VARCO BJ

ROTARY
EQUIPMENT
CARE &
MAINTENANCE
HANDBOOK

1
 CARE AND MAINTENANCE
HANDBOOK
TABLE OF CONTENTS

Section Page
Number Topic Number

I. KELLYS AND KELLY BUSHINGS

Proper Handling of Kellys .......................... 7
Care of Kellys ............................................. 12
Description of Kelly Drive Bushings ........... 13
Varco Kelly Bushings ................................. 15
Installation ............................................. 17
Operation ............................................... 17
Maintenance .......................................... 18
Inspection .............................................. 19
Indexing a Kelly...................................... 23
Drive Pin Repair ..................................... 23
Kelly Bushings with Drive Pin Locks ...... 24
II. MASTER BUSHINGS AND SLIPS
Proper Handling of Master Bushings
and Slips .................................................... 25
Varco Master Bushings .............................. 27
Installation ............................................. 28
Casing Bushings .................................... 29
Bit Breaker Adapter Plate ....................... 29
Maintenance .......................................... 30
Inspection .............................................. 30
Drive Hole Bushing replacement ............ 37
Varco Slips................................................. 38
Multipurpose Safety Clamp.................... 41
Slip Inserts............................................. 41
Operation ............................................... 42
Maintenance .......................................... 43
Spring Slips ........................................... 45
Summary ............................................... 46
III. TECHNICAL DATA
Appendix.............................................. TD-47

2
 CARE AND MAINTENANCE
LIST OF ILLUSTRATIONS

Figure Page Figure Page

Number Title Number Number Title Number

1. Kelly Sizes................................................... 7 41. Hex Gauge on Kelly ..................................... 19

2. Kelly and Rollers ......................................... 7 42. Maximum Roller Wear ................................ 20
3. Kelly tolerances........................................... 8 43. Split Body Inspection .................................. 20
4. Kelly Inspection........................................... 8 44. Top Nut Inspection...................................... 20
5. Maximum Kelly Wear .................................. 8 45. Roller Bearing Inspection............................ 21
6. New Kelly Wear ........................................... 8 46. New Roller Assmebly .................................. 21
7. Kelly and Roller Wear Development ............ 9 47. Roller Pin Wear ........................................... 21
8. Worn Kelly with New Rollers....................... 9 48. Bearing Cage Inspection ............................. 22
9. Maximum Kelly Wear .................................. 9 49. Journal Inspection ...................................... 22
10. Deformed Kelly ........................................... 9 50. Outside Journal Measurement .................... 22
11. Kelly Measurement ..................................... 9 51. Indexed Kelly............................................... 23
12. Driving Edge Wear ...................................... 10 52. Drive Pin Removal ...................................... 23
13. Kelly that Has Turned Thru Rollers.............. 10 53. Drive Pin With Lock .................................... 24
14. Driving Edge Inspection .............................. 10 54. Slips and Master Bushing Forces................ 25
15. Roller Wear ................................................. 10 55. Results of Friction ....................................... 25
16. Unusable Kelly ............................................ 11 56. Distribution of Forces.................................. 26
17. Common Kelly Fatique Locations ................ 11 57. Square Drive Dimensions............................ 26
18. Kelly Re-Milling........................................... 11 58. Pin Drive Dimensions.................................. 26
19. Strength of Kellys........................................ 11 59. Long and Extra-Long Slips.......................... 27
20. Kelly in Scabbard ........................................ 12 60. Square Drive Master Bushings.................... 27
21. Improper Kelly Storage ............................... 12 61. Lifting Slings............................................... 28
22. Kelly in Rathole ........................................... 12 62. Bowl Lock ................................................... 28
23. Heavy Duty Kelly Bushings ......................... 13 63. MPCH Master Bushing................................ 29
24. 4KRS Kelly Bushing .................................... 13 65. Casing Bushings ......................................... 29
25. HDP/4KRP Size Comparison....................... 13 65. Bit Breaker Adapter Plate ............................ 29
26. Kelly Bushing Components ......................... 14 66. Rotary Equipment Wear Points ................... 30
27. Bolt/Stud Retaining Systems ...................... 14 67. Slips Riding High in Master Bushing........... 31
28. Roller Pin Development .............................. 14 68. Slip Riding Low in Master Bushing ............. 31
29. Thrust Washers and Seals .......................... 15 69. Wrapping Test Paper Around Kelly.............. 31
30. HDP Kelly Bushing ...................................... 15 70. Setting Slips................................................ 31
31. HDS Kelly Bushing ...................................... 15 71. Removing Slips........................................... 32
32. MD Kelly Bushing........................................ 16 72. Test Paper Full Contact................................ 32
33. 4KR Kelly Bushing ...................................... 16 73. Test Paper Poor Contact.............................. 32
34. Kelly Bushing Installation............................ 17 74. Master Bushing Wear.................................. 32
35. Kelly Bushing Assembly.............................. 17 75. Rotary Table Wear....................................... 33
36. Kelly Bushing in Position ............................ 17 76. New Bushing and Worn Rotary Table.......... 33
37. Typical Kelly Bushing Roller Assy ............... 18 77. Solid Body Master Bushing......................... 33
38. Typical Pin Drive Kelly Bushing ................... 18 78. Worn Slips in New Bushing......................... 33
39. Typical Square Drive Kelly Bushing ............. 18 79. New and Worn Square Drive Bushings ....... 34
40. Kelly and Roller wear .................................. 19 80. Square Drive Bushing with Worn I.D........... 34

3
 LIST OF ILLUSTRATIONS (Continued)

Figure Page Figure Page

Number Title Number Number Title Number

81. Checking Master Bushing I.D...................... 34 121. Slip Segment Damage................................. 44

82. Checking Master Bushing Bowl Taper ......... 34 122. Hinge Pin Removal...................................... 44
83. Square Drive Bushing Wear ........................ 35 123. Slip Segment............................................... 44
84. New and Worn Pin Drive Bushings ............. 35 124. Setting Slips................................................ 45
85. Comparison of New and Worn MPCH ......... 35 125. Slips in Set Position .................................... 45
86. Pin Drive Bushing with Worn I.D................. 36 126. PS-15 Assembly ......................................... 45
87. Measuring Master Bushing ......................... 36
88. Bowl Showing Maximum Wear ................... 36
89. Pin Drive Bushing Wear .............................. 36
90. Measuring Master Bushing Upper I.D ......... 36
91. Measuring Wear in Hull Lower I.D .............. 37
92. Worn Out Master Bushing........................... 37
93. Drive Hole Bushing Removal....................... 37
94. Drive Hole Bushing Replacement ................ 37
95. SDS-Short Rotary Slips .............................. 38
96. SDS-Grip Length......................................... 38
97. SDML-Medium Rotary Slips ....................... 38
98. SDML-Grip Length ...................................... 38
99. SDXL-Extra-Long Rotary Slips.................... 38
100. SDXL Grip Length ....................................... 39
101. Rotary Slip Set Parts................................... 39
102. DCS-Multi-Segment Drill Collar Slips.......... 39
103. DCS Parts ................................................... 39
104. DCS Grip Lengths ....................................... 40
105. CMS-XL Casing Slips .................................. 40
106. CMS-XL Parts ............................................. 40
107. CMS-XL Grip Length................................... 40
108. CP-S- Conductor Pipe Slips ........................ 40
109. Multipurpose Safety Clamp ......................... 41
110. Safety Clamp Assembly .............................. 41
111. Safety Clamp Parts...................................... 41
112. Rotary and Casing Slip Inserts.................... 41
113. Stopping Pipe with Rotary Slips ................. 42
114. Incorrect Use of Rotary Slips ...................... 42
115. Drill Collar Slip Insert Damage .................... 42
116. Setting Slips on Tool Joints......................... 43
117. Rotary Slips in Position............................... 43
118. Surfaces that Require Dressing................... 43
119. Bent, Worn Slips ......................................... 44
120. Checking Slip Segments ............................. 44

4
 INTRODUCTION

This handbook was devised to highlight the

importance of rotary equipment to the overall
drilling operation. The kelly is the direct link
between the power drive of the rotary and the drill
bit. To keep turning to the right, the kelly and
equipment that handless it must be taken care of
and kept in top working order.

It is Varco’s hope that this handbook will find its

way to every head and hand in the oil patch, that it
will be useful to them, and that it will be an aid to
keeping things running smoothly.

SO, USE IT, GET IT DIRTY, AND ASK FOR

ANOTHER ONE!

Holland
Houston
Montrose
Singapore

5
The care and maintenance of rotary
equipment

The search for energy continues at an ever-

increasing rate. Wells are being drilled daily to
greater depths than were thought possible only a
generation ago. These deep wells place great
demands on both the rig’s rotary equipment and
the crews that operate and maintain it.

Th rotary equipment is the very heart of the drilling

operation. All drilling operations center around the
master bushing, slips, kelly and kelly bushing. Even
though this equipment is designed for long service
life and is able to absorb a certain amount of
mistreatment, it will eventually wear out.
When a piece of rotary equipment fails in use, the
results are often dangerous and always expensive.

A planned program of regular inspection and

maintenance will save a great deal of rig time and
money. The real problem seems to be that rotary
equipment on the rig may remain in service for
several years without failure, and its performance is
taken for granted. All too often, the only time a
problem appears is when a kelly turns through a
kelly bushing, or when pipe is inspected, and
several joints must be discarded due to
bottlenecking in the slip area.

The purpose of this handbook is to avoid expensive

damage to drill pipe, drill collars, and kellys due to
improper handling and equipment maintenance.

Although Varco BJ equipment is shown extensively

throughout this handbook; inspection,
maintenance, and operating principles are
essentially the same for all manufacturers’
products.

6
5
 SECTION I
KELLYS AND KELLY BUSHINGS
Proper handling of kellys
The width of the driving surface on the kelly is
directly proportional to the amount of clearance
between the kelly and the kelly bushing rollers. The
tighter the clearance, the wider the driving surface
will be.
A few facts about kellys and the causes of wear will
give better insight to the importance of kelly
bushing maintenance.
The 5-1/4 inch hex kelly is the most popular size
kelly in use today. Due to its strength, small OD
tool joint on the pin end and large bore for better
hydraulics, it is also one of the hardest kellys to
maintain. The kelly measures 5-1/4 inches (133
mm) across the flats and only 6 inches (152 mm)
across the corners. The kelly is almost round to
start with and must be run in a good kelly bushing
(Figure 2).

Kellys are manufactured either from bars with an

as-forged drive section, or from bars with fully
machined drive sections . They may be hexagonal
or square. When new, both kellys and kelly
bushings form perfect hexagons or squares. Figure
1 shows the standard size kellys currently in use.

*SQUARE * HEX
2-1/2 In. 3.0 In.
3.0 In. 3-1/2 In.
3-1/2 In. 4-1/4 In.
4-1/4 In. 5-1/4 In.
5-1/4 In. 6.0 In.

Kelly Sizes
Figure 1

For additional information on kellys of other sizes,

refer to API Specification 7.

When the kelly and bushing are new, there is a

perfect fit between the two hexagonal surfaces.

When the kelly is put into service, one small mark

starts on the roller from kelly contact, the kelly
deforms to provide driving surface on the kelly.

7
 .013 to 0.06 In. Wear pattern width is determined by:
(0,33 to 1,5 mm)
WEDGE
1. Kelly size.
2. Total clearance between kelly and rollers.
3. Roller to kelly contact angle.

.187 In.
5-1/4 In. + 1/32 -0) 1-1/4 In. (32mm) (5 mm)
(133 mm + 0,8 -0)
8° 37’

MAX CONTACT
.013 to 0.06 In. ANGLE USES
(0,25 to 1,5 mm) ALMOST
ALL THE
RADIUS

WEDGE

Maximum Kelly Wear

4-1/4 In. + 3/32 .0 Figure 5
(108 mm + 2,4 .0)

Kelly Tolerances The maximum possible width of wear pattern on a

Figure 3
Figure 3 shows the API specifications for the two
most popular kellys, the 5-1/4 inch hex and the 4-
1/4 inch square. Note the tolerances: 5-1/4 + 1/32, -
0 inch hex and 4-1/4 + 3/32, -0 inch square.
5-1/4 inch hex kelly is 1-1/4 inches (32mm)
(Figure 5). Notice that with this amount of drive, the
radius on the corner is almost worn off but no metal
has started rolling over.

WIDE WEAR
PATTERN

SMALL FLAT
CONTACT SURFACE
ANGLE

Kelly Inspection
Figure 4 Figure 6

A good indicator of the condition of the kelly and

kelly drive bushing is the width and appearance of
the wear pattern on the kelly flats (Figure 4).
Recognizing wear patterns can give early warning
of when the kelly drive bushing requires more than
routine maintenance.
Figure 6 shows the wear pattern on a new kelly
with a kelly bushing in new condition. The driving
edge is flat and there is a full 1-1/4 inches (32 mm)
of driving edge.

8
 HIGH
CONTACT
ANGLE

NO FLAT
SURFACE

Maximum Kelly Wear Pattern Width (Inches)

Figure 9
Kelly and Roller Wear Development
Figure 7 What causes kelly wear?

Figure 7 shows the condition that exists with a

worn kelly and worn parts in the kelly drive
bushing. Due to roller wear, the driving edge is no
longer flat and the corners have begun to round off.

REDUCED
WIDTH

INCREASED FLAT
SURFACT
Deformed Kelly
CONTACT
ANGLE NO Figure 10
CURVATURE
The kelly in Figure 10 has been deformed by drive
forces received from the rollers. The greater the
clearance between the rollers and the kelly, the
smaller the available drive surface will be.

Worn Kelly with New Rollers

Figure 8

Figure 8 shows a kelly with considerable wear in a

kelly drive bushing with new roller assemblies. The
clearance between the kelly and the rollers has
increased, resulting in reduced width of the driving
edge and an increased contact angle.

Maximum possible wear pattern widths vary with

respect to the size of the kelly (Figure 9). Notice the
5-1/4 inch hex kelly has a 1-1/4 inch (32 mm) drive Kelly Measurement
pattern. These measurements are only obtainable Figure 11
with a new kelly in a new kelly bushing. Narrower
drive patterns than those shown are due to
additional clearance between kelly and drive
rollers.

9
Figure 11 shows the kelly driving edge being
measured. The older driving surface measured 1-
1/4 inches (32 mm). Before this kelly was taken out
of service, however, the area was reduced to 1/2
inch (12,7 mm) due to excessive clearance
between the kelly and the rollers.
Driving Edge Wear
Figure 12
Figure 12 shows the same kelly with an extreme
roll-over of the kelly’s driving edge. A watchful eye
and the replacement or adjestment of worn parts in
the drive bushing would have extended the life of
this kelly.
Kelly That Has Turned Through Rollers
Figure 13
Figure 13 shows a kelly in a drive bushing that was
still in use. Observe the area of the kelly just above
the drive bushing. The kelly has turned through the
rollers of the bushing at this point. A kelly will not
turn through the rollers unless too much clearance
exists between the rollers and the kelly, reducing
the driving surface and increasing the contact
angle. If the kelly is put in a high torque situation
with this much clearance, the kelly will turn through
the bushing again and again.
10
Therefore, the kelly bushing must be taken out of
service and thoroughly inspected for wear.
Driving Edge Inspection
Figure 14
Figure 14 shows a kelly that has been in service for
only three months. The driving edge is not 1-1/4
inches (32 mm) but only 1/2 inch (12,7 mm). If the
kelly bushing or its parts are not replaced, the kelly
will turn through the worn kelly bushing in as little
as three more months. The cost of replacing this
kelly can be avoided.
Roller Wear
Figure 15
Figure 15 shows a roller with a driving surface
about one inch (25,4 mm) wide, which is pretty
good. The wear pattern, however, should be at the
bottom on one side of the V and at the top of the
other side. This shift in the placement of the driving
surface on the rollers is due to wear in assembly
parts or in the body of the bushing.
A kelly may be unusable for three reasons:

1. It is bent.
2. Metal fatique.
3. The corners of the drive surfaces are worn.

Unusable Kelly
Figure 16

1. Bent kellys
If a kelly has become bent (Figure 16), is
should be straighetened to avoid high bending Kelly Re-Milling
stresses and early fatique damage. Figure 18

Before a kelly is sent in to be milled, there are

several checks that should be made to see if it will
qualify:
UPPER FILLET CENTER LOWER FILLET a. It should be magnafluxed over its entire length
Common Kelly Fatigue Locations to check for cracks.
Figure 17
b. Check the OD across the corners and across
2. Kelly fatigue the flats.
Kelly fatigue is likely to occur in three places
(Figure 17): c. Check the ID.

a. The upper fillet d. The wall thickness should be checked by

b. The lower fillet ultrasonic measurement over its entire length.
c. In the middle of the kelly body
e. Check the remaining tong area on the toll
The fillet is a transition area from the more joints.
flexible body of the kelly to the very rigid tool
joint section. Even with the 37-degree taper,
this transition area is susceptible to fatigue.

When the kelly is bored from both ends during

manufacture, a misalignment of the two bores
may occur at the center due to the boring
tools drifting slightly. this creates a possible
fatigue point.
Strength of Kellys (New vs. Re-Milled)
3. Worn Kelly Drive Surfaces Figure 19

If a 5-1/4 inch hex kelly has not turned through
the bushing due to wear, it can be milled down
1/8 inch (3,2 mm) on each flat and cleaned up.
This kelly would then be referred to as a 5 inch
special hex kelly.
The weakest section of a kelly is the lower pin
connection. As shown in the chart (Figure 19),
a 5-1/4 inch hex kelly, bore will have an increased
diameter of 3-1/4 to 3-1/2 inches (82 to 89 mm).
This weakens the pin section slightly

If a kelly is re-milled it will be necessary to

replace the rollers with rollers for the next
smaller size kelly.

11
Some dos and don’ts on Kellys:

Do’s:

Do inspect the kelly frequently.

Do keep the drive surfaces lubricated and use a

kelly wiper rubber.

Do use a saver sub to prevent wear of the lower pin

connection.

Do use new roller assemblies when a new kelly is

put into service.

Don’ts: Improper Kelly storage

Figure 21
Don’t weld on drive corners.

Don’t move or store a kelly without the use of a

scabbard.

Don’t use a crooked kelly.

Care of kellys
Here are some tips on handling kellys to get
maximum life from them.

Kelly in Rathole
Figure 22

Kelly In Scabbard The kelly should be tied back to prevent it from

Figure 20
The drive section of a kelly is quite flexible. Due to
its length and weight, a kelly should never be
handled or moved without being in a scabbard
(Figure 20). Always support the scabbard in two
places rather than one.
Shown in Figure 21 is an empty scabbard and an
unprotected kelly on the bottom of the rack. This
should never be done.
being bent (Figure 22). The weight of the swivel
above the kelly will bend it unless tie back
precautions are taken. This is especially important
on smaller size kellys.
When the kelly is picked up or set back, care
should be taken to ease the kelly fillet into the kelly
bushing. The shock loads from running the fillet into
the rollers of the kelly bushing can damage
bearings in the bushing.

12
 Description of kelly drive
bushings
The kelly drive bushing engages the master
bushing in the rotary (either square drive or pin
drive). As the rotary turns, the kelly drive bushing
turns with it, to drive the kelly. At the same time, as
the kelly worksdown, the rollers in the bushing
allow the kelly free movement and keep it centered
in the rotary bore.

the earlier square kelly bushings worked fine in the

square drive master bushings, but as wells became
deeper, longer slips were needed, so the pin drive
system was developed. While developing the pin
drive kelly bushings, Varco also increased the
capability of both the pin drive and square drive,
better enabling them to meet the challenges of
today’s deeper wells. This development became the
Heavy Duty, of HD series. The 4KR series of 4KRS Kelly Bushing
square drive bushings is available for slim hole Figure 24
drilling or workover rig applications.

The Varco HDS and HDP (heavy duty square and

heavy duty pin drive) kelly bushings (Figure 23)
have been available since 1967, answering the
need for better, stronger kelly bushings for high
torque, high speed drilling operations.

APPROX
3 In.
(76 mm)

HDP APPROX 3 In. (76mm) 4KRP

150 lb
(68 kg)
HEAVIER
JOURNAL AREA

HDS HDP

HDP/4KRP Size Comparisons

Heavy Duty Kelly Bushings
Figure 23
HDS and HDP bushings are replacing the older
4KRS and 4KRP bushings (Figure 24) that first
entered the market about 35 years ago.
Figure 25
The HD series kelly bushings, are 3 inches (76,2
mm) shorter, 3 inches (76 mm) narrower, and 150
pounds (68 kg) heavier, than the 4KR series kelly
bushings. The additional weight has been placed in
the journal area.

13
 All too often when this occurs, rig personnel will not
take the time to remove the nut from the stud and
replace the stud in the body with proper torque.
Instead, the nut is left on the stud and assembled
as a bolt. The stud becomes tight in the nut and the
nut torques down a little more on the stud, causing
the stud to back out in even less time. As a result
the top becomes loose, the viselike grip on the
roller pins is no longer effective and the roller pins
can rotate a small amount in the hournal area,
wearing pin and journal, creating slack in the
bushing. In addition, the eccentric design of the
pins allows the rollers to rotate away from the kelly,
causing excessive clearance between kelly and
rollers.

The newer HD series bushing uses bolts pushed

up into recesses in the lower body section and
locked in place with setscrews. The top nuts are
tightened as before but is is impossible for the bolt
to back out in service.

The newer HDP bushing uses straight roller pins

Kelly Bushing Components that lock against each other. Also, the hold-down
Figure 26 bolts are outside the load to provide a vise-like grip
on the pins (Figure 28). The 4KR had an eccentric
The same bearings and rollers are used in both the roller pin held in position by a lock pin. If the top
4KR series and the newer bushings. Major nuts became loose, the eccentric pin would tend to
changes are in the bodu, the roller pins, and the move up and out when the kelly was raised, and
thrust washers (Figure 26). would tend to move down and out when the kelly
was lowered. This movement caused excessive
NUT IS FROZEN TO wear in the bushing’s journal area.
STUD AND STUD
COMES OUT WITH NUT
ROLLER
STUD THRUST WASHER
TOP VIEWS
HOLD DOWN
BOLTS
ROLLER

STUD
RETAINING HDP 4KRP
PIN

Bolt/Stud Retaining Systems HDP 4KRP

STRAIGHT ECCENTRIC
Figure 27 ROLLER PIN ROLLER PIN

In the older 4KR series bushings, the hold-down

nuts would often become frozen to the top of the
stud (Figure 27). During disassembly, the stud Roller Pin Development
would back out of the lower body rather than the Figure 28
nut coming off the stud.

14
A significant improvement to the thrust washer has
been the O-rings on both the OD and the ID that
prevent mud and grit from entering the bearing
area and also retain grease. Keeping the bearing
surfaces clean in this manner results in much
longer bearing life.
THRUST
LOCK PIN WASHERS ROLLER PIN
By changing roller sizes, one bushing can handle
several kelly sizes. Other features are a
selfcentering stabbing skirt, roller bearings or
optional fibre sleeve bearings. The Varco HDP
series kelly bushing is widely recognized as the
drilling industry standard.
The Varco 27 HDP roller kelly bushing is used with
Varco pin drive master bushings for 23, 26, 27-1/2,
37-1/2, and 49-1/2 inch rotary tables. The 27 HDP
has 3-5/16 inch (84 mm) diameter drive pins on a
25-3/4 inch (654 mm) diameter pin center and will
accommodate kelly sizes from 3 to 6 inches hex or
square. This heavy duty kelly drive bushing is
designed for high torque, high speed conditions.

BEARING O-RING
SEALS
ROLLER
Thrust Washers and Seals
Figure 29
Like the rest of the rotary equipment, the kelly drive
bushing has a very long service life (approximately
8 years). Due to this long life, maintenance is often
neglected, and premature failure results.

Varco BJ kelly bushings

Varco HD Series Kelly Bushings

The Varco HDP pin drive roller kelly bushing
(Figure 30) is designed for the most rugged, high
torque, high speed drilling conditions in the world.
Its roller assembly provides an efficient driving
mechanism that maintains good driving edges on
the kelly and allows proper feed of the kelly without
binding.
HDS Kelly Bushing
Figure 31
the Varco 20 HDP roller kelly bushing is used with
Varco pin drive master bushings for 20-1/2, 21, and
22 inch rotary tables. The 20 HDP has 2-1/2 inch
(63,5 mm) diameter drive pins on a 23 inch (584
mm) diameter pin center. It uses the same rollers,
roller assemblies and wiper assemblies as the 27
HDP.

The Varco HDS (square drive) roller kelly bushing

(Figure 31) is a heavy duty bushing designed for
rugged, high torque applications. The HDS will
accommodate square or hex kellys from 3 to 6
inches (76 to 152 mm).

The Varco HDS is used with master bushings

having an inside drive square dimension of 13-9/16
inches (344 mm). This bushing uses the same
rollers, roller assemblies, and wiper assemblies as
the 27 HDP.

HDP Kelly Bushing

Figure 30

15
Varco MD Series Kelly Bushings
Varco’s MD kelly drive bushing is used for shallow
and medium depth drilling operations. Available
either as pin drive (MDP) or square drive (MDS) it
will accommodate 3, 3-1/2, and 4-1/4 inch hex
kellys and 2-1/2, 3-1/2, and 4-1/4 inch square
kellys.
MDP
MDS
MD Series Kelly Bushings
Figure 32
A direct descendant of Varco’s heavy duty (HDP
and HDS) kelly drive Bushing, this medium duty
drive bushing has the same rugged characteristics
built into it. Installation, operation, and maintenance
are the same as for the larger bushings.
The MDP can be used on any drilling rig that has
the Varco pin drive master bushing in either a 17-
1/2 or 20-1/2 inch rotary table. The MDS has an
API square to match the API squares in standard
square drive master bushings.
16
Varco 4KR Series Kelly Bushings
The Varco 4KRVS and 4KRBM kelly bushings,
(Figure 33), are square drive units used with Varco
MSS or API square drive master bushings. Both of
these units will accomodat square and hexagonal
kellys by changing roller sizes.
4KRBM
4KRVS
4KR Series Kelly Bushings
Figure 33
The 4KRVS roller kelly bushing is applicable for
shallow to medium depth drilling, and will
accomodate 2-1/2 thru 5-1/4 inch square or 3 thru
4-1/2 inch hexagonal kellys. The 4 KRBM roller
kelly bushing is applicable for shallow, slim hole
drilling and workover rigs. The 4KRBM will
accommodat 2-1/2 thru 4-1/4 inch square or 3 thru
4-1/4 inch hexagonal kellys.
 g. Lift top half of bushing and reinstall roller
assemblies.
h. Lower the top half the kelly bushing, aligning it
with the locating pin.
i. Instal lockwashers and nuts, then tighten
alternately until secure.
j. Apply multipurpose, water resistant grease to
the roller pin grease fitting before putting the
kelly drive bushing into service

Kelly Bushing Assembly

Figure 35

Operation
a. Lower kelly bushing into the master bushing
(Figure 36). The skirt will follow the taper down
into the throat of the master bushing. The
floating ring (HDP and MDP bushing) will seat in
Kelly Bushing Installation the upper portion of the master bushing,
Figure 34 centering the kelly bushing.

Installation of kelly bushings

a. Lift and set kelly bushing in master bushing.
b. Remove four nuts and lockwashers.
c. Lift top half of kelly bushing off studs and set
aside.
d. Remove the four roller assemblies from lower
half of kelly bushing.
e. Set top half of the kelly bushing loosely on
bottom half.

Note

Make sure that thrust washer lock pins (Figure

35) are toward the center of bushing and lie in
the recessed areas of the lower body half.

All kelly bushing thrust washers come with O-

rings on the inside and outside diameters.
These )-rings help retain grease in the roller
bearing while keeping mud and water out.
Kelly Bushing in Position
f. Stab kelly through bushing. Figure 36

17
Operation (cont.)

b. It is recommended that the rotary table be

turned slowly as the kelly bushing is being
lowered. The bushing will center and the drive
pins* will stab into the drive holes of the master
bushing.
c. The skirt should be greased to allow the kelly
floating ring* to move up easily.
d. Care should be taken when lowering the kelly
into the rathole. Any sudden, jarring stop when
the kelly upset strikes the rollers, can damage
the roller assembly.
e. the life of the kelly and drive bushing parts can
be increased at least 20 percent by using a kelly
wiper rubber. The wiper will keep dirt and other
material from getting between the kelly and the
rollers, resulting in less wear on all parts.

* HDP and MDP bushings.

Note

Applying grease to the kelly will increase the life of

the wiper rubbers.

Maintenance
a. Tighten holddown nuts weekly (Figure 36).
b. Grease roller assembly daily at four fittings. Typical Pin drive Kelly Bushing
c. Grease stabbing skirt for ease of stabbing.* Figure 38
d. Replace drive pins when bottom taper is too
worn to aid in stabbing.
e. Replace the drive hole bushing in master
bushing when worn to an egg shape.
f. replace API drilling bowl when wear in throat
area exceeds 10-7/8 inches (276 mm). Proper
throat size is necessary for good stabbin.
g. Between the top and bottom body halves there
should be 1/8 inch (3,2 mm) clearance; if there
is none, worn journals are indicated and the
kelly bushing should be replaced.

* HDP and MDP bushings.

SLEEVE BEARING
V-ROLLER
OPTIONAL

ROLLER
BEARING
FLAT ROLLER
ROLLER PIN

THRUST WASHER

Typical Square Drive Kelly Bushing

Typical Kelly Bushing Roller Assembly Figure 39
Figure 37

18
 d. Check rollers and assemblies for wear.
5-1/4 in. MAXIMUM e. Check the body for wear.
KELLY DRIVING
SURFACE The amount of driving suface on the kelly is
1-1/4 in inversely proportional to the amount of slack
(32 mm) present between the roller and the face of the kelly.
If, for example, there is only 1/16 inch (1,6 mm)
clearance between the roller and the kelly, the
driving surface of the kelly will be wide and with the
driving forces spread over this wide area, wear will
be minimal. However, if this roller-to-kelly
dimension were 1/4 inch (6,3 mm), the driving
NEW KELLY surface would then be considerably reduced and
NEW ROLLERS the concentrated force of the rotary would begin to
roll the corners of the kelly over (see Figure 3).

Figure 41 shows a 5-1/4 inch hex gauge in a used

kelly bushing. The amount of clearance is greater
than 1/8 inch (3,2 mm). If the gauge were a kelly
and torque was applied, the corners of the kelly
REDUCED would be against the worn spots on the rollers.
DRIVING
SURFACE
1/2 in.
(13 mm)

WORN KELLY
WORN ROLLER

Kelly and Roller Wear

Figure 40 Hex Gauge on Kelly
Figure 41

Inspection During a kelly bushing inspection, the roller

The routine inspection of the kelly bushing is
performed as follows:
a. Check to see if top nuts are tight.
b. Use a bar to check for body wear and roller
assembly wear.
c. Check clearance between rollers and kelly.
assemblies must be checked. The maximum wear
suggested by manufacturers is 1/16 inch (1,6 mm)
for a hex kelly and 1/8 inch (3,2 mm) on rollers for a
square kelly. Only half the life of the roller assembly
in Figure 42 has been used. If the roller assembly
is turned 180 degrees in the body, however, a
completely new drive surface is exposed to the
kelly (see page 17).

19
 ROLLER ASSY TOP NUTS ROLLER ASSY

UPPER LOWER
1/16 in. (1,6 mm) BODY
BODY
HALF HALF

PRY BAR

MAXIMUM ROLLER
WEAR WITH
1/8 In. (3,2 mm)
HEX KELLY ROLLER PIN
CLEARANCE
BETWEEN TOP AND
BOTTOM BODY HALVES

Split Body Inspection

Figure 43

1/8 in. (3,2 mm) Before inspecting a kelly bushing with a split body
for wear, make sure the top nuts are tight. To
prevent excessive wear, the nuts (Figure 43)
should be checked weekly to make sure they are
tight (Figure 44).

MAXIMUM ROLLER
WEAR WITH
SQUARE KELLY

Maximum Roller Wear

Figure 42 Top Nut Inspection
Figure 44

20
Varco kelly bushings have 1/8 inch (3,2 mm)
clearance between the top and bottom body halves
(in new condition). When the top nuts are tight, this
provides a vise-like grip on the roller pins. To check
wear in roller assemblies, place a bar under the
roller and pry the rollers up. The assembly should
not move upward over 1/32 inch (0,79mm). While
checking for roller movement, be sure there is no
movement of the roller pin itself by watching the
end of the pin. If there is m ovement of the roller
pin, the kelly bushing body has journal wear. If
there is more than 1/32 inch (0,79 mm) movement
of rollers, but the pin itself does not move, then the
roller bearings should be replaced and the pin
inspected for wear.
New Roller Assembly
KELLY PRY BAR Figure 46

ROLLER PIN
THRUST WASHER

W
NE

O-RING
LOCK PIN

O-RING MISSING

RN
WO
DEEP WEAR PATTERN

1/8-in. CLEARANCE INNER SURFACE OF THRUST WASHER

(3,2 mm) MAXIMUM SHOWS EXCESSIVE WEAR
ROLLER
LOCK PIN MISSING

Roller Bearing Inspection

Figure 45
With the kelly bushing on the kelly, the clearance
between the drive rollers and the kelly should be
checked. Force a bar between the roller and the
kelly flat surface (Figure 45). The clearance should
not be more than 1/8 inch (3,2 mm) clearance,
there is wear in the roller assemblies and the
bushing body.
Figure 46 shows a new roller assembly in position
in a new, lower body half. The thrust washer lock
pins are retained in the recesses of the lower body
half when the top is bolted in place.
Roller Pin Wear
Figure 47
Figure 47 shows the results of very little lubrication
and a lock pin is missing on the outside of the right
thrust washer. The thrust washer must be locked in
the body by the lock pins so that it will not turn on
the roller pin. If the pin is missing, the thrust
washer will turn, and a deep wear pattern on the
roller pin will result. In this case, the thrust washer
will no longer absorb the load it was designed to
take. This will result in rapid bearing wear, allowing
unacceptable clearance between the kelly and
kelly bushing rollers.

21

Bearing Cage Inspection
Figure 48
Check the bearing cage by taking one end in each
hand and trying to twist the ends in opposite
directions. If there is any movement, the bearing
needs to be replaced. If bearings are checked
every three months or every rig move and replaced
when the bearing cage has movement, before
failure occurs, maximum life can be obtained from
the kelly and kelly bushing.
Journal Inspection
Figure 49
Here is a new roller pin in an old bushing. With use
of a screwdriver, 1/8 inch (3,2 mm) wear in the
journal area is revealed. This wear was caused by
not keeping the top nuts tight on a split body
bushing, or by an accident where the kelly was
either drilled or dropped into the bushing.
22
MAXIMUM ALLOWABLE
MEASUREMENT
Outside Journal Measurement
Figure 50
Here, the outside dimension of the body journals is
being measured. The pencil points out where the
new measurement is and shows that there is
approximately 1/16 inch (1,6 mm) wear indicated.
The exact original measurement is 16-15/16 inches
(430 mm).
Figure 50 shows maximum allowable wear
dimensions across outside journal areas. This type
of inspection can be done to determine body wear
or spread in the body. Spread in the body of the
kelly bushing itself can occur if the total weight of
the upper fillet of the kelly in the rollers of the kelly
bushing. This situation can occur if there is a break
in one of the tool joints above the body of the kelly.
If such an accidental situation should arise, the
kelly bushing body and assemblies must be
inspected for damage as soon as possible.
Again, the routine inspection of the kelly bushing is
as follows:
a. Check to see if top nuts are tight.
b. Use a bar to check for body wear and roller
assembly wear.
c. Check clearance between rollers and kelly
d. Check rollers and assemblies for wear.
e. Check the body for wear.
INCREASED REDUCED To index the kelly, remove the top nuts on the
DRIVE ANGLE DRIVE bushing, lift the top and remove the roller
SURFACE assemblies. Turn the kelly in the bushing 1/6 of a
turn so that the two corners which were against the
ROLLED
flat rollers are now in the V of the other rollers.
OVER
Longer roller assembly life can be achieved by
EDGE
turning the roller assemblies 180 degrees in the
bushing body, each time the kelly is indexed. Lower
the top and tighten the nuts alternately until it is
secure, using a hammer wrench.

WELDMENT
DRIVE PIN WASHER

CHISEL
REDUCED INCREASED
DRIVE DRIVE
ANGLE SURFACE

KELLY BUSHING TAPERED AREA

FLANGE

DRIVE PIN

Drive Pin Removal

Figure 52

WITH KELLY
INDEXED 1/6
Drive pin repair
TURN ROLLED
OVER EDGE
After several years of service, the lower taper of the
ALL ROLLER ASSEMBLIES
WILL BE
drive pins on the kelly bushing will be worn down to
ARE ROTATED 180° WITHIN
DRESSED IN
the top of the taper. The following steps should be
THE BUSHING TO PRESENT
’’VEE’’ OF
followed to replace the drive pins:
NEW DRIVE SURFACES.
ROLLER
Indexed Kelly a. Freeze new drive pins.
Figure 51 b. Remove weld on top of the washer next to the
top of the drive pin in the bushing.
Indexing a kelly c. Use a chisel to drive the washer up from the
flange of the kelly bushing.
Figure 51 shows the difference in the condition of d. Drive the pin down and out with a sledge
the corners of the kelly. The corners that are hammer.
against the flat rollers are rolled over more than the e. After old pins are removed, clean the rust and
corners that are in the V of the other two rollers. burrs from the inside of the taper in the bushing.
f. Turn the kelly bushing upside down and preheat
What has happened is that the driving action of the the area around the hole 400-450° F (204.4-
bushing has forced the corner against both sides of 232.2° C).
the V-roller. This action has dressed the rolled over g. Take the pins one at a time from the freezer and
metal back down. drive them into the bushing until they seat
completely.
If a procedure called indexing the kelly is followed, h. Turn the kelly bushing over and place the drive
the maximum possible life of the kelly can be pin washer over the extended end of the pin and
extended 30-40 percent if the kelly is indexed after weld it in place. Fill the recessed area of the
every rig move when the kelly bushing is broken washer around the drive pin with weld.
down or once every three months, whichever
comes first.

23
Kelly bushings with drive pin locks these conditions, have two drive pins equipped with
special locks. These locks must be manually
When using a motion compensator on a floating operated to lock the drive pins into the master
operation, the kelly bushing must be locked to the bushing drive holes.
master bushing to prevent the kelly bushing from
being pulled out of the drive holes in adverse
conditions. Kelly bushings ordered especially for

KELLY BUSHING

LOCKING HANDLE

LOCK 180Þ APART

DRIVE PIN (2 PLACES)

DRIVE HOLE WITH MASTER

LOCKING POCKET BUSHING

LOCK RECESS

BOWL

Drive Pin with Lock

Figure 53

24
 SECTION II
MASTER BUSHINGS AND SLIPS
Proper handling of master
bushings and slips
One of the most expensive pieces of equipment on
the rig is the drill pipe. Not only is it expensive, but
it is in very short supply. Typically, worn master
bushings and slips are discovered when inserts are
wearing out much more rapidly than usual or when
a drill pipe inspection reveals crushed or
bottlenecked pipe. This is a needless waste of
valuable material - a regular program of rotary
equipment inspection could have spotted the
problem in plenty of time to make corrections,
without damaging the drill pipe.
AXIAL
FORCE
TRANSVERSE FORCE
Slips and Master Bushing Forces
Figure 54
In simple terms a comparison can be made
between slips and a wedge driven into a log. The
wedge’s taper produces a side load or transverse
force which is transmitted into the log. This
transverse force is much greater than the axial
force applied by the hammer to the wedge. If the
wedge is clean and well lubricated, the coefficient
of friction between the wedge and the wood is low.
Thus, the ratio between the force applied by the
hammer and the resulting splitting force on the
wood is much greater. If the wedge is dry, dirty, or
rusty with insufficient lubrication the coefficient of
friction is high. When the coefficient of fricition
increases, drag increases between the wood and
the wedge and it takes a much greater axial force
applied by the hammer to split the log.
25
A related principle applies with slips and master
bushings that are suspending pipe in the rotary.
The slip is the wedge. The hook load is the axial
force or vertical load. However, when splitting a
log, the two halves of the log are not restrained
from outside forces as in the case of slips and pipe
in a master bushing. The slips’ job is not to actually
do work - it simply supports a static load. Due to
the fact that the master bushing is restraining the
outward force, the weakest component becomes
the drill pipe.
Results of Friction Between
Slips and master Bushing
Figure 55
Figure 55 shows the coefficient of friction between
the rotary slip and the master bushing, depending
on the condition of the mating surfaces. The lower
the coefficient of friction between the slip and the
master bushing taper, the greater the amount of
transverse or crushing force per pound of axial or
hook load. If, for example, a hook load of 100,000
pounds (45,360 kg) is used, it can be seen from
this chart what the resulting transverse load would
be. With dirty, dry, or rusty slips and master
bushing tapers, the ratio is 1.4 to 1. With new,
clean, well lubricated slips and master bushing
tapers, the ratio would be 4.4. to 1. The average
ratio would be 3 to 1. This means that 100,000 Ibs
(45,360 kg) results in 300,000 Ibs (136,079 kg) of
transverse load. This high transverse load is why
the master bushing and slips must be kept in good
condition (or pipe may become bottlenecked.
One question is very important: How is this force
distributed along the length of the slip inset contact
area? the hook load or axial force starts at zero at
the top and increases to a maximum at the toe of
the slip. The transverse load or crushing force
begins with a minimum at the top, increasing to a
maximum in the center, then decreasing to a
minimum again at the toe.

In practical application on a rig, these two forces

act upon each other, resulting in a concentration of
force slightly less than halfway above the throat of
the master bushing.

HOOK CRUSHING
LOAD PRESSURE

API Standard Split Square Drive

Master Bushing Dimensions
Figure 57
The square drive bushing was approved by the
API over 35 years ago when a 10,000 foot (3048
m) well was considered deep. As hook loads
THE CRUSHING became heavier, drill pipe was being crushed
THE HOOK LOAD IS
PRESSURE DIMINISHES more frequently. Slip manufacturers increased the
GREATEST AT THE
AXIAL TO ZERO AT TOP AND slip insert area from 12 to 18 inches (305 to 457
BOTTOM OF THE SLIP
LOAD BOTTOM OF SLIP mm) and more, without increasing the support
F area for the slips themselves. This did not solve
the probelm.
Distribution of Forces
Figure 56
Heavy strings of drill pipe can be handled without
any damage to pipe in the slip area, if the rotary
slip is supported so that the load is distributed
equally on all of the inserts. If the slips are not
supported correctly, bottlenecking of drill pipe will
occur.

If slips and master bushings are kept in good

condition, then the massive crushing force that
exists will be equally distributed. With this force
distributed along the entire length of the slip, pipe
will not be damaged. Wear in both the ID of the
master bushing and on the backs of the slips,
however, reduces the length of load distribution to
only the area near the top of the slip, resulting in
bottlenecking and of drill pipe.
API Standard Slid Pin Drive
The API standard master bushing is 10-1/8 inches Master Bushing Dimensions
(257 mm) in diameter at the throat, tapering at a Figure 58
rate of 4 inches per foot, to a diameter of 13-1/16
inches (332 mm) at the top. The tapered section is In the late 1950s, Varco realized the need for
8-13/16 inches (224 mm) in length. Notice that the additional support for the slip bodies. In an effort to
remaining 4 inches (102mm) of the master bushing gain this needed support, the kelly drive was
is recessed to accept the square drive of the kelly
bushing.

26
transferred tot he top of the master bushing by the
use of pins. The taper was then brought to the top
of the master bushing, providing an additional 4
inches (102 mm), or almost 50 percent increase in
slip support (Figure 60). This increased the taper
length to 12-3/4 inches (324 mm) as opposed to 8-
13/16 inches (224 mm) in the standard square
drive master bushing.
CONVENTIONAL LONG
ROTARY SLIPS EXTRA LONG
ROTARY SLIPS
STANDARD API PIN DRIVE BUSHING
SPLIT MASTER WITH EXTENDED API
BUSHING INSERT BOWL
Long and Extra Long Slips
Figure 59
Both long and extra-long rotary slips have the
same amount of insert contact. The major
difference between the two slips is the length of the
tapered area. This longer bowl backup results in
lower overall cost, longer life, and increased
protection for the drill pipe.
Varco BJ master bushings
Varco 17-1/2 thru 27-1/2 Solid Body Square
Drive Master Bushing (MSS)
The Varco MSS Solid Body Square Drive Master
Busing is available for all sizes of rotary tables from
17-1/2 thru 27-1/2 inches and is designed for all
drilling operations. A 4 inch (102 mm) deep recess
allows a square drive kelly bushing to sit within the
master bushing. Developed for use when a 10,000
foot (3048 m) well was considered deep, the MSS
still serves a useful purpose where a large slip
backup area is not required. The MSS will handle
drill pipe, tubing, and casing from 2-3/8
27
thru 13-3/8 inches. The solid outer body takes all
transverse loads and provides proper backing for
the split insert bowls, allowing the rotary table to
rotate freely, unimpaired by transverse loads. As
with all Varco master bushings, the MSS has a 500
ton rated load capacity.
With the use of Varco extended bowls and the
Varco SDXL extra long slip, maximum protection is
attained for proper and safe handling of drill pipe
Square Drive Bushings
Figure 60
Varco 20-1/2 thru 27-1/2 Solid Body Pin Drive
Master Bushing (MSPC)
the Varco MSPC Solid Body Pin Drive Master
Bushing is designed for all drilling operations. The
pin drive allows the kelly bushing to ride on top of
the roatary table and permits extended bowls to be
used for better slip backup. Better slip backup
means heavier strings can be run without the
danger of bottlenecking. With the extended API
insert bowl No. 3, the MSPC will handle 2-3/8 thru
8-5/8 inch OD drill pipe, drill collars, tubing, and
casing. Insert bowl No. 2 can handle tubular goods
9-5/8 and 10-3/4 inches OD; while insert bowl No. 1
is good for 11-3/4 and 13-3/8 inches OD. The
MSPC, with proper insert bowls to accommadate a
given diameter string, has a maximum capacity of
500 tons. The MSPC has locks that hold the bowls
securely in the bushing. The solid outer body takes
all transverse loads and provides proper backing
for the split insert bowls, allowing the roatary table
to rotate freely, unimpaired by transverse stress.
Master bushing installation bushings. MDSP bushings are available for 17-1/2
and 20-1/2 inch rotary tables. If the rotary table
a. Inspect the top side of the rotary table master bore has over 3/16 in. (5 mm) wear, however, it
bushing bore and the drive square or drive lug must be re-built or a solid bushing must be used.
slots for peened-over edges. Chamfer as
required to allow master bushing to enter the
rotary table freely. Clean and grease the inside
surface of the square of the rotary table.

b. Remove the insert bowls by lifting them out one

half at a time with the lifting sling provided. Note
that the hooks engage both bowl halves from
the inside.
Note

The MPCH Master Bushing is equipped with a four-

hook sling. Do not use a two-hook sling to handle
this heavy unit.

c. When removing either one or both bowl halves,

retract the locks first (except on the 27-1/2 MSS
Model).

d. After the insert bowls are removed, pick up the

main body with the lifting sling and lower it into
the rotary table.

e. Lower insert bowls into body one half at a time

to complete the installation. 4-Way Lifting Sling 2-Way Lifting Sling
P/n 6699 P/n 1021
f. Retract the two locks before lowering the insert
bowl halves. This is done by lifting and turning
the two pins 180 degrees, then dropping them
back into the recesses. After inserting lock
bowls in place.
Note

In all instances, the insert bowl to be used should

fit flush with top of the master bushing body. When
changing from one size range to another, replace
the bowl in use with one that corresponds to the
new pipe size.

g. The eccentric pins and locks must be washed

frequently to remove mud and then lubricated
with oil.
Note

Steps f and G do not apply to 27-1/2 MSS Model

Varco 17-1/2 and 20-1/2 Split Pin

Dive Master Bushing (MDSP)

The MDSP Split, Pin Drive Master Bushings give Bowl Lock
superior load handling capability because they Figure 62
provede 50% more slip support than square drive

28
Varco 37-1/2 and 49-1/2 Hinged Pin Drive
Master Bushing (MPCH)

The MPCH Pin Drive Hinged Master Bushing is CU

specially designed for floating and
semisubmersible drilling operations. With insert
bowl No. 3 and optional insert bowls 1 and 2, the
MPCH will handle 2-3/8 to 13-3/8 inch OD drill
pipe, drill collars, tubing and casing (with a design
capacity of 500 tons). The MPCH has all the
performance features of a solid master bushing yet CUL
with a hinged design, the MPCH can be removed
from the drill string to pass large bit and pipe
connections directly through the rotary table.

The MPCH incorporates locking latches that lock

the bowls into the bushing. Bowls are also
equipped with retainer pins to prevent them from
falling out when the master bushing is hinged open. CB
The MPCH can also be equipped with latches that
lock into the rotary table.

MPCH
Casing Bushings
Figure 64

Bit breaker adapter plate

A bit breaker adapter plate, Figure 65, is furnished
with every Varco pin drive master bushing to
convert the round opening of a pin drive master
bushing to a 13-9/16 inch standard, API square
drive opening. All rock bit companies furnish bit
break-out boxes which fit into this opening. The
adapter plate is held in place with four pins which fit
into the four drive pin holes of the bushing.

When using bits in excess of 12-1/4 inches, such

Pin Drive Hinged Master Bushing as the 15-1/2 inch bit, it is suggested that a 15-1/2
Figure 63 inch box (394 mm) be welded on top of a standard
size box which will, in turn, fit into the Varco bit
Varco BJ casing bushings breaker adapter plate.

CU, CUL, and CB Casin Bushing are inserted

directly into the rotary table and insure that the
casing being run is perfectly aligned with the center
of the hole. Models CU and CUL are solid bushings
and Model CB is a split bushing. All of these
bushings accept bowls of different sizes to
accommodate a wide range of casing. Used with
Varco’s CMS-XL Slips, these bushings can handle
the longest casing strings currently being set. Also,
since these bushings fit into the rotary table, the
casing string can be rotated during cementting Bit Breaker Adapter Plate
operations. Figure 65

29
 Maintenance Inspection
Inspection is the most important aspect of
1. When changing insert bowls, check top preventive maintenance. Inspection consists of
diameter of bushing bore and insert bowl seat observing, measuring, and testing.
for burrs and peened-over edges; file or grind
flush as required. This procedure will ensure
GRIPPING AREA PIPE IS
easy installation and proper fit.
OF SLIPS BOTTLENECKED
ISGREATLY REDUCED
2. Clean the inside taper of the drilling bowls of
any abrasive material. This will cut down the
rapid wear on both slip backs and taper. It will
also provide easy handling of slips and keep
them from sticking in the bushing.

3. Lubricate the inside taper of the drilling bowls WORN WORN

(when tripping) to prevent slips from sticking in MASTER TAPER
the bowls. BUSHING IN BOWL

WORN
4. Lubricate the back of the drilling bowl each time
ROTARY
it is removed from the hull. This will prevent the REDUCED BACKUP
TABLE
bowls and slips from sticking and reduce master AREA CAUSES WEAR
bushing ID wear. AND CRUSHING IN SLIPS UNDER THESE
BACKS OF SLIPS. CONDITIONS ARE
5. Replace lock assembly when it ceases to READILY DEFORMED
function.
Rotary Equipment Wear Points
Figure 66
6. Replace the API drilling bowls when throat
measurement exceeds 10-7/8 inches (276 mm) Figure 66 shows typical conditions that can affect
on extended API bowls. slip support:

7. Replace API drilling bowls when a straight edge a. There is wear in the ID of the rotary table which
held against taper indicates wear from the tool gives insufficient support for the master bushing
joint in the tapered section of the bowls itself.

8. When the backs of the rotary slips and the taper
of the bowls become rough, both of these
surfaces must be polished by using emery cloth
on the backs of the slips or a flexible, fine
sandpaper disk. Keeping these surfaces
polished will help prevent sticking.
9. Hinge Pins (MPCH Only)
a. The stationary hinge pin (without bail) has one
lube fitting located at top center. This pin should
be greased daily.
b. The removable hinge pin (with bail) should be
cleaned up and greased each time it is taken
out. It has a lube fitting located at top center.
b. The OD of the master bushing is worn.
c. There is excessive wear in the taper and the
throat ID.
These wear conditions affect the function of the
slips themselves:
a. The reduced backup area for the slip causes
wear and crushing in the backs of the slips.
b. The gripping area of the slips on the pipe is
greatly reduced.
c. Slips used under these conditions are easily
deformed. Drill pipe damage is likely to occur.

30
 For accurate results, use a hook load of at least
100,000 pounds (45,360 kg):

a. Clean an area of pipe where there are no insert

marks. Clean slip inserts with a wire brush.

Slips Riding High in Master Bushing

Figure 67

Observing the height of set slips in the master

bushing is an easy means of checking for wear.
The slips ride high in the master bushing when the
rotary equipment is in good condition.
Wrapping Test Paper Around Kelly
Figure 69
b. Wrap a layer of test paper around the cleaned
section of pipe. Varco can supply test paper or a
layer of mud sack paper will serve the purpose.
Use friction tape to hold the paper to the pipe.

Slips Riding Low in Master Bushing

Figure 68

As the system wears, slips ride lower in the master

bushing.

Slip Test Procedure Setting Slips

A slip test is the best way to determine the degree
of rotary equipment wear. This test should be
performed every three months and each time a
new master bushing or slip set is put into service.
Figure 70
c. Place the slips around the pipe and hold them
while the pipe is lowered at normal speed.

31

Removing Slips
Figure 71
d. After the slips have been set, hold them firmly
around the pipe as it is raised. they should be
removed carefully to prevent damage to the
paper.
Slip Test Paper
(Full Contact)
Figure 72
Evaluation should be done using the secont layer
of the paper because the outside layer will have
misleading slip impressions. If full insert contact is
indicated, the master bushing and slips are in good
condition and no further analysis is necessary.
32
Slip Test Paper Poor Contact (Top only)
Figure 73
If there is not full contact, the test should be run
again with new slips. If the second test results in
full contact, discard the slips because they are
worn, crushed or otherwise distorted. Cut off the
toes of discarded slips so they cannot be
refurbished and used again. If the results of the
second test indicate top contact only, the master
brushing and/or bowls are worn and should be
inspected for replacement.
Master Bushing Wear
Figure 74
This is a worn split master bushing in a rotary. The
space at the top, approximately 1/4 inch (6,5-mm)
between these two bushing halves. The space at
the bottom however, has increased to more than
3/4 inch (19 mm). This reduces support for the slips
and causes drill pipe damage. The white line (see
arrow) indicates where the throat of the master
bushing was when new.
 WORN TOTARY
TABLE BORE
Worn Rotary Table Bore
New Standard API Split Master Bushing
Rotary Table Wear
Figure 75
The increased gap at the bottom, between the
master bushing halves, and the lack of slip support
shown in Figure 75, is not caused by wear in the
master bushing, but by wear in the ID of the rotary
table.
NEW STANDARD API
SPLIT MASTER BUSHING
WORN ROTARY
TABLE BORE
New Bushing and Worn Rotary Table
Figure 76
Placing a new split master bushing in the worn
rotary will not solve this problem. It can be
corrected by removing the rotary and having it built
up to original specifications. Repairing the bore of a
table is expensive and time consuming, requiring
that the complete rotary table be taken out of
service, disassembled and repaired.
33
Solid Body Master Bushings
Figure 77
A second and less expensive solution would be to
replace the split master bushing with a solid
master bushing which does not depend on the
rotary bore for support. The solid master bushing
will contain the complete load of the string (and has
a capacity of 500 tons).
Worn, Deformed Slips in a New Bushing
Figure 78
When a master bushing is replaced, the rotary slips
must be checked. Figure 78 shows a new master
bushing with worn rotary slips. A set of slips
conforms or wears in relation to the condition of the
master bushing. If a master bushing is worn and
must be replaces; it is probable that the slips are
also worn, due to improper support from the old
bushing. If worn and deformed slips do not receive
proper support from the new master bushing, they
will cause continued damage to the drill pipe. A
worn or bent slip will bend back in a new bushing,
causing cracks in the slip body.
 Figure 80 shows a solid master bushing that has
NEW WORN been sent in for repair. The first thing that can be
noticed is that the bowls are together at the top and
open at the bottom. This condition means there is
wear on the back of the bowls and inside of the
outer hull.

10-1/8 in.
(257 mm)
NEW

10-5/8 in
22 in. (559 mm) NEW
(270 mm)
MAX. 22-3/16 in. (563 mm) WORN

New and Worn Square Drive Bushings

Figure 79
Checking Master Bushing ID
Square Drive Solid Master Bushing Inspection Figure 81
While the ID of the top of this hull is correct,
Here is a comparison of new and worn conditions
inspection shows that the ID at the bottom is worn
for a square drive master bushing and their effects
3/16 inch (4,8 mm), enough to cause the
on slip support: the API specification for the throat
separation between the bowls.
measurement is 10-1/8 inches (257 mm).
The master bushing should be replaced when the
measurement reaches 10-5/8 inches (270 mm).

Due to reduced support in the critical area of a

worn master bushing, the slip body will be
concentrated in the upper portion of the slip body
only, causing bottlenecking of the drill pipe. A
similar condition can occur when the ID of the
rotary itself is worn beyond the 3/16 inch (4,8-mm)
recommended limit.

Checking Master Bushing Bowl Taper

Figure 82

In Figure 82 the inspector is checking the taper.

The length of the original taper was 8-13/16 inches
(224 mm). this is now reduced to approximately 7
inches (178 mm) which amounts to 2 inches (50,8
mm) less support for the rotary slip. Notice the
circular line at the end of the rule. This mark
Square Drive Master Bushing with Worn ID indicates tool joint wear.
Figure 80

34
 ID of the outer hull were in good condition, the slips
would still have good support and proper contact
with the drill pipe. Even though there would not be
damage to drill pipe, deformities in the drill collar
would still occur.
HARD
BANDING 12-3/4 in. NEW WORN
(324 mm)
NEW

INCORRECT REDUCED
10-5/8 in.
TAPER CUT BY BACK UP
(270 mm) WORN
TOOL JOINT

Square Drive Bushing Worn By Tool Joint

Figure 83
WEAR
Figure 83 shows the start of the new taper that has DUE
10-7/8 in.
been cut by the wear of tool joints which pass TO PIPE
(276 mm)
through the rotary. The effective backup for the DRAGGING
WORN
rotary slip has now been reduced to 5 inches (127 THRU BUSHING
mm). When using a long rotary slip, the total length 10-1/8 in.
of the slip is 20 inches (508 mm) with 16-1/2 inches (257 mm)
(419 mm) of inserts. Working in a bushing in this NEW
condition with only 5 inches (127 mm) of tapered 19 in. (482 mm)
area for backup will cause the backs of the slips to NEW
crush. 19-3/16 in. (487 mm)
WORN

NEW WORN WORN HINGE PIN

(MAX. WEAR OCCURS

AT BOTTOM OF PIN)

0.032 in.
(0.81 mm)
MAX

New and Worn Pin Drive Bushings
Figure 84
Pin-Drive Solid Master Bushing Inspection
Figure 84 compares new and worn conditions for a
pin drive master bushing and the effects on slip
support. The API specification for the throat
measurement is 10-1/8 inches (257 mm). However,
the maximum allowable wear has increased to 10-
7/8 inch (276 mm) limit is to avoid damage to drill
collar slips which were designed for the shorter
taper of the square drive master bushing. Notice
that the toe of the slip has pulled aqay from the drill
pipe. This is due to the combination of wear in the
throat area and the outer hull. If the
Comparison
of New and Worn Hinged Master Bushing
Figure 85
In recent years, due to the introduction of larger
rotaries, a new hinged 37-1/2 inch master bushing
has come into the market. The throat and outer hull
wear measurements are the same as for the
extended bowl. A new wear zone must be
considered - the hinge pin. Maximum suggested
wear is .032 inch (0,8 mm). Beyond this point,
conditions similar to wear in the ID of the rotary on
a split square drive master bushing will exist,
allowing the bushing halves to separate and reduce
slip back-up area. Use bar at the hinged section to
move the bushing back and forth, to determine
wear. maximum movement should not exceed 1/16
inch (1,6 mm).

35
 Pin Drive Master Bushing with Worn I.D. Bowl with Maximum Throat Wear
Figure 86 Figure 88
REDUCED SLIP BACKUP
Figure 86 shows a pin drive master bushing that
has been sent in for repair. As With the square
drive bushing, the obvious problem is that the 9 in.
bowls are together at the top and open at the (229 mm)
WORN
bottom. 12-3/4 in.
(324 mm) HARD
NEW BANDING

10 7/8 in. # 3 Bowl

INCORRECT 12 7/8 in. # 2 Bowl
TAPER CUT 15 5/8 in. # 1 Bowl
BY TOOL JOINT MAX THROAT WEAR

Pin Drive Bushing Worn by Tool Joint

Figure 89
Halfway down the tapered area is a line where the
tool joints of the drill pipe have hit the taper and
worn a recess in the slip backup area. This wear
alone has reduced the area of slip support by 4
Measuring Master Bushing Throat inches (101,6 mm).
Figure 87

To measure a bushing, first make sure the bowls

are pushed back against the hull. measure the
throat or the bottom of the taper with calipers as
shown here. The manufactured dimension is 10-1/8
inches (257 mm). The recommended maximum
wear dimension is 10-7/8 inches (276). The
measurement of this bushing is 11-1/16 inches
(281 mm) or 3/16 inch (5 mm) over the allowable
maximum.

Where does all this wear occur?

The inspector in Figure 88, is measuring the throat

of one insert bowl. The measurement is 10-7/8
inches (276 mm) across the throat. This bowl is Measuring Master Bushing Upper ID
worn to the maximum allowable dimension. Figure 90

36
Inspecting the hull shows there is no measurable
wear in the ID of the upper portion. However, wear
can easily be seen at the point where the hull
extends below the bowls.
With the drill pipe tight against one side of the
table, the hard band area of the box will hit the
taper 4 inches (101,6 mm) above the throat. the
hard band will grind the bowl and cut a second
taper.
Drive hole bushing replacement
After a period of time, the drive holes in the MSPC
and MPCH master bushing will become deformed
and the bushings in these holes will need
replacement.
a. Place new drive hole bushings in a freezer.
b. Cut the worn bushing top to bottom with a torch
in two places about 180° apart. Drive out the
pieces from the mud drain hole.

TO REPLACE
DRIVE HOLE BUSHING:
TORCH CUT 2 PLACES
180° APART AND DRIVE
OUT FROM DRAIN HOLE

Drive Hole
Bushing Removal
Figure 93
c. Clean out the drive holes, remove any rust and
Measuring Wear in Hull lower ID deburr the top edge.
Figure 91
In Figure 91 lower ID wear is being measured, and d. Preheat the master bushing body around the
the reruslt is 19-3/16 inches (487 mm) or 3/16 inch drive hole bushing area to 400-450° F(204.4-
(5 mm) of wear, which is the recommended 232.2° C).
maximum allowable wear.
DRIVE IN BUSHING
UNTIL FIRMLY SEATED

Drive Hole
Bushing Replacement
Figure 94

e. Remove drive hole bushings one at a time from

Worn Out Master Bushing
Figure 92
f. Make sure master bushing drive hole area is at
The combination of wear in the bowls and wear in
the ID of the hull have reduced the effective slip
support area by almost 50 percent. There is no
longer proper support in the critical area of the slip
37
freezer when ready to install.
the proper temperature. Drive the bushing in,
using a wooden block on top of it to prevent
damage to the bushing. Drive the bushing into
the hole as fast as possible with a sledge
hammer. If too much time is taken, the bushing
will expand in the drive hole and prevent full
seating.
 Varco BJ slips
SDS, SDML, and SDXL Rotary Slips

These models are for use in API standard insert

bowls. These slips feature improved contact on drill
pipe through a superior wrap around configuration
and unique insert design that helps to prevent
bottlenecking and gouging damage. The buttress
design of the body segments provides great SDML
strength while minimizing weight for ease of
handling.

Varco rotary slips provide long and troublefree

service under the most severe conditions. Inserts
are held securely in dovetail slots and are easily SDML-Medium Rotary Slips
changed by removing the nuts, bolts, and retainer Figure 97
at the top of the slots.
VARCO
NO. 3 BOWL API BOWL
SDS Slips are designed for shallow hole drilling

SDML Slips are the perfect choice for all medium

depth drilling. With the proper drill string design
they can handle depths beyond 20,000 feet.

Varco SDXL Slips are designed for deep drilling.

VARCO PIN DRIVE ANY API STANDARD

MASTER BUSHING SQUARE DRIVE
SDS MASTER BUSHING

SDML Grip Length and Insert Bowl Contact

Figure 98

SDS-Short Rotary Slips

Figure 95
API BOWL

SQUARE
11 in. DRIVE
(279 mm) MASTER
BUSHING SDXL

SDS Grip Length SDXL- Extra Long Rotary Slips

Figure 96 Figure 99

38
 Varco DCS Drill Collar Slips

VARCO NO. 3 BOWL Varco DCS slips provide superior holding power
under all conditions. Each segment, manufactured
from a rugged drop forging, has an extra long back
to give maximum support to the circular button
gripping elements. Full wrap-around design
compensates for irregularities in wear. Circular
16-1/2 in. buttons hold against load from all directions to
(419 mm) assure positive holding and slip setting. Drill collar
slips are flat on top to accommodate the MP
Clamp.

VARCO PIN DRIVE

MASTER BUSHING

SDXL Grip Length

Figure 100 DCS

SLIP
HANDLE
SEGMENT
DCS-Multi-Segment Drill Collar Slips
CENTER
CENTER
Figure 102
HANDLE- RETAINING RETAINING
INTERMEDIATE COTTER SCREW
HANDLE
LEFT HANDLE
HANDLE PIN RIGHT
W/COTTER PIN
& WASHER HANDLE
PIN
SLIP SEGMENT
LEFT SLIP
SEGMENT HINGE PIN
HINGE PIN RIGHT CIRCULAR
W/COTTER PIN BUTTONS

HANDLE-
L&R
SDXL

RETAINING RING
BODY
SEGMENT
Rotary Slip Set Parts
Figure 101
DCS-Multi-Segment Drill Collar Slips Parts
Figure 103

39
 HANDLE-
L&R
HANDLE
INTERMEDIATE BODY
SEGMENT

7-7/8 in. 9 in.

7-1/8 in. (200 mm) (229 mm)
(181 mm)
HANDLE
PIN

DCS-S DCS-R DCS-L

RANGE RANGE RANGE RETAINING
3-4-7/8 4-1/2-7 5-1/2-14 CIRCULAR
SCREW
HINGE PIN BUTTONS

DCS-Drill Collar Slip Grip Lengths

Figure 104 CMS-XL-Casing Slips Parts
Figure 106

CMS-XL Casing Slips

CMS-XL Slips will handle the longest casing strings

currently being set. Manufactured from drop 13-1/2 in.
forgings, their reindorced design will stand up to (343 mm)
the most severe service. The self-centering, full
wrap-around grip holds positively while preventing
damage - even to thin wall casing. By varying the
circular button size and adding or removing body
segments, casing from 6-5/8 to 30 inches OD can CMS-XL- Casing Slip Grip Length
easily be accommodated. Light and easy to handle, Figure 107
Varco CMS-XL casing Slips are unexcelled.
CP-S Conductor Pipe Slips

CP-S Slips are used in offshore or marshy

locations when conductor pipe is used. These slips
are available in three models to handle conductor
pipe with OD’s of 24, 26 or 30 inches (610, 660 or

CMS-XL

CP-S

CMS-XL-Casing Slips
Figure 105 CP-S-Conductor Pipe Slips
Figure 108

40
 Multipurpose safety clamp HANDLE SCREW PIN BUSHING
SCREW
The MP Multipurpose Safety Clamp provides safe SCREW PIN
handling of all typesof flush joint pipe, liners and
drill collars during makeup, breakout and setting
SIDE
through the rotary table. The MP Clamp can be
THRUST BARS
adapted to act as an elevator shoulder whenever
the necessity arises, or fitted with lifting eyes to WASHER
LINK
handle large diameter pipe. This provides a
convenient and safe method of handling surface MAKEUP
pipe, drilling risers and other types of large NUT
diameter tubular products during installation. The
MP Clamp can also be inverted and fitted with LINK PIN
holddown lugs for use in all types of snubbing
operations. Interchangeable handles, lifting eyes, LATCH LINK
and holddown lugs are forged and heat-treated Safety Clamp parts
steel for maximum durability and long life. Figure 111
See also page 87.
Slip inserts
Varco rotary slips, drill collar and casing slips are
uniquely designed to provide even distribution of
load on pipe. Varco inserts fall midway between the
two extremes of high ratio and low ratio in pounds
per linear inch of contact. The rotary slip insert
gripping dies have a 0.01 inch (.25 mm) wide flat
on the top of each tooth. This flat will peen, rather
than cut, the metal of the pipe, which reduces
potential stress risers.
Multi-Purpose Safety Clamp
Figure 109 Varco Gripping Dies Last Longer. After machining,
the gripping dies must pass a rigorous inspection,
then they are heat treated and brought to a
hardness of 58062 Rockwell C., to ensure
CASE longevity.

MP Complete With
Case and Wrench
DIE CARRIER
GRIP DIE

Rotary and Casing Slip Inserts

Figure 112
HAMMER
WRENCH Resistant to Fracture and Chipping - Varco casing
ROLL and drill collar slips use circular button gripping
LINK ASSEMBLY dies, which do not create stress risers. This is
PIN
SPRING especially important on thin wall casing where a
heavy pull is exerted due to the casing length.
Circular buttons have no exposed edges that can
fracture and chip.
Carrier With Gripping
Die Parts Disassembled
Specify Varco gripping dies as replacements for
worn of damaged gripping dies to ensure that
Safety Clamp Assembly Varco’s high standards of quality will be on your
Figure 110 side when handling all tubulars.

41
The industry has had many accidents caused by Proper use of Rotary Slips
slips being set on moving pipe. The drill pipe must
be stopped completely before the slips are set on
the pipe. The driller should look at the weight
indicator to see that he is holding the full load. If the
bit should hit a ledge which supports part of the
weight of the string, when the elevator is removed
the pipe could be jarred free and the full shock load
dumped on the slips. When the shock load hits the
slips, the drill string acts like a rubber band. A Pipe too large
Pipe too small
15,000 foot (4572 m) string of 4-1/2 inch drill pipe EXCESSIVE
can stretch approximately 38 feet (11 m). The RIBS RIBS STRESS
string will start to bounce and could cause the slips CRACKED CRACKED PLACES
to be thrown out of the rotary table; then the pipe ON SLIP
will be dropped in the hole. If the pipe does not go DEFORMED BODY AND
in the hole and the slips do hold, another problem INSERTS
could occur; the drill pipe is could be permanently
deformed and cracked just below the slips,
resulting in wash-outs.

Incorrect Use of Rotary Slips

Figure 114

OVERSTRESSED OR
’’STRETCHED’’PIPE

Stopping Pipe With Rotary Slips INSERT SLOT DAMAGED

Figure 113
RETAINING SCREW
HEX HEAD CRUSHED DRILL
Operation COLLAR
INSERTS CRUSHED SLIP
Do not set slips on larger size pipe than they were SEGMENT
designed to hold. Figure 114 shows the effects of
using slips on the wrong size pipe. When 5 inch Results of Improperly set Drill Collar Slips
slips for example, are used on 5 inch pipe, the Figure 115
inserts have the proper contour. If the slip is used
on larger pipe or on tool joints, the stress is placed
on the outside corners of each segment. This If drill collar slips are used on collars with recessed
causes the slip bodies to spread and crack. After areas, care should be taken in setting. If set
the slip has been used on larger pipe and then partially on the upset area, the insert and insert
placed on the pipe size for which it was designed, slot will be damaged, making it difficult, if not
the slip bodies will conform to their original contour. impossible, to change inserts. The retaining screw
This could cause the slips to break and allow or cotter pin area, could be damaged so that it will
pieces to fall into the hole. be difficult to remove.

42
 Cleaning and Lubrication

CRUSHED Clean the inside taper of the drilling bowls of any

INSERTS abrasive material. Lubricate the inside taper of the
drilling bowls frequently with grease to prevent slips
from sticking in the bowls. It is suggested that the
SLIP outside surface of the bowl and the inside diameter
BACKS of the hull be cleaned and well lubricated. This will
WILL allow the bowls to move up slightly when the drill
BEND pipe is picked up. At this time, either the rotary slip
will release between the backs and the taper of the
bowl, or the rotary slip together with bowl, will move
up a short distance until the bowl hits the lock,
Setting Slips on Tool Joint whick will then free the slips. If this area between
Figure 116 the bowls and the master bushing is kept clean and
well lubricated, the slips will not stick in the master
One final word of caution: There are times when bushing.
setting the slips that the driller does not pick up Warning: Never use pipe dope to grease the back
enough to get the rotary slips around the pipe. In of the slips.
this case the top of the rotary slips is on the tool
joint. When the drill pipe is lowered, the slip’s body
is bridged between the master bushing and the
pipe. This causes the back of the slips to bend. The
normal reaction is to raise the string and let the slip
segment settle around the pipe. The slip segments
have been bent and when placed in the master
bushing around the pipe, they will bend back to
their original form, however, cracks may have
developed in the slip bodies. As a result of this, the
toe of the slip could break and fall into the hole. If
the driller runs into a slip, inspect it or use a new
set until the damaged slip can be inspected
properly.

Maintenance

LOCK ASSY
Surfaces that Require Dressing
Figure 118

RETAING PIN

Dressing Slips and Insert Bowls

LOCK The slips and bowl ID should be dressed as well as

cleaned to prevent sticking of the slips. Abrasive
materials in the drilling mud can cause horizontal
lines of wear in the mating surfaces of the slips and
ECCENTRIC PIN
bowls.

CLEAN AND LUBRICATE Dressing these surfaces, using an up and down

THESE SURFACES motion with emery cloth will result in the grain of
the two parts running with each other to
Rotary Slips in Position significantly reduce friction.
Figure 117

43
 GREATLY Webs and toes of slips can develop cracks from
REDUCED SLIP BACKS excessive wear or from use in a badly worn
GRIPPING WORN & BENT bushing. If cracks are present, destroy the slips and
AREA remove them from the site. If cracked slips are kept
in service, parts could break off and fall into the
hole.

SLIP BACKS CRACKED

WORN & BENT WEBS HINGE PIN
WITH
COTTER PIN
WORN BOWL
CRACKS
RESULTS IN REDUCED
SLIP BACK UP

Bent, Worn, Slips

Figure 119
Hinge Pin Removal
Slip Inspection
Figure 122
Periodic inspections should be performed on drill Slip segment hinges should be inspected regulary
pipe and drill collar slips as a preventive measure. to see that the hinge pin is locked into position with
Areas of particular concern are slip segment the cotter pin and not worn or cracked. Slips that
hinges and the hinge pins. sag or flop over when standing alone on the rig
floor, are extremely worn in the hinge area. Pull
thee hinge pins and check for straightness. A bent
hinge pin will indicate oversize hinge pin holes.
Oversize hinge pin holes are cause for replacint the
slips. If not replaced, wear will increase at an
BENT BACKS
accelerated rate until the slips do not set correctly
in the master bushing. This could damage drill pipe.

SLIP SEGMENT
1/8 - 3/16 in. (3-5 mm)
Checking Slip Segments MAX. CREARANCE
Figure 120
Placing a straight edge against the backs and
inside face of the slips will indicate if they are bent
or worn. A good slip back is straight, smooth, and
well greased.

SLIP INSERT SLIP SLOT

Slip Segment (shown without retaining ring)

Figure 123

Check inserts and insert slots for damage ar wear.

CRACKS
When the insert slots are badly worn, danger of
losing an insert down the hole exists. Replace the
slips before a costly failure occurs. Slips should be
CRACKS
replaced when there is over 1/8 inch to 3/16 inch
Slip Segment Damage (3.2 to 4.8 mm) clearence between the back of the
Figure 121 inserts and the insert slot.

44
 PS-15 and PS-16
Spring Slip Assemblies
Another Varco Innovation to improve Efficiency
and Reduce Crew Fatigue.

Lifting and setting slips is one of the most

backbreaking jobs on a rig. Varco’s spring slips
eliminate this tough hand work. These models are
set by foot pressure on the slipset ring, rather than
sheer muscle power. The spring slips enable faster
and safer handling of pipe.

Spring Slips in Set Position

Figure 125

Varco Spring Slips fit directly into Varco Master

Bushings. The PS-15 handles 3-1/2 to 5-1/2 inch
O.D. drill pipe. The PS-15 can be used with Varco
’’Big Foot’’ pipe handling system for maximum
efficiency, safety and speed.
For more information on the PS-16, please refer to
the PS-16 manual.

Setting Spring Slips

Figure 124

How Varco Spring Slips Operate

The PS-15 uses coll springs as a counterbalance

to offset the weight of the slips when in the upper,
released position. Slips are set by standing on the
slipset ring. The foot pedal is pressed to release
the slips. Slips remain set until the driller picks up
the drill string.

The PS-16 is an air operated version of the PS-15.

Varco’s spring slips provide even distribution of
load on the pipe. Model features slip segments and PS-15 Spring Slip Assembly
inserts designed to protect expensive drill pipe and Figure 126
tubing.

45
 Summary
Properly maintained master bushing and rotary
slips can prevent premature damage to drill pipe.
Normal maintenance is frequently forgotten
because of the durability of Varco BJ. equipment.
Many times the first inkling of a problem is when an
inspection reveals damaged drill pipe. Knowing the
maximum limits of master bushing wear and what
to look for when inspecting rotary slips can go a
long way toward preventing drill pipe damage in the
slip area.

Points to keep in mind:

1. Replace worn or defective equipment.

2. Stop the drill pipe completely before the slips

are set on the pipe. The driller should look at his
weight indicator to see that he is holding the full
load.

3. Perform a slip test every three months.

In this handbook we have presented the proper

inspection and maintenance procedures required
for trouble-free operation and maximum service life
of your rotary equipment. Become familiar with
these procedures, and put them into operation.

The Continuing Search for energy requires highly

sophisticated equipment and crews trained to
operate and care for it properly.

As this information is put to use, the result will be

less ’’downtime’’ and more productive hours spent
’’turning to the right.’’

46
 SECTION III
TECHNICAL DATA

47
Technical Data Technical Data
Table of Contents Table of Tables
Page Table Page
Subject Number Number Title Number

Metric Conversion Factors ................................... 49 TD-1. Measurement of a New Square Kelly ....... 50
Abbreviations Commonly Used............................ 49 TD-2. Square Kelly end Connections ................. 50
Kellys ................................................................... 50 TD-3. Measurement of a New Hex Kelly ............ 51
Kelly Bushings ..................................................... 52 TD-4. Hex Kelly end Connections ...................... 51
Master Bushings .................................................. 64 TD-5 HDP and HDS Kelly Bushing Parts........... 54
Rotary Slips ......................................................... 76 TD-6. HDP and HDS Roller Assy ....................... 57
TD-7. HDP and HDS Rollers Only ...................... 57
Drill Collar Slips ................................................... 81 TD-8. 4KRVS Roller Assy .................................. 57
CMS-XL Casing Slips ........................................... 84 TD-9. 4KRVS Roller Only................................... 58
CP-S Conductor Pipe Slips .................................. 85 TD-10. 4KRBM Roller Assy ................................. 58
Multi-Purpose Safety Clamp ................................ 86 TD-11. 4KRS and 4KRP Kelly Bushing Parts ....... 59
PS-15 Spring Slip ................................................ 89 TD-12. 4KRVS and4KRP Roller Assy................... 60
Appendix.............................................................. 90 TD-13. MDS and MDP Kelly Bushing Parts ......... 62
TD-14. Rotary Table Dimensions ......................... 64
TD-15. Insert Bowl Dimensions........................... 64
Technical Data TD-16.
TD-17.
Master Bushing Dimensions....................
MSS Master Bushing Parts......................
66
67
List of Figures TD-18. MSS Master Bushing
Ordering Information ............................... 68
TD-19. MSPC Master Bushing Parts ................... 69
Figure Page TD-20. MSPC Ordering Information .................... 70
Number Title Number TD-21. MPCH Master Bushing Parts ................... 72
TD-22. MPCH Ordering Information .................... 72
TD-1. Square Kelly............................................. 50 TD-23. Master Bushings and Insert Bowls .......... 73
TD-2. Hex Kelly.................................................. 51 TD-24. Casing Bushings and Insert Bowls........... 75
TD-3. 20 HDP Roller Kelly Bushing ................... 52 TD-25. Hinged Casing Spiders and Insert Bowls . 75
TD-4. 27 HDP Roller Kelly Bushing ................... 53 TD-26. SDS Rotary Slips Ordering Information... 76
TD-5. HDS Roller Kelly Bushing ........................ 53 TD-27. SDS Rotary Slips Parts............................ 76
TD-6. Roller Assembles and Part....................... 56 TD-28. SDML Rotary Slips Ordering Information 77
TD-7. MDP Roller Kelly Bushing........................ 61 TD-29. 3-1/2 and 4-1/2 Inch SDML Parts............ 78
TD-8. MDS Roller Kelly Bushing........................ 61 TD-30. 5 and 5-1/2 Inch SDML Parts .................. 78
TD-9. API Rotary Table Openings ...................... 64 TD-31. SDXL Rotary Slips Ordering Information. 79
TD-10. API Insert Bowls ...................................... 64 TD-32. 3-1/2 and 4-1/2 Inch SDXL Parts............. 80
TD-11. Master Bushing Dimensions.................... 65 TD-33. 5 and 5-1/2 Inch SDXL Parts ................... 80
TD-12. MSS Master Bushings ............................. 67 TD-34. DCS-S Drill Collar Slips Parts .................. 82
TD-13. MSPC Master Bushings ........................... 69 TD-35. DCS-R Drill Collar Slips Parts .................. 82
TD-14. MPCH Master Bushings........................... 71 TD-36. DCS-L Drill Collar Slips Parts................... 82
TD-15. SDS Rotary Slips ..................................... 76 TD-37. DCS Ordering Information ....................... 83
TD-16. SDML Rotary Slips .................................. 77 TD-38. Circular Buttons for Drill Collar Slips ....... 83
TD-17. SDXL Rotary Slips ................................... 79 TD-39. CMS-XL Casing Slips
TD-18. DCS Drill Collar Slips ............................... 81 Ordering Information ............................... 84
TD-19. CMS-XL Casing Slips............................... 84 TD-40. CMS-XL Casing Slips Parts ..................... 84
TD-20 CP-S Conductor Pipe Slips ...................... 85 TD-41. CP-S Ordering Information ...................... 85
TD-21. MP Safety Clamp ..................................... 86 TD-42. Circular Buttons for Casing and
TD-22. MP Safety Clamp Parts ............................ 87 Conductor Pipe Slips ............................... 85
TD-23. MP Safety Clamp ..................................... 88 TD-43. MP Safety Clamp Ordering Information ... 86
TD-24. Spring Slip............................................... 89 TD-44. MP Safety Clamp Parts ............................ 87
TD-25. Galling ..................................................... 91 TD-45. PS-15 Ordering Information .................... 89
TD-26. Pipe Cup Failure....................................... 92
TD-27. Pipe Flat Failure ....................................... 92

49
48
 METRIC CONVERSIONS
Metric conversions thruout this handbook conform
to the Systeme Internationale (SI) metric
equivalents.

The formulas used are:

inches x 25.4 = millimetres (mm)

feet x .3048 = metres (m)
pounds x .4536 = kilograms (kg)
ounces x .0283 = kilograms (kg)
tons x .9078 = tonnes (t)

ABBREVIATIONS
°C - Celsius or Centigrade
dia. - diameter
°F - Fahrenheit
ft - foot or feet
hex - hexagon or hexagonal
ID - inside diameter
in. - inch(es)
kg - kilogram(s)
lb - pound(s)
m - metre(s)
mm - millimetre(s)
no. - number
OD - outside diameter
oz - ounce(s)
P/N - part number
qty. - quantity
sq - square
w/ - with
wt - weight

49
 Kellys
Kellys are manufactured with one of two basic configurations - square or hexagonal. The size of a kelly is
determined by the distance across the drive flats (See Figure TD-1 and TD-2).
API kellys are manufactured in two standard lengths: (1) 40 feet (12.2 metres) overall with a 37 foot (12
metres) working space or (2) 54 feet (16.5 metres) overall with a 51 foot (15.5 metres) working space.

Square Kelly

*6-inch square not API

50
Hex Kelly

51
 Roller kelly bushings

20-HDP Heavy duty pin drive roller kelly bushing.

Figure TD-3

52
 HDS Heavy duty square drive roller kelly
bushing.
Figure TD-5

Used for heavy duty drilling in 17-1/2- to 27-1/2-in.

27-HDP Heavy duty pin drive roller kelly Rotary tables with square drive master bushings.
bushing. Fits any standard 17-1/2- to 27-1/2-in. Split Master
Figure TD-4 Bushing and Varco MSS

53
Table TD-5 Parts List for Varco Type 20 HDP, and 27 HDP, HDS, Roller Kelly Bushings

(Continued)

54
 (Continued)

Table TD-5 Varco Tyype HDS and HDP Roller Kelly Bushings

55
 Roller assemblies and parts
HDP & HDS
4KRBM
BEARING 1312

BEARING 5218

V-ROLLER V-ROLLER
FLAT ROLLER FLAT
SLEEVE BEARING 1326 ROLLER
OPTIONAL
THRUST WASHER 3618 THRUST WASHER 2912
W/O-RINGS & LOCK PIN ROLLER PIN
2910
ROLLER PIN 3609

4KRVS
SLEEVE
BEARING 1422
OPTIONAL
V-ROLLER

FLAT ROLLER

BEARING 1412

ROLLER PIN THRUST WASHER

1411 1413

Replacement parts, roller kelly bushings

20-4 KRP, 27-4KRP, 4 KRS (discontinued)

V-ROLLER
FLAT ROLLER

1312
1210 1208 1311

1605 1313
or 1505

50924 1316
1506

Roller Assemblies and Parts for Heavy Duty Roller Kelly Bushings
Figure TD-6

56
57
58
59
 Table TD-12 4 KRS 20-4KRP and 27-4KRP, Complete Roller Assemblies

* Note: Rollers, Bearings and Wipers for Varco HDP, HDS, 4KRS and 4 KRP Kelly Drive Bushings
are interchangeable

60
17 and 20-MDP Medium Duty MDS Medium Duty Square Drive
Figure TD-7 Figure TD-8

MDP-Dimensional data

Used for medium duty drilling in 17-1/2 to 27-1/2 in.

Rotary tables with square drive master bushings.
Fits any standard 17-1/2 to 27-1/2 in.
Split Master Bushing and Varco MSS

61
Table TD-13 Varco Type MDS, 17 MDP, and 20 MDP Roller Kelly Bushings Parts List

(Continued)

62
 (Continued)
Table TD-13 Varco Type MDS, 17 MDP, and 20 MDP Roller Kelly Bushings Parts List

* Recommended Spares include two wiper rubbers for each size kelly for bushings with wiper assemblies.

63
 Master bushings

API Rotary Table Opening

Figure TD-9

Table TD-14 API Rotary Table Dimensional Data

API Insert Bowls

Figure TD-10

Table TD-15 API Insert Bowls Dimensional Data

64
MDSP
PIN DRIVE

MSS MSPC
SQUARE PIN
DRIVE DRIVE

Figure TD-11 Master bushing Dimensions in inches (mm)

(See Next Page for data)

65
 Table TD-16 Varco Rotary Table Master Bushings

*API STANDARD
VARCO SOLID
**17-3/16 inch (437 mm)
** 20-1/8 inch (511 mm)
** 27-3/8 inch (695 mm)

66
 For 20-1/2 in. Tables For 27-1/2 in. Tables

17-1/2 thru 27-1/2 MSS Solid Body Square Drive Master Bushings
Figure TD-12

Table TD-17 MSS Parts List

Note: * No locking device is used for the insert bowl of these two sizes.
When ordering or requesting quotation, please specify make, size and type of rotary table.

Note: ** Special API extended insert bowl for round trips only.

67
Table TD-18 17-1/2 thru 27-1/2 Solid Body Square Drive Master Bushing (MSS) Ordering Information

68
 For 23, 26 and 27-1/2 In. tables - For 20-1/2, 21, and 22-1/2 in. tables-
Shown with API extended insert bowl no. 3 Shown less insert bowls.
Uses Varco 27 HDP or 27 KRP Kelly Bushings Uses Varco 20 HDP and 20 4KRP Kelly

20-1/2 thru 27-1/2 MSPC Solid Body Pin Drive Master Bushings
Figure TD-13

Table TD-19 MSPC- Parts List

(Continued)

69
 (Continued)

Table TD-19 MSPC- Parts List

Note: Split Pin Drive Master Bushing for 27-1/2 In. Rotary Tables
available on Special order only... P/N 5429

CONTINAL IDECO NATIONAL OILWELL

EMSCO

Table TD-20 MSPC Ordering Information

(Continued)

70
 (Continued)

Table TD-20 MSPC Ordering Information

MPCH master bushings

MPCH Hinged Pin Drive Master Bushing

Figure TD-14

71
 Table TD-21 MPCH Parts List

Note: When ordering or requesting quotation, please specify size, make and model of rotary table.

Table TD-22 MPCH-Ordering Information

72
Table TD-23 Master Bushings and Insert Bowls

Al Dimensions in Inches

(Continued)

73
 (continued)

Table TD-23 Master Bushins and Insert Bowls

Al l Dimensions in Inches

74
Table TD-24 Casin Bushings and Insert Bowls

Table TD-25 Bowls used with HCS Spider

All Dimensions in Inches

75
 Rotary slips

API BOWL

SQUARE
11 in.
DRIVE
(279 mm)
MASTER
BUSHING

SDS-Short Rotary Slips

Figure TD-15

Table TD-26 SDS Ordering Information

* Kits contain bevelled inserts.

Table TD-27 SDS-Short Rotary Slips Parts List

76
 VARCO
NO. 3 BOWL API BOWL

VARCO PIN DRIVE ANY API STANDARD

MASTER BUSHING SQUARE DRIVE
MASTER BUSHING

SDML-Medium Rotary Slips

Figure TD-16

Table TD-28 SDML Ordering Information

* Kits contain bevelled inserts.

77
 Table TD-29 3-1/2 and 4-1/2-in. SDML Parts List

**6 required for this one only

Table TD-30 5 and 5-1/2 in. SDML Parts List

78
 VARCO NO. 3 BOWL

16-1/2 in.
(419 mm)

VARCO PIN DRIVE

MASTER BUSHING

SDXL-Extra Long Rotary Slips

Figure TD-17

Table TD-31 SDXL Ordering Information

* Kits contain bevelled inserts.

79
Table TD-32 4-1/2 and 5 in. SDXL Parts List

Table TD-33 5 1/2 and 7 in. SDXL Parts List

80
 Drill collar slips

HANDLE-
RETAINING COTTER RETAINING SCREW
INTERMEDIATE

HANDLE PIN

HINGE PIN
CIRCULAR BUTTONS
HANDLE-L&R

BODY SEGMENT

DCS-Multi-Segment Drill Collar Slips DCS-Multi-Segment Drill Collar Slips Parts

7-1/8 in. 7-7/8 in. 9 in.

(181 mm) (200 mm) (229 mm)

DCS-S DCS-R DCS-L

RANGE RANGE RANGE
3-4-7/8 4-1/2-7 5-1/2-14

DCS-Drill Collar Slip Grip Lengths

DCS-Drill Collar Slips

Figure TD-18

81
Table TD-34 DCS-S Drill Collar Slip Parts List

Table TD-35 DCS-R Drill Collar Slip Parts List

Table TD-36 DCS-L Drill Collar Slip Part List

82
 Table TD-37 DCS Ordering Information

Notes: * This size is furnished with 4 handles

All Varco DCS Drill Collar Slips have an API taper of 4 in./ft on the diameter.

Tabele TD-38 Circular Buttons for DCS Drill Collar Slips

83
 Casing slips

HANDLE-
L&R
HANDLE-
INTERMADIATE BODY
SEGMENT

13-1/2 in.
HANDLE (343 mm)
PIN

RETAINING
SCREW CIRCULAR
CMS-XL HINGE PIN BUTTONS
CMS-XL Casing Slips Parts
CMS-XL Casing Slip
Figure TD- 19 CMS-XL Casing Slips Grip Length
Table TD-39 CMS-XL Ordering Information

Notes: *Theses sizes are furnished with 4 handles.

All Varco CMS-Extra Long Casing Slips have
an API taper of 4 in./ft on the diameter.
Table TD-40 CMS-XL Parts List

84
 CP-S Conductor Pipe Slip
Figure TD-20

Table TD-41 CP-S Ordering Information

Table TD-42 Circular Buttons for CMS-XL & CP-S Slips

85
 CASE

MP Complete With
Case and Wrench
DIE CARRIER

GRIP DIE

HAMMER
WRENCH
ROLL
SPRING
PIN
Multipurpose Carrier With Gripping
Safety Clamp Die Parts Disassembled
LINK ASSEMBLY
Carrier With Gripping
Die Assembled in Link
MP-Multipurpose Safety Clamp
Figure TD-21

Table TD-43 MP Ordering Information

86
 SCREW PIN BUSHING
HANDLE SCREW

SCREW PIN

SIDE
BARS
THRUST
LINK
WASHER

MAKEUP
NUT
LINK PIN

LATCH LINK
Safety Clamp Parts
Figure TD-22
Table TD-44 MP Ordering Information

AR = As Required
Opt = Optional

87
Pipe Handle

Link pin All gripping dies

must be making
good even contact
with the pipe

Latch jaw
All movement
restriction dowel
Remove the dowel
pins must be clear
pin of the latch jaw
of the locating
shoulders on the
Adjustment
connecting links

Multipurpose Safety Clamp

Figure TD-23

Wear data (inches)

Link Handle
Link part number 3307 Handle part number 3305
Total clearance “A” 0.04 Total clearance “A” 0.04
Pin dia. New Max. 0.872 Pin dia. New pin 0.872
Bore dia. New Max. 0.895 Bore dia. New max. 0.895
Bore dia Worn max. 0,905 Bore dia. Worn max. 0,905

Insert carrier

Latch
Link part number 3307
Total clearance “A” 0.04
Pin dia. New Max. 0.872
Bore dia. New Max. 0.895
Bore dia Worn max. 0,905 Insert Maximum clearance “B”
insert carrier/insert: 0.04”

88
 Spring slip assemblies

33 in. (838 mm)

SLIPS RELEASED

SLIPS SET
19 in.
(483 mm)
11 in.
(279 mm)

GRIP
LENGTH
16-1/2 in.
(533 mm)
SLIP

PIN DRIVE SOLID GUIDE BOWL

MASTER BUSHING RING

PS-15 Spring Slip Assembly

Figure TD-24

Table TD-45 PS-15 Ordering Information

*When fitted with specified slip set and guide ring

89
 Appendix

Drill stem care and Maintenance

Handling the Drill Stem Making up The Drill Stem (Torque)

Picking up and laying down PROPER MAKEUP IS THE MOST IMPORTANT

The Drill Stem
Use thread protectors when available. When
threads and shoulders are unprotected, doe not
permit the tool joints to strike steel surfaces such
as walks, stairs, or machinery. USE WOOD SURFACES
IN PLACES WHERE THE TOOL JOINT MAY HIT.
SINGLE FACTOR IN PREVENTION OF TOOL
JOINT FAILURE. Observe the following steps:
1. Torque measuring equipment must be used
2. When using tongs, it is imortant that line
pull be measured when the line is at right
angles or 90° to the tong handle.

Cleaning and Lubrication 3. When applying line pull, do not jerk the
(thread Compounds) tongs.

4. OVER-TORQUE CAN BE JUST AS

Pin and box threads and shoulders should be DAMAGING AS UNDER-TORQUE.
thoroughly cleaned. Use solvent and wipe dry with
a clean rag. Inspect carefully for any burrs or nicks 5. Use both tongs (when tongs are used)
on the shoulders or threads. DAMAGED when making up tool joints.
CONNECTIONS SHOULD NEVER BE RUN IN
THE HOLE. 6. Do not make up pipe using spinners only.
After cleaning, apply tool joint thread comound to Torquing devices must be used.
threads and shoulders with a round, stiff bristle
brush. Use thread compounds containing 40% to
50% by weight of finely powdered metallic zinc. Breaking-in New Connections
NEVER, UNDER ANY CIRCUMSTANCES, USE
CASING AND TUBING LUBRICANT. THREAD
COMPOUND MUST BE APPLIED TO THE TOOL Initial makeup is most critical and extra care is
JOINT EVERY TIME IT IS MADE UP. essential for long trouble-free service. Follow these
steps:

Stabbing and spinning The Drill Stem 1. Inspect threads and shoulder for any
damage.

DO NOT ALLOW THE ENDS OF THE PIN TO 2. Clean and Lubricate as indicated above.
STRIKE THE BOX SHOULDERS. THE
SHOULDER MUST NOT BE NICKED OR 3. Walk in or slowly rotate joints together.
OTHERWISE DAMAGED. Before spinning the pipe,
make sure connections are in alignment. Do not 4. Makeup to recommended torque.
rotate the pipe too fast, especially when wobbling
or binding occurs. 5. Breakout and slowly spin out.
Extra care is necessary when a power-operated
spinner is used.

90
 Breaking and Spinning-out
The Drill Stem
When breaking out the joint, use both tongs (when
tongs are used).
Always follow these steps:
1. Do not let the end of the pipe strike the box
shoulder.
2. Come out of the hole on a different break
each trip so that every connection con be
periodically broken and its condition and
torque checked.
3. When standing the pipe back, be sure the
set back area is clean where the pin will
rest.
Limitations on The Drill Stem
Cautions
1. Most drill pipe failures are a result of
fatigue. Drill pipe should be routinely
inspected for fatigue cracks.
2. Notches from stamps, grooves, tong
marks, junk cuts, etc. on the drill pipe will
accelerate fatigue and failure.
3. Remove damaged pipe from the drill string
immediately.
4. Never guess at makeup torque, pipe grade,
size, weight or tool joint type. LOOK IT UP!
Corrosion
Corrosion (rust, pitting and loss of metal) is caused
by mud composition and pH, formation fluid inflow,
and oxygen. THE MOST SEVERE CONDITION
USUALLY ENCOUNTERED IS THE PRESENCE
OF SOUR GAS (H2S). When H2S is present,
obtain expert advice to prevent premature failure,
especially when high strength drill pipe is being
used. WHEN USING WATER BASE DRILLING
FLUIDS, MAINTAIN A MINIMUM pH OF 9.5 (11 TO
13 IS PREFERRED). Determine if corrosion
inhibitors in the drilling mud will be effective and
economical.
91
Hole Deviations
Directional wells or doglegs caused by hole angle
or direction change, often contribute to drill pipe
fatigue. If doglegs are present, it is a good practice
to string ream the dogleg area. The portion of the
string immediately above the drill collars is most
likely to suffer fatigue failure. These joints should be
marked, inspected more frequently, and moved up
the hole each trip. A shallow dogleg in a deep hole
can cause as much damage as a severe dogleg,
due to the high tension load at the top of the drill
string.
Drill Stem Tests
When emptying the pipe, the bottom joints are
subject to collapse from the pressure of the drilling
fluid. Consult an expert or the API/ADC tables for
maximum external pressures. When using plastic
coated pipe, limit testing to as brief a period as
possible to minimize errosion damage to the
coating. DO NOT TEST IN H2S ENVIRONMENTS
WITHOUT EXPERT ADVICE.
Troubleshooting The Drill Stem
(Remember, damaged pins or boxes mean two
joints of pipe must be removed.)
A. DRY OR MUDDY CONNECTION-(no
lubricant when broken out)- is positive
indication of damaged shoulders which will
result in a washout.
B. GALLED SHOULDER. Galls 180° apart are
indications of insufficient makeup torque
resulting in wobble and thread section
failure.
Galling
Figure TD-25
C. GRAY RING ON OUTSIDE OF
SHOULDERS is indication of insufficient
makeup torque.

D. ABNORMALLY HIGH BREAKOUT

TORQUE is a sure sign of damaged
connection. Remove from string for thread
inspection.

E. CUP TYPE THREAD FAILURE is usually

caused by excessive torque (tension
failure).

Flat failure (Fatigue)

Figure TD-27

H. THIN SHOULDERS caused by wear of tool

joint, either eccentrically or uniform, will
result in twist-offs.

I. UNDERCUTS next to hardfacing

(stepwear) will result in failure. Remove
from string.

J. CORROSION GROOVES are sometimes

found under rubber protectors, especially
Cup Failure (Tension) on high strength drill pipe. Remove from
Figure TD-26 string.

F. FLAT TYPE THREAD FRACTURE - is K. PIPE FATIGUE FAILURE is accelerated by

usually caused by insufficient makeup
torque (fatigue failure) or by sour gas
(hyrdogen embrittlement) accelerating
fatigue (when makeup torque is known to
be sufficient).
rotating in severe doglegs, or by bent pipe
or kellys. Notches, grooves, etc. also
accelerate fatigue failure.

G. SHARP OR BROKEN THREADS are

evidence of insufficient makeup torque.

92
Notes

93
Notes

94
Notes

95
Nijverheidsweg 45
4879 AP Etten-Leur
P.O. Box 17
4870 AA Etten-Leur
The Netherlands
Tel.: (3176) 5083000
Fax: (3176) 5016948

12950 West Little York Road

Houston, Texas 77041
P.O. Box 800457
Houston, Texas 77280-0457
U.S.A.
Tel.: (1713) 937-5500
Fax: (1713) 937-5050

Badentoy Cresent
Badentoy Industrial Estate
Aberdeen
AB12 4YD
Scotland
Tel.: (01224) 343630
Fax: (01224) 343643

8, Sixth Lok Yang Road.

Jurong
Singapore 628106
Tel.: 65-265 5066
Fax: 65-264 0578

Varco BJ Sales Office

c/o Al Mansoori Specialized Eng.
P.O. Box 3374
Abu Dhabi
United Arab Emirates
Tel.: 971-2-5552668
Fax: 971-2-5540012

96