You are on page 1of 21

TDS-4S

TDS-4H
T

Contents
LUBRICATION
Major Components ....................................2
Maintenance Schedules ............................4
Recommended Lubricants .....................11
Lubrication Points ...................................12
MAINTENANCE AND SPARES
Adjustment Procedures ..........................20
Consummables ........................................27
Washpipe Assembly ................................28
Making Up the Drill Stem ........................32
GENERAL INFORMATION
Torque Values ..........................................34
Service Centers .......................................36
Specifications ..........................................38

Varco P/N

30153911
Rev.

TDS-4H Top Drive


Major Components

TDS-4S Top Drive


Major Components
Pressure
Filter

Guide Dolly
Assembly

Counterbalance
Assembly

Pressure
Filter

Guide Dolly
Assembly

Counterbalance
Assembly
S-Pipe

S-Pipe

LO
LO

Drilling
Motor and
Transmission
Assembly

Drilling
Motor and
Transmission
Assembly

Electrical
Service
Loop
Pipehandler
Assembly

Electrical
Service
Loop

Fluid
Service
Loop

Standard
Mud Hose

Pipehandler
Assembly

Fluid
Service
Loop

LUBRICATION

LUBRICATION

Standard
Mud Hose

TDS-4S/4H Maintenance
Round Trip Schedule

No more than once daily,


no less than once weekly
Item
Drill Pipe Elevator
Power Slips
RBS
Guide Dolly Rollers

Points

Lubrication

Various
Various
Various
20

Grease
Grease
Grease
Grease

TDS-4S/4H Maintenance
Daily Schedule
Or after 8 hrs drilling

Item

Points

Lubrication

1
4
2
1
2

Grease
Grease
Grease
Grease
Grease

Bonnet Seal*
Link Adapter Wear Shoe
Torque Tube Clevis Pin
Wash Pipe Assy*
Safety Valve IBOP Actuator
Cranks

Item
Pipe Handler
RBS

Inspect for

Action

Worn or Broken
Dies
Worn or Broken
Dies

Brush Clean or
Replace as Necessary
Brush Clean or
Replace as Necessary

These round trip activities should take


approximately 10 minutes to perform
Unless otherwise specified, apply
two pumps of grease where noted

Item
TDS Motor and
Guide Dolly
Assemblies
Pipe Handler
TDS
TDS Controls*

Inspect for

Action

Loose Bolts, Fittings,


Safety Wire and
Cotter Pins
Loose Bolts, Fittings,
Safety Wire and
Cotter Pins
Check Leaking
Hoses and
Connectors
Verify Operation

Repair or
Replace as
Necessary
Repair or
Replace as
Necessary
Repair or
Replace as
Necessary
Repair or
Replace as
Necessary
Replace as
Necessary
Replace as
Necessary
Fill as
Necessary
Fill as
Necessary

These daily activities should take


approximately 20 minutes to perform
Unless otherwise specified, apply
two pumps of grease where noted

* These items are high priority and must be


4

completed daily

LUBRICATION

LUBRICATION

Hydraulic Pressure
Filter (on TDS)
Hydraulic Return
Filter (on HPU)
Air Supply Lubricator Check Level
(in Derrick)
Gear Box Oil
Check Level
(Pump Off)*

TDS-4S/4H Maintenance
Weekly Schedule
Or after 60 hrs drilling
Item

Points

Lubrication

Upper Quill Shaft Bearing


1
Dolly Motor Trunnions
2
IBOP Actuator Arms
4
Rotating Head
4 or 5
Rotating Head Roller
1
Hydraulic Link Tilt
8
Upper IBOP Valve
1
IBOP Actuator Cam Followers 2
Link Spreader (if Equipped)
6
Solid Body Elevators
2 or 4
Ph-85 Clamp Body Cylinder
4
Trunnion
Ph-85 Clamp Body
8
Elevator Support
7
Master Bushing Wear Guide
4
Retract Dolly (if Equipped)
8
Bail Pins
2
Ph-85 Support Shaft
(Grease Contact Points)
Elevator Links (Grease
Eye Contact Points)
Hydraulic Rotating Head Gear
(Grease Teeth)

Grease
Grease
Grease
Grease
Grease
Grease

Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease

Remove 1/4" NPT plug, install grease fitting


and apply ten pumps of grease

Or after 60 hrs drilling

Item

Inspect for

Action

TDS
Transmission

Shift Between High Repair as Required


and Low and Rotate
in Each Gear
Air Filter and
Check Air Pressure
Adjust Repair
Regulator
as Necessary
RBS
Function Test
Repair as Required
Dolly Rollers
Loose or Broken
Repair or Replace
Bearing, Flat Spots
as Necessary
Rotating Head
Seal Leakage
Repair as
Necessary
Cooling System Leaks or Damaged Repair and Replace
Hoses
as Necessary
Pneumatic Link
Condition of Air
Repair as
Tilt
Bladder
Necessary
Pivot Pin and Stops
Service Loops
Damage, Abrasions Repair or Replace
and Snag Points
as Necessary
Oil Heat
Visual Inspection
Clean or Repair
Exchanger
as Necessary
Motor Alignment
Operate and
Record Results
Cylinder (HPU Off) Note Pressure
Counterbalance
Note Pressure
Record Results
Cylinder (HPU Off)
Cooling System
Check Heat
Repair as
(Closed Loop)
Exchanger
Necessary
for Water Leaks
Spark Arrestors
Visual Inspection
Clean or Replace
for Holes and
as Necessary
Cleanliness
Lower IBOP
Fully Close and
Repair or Replace
Open Lower IBOP
as Necessary
Valve

These weekly activities should take


approximately 20 minutes to perform

LUBRICATION

LUBRICATION

Unless otherwise specified, apply


two pumps of grease where noted

TDS-4S/4H Maintenance
Weekly Schedule

TDS-4S/4H Maintenance
Monthly Schedule
Or after 250 hrs drilling
Item
Motor Frame/ Dolly Hinges
Transmission (Oil Sample)

Item
DC motor

Purge system

Alarms

DC motor

Blower motor

Oil pump motor

Lubrication

4
1

Grease
Gear Oil

Inspect for

Action

Visual inspect
brushes and
commutator
Alarm operation
at VDC and
transfer panel
Low lube oil,
Blower differential
pressure
Runs smoothly
no excessive
vibration
Runs smoothly
no excessive
vibration
Runs smoothly
no excessive
vibration
Loose connection,
moisture trap,
cleanliness

Clean or replace
as necessary
Repair as necessary

Repair as necessary

Repair as necessary

Repair as necessary

Repair as necessary

Clean and repair


as necessary

These monthly activities should take


approximately 45 minutes to perform
(plus daily and weekly activities)
Unless otherwise specified, apply
two pumps of grease where noted

Or after 750 hrs drilling

Item

Points

Lubrication

1
2
1

Motor Grease
Grease

Drilling Motor Pinion Motor


Blower Motor
Gear Oil Filter
(Screw on Type)

Item

Inspect for

Action

Blower Motor
Oil Pump Motor
HPU Motors
DC Motor

Running Amps
Record Results
Running Amps
Record Results
Check Running Amps Record Results
Brush Length,
Clean and
Freedom of Movement,
Replace as
Spring Tension
Necessary
Commutator for Flash Over,
Cleanliness
Meg Motor and
Record Reading
Meg Motor Field (Shunt)
and Record Reading
DC Motor
Check Heater
Repair as
Operation
Necessary
Disc Brakes
Check Pads
Replace as
Necessary
Hydraulic Filter
Change Filter
Gear Oil Filter
Change Filter
(Screw on Type)
Transmission
Change Oil (Unless
Samples Tell Otherwise)
Clean Suction Screen when
Replacing the Oil
HPU
Check Magnet Plug for
Clean as
Metal Particles Change
Necessary
Return Filter Drain Water
From Bottom of Tank
Upper Bearing
Check Inline Oil
Clean or Replace
Strainer for Oil Flow
as Necessary

Unless otherwise specified, apply


two pumps of grease where noted
8

LUBRICATION

LUBRICATION

Transfer Panel

Points

TDS-4S/4H Maintenance
Quarterly Schedule

TDS-4S/4H Maintenance
Semi Annual Schedule
Or after 1500 hrs drilling
Item

Points

Lubrication

Motor Grease

DC Motor Commutator

Item
Oil Temp Switch

Inspect for

Action

Operational Check

Replace as
Necessary
Air Temp Switch Operational Check
Replace as
Necessary
Water Temp
Operational Check
Replace as
Switch
Necessary
Split Landing
Disassemble, Inspect
Replace as
Collar
all Parts for Wear
Necessary
Field Supply
Verify Field Outputs
Adjust as
Necessary
J-Boxes
Inspect and Tighten Tighten or Repair
all Connections
as Necessary

Annual Schedule

Or after 3000 hrs drilling

QA-26
QA-73
Load Bearing
Components
Main Shaft
Counterbalance
Accumulator
Motor Alignment
Accumulator

Inspect for

Action

Mechanical Check
Electronic Check
MPI and Visual

Record Results
Record Results
Record Results

Check End Play


Check Run Out
Check Pressure

Record Results

Check Pressure

5 Year shop overhaul - contact


service center for details
10

Adjust as
Necessary
Adjust as
Necessary

Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union

General Purpose Grease

Below -20 C

Above -20 C

N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1

MP Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2

(Below -4 F)

(Above -4 F)

Viscosity Index
1
NGLI
Mfr.
Ambient
Temperature
Range
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union

2
Gear Oil

-6 to 16 C

7 to 30 C

Above 21 C

Alpha LS-68
NL Gear 68
Spartan EP68
EP Lube HD68
MobilGear 626
Omala 68
Loadway EP68
Meropa 68
Carter EP 68
Extra Duty NL2EP

Alpha LS-150
NL Gear 150
Spartan EP150
EP Lube HD150
MobilGear 629
Omala 150
Loadway EP150
Meropa 150
Carter EP 150
Extra Duty NL4EP

Alpha LS-320
NL Gear 320
Spartan EP320
EP Lube HD320
MobilGear 632
Omala 320
Loadway EP320
Meropa 320
Carter EP 320
Extra Duty NL6EP

N/R
4EP
150

N/R
6EP
320

(20 to 60 F)

(45 to 85 F)

Viscosity Index
N/R
2EP
68

NGLI
AGMA
ISO
Viscosity
Grade
Mfr.

Motor Grease

Shell

Cyprina RA (All Temperatures)


11

(Above 70 F)

LUBRICATION

LUBRICATION

Item

Lubricants
Mfr.
Ambient
Temperature
Range

TDS-4S Top Drive


Lubrication Points
Apply two pumps of grease
to each grease fitting

TDS-4H Top Drive


Lubrication Points
Retractable
Guide Dolly

Bail Pins

Washpipe
Assembly

Upper Bonnet
Seal

Gear Oil
Filter

Swing Guide
Dolly

Washpipe
Assembly

Gear
Oil
Filter
Swing
Guide
Dolly

LO
LO

Motor
Trunnions

Gear Oil Fill

Gear Oil Drain


and Sample Valve

12

Gear Oil
Fill

Gear Oil
Sight Gage

Bail Pins
Gear Oil
Sight Gage
Gear Oil Drain
and Sample Valve

Upper Quill
Shaft Bearing

Apply two pumps of grease


to each grease fitting
13

LUBRICATION

LUBRICATION

Retractable
Guide Dolly

Swing Guide Dolly


Lubrication Points

Hydraulic Link Tilt


Lubrication Points
Hydraulic
Link Tilt

Swing Guide
Dolly Hinge

Apply two pumps


of grease to
each grease fitting

650/750 Ton
Powered Rotating Head
Lubrication Points
Powered Rotating
Head Bull Gear
Brush with grease

Motor
Trunnions

Apply two pumps of grease


to each grease fitting
650/750 Powered
Rotating Head
14

15

LUBRICATION

LUBRICATION

Swing Guide
Dolly

PH-60 Pipehandler
Lubrication Points
500 Ton Capacity

PH-60 Pipehandler
Lubrication Points
650/750 Ton Capacity
Rotating
Head
Position
Roller

500 Ton
Rotating
Head

650/750 Ton
Rotating
Head
Support Shaft
Brush with
grease

Support Shaft
Brush with
grease

500 Ton
Link Adapter

IBOP
Actuator
Cranks

Link Adapter
Wear Shoe

Upper
IBOP
Valve

IBOP
Actuator
Cranks

Link Adapter
Wear Shoe

Upper
IBOP
Valve

IBOP
Actuator
Cam
Followers

IBOP
Actuator
Cam
Followers

IBOP
Actuator
Arms

Link
Spreader

Link
Spreader

IBOP
Actuator
Arms

Clamp
Body
Cylinder
Trunnion

Torque Tube
Clevis Pins

Clamp
Body
Cylinder
Trunnion

Clamp
Body

Torque Tube
Clevis Pins

Elevator
Link Eyes
Pipe Dope

Clamp
Body

Elevator
Link Eyes
Pipe Dope

Apply two pumps


of grease to
each grease fitting
16

Apply two pumps


of grease to
each grease fitting
17

LUBRICATION

LUBRICATION

650/750 Ton
Link Adapter

PH-85 Pipehandler
Lubrication Points
500 Ton Capacity

PH-85 Pipehandler
Lubrication Points
650/750 Ton Capacity
Rotating
Head
Positioning
Roller

500 Ton
Rotating
Head

650/750 Ton
Rotating
Head
Support Shaft
Brush with
grease

Support Shaft
Brush with
grease

500 Ton
Link Adapter
IBOP
Actuator
Cranks

Link Adapter
Wear Shoe

Upper
IBOP
Valve

IBOP
Actuator
Cranks

Link
Adapter
Wear
Shoe

Upper
IBOP
Valve

IBOP
Actuator
Cam
Followers

IBOP
Actuator
Cam
Followers
Link
Spreader

IBOP
Actuator
Arms

Clamp Body
Cylinder
Trunnion

Torque Tube
Clevis Pins

Link
Spreader
IBOP
Actuator
Arms

Clamp
Body
Cylinder
Trunnion

Torque Tube
Clevis Pins
Clamp
Body

Clamp
Body

Elevator
Link Eyes
Pipe Dope

Elevator
Link Eyes
Pipe Dope

Apply two pumps


of grease to
each grease fitting

Apply two pumps


of grease to
each grease fitting
18

19

LUBRICATION

LUBRICATION

650/750 Ton
Link Adapter

Adjusting the
Counterbalance System

Procedure

Procedure
Leave the HPU on during the entire adjustment
procedure, and disconnect the TDS from the drill string
near the bottom of the rails, but well off the stops.
1. Remove the caps and loosen the lock nuts on the
needle valve and PRV located on the
counterbalance manifold. It is not necessary to
remove the front guard for access to the manifold.
A small amount of oil will leak around the adjusting
stems after removing the caps.
2. Open the needle valve and let the stem circulate
for two minutes. Crack both upper cylinder fittings
and bleed air from system. Tighten the fittings.
Close the needle valve.
3. Using a hex wrench, screw in the PRV until the
cylinder retracts, raising the TDS.
4. Slowly back out the PRV. The pressure decreases
and the cylinder rods begin extending. When the
integrated swivel bail contacts the hook, note the
pressure on the gauge. Allow the pressure to
decrease an additional 25 psi and tighten the
locknut. Replace the caps on the valve adjustment
stem.
Counterbalance Manifold
Upper Motor Frame
Crossmember (Ref.)

Needle Valve
(on opposite
side)
Pressure
Gauge

Pressure
Reducing
Valve
20

Once the alignment cylinder is installed, use the


following procedure to properly adjust the motor
alignment before operating TDS systems that have a
separate alignment cylinder accumulator and valve
manifold.
1. With the HPU turned off, bleed down the alignment
cylinder accumulator by opening the needle valve
located at the alignment cylinder valve manifold.
2. Remove the split shipping brace from the motor
alignment cylinder.
3. Turn on the HPU and allow the system to circulate
for approximately two minutes.
4. Close the needle valve.
5. Open the two flow control valves located at the
alignment cylinder supply return lines 1-1/2 turns
off their seats.
(The pressure setting is adjusted by screwing the PRV
in or out with a hex wrench. 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.)
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
21

MAINTENANCE / SPARES

MAINTENANCE / SPARES

Adjusting the Motor


Alignment Cylinder

Adjusting the Motor


Alignment Cylinder
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.
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.)

Motor Alignment Accumulator


Gas Valve
Bracket

Accumulator

Needle Valve
Alignment
Cylinder Manifold
Pressure Reducing
Valve
Motor Alignment Cylinder

Motor Alignment
Cylinder

2 3/8 in.

Gland

22

Rod
Threads

Jam
Nut

Clevis

23

MAINTENANCE / SPARES

MAINTENANCE / SPARES

Procedure Continued

Adjusting the Motor


Alignment Cylinder

Adjusting the Torque


Wrench

Procedure Continued

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.)
2. With the HPU off, screw the RECYCLE, CLAMP,
and TORQUE sequence valves on the torque wrench
manifold fully in.
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.
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.
24

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.

25

MAINTENANCE / SPARES

MAINTENANCE / SPARES

Procedure

Adjusting the Torque


Wrench

Adjusting the Torque


Wrench
Torque Wrench Control Manifold

Pipehandler
Consummables
Typical for PH-60 and PH-85

Torque Gauge
0 - 2500 PSI

90

500

60

1500
1000

50

10

20

40

2000

80

70

2500

Make/Break
Valve

10

Torque Wrench
Manifold

30

PRV

Link Adapter
Wear Shoe

Upper IBOP
Valve Seals
Lower IBOP
Valve Seals

CLAMP

Clamp
Sequence
Valve

Saver Sub

LIFT LOWER

RECYCLE

Torque
Sequence
Valve

Tong Dies
Guide Flippers

Recycle
Sequence
Valve

Lift/Lower
Flow Control
Valve

Hydraulic
Pressure
Return
26

Hydraulic
Pressure
Inlet

See Technical Drawing Book


for Varco part numbers
27

MAINTENANCE / SPARES

MAINTENANCE / SPARES

TORQUE

IBOP Actuator
Cam Followers

Wash Pipe Assembly


Typical Assembly View

The wash pipe nut


and the packing
box have
left-handed
threads
Slide the
wash pipe nut
and the packing
box together
for installation

Dowel
Pin

Hand pack all


seals with
multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void

The wash pipe should be replaced when any measurable


wear or grooving is present
If the packing box is properly tightened, and a leak is still
present, do not attempt to eliminate the leak with additional
hammering (See Installation Procedure)

28

Installation Procedure
1. Install the wash pipe assembly on the Top Drive and
hand tighten the wash pipe nut and packing box
(apply pipe dope to the threads)
2. Manually rotate the mainshaft 1 or 2 revolutions to
seat and align the pipe in the packing box
3. Set the Top Drive brake
4. Tighten the packing box first with the wash pipe
wrench or by hammering a few blows on every other
lug, releasing the brake, turning the mainshaft and
reseting the brake with each blow (the packing box
should tighten at approximately 3/4 turn or advance
1/4 inch from the hand tightened position)
5. Tighten the wash pipe nut next with the wash pipe
wrench or by hammering gently on a lug (the wash
pipe nut should tighten at approximately 1/4 turn or
advance 1/10 inch from the hand tightened position)
6. Apply 6 to 8 pumps of multipurpose lithium-based or
high temp moly-based grease to the grease fitting
7. Rotate the Top Drive at approximately 50 rpm for 1
minute without mud pumps
8. Turn on the mud pumps and check for leaks (if leaks
occur, disassemble and repeat all previous steps)
9. If leaks continue, see the Top Drive service manual
for inspection of alignment and runout of mating parts.
29

MAINTENANCE / SPARES

MAINTENANCE / SPARES

Ensure that the nose of the


socket head dog nose screw
is fully engaged in the groove of
the lower spacer

Wash Pipe Assembly


Reassembly Procedure
1. With the packing box upside down, assemble the
packing seals and spacers into the packing box using
care to line-up the upper spacer slot with the dowel pin
2. Hand pack all seals with multipurpose lithium-based or
high temperature moly-based grease using care not to
grease the outside diameter of the spacers
3. Install the socket head dog nose screw, ensuring that
the screw nose is fully engaged in the groove of the
lower spacer
4. Install the grease fitting and turn the packing box upright
5. Install the wash pipe into the packing box assembly
(slotted end up)
6. Install the wash pipe nut onto the wash pipe
7. Grease the packing seal and install into the holding
ring using care not to grease the outside diameter
of the holding ring
8. Install the packing seal and holding ring over the
slotted end of the wash pipe
9. Install the snap ring
10. Install the upper and lower o-rings using grease to
hold them in place
11. Compress the assembly to the length of the wash pipe

Wash Pipe Assembly

Wash Pipe Assembly

Special Tools

Wash Pipe Wrench

Parts Breakdown

Recommended for proper


tightening of the wash pipe
nut and packing box

3" Bore
Wash Pipe Wrench
30150084
4" Bore
Wash Pipe Wrench
141481

4" Bore Packing Kits

4" Bore

O-Ring
51300-348-F
Snap Ring
123562
Holding Ring
123288
Packing Seal
(5 per Set)
123292-2 or
123292-3

O-Ring
51300-359-F
Snap Ring
123634
Holding Ring
123437
Packing Seal
(5 per Set)
123584-2 or
123584-3

Wash Pipe
Nut
123284

Wash Pipe
Nut
123431

Part #'s

Contents

Comments

Wash Pipe
123289
*123289-TC
* Tungsten Coated

Wash Pipe
123438
*123438-TC
* Tungsten Coated

123440-PK
(Standard)

(1) Packing Set 123584-2


(2) O-Rings 51300-359-F
(1) Grease Fitting 53219-1

Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123438 or 123438-TC)

123440-PK-1 (1) Packing Set 123584-3


(High Pressure) (2) O-Rings 51300-359-F
(1) Grease Fitting 53219-1

Nitrile/Armide, Pressure
rated at 7,500 psi
(Use with Wash Pipe
123438-TC only)

Packing Box
123563

Packing Box
123626

Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564

Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564

3" Bore Packing Kits


Part #'s

Contents

Comments

Long-Arm
Allen Wrench
53303-14
Upper Spacer
123285

Long-Arm
Allen Wrench
53303-14
Upper Spacer
123434

123290-PK
(Standard)

(1) Packing Set 123292-2


(2) O-Rings 51300-348-F
(1) Grease Fitting 53219-1

Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123289 or 123289-TC)

123290-PK-1 (1) Packing Set 123292-3


(High Pressure) (2) O-Rings 51300-348-F
(1) Grease Fitting 53219-1

Nitrile/Armide, Pressure
rated at 10,000 psi
(Use with Wash Pipe
123289-TC only)

Middle Spacer
123286

Middle Spacer
123435

Middle Spacer
123286

Middle Spacer
123435

Lower Spacer
123287

Lower Spacer
123436

O-Ring
51300-348-F

O-Ring
51300-359-F

30

123440 &
123440-750

31

MAINTENANCE / SPARES

MAINTENANCE / SPARES

3" Bore

123290 &
123290-1000

Drill Stem
Torque Values

Drill Stem
Rotating Head
Inside
Diameter
(inches)

Connection

Outside
Diameter
(inches)

Swivel to Main Shaft


3
7-5/8 API Reg.
8-5/8
Link Adapter

Torque
Arrestor
Link Adapter
Support Plate

Torque
(ft-lb)

65,500

3-1/2

8-5/8

65,500

8-3/4

71,000

3-1/2

8-3/4

71,000

8-7/8

77,000

3-1/2

8-7/8

75,000

83,000

3-1/2

79,000

9-1/4

88,000

3-1/2

9-1/4

79,000

Main Shaft to Upper IBOP Valve


3
6-5/8 API Reg.
7-3/4
52,000

1735

Upper IBOP Valve to Lower IBOP Valve


3
6-5/8 API Reg.
7-3/8
48,000
1600

Upper
IBOP Valve

Lower IBOP Valve to Saver Sub


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

1535

Crossover Sub to Lower IBOP Valve


3
6-5/8 API Reg.
7-3/8
46,000
1535
* Read the psi at the gauge on the torque wrench manifold

IBOP
Valve Actuator

Lower
IBOP Valve

Saver Sub
32

33

MAINTENANCE / SPARES

MAINTENANCE / SPARES

Pressure
(psi*)

Torque Values

Torque Values

Bolts Lubricated with


Anti-seize Compound

Bolts Lubricated with


Light Machine Oil

Grade 5

Grade 5
Max.
Torque
(ft lb)

Clamp
Force
(lb)

Coarse Thread Series, UNC


1/4
20
7.6
8.4

2020

Diameter

Threads
per inch

Min.
Torque
(ft lb)

Threads
per inch

Max.
Torque
(ft lb)

Coarse Thread Series, UNC


5.7
6.3
1/4
20

Clamp
Force
(lb)

2020

5/16

18

16

18

3340

5/16

18

12.1

13.4

3340

3/8

16

29

32

4940

3/8

16

21.4

23.6

4490

7/16

14

48

53

6800

7/16

14

36

39

6800

1/2

13

71

79

9050

1/2

13

53

59

9050

9/16

12

105

116

11600

9/16

12

78

87

11600

5/8

11

143

158

14400

5/8

11

107

118

14400

3/4

10

247

273

21300

3/4

10

185

205

21300

7/8

409

452

29400

7/8

306

339

29400

608

672

38600

456

504

38600

1-1/8

760

840

42300

1-1/8

570

630

42300

1-1/4

1064

1176

53800

1-1/4

798

882

53800

1-3/8

1387

1533

64100

1-3/8

1040

1150

64100

1-1/2

1843

2037

78000

1-1/2

1382

1528

78000

Fine Thread Series, UNF


1/4
28
9.5

Fine Thread Series, UNF


7.1
1/4
28

7.9

2320

5/16

24

18

20

3700

5/16

24

13.5

15.0

3700

3/8

24

33

37

5600

3/8

24

25

28

5600

7/16

20

52

58

7550

7/16

20

39

43

7550

1/2

20

86

95

10700

1/2

20

64

71

10700

9/16

18

114

126

12950

9/16

18

86

95

12950

5/8

18

162

179

16300

5/8

18

121

134

16300

3/4

16

285

315

23800

3/4

16

214

236

23800

7/8

14

447

494

32400

7/8

14

335

370

32400

14

665

735

42200

14

499

551

42200

1-1/8

12

836

924

47500

1-1/8

12

627

693

47500

1-1/4

12

1178

1302

59600

1-1/4

12

884

977

59600

1-3/8

12

1596

1764

73000

1-3/8

12

1197

1323

73000

1-1/2

12

2090

2310

87700

1-1/2

12

1568

1733

87700

10.5

2320

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi


T.S. = 105,000 psi 1-1/8" to 1-1/2" dia. Proof Strength = 74,000 psi

34

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi


T.S. = 105,000 psi 1-1/8" to 1-1/2" dia. Proof Strength = 74,000 psi

35

GENERAL INFORMATION

GENERAL INFORMATION

Diameter

Min.
Torque
(ft lb)

Service Centers

Service Centers

United States of America

India

Varco
12950 West Little York Road
Houston, TX 77041
P.O. Box 1473
Houston, TX 77251
USA

Varco
Contact: Support Help Desk
Telephone: (713) 856-4128
Fax: (713) 849-6189
Contact: Service Manager
Office: (713) 937-5500

Varco
8404 West Hwy. 90
New Iberia, LA 70560
USA

Contact: Service Manager


Office: (318) 364-4583
Fax: (318) 365-2545

Australia
Varco
1378 Sale
Victoria, 3850
Australia

Varco do Brasil Ltda.


Estrada So Jos Imboassica,
sn-Imboassica
Maca
Rio de Janeiro 27902-000

Office: 55-24-27-730600
Fax: 55-24-27-730600

Contact: Workshop Manager


Mobile: (65) 96320997

China
Varco

Contact: Service Manager


Mobile: (86) 1393008965
Contact: Service Manager
Office: (86) 106-495-3025
Mobile: (86) 1391224037

36

37

GENERAL INFORMATION

GENERAL INFORMATION

Contact: Service Manager


Office: (011) 44-1674-677-222
Fax: (011) 44-1674-677-379

Contact: Regional Service Manager


Mobile: (65) 97313441
Contact: Offshore Supervisor
Office: (65) 265-5066
Fax: (65) 265-7485
Mobile: (65) 98314736

United Kingdom
Varco (U.K.) Ltd. Systems
Forties Road
Montrose, Angus DD109ET
Scotland

Contact: Service Manager


Office: (61) 893-363-988
Fax: (61) 893-363-987

Singapore
Varco
No. 8, Sixth Lok Yang Road
Singapore 628106

Brazil

Contact: Service Manager


Office: (91) 36-155-1621

Specifications
Motor

GE 752 Series or
Shunt Hi-Torque DC Motor, 1130 hp
API Hoisting Capacity

500, 650 or 750 ton


Dolly Sizing (custom configurations available)

Swing/Non-Swing
Retract
30 x 72
91 x 108
32 x 72
39 x 66
48 x 62
(inches setback x spacing)
D

Pipe Handler

PH-60

60,000 lb ft torque

PH-85

85,000 lb ft torque

Drill Pipe Sizes

3 1/2" to 6 5/8" (4 5/8" to 8 1/4" OD Tool Joint)

GENERAL INFORMATION

Stack Up Height

TDS-4S
20.8 ft (6.3 M)

TDS-4H
26.2 ft (7.9 M)
(includes separate
typical swivel)
B

System Output

Series
Torque (lb ft)

Hi

Lo

Shunt
Hi

Lo

Continuous

32500 50900

29640 46380

Intermittent

43400 67800

39500 61800

Maximum RPM
@Full Power

190

120
38

205

130