Failing to apply the correct amount of torque when using the torque wrench to makeup connections can result in equipment damage and injury to rig personnel. Do not switch the Make/Break valve to BREAK until completing the makeup sequence, which may require repeating the makeup sequence several times. Verify the torque pressure regulating valve setting after every makeup sequence before releasing the makeup valve. Repeat the makeup sequence until the torque cylinders do not stroke more than one inch during the final sequence, repeat the sequence if uncertain. Varco recommends that the driller operating the pipehandler verify that the torque cylinders do not stroke more than one inch on the last makeup cycle. Varco also recommends checking the torque gauge on the pipehandler while making connections to make sure the torque wrench applies the correct amount of torque to the connection. Stop and verify correct operation whenever the operator observes unsteady or inconsistent hydraulic pressure readings, or finds it difficult to adjust set points. Varco recommends that a second individual assist the driller when making connections with the torque wrench. The second person can verify that the torque wrench applies the correct torque to connections.
3-18
TDS-4S Operation
PH-60d
To operate the torque wrench with a 3 1/2 in. drill string, install a separate drill string handling kit. The following lists available kits for a PH-60d: t Part No. 78652-1 Includes stabbing guide assembly, jaw assemblies, saver subs, installation drawing. t Part No. 78652-2 Includes stabbing guide assembly, jaw assemblies, installation drawing.
Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No. 78652-2 does not. By purchasing the latter, the user assumes responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver subs separately. Specifications for these are available from the factory or any Varco service center.
TDS-4S Operation
3-19
6 5/8 in. API Reg. 7 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 6 5/8 in. API Reg. 7 3/8 in. 7 5/8 in. API Reg. 7 5/8 in. API Reg. 9 in. 9 in.
7 5/8 in. API Reg. 7 5/8 in. 7 5/8 in. API Reg. 9 in.
3-20
TDS-4S Operation
Drilling ahead
Drilling ahead with triples
Drilling ahead with triples is the common drilling mode for the TDS. There are various sources for triples. On skidding rigs drilling multiple well platforms, drill pipe can be left racked and used to drill the next well. If triples do not currently exist, there are two recommended methods of obtaining them. One is to leave some triples racked in the derrick when tripping back in the hole and finish the trip with singles. Leave enough triples racked to handle anticipated bit life. The second method for obtaining triples is to make up triples in the mousehole while drilling ahead or during idle rig time. For safety reasons a pivoting mousehole is best because it can pivot to a vertical plane to simplify making connections. Use the following procedure to drill ahead with triples (Figure 3-6): 1. Drill down until the saver sub is within three feet of the rotary table. 2. Circulate bottoms up as necessary. 3. Stop the string rotation. 4. Pick up the string and set slips for a connection four feet off the rig floor. 5. Switch the TDS motor from FORWARD to REVERSE. 6. Stop the mud pumps. 7. Close the IBOP. 8. Break out the drill pipe connection using the torque wrench on the pipehandler. 9. Using the TDS motor, spin out of the box while hoisting the TDS with the drawworks (follow with the drawworks, do not lead).
TDS-4S Operation
3-21
Set slips on string Stop circulation Breakout connection using pipehandler and drilling motor (in reverse)
Lower block to stab motor into top of stand Spin in motor and stand Makeup both connections with motor
1
Link Tilt
Makeup
Start Circulation
3-22
TDS-4S Operation
10. Stop the spin out mode. 11. Open the drill pipe elevators. 12. Retract the TDS away from the hole. 13. Hoist the TDS to the racking board level to get the next stand. 14. Latch the backup tong on the box connection. 15. Thoroughly dope the box connection in the rotary table. 16. When the TDS is fully raised, extend the TDS. 17. Tilt the links. 18. Switch the TDS motor from REVERSE to FORWARD. 19. Derrickman latches the elevator on the next stand. 20. Hoist the pin off setback area and clear the box with the stand. 21. Release the link tilt. 22. Stab the connection at the floor. 23. Switch the TDS to SPIN IN mode. 24. Continue to slack off approximately two feet to stab the upper connection of the stand with the TDS. 25. Slack off to allow connection to shoulder up (lead with the drawworks, do not follow). 26. Switch to TORQUE and hold for approximately six seconds. The makeup torque is preset. 27. Verify full makeup to the correct value on the torque meter. 28. Switch to DRILL mode. 29. Unlatch the backup tong. 30. Open the IBOP. 31. Start the mud pumps. 32. Pick up to pull the slips. 33. Drill ahead.
TDS-4S Operation
3-23
3-24
TDS-4S Operation
Set slips on string Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse)
Pickup single with elevator Release link tilt Stab bottom of single onto string
Lower block to stab motor into top of single Spin in motor and single Makeup both connections with motor in torque mode
Makeup
TDS-4S Operation
3-25
Raise block Extend RBS and adjust height Pickup stand Stab stand using RBS to assist
Makeup
Start Circulation
TDS-4S Operation
3-27
Tripping
Perform tripping operations in the conventional manner. Use the link tilt feature to tilt the elevator to the derrickman so the derrickman can quickly latch it around the pipe. The hydraulic link tilt allows the elevator to also reach the mousehole. The air actuated link tilt has an intermediate stop which is adjustable to set the elevator at a convenient working distance from the monkeyboard. The intermediate stop tilts out of the way to allow the elevator to reach the mousehole. If a tight spot or key seat is encountered while tripping out of the hole, spin the drilling motor into the stand at any height in the derrick. Establish circulation and rotation immediately to work the pipe through the tight spot.
3-28
TDS-4S Operation
Reaming out
The TDS permits reaming out of an open hole to prevent pipe sticking and to reduce key seat formation, without affecting racking functions associated with normal tripping (i.e., there are no singles to contend with). The pipehandler torque wrench can break out 90 ft. stands in the derrick. Use the following procedure to ream out of the hole (Figure 3-9): 1. Hoist the block while circulating and rotating the drilling motor until the third connection appears. 2. Stop circulation and rotation and set the slips. 3. Break out the drilling motor from the top of the stand using the pipehandler torque wrench. Hold a backup at the floor and spin out the drilling motor. 4. Break out the stand at floor level, and spin out using pipe spinners. 5. Pick up the stand with the drill pipe elevator. 6. Rack the stand back. 7. Lower the block and TDS to the floor. 8. Stab the drilling motor into the box, spin up and torque it with the drilling motor. With light slip loads, the pipehandler torque wrench can be used to torque the connection. 9. Resume circulation and continue reaming out of the hole.
TDS-4S Operation
3-29
Hoist while circulating and rotating When 3rd connection surfaces, stop rotation and circulation
Set slips on string Breakout connection using pipehandler and drilling motor (reverse) Breakout and spinout stand at floor
Lower block, stab motor into string Spin in motor and makeup connection with motor Start circulation, pull slips, hoist and rotate
1
Breakout
2
Hoist
4
Setback
Breakout
3-30
TDS-4S Operation
TDS-4S Operation
3-31
Running casing
For casing operations, longer elevator links (180 in.) must be used to allow clearance for the cementing head under the torque wrench in the pipehandler. Attach a short piece of hose to the saver sub in the pipehandler to fill the casing while lowering. Use the remotely controlled upper IBOP valve to start and stop the fluid flow. If desired, run casing conventionally using the block and hook and swinging the TDS aside. Use longer bails (180 in.) to prevent the block dolly (if used) from contacting the TDS dolly.
3-32
TDS-4S Operation
A
Drill Pipe Elevator
A
100 TON VARCO
8 in.
A-A
TDS-4S Operation
3-33
3-34
TDS-4S Operation
4-2
Contents
Preface/Manual conventions
Safety information ........................................................... 4-7 Directional references ...................................................... 4-8 Manual layout.................................................................. 4-8
Chapter 1 Maintenance
Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Maintenance and Troubleshooting 4-3
Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97
4-4 TDS-4S Maintenance and Troubleshooting
Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111
This section contains some information regarding the GE motor. Refer to the GE Motor Service Manual, VDR00023 (included in VDP0001) for specific details such as: t Inspection and maintenance schedule t Recommended storage instructions drilling motors and generators t Removing motors or generators from storage
4-5
4-6
Safety information
Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the readers attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.
z e
Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.
Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
4-7
Directional references
References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.
Manual layout
This binder contains several separate books that you can remove individually for convenience.
4-8
Chapter 1 Maintenance
Inspection
TDS swing out procedure
Varco top drives with swing-out guide dollies can be quickly swung aside on their own dolly frames for inspection, maintenance, running casing, or to allow drilling operations requiring a kelly and rotary table. Electrical, hydraulic, and air supplies do not have to be disconnected. Use the following procedure to swing out the TDS only if your rig has a guide dolly with hinge pins (refer to the engineering drawings for information specific to your rig configuration): 1. If you have a retract system, operate the switch on the VDC to retract the TDS. 2. Slowly lower the TDS until the elevator nears the rig floor. 3. Remove the elevator and elevator links. 4. Lower the TDS guide dolly to the stop.
4-9
On some rigs, it may be necessary to secure the traveling block frame to the guide dolly frame using chain and/or rope. 5. Turn off the Hydraulic Power Unit (HPU) and bleed down hydraulic pressure by opening the needle valve on the counterbalance manifold. (The counterbalance manifold is located on the upper motor frame.) 6. Detach the counterbalance system cylinders from the hook or block by unhooking the pear links from the ears on the hook or block. 7. Disconnect the air intake hose. 8. Disconnect the mud hose from the TDS S-tube.
Unlatching the hook from the integrated swivel bail may cause the TDS motor assembly and/or the hook to lurch suddenly. Always keep adequate tension on the tailing lines to prevent sudden movement of these assemblies. 9. Unlatch the hook. 10. Attach tugger lines to the TDS motor frame, opposite the frame hinges, to assist in swinging out the TDS motor assembly. Use tailing lines on the motor frame to control swing out. 11. Unfasten the two swing-out bolts, opposite the hinges, holding the motor frame to the guide dolly. 12. Operate the air tuggers to slowly pull on the motor frame while unhooking the traveling block from the swivel bail. 13. When the traveling block is disconnected, continue swinging out the TDS 180 and secure the motor assembly to the derrick with chain and/or rope.
4-10
To swing the TDS back in for operation after inspection or maintenance, perform the following procedure: 1. Lower the guide dolly far enough to allow swinging the TDS back into place. 2. Retract the TDS and secure it.
While latching the hook to the integrated swivel bail, the swivel and/or the TDS motor assembly may suddenly lurch. Always keep adequate tension on tailing lines to prevent sudden movement of these assemblies. 3. Attach tugger lines to the TDS motor assembly, opposite the hinges, to aid in swinging back the TDS assembly. Use tailing lines on the motor frame to control swing back. 4. Release the chain and/or rope securing the TDS motor assembly to the derrick and slowly swing back the TDS motor assembly to the guide dolly. While swinging it back, latch the hook onto the swivel. 5. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the hinges. 6. Connect the mud hose to the S-tube. 7. Connect the air intake hose. 8. Hook the counterbalance system pear links onto the ears of the hook or block. 9. Turn the HPU on and bleed air out of the system.
4-11
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide dolly assembly for loose bolts and fittings daily. If any safety wire or cotter pins were removed to facilitate repairs, replace them immediately.
The DC motor has a complete manufacturers service manual for your reference provided in the Vendor Documentation Package.
The alignment cylinder is not intended to be used to align the pin with the box at the well bore. It is a device to counterbalance the offset weight of the DC motor and allow the system to accommodate external forces. It is adjustable to ensure that the mainshaft is straight at well centerto compensate for design tolerances in the guide rails and dolly. To work properly, the guide rails must be properly located, and the dolly must fit within design tolerances. Check alignment cylinder operation weekly. Also, inspect all moving parts and check accumulator pressures on a weekly basis.
4-12
Varco supplies a filter/regulator/lubricator in the derrick installation kit and recommends installing it at the fingerboard level in the derrick. Improperly adjusted regulators can cause poor device performance at reduced pressures, or valve and cylinder seals and O-ring extrusion at excessive pressures. Inspect the entire filter/regulator/lubricator monthly for damage to the filter bowl, overall body, or inlet and outlet fittings. Replace any damaged, corroded, or improperly functioning components. Adjust the pressure regulator outlet pressure to 100-120 psig monthly. Clean and drain the filter weekly. Fill the lubricator with petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU at 100F (ISO 32/34).
Do not use fluids such as Marvel Mystery Oil, motor oil, or Dextron II in the lubricator. Swollen seals may result.
4-13
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire or cotter pins were removed during repairs, replace them immediately. Inspect the hinge bolts daily to make sure they are not separating from the pipehandler. Make sure the hinge pins are not loose due to excessive wear in the bore of the clamp clevis or a broken retaining bolt.
Inspect the link tilt intermediate stop and adjustment device for overall integrity weekly. Replace the components if there is excessive looseness of the threaded rod in the threaded hole of the pivot arm (Figures 4-24 and 4-25). An indication of a possible problem is if the two intermediate stops are not adjusted equally (i.e., if the thread engagement differs between the two stops). Failure to perform this inspection and/or component replacement can result in injury to rig personnel.
NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on the elevator link eyes (Figure 4-1). Compare the measurements with the Wear Chart (Figure 4-1) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.
4-14
B = 4 1/2 in., 500-Ton 6 in. 5 3/4 in. 5 1/2 in. 5 1/4 in. 3 1/2 in. 3 1/4 in. 3 in. 2 3/4 in. 500 420 325 250 A
B = 6 1/4 in., 750-Ton 7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in. 7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in. 350 300 225 175
To determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link.
A
Lower Eye (Elevator)
4-15
Landing collar
Disassemble and inspect the landing collar every six months. Use the following procedure to disassemble the landing collar (Figure 2-5) for inspection: 1. Disconnect the top drive from the drill string. 2. Remove the IBOPs and pipehandler. 3. Raise the solid body elevator to expose the landing collar retainer. 4. Straighten the retainer tabs. 5. Slide the retainer ring above the split landing collar halves. 6. Drive out one roll pin. 7. Remove the landing collar halves. 8. Slide the retainer off the drive stem. After disassembly, inspect all landing collar parts for wear, damage, or corrosion. Check for: t Grooves or other radial wear marks indicating that the bore of the solid body elevator is rubbing on the outside diameter of the landing collar retainer shell t Radial grooves on the inside diameter of the retainer shell t Missing tabs from the retainer shell t Wear or corrosion induced pitting on the retainer shell shoulder t Wear, corrosion, or fatigue cracks on the inside or outside diameter of the landing collar halves t Evidence of drive stem contact with the solid body elevator t Evidence of inside bore wear on the solid body elevator indicating contact with the drive stem or landing collar retainer. Wear on the inside shoulder of the elevator should not exceed 1/8 in. t Evidence of wear, corrosion, or fatigue cracks on the safety links
4-16
Replace the appropriate part(s) if any of the above conditions exist. Use the following procedure to reassemble the landing collar: 1. Replace the existing O-ring in the retainer shell. 2. Grease the inside diameter of the retainer shell. 3. Slide the retainer onto the drive stem above the landing collar grooves. 4. Install one new roll pin and safety links on the split landing collar halves. 5. Coat the landing collar halves with a generous amount of water resistant grease. 6. Place the landing collar halves on the drive stem with 15 taper closest to the top drive. 7. Drive in the remaining roll pin. 8. Slide the retainer shell over the landing collar halves. 9. Use a hammer and drift to bend all 32 retainer tabs to secure the retainer shell. 10. Coat the retainer shell and drive stem with a generous amount of water resistant grease to prevent corrosion. 11. Reinstall the IBOPs and pipehandler.
4-17
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear. Remove the drive stem/mainshaft from service if bore wear is greater than the dimensions shown in Figure 4-2. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections.
650-Ton
1.30 Minimum @ Landing Collar Grooves (2.45 New) (1.70 New) 3.75 Diameter (New)
9.000 Diameter
750-Ton
1.30 Minimum @ Landing Collar Grooves (2.45 New) (1.70 New) 3.00 Diameter (New)
9.000 Diameter
Figure 4-2. Typical minimum bore wear dimensions (Refer to engineering drawings for exact dimensions)
4-18
Use the following API recommended guidelines (Figures 4-3) to determine the tensile load bearing capacities of the drive stem/ main shaft landing collar.
3800000 3700000 3600000 3500000 3400000 3300000 3200000
Load (Lbs)
3100000 3000000 2900000 2800000 2700000 2600000 2500000 2400000 2300000 2200000
1.75
1.70
1.65
1.60
1.55
1.50
1.45
1.40
1.35
1.30
1.25
1.20
1.15
1.10
1.05
1.00
Figure 4-3. 750-Ton and 650-Ton drive stem/main shaft landing collar tensile dimensions
0.95
4-19
4-20
Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a components integrity. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.
Safety valve inspection procedures (IBOP)
Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).
4-21
4-22
Chapter 2 Lubrication
4-23
3. Repack the inside area with grease every six months (refer to Figures 1-9 and 1-10 in the Description book). 4. Inspect the gears for corrosion or damage. Clean, lubricate or replace components as required. There is a timing mark on the gears to ensure correct orientation. If these marks are not visible when removing the gears, mark the gears before removal to ensure correct orientation when reinstalling them. If there are problems shifting from one gear to the other, use the following procedure to shift the gears: 1. Turn the drive stem with chain tongs to make sure the gear mesh aligns properly. Do not turn the DC motor while shifting gears. 2. Insert two 3/8 in. bolts in the threaded holes on the bottom of the shafts while shifting the gears and use a bar to turn the shaft in the proper direction. Do not shear the bolts. Eccentric shaft rotation direction is the same as the shifter input shaft when shifting into gear. 3. If the shift input mechanism slips when attempting to shift gears, use a torque wrench to check the torque of the shifter when the clutch begins to slip. If the torque is less than 65 ft lb, then use the Torque setting procedure to adjust the clutch
Gearbox oil must be drained before removing clutch. The factory setting of the clutch is 45 ft lb. However, increase the torque if there are persistent problems. 4. Remove the 3 in. inspection plugs on the rear of the gearcase and make sure the compound gears are free to turn with the unit in neutral. If the gears cannot turn, it indicates a larger problem (i.e., contaminants in gears, damaged bearings, etc.).
4-24
4-25
,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,
Gear Subplate
Lower Gearcase
,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,,
,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,, ,,,,,,,,,,,,
Detail A
4-26
4-27
Oil capacity
The TDS-4S holds approximately 10-20 gallons of oil, but oil capacities vary according to the type of cooling systems, etc. installed. Always fill the transmission to the middle of the sight glass. Use the following procedure to fill the transmission for the first time on a new top drive: 1. Fill the gearbox to the top of the sight glass (approximately 10-20 gallons). 2. Operate the top drive 10-15 minutes and check the sight glass. 3. The oil level should be near the middle of the sight glass. If the oil level is below the middle of the sight glass, add more oil until the level reaches the middle of the sight glass. If the oil level is at, or above the middle of the sight glass, do not add any additional oil to the gearcase. After installation and initial operation of the top drive, always fill the transmission to the middle of the sight glass. When draining oil from the drain plug at the bottom of the gearcase, only the 5-6 gallons of oil at the bottom of the gearcase actually drains. Oil still remains in the rotating head cavity (approximately 1-2 gallons), the oil lube/pump/cooler system (approximately 1-2 gallons), and the wetted surfaces inside the motor housing assembly (approximately 2-3 gallons). Removing the suction hose from the cover plate below the pinion shaft allows more oil to drain and also removes sediment that collects there. Removing the oil drain plug from the rotating head allows more oil to drain.
4-28
Excessive lubrication of electric motors can cause motor failure due to shorting or heat buildup from grease coming in contact with the field windings.
4-29
Bonnet
4-30
Grease Fittings
Grease Fitting
Grease Fittings
4-32
Grease Fitting (6 on IBOP Actuator Rollers, Cylinder Pins and Arm Pins)
4-34
Open Position
Grease Fitting
4-35
4-36
A preferred method is to rework the roller assembly for drill and tap operation, but the staking method is also effective. At each bottom corner of the motor frame are the two grease points for the motor trunnions (Figure 4-13). Lubricate these weekly. Lubricate the washpipe packing daily with the mud pump off. Daily, with the hydraulic power on, check the filter gauge on the pressure filter to determine the condition of the filter element. Replace the element when a bypass condition is indicated.
Do not weld or torch cut on or near the motor frame without removing hydraulic accumulators.
4-37
Grease Fittings
Grease Fittings
4-38
Grease Fitting
Grease Fitting
Grease Fittings
4-39
Grease Fittings
Grease Fittings
4-40
Bail
Bail Pin
Bail Pin
Grease Fitting
Grease Fitting
Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower
Transmission Cooler
4-42
Grease Fitting
Grease Fitting
Heat Exchanger
Heat Exchanger
4-43
Lubrication schedule
Frequency Daily Daily Daily Daily Daily Daily Daily Each trip Each trip Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly 750 hrs/90 days 1,500 hrs/6 mos. Monthly Monthly 3 months 3 months 3 months Location Bonnet seal Torque wrench (PH-85) Gearbox oil (check level) Rotating head Safety valve actuator cranks Hydraulic pressure filter Wash pipe assembly BNC drill pipe elevator Guide dolly rollers (Retract ) Gearbox (shift gears) Dolly motor trunnions Air filter/regulator/lubricator IBOP actuator arms Link adapter (650-Ton) Elevator support Master bushing wear guide Link tilt (check condition) Bail pins GE drilling motor pinion bearing GE drilling motor commutator bearing Motor frame/dolly hinges (Retract ) Cooling system cleaning AC blower motor Change gearbox oil Gear oil filter/suction strainer Lubricant code* 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 2 4 2 1 1 Number of points 2 6 1 5 2 1 7 20 2 6 4 7 4 2
* See Table 4-1, Recommended lubricants Check condition and replace as necessary Refer to Retract Guide Dolly supplement
Use only 10-wt. hydraulic oil or non-detergent motor oil as a lubricant in the air control system. Using any other type of oil or synthetic additive causes the seals in the air valves to swell and cease to function.
4-44
Lubricant specifications
TDS-4S transmissions operate under a combination of heavy and shock loads. Under these conditions oil tends to extrude out of the gear mesh. Keeping an effective film of oil on the gear mesh requires oil with an AGMA extra pressure rating, and a minimum viscosity of 100 SUS at operating temperature. Varco top drives also operate under a wide variety of temperatures. Select lubrication for the TDS based on the minimum ambient temperature to be expected before the next oil change. Under all but the most severe operating conditions, Varco recommends changing the oil every three months. Introducing an oil viscosity greater than required by the ambient temperature can: t Damage the gearbox due to reduced oil flow t Damage the oil pump because of excessive load All oils change viscosity with temperature and EP oil is no exception. The TDS transmission lubrication system is limited to pumping oils of a maximum of 9,000 SUS viscosity. Varco recommends measuring the oil temperature with a contact thermometer. Measure on the pump discharge fitting on the TDS. The following tables will aid in your lubricant selection and keep your TDS-4S transmission operating properly: Minimum ambient temperature F C Below 20 20 to 60 45 to 85 Above 70 -6 -6 to 16 7 to 30 21 Oil type required See note below 2EP, ISO 68 4EP, ISO 150 6EP, ISO 320 Varco P/N See note below 56004-1 56004-BSC 56004-2
For minimum temperatures below 20F, the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20F.
4-45
If the oil temperature falls below 20F, Varco recommends running the TDS at very light loads (less than 100 Amps) until the oil is above 20F. If drilling conditions dictate oil temperatures below 20F, consult Varco engineering. If the oil temperature rises above 200F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200F If drilling conditions dictate oil temperatures above 200F, consult Varco engineering.
General Purpose Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade Above -4F (-20C) MP grease Avi-Motive Lidok EP2 Below -4F (-20C) Avi-Motive W Lidok EP1 Above 70F (21C) Alpha LS-320 NL Gear 320 Spartan EP320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320
Gear Oil 45 to 85F (7 to 30C) Alpha -150 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 20 to 60F (-6 to 16C) Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Statoil Meropa 68 Carter EP 68
Gulf Crown EP32 Gulf Crown EP31 Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 1 -
Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP 6EP 320 4EP 150 2EP 68
4-46
Motor Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGL1 AGMA ISO Viscosity Grade All temperatures Cyprina RA -10 to 85C
Hydraulic Oil -15 to 75C Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 32
Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 1 46
4-47
4-48
Chapter 3 Maintenance
Adjustment procedures
Adjusting the torque wrench
Use the following procedure to adjust the pipehandler torque wrench:
The pipehandler torque wrench is properly adjusted and tested in the factory before it is shipped. Perform the adjustment procedure after performing maintenance on the torque wrench or if the torque wrench does not function correctly. 1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight. Be sure to use the correct thread compound when making up.
When adjusting torque wrench manifold needle valves, loosen the locknut around the valve stem and use a 5/32 in. hex wrench to adjust the valve. After obtaining desired setting tighten locknut around valve stem.
4-49
2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUE sequence valves on the torque wrench manifold fully in (Figure 4-18). 3. Fully back out the Pressure Reducing Valve (PRV), then screw in one turn. 4. Turn the LIFT/LOWER flow control valve fully in, and then back it out three turns. 5. Turn on the HPU. 6. If the torque cylinders are in their full clockwise position, set the Make/Break valve to MAKE. If they are in their full counterclockwise position, set Make/Break valve to BREAK. Note that torque cylinders should not move if the recycle sequence valve is fully in. 7. Slowly back out the RECYCLE sequence valve until torque cylinders just start to move, then screw out an additional full turn.
Make/Break Valve
BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE
MAKE
PRV
40
50
60
70
30
1000
1500
80
LIFT LOWER
20
500
2000
90
10
2500
10
PSI Ft.Lbs.
x1000
8. Move the Make/Break valve to BREAK. Set the PRV to 750 psi. 9. Switch the lever between MAKE and BREAK to adjust the RECYCLE sequence valve until full rotation in each direction takes six to eight seconds. Tighten the locknut around the RECYCLE sequence valve adjustment screw. 10. Set the Make/Break valve to MAKE. 11. Depress and hold the torque wrench operating button on the VDC. The torque wrench should lift and the clamp jaws should remain retracted. 12. Slowly back out the CLAMP sequence valve until the clamp jaws just begin to clamp onto the tool joint. Screw out an additional half turn. Lock the CLAMP sequence valve adjustment screw in position by tightening the locknut. 13. Back out the TORQUE sequence valve until the torque cylinders just begin to stroke, then back out an additional half turn. Tighten the locknut around the TORQUE sequence valve adjustment screw. 14. Release the torque wrench operating button on the VDC. The torque wrench should start to unclamp and drop, then the torque cylinders should recycle. 15. If the torque cylinders recycle before the clamp cylinders retract, screw in the RECYCLE sequence valve until the torque cylinders do not move before clamp cylinders have fully retracted. Tighten the RECYCLE sequence valve adjustment screw locknut. 16. Cycle the torque wrench as many times as required to makeup the connection. 17. Set the Make/Break valve to BREAK. 18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub, without breaking out the saver sub or lower IBOP. 19. The torque wrench is ready for operation.
4-51
Adjusting the upper safety valve (IBOP) and safety valve actuator system
Refer to the IBOP Service Manual for upper IBOP and safety valve actuator system adjustment procedures.
4-52
Pressure Gauge
4-53
4-54
Needle Valve
4-55
Needle Valve
4-56
Shipping Brace
4-57
The pressure setting is adjusted by screwing the PRV in or out with a hex wrench (Figure 4-19). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the PRV reduces pressure and moves the saver sub away from the rails (see additional notes at the end of this procedure). 6. Verify the correct pressure setting using the following procedure: a. With the HPU on, back down the pressure using the PRV until the saver sub begins to pivot away from the rails. Record this pressure. b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a dead band area. c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs. d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by two. The resulting pressure dead band provides equal pre-load in each direction both toward and away from the rails. e. Record the pressure setting for future reference. 7. Set a joint of drill pipe in the slips. 8. Bring the top drive down as if stabbing the saver sub into the box. The pin and the box should be in alignment so that the OD of the pin clears the shoulder of the box. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box. b. Turn off the HPU and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame. c. Loosen the lock tab and jam nut on the cylinder clevis.
4-58
d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4 in. of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2 3/8 1/8 in. gland to rod threads when the system is properly aligned. e. Secure the jam nut and lock tab. f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2 in. of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats. g. Tighten the lock nuts and replace the caps on all valve stems.
If the alignment cylinder is removed for service, install the alignment cylinder replacement brace to support the motor housing assembly while continuing to operate the TDS. After reinstalling the alignment cylinder, use the three bleed holes (located along top of cylinder barrel) to remove air trapped in the cylinder. Rail spacing and setback from the centerline of the well must be held within recommended tolerances in order to maintain vertical alignment of the TDS.
4-59
4-60
Do not loop or twist hose as it stiffens when gas pressure is released from nitrogen bottles. Never loosen the swivel nut attached to the gas valve in the accumulator without first backing the gas chuck stem all of the way out. Do not reduce accumulator precharge by depressing valve core (high pressure may rupture rubber valve seat). Instead, slowly turn gas valve out until gas begins to escape through bleed hole drilled through threads of valve. This hole is a safety feature, it warns of stored pressure whenever gas valve is being removed. Install new gas valve O-ring each time gas valve is removed.
4-61
4-62
Torque Tube
V a r c o
Torque Cylinders
4-63
Clamping Jaws
Body
Stabbing Guide
4-64
Mounting Shaft
Frame
Guard
4-65
4-66
Frame
Mounting Shaft Safety Valve Actuating Cylinders (2) Vertical Positing Cylinder
Stop Tube
Guard
Stabbing Guide
4-67
Reassembly is accomplished in the reverse order of the above procedure. Pay close attention to the following points: 1. Replace all seals. 2. Take great care when installing the clamping piston and gland. If they are not closely aligned with the bore, they may become jammed and could be extremely difficult to remove. 3. Use the following torque values: Cylinder rod end to cylinder rod* 944 ft lb Frame to clamp cylinder body 250 ft lb Stabbing guide to body 250 ft lb Die retainer screws 380 ft lb Body hinge pin retainer screws 150 ft lb Stabbing guide spring retainer screws 75 ft lb Jaw retaining screws 110 ft lb *The torque cylinder rod ends are threaded into the rods with locktite and cross pinned.
Replacing the torque wrench clamping piston seal
The following procedures require that the torque wrench be removed from the pipehandler.
Replacing the front and rear piston seals
1. Remove the slotted hex nut and cotter pin attaching the two halves of the stabbing guide together at the front and swing the guides out to each side. 2. Vent the clamping cylinder as follows: disconnect the hydraulic lines to the clamp port and front unclamp port on the clamp body cylinder at the torque wrench manifold clamp and unclamp ports.
4-68
3. Remove the jaw pins from the rear clamping jaw and remove the jaw. 4. Remove the two screws holding the jaw spacer to the front clamp cylinder piston and remove the spacer and jaw spacer. 5. Remove the two screws holding the clamp clevis to the rear clamp cylinder piston. 6. Remove the pins holding the clamp body to the clamp clevis and remove the clamp clevis. Be sure to remove the spacer from the piston rod slot. 7. Push in the cylinder gland from the rear cylinder head retainer ring and remove the ring with a screwdriver. 8. Attach the sliding hammer to the rear piston rod and carefully pull the piston until the cylinder gland can be removed. 9. Continue to pull until the piston comes out. 10. Using a piece of wood or brass bar, tap the front clamp piston from the front and remove it from the rear. 11. Remove and discard the piston seals, rod seals, and rod wipers. 12. Remove the front piston rod seal and rod wiper from the clamp cylinder body and discard. 13. Inspect the clamp cylinder bore thoroughly for dirt, burrs, nicks, gouges, and pitting. Repair and clean as necessary.
Assembly
1. Insert a new front rod seal and rod wiper in the clamp cylinder body and lubricate with clean hydraulic fluid. 2. Install a new piston seal in the front piston groove and lubricate with hydraulic fluid. 3. Insert the front piston into the clamp cylinder body with the two jaw spacer screw holes orientated vertically. 4. Gently and evenly tap the piston into place until the rod appears beyond the front cylinder bore.
4-69
5. Install a new piston seal in the rear piston groove and lubricate with hydraulic fluid. 6. Insert the rear piston into the clamp cylinder body with the two screws holes on the rod oriented to the horizontal position. 7. Gently tap piston into place until there is enough space between the piston face and retaining ring groove to insert cylinder gland and retainer ring. 8. Install the rod seal and rod wiper in the inside grooves of the cylinder gland. 9. Install the piston seal in the outside groove. 10. Lubricate all seals with hydraulic fluid. 11. Insert cylinder gland into the bore rod and piston seals first. Push the gland past retainer groove and install the retainer ring. 12. Insert the spacer and attach the clamp clevis to the rear cylinder rod with the two hex head cap screws and flat washers. Tighten firmly and lockwire. 13. Adjust orientation of the clamp clevis and attach to the clamp body using the two clevis pins and cotter pins. 14. Attach the rear clamping jaw spacer to the front piston rod using the spacer and two hex head cap screws and flat washers. Tighten firmly and lockwire. 15. Attach the clamping jaw with the two jaw pins. 16 Swing the stabbing guide back into position and attach with the slotted nut and cotter pin. 17. Reconnect the hydraulic lines from the clamp body cylinder clamp port and front unclamp port at the torque wrench manifold clamp and unclamp ports. 18. Reinstall and adjust the torque wrench (refer to Adjusting the torque wrench earlier in this chapter).
4-70
Rotary glyd ring replacement is indicated when hydraulic oil is detected in the pipehandler air supply. An indication of oil contaminating the air supply would be an accumulation of oil in the link tilt air actuator (bag). The following disassembly and assembly procedures assume that the TDS is swung out for maintenance in accordance with the TDS swing out procedures (refer to TDS swing out procedure in Chapter 1 of this book). Refer to Figures 4-28 and 4-29, when performing the following procedures.
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return Cylinder
Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown)
4-71
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Push the cam follower away from the rotating block cam. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. 15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
4-72 TDS-4S Maintenance and Troubleshooting
Return Cylinder
Cam
Cotter Pin
,, ,,
Cylinder Clevis Excluder Cap
Detail
Retainer Ring
,,, ,,,,,, ,,, ,,,,,, ,,, ,,,,,, C ,,, ,,,,,, ,,,,,, ,,,,,,
Excluder Cap Gasket
Ball Bearing
C
Stationary Flange
4-73
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the quick disconnect hydraulic fittings on the rotating block. 7. Attach the return cylinder rod to the clevis with the clevis pin and install the slotted hex-head nut and cotter pin. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book.
4-74
1. Order eleven replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt, and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Remove the hydraulic motor assembly. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange.
4-75
15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eleven new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the QD hydraulic fittings on the rotating block. 7. Reinstall the hydraulic motor assembly. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book.
4-76
Disassembly
1. Disconnect the air hose from the rotating head rotating block to the link tilt assembly. 2. Support the link tilt and remove the two upper and two lower screws attaching the link tilt to the link adapter. 3. Lower the link tilt to the floor with the air actuator to be replaced facing up. 4. Remove the cotter key and pin from one end of chain connecting the two sealing plates. 5. Remove the safety wire from the four hex-head cap screws holding the air actuator sealing plate to the link tilt base or lever and remove the screws. 6. Lift the lever or base off the air actuator sealing plate, and rotate it 180 on the link tilt pivot pin and lay down. 7. Remove the nuts and washers holding the sealing plate to the air actuator and remove the plate. 8. Using a pry bar or screwdriver, pry the air actuator away from the screws, attach the actuator to the hanger plate and remove the screws using a hex wrench. 9. Remove and discard the air actuator. 10. Remove any burrs or gouges on sealing surfaces of the hanger and sealing plates.
4-77
Pressure Regulator
Sealing Plate Bolt (4) Quick Exhaust Valve Lever Intermediate Stop (2)
4-78
Nuts, Lock Washers (18) Air Actuator (2) Sealing Plate Bolt (4) Pressure Regulator Base
Hanger Plate
Connecting Chain Stop Pivot Arm Elevator Link (Ref) Stop Release Loop
4-79
Assembly
1. Place a new actuator on the hanger plate. 2. Attach the air actuator to the hanger plate with the 18 buttonhead cap screws. Coat the screw threads with locktite before installation.
The air actuator has aluminum neck bead rings on both sealing surfaces. These beads must be compressed equally to ensure a good air seal. This requires more than one tightening pass to accomplish. Over-torquing may cause hex sockets to strip. 4. Torque the cap screws to the hanger plate at 80 ft lb. 5. Insert the 18 bolts into the neck ring of the air actuator. 6. Reinstall the air actuator sealing plate, coat the bolt threads with locktite and fasten with the lockwashers and nuts provided. 7. Torque the nuts to the sealing plate at 80 ft lb. (See Caution above.) 8. Lift and rotate the link tilt lever or base to line up with the air actuator sealing plate. Attach with the four hex-head cap screws and torque to 250 ft lb. 9. Safety wire the four screws. 10. Reconnect the chain between the two sealing plates. 11. Reinstall and adjust the link tilt per the Installation and Commissioning book.
4-80
Rear jaw
1. On the rear jaw, remove the cotter pins from the retaining bolts and slotted nuts. 2. Support the retaining bolt while removing the slotted nut. 3. Remove the retaining bolt from the piston jaw. 4. Support the remaining retaining bolt while removing the slotted nut and upper die retainer. 5. Remove the retaining bolt and lower die retainer. 6. Remove the tong dies from the jaw.
4-81
Rear jaw
1. Loosen the socket head cap screws securing the jaw assembly to the piston. 2. Support the jaw assembly and remove the socket-head cap screws and washers from the jaw assembly and piston. 3. Remove the rear jaw assembly from the piston.
4-82
4-84
DC Drilling Motor
Bull Gear
Geneva Mechanism
Shaft
LO
HI
4-85
Refer to the GE Electric Motor Manual for procedures to remove the pinion or hub on the armature shaft, or to service the motor itself. Once the unit has been disassembled, inspect the following assemblies for any wear or damage that may be critical: 1. Gear set: Check the teeth and splines for chips or heavy wear. The wear pattern should be even and symmetrical. If not, replace it. Expect some small surface pitting. It is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090 in. 4. Main shaft: Check fit to bull gear, wear sleeve surfaces, and retaining threads. 5. Seals: Always replace seals and gaskets when removed. 6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gearcase are critical. Clean up any nicks or gouges prior to reassembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface. 9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems are malfunctioning, remove the appropriate valve and repair or replace. Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. Replace all grease seals and O-rings, and refer to the following torque chart for bolt tightening guidelines.
4-86
Torque Chart Motor support/bonnet to main body Main body to motor support/bonnet Bull gear to hub Lower gearcase to main body Rotating head to lower gearcase Brake adapter ring to motor Brake to brake adapter plate Brake drum to hub Brake cover to brake
Installing a pinion gear can be dangerous to personnel installing it as well as anyone witnessing the procedure. Exercise caution at all times. Use the following procedure to install a TDS motor pinion: 1. Clean the motor shaft by hand and cover with a thin layer of Engineers Blue. 2. Firmly install the pinion on the motor shaft by hand. Mark reference lines on the pinion and the shaft to ensure identical angular orientation each time. 3. There must be a minimum of 75% surface contact between the pinion and motor shaft. Dress the motor shaft/pinion very lightly with a fine emery cloth and repeat the blueing procedure if necessary until there is at least 75% surface contact between the pinion and motor shaft. 4. After thoroughly cleaning all blueing, oil, and/or grease from the pinion bore and shaft, trial mount the cold pinion gear on the motor shaft, lining up the reference marks.
4-87
5. Make sure the fixture is clean and the horse shoe face and bar are parallel. 6. Place the fixture on the motor shaft with the horse shoe end against the inner face of the gear and the bar against the outer face of the gear, sandwiching the pinion gear in the fixture. 7. Adjust the adjusting screw to butt against the end of the motor shaft. 8. Attach a calibrated dial indicator gauge to the fixture and set to zero. 9. Back off the adjusting screw until the gauge reads 0.0720.074 in. Then lock the screw in place with a locknut. 10. Remove the fixture from the pinion gear assembly.
Do not put the fixture in the oven. 11. Heat the pinion gear to 360-385F (182-196C) for three hours in an oven. After heating for three hours, remove the pinion gear assembly and immediately attach the fixture. 12. Place the pinion gear assembly and fixture on the motor shaft, lining up the reference marks. 13. Gently tap the pinion gear assembly and fixture into place until the adjusting screw butts against the motor shaft. 14. Wait 2-3 minutes and back off the nuts holding the fixture in place. There may be some noise as the pinion gear cools. 15. The pinion creeps up the shaft as it cools to the required position of 0.085 0.005 in. advancement. 16. When the pinion is fully cooled, fit the fixture and check final advancement. 17. Complete the required documentation recording pinion advancement.
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4-89
Transmission Cooler
Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket FLL-X Duct Connection Point Mounting Plate
Spark Arrestor
4-90
Use the following procedure to install a new motor in the local cooling system: 1. Install wear sleeves on the blower motor shaft. 2. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 3. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Use two 3/8 in. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. b. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. 4. Install shaft seal assemblies inside both blower housing assemblies. Make sure the seals are centered. 5. Tighten and safetywire the retainer plates in place on both sides. 6. Install the impellers and taper lock bushings on both sides and safetywire the bolts. 7. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. 8. Hoist the entire cooling system assembly onto the TDS. If the alignment holes were properly used, the cooling system assembly should line up perfectly on the TDS. 9. Install and safetywire the four bolts connecting the blower mount to the brake cover. 10. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. 11. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 12. Connect the electrical wires to the blower motor.
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4-92
Impeller (2)
Water Connections
4-93
Use the following procedure to install a new motor in the local cooling system: 1. Install wear sleeves on the blower motor shaft. 2. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 3. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Use two 3/8 in. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. b. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. 4. Install shaft seal assemblies inside both blower housing assemblies. Make sure the seals are centered. 5. Tighten and safetywire the retainer plates in place on both sides. 6. Install the impellers and taper lock bushings on both sides and safetywire the bolts. 7. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. 8. Hoist the entire cooling system assembly onto the TDS. If the alignment holes were properly used, the cooling system assembly should line up perfectly on the TDS. 9. Install and safetywire the four bolts connecting the blower mount to the brake cover. 10. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. 11. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 12. Connect the electrical wires to the blower motor.
4-94
Torque fasteners before safety wiring any screw, nut, plug, or other fastener. Never overtorque or loosen a torqued fastener to align safety wire holes. Use the size and type of safety wire required in the applicable specifications and drawings. Whenever possible, use double-twist safety wiring.
n n
Limit single-twist wiring to the following: small screws located in closely spaced, closed geometrical patterns (e.g., triangles, squares, rectangles, or circles), parts in electrical systems, or parts that are difficult to reach.
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 the round, perforated slider in the center of the pliers from the hook lock. 3. Grip both safety wires in the jaw. Squeeze the handles together with one hand and pull the slider toward the rear of the pliers with the other hand to lock the pliers. 4. Twist the safety wire by pulling the aluminum knob and twist the rod out from the pliers. Let the pliers spin free. 5. Return the knob and twist the rod by holding the pliers steady with one hand and pushing against the end of the knob the with other hand (step 4 in Figure 4-35). 6. Repeat the previous twisting cycle.
4-95
7. After threading the safety wire through the hole in the fastener, pull the wire straight through without nicking the wire. Twist four to five complete revolutions per inch of wire. 8. Make a pigtail of approximately 1 in. (25 mm) length (four twists minimum) at the end of the wiring and bend back or under to prevent it from becoming a snag.
1 2
4-96
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 the nut. For best results, let the wire leave the fastener in a clockwise direction t Twist the safety wire so the loop around the bolt or head has sufficient tension to keep it from slipping up and over the bolt head, with resulting slack in the safety wiring.
When securing castellated nuts with safety wire, tighten the nut to the low side of the selected torque range, unless otherwise specified. If necessary, continue tightening within specified torque limits until a slot aligns with the hole. t The number of nuts, bolts or screws that can be safety-wired together depends on the application. As a guide, when safetywiring widely spaced bolts by the double-twist method, a group of three, or a 24 in. (610 mm) length of safety wire is usually the maximum.
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Chapter 4 Troubleshooting
Dirty or defective PRV valve. See adjustment procedure. Clean or replace. Dirty or stuck check valve. Clean or replace.
Counterbalance control valve Return valve to drilling position. in rig down position. Cylinder rods remain retracted (closed). Pressure setting too high. Adjust per adjustment procedure.
When activating or reactivating the counterbalance system, never start an empty system with the needle valve closed. Always start the Hydraulic Power Unit (HPU) first, run for 3-5 minutes, then slowly close needle valve with HPU running. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals.
TDS-4S Maintenance and Troubleshooting 4-99
Possible problem with Counterbalance system hydraulic system works erratically or does not components. work at all.
Loss of nitrogen precharge in Recharge accumulators as per the procedure in the Troubleshooting the accumulators located in counterbalance section of this book. motor dolly upright frame. System does not hold pressure. Needle valve is not closed. Cylinder rod seals leak. Fittings or hoses leak. Saver sub on TDS does not align with drill pipe. Alignment cylinder pressure too high or too low. See the adjustment procedure. Replace seals. Tighten or replace as required. See the adjustment procedure.
Alignment cylinder rod Adjust according to procedure. adjustment too long or short. Rails not properly aligned with centerline of well. Check to make sure that rotary is in center of floor and then check alignment of rails in relation to rotary. See the adjustment procedure. Normal adjustment is 1 1/2 turns from full closed position on flow control valves. If there is excessive movement close to 3/4 turn from full closed position.
4-100
Lubricate, repair with repair kit or replace valve. Check air supply lubricator. Clean or replace.
4-101
Oil level too low or too high. Adjust oil level to recommended level in sight glass. Incorrect lubricant used. Clogged oil suction screen. Check recommended lubricants chart and replace as needed. Remove suction screen from oil pump. Check discharge or pressure hoses at outlets to confirm circulation.
Check heat exchangers for air flow Clogged or dirty heat exchangers on unit equipped or water flow to ensure adequate heat transfer and dissipation. with such.
4-102
Incorrect motor rotation. Dirty or clogged oil pump suction screen. Oil pump cavitatingevidence of air bubbles in discharge lines. Defective or improperly adjusted pressure switch. Failure of oil pump drive coupling. Faulty or worn oil pump.
4-103
Worn or defective seal or wear sleeve. Loose or vibrating blower motor, wearing seals excessively.
Correct blower mounting problem or faulty motor bearing and replace blower shaft seals. Verify blower rotation. Correct as needed.
Remove spark arrestors from motor and clean screens if screens are damaged with holes. Replace as needed.
Clogged water or air passages Remove and clean passages as needed. in water cooled exchangers (closed loop cooling).
4-104
Remedy Check service manual for continuous Amp motor rating and adjust drilling program accordingly.
e z
DC motor should never be stalled for more than 5 seconds with over 300 Amps applied. Serious damage could occur to the motor if this is done.
Faulty temperature switch or Repair or replace as needed. probe. Do not readjust or raise heat range setting.
Improper cooling water flow See the Installation and or incoming water temp too Commissioning book for recommended or required flow rates high (closed loop cooling). and water temp. Restricted air flow (local or remote cooling). Check and clean spark arrestors as needed. Check air intake on blower to ensure there are no restrictions. Verify proper blower rotation. WATER DETECTOR alarm is on (closed loop system). Moisture in air inside DC motor. Check for leaks in heat exchanger. Check air purge line filters. Ensure dry air is going into motor. Clean or replace as needed.
4-105
Improperly connected Quick Check QDs to make sure they are Disconnects (QDs). properly plugged together and flowing in both directions. Needle valve in counterbalance manifold is open. Defective cartridge valve or PRV valve. Improper component or component installation. Close needle valve (always with HPU running). Inspect valves for damaged seals or stuck spools. Replace if necessary. Valve cartridge replaced with wrong type. When changing the Make/Break valve, make sure the valve is properly oriented when installed.
Die retainer and die retainer bolts damaged while breaking. Torque wrench does not lift.
Improper saver sub length or Saver sub length too long. Sub machining. should also have proper chamfer on both shoulders. Oil bypass in pipehandler hydraulic components. Listen for oil bypassing in pipehandler cylinders or manifold. Locate and repair bypass as necessary.
4-106
Symptom
Probable cause
Remedy Remove air supply line to verify air supply when solenoid valve is activated.
Tool goes up, clamps, Air pilot valve on counterbalance manifold stuck or and cycles, but inoperative. remains clamped on pipe when switch is released. Pilot valve dirty.
If air supply is available remove end cap on pilot valve, clean and lubricate. If air pilot valve is operable, hook both pipehandler hoses together and verify flow in both directions by activating switch with hydraulics on. If there is flow in only one direction, check QDs. If QDs are properly connected, check hydraulic pilot valve for stuck spool.
Hydraulic valve not shifting. Repair or replace. Saver sub breaks out instead of tool joint. Saver sub not made up properly. Make up saver sub per procedure described in the IBOP Service Manual, increase previous torque makeup by 10% to maximum torque recommended in the IBOP Service Manual (for original Varco OEM subs). Readjust per procedure. Replace tong dies. If saver sub is made up to recommended torque and continues to break out instead of drill pipe connection, break out using rig tongs. If saver sub or drill pipe will not break out using pipehandler, remove pipehandler and break out with rig tongs at floor.
4-107
Adjust jam not on passive stop to position elevators over well center. Adjust pressure setting. Adjust jam not on passive stop to position elevators over well center.
4-108
Faulty or loose wiring. IBOP valve actuator remains either in closed or open position. No air supply or air supply incorrect.
Crank assembly, actuator Check crank assembly, actuator arms and cylinders. Repair as needed. arms or cylinders sticking. Solenoid valves stuck in the open position or in center position. IBOP valve does not fully Actuator cylinder out of open or close. adjustment. Cam follower rollers sticking. Crank assembly retainer bolts loose. Check solenoid valves to see if they are not stuck in the open position or in center position. Repair or replace valve as needed. Check actuator cylinder adjustment and adjust as needed. Check cam follower rollers on crank assembly and arms. Check crank assembly retainer bolts to assure tightness. Crank assembly retainer bolts should be checked weekly to make sure they remain tight.
4-109
Yellow and red indicator constantly flash while traveling assembly is below ten feet.
Defective sensor cable between the sensor junction box and control electronics. Defective upper sensor bracket assemblies. Defective upper proximity switches.
Check the mechanical operation of the upper sensor bracket assembly. Check voltages from upper proximity switch by measuring voltage between TB3 and TB2 for upper sensor at the sensor junction box. A measurement of less than 2.0 VDC indicates a working sensor when metal is detected. Replace proximity switches as required. Replace electronic control module.
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4-111
4-112
Control System
SM00620-5
5-2
Contents
TDS-4S Control System
General description .......................................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................................................ 5-7
5-3
5-4
General description
The Top Drive Drilling System (TDS) typically operates from the same SCR as the rotary table. A transfer panel, located in a Central Electronics Enclosure (CEE), switches power from one to the other. The CEE typically contains the following components: t DC contactors t A programmable logic controller (PLC) t Auxiliary AC components t Rig instrumentation interfaces for recording TDS torque and speed
5-5
In dedicated top drive SCR configurations, the SCR runs the top drive only. The transfer panel features a purge control system so it can be located in hazardous areas. If the transfer panel is located in the SCR room, a purge system is not required. The transfer panel is designed to be compatible with all presently installed SCR systems and is configured at installation for the specific SCR used on a rig. Logic and alarm functions are connected to the TDS via PLC programming so the TDS can operate existing rig systems. Also, TDS interlocks and limits, such as spin-up and makeup speeds, are programmed into the PLC and are the same for all installations.
5-6
5-7
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