01.17510.0003 - VDB027 - Rev 00 - A

OFFICIAL COPY - 01.17510.
0003 - VDB027 - 0 - Approved(A) - - - 04-Dec-2008 03:52 PM
Bill of Material
Item Quantity Part Number Description
1 1 SM00969 Service Manual, PRS-8i

2 1 SM00970 Service Manual, PRS-8i Handling Tools
3 1 SM00966 Service Manual, Foxhole Slip Assembly
4 1 D811000367-DOS-001 Technical Drawing Package
5 1 30171934 Mechanical Spares, PRS-8i
6 1 30177849 Electrical Spares, PRS-8i
7 1 30175005 Foxhole Slip Assembly Spares
8 1 M844000072 Installation Procedure, PRS-8i
9 1 3FIP00248 Commissioning Procedure, PRS-8i
10 1 3PS00091 Functional Design Description, PRS-8i
11 1 3PS00063 Functional Design Description, Foxhole Slip Assembly
NEXT ASSY PRODUCT
D844000005-GEN-001 PRS-8i
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco Owner’s Manual
CURRENT INITIAL SBM, LONESTAR

PRS-8i
DRAWN J. Kellstrom SCALE: WT LBS: SIZE: SHT:
CHECKED K. Schmidt AV 1 OF 1
DWG NO.: REV:
APPVD B. Levay
D811000367-MAN-001 01
DATE 03/06/08
D811000457-GEN-001/01
OFFICIAL COPY - 01.17510.0003 - VDB027 - 0 - Approved(A) - - - 04-Dec-2008 03:52 PM
PRS-8i
Pipe Racking System
Service Manual
SM00969
Revision A
© Copyright 2003 Varco International, Inc.
All rights reserved. This publication is the property of, and contains information proprietary to
Varco International, Inc. No part of this publication may be reproduced or copied in any form, or by
any means, including electronic, mechanical, photocopying, recording or otherwise, without the
prior written permission of Varco International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.
Information in this manual is subject to change without notice.

General Information 1
Specifications 2
Maintenance 3
Troubleshooting 4
Glossary 5
1 General Information
2 Specifications
3 Maintenance
4 Troubleshooting
5 Glossary
General Information
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
PRS-8i Pipe Racking System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Horizontal Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 3
Rotation Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hoisting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Upper Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Lower (Tailing) Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 4
Control System, SBC Section . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Control System, VFD Section . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Junction Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 5
Circuit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Fingerboard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Fingerboard Control Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Fingerboard Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Doubles Latch Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Fingerboard Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Control System, SBC Section . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Control System, VFD Section . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Operator Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Control System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Primary Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Override Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Alarm and Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
PRS-8i
General Information
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1 Operating the Upper Grip Jaw and Roller Jaw . . . . . . . . . . . . . 1-40
Operating the Upper Arm Claw . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Operating the Lower Claw Assembly . . . . . . . . . . . . . . . . . . . . 1-41
Regulating Speed of Movements . . . . . . . . . . . . . . . . . . . . . . . 1-41
Stowing the PRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
2
Varco
General Information
Intended Audience
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco International, Inc., will not be held liable for errors in this 1
material, or for consequences arising from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with
additional information, and to advise the reader to take specific action to protect
personnel from potential injury or lethal conditions. They may also inform the reader of
actions necessary to prevent equipment damage.
Please pay close attention to these advisories.
Note:
i
The note symbol indicates that additional information is
provided about the current topics.
Caution:
!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning:
The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant
property loss, or significant equipment damage.
Illustrations
Figures provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not
be drawn to scale.
For more specific component information pertinent to your rig configuration, see the
technical drawings included with your Varco documentation.
PRS-8i 1-3
General Information
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment
involving hazardous operations and situations. Proper service and repair is important for
1 safe and reliable operation. Operation and service procedures provided by Varco
manuals are the recommended methods of performing those operations.
!
CAUTION: To avoid injury to personnel or equipment
damage, carefully observe the following safety
requirements.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on
the equipment, or those in the vicinity of the equipment, should be trained on rig safety,
tool operation, and maintenance to ensure their safety.
!
CAUTION: During installation, maintenance, or repair of
equipment, personnel should wear protective gear.
Protective gear must be worn during certain operation.
Contact the Varco Drilling Equipment training department for more information about
equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
being described. Varco recommends that only those tools specified be used when
stated. Ensure that personnel and equipment safety are not jeopardized when using
service procedures or tools not specifically recommended by Varco.
1-4 Varco
General Information
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities,
such as electrical, hydraulic, pneumatic, or cooling water.
1
!
CAUTION: Before installing or performing maintenance or
repairs on equipment, read the following instructions to
avoid endangering exposed persons or damaging
equipment.
Isolate all energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or
repair.
Replacing Components
Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during disassembly and reassembly of equipment to ensure correct installment.
Replace failed or damaged components with Varco certified parts. Failure to do so
could result in equipment damage, or personal injury.
Routine Maintenance
Equipment must be maintained on a regular and routine basis. See the service manual
for maintenance recommendations.
!
CAUTION: Failure to conduct routine maintenance could
result in equipment damage or injury to personnel.
Proper Use of Equipment

Varco equipment is designed for specific functions and applications, and should be used
only for their intended purpose.
PRS-8i 1-5
General Information
Description
The PRS-8i Pipe Racking System (PRS) is used to move pipe stands (sometimes called
tubulars) from the pipe setback area to well-center during tripping-in operations, and
1 move pipe stands from well-center to the pipe setback area during tripping-out
operations. It is also used to build pipe stands.
The PRS is a computer-assisted, dual-arm, vertical pipe handling system that provides
for semiautomatic, remote handling of drill pipe stands and drill collar stands.
The main components of the PRS are:
Vertical Column
Upper and Lower Drive Assemblies
Upper and Lower Arm Assemblies
Fingerboards (functionally part of the PRS)
The vertical column supports the arm assemblies as it travels the rig floor between the
pipe setback area and well-center. The column is driven on tracks by a horizontal drive
system that includes the upper and lower drive assemblies. A drive shaft within the
column synchronizes upper and lower drive movements to keep the column in vertical
orientation at all times. The combination of pinion gear sizes and gearbox gear ratios
ensures identical upper and lower column movement.
The vertical column is rotated 112.5º to the right or 112.5º to the left by a rotation drive
system. The upper and lower arm assemblies rotate with the column.
The arm assemblies are extendable. The upper arm assembly has a a lift jaw assembly
that grips and guides the pipe stand while the arm does the hoisting.The lower arm
assembly has a claw assembly that encircles and captures the lower end of the pipe
stand to stabilize and guide the stand.
Hoisting of the upper arm is done by a hoisting system. The hoisting system has two
independent, but synchronized hoisting arrangements. Each contains a variable-speed
electric motor that is coupled to right-angle, inline planetary gearboxes. The motor and
gearbox drive a wire rope spooling drum. The wire rope is reeved over the crown
sheaves at the upper end of the column, then through a hoist carriage sheave, and back
to a counterbalance assembly where it is finally anchored. Reeling the wire rope will
raise or lower the hoist carriage to which the upper arm is attached.
The counterbalance assembly:
Limits the amount of carriage weight applied to the tubular when setting down or
stabbing tubulars
Detects when setdown occurs to permit safe release of the grip jaw
Prevents the wire ropes from slacking at setdown
Thus, the double-hoist arrangement provides for two independent load paths that
operate in unison, allowing for each hoisting arrangement to independently hold and
distribute the load.
A derrick-supplied hydraulic system provides pressurized hydraulic oil for operating
actuators in the arms, jaws, claws, and counterbalance assembly.
1-6 Varco
General Information
Description
The fingerboards (sometimes called the pipe setback area) secure the pipe stands
within the derrick structure, and provide accurate positioning of the stands for
semiautomatic operations. The fingerboards are welded structures on opposite sides of 1
the derrick at the upper level. Each fingerboard has sets of parallel steel fingers that
extend from their mounting frame towards the upper track, where they are open-ended.
Each set of fingers is designed to handle different size diameters of pipe. Fingerboard
configurations will vary for each rig.
Along each finger are electrically-controlled, pneumatically-operated latches that hold
the pipe stand in place. As a pipe stand is placed through the open end and into a pipe
slot, the latch closes to secure the pipe stand.
A doubles latch is used for the building of double pipe stands.
A control system, located in the operators cabin, processes all data from the operator
controls to the PRS and all feedback from the PRS. The processed data is used to
control all tool functions and inform the operator of tool operations and status.
The control system has two sections:
Single-Board Computer (SBC) section. This section does the primary processing
of data.
Variable-Frequency Drive (VFD) section. This section contols the hoist, horizontal
drive, and rotation motors. When commanded to drive a motor, the VFD sends a
modulated signal to the motors. It also sends a brake release signal to the brake.
A dynamic braking resistor is associated with the VFD section. The brake resistor
is used to dissipate excessive back EMF produced by the hoist motors.
Communication between the control system and tool components is done over
PROFIBUS/Ethernet networks. The PROFIBUS network is used for motion control. It
provides communication links with the VFDs.
The Ethernet network is used for zone management. It provides communication links
between PRS control, fingerboard control, AR5000 control, and the Zone Management
System (ZMS).
Special handling tools may be supplied with the PRS as optional equipment. Should this
be the case, a separate manual will be provided as a supplement.
PRS-8i 1-7
General Information
PRS-8i Pipe Racking System
1 Fingerboard
Manual Input Upper Track
i
Station PRS Control System not shown.
Fingerboard
Control Tower
Fingerboards
Secure tubular stands
in storage location
Power
Supply
J-Box
Upper Drive Assembly
Drives vertical column
on upper track
Upper Service
Loop Bracket
Upper Inlet Upper Arm Assembly

Panel Assembly Hoists and carries
Hydraulic tubular stand
Doubles
Latch Control
Lift Jaw Assembly
Grips and guides
tubular stand
Doubles
Latch
Lower Service
Loop Bracket
Lower Inlet Vertical Column

Panel Assembly Supports arm
Hydraulic assemblies
Floor Track Claw Assembly

Captures lower end
of tubular stand
for stabilization
Lower Drive Assembly Lower Arm Assembly

Supports and drives Guides lower end
vertical column of tubular stand
on floor track
1-8 Varco
General Information

Horizontal Drive System
Driveshaft components synchronize movement of

1
Upper Track upper and lower drive assemblies to keep column in
Gear Rack vertical orientation at all times.
Upper Upper Drive

Horizontal Pinion Gear Vertical Driveshaft
Travel 12" Pitch Dia. 2,500 ft-lbs
Gearbox Peak Torque
6:1 Ratio 230 rpm
Max. Speed
Parallel Shaft
Gearbox
1.48:1 Ratio,
Upper Driveshaft Chain Drive
2,500 ft-lbs
Peak Torque
230 rpm Horizontal
Max. Speed Travel
Gearbox
Driveshaft 8.7:1 Ratio
Bearing
Lower Driveshaft
Dampener
Horizontal 2,500 ft-lbs
Travel Peak Torque
Brake 230 rpm
Max. Speed
Horizontal
Travel
Position
Encoder
Horizontal
Travel Lower
Motor Horizontal
Travel
Gearbox
3.5:1 Ratio
Lower Track
Driveshaft
Gear Rack
Support Bearing
Lower Drive
Pinion Gear
7" Pitch Dia.
PRS-8i 1-9
General Information

Rotation Drive System
1 Rotation of the vertical column allow tubular stands to be moved
between the fingerboards and well center.
Rotation Limits: 225∞ (112.5∞ to the left or right from well center.)
Upper Drive
Assembly
Neck
Upper Drive
Assembly
Upper Column
Rotation Guide
Rollers
6 Places
Rotation Drive
Motor
Variable-frequency
Rotation Drive
Brake
Rotation Drive
Gearbox
Rotation Drive
Turntable Pinion Gear
Bearing
Rotation Drive
Ring Gear
Lower Drive
Assembly
1-10 Varco
General Information

Hoisting System
1
Crown
Crown
Sheave
Sheave
Counterbalance
Assembly Upper Arm
2 Places Assembly
Hoist
Carriage
Sheave
2 Places
Hoist
Carriage
Wire Rope
Wire Rope
Wire Rope
Hoist
Motor Wire Rope
Spooling
Drum
Hydraulically
Released
Brake
Position Connecting
Encoder Shaft
90∞ Gearbox 90∞ Gearbox
Hydraulically
Released
Brake
Wire Rope
Spooling
Drum Position
Encoder
Hoist Motor
PRS-8i 1-11
General Information

Upper Arm Assembly
1
Upper arm hoists and carries the complete
load of the tubular stand.
Hoist Carriage
Hoist Carriage
Guide Rollers Rotated
4 Places 90 Degrees
Crown
Sheaves
2 Places
Handling Tool
Manifold
Wire Rope
2 Places
Wire Rope
Sheaves
2 Places Hoist Jaw
Manifold
Remote Output Upper Arm

N.I.S J-box Valve
Assembly
Hoist Carriage
Moves arm Hoist Arm
assembly Hydraulically
up and down actuated
the column Arm Extension
Hydraulic
Cylinder
Lift Jaw Assembly
Lift Jaw
Positioning Grip Jaw
Hydraulic
Cylinder
Roller Jaw
Claw
View from rear
1-12 Varco
General Information

Upper Arm Assembly
Lift Jaw Assembly 1
The two main functions are to guide and to grip.
Grip Jaw - The hydraulically actuated grip jaw can grip the outer diameter of a tubular
stand at any postion within the hoisting range. It normally grips the tubular stand at
about 30 feet (9,144mm) below the upper box.
Roller Jaw - Prior to activating the grip jaw, the roller jaw clamps onto the tubular.
Rollers in the roller jaw center the tubular in the jaw dies. The grip jaw holds the
centered tubular, with the force pressing the jaw dies into the surface of the tubular. Grip
force varies with the diameter of the tubular.
Claw - Used to guide and stab.
Guide function closes the claw and loosely prevents the tubular from lateral movement,
while allowing it to move up and down through the claw. While the hoisting arm lifts the
tubular from the Foxhole, the claw maintains control of the bottom of the tubular.
The stab function is activated while the claw is closed. Activating the position cylinder
pivots the claw at its wrist, firmly centering the tubular in the claw without actually
gripping. The claw provides lateral control of the tubular for stabbing into a box at well-
center, at the Foxhole, or for setting down in the fingerboards.
Grip Jaw
Die Jaw
Insert
6 Places
Die Jaw
Insert Carrier
2 Places
Roller Jaw
Roller
4 Places
Claw
PRS-8i 1-13
General Information

Lower (Tailing) Arm Assembly
1
Lower arm assembly does not have hoisting or weight-
carrying capability. It only captures and guides the lower
end of the tubular for control and stability.
Arm Extension
Hydraulic
Cylinder
Lower Arm
Junction Boxes
Located on
backside of
column
Claw Assembly
Claw Assembly
Hydraulically
actuated
Claw Fingers
Claw Assembly Captures tubular
Positioning
Hydraulic
Cylinder
Maintains vertical
alignment
of claw assembly
Claw Rotation
Hydraulic Cylinder
Rotates claw assembly
in horizontal axis to
center tubular at well center
Lower Arm
1-14 Varco
General Information

Lower (Tailing) Arm Assembly
Claw Assembly Tilt Function 1
Claw Assembly
Rotated into
centralizing position
Claw
Assembly
Positioning
Hydraulic
Cylinder
Tubular
Claw Rotation
Hydraulic
Cylinder
PC6 Claw
Centralization
Pressure
Adjustment
View from Rear
View from Front
PRS-8i 1-15
General Information

Hydraulic System Components
1 The hydraulic system drives the following actuators:
Arm position cylinders
Jaw position cylinders
Hydraulic-released brakes (for electric motors)
Pipe claw with open/close and centralize cylinders
Lift jaw with pipe guide, roll jaw, and grip jaw cylinders
Counterbalance cylinders for both hoisting wire ropes
1-16 Varco
General Information

Upper Inlet Panel Assembly 1
Located on the derrick wall in the setback area at the 840-inch level (21,336mm).
Provides filtering for hoist carriage hydraulic circuits.
Remote Power
Supply J-box
Pressure Hydraulic
Switch Oil Filter
Electronic
Driver J-box
Valve Control
Handle
Directional
Solenoid
Valve
Inlet Filter
Manifold
PRS-8i 1-17
General Information

1 Lower Inlet Panel Assembly
Located on the derrick wall in the setback area at the 400-inch level (10,688mm).
Provides filtering for lower arm assembly and counterbalance hydraulic circuits.
Remote Power
Supply J-box
Hydraulic
Oil Filter
Derrick Power
J-box
Pressure Valve Control

Switch Handle
Directional
Solenoid
Valve
Inlet Filter
Manifold
1-18 Varco
General Information

Control System, SBC Section
1
The SBC (Single Board Computer) section processes

data from operator controls. The processed data is us
to direct tool movement and jaw action.
Circuit TB4
CB1
2 4 2
CB2
4 2
CB3
4
CB4
2 4 2
CB5
4
CB6
2 4 2
CB7
4
CB8
2 4
Breakers 20A 2A 2A 2A 6A 6A 6A 6A
Typical 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3
OK
PS1 OK
PS2
230V VOLTAGE 230V VOLTAGE
SELECTOR SELECTOR
Power
Supplies
SITOP SITOP
power 5 power 5
6EP1 333-1SL11 6EP1 333-1SL11
External MAINTENANCE
MODE ACTIVE
CPU
RUNNING
MAINTENANCE
MODE
VARCO
PRS-8i CONTROL SYSTEM
SIEMENS P/N : SISYS-01-5541-2
MANUFACTURER : SIEMENS CANADA LTD
Controls
MANU. REF : AEX-5541
DATE : 01/02
ELECTRICAL RATING
POWER VOLTAGE: 120 VAC
FREQUENCE: 60 Hz
ISOLATOR UPS AMPS: 2A
NON UPS AMPS: 20 A
Terminal TBPS1+ TBPS1- TBPS2+ TBPS2-
Blocks
11
11
10
12
13
15
16
17
10
12
13
15
16
17
18
14
14
1
1
9
9
2
3
7
8
2
3
7
8
2
3
7
8
2
3
7
8
4
6
11
11
10
12
13
15
16
17
10
12
13
15
16
17
18
14
14
1
1
9
9
2
3
7
8
2
3
7
8
2
3
7
8
2
3
7
8
4
Typical
Single Board
Computer
SBC
SIEMENS SM 322 SM 321
32X24VDC,0.5A 32X24VDC,DI
SF DP
BUSF
0 0 0 0
ON
1 1 1 1
2 2 2 2
3 3 3 3
Interface Module,
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
SIMATIC
ET 200M 0 0 0 0
Digital I/O Modules

1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
2A 4A 5A
RL1
RL2
RL3
RL4
RL5
RL6
Repeaters Relays
Exterior View
RJ45 OLM 1
Optical Link
CHANNEL 1
LWL1 PA PA
CHANNEL 2
SIEMENS
Ethernet
RS485/PROFIBUS LWL-RING-KOPPLER
RS485/PROFIBUS FIBRE OPTIC RING-LINK
RJ4C1 BUS
Fault 2 rd
Modules
Fault 1 ye
X
A AX B B Error L- L+
Connection
10 9 8 7 6 5 4 3 2 1
TB1
1 1 1 1
TB3
2 2 2 2
3 3 3 3
4 4
TB2
4 4
5 5
6 6
7 7 1 1
8 8 2 2
TB E-STOP1
9 9 3 3
10 10 4 4
TB5
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5
TB6
6 6
1 1
7 7 2 2
8 8
3 3
9 9
4 4
10 10
TB7
11 11
12 12 1 1
13 13 2 2
14 14 3 3
TB E-STOP2
15 15 4 4
16 16
TB8
1 1
1 1 2 2
2 2 3 3
3 3 4 4
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
Fiber
Patch
Panel
Interior View
Door Removed
PRS-8i 1-19
General Information

Control System, VFD Section
1 The VFD section controls the hoist, horizontal drive, and rotation
motors through use of four variable-frequency drivers. Inputs to the
VFD include direction control and speed reference signals that control
the speed and direction of the motor rotation. When signaled to drive GROUND
FAULT
METER 1 PRS-8i CONTROL SYSTEM
VARCO P/N
MANUFACTURER
: 141664
: SIEMENS
a motor, the VFD sends a modulated output to drive the motors. It

MANU. REF :
DATE :
ELECTRICAL RATING
VOLTAGE: 440-480 VAC
FREQUENCY: 60 Hz CE
AMPS: 150 A
GROUND
Exterior
FAULT
also sends a brake release signal to release the brake.

SYSTEM
START/RESET
MAIN SUPPLY
ISOLATOR
VFD POWER
ISOLATOR
Controls
SS Outdoor Brake Resistor VDF Section

Dissipate any excessive back
electromotive force (EMF)
produced by the hoist motors.
Fuse Main
Typical Circuit
Breaker
F1 F2 F3 F4
F5
X1 X1 X1 X1
Dynamic
Brake
Variable CR1
Chopper
Frequency
Drives
DRIVE 1 DRIVE 2 DRIVE 3 DRIVE 4
Common
X2 X2 X2 X2 DBC1 Rectifier
TB5 TB6
Relays
10
11
10
11
12
13
14
15
16
17
18
19
21
12
13
14
15
16
17
18
19
1
1
20
20
22
23
24
25
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
10
11
10
11
12
13
14
15
16
17
18
19
21
12
13
14
15
16
17
18
19
1
1
20
20
22
23
24
25
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
K2
A2 A1 A2 A2 A1 A2 A2 A1 A2 A2
E-STOP
A1 A2
Power MR1 MR2 MR3 MR4

Motor
K5
K3
K4
K6
KE1 KE2
Supply Reactors
24 22 24 14 22 24 14 22 24 14 22 14
21 12 21 11 12 21 11 12 21 11 12 11
L1 N
1 AC 230 V
SITOP
power 20
TBP101
6EP1 336-1SH01 SHORT

OK
DC 24V / 20A
L+ M M
Repeater CB2
2 4
CB3
2 4
CB4
2 4
CB5
2 4
CB6
2 4
CB7
2 4
CB8
2 4
CB9
2 4
CB10
2 4
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
Positive
F F
P P P P
T T T T
5A 8A 5A 4A 2A 1A 1A 1A 1A
C C C C
RFI
1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3
1 2 3 4
L+ M PE M5 SIEMENS SM 332 SM 331 SM 322
Temperature
AO 4X12 BITS AI 4X12 BITS 32X24VDC,0.5A
SF DP
SF SF
BUSF
0
1
0
1
F6 CIRCUIT BREAKERS
ON
2 2
3 3
4 4
A1 B1 A1 B1
5 5
6 6
7 7
RP1
Filter
SIMATIC
ET 200M 0 0
1 1
Coefficient
2 2
K1
SIEMENS
3 3
RS 485-REPEATER 4 4
A2 B2 A2 B2
5
6
5
6
TB2 TB3 TB4
TBP100
7 7
10
11
10
11
10
11
12
12
13
14
15
16
17
18
12
13
14
15
16
17
18
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2A 4A 5A 6A
L1
10
11
10
11
10
11
12
12
13
14
15
16
17
18
12
13
14
15
16
17
18
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
1 2 3
TBN200 TBN201 TBN202

Circuits
1 2 3
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
1
2
3
4
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
Rack A
TBN203
Terminal T1
Main
Blocks Contactor
Typical
Circuit Breakers Transformer Line

Typical Reactor
Interior View Interior View
Right Side Doors Removed
1-20 Varco
General Information

Junction Box Assemblies
Junction box assemblies (J-boxes) provide junction points, or terminals, for the cables 1
that connect input and output devices between the PRS and its control system. Most
J-boxes are passive devices in that they provide junction points for inter-connecting PRS
cables. However, some J-boxes play a more active role in that they contain digital,
analog, or electronic driver modules that condition the signals between the input and
output devices. Input and output devices are components such as sensors, solenoids,
switches, and encoders.
Junction boxes that contain digital, analog, or electronic driver modules are discussed in
more detail in Chapter 4, Troubleshooting.
Sensors
Sensors monitor equipment functions. Several types are used:
Proximity sensors are used for limit sensing. They also provide absolute position
for determining the position of the PRS
Absolute encoders are used to measure travel distances
Linear transducers are used to measure arm extension and jaw position
A pressure switch is used to regulate proper air pressure to the fingerboards
Positive temperature coefficient (PTC) and overload sensors, located in the drive
motors, provide overtemperature information to the control system
PRS-8i 1-21
General Information

Sensors
1 Sensor Locations (upper)
1-22 Varco
General Information

Sensors
Sensor Locations (lower) 1
Hoist Carriage
Lower Index
Sensor
Located on rear
of column
Hoist Motor
Absolute
Hoist Motor Position
Absolute Encoder
Position Claw Assembly
Encoder Angle
Linear
Transducer
Rotation Drive
Absolute
Position
Encoder
Horizontal
Travel
Absolute
Position
Encoder
Lower Arm
Extension
Linear
Transducer
PRS-8i 1-23
General Information

Service Loops
1 Because PRS components move in various directions, the power cables, hydraulic
hoses, and control cables are carried in service loops from the derrick to the PRS.
Power cables are carried in the lower service loop from J-boxes on the derrick wall, at
the 35 ft level (10.7m), to J-boxes on the lower column.
A signal/control cable associated with the upper arm assembly is carried in the upper
service loop from J-boxes on the derrick wall, at the 60 ft level (18.3m), to the J-box on
the hoist carriage.
Hydraulic hoses from the upper arm assembly are carried in the upper service loop
between the derrick and the hoist arm carriage. Hydraulic hoses for the lower arm
assembly are carried in the lower service loop between the derrick and the lower
column.
Circuit Isolation
Power, signal, and control circuits are isolated to minimize susceptibility to noise or
signal deterioration. Isolation is accomplished by using separate J-boxes and separate
cables. J-boxes are constructed to Intrinsically Safe (IS) standards. All cables are
separated by a metallic barrier between each type of cable to eliminate crosstalk.
1-24 Varco
General Information
Fingerboard System
5 1/2 Drill
Pipe Slots
Fingerboard Walkways 1
Control Typical
Tower
9 1/2" Drill
Pipe Slots
Power
Supply North
J-Box Fingerboards
Fingerboard
Manual Input
Station ts
Slo
5 1/2" Drill 6 1/2" Drill

Pipe Slots Pipe Slots
8 1/2" Drill
South Pipe Slots
Fingerboards Doubles
Fingerboard
Doubles
Latch Control
Panel
Tubular Capacity
Size Type Stands Length (ft) Total Length (ft) Weight (lbs/ft)
5 1/2" Drill Pipe 360 93 33,480 25.0
6 1/2" Drill Collar 8 93 744 107.0
8 1/2" Drill Collar 5 93 465 187.0
9 1/2" Drill Collar 5 93 465 234.0
i
Fingerboard Control System not shown.
PRS-8i 1-25
General Information
Fingerboard System
Fingerboard Control Tower
1
Fingerboard Control
Tower
Door removed
for clarity
Profibus Node
Interface
Fiber Patch
Panel
Filter/
Regulator
Solenoid Valve Gage
Manifold
Controller
Mist
Air Line
Lubricator
Filter/
Regulator
Optical Link
Module
Pneumatic Pressure Switch Terminal Blocks
1-26 Varco
General Information
Fingerboard System
Fingerboard Control Station
1
Mounting
Plate
P/N 30155009
FINGERBOARD CONTROL
STATION
FINGERBOARD SET-UP
DERRICKMAN RACKER UNLATCH LATCH ACTIVATE
Air Inlet #1
SECTION
#2
6
SLOT BOUNDARIES
8 6 8
5 9 5 9
4 10 4 10
3 11 3 11
2 12 2 12
1 13 1 13
OFF 14 OFF 14
15 15
FROM TO
Emergency
Stop Switch
I-R Valve
Shutoff
EMERGENCY STOP
P/N 124952
SWITCH
Pressure
Gage
Pressure Breather/Drain
Switch
Pushbutton
Valve
PRS-8i 1-27
General Information
Fingerboard System
Doubles Latch Control Panel
1
Filter/Regulator Lubricator
Mounting
Plate
Air Inlet
Shut-off
Valve
Pressure Air Outlet

Gage
SOV-131
Mounting Plate
Filter/Regulator
Shut-off
Valve
Rig Air
Connection
Set at Lubricator
100 PSIG
690 kpa
Pneumatic Schematic Doubles Latch

1 Place
1-28 Varco
General Information
Controls and Indicators
Fingerboard Control Station 1

The fingerboard control station enables the derrickman to control the pipe racking
sequence from the derrick.
P/N 30155009
FINGERBOARD CONTROL
STATION
FINGERBOARD SET-UP
DERRICKMAN RACKER UNLATCH LATCH ACTIVATE
SECTION SLOT BOUNDARIES

#1 #2 6 8 6 8
5 9 5 9
4 10 4 10
3 11 3 11
2 12 2 12
1 13 1 13
OFF 15 14 OFF 15 14
FROM TO
PRS-8i 1-29
General Information

Fingerboard Control Station
1
Control/Indicator Function
DERRICKMAN/FINGERBOARD 3-position selector switch. When operator selects DERRICKMAN,
SET-UP/RACKER selector switch the racking sequence is placed under control of the derrickman at the
derrick. When the operator selects RACKER, the racking sequence
is placed under control of the racker at the operators chair. Center
position is FINGERBOARD SET-UP, which is not used.
UNLATCH/LATCH selector switch 2-position selector switch. Selects the operational sequence of the air
latches. Use UNLATCH to run tubulars into the hole. Use LATCH to
back rack tubulars.
ACTIVATE pushbutton switch Operates the selected slot air latch to sequentially latch or unlatch
each time the switch is pressed.
SECTION selector switch 2-position selector switch. Selects the fingerboard racking section
(#1 or #2) from which to rack or unrack tubulars.
SLOT BOUNDRIES selector 16-position selector switch. These switches select the starting and
switches FROM and TO ending slots between which sequence racking, within the row, will be
bounded for removing (FROM) or placing (TO) tubulars.
Remote actuator (Not part of the Sequentially operates latches in the slot selected by the FROM and
fingerboard control station. It is TO selector switches.
attached to the derrick at the 40 ft
level [12.19m])
1-30 Varco
General Information

1
Fan and
Filter
Maintenance
Mode
Keyswitch
Maintenance S2
Mode Indicator
L4
MAINTENANCE
MAINTENANCE CPU
MODE
MODE RUNNING
KEYSWITCH
PRS-8i
CONTROL SYSTEM
P/N : TBD
MANUFACTURER : SIEMENS CANADA LTD
MANU. REF : AEX-XXXX
DATE : MM/YY
ELECTRICAL RATING
VOLTAGE: 220 VAC
FREQUENCY: 60 Hz
AMPS: 2A
NON UPS AMPS: 20 A
POWER
ISOLATOR
Power CPU
Isolator Running
Switch Indicator
S1 L1
Filter
PRS-8i 1-31
General Information

1
i
Control system controls and indicators are used primarily
during maintenance and troubleshooting functions.
Controls and indicators not listed are not used.
POWER ISOLATOR switch S1 Controls application of power to the cabinet.
MAINTENANCE MODE Key-operated switch. The switch is turned on to override the system
KEYSWITCH S2 interlocks. Used when performing maintenance.
CPU RUNNING indicator L1 Illuminates to indicate the Central Processing Unit (CPU) in the SBC
(green) is processing data.
MAINTENANCE MODE indicator Illuminates to indicate the MAINTENANCE MODE KEYSWITCH is
L4 (red) set to the on position.
WARNING LIVE 120VAC label Warning label.
1-32 Varco
General Information

1
Floppy Disk
Drive
Exhaust
Filter
(3 Places)
GROUND
FAULT
METER 1
PRS-8i CONTROL SYSTEM
VARCO P/N : 141664

MANUFACTURER
: SIEMENS
MANU. REF :
DATE :
ELECTRICAL RATING
VOLTAGE: 440-480 VAC
FREQUENCE: 60 Hz CE
AMPS: 150 A
GROUND
FAULT
MAIN SUPPLY
SYSTEM
START/RESET System
ISOLATOR
Start/Reset
Switch S2
VFD POWER
ISOLATOR
VFD
Power
Isolator
Main
Supply
Isolator
Switch S1
Intake
PRS-8i 1-33
General Information

1
i
Control system controls and indicators are used primarily
during maintenance and troubleshooting functions.
Controls and indicators not listed are not used.
SYSTEM START/RESET switch When pressed, enables main power contactor during initial startup
S2 and after a fault is cleared.
VFD POWER ISOLATOR key Key-operated switch. Controls the application of power to the
switch common rectifier which provides DC voltage to the VFDs.
MAIN SUPPLY ISOLATOR switch When set to off position, isolates the main power source.
S1
1-34 Varco
General Information
Operation Overview
The operator uses a joystick and other controls to direct PRS operations. Movement of
the joystick and control actions are interpreted by the control system as operator
commands. The control system verifies the commands are within the operational 1
parameters of the tool, then executes the commands to ensure safe operation. If the
commands are not within operational parameters and proper sequence, the control
system will stop the PRS. An example is when the PRS is carrying a pipe stand; rotation
is prevented until the PRS moves to the end of the upper track assembly.
i
All machine motions are governed by dead-man control,
i.e., whenever the operator releases the switch on the
joystick, the associated movement stops immediately.
Operator Actions
Raise or lower the hoist carriage
Extend or retract the arm assemblies
Rotate the vertical column
Drive between the setback area and well-center
Actuate the roller and grip jaws and the upper and lower claws
i
The driller is ultimately responsible for operating the PRS
in a manner that avoids collisions, and does not damage
the equipment.
Control System Functions

Regulates speed of motion
Determines stopping destinations
Coordinates movement of all components
Provides safety interlock and alarm information
PRS-8i 1-35
General Information
Modes of Operation
1
i
Modes of operation may be changed at any time during
operation, but interlocks will be enforced to prevent
damage to the equipment.
Primary Modes
There are five primary modes of operation. Each mode is configured during initial setup
of the PRS. These modes require that the hardware configurations match the mode
selection to ensure proper operation:
Tripping - This mode is used to trip tubulars in and out of the hole, and into and out
of the fingerboard.
Building stands - This mode is used to build stands in the Foxhole and rack the
stands back into the fingerboard. It is also used to grab stands from the
fingerboard and break down the stands in the Foxhole.
Singles - This mode is used to grab singles off of the conveyor and to take the
singles to well-center. It is also used to grab singles at well-center and lay the
singles down on the conveyor.
Riser tailing - This mode is used in conjunction with a special tool attached to the
upper jaw. In this configuration the PRS will tail the riser from the conveyor to well-
center.
Parking - This mode is used to park (stow) the PRS in a safe position in the derrick
during rig movements and hazardous weather.
Override Modes
There are three override modes to facilitate non-standard operations that might require
overriding the normal control of the PRS. Override modes can be selected at any time
using the override pushbutton switches on the operator control screen, and the
MAINTENANCE MODE KEYSWITCH on the control system cabinet door:
X-Y override - The operator controls the position of the jaw with limited interlocks,
the column is frozen relative to the rig. The jaw will move in the direction that
joystick is pushed. The ZMS is still active in this mode.
Traverse override - The operator controls the position of the column with limited
interlocks the jaw is frozen relative to the column. The column will move in the
direction the joystick is pushed. The ZMS is still active in this mode.
Maintenance mode - All axis of movement are controlled individually by the
operator, with no interlocks. This mode is activate with the MAINTENANCE
MODE KEYSWITCH on the control system cabinet door. This mode may be used
in emergency situations, or for maintenance or troubleshooting of the PRS.
1-36 Varco
General Information
Interlocks
A general list of interlocks follows, but these are not necessarily the only factors that will
stop the PRS from moving. The PRS will automatically stop when it has reached its
preset destination, or when operator action is required, without displaying an interlock 1
message. A message, or indiction for the appropriate event will be displayed, but may
not constitute an interlock condition.
ZMS Interlock - the PRS is attempting to move into a ZMS zone that is occupied
by another piece of equipment, or the derrick
Jaw Holding Weight Interlock - The operator is attempting to open the grip jaw
while the PRS is still supporting the weight of the pipe stand
Fingerboard Interlock - The operator is attempting to move the PRS from the
fingerboard before the latch has been activated, or the operator is attempting to
remove the pipe stand from the fingerboard without unlatching the stand
Pipe Setdown Interlock - The operator is attempting to move the PRS while it is
gripped onto a pipe stand that is set down on the rig floor
Foxhole Interlock - The operator is attempting to hoist a tubular from the Foxhole
without opening the Foxhole
PRS-8i 1-37
General Information
Alarm and Event Messages

Alarm Messages
1 Some events are alarmed because they will stop operation of the PRS. The alarm
messages for these events are as follows:
Motor PTC Fault (one for each motor) - Motor temperature exceeded
Encoder Failure Detected (one for each encoder) - Control system has detected
an encoder failure
VFD Fault (one for each VFD) - VFD has faulted out, error message will be
displayed
Loss of Air Pressure - Insufficient air pressure available to fingerboard
Loss of Hydraulic Pressure - Insufficient hydraulic pressure to PRS
Loss of Communications to Tool-Mounted Remote I/O Devices
Loss of Communications to ZMS
Loss of Communications to Fingerboard Controller
Event Messages
Some event messages are simply displayed to the operator for information and ease of
operation purposes. These messages do not stop operation of the PRS, but may have
an affect on operational decisions made by the operator.
PRS On/Off
Maintenance Mode Active - The MAINTENANCE MODE KEYSWITCH has been
activated
X-Y Override Active - X-Y Override is being used by the operator
Traverse Override Active - Traverse Override is being used by the operator
Maximum Load Limit - Load being held is at, or near the maximum load limit
1-38 Varco
General Information
Operating Procedures
i 1
In some PRS systems, operator controls are provided by a
third party. These controls may be in the form of a remote
I/O and human-machine interface (HMI) devices. In such
cases, refer to the third-party documentation for
information on their devices.
i
Unless indicated otherwise, the controls and indicators
used in these procedures are located at the operators
chair.
Ensure PRS operational area is clear of personnel and

equipment before applying power.
i
There is no need to set or adjust any controls inside the
control system cabinets. Internal controls were set during
installation and commissioning of the equipment.
PRS-8i 1-39
General Information
Applying Power
1. At the SBC section of the control system cabinet, check the following:
a. MAINTENANCE MODE KEYSWITCH is set to off position (not locked out)
1
b. POWER ISOLATOR switch is set to on position
2. At the VFD section of the control system cabinet, check the following:
a. VFD POWER ISOLATOR switch is set to on position
b. MAIN SUPPLY ISOLATOR switch is set to on position
3. Check that VFD LCD reads 008, READY TO OPERATE.
4. At the operators chair, set RACKER MODE switch to ON.
5. Check for system fault indications. If present, troubleshoot the PRS and clear
fault.
Operating the Upper Grip Jaw and Roller

Jaw
1. To open the upper grip jaw and roller jaw, set UPPER GRIP JAW control to
OPEN.
2. To close the roller jaw, set UPPER GRIP JAW control to ROLLER. The roller jaw
will center the pipe for the grip jaw, which remains open at this time.
3. To close the grip jaw, set UPPER GRIP JAW control to GRIP. The upper arm
assembly can now hoist the pipe.
i
Interlocks prevent the grip jaw from opening if the control
system detects that the PRS is supporting a tubular. The
JAW HOLDING WEIGHT indicator will illuminate.
Operating the Upper Arm Claw

Use UPPER GUIDE control to open or close the upper arm claw.
1-40 Varco
General Information
Operating the Lower Claw Assembly

Use the LOWER GUIDE control to open or close the lower claw assembly. Tilting of the
claw for pipe centralization is automatically set by the control system when lowering pipe
at well-center, setback area, or the Foxhole. 1
i
Interlocks prevent the lower claw assembly from opening if
the control system detects that the PRS is supporting a
tubular. The JAW HOLDING WEIGHT indicator will
illuminate.
Regulating Speed of Movements

The control system regulates the speeds of the various PRS movements. The PRS
operates at maximum speed when empty, or when handling drill pipe or tubing, since
these are the lightest of the tubulars.
For each operating function (hoist, rotate, travel, arm movement) the degree of joystick
movement determines the speed of PRS movement. For example, if you move the
joystick only slightly, the PRS operates at a slow speed. If you move the joystick all the
way, the PRS operates at maximum speed.
i
The control system will slow the speed of the arm
assemblies as the jaws approach a known position. This
avoids striking a tubular with too much force.
PRS-8i 1-41
General Information
Stowing the PRS

Stow the PRS when weather conditions are extreme, during rig relocation, and when not
in use.
1
Upper Track Assembly Hard Stop
Stow the PRS

To stow PRS, upper and lower arms
must be fully retracted and hoist carriage
must be at its lowest point. The PRS is
then moved to its stowed position and
both lower and upper drives must be Detent
secured. Stowage
Pin Latch
1. Upper and lower arms:
a. Place upper and lower arms in
their fully retracted position.
b. Move hoist carriage to its lowest
position.
2. Lower drive:
a. Move PRS to its stow position
(furthest from well center). Typical
2 Places
b. Install bolt-on block in track on
the rig floor and tighten bolts to
secure. Hoist Carriage
3. Upper drive: Lowest Position
a. Ensure PRS is in its stowed
position.
b. Remove detent pins from
stowage latches. The PRS can be damaged if operated in an
c. Engage stowage latches to hold environment that exceeds the environmental
upper drive in stow position and specifications, and if PRS is not properly stowed
replace detent pins. when conditions dictate.
Upper Arm
Retracted Position
Lower Arm Bolt-on

Retracted Position Block
PRS Stowed Position
Lower Track Assembly

Hard Stop
1-42 Varco
Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 1
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
PRS-8i
Specifications
Varco
Specifications
Specifications
Physical Specifications
Size: Height (approx) 90 ft. (26,822 mm)
Weight: Total weight (w/o 64,000 lbs (29,056 kg) (approx)
fingerboard)
Dynamic (traversing) 55,000 lbs (approx) (24,970 kg)
weight
2
Stationary (upper 9,000 lbs (4,086 kg)
track, derrick plates,
floor tracks)
Functional Specifications
Travel:
Upper arm: Max. reach from 12 ft (3,657 mm)
column centerline
(CL) to tubular CL
Min reach from 24.5 in. (662 mm)
column pivot CL to
tubular CL
Min swing radius 31 in. (787 mm)
(to end of jaw)
Rotation 225º (112.5º from well CL)
Hoist stroke: Max. from drill floor 64.5 ft (19,660 mm)
Min from drill floor 12.5 ft. (318 mm)
Lower arm: Max. reach from 12 ft (3,657 mm)
column CL to tubular
CL
Min reach from 24.5 in. (662 mm)
column pivot CL to
tubular CL
Min swing radius 31 in. (787 mm)
(to end of jaw)
Rotation 225º (112.5º from well CL)
Hoist stroke None
Claw level above rig Retracted: 20 ft. (6,096 mm)
floor Extended: 15 ft. (4,572 mm)
PRS-8i 2-3
Specifications
Specifications
Functional Specifications
Speeds:
Handling drill Arm in/out (avg) 2.0 ft/sec (610 mm/sec)
pipe:
Hoist 2.4 ft/sec (731 mm/sec)
2 Column rotation 30º per second

Horizontal travel 2.0 ft/sec (610 mm/sec) max.
Handling drill Arm in/out (avg) 1.0 ft/sec (305 mm/sec)
collar:
Hoist 1.2 ft/sec (366 mm/sec)
Column rotation 12º per second
Horizontal travel 1.0 ft/sec (305 mm/sec) max.
Capacities: Drill pipe size 2 3/4 to 9 3/4 in.
Drill collar size 9 3/4 in. max.
Hoist: 120 in. extension 22,000 lb (10,000 kg)
144 in. extension 16,000 lb (7,257 kg)
i
On non-dynamic installations, the full 22,000 lb-rated load
may be allowed at full 144-inch extension. (See the
certifying agency approval documentation.)
2-4 Varco
Specifications
Specifications
Power Requirements
Electrical
Customer furnished 460 VAC, 3-phase, 60Hz, 150A
Control system 120 VAC, 69 Hz, 15A
Hydraulic
Pressure 2500 psi, closed centered
Flow rate 60 gpm
Pneumatic
Pressure 90 to 125 psi
Flow rate 50 cu ft/min (1.4 cu m/min)

(fingerboard)
PRS-8i 2-5
Specifications
Specifications
Environmental Specifications
i
It is the responsibility of the operator to ensure that the
PRS is operated within these specifications.
The PRS can be damaged if operated in an

environment that exceeds the environmental
specifications. Stow the PRS when weather conditions
are extreme.
Operational
Roll and pitch 7º pitch, single amplitude on 10-second period
50 ft (15,240 mm) roll center below rig floor
Heave 12% acceleration force applied to dead as well as live weight
Wind 65 knots (33.5 m/s) maximum from any direction
Temperature range -20º C minimun to 40º C maximum
Ice thickness Maximum on all horizontally projected surfaces - None
Survival (Nonoperational)
Roll 30º pitch, single amplitude on 10-second period
50 ft (15,240 mm) roll center below rig floor. (PRS in secured

park position)
Pitch 8º pitch, single amplitude on 8-second period
50 ft (15,240 mm) roll center below rig floor. (PRS in secured

park position)
Heave 36 ft (10,973 mm) on 10-second period. (PRS in secured park

position)
2-6 Varco
Maintenance
General Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Inspecting Load-Carrying Components . . . . . . . . . . . . . . . . . . . 3-5
Inspection After Each Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Weekly Inspection - Upper Section . . . . . . . . . . . . . . . . . . . . . . . 3-8 2
Weekly Inspection - Lower Section . . . . . . . . . . . . . . . . . . . . . . . 3-9
Monthly Inspection - Overall PRS . . . . . . . . . . . . . . . . . . . . . . . 3-10
Monthly Inspection - Upper Section . . . . . . . . . . . . . . . . . . . . . 3-11
Monthly Inspection - Lower Section . . . . . . . . . . . . . . . . . . . . . 3-12
Quarterly Inspection - Upper Section . . . . . . . . . . . . . . . . . . . . 3-13 3
Quarterly Inspection - Lower Section . . . . . . . . . . . . . . . . . . . . 3-14
Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Lubrication When New and After 50 Hours . . . . . . . . . . . . . . . . 3-19 4
Weekly Lubrication - Upper Section . . . . . . . . . . . . . . . . . . . . . 3-24
Weekly Lubrication - Lower Section . . . . . . . . . . . . . . . . . . . . . 3-25
Weekly Lubrication - Fingerboards . . . . . . . . . . . . . . . . . . . . . . 3-27
Weekly Lubrication - Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . 3-28
Monthly Lubrication - Upper Section . . . . . . . . . . . . . . . . . . . . . 3-29 5
Monthly Lubrication - Lower Drive . . . . . . . . . . . . . . . . . . . . . . 3-30
Monthly Lubrication - Drive Shafts . . . . . . . . . . . . . . . . . . . . . . 3-31
Yearly Lubrication - Overall PRS . . . . . . . . . . . . . . . . . . . . . . . 3-32
Positioning and Securing the PRS . . . . . . . . . . . . . . . . . . . . . . 3-38
Positioning the PRS for Removing Upper Drive Gearbox . . . . . 3-39
Positioning the PRS for Removing Upper or Lower Drive Shaft 3-39
Releasing Torque from Driveshaft . . . . . . . . . . . . . . . . . . . . . . 3-39
Replacing PRS Components . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Upper Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Lower Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Upper Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Lower Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Parallel Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Pinion Gear Locking Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Driveshaft Dampener Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Encoder Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Encoder Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . 3-59
Reeving the Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Adjusting 10mm Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . 3-63
Adjustable Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Adjustable Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
PRS-8i
Maintenance
Varco
Maintenance
General Maintenance Practices
Equipment Maintenance Records

Keep a record book of all maintenance procedures performed. Date each procedure,
followed by a description and the technician who performed it. This data is valuable for
fault finding and problem solving, should technical problems arise.
i
Procedures in this chapter relate to Varco only
components. See the supplier manuals for maintenance
procedures and schedules for the vendor equipment.
3
Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the
important safety notes highlighted as Notes, Cautions, and Warnings used throughout
this manual.
To avoid serious injury or death, read and understand the following Warnings before
performing maintenance or troubleshooting procedures:
Unless instructed otherwise, properly lock out the

main power source before performing any
maintenance procedure.
Wear protective glasses to prevent eye injuries.
PRS-8i 3-3
Maintenance
Do not attempt any adjustments while the machine

is moving.
3
Read and understand all safety precautions and
warnings before performing maintenance
procedures.
3-4 Varco
Maintenance
Inspection Procedures
The inspection procedures assume normal operating conditions. Some conditions
(excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may
warrant more frequent inspection intervals. Perform the maintenance procedures
indicated, as warranted by the inspection.
Inspecting Load-Carrying Components

Because the load-carrying components are critical to performance, Varco recommends
performing visual inspections on a regular basis.
Visually inspect all load-carrying components for corrosion, fatigue, or other
deterioration. If you detect any excessive wear and tear on any component, replace the
component.
The criteria for inspection of load-carrying components are determined by your
installation manager and by local regulatory requirements. 3
i
Before checking hydraulic lines on the PRS, make sure
that the power is off. Before checking pneumatic lines on
the fingerboards, make sure that the pneumatic pressure is
removed.
PRS-8i 3-5
Maintenance
Inspection After Each Trip
Grip Jaw Die

2 Places
Wire brush to remove any
debris that might impede proper
gripping and inspect for wear.
Replace any components
showing signs of wear.
Hoist Wire Rope

2 Places
Inspect for kinking, broken
strands, corrosion, or improper
reeving on the drum.
Repair as necessary.
All Hoses and Fittings

Inspect for leaks or loose fittings.
Seal, repair, or
replace as required.
3-6 Varco
Maintenance
Daily Inspection
Upper Drive Assembly

Inspect to ensure drive tracks
are free of debris.
Clean and lubricate.
Upper Arm Assembly

Inspect to ensure arm fully extends
and retracts smoothly, freely,
and without excessive noise.
Repair as required.
3
Hoist Carriage
Inspect to ensure carriage travels Lift Jaw Assembly
fully up and down the Inspect to ensure grip jaw,
column smoothly, freely, roller jaw, and upper claw
and without excessive noise. operates smoothly and freely.
Repair as required. Repair as required.
PRS Travel
Inspect to ensure PRS travels
fully forward, backward, and
rotates smoothly and freely,
without excessive noise.
Repair as required.
Claw Assembly
Inspect to ensure the claw
operates smoothly and freely.
Repair as required.
Lower Arm Assembly

Lower Drive Assembly Inspect to ensure arm fully extends
and retracts smoothly, freely,
Inspect to ensure drive tracks
and without excessive noise.
are free of debris.
Repair as required.
Clean and lubricate.
PRS-8i 3-7
Maintenance
Weekly Inspection - Upper Section
3-8 Varco
Maintenance
Weekly Inspection - Lower Section
PRS-8i 3-9
Maintenance
Monthly Inspection - Overall PRS
Fingerboards
Inspect pneumatic lines and
connections for air leakage.
Tighten or replace as required.
Fingerboard Control Cabinet

Inspect pneumatic lines and
connections for air leakage.
Electrical J-boxes
Dryness, tightness, and proper
fit of all glands and seals.
Tighten, seal or replace as required.
PRS
Loose hardware and fittings.
Load-Carrying Components
Inspect for corrosion, fatigue
or other deterioration
Repair as required.
3-10 Varco
Maintenance
Monthly Inspection - Upper Section
Column and Hoist Carriage Upper Drive Assembly

Wire Rope Sheaves Inspect rollers for wear
Inspect sheave for debris buildup, and bearing integrity. 3
cracks or deterioration. Replace as required.
Clean or replace as required.
Upper Arm Assembly

Inspect all hydraulic hoses and lines for
abrasion, pinching, kinking, cracking and
excessive bending or twisting. Observe
the hoses and lines while operating
the PRS.
Adjust, repair or replace as required.
Inspect sensor mounting hardware

for tightness.
Tighten. Sensor alignment may be required.
Hoist Carriage
Inspect rollers for wear
and bearing integrity.
Replace as required.
Column
Inspect roller surfaces on the column.
Clean as required.
Make sure drive shaft turns smoothly,
freely and without excessive noise.
Repair as required.
Check hydraulic lines and fittings.

Adjust, repair or replace as required.
PRS-8i 3-11
Maintenance
Monthly Inspection - Lower Section
Lower Arm Assembly

Inspect sensor mounting
hardware for tightness.
Tighten. Sensor alignment
may be required.
Lower Drive Assembly

Lower Drive 6 inch Inspect rollers for wear
Cam Rollers and bearing integrity.
4 Places Replace as required.
Lower Drive 4 inch

Cam Rollers
2 Places
3-12 Varco
Maintenance
Quarterly Inspection - Upper Section
Pivot Pins and Bearings
3
Upper Arm Assembly
Inspect pivot pins and bearings
for wear and bearing integrity.
Inspect hydraulic cylinder
clevis and trunnion pins.
Hydraulic Cylinder
Clevis and Trunnion Pins
Pivot Pins
and Bearings
PRS-8i 3-13
Maintenance
Quarterly Inspection - Lower Section
Hydraulic Cylinder
Clevis and Trunnion Pins
Pivot Pins
and Bearings
Lower Arm Assembly

Inspect pivot pins and bearings
for wear and bearing integrity.
Pivot Pins Replace as required.
and Bearings Inspect hydraulic cylinder
clevis and trunnion pins.
3-14 Varco
Maintenance
Yearly Inspection
Bearing
Retainer
Driveshaft
Dampener
Column Bearing
Gasket Inspect for wear
Column Replace as required
Cover
Dampener
Bearing Driveshaft
Dampener
Fixed
Bearing
Driveshaft
Inspect for wear
Replace as required
PRS-8i 3-15
Maintenance
Lubrication Procedures
Recommended Lubricants
Recommended Gear Oils
Manufacturer -6° to 16° C 7° to 30° C Above 21° C

(20° to 60° F) (45° to 85° F) (Above 70° F)
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
3 Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 68 Omala 150 Omala 320
Statoil Loadway EP68 Loadway EP150 Loadway EP320
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Viscosity Index
AMGA 2EP 4EP 6EP
ISO Viscosity 68 150 320

Grade
!
Oils of insufficient viscosity can damage gears by allowing
metal to metal contact.
3-16 Varco
Maintenance
Recommended Hydraulic Fluids
Manufacturer -15° to 75° C -10° to 85° C

(5° to 167° F) (14° to 185° F)
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25

3
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity 32 46
Grade
Recommended Motor Grease
Manufacturer Motor Grease
Chevron Black Pearl EP2 (Do Not Substitute)
PRS-8i 3-17
Maintenance
Recommended General Purpose Lubricants
Manufacturer Below -20° C Above -20° C

(Below -4° F) (Above -4° F)
Castrol - MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
3 Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2
Viscosity Index
NGLI 1 2
3-18 Varco
Maintenance
Lubrication When New and After 50 Hours
Gearbox
Expansion Tank
Hoisting
Gearbox Hoisting Second

Expansion Stage Gearbox
Upper Horizontal
Tank Drain and replace Travel Gearbox
gear oil
Drain and replace
gear oil
3
Hoisting Brake
Drain and replace
hydraulic fluid Rotation
Brake
Expansion
Hoisting First
Gearbox Tank
Stage Gearbox
Expansion
Drain and replace Brake Tank
gear oil Expansion
Tank Rotation
Drive
Brake
Drain and
replace
hydraulic fluid
Horizontal Travel
Parallel Gearbox Rotation
Filler/ Breather Drive
Gearbox
Parallel Gearbox Drain and
Drain and replace replace
automatic transmission gear oil
fluid
Gearbox
Expansion Tank
Brake
Expansion Tank
Horizontal
Travel Gearbox Lower Horizontal
Drain and replace Travel Gearbox
gear oil Reservoir
Horizontal
Travel Brake Lower Horizontal
Travel Gearbox
Drain and replace
hydraulic fluid Drain and replace
gear oil
PRS-8i 3-19
Maintenance
Upper Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

Filler/Breather Cap 1. Remove filler/breather cap on gearbox expansion tank
to vent gearbox.
Upper Sight Glass 2. Remove gearbox drain plug to drain oil.
Expansion Check magnetic drain plug for any metallic parts. If
Tank any are present, problems may exist with gearbox
Lower Sight Glass and it may require replacement.
3. Clean and replace drain plug after oil has completely
drained.
4. Remove uppermost plug on gearbox.
5. Fill gearbox with a cleaning solution recommended by
3 lubricant manufacturer. Install plugs, then run gearbox
for a few minutes. Drain cleaning solution (steps 1
through 3 above).
To Expansion
Tank 6. Remove vent plug. Fill expansion tank with oil until oil
rises to the open plug on top part of gearbox, then
Vent Plug replace plug.
7. Continuing filling until oil appears in the lower sight
glass on expansion tank. Do not fill past the lower
sight glass. Space is need for oil expansion when oil is
heated.
8. Replace filler/breather cap on gearbox expansion tank.
Drain Plug
9. Operate gearbox for several minutes to eliminate air
bubbles, then recheck oil level. Add oil as required.
Hoisting First Stage Gearbox Upright Hoisting First Stage Gearbox Inverted
Filler/Breather Cap
Filler/Breather Cap
Upper Sight Glass
Upper Sight Glass Expansion
Expansion
Tank
Tank Lower Sight Glass
Lower Sight Glass
To Expansion
Tank
To Expansion Vent Plug

Tank
Vent Plug
Drain Plug
Drain Plug
3-20 Varco
Maintenance
Hoisting Second Stage Gearbox Drain and Refill Gearbox Procedure

1. Lower hoist carriage to its lowest position.
2. Raise hoist carriage until second stage gearbox
rotates to a position showing a plug at the top, side
and bottom.
3. Remove fill plug to vent gearbox.
4. Remove gearbox drain plug to drain oil.
Fill
Check magnetic drain plug for any metallic parts. If
Plug
any are present, problems may exist with gearbox and
it may require replacement.
Oil Level
drained.
3
Plug lubricant manufacturer. Install plugs, then run gearbox
through 5 above).
7. Remove oil level plug, fill gearbox with oil until oil rises
to open plug in side of gearbox, then replace plug. Do
Drain not fill past oil level plug. Space is need for oil
Plug expansion when oil is heated.
8. Replace fill plug on gearbox.
Parallel Gearbox Drain and Refill Gearbox Procedure

1. Remove gearbox drain plug to drain automatic
transmission fluid (ATF).
Check magnetic drain plug for any metallic parts.
Full ATF Filler/Breather Cap If any are present, problems may exist with gearbox
Level Plug and it may require replacement.
2. Clean and replace drain plug after ATF has completely
drained.
3. Remove filler/breather cap and Full ATF Level plug.
Fill gearbox with ATF until the ATF rises to the open
Full ATF Level plug in the side of gearbox, then
replace plug.
4. Replace filler/breather cap on gearbox.
Add ATF Drain Plug bubbles, then recheck the ATF level at the Full ATF
Inspection
Level Inspection plug. Add ATF as required.
Level Plug
PRS-8i 3-21
Maintenance
Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

1. Remove filler/breather cap on gearbox expansion tank
to vent gearbox.
Filler/Breather Cap 2. Remove gearbox drain plug to drain oil.
Upper Sight Glass any are present, problems may exist with gearbox and
Expansion it may require replacement.
Tank
Lower Sight Glass 3. Clean and replace drain plug after oil has completely
drained.
4. Remove vent plug on gearbox.
through 3 above).
6. Remove vent plug. Fill expansion tank with oil until oil
rises to open plug on top part of gearbox, then replace
To Expansion plug.
Vent 7. Continuing filling until oil appears in the lower sight
Tank
Plug glass on expansion tank. Do not fill past lower sight
glass. Space is need for oil expansion when oil is
Drain heated.
Plug 8. Replace filler/breather cap on gearbox expansion tank.
Rotation Drive Gearbox
Filler/Breather Cap
Upper Sight Glass

Expansion
Tank
Lower Sight Glass
To Expansion
Tank
Vent Plug
Drain Plug
3-22 Varco
Maintenance
Lower Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

Filler/Breather Cap 1. Remove filler/breather cap on gearbox reservoir tank
to vent gearbox.
Reservoir Check magnetic drain plug for any metallic parts.
Lower Sight Glass
Tank If any are present, problems may exist with gearbox
and it may require replacement.
drained.
5. Fill gearbox with a cleaning solution recommended
by lubricant manufacturer. Install plugs, then run
3
To Reservoir gearbox for a few minutes. Drain cleaning solution
Tank (steps 1 through 3 above).
6. Remove vent plug. Fill reservoir tank with oil until
oil rises to open plug on top part of gearbox, then
replace plug.
Vent Plug 7. Continuing filling until oil appears in the lower sight
glass on reservoir tank. Do not fill past lower sight
Drain Plug glass. Space is need for oil expansion when oil is
heated.
8. Replace filler/breather cap on reservoir tank.
Disk Brake Drain and Refill Brake Procedure

1. Remove filler/breather cap on brake expansion tank to
vent brake.
Filler/Breather Cap 2. Remove brake drain plug to drain hydraulic fluid.
Upper Sight Glass 3. Clean and replace drain plug after hydraulic fluid has
Expansion completely drained.
Tank 4. Remove vent plug. Fill expansion tank with hydraulic
Lower Sight Glass fluid until hydraulic fluid rises to open plug on top part
of brake, then replace plug.
5. Continuing filling until hydraulic fluid appears in lower
sight glass on expansion tank. Do not fill past lower
sight glass. Space is need for hydraulic fluid
expansion when hydraulic fluid is heated.
6. Replace filler/breather cap on expansion tank.
7. Operate brake for several minutes to eliminate air
Vent Plug bubbles, then recheck hydraulic fluid level. Add
To Expansion hydraulic fluid as required.
Tank Drain Plug
PRS-8i 3-23
Maintenance
Weekly Lubrication - Upper Section
3 F
Uppe
G
Low
G
Check
whe
is
3-24 Varco
Maintenance
Weekly Lubrication - Lower Section
Typical Expansion Tank

Hoisting First Stage
Gearbox Expansion Filler/Breather
Tank Cap
Check oil level
Upper Sight
Glass
Hoisting First
Lower Sight
Stage Gearbox
Glass
Expansion
Check for leaks
3
Hoisting First Stage Tank Expansion
Brake Expansion when no fluid
Check oil level Tank
Tank is visible
Check hydraulic
fluid level
!
Do not fill past the lower sight glass.
Hoisting First Space is need for oil expansion when
Stage Brake oil is heated.
Expansion
Tank
Check hydraulic
Horizontal Travel fluid level
Gearbox Expansion
Tank
Check oil level
Rotation Drive
Gearbox
Expansion
Tank
Check oil level
Horizontal Travel
Brake Expansion
Tank
Check hydraulic
fluid level Rotation Drive
Brake
Expansion
Tank
Check hydraulic
fluid level
Lower Horizontal
Travel Gearbox
Reservoir
Check oil level
Check for leaks when no oil
is visible at lower sight glass.
PRS-8i 3-25
Maintenance
Weekly Lubrication - Lower Section
Check Hoisting Second

Stage Gearbox
1. Lower hoist carriage to its lowest
Hoisting Second
position.
Stage Gearbox
2. Raise hoist carriage until second stage
Check oil level at
gearbox rotates to a position showing
the half-full oil
a plug at the top, side and bottom.
level plug
Check oil level in gearbox.
3. Remove oil level plug.
4. Oil should be up to half level. If not at
half level. Add oil. Check for leaks.
5. Replace oil level plug.
3 Hoist drum gearboxes do not use
expansion tanks. Hoist drum gearboxes
operate with oil level at half full. Since the
Hoisting Second oil fill, half level, and drain openings are on
Stage Gearbox the section of gearbox that rotates, hoist
Check oil level at will have to be moved slightly up or down
the half-full oil to properly orient the openings. This may
level plug have to be done for each hoist drum
gearbox.
Parallel Gearbox
Check ATF level
at add ATF inspection
level plug
Check Parallel Gearbox

1. Carefully remove lower inspection plug.
If fluid runs out, replace the plug. The
fluid level is adequate. If fluid does not
run out perform steps 2 through 5.
2. Replace lower inspection hole plug.
3. Remove upper inspection hole plug.
4. Remove filler/breather cap and add ATF
(Automatic Transmission Fluid) until it
runs out the upper inspection hole plug.
5. Replace upper inspection hole plug
and filler/breather cap.
When fluid is not present at lower
inspection hole during weekly checks,
check for leaks.
3-26 Varco
Maintenance
Weekly Lubrication - Fingerboards
PRS-8i 3-27
Maintenance
Weekly Lubrication - Inlet Manifold
The PRS contains two inlet hydraulic oil filters. The filters are located on the upper and
lower derrick plates. The upper derrick plate is located on the derrick wall in the pipe
setback area at the 840-inch level (21,336 mm). The lower derrick plate is located on the
derrick wall in the pipe setback area at the 420-inch level (10,668 mm).
The upper filter provides filtering for the hoist carriage hydraulic circuits. The lower filter
provides filtering for the lower arm assembly and the counterbalance hydraulic circuits.
Upper Derrick
Plate Assembly
Hydraulic
Oil Filter
Lower Derrick
Plate Assembly
Valve Control
Handle
Indicator
Filter Replacement
1. Check indicator on front
of filter.
2. If indicator shows filter to be
dirty, close input hydraulic
valve using valve control
handle.
3. Replace filter
3-28 Varco
Maintenance
Monthly Lubrication - Upper Section
Upper Horizontal
Drive Track
Wipe off any contamination
on the gears and
apply fresh grease
Upper Drive Roller Upper Column

Grease Fittings Rotation Guide Rollers 3
8 Places Grease Fittings
6 Places
Crown Sheave
Grease Fittings
2 Places
Upper Arm Hoist Arm

Pivot Pin Extension
Grease Fittings Cylinder Pin
Grease Fittings
2 Places
Wire Rope
Lubricate rope
Wire Rope Sheave

Grease Fittings
2 Places
Hoist Carriage
Guide Roller
Grease Fittings
8 Places
Hoist Arm
Extension
Cylinder Pin
Grease Fittings
PRS-8i 3-29
Maintenance
Monthly Lubrication - Lower Drive
Lower Horizontal
Drive Track
Wipe off any contamination
on gears and
apply fresh grease
Rotation Drive
Ring Gear
3 and Pinion Gear
Wipe off any
contamination
on gears and
apply fresh grease
Lower Drive
Lower Drive Trunnion
Grease Fittings
Lower Drive Turntable 4 Places
Grease Fittings
4 Places
Lower Drive 4"

Cam Rollers
Grease Fittings
2 Places
Lower Drive 6"

Cam Rollers
Grease Fittings
4 Places
Lower Drive Shown from Underside
3-30 Varco
Maintenance
Monthly Lubrication - Drive Shafts
Driveshafts
Fixed Fixed
Upper Driveshaft Driveshaft Driveshaft Lower
Journal Grease Fitting
Grease Fitting 3
Upper Driveshaft
Slip Yoke
Grease Fitting
Upper
Driveshaft
Lower Driveshaft
Journal
Grease Fitting
Upper Driveshaft
Journal
Grease Fitting
Lower
Driveshaft
Fixed
Driveshaft Upper Lower Driveshaft
Grease Fitting Slip Yoke
Grease Fitting
Lower Driveshaft
Journal
Grease Fitting
PRS-8i 3-31
Maintenance
Yearly Lubrication - Overall PRS
Gearbox
Expansion Tank
Hoisting

Upper Horizontal
gear oil
Drain and replace
gear oil
3
Hoisting Brake
Drain and replace
Brake
Expansion
Hoisting First
Gearbox Tank
Stage Gearbox
Expansion
gear oil Expansion
Tank Rotation
Drive
Brake
Drain and
replace
hydraulic fluid
Horizontal Travel
Gearbox
fluid
Gearbox
Expansion Tank
Brake
Expansion Tank
Horizontal
gear oil Reservoir
Horizontal
Travel Gearbox
Drain and replace
gear oil
3-32 Varco
Maintenance
Gearbox
Expansion Tank
Hoisting

Upper Horizontal
gear oil
Drain and replace
gear oil
Hoisting Brake
3
Drain and replace
Brake
Expansion
Hoisting First
Gearbox Tank
Stage Gearbox
Expansion
gear oil Expansion
Tank Rotation
Drive
Brake
Drain and
replace
hydraulic fluid
Horizontal Travel
Gearbox
fluid
Gearbox
Expansion Tank
Brake
Expansion Tank
Horizontal
gear oil Reservoir
Horizontal
Travel Gearbox
Drain and replace
gear oil
PRS-8i 3-33
Maintenance
Upper Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

Filler/Breather Cap 1. Remove filler/breather cap on gearbox expansion tank
to vent gearbox.
Expansion Check magnetic drain plug for any metallic parts. If
Tank any are present, problems may exist with gearbox
Lower Sight Glass and it may require replacement.
drained.
4. Remove uppermost plug on gearbox.
lubricant manufacturer. Install plugs, then run gearbox
3 for a few minutes. Drain cleaning solution (steps 1
through 3 above).
To Expansion
Tank 6. Remove vent plug. Fill expansion tank with oil until oil
rises to the open plug on top part of gearbox, then
Vent Plug replace plug.
7. Continuing filling until oil appears in the lower sight
glass on expansion tank. Do not fill past the lower
sight glass. Space is need for oil expansion when oil is
heated.
8. Replace filler/breather cap on gearbox expansion tank.
Drain Plug
Hoisting First Stage Gearbox Upright Hoisting First Stage Gearbox Inverted
Filler/Breather Cap
Filler/Breather Cap
Upper Sight Glass
Upper Sight Glass Expansion
Expansion
Tank
Tank Lower Sight Glass
Lower Sight Glass
To Expansion
Tank
To Expansion Vent Plug

Tank
Vent Plug
Drain Plug
Drain Plug
3-34 Varco
Maintenance
Hoisting Second Stage Gearbox Drain and Refill Gearbox Procedure

1. Lower hoist carriage to its lowest position.
2. Raise hoist carriage until second stage gearbox
rotates to a position showing a plug at the top, side
and bottom.
3. Remove fill plug to vent gearbox.
4. Remove gearbox drain plug to drain oil.
Fill
Plug
any are present, problems may exist with gearbox and 3
it may require replacement.
drained.
Oil Level 6. Fill gearbox with a cleaning solution recommended by
Plug lubricant manufacturer. Install plugs, then run gearbox
through 5 above).
7. Remove oil level plug, fill gearbox with oil until oil rises
to open plug in side of gearbox, then replace plug. Do
Drain not fill past oil level plug. Space is need for oil
Plug expansion when oil is heated.
8. Replace fill plug on gearbox.
Parallel Gearbox Drain and Refill Gearbox Procedure

1. Remove gearbox drain plug to drain automatic
transmission fluid (ATF).
Check magnetic drain plug for any metallic parts.
Full ATF Filler/Breather Cap If any are present, problems may exist with gearbox
Level Plug and it may require replacement.
2. Clean and replace drain plug after ATF has completely
drained.
3. Remove filler/breather cap and Full ATF Level plug.
Fill gearbox with ATF until the ATF rises to the open
Full ATF Level plug in the side of gearbox, then
replace plug.
4. Replace filler/breather cap on gearbox.
Add ATF Drain Plug bubbles, then recheck the ATF level at the Full ATF
Inspection
Level Inspection plug. Add ATF as required.
Level Plug
PRS-8i 3-35
Maintenance
Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

1. Remove filler/breather cap on gearbox expansion tank
to vent gearbox.
Filler/Breather Cap 2. Remove gearbox drain plug to drain oil.
Upper Sight Glass any are present, problems may exist with gearbox and
Expansion it may require replacement.
Tank
Lower Sight Glass 3. Clean and replace drain plug after oil has completely
drained.
through 3 above).
6. Remove vent plug. Fill expansion tank with oil until oil
rises to open plug on top part of gearbox, then replace
To Expansion plug.
Vent 7. Continuing filling until oil appears in the lower sight
Tank
Plug glass on expansion tank. Do not fill past lower sight
glass. Space is need for oil expansion when oil is
Drain heated.
Plug 8. Replace filler/breather cap on gearbox expansion tank.
Rotation Drive Gearbox
Filler/Breather Cap
Upper Sight Glass

Expansion
Tank
Lower Sight Glass
To Expansion
Tank
Vent Plug
Drain Plug
3-36 Varco
Maintenance
Lower Horizontal Travel Gearbox Drain and Refill Gearbox Procedure

Filler/Breather Cap 1. Remove filler/breather cap on gearbox reservoir tank
to vent gearbox.
Reservoir Check magnetic drain plug for any metallic parts.
Lower Sight Glass
Tank If any are present, problems may exist with gearbox
and it may require replacement.
drained.
5. Fill gearbox with a cleaning solution recommended
by lubricant manufacturer. Install plugs, then run
To Reservoir gearbox for a few minutes. Drain cleaning solution
3
Tank (steps 1 through 3 above).
6. Remove vent plug. Fill reservoir tank with oil until
oil rises to open plug on top part of gearbox, then
replace plug.
Vent Plug 7. Continuing filling until oil appears in the lower sight
glass on reservoir tank. Do not fill past lower sight
Drain Plug glass. Space is need for oil expansion when oil is
heated.
8. Replace filler/breather cap on reservoir tank.
Disk Brake Drain and Refill Brake Procedure

1. Remove filler/breather cap on brake expansion tank to
vent brake.
Filler/Breather Cap 2. Remove brake drain plug to drain hydraulic fluid.
Upper Sight Glass 3. Clean and replace drain plug after hydraulic fluid has
Expansion completely drained.
Tank 4. Remove vent plug. Fill expansion tank with hydraulic
Lower Sight Glass fluid until hydraulic fluid rises to open plug on top part
of brake, then replace plug.
5. Continuing filling until hydraulic fluid appears in lower
sight glass on expansion tank. Do not fill past lower
sight glass. Space is need for hydraulic fluid
expansion when hydraulic fluid is heated.
6. Replace filler/breather cap on expansion tank.
7. Operate brake for several minutes to eliminate air
Vent Plug bubbles, then recheck hydraulic fluid level. Add
To Expansion hydraulic fluid as required.
Tank Drain Plug
PRS-8i 3-37
Maintenance
Positioning and Securing the PRS
!
Before performing any disassembly, move the PRS to a
position suitable for the service being performend, and
clear of well-center operations.
3
Before attempting removal of any horizontal drive
system components, secure both upper and lower
drives to prevent movement along upper and lower
tracks. Failure to do so can result in the column falling
out of upper and lower tracks, resulting in equipment
damage or injury to personnel.
!
Use care when handling driveshafts to ensure that the
telescopic section is restrained from exceeding its fully
extended position. The driveshaft can separate, damaging
the cap and seal and possibaly dropping the unsupported
section to the rig floor.
3-38 Varco
Maintenance
Positioning the PRS for Removing Upper

Drive Gearbox
1. Position upper drive gear centered on the access hatch in the upper track
assembly.
2. Orient column facing either setback area.
3. Fully retract lower arm assembly.
4. Position upper arm assembly at its lowest, fully retracted position.
5. Install suitable clamps on rolling flanges in front of both forward side rollers and
behind both rear side rollers of upper drive. This prevents movement of upper
drive.
3
Positioning the PRS for Removing Upper or
Lower Drive Shaft
1. Position column along the track in a suitable place clear of well-center operations.
2. Orient column facing either setback area.
3. Fully retract lower arm assembly.
4. Position upper arm assembly at its lowest, fully retracted position.
5. Restrain lower drive from forward or reverse motion by using tag lines in both
directions.
Releasing Torque from Driveshaft
1. Check that electrical power to the horizontal travel drive is locked out.
2. With power unit on, release horizontal travel brake by depressing the manual
override on directional control valve SV4 on lower arm manifold assembly.
3. Rotate driveshaft in both directions to check if gearing backlash can be felt. It may
be necessary to use a strap wrench on the driveshaft for this operation. If no
backlash, adjust the horizontal front-to-rear until backlash is felt. Use tag lines to
move the lower drive to adjust the horizontal front-to-rear until gear backlash can
be felt.
PRS-8i 3-39
Maintenance
Replacing PRS Components
Always make sure power is removed from PRS before

removing and replacing components.
3 i
Use the assembly drawings contained in the Technical
Drawing Package, 3TDP0102, for these procedures.
3-40 Varco
Maintenance

Upper Driveshaft
Remove Upper Driveshaft

Before attempting disassembly of any
driveshaft component ensure the column is
secured top and bottom and that driveshaft
torque is released.
Do not rotate column with forward and reverse
securing devices attached to upper or lower drive.
Failure to follow this warning could result in damage to
horizontal driveshaft components.
1. Position and secure PRS.
2. Clean universal joint at both ends of driveshaft. Universal
3. Remove lockstraps and four bolts connecting the Joint 3
two bearings to the end yoke at both ends of
driveshaft.
4. Remove the two bearings from end yoke at both
ends of driveshaft.
5. If necessary, adjust restraining tag line tension to
Upper
eliminate driveshaft torque before bearing can be
Driveshaft
removed.
6. Remove journals from end yokes.
7. Remove lower driveshaft from column through
access hatch on back of column.
8. Place bearings back on journals and secure with
tape to retain internal needle bearings.
Universal
Typical Universal Joint Joint
Bearing
Lockstrap Access
Hatch
Bolt
Upper
Driveshaft
Replace Upper Driveshaft

1. Remove taped bearings from journals.
End Yoke 2. Insert upper driveshaft into column
through access hatch on back of column.
Fixed 3. Align journals to end yokes.
Journal Driveshaft
4. Replace the two bearings on each end
yoke.
5. Replace lockstraps and four bolts
connecting the two bearings to each end
yoke.
After completing driveshaft replacement,
follow Aligning the Column Vertically
Procedure.
PRS-8i 3-41
Maintenance

Lower Driveshaft
Typical Universal Joint Remove Lower Driveshaft

Before attempting disassembly of
Lower any driveshaft component ensure
Driveshaft the column is secured top and
bottom and that driveshaft torque is
released.
Do not rotate column with forward and
reverse securing devices attached to upper
Bearing or lower drive. Failure to follow this warning
Lockstrap could result in damage to horizontal
Bolt driveshaft components.
3 1. Position and secure PRS.
2. Clean universal joint at both ends of
driveshaft.
3. Remove lockstraps and four bolts
connecting the two bearings to the end
End Yoke yoke at both ends of driveshaft.
Journal 4. Remove the two bearings from end yoke
at both ends of driveshaft.
5. If necessary, adjust restraining tag line
tension to eliminate driveshaft torque
before bearing can be removed.
Fixed 6. Remove journals from end yokes.
Driveshaft
7. Remove lower driveshaft from column
through access hatch on back of column.
8. Place bearings back on journals and
secure with tape to retain internal
needle bearings.
Universal
Joint
Replace Lower Driveshaft
Upper 1. Remove taped bearings from journals.

Access 2. Insert lower driveshaft into column
Hatch Parallel through access hatch on back of column.
Gearbox 3. Align journals to end yokes.
4. Replace the two bearings on each end
yoke.
Lower 5. Replace lockstraps and four bolts
Driveshaft connecting the two bearings to each end
yoke.
After completing driveshaft replacement,
Lower follow Aligning the Column Vertically
Access Procedure.
Hatch
Universal Lower
Joint Gearbox
3-42 Varco
Maintenance

Upper Drive Gearbox
Upper Drive Removing upper drive gearbox

Pinion Gear
Before attempting disassembly of any
Oil Reservoir Upper Track driveshaft component ensure the
and Assembly column is secured top and bottom and
Reservoir Access Hatch that driveshaft torque is released.
Mounting
Bracket Do not rotate column with forward and reverse
Gearbox securing devices attached to upper or lower
Mounting drive. Failure to follow this warning could result in
Plate damage to horizontal driveshaft components.
1. Position and secure PRS.
2. Clean upper universal joint.
3. Remove lockstraps and four bolts connecting
the two bearings to upper end yoke.
3
4. Remove the two bearings from end yoke.
5. If necessary, adjust restraining tag line
tension to eliminate driveshaft torque before
bearing can be removed.
6. Remove journal from end yoke.
7. Place bearings back on journal and secure
with tape to retain internal needle bearings.
8. Remove oil reservoir and reservoir mounting
bracket.
9. Working through the upper track assembly
Upper access hatch, remove eight bolts from
Universal gearbox mounting plate.
Joint 10. Using straps around pinion gear or a M20
threaded eye-bolt in the end of gearbox shaft,
lift gearbox and its mounting plate through
upper track assembly access hatch.
Upper Upper Universal Joint

Driveshaft
Upper
Gearbox
Bearing
Lockstrap
Bolt
End Yoke
Journal
Upper
Driveshaft
PRS-8i 3-43
Maintenance

Upper Drive Gearbox
Upper Drive Replacing upper drive gearbox

Pinion Gear
Before reinstalling gearbox, fill it completely with
Oil Reservoir Upper Track gear oil and plug the fill port.
and Assembly
Reservoir 1. Using straps around pinion gear or a M20
Access Hatch threaded eye-bolt in end of gearbox shaft, lower
Mounting
Bracket gearbox and its mounting plate through upper
Gearbox track assembly access hatch.
Mounting 2. Working through upper track assembly access
Plate hatch, align pinion gear to gear rack and end yoke
to driveshaft. Replace eight bolts on gearbox
mounting plate.
3 3. After installing gearbox, install oil reservoir
and fill it to lower sight glass.
4. Reconnect upper driveshaft to the gearbox.
a. Remove taped bearings from journal.
b. Align journal to end yoke.
c. Replace the two bearings on end yoke.
d. Replace lockstraps and four bolts connecting
the two bearings to end yoke.
When replacing gearbox, make sure replacement
gearbox has proper gear ratio, otherwise equipment
damage and/or injuries may occur. The upper and
lower gearboxes look identical but have different gear
Upper ratios.
Universal The gear ratios are as follows:
Joint • Upper gearbox ratio: 6.00:1
• Lower gearbox ratio: 3.50:1
After completing gearbox replacement, follow
Aligning the Column Vertically Procedure.
Upper Upper Universal Joint

Driveshaft
Upper
Gearbox
Bearing
Lockstrap
Bolt
End Yoke
Journal
Upper
Driveshaft
3-44 Varco
Maintenance

Lower Drive Gearbox
Removing Lower Drive Gearbox
!
Use care when lifting gearboxes suspected of being faulty.
It is recommended to hoist by the gear case, rather than
attaching lifting device to the input or output shafts.
Damaged or broken parts may separate from the gearbox
assembly when lifting.
1. Position lower drive at one end of lower track.

3
2. Position and secure column for driveshaft removal (refer to 3-39).
3. Remove two floor plates from other end of lower track.
4. Replace floor plates with 1-inch thick (25.4mm) temporary plates that match the
remaining floor plates. A separation of 9 inches (228.6mm) allows pinion gear to
pass through the temporary plates.
5. Secure temporary plates to base of floor track.
6. Attach tag lines to lower drive in the direction of travel.
7. Attach adjustable tag lines to each side of lower drive, perpendicular to the
direction of travel, at the end towards the temporary floor plates. Keep tag lines
taut to control side-to-side motion of lower drive.
8. Release travel brake by operating manual solenoid.
9. Adjust tag lines as necessary and drag PRS onto the temporary floor plates until
pinion gear is clear. Keep tag lines taut to hold lower drive in place as slot roller
exits slot in plates.
10. Remove column base cover to gain access to lower universal joint.
11. Clean lower universal joint.
i
If necessary, adjust restraining chain tension to eliminate
driveshaft torque before removing bearings.
12. Remove lockstraps and four bolts connecting two bearings to lower end yoke, and
remove two bearings.
13. Remove journal from lower end yoke.
14. Place bearings on journal and secure with tape to retain internal needle bearings.
15. Remove lower drive gearbox oil reservoir.
16. Remove bolts attaching lower drive gearbox to lower drive chassis.
17. Attach a tugger or hoist to top of lower drive gearbox housing and pull housing up
and forward through column base access hole at front of column.
PRS-8i 3-45
Maintenance

Lower Drive Gearbox
Lower
Lower Track Driveshaft
Column Base
Access Cover
3
Universal
Joint
Lower Drive
Gearbox Oil
Reservoir
Lower Drive
Gearbox
Floor
Attaching
Plates
Bolts
Lower Drive 9 in.

Chassis (228.6 mm)
Typical Universal Joint
Lower
Driveshaft
Temporary
Journal Floor Plates
2 Places
Bearing
Lockstrap
End Yoke
Bolt
Lower Drive
Gearbox
3-46 Varco
Maintenance

Lower Drive Gearbox
Replacing Lower Drive Gearbox
!
Use care in lifting gearboxes suspected of being faulty. It is
recommended to hoist by the gear case, rather than
attaching lifting device to the input or output shafts.
Damaged parts may separate from the gearbox assembly
when lifting.
Replacing the lower drive gearbox is performed in the reverse order of removal, except
as follows: 3
1. Ensure replacement gearbox has the proper gear ratios, otherwise damage and/
or injuries may occur. The upper and lower gearboxes look identical but have
different gear ratios. The gear ratios are:
Upper drive gearbox: 6.00:1
Lower drive gearbox: 3.50:1
2. Before installing replacement gearbox, fill it completely with gear oil, then plug the
fill port.
3. After installing the replacement gearbox, install the oil reservoir and fill it to a level
between the two sight glasses.
PRS-8i 3-47
Maintenance

Parallel Gearbox
Removing Parallel Gearbox
1. Move PRS to its stowed position.
2. Rotate column until it faces pipe setback area.
3. Working through the access hole in back of column, disconnect lower end of
upper driveshaft and remove bearings, lockstraps, bolts, and journal from end
yoke.
4. Attach a hoisting line to the fixed driveshaft.
5. Remove four bolts and washers from fixed driveshaft bearing housing.
6. Remove cover plates above and below the parallel gearbox.
7. Carefully hoist fixed driveshaft upwards while pulling bearing housing free of the
3 column, and splines section free of the parallel gearbox. Hoist fixed driveshaft until
it is fully disengaged from gearbox, as can be seen through opening behind upper
cover plate.
8. Secure fixed driveshaft.
9. Working through the access hole in back of column, disconnect upper end of
lower driveshaft and remove bearings, lockstraps, bolts, and journal from end
yoke.
10. Disconnect motor cabling brake hydraulic hose.
11. Disconnect and remove encoder assembly from side of gearbox adapter housing.
Be sure to protect the encoder from damage.
12. Remove attaching hardware between parallel gearbox and planetary gearbox.
13. Remove attaching hardware from motor support bracket.
14. Remove motor, motor support bracket, brake, gearbox adapter housing and
planetary gearbox as one unit.
15. Attach a hoist line to the lifting lug on top of parallel gearbox and apply tension.
i
The gearbox is full of oil. Oil may spill out if the gearbox is
tipped to far, or is laid down.
16. Remove eight mounting bolts from gearbox and slide gearbox out of the side of
the column.
Replacing Parallel Gearbox
Perform removal procedure in reverse order.
3-48 Varco
Maintenance

Parallel Gearbox
Upper Fixed Drive Shaft

Driveshaft Access Removal Hole
Hole
Bearing Fixed
Lockstrap Driveshaft
Bolt Bearing Housing
Upper Track
Bolts and Assembly
Washers
4 Places
End Yoke Column 3

Fixed
Journal Driveshaft
Upper
Cover Plate
Parallel Gearbox
Lifting Lug
Parallel
Gearbox
Planetary
Gearbox
Encoder
Assembly
Lower
Cover Plate
Gearbox
Adapter Access
Housing Hole
Brake
Motor
Support
Bracket
Motor
PRS-8i 3-49
Maintenance

Pinion Gear Locking Assembly.
i
This procedure includes replacement of the pinion gear.
Locking assemblies secure pinion gears to the upper and lower drive shafts, and to the
horizontal drive motor shaft. The locking assembly transmits torque by contact and
friction pressure between the driveshaft and pinion gears. To provide accurate transfer
of torque and power, mating surfaces must be kept clean and the attaching hardware
must be properly installed and torqued.
3-50 Varco
Maintenance

Pinion Gear Locking Assembly
Removing Pinion Gear Locking Assembly
Due to component weight, two persons are required to

remove the locking gear assembly and pinion gear
from the lower driveshaft, or the horizontal drive motor
shaft. A bracing system may also be needed.
1. Loosen all capscrews a few turns each.

2. Remove all plastic caps on front thrust rings. 3
3. Remove and transfer each capscrew into the adjacent openings (push-off
threads).
i
Due to the configuration and location of the push-off
threads, not all capscrews will be the same height when
initially inserted into the locking assembly.
4. Tighten all capscrews using a diametrically opposite tightening sequence, except

for the two adjacent capscrews next to the slit. These must be tightened in
sequence to prevent distortion.
i
Tightening the capscrews causes the front and rear thrust
rings to push away from the outer ring, thus allowing easier
removal of the locking assembly.
5. Remove the pinion gear and locking assembly from the shaft.
i
The rear thrust ring could remain on the drive motor shaft
and eventually drop off after removing the locking
assembly. Make sure to remove all parts from the shaft.
PRS-8i 3-51
Maintenance

Pinion
Gear
Plastic Capscrews
Cap (12)
Slit
3
Front
Thrust
Slit
Ring
12 Locking
11 1 Assembly Outer
Ring
10 2 Slit
Rear
9 3 Thrust
Ring
8 4
Gearbox
7 5
6
Tightening Sequence
from Slit
Screw Size M10 Disassembly of

Capscrew
Hexkey Size 8mm Locations Locking Assembly
Torque (Final) 61ft-lbs to Push-off
Front Thrust
Ring Front
Thrust
Ring
Capscrew Outer
Locations Ring
to Push-off
Rear Thrust
Ring Rear
Thrust
Ring
3-52 Varco
Maintenance

Replacing Pinion Gear Locking Assembly.
Due to component weight, two persons are required to

remove the locking gear assembly and pinion gear
from the motor shaft. A bracing system may also be
needed.
! 3
Do not use Molybdenum Disulfide (Molykote) or other
similar lubricants.
TOOLS REQUIRED: Torque wrench, 100 ft-lb

1. Visually inspect all contact surfaces, including capscrews and screwhead bearing
surfaces. Make sure they are clean and lightly oiled.
2. Back off all capscrews by at least two turns.
3. Remove at least three capscrews equally spaced apart.
4. Remove plastic caps from the adjacent push-off thread openings and screw the
removed capscrews into the push-off threads. Only a few turns are needed.
i
Screwing the capscrews into the adjacent push-off
threads, through the front thrust ring and outer ring, will
keep the locking assembly apart for easier installation.
5. Place locking assembly into pinion gear, place the assembled unit onto the shaft.
Make sure capscrews are facing end of driveshaft.
i
Locking assembly must be centered inside the pinion gear.
Capscrews should not extend beyond outer surface of
pinion gear.
6. Remove capscrews that were installed into adjacent push-off threads and screw
them back into the original holes on the rear thrust ring. Replace the plastic caps
into the push-off holes.
PRS-8i 3-53
Maintenance

Replacing Pinion Gear Locking Assembly
7. Tighten all capscrews until pinion gear and locking assembly stays in position on
shaft without external support..
i
The upper and lower surfaces of the pinion gear should be
flush with or centered with the upper and lower surface of
the teeth of the drivetrack.
3
!
When tightening capscrews, it is important to remain
aware of where you are in the tightening sequence. Failure
to maintain sequence can result in incorrect operating
torque.
8. Starting at the slit line and working in a clockwise (cw) direction, hand tighten all
12 capscrews until equally snug. After one full tightening sequence you will notice
that the previously tightened capscrews are now loose. Continue the tightening
sequence around-and-around until all capscrews remain snug. This indicates that
the multiple elements of the locking assembly are fully seated and in contact with
each other such that all installation clearances are removed.
i
When starting the tightening sequence using torque
wrench, start at same capscrew at the slit line where hand
tightening was started. Use a Small-Equal-Turn-of-Bolt
method where quarter-turns are applied but not more than
torque wrench settings.
9. Using torque wrench set at 35 ft-lb, apply 1/4-turn to the first capscrew but not
more than the torque wrench setting if setting is achieved before the 1/4-turn is
completed. Move to next capscrew clockwise and repeat tightening sequence.
Continue clockwise until all 12 capscrews have been tightened 1/4-turn, or until at
the torque limit.
10. After completing one full tightening sequence, you may notice that the previously
tightened capscrews are loose. Disregard looseness and apply another 1/4-turn
but no more than the 35 ft-lb torque limit if already achieved. Be sure to start at the
same capscrew at the slit line. Continue the tightening sequence around-and-
around until all capscrews remain tight and are not at, or close to, the 35 ft-lb
torque setting. This may require two or more full revolutions to achieve.
3-54 Varco
Maintenance

Replacing Pinion Gear Locking Assembly
11. Using torque wrench set at 45 ft-lb, continue tightening all 12 capscrews in a
manner identical to that described in steps 9 and 10 until all capscrews are at, or
close to, the 45 ft-lb torque setting.This may require two or more full revolutions to
achieve.
12. Using torque wrench set at 55 ft-lb, continue tightening all 12 capscrews in a
manner identical to that described in steps 9 and 10, except reduce the turn to
1/8-turn. Tighten until all capscrews are at, or close to, the 55 ft-lb torque
setting.This may require two or more full revolutions to achieve.
13. Using torque wrench set at 64 ft-lb, repeat step 12 for two or more full revolutions.
14. Using torque wrench set at 61 ft-lb, check each capscrew to ensure that it is
tightened to at least 61-ft-lb or more. No capscrew should turn when checking 3
torque setting. It a capscrew turns, continue to check tightness until all capscrews
are at, or above, the 61 ft-lb torque setting.
PRS-8i 3-55
Maintenance

Driveshaft Dampener Bearing
Remove Dampener Bearings

1. Remove column cover and gasket.
2. Remove bearing retainer.
3. Pry front dampener bearing up and
remove.
3 4. Spin rear dampener bearing into front
position and pry up to remove.
Bearing
Retainer
Driveshaft
Column Dampener
Gasket Bearing
Column
Cover
Dampener
Bearing
Driveshaft
Fixed Dampener
Driveshaft Bearing
Replace Dampener Bearings

1. Install rear dampener bearing into front
position and slide down into place.
2. Spin rear dampener bearing into rear
position.
3. Install front dampener bearing into front
position and slide down into place.
4. Replace bearing retainer.
5. Replace column cover and gasket.
3-56 Varco
Maintenance

Encoder Adapter
Flanged Motor
Adapter
O-ring
Nut
Encoder
Washer Adapter
Assembly
Bolt
Electrical
Cable
Removing encoder adapter assembly

1. Remove and isolate all power from the PRS.
2. Disconnect electrical cable from terminal block in the
respective J-box.
3. Remove two 3/4 inch bolts, washers and nuts securing
encoder adapter assembly to flanged motor adapter.
4. Remove O-ring.
5. Move encoder adapter assembly radially from the
motor.
PRS-8i 3-57
Maintenance

Encoder Adapter
Locating
Dowel Pins
O-ring
Washer
Bolt
Nut
O-ring
3
Flanged Motor
Adapter
Encoder
Adapter
Assembly
Encoder
Electrical Adapter
Cable Cover
Replace encoder adapter assembly

1. Remove encoder adapter cover from encoder adapter.
2. Make sure timing belt is in proper position on pulley and idler sprockets.
3. Inspect flanged motor adapter to insure that locating dowel pins are in place in mating
surface with encoder adapter assembly.
4. Insert encoder adapter assembly into mating opening in flanged motor adapter, ensuring
the O-ring between flanged motor adapter and encoder adapter is in proper position. Do
not secure encoder adapter assembly at this time.
5. Again check position of timing belt through the opening from encoder adapter cover.
If encoder adapter assembly fails to easily mate to flanged motor adapter, do not force into
position. Ensure timing belt is in position on the pulley and idler sprockets, then mate the
encoder adapter assembly again.
6. Secure encoder adapter assembly to flanged motor adapter using two bolts, washers and
self-locking nuts.
7.Secure encoder adapter cover and O-ring to encoder adapter assembly using six bolts and
washers.
8. Connect electrical cable to the terminal block in the respective J-box.
9. Restore power.
3-58 Varco
Maintenance

Encoder Disassembly/Reassembly
Disassembling Encoder
Encoder
1. Loosen the six bolts securing gland plate to top
of encoder mount.
2. Remove the six bolts securing encoder mount to
encoder adapter.
Gland 3. Pull encoder and encoder mount away from
Plate encoder adapter while feeding timing belt
through opening in encoder adapter.
4. Loosen set screw from pulley hub and remove
pulley hub from encoder shaft.
O-ring
5. Remove three bolts securing encoder to encoder
mount and remove encoder. 3
O-ring
Encoder
Encoder
Mount
Adapter
Cover
O-ring
Set
Screw
Idler Pulley
Assembly Pulley
Assembly
Encoder
Timing Belt
Adapter
Reassembling Encoder
1. Insert encoder into encoder mount, ensuring O-ring (retained by the gland plate) stays in correct position.
Tighten the six bolts securing the gland plate to the encoder mount.
2. Install pulley on encoder shaft with .06 inch protruding through the pulley. The pulley should rotates freely.
3. Tighten set screw against the flat on encoder shaft.
4. Remove six bolts securing encoder adapter cover to encoder adapter.
5. Remove the encoder adapter cover and O-ring.
6. Feed timing belt into position around idler sprockets in encoder adapter. Insert encoder/mount/pulley
assembly through hole in adapter ensuring timing belt stays in position.
7. Ensure the O-ring on the nose of the encoder mount is in the correct position.
8. Secure encoder mount to encoder adapter with six bolts.
9. Loosely secure encoder adapter cover to encoder adapter with O-ring in place.
PRS-8i 3-59
Maintenance

Reeving the Wire Rope
i
Replace wire rope yearly or when rig policy dictates. Both
wire ropes should be replaced. Varco replacement wire
rope is pre-cut to the correct length for this PRS.
The wire rope spooling drums are mounted to gearboxes with an engage/ dis-
engagement plate. When in the engage position, the plate secures the drum to the
gearbox. When in the disengaged position, the plate disengages the gearbox (neutral)
for spooling wire rope onto and off of the drums.
3
i
The following procedures apply to both wire ropes.
Removing Wire Rope

1. Extend upper arm assembly.
2. Retract lower arm assembly.
3. Lower hoist carriage until it rests on the lower stops.
4. Remove disengagement plate from the spooling drum from which the wire rope is
to be remove.
5. Turn disengagement plate over and reinstall. The raised center of the plate will be
towards the gearbox, pressing on and disengaging the gearbox input shaft.
6. Manually turn the drum to loosen wire rope. Loosen four capscrews to disengage
outer wire rope anchor and disconnect rope.
7. Remove cotter pin, pin, and washers to disconnect wire rope spelter socket at
threaded compensation hydraulic cylinder. Carefully pull wire rope through hoist
carriage sheaves and remove rope.
3-60 Varco
Maintenance

Crown
Sheave
Thread
Compensation
Hydraulic
Cylinder
Wire Compensator
Washer
4 Places
Rope Assembly
3
Spelter
Socket
Pin Hoist
Carriage
Sheave
Hoist
Cotter Carriage
Pin
2 Places
Hole in Wire Rope

Wire Rope
Drum Spooling
Hoist Gearbox
Flange Drum
Disengagement
Plate
Shown in
Engage Position
Hoist Gearbox
Disengagement
Plate
Shown in
Disengage Position
Wire Rope
Anchor
Cap Screw Wire Rope
4 Places Anchor
PRS-8i 3-61
Maintenance

Replacing Wire Rope
1. Ensure that hoist carriage is resting on its lower stops, upper arm assembly is
extended, and lower arm assembly is retracted.
2. Using washers, pin, and cotter pins, attach wire rope spelter socket to threaded
compensation hydraulic cylinder.
3. Carefully reeve wire rope down and around hoist carriage sheave, then up and
around crown sheave, then down to spooling drum.
4. Pull wire rope through hole in drum flange. Secure rope with wire rope anchor and
capscrews. Manually wrap wire rope counterclockwise around spooling drum
starting at the outside groove. Make sure rope is placed in the grooves as it is
wrapped around the spooling drum.
3
5. Remove disengagement plate, turn plate over, and reinstall in the engaged
position.
3-62 Varco
Maintenance
Adjustment Procedures
Adjusting 10mm Proximity Sensor
Carriage Upper Limit
Sensor
Sensor
Target 3
Carriage Lower Limit
Sensor
Sensor
Target
Adjusting the 10 mm proximity sensor

1. Move the hoist carriage to the position where the limit will
detected.
2. Check the gap between the sensor and the sensor target.
(Gap is normally between 4.5 and 5.5 mm).
3. Loosen sensor or sensor target:
a. For sensor, loosen nuts on the sensor.
b. For sensor target, loosen attaching screws.
4. Move sensor or sensor target to achieve a gap of 5 ±0.5 mm.
5. Tighten sensor nuts on sensor or attaching screws on sensor
target.
6. Recheck the measurement.
PRS-8i 3-63
Maintenance
Adjustable Hydraulic Valves
Counterbalance
Manifold
Valve PC1
1800 psi
3
Hoist Jaw Handling Tools
Manifold Manifold
Valve PC2 Valve PC3
400 psi 450 psi
Valve PC4
1500 psi
Upper Arm
Valve
Assembly
Valve PCX
400 psi
Valve RCVR
1800 psi
Handling Tool
Adjustment Manifold
Adjust when changing
handling tools.
Turn relief valve
capscrew until
handling tool moves,
Lower Arm then back off
Valve capscrew 1/4 turn.
Assembly
Valve PCX
400 psi
Valve RCVR
1800 psi
Lower Arm
Manifold
Valve PC6
Column 1800 psi Column
Front View Valve PC7 Rear View
400 psi
3-64 Varco
Maintenance
Adjustable Hydraulic Valves
The only adjustment that needs to be made is the relief valve on the handling tool
adjustment manifold. This valve is adjusted whenever a handling tool is changed. All
other adjustable hydraulic valves are preset at the factory when the PRS is assembled.
There is no need to adjust these valves unless a valve has been replaced. Adjustable
valves are located on the various manifold assemblies and valve assemblies shown in
the illustration preceding. If adjusting a replacement valve, refer to the Hydraulic
Schematic Diagram for pressure settings.
Adjustable Pressure Switches

The adjustable pressure switches are preset at the factory when the PRS is assembled.
There is no need to adjust the switches unless a switch has been replaced. Adjustable
switches and their pressure settings are shown in the Hydraulic Schematic Diagram.
3
PRS-8i 3-65
Maintenance
3-66 Varco
Troubleshooting
Troubleshooting Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Running Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Helpful Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 1
Troubleshooting Horizontal Drive System . . . . . . . . . . . . . . . . . 4-4
Troubleshooting Rotation Drive System . . . . . . . . . . . . . . . . . . 4-5
Troubleshooting Upper Arm Assembly . . . . . . . . . . . . . . . . . . . 4-6
Troubleshooting Lower Arm Assembly . . . . . . . . . . . . . . . . . . . 4-9
Troubleshooting the Control System . . . . . . . . . . . . . . . . . . . . 4-11 2
Control System Components, SBC Section . . . . . . . . . . . . . . . 4-12
Control System Components, VFD Section . . . . . . . . . . . . . . . 4-14
Troubleshooting the Fingerboard Control Tower . . . . . . . . . . 4-18
Troubleshooting the Fingerboard Control Station . . . . . . . . . . 4-20
Troubleshooting Junction Boxes . . . . . . . . . . . . . . . . . . . . . . . . 4-21 3
Upper Derrick Electronic Driver J-Box . . . . . . . . . . . . . . . . . . . 4-22
Remote I/O IS/NIS J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Lower Derrick Remote Power Supply J-Box . . . . . . . . . . . . . . . 4-24
Upper Derrick Remote Power Supply J-Box . . . . . . . . . . . . . . . 4-25
Remote Power Supply I/O J-Box . . . . . . . . . . . . . . . . . . . . . . . 4-26 4
Troubleshooting Hydraulic Components . . . . . . . . . . . . . . . . . 4-27
Hydraulic Power Requirements and Inlet Circuit . . . . . . . . . . . 4-27
Arm Position Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Jaw Position Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Hydraulic-Release Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4-28 5
Pipe Claw Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lift Jaw Assembly Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Counterbalance Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Test Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
PRS-8i
Troubleshooting
Varco
Troubleshooting
Troubleshooting Fault Symptoms

Potential component failures fall into the following categories:
Electrical components
Mechanical components
Pneumatic components
To help determine the nature of the problem use the troubleshooting tables contained in
this chapter.
i
The troubleshooting procedures in this chapter do not
necessarily cover all possible symptoms. The tables
provide an insight to typical symptoms, their possible
causes, and what components to check.
Running Diagnostics
Diagnostics is a valuable troubleshooting tool. Use the instructions contained in the
V-ICIS Users Manual to run PRS diagnostics.
4
Helpful Documents
The Technical Drawings Package contains assembly drawings for component locations,
and electrical and hydraulic schemetic diagrams for signal tracing.
PRS-8i 4-3
Troubleshooting
Troubleshooting Horizontal Drive

System
Symptom Probable cause Remedy

Horizontal travel - does Command is not allowed by Check control system for fault indication
not move at all the software or interlock condition.
VFD fault If a fault is displayed on the VFD, refer to
vendor documentation for fault codes.
Mechanical interference or 1. Make sure arm assemblies are not
failure interfering with the rig structure or other
pieces of equipment.
2. Check for obstructions between
horizontal rack and drive pinion gears.
3. Check for obstructions in upper drive
assembly.
4. Check that motor brake disengages
when activated.
Motor brake does not 1. Check for hydraulic leaks between
4 disengage manifold and brake assembly.
2. Check for correct hydraulic pressure at
test port.
3. Check operation of directional control
valve DCV.
4. Check brake release circuit in
horizontal travel VFD.
Damaged or faulty encoder Check control system for an encoder fault
indication. Replace faulty encoder.
4-4 Varco
Troubleshooting
Troubleshooting Rotation Drive

System

Column does not Command is not allowed by Check control system for warning or
rotate the software interlock condition.
vendor documentation.
Mechanical interference or 1. Make sure arm assemblies are not
failure interfering with the rig structure or other
pieces of equipment.
2. Check for obstructions between
rotation ring gear and rotation drive pinion
gear.
3. Check for obstructions in upper drive
assembly.
4. Check that motor brake disengages
when activated.
Motor brake does not
disengage
1. Check for hydraulic leaks between
manifold and brake assembly.
4
valve DCV.
4. Check brake release circuit in rotation
VFD.
Damaged or faulty encoder Check control system for an encoder fault
indication. Replace encoder if faulty.
Damaged or faulty linear Check linear transducer. Replace if faulty.
transducer
PRS-8i 4-5
Troubleshooting
Troubleshooting Upper Arm

Assembly
Hoist carriage does Command is not allowed by Check control system for warning or
not move up or down the software interlock condition.
vendor documentation.
Mechanical interference or 1. Make sure neither the jaw nor arm
failure assembly is interfering with the rig
structire or other pieces of equipment.
2. Check for obstructions between cam
rollers (located on sides of idler sheave
assembly) and roller surfaces on the
column.
3. Check for obstructions in wire rope
sheaves.
4. Check for obstructions to the
movement of either hoist carriage sheave.
5. Check that hoist motor brakes
disengages when activated.
4
Motor brake does not 1. Check for hydraulic leaks between
disengage manifold and brake assembly.
valve DCV.
4. Check brake release circuit in hoist
VFD.
Racker overload Check that load does not exceed hoist
load rating.
Damaged or faulty encoder Check the control system for an encoder
fault. Replace the encoder.
Damaged or faulty linear Check linear transducer. Replace if faulty.
transducer
Arm does not Command is not allowed by Check the control system for warning or
extend or retract the software interlock condition.
Mechanical interference or 1. Make sure neither the jaw nor arm
failure assembly is interfering with the rig
2. Check for obstructions between the
vertical column and the arm carriage
rollers.
3. Check the linear transducer.
4. Check the bushings at all arm pivot
points.
Damaged or faulty linear Check the control system for a linear
transducer transducer fault indication. Replace the
linear transducer if faulty.
4-6 Varco
Troubleshooting
Troubleshooting Upper Arm Assem-

bly
Lift jaw does not Mechanical interference or Check for obstructions between the arm
maintain vertical failure and the lift jaw assembly.
position
Grip jaw does not Command is not allowed by Check the control system for warning or
open or close the software interlock condition.
Mechanical interference or Check for obstructions to the movement
failure of grip jaw.
No hydraulic pressure 1. Check for damage to hydraulic hose
and tubing from hydraulic input panel to
lift jaw assembly.
2. Check for hydraulic pressure at
manifold.
3. Check digital output module in upper
arm remote I/O J-box.
4
4. Check grip jaw directional control valve
DCV and solenoid.
Pressure regulator circuit Check pressure to grip jaw cylinder
malfunction assembly on hoist jaw assembly.
Malfunction of grip jaw 1. Check for hydraulic leak between
directional control valve DCV, or hydraulic input panel and lift jaw
solenoid assembly.
3. If 1 and 2 check normal, replace the
valve or solenoid.
No electrical power to the 1. Check indicator panel for a warning or
solenoids interlock condition.
Roller jaw does not Command is not allowed by Check the control system for warning or
open or close the software interlock condition.
failure of roller jaw.
lift jaw assembly.
manifold.
Pressure control circuit 1. Check pressure at manifold on hoist
malfunction carriage.
PRS-8i 4-7
Troubleshooting
Troubleshooting Upper Arm Assem-

bly
Roller jaw does not Malfunction of roller jaw 1. Check for damage to hydraulic hose
open or close (cont) directional control valve and tubing from hydraulic input panel to
DCV, or solenoid lift jaw assembly.
valve or solenoid.
Claw does not open Command is not allowed by Check the control system for warning or
or close the software interlock condition.
failure of claw.
4 and tubing from hydraulic pump to lift jaw
assembly.
manifold.
3. Check for hydraulic leak between
hydraulic input panel and lift jaw
assembly.
Malfunction of claw Check digital output module in upper arm
directional control valve DCV, remote I/O J-box. If nomal, replace the
or solenoid valve or solenoid.
Pipe slips in grip jaw Contaminated grip dies Clean with wire brush.
Worn grip dies Replace.
Grip dies do not slide in jaw Clean and grease die carriers. Verify
arm carriers slide freely.
Pressure regulator circuit Check load-holding valve at grip jaw
malfunction hydraulic cylinder.
Malfunction of grip jaw 1. Check for hydraulic leak between
directional control valve hydraulic input panel and lift jaw
DCV, or solenoid assembly.
valve or solenoid.
4-8 Varco
Troubleshooting
Troubleshooting Lower Arm

Assembly
Lower arm does not Command is not allowed by Check the control system for warning or
extend or retract, or the software interlock condition.
it moves irregularly
Mechanical interference or 1. Make sure neither the claw nor lower
failure arm assembly is interfering with the rig
structure or other pieces of equipment.
2. Check bushings at all arm pivot points.
claw.
manifold.
Pressure regulator circuit 1. Check pressure at manifold on column.
malfunction 2. Check electronic driver module in the
control system.
4
Claw does not open Command is not allowed by Check the control system for warning or
or close the software interlock condition.
failure of claw.
claw.
manifold.
Malfunction of hydraulic valve, 1. Check for hydraulic leak in service loop
or solenoid lines to claw assembly.
2. Check valve operation.
3. Check digital output module in lower
4. If 1, 2, and 3 check normal, replace the
valve or solenoid.
solenoid interlock condition.
Claw centralizer Command is not allowed by Check the control system for warning or
does not rotate the software interlock condition.
failure of claw.
PRS-8i 4-9
Troubleshooting
Troubleshooting Lower Arm Assem-

bly
Claw centralizer does No hydraulic pressure 1. Check for damage to hydraulic hose
not rotate (cont) and tubing from hydraulic input panel to
claw.
manifold.
Mechanical interference or 1. Make sure neither the claw nor lower
failure arm assembly is interfering with the rig
2. Check bushings at all arm pivot points.
claw.
manifold.
Malfunction of hydraulic valve, 1. Check for hydraulic leak in service loop
or solenoid lines to claw assembly.
4 2. Check valve operation.
4. If 1, 2, and 3 check normal, replace the
valve or solenoid.
failure of claw.
4-10 Varco
Troubleshooting
Troubleshooting the Control System

Troubleshooting the control system requires that you first determine if any of the
components of the PRS are at fault, or if the control system is at fault. To do so, first
check the inputs to the control system then ascertain if the corresponding output was
energized. If the control system inputs and outputs are normal, then one or more of the
PRS components is the probable malfunction.
The location and description of control system components are provided to help you
troubleshoot to a faulty component in the control system. Also note that some cards and
modules have their own status and error indicators. These indicators can be used to
troubleshoot control system faults.
i
When replacing cards or modules, always set replacement
card switch settings to match those of the card being
replaced.
PRS-8i 4-11
Troubleshooting

Control System Components, SBC Section
Door Switch
S5 Light
Circuit
Breakers
CB1-CB8
CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8
2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4
TB4
20A 2A 2A 2A 6A 6A 6A 6A
1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3
PS1 PS2
Power
OK OK
230V VOLTAGE 230V VOLTAGE

SELECTOR SELECTOR
Supplies
PS1, PS2
SITOP SITOP
power 5 power 5
6EP1 333-1SL11 6EP1 333-1SL11
Terminal
Blocks TBPS1+ TBPS1- TBPS2+ TBPS2-
11
11
10
12
13
15
16
17
10
12
13
15
16
17
18
14
14
1
1
9
9
2
3
7
8
2
3
7
8
2
3
7
8
2
3
7
8
4
6
TBPS1,
11
11
10
12
13
15
16
17
10
12
13
15
16
17
18
14
14
1
1
9
9
2
3
7
8
2
3
7
8
2
3
7
8
2
3
7
8
4
6
TBPS2
Single Board
4 Computer
SBC
SIEMENS SM 322 SM 321
32X24VDC,0.5A 32X24VDC,DI
SF DP
BUSF
0 0 0 0
ON
1 1 1 1
2 2 2 2
3 3 3 3
Interface Module,
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
SIMATIC
ET 200M 0 0 0 0
Digital I/O Modules

1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
2A 4A 5A
Repeaters
L+ M PE M5 L+ M PE M5
RP1,RP2
A1 B1 A1 B1 A1 B1 A1 B1
Relays
RL1
RL2
RL3
RL4
RL5
RL6
RP1 RP2
SIEMENS
RS 485-REPEATER
A2 B2 A2 B2
SIEMENS
RS 485-REPEATER
A2 B2 A2 B2
RL1-RL6
OLM 1
RJ45 RJ4C1
CHANNEL 1
LWL1
RS485/PROFIBUS LWL-RING-KOPPLER
PA
RS485/PROFIBUS FIBRE OPTIC RING-LINK
BUS
PA
CHANNEL 2
SIEMENS
Ethernet
Fault 2 rd
Fault 1 ye
X
A AX B B Error L- L+
10 9 8 7 6 5 4 3 2 1
Connector
Terminal
TB1
1 1 1 1
Terminal
TB3
2 2
Block
2 2
3 3 3 3
4 4
TB2
4 4
5 5
6 6
7 7 1 1
8 8 2 2
TB E-STOP1
9 9 3 3
Blocks
4 4
TB3
10 10
TB5
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5
TB6
TB1,TB2,
6 6
1 1
7 7 2 2
8 8
3 3
9 9
4 4
10 10
TB7
11 11
12 12
Terminal
1 1
13 13 2 2
TB5-TB8
14 14 3 3
TB E-STOP2
15 15 4 4
16 16
TB8
1 1
1 1 2 2
2 2 3 3
Blocks
3 3 4 4
4 4
5 5
6 6
7 7
8 8
9 9
10 10
TBE-STOP1,
11 11
12 12
13 13
14 14
15 15
16 16
TBE-STOP2
Fiber
Patch
Panel
FPP
Interior View
Door Removed
4-12 Varco
Troubleshooting

Control System Components, SBC Section
Component Function
CB1 20-amp circuit breaker that protects 220 VAC input line to power
isolator switch and other circuit breakers.
CB2 2-amp circuit breaker that protects 220 VAC input to 24 VDC power
supply PS1.
CB3 2-amp circuit breaker that protects 230 VAC input to 24 VDC power
supply PS2.
CB4 2-amp circuit breaker that protects cabinet lights and fan.
CB5 6-amp circuit breaker that protects a remote I/O panel.
Slot 2 interface module ET 200M PROFIBUS-DP interface module, Type IM-153-1. Connects
digital I/O modules to the PROFIBUS-DP. Also supplies operating
voltage to the backplane bus. The module has status and error
indicators (LEDs) that inform you of the currently active operating
4
mode of the module.
Slot 3 interface module Digital input module, 16-channel, Type SM 321. Converts input
signals to logic ones and zeros for the SBC. Receives its inputs from
V-door switches, and sensors. The front panel has a column of green
LED indicators that inform you of the status of the inputs.
Slot 4 interface module Digital output module, 16-channel, Type SM 322. Provides output
signals that drive solenoids on the tool. The front panel has a column
of green LED indicators that inform you of the status of the inputs.
PS1 5-amp power supply that provides 24 VDC to the following:
•Repeaters RP1 & RP2
•SBC
•ET 200M PROFIBUS-DP interface module
PS2 5-amp power supply that provides 24 VDC to the following:
•Digital I/O modules
•E-stop relay coils
•Cabinet door controls and indicators
RP1repeater Provides PROFIBUS communication interface link between
fingerboard remote I/O modules, the digital input card in the
fingerboard control station, and the SBC control system.
RP2 repeater Provides PROFIBUS communications interface link to the lower arm
and hoist carriage remote I/O.
S5 door switch Interlock switch that disconnects power to cabinet when door is
opened.
Terminal blocks Provides terminal points for electrical cables/wires that interconnect
SBC control system components.
PRS-8i 4-13
Troubleshooting

Control System Components, VFD Section
Free
Fuses Wheel
Light Fuses Diode Fuse
F1, F2
Door (3 Places) F3, F4 FWD1 F5
Switch
(3 Places) Main
Circuit
Variable Breaker
Frequency CB1
Drives
F1 F2 F3 F4
VFD1-VFD4 F5
Relays X1 X1 X1 X1
Dynamic
K2-K6 Brake
CR1
Chopper
Terminal Terminal DBC1
Block Block Emergency
4 TB5 TB6 DRIVE 1 DRIVE 2 DRIVE 3 DRIVE 4
Stop Relays Common
KE1, KE2 X2 X2 X2 X2 DBC1 Rectifier
CR1
Fuse
TB5 TB6
Power F6
10
11
10
11
12
13
14
15
16
17
18
19
21
12
13
14
15
16
17
18
19
1
1
20
20
22
23
24
25
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
10
11
10
11
12
13
14
15
16
17
18
19
21
12
13
14
15
16
17
18
19
1
1
20
20
22
23
24
25
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
E-STOP
Supply Motor
MR1 MR2 MR3 MR4
PS1
A2 A1 A2 A2 A1 A2 A2 A1 A2 A2 A1 A2
K2
Reactors
K5
K3
K4
K6
KE1 KE2
24 22 24 14 22 24 14 22 24 14 22 14
21 12 21 11 12 21 11 12 21 11 12 11
MR1-MR4
SITOP
power 20
L1
1 AC 230 V
N
Repeater TBP101
6EP1 336-1SH01 SHORT

OK
DC 24V / 20A
L+ M M
RP1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9 CB10
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
RFI
Filter
10 10
11 11
2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 12 12
F F
P P P P
T T T T
5A 8A 5A 4A 2A 1A 1A 1A 1A
C C C C
RF1
1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3
1 2 3 4
L+ M PE M5 SIEMENS SM 332 SM 331 SM 322
AO 4X12 BITS AI 4X12 BITS 32X24VDC,0.5A
SF DP
SF SF
BUSF
0
1
0
1
F6 CIRCUIT BREAKERS
I/O Modules
ON
2 2
3 3
4 4
A1 B1 A1 B1
5 5
6 6
7 7
RP1 SIMATIC
ET 200M 0 0
1 1
2 2
K1
Terminal
SIEMENS
3 3
RS 485-REPEATER 4 4
A2 B2 A2 B2
5
6
5
6
TB2 TB3 TB4
TBP100
7 7
10
11
10
11
10
11
12
12
13
14
15
16
17
18
12
13
14
15
16
17
18
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2A 4A 5A 6A
L1
10
11
10
11
10
11
12
12
13
14
15
16
17
18
12
13
14
15
16
17
18
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
1 2 3
TBN200 TBN201 TBN202

Positive Block
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
1
2
3
4
1
2
3
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
Temperature
1 2 3
TB1
Coefficient
11 11 11 11
12 12 12 12
TBN203
T1
Circuits Main
PTC1-PTC4 Contactor
K1
Terminal Terminal
Block Block Circuit Breakers Transformer Terminal Line
TBN200 TBN202 CB2-CB10 T1 Block Reactor
Terminal Terminal TBP100 L1
Terminal Blocks Block
Block TB2-TB4 TBP101
TBN201,TBN203
Interior View Interior View

Right Side Doors Removed
4-14 Varco
Troubleshooting

Component Function
CB1 175-amp solid-state main circuit breaker that controls all electrical
power to the VDF system.
CB2 6-amp circuit breaker for redundant protection and isolation of the
220 VAC circuits to CB5 and CB6.
CB3 8-amp circuit breaker that protects the 220 VAC line to the common
rectifier, the VFDs, and heater relay.
CB4 5-amp circuit breaker that protests the 220 VAC input line to
powersupply PS1.
CB5 4-amp circuit breaker that protects the 220 VAC line to the cabinet
door switches.
CB6 2-amp circuit breaker that protects the 220 VACline to the power
isolator door switch, the PTCs, and the main contactor.
CB7 1-amp circuit breaker that protects hoist drive motor A heater.
CB8 1-amp circuit breaker that protects the hoist drive motor B heater.
CB9 1-amp circuit breaker that protects the rotation (slew) drive motor
4
heater.
CB10 1-amp circuit breaker that protects the lower (horizontal) drive motor
heater.
CR1 common rectifier Rectifies 460 VAC, 3-phase, 50 or 60 Hz power to 620 VDC, which
supplies each inverter.
DBC1 dynamic braking unit Diverts excess power to braking resistors when motors act as a
generator. This action is caused by movement of the drilling platform
or the lowering of the hoist carriage.
F1A and F1B fuses VFD 1 (hoist motor A) DC bus fuses. These fuses are in the DC input
line to the hoist drive 1. Fuses are 160 amperes each. They protect
the VFD. Fuse F1C is a spare.
F2A and F2B fuses VFD 2 (hoist motor B) DC bus fuses. These fuses are in the DC input
line to hoist drive 2. Fuses are 160 amperes each. They protect the
VFD. Fuse F2C is a spare.
F3A and F3B fuses VFD 3 (column rotation) DC bus fuses. These fuses are in the input
line to drive 3. Fuses are 160 amperes each. They protect the VFD.
Fuse F3C is a spare.
F4A and F4B fuses VFD 4 (horizontal drive) DC bus fuses. These fuses are in the input
line to drive 4. Fuses are 160 amperes each. They protect the VFD.
Fuse F4C is a spare.
F5 fuse 200-amp fuse that protects the DBC.
F6A and F6B fuses 10-amp fuses that protect the AC input line to transformer T1.
FWD1 free wheel diode Connected across the DC output lines from rectifier CR1.
PRS-8i 4-15
Troubleshooting

Component Function
K1 relay Three-phase line relay that controls application of 460 VAC, 3- phase,
50/60-Hz power to the drive circuits. K1 is controlled by the VFD
SECTION POWER ISOLATION switch on the SBC control system
cabinet door, PTC circuits, and VFD fault circuits.
K2 relay Heater relay to motor heaters.
K3 relay Common rectifier fault relay.
K4 relay Brake resistor fault relay. Deactivated when the brake resistor fault
contacts open. Sends fault signal to digital input module.
K5 relay Brake chopper fault relay. Deactivated when the brake chopper fault
contacts open. Sends fault signal to digital input module.
K6 relay VFD fault relay. Deactivated when a common rectifier fault occurs (K3
drops out), brake resistor fault occurs (K4 drops out), or brake
chopper fault occurs (K5 drops out). SYSTEM START/RESET switch
S1 resets this relay.
4 Emergency stop relays: Emergency stop relays KE1 through KE3 are energized and
deenergized by the same ESD signals, however they control
different circuits. These relays are deenergized whenever an
ESD switch is activated.
KE1 relay When KE2 is deenergized, the VFDs are disabled.
KE2 relay Spare.
L1 line reactor Line Reactor LR1 is connected between the input RFI filter and the
common rectifier. The line reactor limits current spikes in the three-
phase supply, which are caused by supply voltage disturbances.
Motor Reactors: The motor reactors provide a certain amount of smoothing to
the VFD output. They also compensate for capacitive recharging
currents, due to excessive motor feeder cable length. This
smoothing results in increased voltages at the motor terminals
and additive current spikes to the drives.
MR1 motor reactor Motor reactor for hoist drive motor A.
MR2 motor reactor Motor reactor for hoist drive motor B.
MR3 motor reactor Motor reactor for the rotation (slew) drive motor.
MR4 motor reactor Motor reactor for the lower (horizontal) drive motor.
PS1 power supply 24 VDC, 20-amp power supply. Provides DC voltage for distribution
throughout the VDF system.
Positive Temperature Coefficient Temperature-sensing devices (PTCs) are embedded in each
(PTC) Circuits: winding of each motor. These windings are wired in series
within the motor. PTCs measure the internal temperature of the
windings and protect them from thermal overload caused by
overcurrent faults. When the motor operating temperature is
exceeded, the PTC circuit resistance changes as the winding
temperature rises causing the PTC amplifier to trip. When
tripped, the amplifier causes main power contactor K1 to drop
out, disables all 3-phase power.
4-16 Varco
Troubleshooting

Component Function
Positive Temperature Coefficient Also wired in series with the PTCs are relay contacts of the
(PTC) Circuits: (continued) common rectifier fault relay, brake resistor fault relay, brake
chopper fault relay, and VFD fault relay. If a fault occurs in any
of these components, relay K1 will drop out.
PTC1 PTC trip amplifier for hoist motor A.
PTC2 PTC trip amplifier for hoist motor B.
PTC3 PTC trip amplifier for the rotation drive motor.
PTC4 PTC trip amplifier for the horizontal travel motor.
RF1 filter (RFI) Filters the 460 VAC, 3-phase, 50/60-Hz power input to the AC/DC
common rectifier. Prevent EMI/RFI noise emissions caused by the
VFDs being fed back onto the main power supply lines.
RP1 repeater RS 485 PROFIBUS repeater module. Provides the PROFIBUS
communications interface link between drive motors and ET 200M
PROFIBUS-DP interface module.
T1 transformer Steps down the main power input of 460 VAC to 240 VAC for use by 4
the power supplies, video driver, touch screen PC, PTCs, and the
control system cabinet fans and lights.
Terminal blocks Provides terminal points for the electrical cables/wires that
interconnect the VFD system components.
Variable Frequency Drives The VFD pulse-width modulates the DC voltage from the
(VFDs): common rectifier to produce a three-phase, variable voltage and
frequency output to operate the drive motors. Communication
boards are included as part of each drive.
VFD1 VFD for hoist drive motor A.
VFD2 VFD for hoist drive motor B.
VFD3 VFD for the rotation (slew) drive motor.
VFD4 VFD for the lower (horizontal) drive motor.
Input/Output (I/O) modules: Provides interface between the sensors and actuators, and the
control system. Refer to the Siemens vendor manuals for
detailed information.
Slot 2A and 2B ET 200M PROFIBUS-DP interface module.
Slot 5B 32-channel digital input module, Type SM 321.
Slot 6A and 6B 32-channel digital output module, type SM 322.
PRS-8i 4-17
Troubleshooting
Troubleshooting the Fingerboard

Control Tower
The location and description of fingerboard control tower components are provided to
help you troubleshoot to a faulty component.
Fingerboard Control
Tower
Door removed
for clarity
4 Profibus Node
Interface
Fiber Patch
Panel
Filter/
Regulator
Solenoid Valve Gage
Manifold
Controller
Mist
Air Line
Lubricator
Filter/
Regulator
Optical Link
Module
Pneumatic Pressure Switch Terminal Blocks
4-18 Varco
Troubleshooting

Control Tower
Component Function
PROFIBUS node interface The PROFIBUS node interface modules receive control data from
modules RS485 repeater in the fingerboard control system, via the
PROFIBUS. The modules decode the data to determine which
solenoid is to operate in the solenoid valve manifold. Each module
controls up to 16 solenoids.
Solenoid valve manifold These manifolds receive solenoid activation signals from the
PROFIBUS node modules. The activated solenoid operates the
associated valve sending air pressure to the respective latch air
cylinder to operate the latch.
Filter/Regulator Filters the air and regulates air pressure.
Optical link module Converts fiber optic signals to electrical signals.
Mist air line lubricator Provides lubrication to the finger actuating cylinders.
Fiber patch panel Provides mechanical connection of rig fiber to control tower fiber.
Pneumatic pressure switch When activated, it signals the control system of a loss of pressure to
the fingerboards.
4
interconnect control tower components with the control system.
Filter/regulator gage Displays regulator pressure setting.
PRS-8i 4-19
Troubleshooting

Control Station
The location and description of fingerboard control station components are provided to
help you troubleshoot to a faulty component.
BARTEC
PROFIBUS
16 x Digital Input Exi
Digital
Input
Card
4 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6
TB1 TB2 TB3
1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6
TB1 TB2 TB3

Internal View
Component Function
Digital input card A 16-output PROFIBUS digital input card. Receives switch control
signals from switches mounted on the FCS. The digital input card
routes this data to the control system via the PROFIBUS.
interconnect digital input card with its power source and to the control
system.
4-20 Varco
Troubleshooting
Troubleshooting Junction Boxes

Some J-boxes contain PROFIBUS digital, analog, or electronic driver modules that
condition the signals between the input and output devices. J-boxes that contain these
types of modules are described in the following pages.
The location and description of J-box components are provided to help you troubleshoot
to a faulty component. Also refer to the Electrical Schematic Diagram.
PRS-8i 4-21
Troubleshooting

Upper Derrick Electronic Driver J-Box
Terminal Block Terminal Block Terminal Block Terminal Block

TB1 TB2 TB3 TB4
11
1
10
12
13
15
16
17
18
2
14
4
6
1
8
4
4
TB-1
TB-2
TB-3
TB-4
11
9
1
10
12
13
15
16
17
18
2
14
4
DRVR-1
DRVR-2
Solenoid Driver Solenoid Driver

DRVR-1 DRVR-2
4-22 Varco
PRS-8i
TB-1 I.S. DUCT
B 1 1 B
B 2 2 B
3 3
DI-1
B 4 4 B
B 5 5 B
TB1
6 6
B 7 7 B 1 2 3 4 5 6 7 8 9 10 11 12
I.S. DUCT
B 8 8 B 1 2 3 4
9 9
B 10 10 B
B 11 11 B 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
setdown sensor
12 12 BARTEC Example
and lower carriage

B 13 13 B PROFIBUS
Terminal Block
B 14 14 B DIGITAL
in INPUT
Provides interface to
15 15 Digital Input Module
B
A
B
A
Bx
Ax
PA
PA
0V
24V
B 16 16 B DI-1
25 26 27 28 29 30 32 33 PA PA L- L+
B 17 17 B ADDRESS
x10 x1
6 6
18 18 4 4
1 1
6 6
ON BF SF
25 26 27 28 20 30 32 33 PA PA L- L+
N.I.S. DUCT
TB-2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
1 2 3 4 5 6 7 8 9 10 11 12
8 8 1 2 3 4
DO-1
9 9
TB2
10 10
N.I.S. DUCT
11 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
12 12 BARTEC Example
13 13
PROFIBUS
14 14 DIGITAL OUTPUT
15 15
B
A
B
A
Bx
Ax
PA
PA
0V
24V
control system to
16 16 D0-1
25 26 27 28 29 30 32 33 PA PA L- L+
17 17 ADDRESS
x10 x1
lower claw solenoid
6 6
18 18 4 4
Terminal Block
19 19 1
6
1
6
ON BF SF
control system for upper Provides interface from
20 20 25 26 27 28 20 30 32 33 PA PA L- L+
Digital Output Module
limit sensors and pipe centralized solenoid and
21 21
22 22
23 23
24 24
TB-3
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8 16 17 18 19
9 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
10 10
11 11
12 12
TB-4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19
TB4
TB-7
1 1
2 2
3 3
TB3
TB-6
4 4
1 1
5 5
2 2
6 6
3 3
7 7
Terminal Block
4 4
8 8
5 5
9 9
6 6
10 10
7 7
Terminal Block
11 11
8 8
12 12
9 9
13 13
10 10
14 14
11 11
15 15
12 12
16 16
Remote I/O IS/NIS J-Box
13 13
17 17
14 14
18 18
15 15
19 19
16 16
20 20
17 17
21 21
18 18
22 22
23 23 19 19
24 24 20 20
21 21
25 25
22 22
26 26
23 23
27 27
28 28 24 24
29 29 25 25
30 30 26 26
31 31 27 27
32 32 28 28
33 33 29 29
TB5
34 34 30 30
35 35 31 31
36 36 32 32
37 37 33 33
38 38 34 34
39 39 35 35
40 40 36 36
41 41
Terminal Block
42 42
43 43
44 44
Troubleshooting
45 45
46 46
47 47
48 48
TB7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
TB-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Terminal Block
TB8
4-23
Terminal Block
4
Troubleshooting

Lower Derrick Remote Power Supply J-Box
Terminal Block Power Supply Power Supply Power Supply

TB1, TB2, TB4 PS1 PS2 PS3
PS1 PS2 PS3

5A 5A 10A
DC 24V DC 24V DC 24V
230V
VOLTAGE 230V
VOLTAGE 230V
VOLTAGE
SELECTOR SELECTOR SELECTOR
6ES7 307-1EA00-0AA0 6ES7 307-1EA00-0AA0 6ES7 307-1KA00-0AA0
4
TB1
TB2
TB4
11 12 21
TB3
TB3
14 22 24 1 1
19
16
17
18
11
10
12
13
15
2 2
14
1
1
9
9
2
8
4
4
6
6
3 3
4 4
5 5
K1
6 6
7 7
TB1
TB2
TB4
8 8
11
10
12
13
15
14
1
1
9
9
2
8
4
4
6
9 9
19
16
17
18
10 10
11 11
A2 A1 A2
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
29 29
30 30
7
31 31
6 32 32
5 33 33
34 34
4
35 35
3 36 36
A.C. POWER
A.C. POWER
37 37
2
38 38
1 39 39
40 40
41 41
42 42
TB5
TB5
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
Terminal Block Electric Relay Terminal Block

Thermostat
TB5 Heater K1 TB3
4-24 Varco
Troubleshooting

Upper Derrick Remote Power Supply J-Box
Terminal Block Power Supply Power Supply Power Supply Relay

TB1, TB2, TB5 PS1 PS2 PS3 K1
PS1 PS2 PS3

5A 5A 10A
DC 24V DC 24V DC 24V
230V
VOLTAGE 230V
VOLTAGE 230V
VOLTAGE
SELECTOR SELECTOR SELECTOR
6ES7 307-1EA00-0AA0 6ES7 307-1EA00-0AA0 6ES7 307-1KA00-0AA0
4
TB1
TB2
TB3
TB5
11 21 12
14
21
22 24
20
19
16
17
18
11
10
12
13
15
14
1
1
9
9
2
8
4
4
6
K1
TB1
TB2
TB3
TB5
11
10
12
13
15
14
1
1
9
9
2
8
4
4
6
6
21
20
19
16
17
18
A1 A2 A2
TB4 TB4
1 1
2 2
3 3
4 4
7
5 5
6
5 6 6
A.C. POWER
A.C. POWER
4 7 7
3
8 8
2
9 9
1
10 10
11 11
TB6 TB6 12 12
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
Terminal Block Electric Terminal Block

Thermostat
TB6 Heater TB4
PRS-8i 4-25
Troubleshooting

Remote Power Supply I/O J-Box
24 VDC, 5A 24 VDC, 10A

Power Supply Power Supply
PS1 PS2
Supplies power to digital I/O modules, Supplies power to digital output
linear transducers and absolute encoders module and lower arm solenoid driver modules
PS1 PS2
5A 10A
DC 24V DC 24V
230V
VOLTAGE 230V
VOLTAGE
SELECTOR SELECTOR
6ES7 307-1EA00-0AA0 6ES7 307-1KA00-0AA0

Terminal
Blocks
TB2, TB3
4
TB2
TB2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
TB3
TB3
1 1
2 2
3 3
Relay
Thermostat K1
K1
Heater Temperature E-stop relay activated
1 2 3 4 5 6 7
by master E-stop
A.C. POWER
A.C. POWER
TB1
TB1
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Terminal 9 9
Blocks
TB1
200 Watt
Heater
Anti-condensation heater
4-26 Varco
Troubleshooting
Troubleshooting Hydraulic
Components
The hydraulic system drives the following actuators, as commanded by the control
system:
Arm position cylinders, upper and lower
Jaw position cylinders, upper and lower
Hydraulic-released brakes (for electric motors)
Pipe claw with open/close and centralize cylinders
Lift jaw with pipe guide, roll jaw, and grip jaw cylinders
Counterbalance cylinders for both hoisting wire ropes
The control system commands the hydraulic system by using solenoid-operated valves.
The solenoid valves for the arm position and jaw position cylinders provide proportional
control. All other solenoid-operated valves provide discontinuous control. The brake-
release solenoid-operated valves are plumbed directly to the brake assemblies. All other
solenoid-operated valves are used to control larger valves that are plumbed to the
actuators.
Hydraulic Power Requirements and Inlet 4

Circuit
The PRS must be connected to an external hydraulic power unit capable of 2500 psi
continuously, without dropping more than 10% with a 60 gpm demand. The hydraulic
power unit is connected to the upper and lower inlet filter manifold assemblies. These
manifold assemblies provide a manual shut-off valve and non-bypass filter in the
pressure line. A logic-cartridge valve blocks fluid from reaching the PRS while a pilot-to-
close check valve decompresses the service loop pressure hose. When the flow enable
solenoid valve is shifted, the logic-cartridge valve opens, the pilot-to-close check valve
closes, and the PRS can operate.
Hydraulic fluid flows between the inlet filter manifold assemblies and the vertical column
through two service loop hose assemblies. Both service loop hose assemblies have a
pressure supply hose, a return hose, a drain hose, and electrical cables.
Arm Position Circuit

The upper and lower arm position is controlled by the arm position cylinder assembly
and the arm valve assembly. The cylinder extends, using a regenerative circuit when
lightly loaded, to provide increased speed.
To move the arm, the proportional pilot valve is commanded to shift the proportional
main stage valve. The cylinder moves with the speed and direction commanded.
Counterbalance valves are directly mounted to the cylinder assembly to prevent
unwanted motion.
PRS-8i 4-27
Troubleshooting
Troubleshooting Hydraulic Compo-

nents
Jaw Position Circuit
The upper and lower jaw position is controlled by the jaw position cylinder assembly and
the jaw valve assembly.
To move the jaw, the proportional pilot valve is commanded to shift the proportional main
stage valve. The cylinder moves with the speed and direction commanded.
Counterbalance valves are directly mounted to the cylinder assembly to prevent
unwanted motion.
Hydraulic-Release Brake Circuit

Four electric motors drive three rotary actions on the PRS: two for hoisting, one for
horizontal travel, and one for rotation. Each motor is fitted with a spring-applied,
hydraulic-release brake. A single-solenoid hydraulic valve controls each brake. When
the solenoid valve is de-energized, the brake-release signal is vented and the springs
set the brake. When the solenoid valve is energized, the brake-release signal is used to
compress the springs, and the brake and motor are free to rotate.
Pipe Claw Circuit

4
The pipe claw has two functions:
Open/close
Centralize
A constant reduced pressure drives the claw to the noncentralized and open position.
To close the claw, full system pressure is applied to the piston-side of the hydraulic
cylinder. The speed of closing is controlled by the difference between full system
pressure and the constant reduced pressure, and by the diameter of the throttle orifice.
To open the claw, the piston-side of the cylinder is connected to the tank line, and the
constant reduced pressure retracts the cylinder.
The centralizer works in the same way as the open/close function, but an additional
pressure control is provided. This allows the operator to select a suitable centralizing
torque for the pipe diameter and wall thickness being handled.
Lift Jaw Assembly Circuit

The lift jaw assembly has three functions:
Pipe guide
Roller jaw
Grip jaw
All three hydraulic cylinders mount directly to the jaw body, which is drilled to provide
hydraulic flow paths to each cylinder. All cylinders are controlled by solenoid-operated,
four-way valves that pilot logic cartridge valves and pilot-to-open check valves.
The pipe guide and roller jaw are opened with constant reduced pressure, and closed
with full system pressure. The grip jaw is open with full system pressure, and closed with
full system pressure in a regenerative circuit for increased speed.
4-28 Varco
Troubleshooting
Troubleshooting Hydraulic Compo-

nents
Counterbalance Circuit
Each carriage hoist rope is anchored to a compensator assembly that includes a
counterbalance cylinder. The counterbalance cylinders operate in tension with a
constant reduced pressure that is slightly less than the pressure required for the
cylinders to retract. When the PRS lowers a section of pipe and transfers the pipe
weight, plus a small amount of carriage weight to another member, the cylinders retract.
The retraction of the counterbalance cylinders creates the signal indicating that it is safe
to open the grip jaw.
Test Fittings
Some hydraulic components are equipped with test fittings that can also be used as a
troubleshooting device to check component operation. Refer to the Hydraulic Schematic
Diagram for location of test fittings.
PRS-8i 4-29
Troubleshooting
4-30 Varco
Glossary
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
1
PRS-8i
Glossary
Varco
Glossary
Definitions
The following are definitions of the acronyms, abbreviations, and terminologies used in
this manual. Standard acronyms and abbreviations, such as VAC, VDC, in., ft-lb, etc.,
and industry-standard terminologies are not listed.
E-Stop - Emergency Stop

J-box - Junction box
PROFIBUS - Process Field Bus. A network that allows PRS devices to communicate
over a common bus without the need for specially designed interfaces.
PRS - Pipe Racking System
PTC - Positive Temperature Coefficient
VFD - Variable Frequency Drive
V-ICIS - Varco Integrated Control Instrument System
ZMS - Zone Management System. A system of monitoring and managing the movement
of equipment within its predefined operational space to prevent interference and
collisions with the rig structure and other equipments.
PRS-8i 5-3
Glossary
5-4 Varco
PRS-8i
Pipe Racking Handling Tools
Service Manual Supplement
SM00970
Revision A
© Copyright 2004 Varco LP. All rights reserved.
Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This publication
is the property of, and contains information proprietary to, Varco International, Inc. No part of this
publication may be reproduced or copied in any form, or by any means, including electronic,
mechanical, photocopying, recording, or otherwise without the prior written permission of Varco
International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.

Specifications 2
Maintenance 3
Troubleshooting 4
Glossary 5
2 Specifications
3 Maintenance
4 Troubleshooting
5 Glossary
General Information
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Proper use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
PRS with Handling Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 3
Positioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Small Flush Joint Elevator Assembly . . . . . . . . . . . . . . . . . . . 1-10
Large Flush Joint Elevator Assembly . . . . . . . . . . . . . . . . . . . 1-11
20-inch Hydraulic Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Riser Claw Assembly (Small Fingers) . . . . . . . . . . . . . . . . . . . 1-13 4
Riser Claw Assembly (Large Fingers) . . . . . . . . . . . . . . . . . . . 1-14
Elevator Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
PRS Tailing Claw Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing Elevator Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 5
Installing Flush Joint Elevator Assembly . . . . . . . . . . . . . . . . . . 1-18
Installing 20-inch Elevator Assembly . . . . . . . . . . . . . . . . . . . . 1-19
Installing Riser Claw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Installing Elevator Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Installing Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Installing 2 7/8-inch to 10-inch Tailing Kit . . . . . . . . . . . . . . . . . 1-23
Installing 10-inch to 20-inch Tailing Kit . . . . . . . . . . . . . . . . . . . 1-24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Picking Up Tubulars at the PTC . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Starting Conditions Check List . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Picking Up Tubular Joint from the PTC . . . . . . . . . . . . . . . . . . . 1-27
Moving Tubular to the Mousehole . . . . . . . . . . . . . . . . . . . . . . . 1-27
Positioning First Tubular Section in the Mousehole . . . . . . . . . 1-28
Picking Up Additional Tubular Section from the PTC . . . . . . . . 1-28
Delivering Next Tubular to the Mousehole . . . . . . . . . . . . . . . . 1-29
Lower the Double into the Mousehole . . . . . . . . . . . . . . . . . . . 1-29
Racking the Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Building Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Tailing Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Stowing the Handling Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
PRS Handling Tools

General Information
Varco
General Information
Intended Audience
contained herein. Varco International Inc. will not be held liable for errors in this material 1
or for consequences arising from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Note:
i
Caution:
!
caution symbol.
Warning:

Illustrations
be drawn to scale.
PRS Handling Tools 1-3

General Information
Safety Requirements
1 safe and reliable operation. Operation and service procedures provided by Varco
!
To avoid injury to personnel or equipment damage,
carefully observe the following safety requirements.
Personnel Training
!
During installation, maintenance, or repair of equipment,
personnel should wear protective gear. Protective gear
must be worn during certain operation.
Recommended Tools
1-4 Varco
General Information
General System Safety Practices

1
!
Before installing or performing maintenance or repairs on
equipment, read the following instructions to avoid
endangering exposed persons or damaging equipment.

repair.
Replacing Components
Routine Maintenance
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
Proper use of Equipment


General Information
Description
Special handling tools are available to provide additional tubular-handling, casing-
tailing, and riser-tailing capacities for the Pipe Racking System (PRS).
1
The handling tools are:
Positioner Assembly
Small Flush Joint Elevator Assembly, 3 1/2-inch to 9 3/4-inch
Large Flush Joint Elevator Assembly, 7-inch to 13 5/8-inch
20-inch Elevator Assembly
9 7/8-inch Adapter Kit
Roller Kit (20-inch Casing)
Riser Claw Assembly, 30-inch to 58-inch (also refered to as Riser Tailing Head)
Small Fingers, 16-inch to 30-inch
PRS Tailing Claw Adapter Kit, 2 7/8-inch to 10-inch
PRS Tailing Claw Adapter Kit, 10-inch to 20-inch
Positioner Assembly
The positioner assembly holds and positions the elevator assembly to enable the PRS to
place or remove single joints of drill pipe, collars, or casing from either the primary or
auxiliary V-door locations. The positioner provides 37.5º of rotation, clockwise and
counterclockwise in 7.5º increments, to bridge the difference in the angle between the
PRS lifting jaw and the tubulars at the pickup position. (A ball joint limits the amount of
swing.)
Two hydraulic cylinders drive the sleeve upwards against the upper plate to stabilize the
positioner in the vertical and hold it rigid. Releasing the hydraulic pressure in the
cylinders allows the positioner to swing in any direction up to 22º from vertical.
Four pins secure the elevator assembly to the positioner.
Flush Joint Elevator Assembly

The small and large flush joint elevator assemblies adapt the PRS for tubulars having
outside diameters of 3 1/2 inches to 9 3/4 inches (small) and 7 inches to 13 5/8 inches
(large). Two grip claws engage the tubular in a carrier assembly. The claws are opened
and closed by a grip claw cylinder. Hydraulically operated cylinders tilt the carrier
assembly to match the incline of a conveyor, such as the Varco Pipe Transfer Conveyor
(PTC).

The 20-inch elevator assembly adapts the PRS for 20-inch tubular diameters. Two
hydraulically operated flippers engage the tubular in a carrier frame. Two hydraulically
operated cylinders tilt the frame to match the incline of the PTC.
1-6 Varco
General Information
Description
Riser Claw Assembly
The riser claw assembly is used for tailing operations. It can tail different sizes of
tubulars, ranging from 16 inches to 58 inches. The riser claw assembly attaches to the
1
claw assembly of the PRS. Two different size fingers are available for the riser claw
assembly. The smaller fingers are used to handle tubulars from 16-inch to 30-inch
diameters. The large fingers are used to handle tubulars from 30-inch to 58-inch
diameters.
Elevator Adapter Kits

Elevator assemblies may require adapter kits in order to fit other pipe diameters. For
example, the 20-inch to 10 3/4-inch adapter kit is installed on the 20-inch elevator to give
the elevator the capability of handling a 10 3/4-inch pipe. An adapter kit contains an
adapter plate and two flipper adapters and mounting hardware.
Roller Kit
A roller kit may be added to the 20-inch elevator assembly to reduce friction when
handling 20-inch casings.
PRS Tailing Claw Adapter Kits

The PRS claw assembly (tailing claw) may require adapter kits to fit other pipe
diameters. These adapter kits attach to the claw assembly (tailing claw) on the PRS.
Adapter kits are provided according to the requirements of your rig.

General Information
PRS with Handling Tools
Lifting Jaw
Positioner
Assembly
PRS-8i Flush Joint

Elevator Assembly
Shown
20-inch Elevator
Assembly
Not Shown
Tailing Claw
1-8 Varco
General Information
Positioner Assembly
1
Ball Joint Hydraulic Hoses
8 Places
Single Hanger
Sleeve
Elevator
Link Carrier
Retainer
4 Places
Elevator Hydraulic
Securing Pin Cylinder
Roller 4 Places 2 Places

General Information
Small Flush Joint Elevator Assembly

Valved Valved
1 Nipple Coupler Valved
Nipple
Valved Eye Bolt Eye Bolt
Nipple Valved
Valved Coupler
Coupler
Elevator
Elevator Link Hose
Link Guides
10 Places
Tilt Cylinder
Hydraulic
Tilt Cylinder Retract

Hydraulic Cylinder Grip Arm
Hydraulic 2 Places
2 Places
Claw
Header
Manifold
Rotate Claw Knuckle

Large Pad Cylinder
Mount on knuckle Hydraulic
for handling pipe 2 Places Claw
less than 5 inch dia.
Small Pad
Mount on knuckle Grip Claw Grip
for handling Cylinder Claw
Carrier
5-6 inch dia. pipe. Hydraulic
Assembly
1-10 Varco
General Information
Large Flush Joint Elevator Assembly
Mounting
Assembly
Elevator Link
Assembly
Elevator
Arm
2 places
Rotate Claw
Actuator
2 places
Jaw Tilt
Hydraulic
Claw Retract/ Cylinder
Extend Hydraulic 2 places
Cylinder
2 places
Claw
2 places
Jaw
Assembly
Jaw Die Block

Assembly
2 places
Die Carrier
2 places Spherical
Bearing
2 places

General Information
20-inch Hydraulic Elevator
Quick Disconnect
Hoses
Link
Link
Hose
Guides
Tilt Cylinder
Assembly
Flipper
Hydraulic
Cylinder
Assembly
Hydraulic
Left
Flipper
Carrier Right
Frame Flipper
1-12 Varco
General Information
Riser Claw Assembly (Small Fingers)
Body
1
Finger
16 to 30 inch
V-Shoe
Rollers
Finger
16 to 30 inch
Fingers
Hydraulic
Locating
Cylinder
Pin
2 Places
Riser Hand
Latch

General Information
Riser Claw Assembly (Large Fingers)

Body
1
Finger
30 to 58 inch
V-Shoe
Rollers
Finger
30 to 58 inch Rollers
Locating
Fingers Pin
Hydraulic
Cylinder
2 Places
Riser Hand
Latch
1-14 Varco
General Information
Elevator Adapter Kits
Adapter Plate
Assembly
Flipper Adapter
Flipper Adapter
Right
Left
Elevator Adapter Kit (Typical)
i
Refer to Technical Drawing Package
for the Elevator Adapter Kits used on
your rig.

General Information
PRS Tailing Claw Adapter Kits
1
Tailing
Claw
Claw
Extension
Tailing Kit
2.88-inch to 10.00-inch
Claw
Extension
Tailing
Claw
Claw
Extension
Tailing Kit
10.00-inch to 20.00-inch
Claw
Extension
1-16 Varco
General Information
Installation
Installing Elevator Positioner
1
Lifting Jaw
Assembly
Pin Lifting Jaw

Pipe Guide
Washer
2 Places
Cotter Pin
2 Places
Hydraulic Hose
8 Places
Installing the Positioner

1. Lower PRS hoist.
Cap Screw 2. Remove cotter pins, washers and pin
8 Places from lifting jaw pipe guide.
Mounting 3. Remove and store lifting jaw pipe guide.
Lock Pin 4. Hoist positioner to lifting jaw assembly.
Washer 4 Places
8 Places 5. Remove the four mounting pins from
positioner.
Retainer 6. Move positioner into mounting position
4 Places and insert the four mounting pins.
a. Insert pins, making sure retainer
link slots are facing down.
b. Insert retainer links and secure
each pin with two cap screws and
two lock washers.
7. Connect hydraulic hoses to the
quick-disconnect fittings on lifting jaw
assembly.
Positioner

General Information
Installation
Installing Flush Joint Elevator Assembly
1
Positioner Elevator
Assembly Securing Pin
4 Places
Pin Clip
4 Places
Lifting Cap Screw

Jaw 8 Places
Lockwasher
8 Places
Mounting
Bar
Elevator
Positioner Retainer
Assembly 4 Places
Mounting
Plate
Flush Joint
Elevator Flush Joint
Assembly Elevator
Assembly
Installing the Elevator

1. Remove the four pin clips and four elevator securing pins from the positioner.
2. Remove the eight cap screws, eight lockwashers, and four elevator retainers.
3. Lower hoist so that positioner reaches elevator on the deck, or lift elevator to reach
positioner.
4. Insert one edge of elevator semicircular mounting bar (located at the top of the link) into
the mounting plates on positioner.
5. Determine elevator rotation required. Rotate elevator to the desired position.
The mounting bar on the elevator link has a series of holes spaced at 7.5 degrees. These
holes allow rotation of the elevator in 7.5 degrees steps up to 37.5 degrees clockwise or
counterclockwise.
6. Insert the four securing pins and the four pins clips.
7. Replace the four elevator retainers, eight lockwashers and eight cap screws. Tighten the
cap screws.
8. Attach the hydraulic hose quick disconnect fittings on the positioner to their respective
fittings on the elevator.
1-18 Varco
General Information
Installation
Installing 20-inch Elevator Assembly
1
Positioner Elevator
Assembly Securing Pin
4 Places
Pin Clip
4 Places
Lifting Cap Screw

Jaw 8 Places
Lockwasher
8 Places
Mounting
Bar
Elevator
Positioner Retainer
Assembly 4 Places
Mounting
Plate
20-inch
Elevator
Assembly
20-inch Elevator
Assembly
Installing the Elevator

1. Remove the four pin clips and four elevator securing pins from the positioner.
2. Remove the eight cap screws, eight lockwashers, and four elevator retainers.
3. Lower hoist so that positioner reaches elevator on the deck, or lift elevator to reach
positioner.
4. Insert one edge of elevator semicircular mounting bar (located at the top of the link) into
the mounting plates on positioner.
5. Determine elevator rotation required. Rotate elevator to the desired position.
The mounting bar on the elevator link has a series of holes spaced at 7.5 derees. These
holes allow rotation of the elevator in 7.5 degrees steps up to 37.5 degress clockwise or
counterclockwise.
6. Insert the four securing pins and the four pins clips.
7. Replace the four elevator retainers, eight lockwashers and eight cap screws. Tighten the
cap screws.
8. Attach the hydraulic hose quick disconnect fittings on the positioner to their respective
fittings on the elevator.

General Information
Installation
Installing Riser Claw Assembly
1
Riser Claw
Assembly
Clip
Latch
Pin
Locating
Pin
Clip
Attachment
Pin
Riser Hand
Latch Locating
Pin
Tailing
Claw
Installing Riser Claw

1. Extend tailing arm.
2. Remove latch pin, attachment pin and clips
from riser claw assembly.
3. Hoist riser claw assembly above tailing claw.
4. Lower riser claw assembly onto tailing claw,
aligning locating pins into their receptacles.
5. Install attachment pin and clip.
6. Swing riser hand latch up under tailing arm
and secure with latch pin and clip.
7. Attach hydraulic hoses.
1-20 Varco
General Information
Installation
Installing Elevator Adapter Kit
1
Adapter Plate
Assembly
Screw
Lock Nut
4 Places
Screw
Lockwire
4 Places
Flipper Adapter
Elevator Adapter Kit (Typical) Flipper Adapter
Right
Left
Installing adapter kit

1. Remove the screws with lock nuts from adapter plate assembly.
2. Align the holes on adapter plate with holes on elevator body.
3. Insert a screw into each of the four holes and tighten securely with a lock nut.
4. Align the two holes on each flipper adapter with the holes on the elevator latches.
5. Install the two screws into the threaded holes on each claw flipper.
6. Securely tighten the two screws on each elevator flipper adapter and secure
with lockwire.
i
Refer to Technical Drawing Package
for the Elevator Adapter Kits used on
your rig.

General Information
Installation
Installing Roller Kit
1
Roller Assembly
Cap Screws
2 per Roller
Assembly
Elevator Assembly
Roller Kit
20-inch Elevator
Assembly
Roller Kit
20 inch Casing
1-22 Varco
General Information
Installation
Installing 2 7/8-inch to 10-inch Tailing Kit
1
Tailing Claw
Long
Screw
Lock Lock
Washer Washer
Short
Screw
Lock
Washer
Long
Screw
Claw
Extension
Lock
Washer
Short Claw
Screw Extension

General Information
Installation
Installing 10-inch to 20-inch Tailing Kit
1
Tailing Claw
Long
Screw
Lock Lock
Washer Washer
Short
Screw
Lock
Washer
Long Claw
Screw Extension
Lock
Washer
Short Claw
Screw Extension
1-24 Varco
General Information
Operation
The following procedures describe operation of the PRS using the handling tools.
1
i
All machine motions are governed by dead-man control,
i.e., whenever the operator releases the switch on the
joystick, the associated movement stops immediately.
The driller is ultimately responsible for operating the PRS

in a manner that avoids collisions, and does not damage
the equipment.
Ensure PRS operational area is clear of personnel and

equipment before applying power.

General Information
Picking Up Tubulars at the PTC
1
i
Use this procedure when making stands.
Before starting a pickup sequence, make sure the PRS is

set to handle singles. Also check that the positioner,
elevator and correct size adapter kit have been installed
and correctly oriented.
!
Make sure elevator clears any obstructions above rig floor
level.
Starting Conditions Check List

Power applied
PRS indexed
PRS positioned at the pipe pickup location (upper arm assembly is lowered and
extended; lower (tailing) arm assembly is retracted, with claws open)
Fingerboard is setup and initialized
Drill pipe size and weight entered
Positioner and elevator attached to PRS lift jaw assembly. Elevator jaw rotated to
the horizontal position, open and ready for tubular
Ensure correct spacer pad is mounted on the flush joint elevator knuckle (depends
on pipe size)
Operator control settings:
Racker Mode - ON
Racker Configuration - STANDS
Racker Tubular Mode - dependent upon tubular being picked up
Fingerboard Mode - AUTO
Elevator Tilt Mode - AUTO
Roughneck positioned to work at the mousehole
Mousehole Spider:
Tubular guide installed
Slips Open - UNCLAMPED
PTC loaded with joint of tubular
1-26 Varco
General Information
Picking Up Tubular Joint from the PTC

1. Feed tubular joint into the elevator using the PTC.
1
i
If not using a Varco PTC, it is the operators responsibility to
position the tubular into the elevator ay the same pickup
location each time.
2. Hoist PRS upper arm assembly until elevator carrier frame engages the tubular.
3. Close elevator flippers to secure tubular.
4. Hoist the PRS upper arm assembly until the tubular is at a 20º angle (approx)
relative to the PRS.
!
Do not allow the pin end of the tubular to come off the PTC
prior to grabbing it with the PRS claw assembly. Failure to
do so may damage the pin end of the tubular.
5. Extend PRS lower (tailing) arm assembly to grab tubular with the claw assembly.
6. Close PRS claw assembly
7. Slowly raise PRS upper arm assembly until tubular clears the PTC
8. Retract PRS upper and lower arm assemblies (they will stop automatically).
Moving Tubular to the Mousehole

1. Rotate PRS to face the mousehole (rotation will stop automatically).
2. Move PRS to the mousehole (PRS will stop automatically).
3. Extend PRS upper and lower arm assemblies (arm assemblies will stop
automatically).
i
If this is not the first tubular section of a stand, go to the
procedure for Picking Up Additional Tubular Section from
the PTC.

General Information
Positioning First Tubular Section in the

Mousehole
1. Lower PRS upper arm assembly until tubular enters the mousehole.
1
2. Open PRS claws to disengage claw assembly.
3. Retract PRS lower (tailing) arm assembly (arm will stop automatically).
4. Lower PRS upper arm assembly until top of tubular is four feet above the drill floor.
5. Clamp the mousehole spider slips.
6. Open elevator flippers and lower PRS upper arm assembly slightly to clear the
tubular box.
7. Retract PRS upper arm assembly (arm will stop automatically).
8. Raise PRS upper arm assembly until elevator clears PRS lower arm assembly.
Picking Up Additional Tubular Section

from the PTC
1. Move PRS to the pickup location at the PTC (PRS will stop automatically).
2. Rotate PRS to the pickup position (PRS will stop automatically).
3. Extend PRS upper arm assembly to the pickup position (arm will stop
automatically).
4. Lower PRS upper arm assembly (arm will stop automatically).
5. Repeat the procedure for Picking Up Tubular Joint from the PTC.
1-28 Varco
General Information
Delivering Next Tubular to the Mousehole

1. Rotate PRS to face the mousehole (rotation will stop automatically).
2. Move PRS to the mousehole (PRS will stop automatically).
1
i
When delivering the next tubular to the mousehole, make
sure tubular pin is higher than the box of the stand in the
mousehole before extending PRS arm assemblies.
3. Extend PRS upper and lower arm assemblies (arm assemblies will stop
automatically).
4. Stab the pin into the box of the tubular joint in the mousehole by lowering PRS
upper arm assembly just until the pin is in the box.
5. Open claw on PRS lower arm assembly.
6. Retract PRS lower arm assembly (arm will stop automatically).
i
Keep elevator flippers closed to contain the tubular while
the connection is being made.
7. Using the roughneck, make the tubular joint connection.
Lower the Double into the Mousehole

1. Raise PRS upper arm assembly to take the load of the double.
2. Unclamp the mousehole spider slips.
3. Raise PRS upper arm assembly slightly to take the weight off the mousehole
spider slips.
4. Lower PRS upper arm assembly until top of double is about four feet above the
drill floor.
5. Clamp the mousehole spider slips.
6. Lower PRS upper arm assembly slightly to clear the elevator flippers from the
tubular box.
7. Open elevator flippers.
8. Retract PRS upper arm assembly.
9. Repeat the procedure for Picking Up Additional Tubular Section from PTC,
followed by the procedure for Delivering the Next Tubular to the Mousehole.
Racking the Stand

Refer to your rig SOP for instructions to remove a stand from the mousehole and racking
the stand in the fingerboards.

General Information
Building Stands
Building stands consists of combining single joints in the mousehole to form doubles
and triples.
1
To make up or break down stands, set up the PRS as follows:
!
Use the handling tools with the PRS only when moving a
single to and from the PTC and/or mousehole as part of
the stand-building process, and lowering a forble into the
mousehole while building stands.
1. Select drill pipe, drill collar, or casing mode for the preferred hoisting speed, in
conjunction with PTC travel.
2. Select stands, if applicable, to enable stand-building destinations.
3. Install and orient the positioner and select the proper handling tools elevator
configuration for the tubular size being handled.
1-30 Varco
General Information
Tailing Risers
The riser tailing sequence takes the operator from a given starting point through the
connection of the riser. The PRS lower arm assembly is disabled when the PRS is in this
mode. 1

General Information
Stowing the Handling Tools

Stow the handling tools when weather conditions are extreme, during rig relocation, and
when not in use.
1
1-32 Varco
General Information
Reference Material
The following drawings provide additional information on the handling tools (refer to the
Technical Drawing Package for your rig):
1
Roller Kit
Small Flush Joint Elevator Assembly
Large Flush Joint Elevator Assembly
Riser Claw Assembly, 30-inch to 58-inch
Small Fingers, 16-inch to 30-inch
Positioner Assembly
PRS Tailing Claw Adapter Kit, 2 7/8-inch to 10-inch
PRS Tailing Claw Adapter Kit, 10-inch to 20-inch

General Information
1-34 Varco
Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Elevator Positioner Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Flush Joint Elevator Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-3 1
20-inch Elevator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
PRS Handling Tools

Specifications
Varco
Specifications
Specifications
Elevator Positioner Specifications

Physical: Height
Weight
Functional: Rotation 37.5º cw and ccw in 7.5º increments
Swing 22º in any direction in the vertical
2
SWL 15,000 lb (6,804 kg) max.
Critical load path Yes

components?
Power Hydraulic pressure 2500 psi, closed centered
requirements:
Hydraulic flow rate 60 gpm
Flush Joint Elevator Specifications

Physical: Height 72 inches (1,524 mm) (approx)
Weight
Functional: Rotation see elevator positioner specifications
Swing see elevator positioner specifications
SWL

components?
Capacities: Drill pipe size 3 1/2 to 9 3/4 inches
Drill collar size 9 3/4 in. max.

Power Hydraulic pressure 2500 psi, closed centered
requirements:

Specifications
Specifications
20-inch Elevator Specifications
Physical: Height 72 inches (1,524 mm) (approx)
Weight
Functional: Rotation see elevator positioner specifications
Swing see elevator positioner specifications
2 SWL

components?
Capacities: Casing size 20 inches o.d.
Power Hydraulic pressures 2500 psi, closed centered

requirements:
Environmental Specifications
i
Refer to the PRS Service Manual for environmental
specifications.
It is the responsibility of the operator to ensure that the

PRS is operated within its environmental specifications.
Handling equipment can be damaged if the PRS is

operated in an environment that exceeds PRS
environmental specifications. Stow the handling
equipment when weather conditions are extreme.
2-4 Varco
Maintenance
General Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Inspecting Load-Carrying Components . . . . . . . . . . . . . . . . . . . 3-4
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Flush Joint Elevator Assembly Lubrication . . . . . . . . . . . . . . . . . 3-6 2
Riser Claw Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Replacing Handling Tool Components . . . . . . . . . . . . . . . . . . . . 3-9
Grip Die Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
PRS Handling Tools

Maintenance
Varco
Maintenance
Equipment Maintenance Records

i
components.
Safety Precautions 3
this manual.


warnings before performing maintenance procedures.

Maintenance
warrant more frequent inspection intervals.
Generally, the handling tools should be inspected after each trip. Particular attention
should be made to checking the hydraulic and pneumatic hoses for leaks, abrasion,
pinching, kinking, cracking, and excessive bending or twisting. Repair or replace the
hoses as necessary.
Inspecting Load-Carrying Components

3 deterioration. If you detect any excessive wear and tear on any component, replace the
component.
installation manager and by local regulatory requirements.
i
Before checking pneumatic lines, make sure that the power
is off and pneumatic pressure is removed from the
handling tool.
3-4 Varco
Maintenance
Recommended Hydraulic Fluids
i
Hydraulic fluids are supplied by the PRS to the handling
tools. Refer to the PRS Service Manual for a listing of
recommended hydraulic fluids.
Recommended General Purpose Lubricants 3

Castrol - MP Grease
Mobil Mobilux EP1 Mobilux EP2
Viscosity Index
NGLI 1 2

Maintenance
Flush Joint Elevator Assembly Lubrication
Grease Fitting
2 Places
Each Trip
Grease Fitting
2 Places
Each Trip
Each Trip
Grease Fitting
2 Places
Each Trip Each Trip

Each Trip
Grease Fitting Grease Fitting
Each Trip Grease Fitting
2 Places Each Trip 2 Places
2 Places on
Grease Fitting Grease Fitting knuckle Underside
2 Places 2 Places
3-6 Varco
Maintenance
Riser Claw Assembly Lubrication
V-Shoe
Each Trip
Grease Fitting
2 Places

Maintenance
This page left blank intentionally
3-8 Varco
Maintenance
Replacing Handling Tool

Components
Always make sure power is removed from PRS before

removing and replacing components.
! 3
Before performing any disassembly, move handling tool to
a position suitable for the service being performend, and
clear of well-center operations.
i
Use the assembly drawings contained in the Technical
Drawing Package to aid in replacing components.

Maintenance

Components
Grip Die Replacement
Small Flush Joint Elevator
1. Turn off hydraulic power to the FJE.
2. On each grip jaw arm, unscrew the two spring retaining screws. Remove the two
screws, lock washers, and springs.
3. Remove the die carrier from the grip jaw arm.
4. On the die carrier, remove the cap screw. Remove the insert keeper and the three
die inserts.
5. Clean the die carrier. Apply a coating of grease to the slots on the die carrier and
insert three new die inserts.
3 6. Reinstall the insert keeper and secure with the cap screw. On the back of the die
carrier, ensure the center of the holes in the two studs extend 3/8 inch (9.5 mm)
beyond the back of the carrier. Also ensure the holes in the studs align with the
holes in the grip jaw arm.
7. Install the die carrier in the grip jaw arm.
8. Install the springs on the two spring retainer screws and encapsulate them with
grease.
9. Apply antisieze compound to the threads and install the two spring retainer
screws and lock washers. Torque 53 to 59 ft/lb.
10. Lubricate the die carrier assembly.
3-10 Varco
Maintenance

Components
Small Flush Joint Elevator
Grip Jaw Arm
Cap Screw
Dies Inserts
3 places
Insert Keeper
Lock
Washers
Die Carrier
Springs
Carrier Assembly
Spring Retainer Studs
Retaining
Screws

Maintenance

Components
Large Flush Joint Elevator
1. Turn off hydraulic power to the FJE.
2. On each grip arm, unscrew and remove the two spring retainer screws, spring
retainer, and three springs.
3. Unscrew the four die block retainer screws. Remove the screws, four lock
washers, two die block retainers, and the die block from each grip arm.
4. On the die carrier, remove the cap screw. Remove the insert keeper and the three
die inserts.
5. Clean the die carrier. Apply a coating of grease to the slots on the die carrier and
3 insert three new die inserts.
6. Reinstall the insert keeper and secure with the cap screw.
7. Lubricate the die block slides with a coating of grease.
8. Install the die block, two die block retainers, four die block retainer screws, and
four lockwashers.
9. Lubricate the three springs.
10. Install the springs, spring retainer, two screws, and two lock washers.
3-12 Varco
Maintenance

Components
Large Flush Joint Elevator
3
Grip Jaw Arm
Cap Screw
Insert Keeper
Die Insert
3 places
Die Spring Die Block

3 places Retainer
2 places
Spring
Retainer
Die Block
Cap Screw,
Lock Washer
2 places
Cap Screw,
Lock Washer
4 places

Maintenance
3-14 Varco
Troubleshooting
Troubleshooting Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Helpful Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting Positioner Assembly . . . . . . . . . . . . . . . . . . . . . 4-3 1
Troubleshooting Flush Joint Elevator Assembly . . . . . . . . . . . . . 4-4
Troubleshooting 20-inch Elevator Assembly . . . . . . . . . . . . . . . . 4-5
Troubleshooting Riser Claw Assembly . . . . . . . . . . . . . . . . . . . . 4-5
PRS Handling Tools

Troubleshooting
Varco
Troubleshooting
Troubleshooting Fault Symptoms

Hydraulic components
this chapter.
i
causes, and what components to check.
Helpful Documents
Use the drawings contained in the Technical Drawing Package to aid in troubleshooting. 4
Troubleshooting Positioner Assembly

Sleeve does not drive Command is not allowed by Check control system for fault indication
upwards against the software or interlock condition. Check PRS.
upper plate
Hydraulic cylinders 1. Check hydraulic pressure from PRS to
positioner assembly.
2. Check hoses for leaks, kinks, or other
damage. Repair, replace.
3. Check hydraulic cylinders. Replace if
faulty.
Positioner does not Mechanical interference or 1. Check for obstructions.
swing in the vertical failure of ball joint 2. Check ball joint.

Troubleshooting
Troubleshooting Flush Joint Elevator

Assembly

Carrier assembly Command is not allowed by Check control system for warning or
does not tilt the software interlock condition. Check PRS.
Hydraulic tilt cylinders 1. Check hydraulic pressure from PRS
through the positioner assembly to the
elevator.
faulty.
Grip claw does not Command is not allowed by Check control system for warning or
open or close the software interlock condition. Check PRS.
Hydraulic grip claw cylinder 1. Check hydraylic pressure from PRS
elevator.
4 damage. Repair, replace.
3. Check hydraylic cylinder. Replace if
faulty.
Grip claw does not Command is not allowed by Check control system for warning or
rotate the software interlock condition. Check PRS.
Hydraulic rotate claw cylinders 1. Check hydraulic pressure from PRS
elevator.
faulty.
Grip arm does not Command is not allowed by Check control system for warning or
extend or retract the software interlock condition. Check PRS.
Hydraulic retract cylinders 1. Check hydraulic pressure from PRS
elevator.
faulty.
4-4 Varco
Troubleshooting
Troubleshooting 20-inch Elevator

Assembly

Carrier assembly Command is not allowed by Check control system for warning or
does not tilt the software interlock condition. Check PRS.
Hydraulic tilt cylinders 1. Check hydraulic pressure from PRS
elevator.
faulty.
Flippers do not Command is not allowed by Check control system for warning or
operate the software interlock condition. Check PRS.
Hydraulic flipper cylinders 1. Check hydraulic pressure from PRS
elevator.
4
faulty.
Troubleshooting Riser Claw Assembly

Flippers do not Command is not allowed by Check control system for warning or
operate the software interlock condition. Check PRS.
Hydraulic flipper cylinders 1. Check hydraulic pressure from PRS
elevator.
faulty.

Troubleshooting
4-6 Varco
Glossary
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
1
PRS Handling Tools

Glossary
Varco
Glossary
Definitions
The following are definitions of the acronyms, abbreviations, and terminologies used in
this manual. Standard acronyms and abbreviations, such as VAC, VDC, in., ft-lb, etc.,
and industry-standard terminologies are not listed.
FJE - Flush Joint Elevator

PRS - Pipe Racking System
SOP - Standard Operating Procedure

Glossary
5-4 Varco
FSA
Foxhole Slip Assembly
Service Manual
SM00966
Rev -
© Copyright 2002 Varco International, Inc.
All rights reserved. This publication is the property of, and contains information proprietary to Varco
International, Inc. No part of this publication may be reproduced or copied in any form, or by any means,
including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of
Varco International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their
respective owners.

Specifications 2
Maintenance 3
Troubleshooting 4
Glossary 5
2 Specifications
3 Maintenance
4 Troubleshooting
5 Glossary
Intended audience
contained herein. Varco International, Inc., will not be held liable for errors in this
material, or for consequences arising from misuse of this material.
Conventions
Notes, cautions, and warnings
Note:
i
Caution:
!
caution symbol.
Warning:

Illustrations
be drawn to scale.
FSA
Safety requirements
safe and reliable operation. Operation and service procedures provided by Varco
!
CAUTION: To avoid injury to personnel or equipment
damage, carefully observe the following safety
requirements.
Personnel training
!
CAUTION: During installation, maintenance, or repair of
equipment, personnel should wear protective gear.
Protective gear must be worn during certain operation.
Recommended tools
Varco
General system safety practices

!
CAUTION: Before installing or performing maintenance or
repairs on equipment, read the following instructions to
avoid endangering exposed persons or damaging
equipment.

repair.
Replacing components
Routine maintenance
!
CAUTION: Failure to conduct routine maintenance could
result in equipment damage or injury to personnel.
Proper use of equipment

FSA
Varco
General Information
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Leveling beam and guide rods . . . . . . . . . . . . . . . . . . . . 1-6 1
Slip and hanger assemblies . . . . . . . . . . . . . . . . . . . . . . . 1-8
Accommodating various tubular sizes . . . . . . . . . . . . . . . . . . . . 1-8
Operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operating considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 2
FSA set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operational sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Changing out the slip assemblies . . . . . . . . . . . . . . . . . . . . . . . 1-12
Installation considerations . . . . . . . . . . . . . . . . . . . . . . . 1-14
Preparing the Foxhole® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 3
Installing the FSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Connecting the control system . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Function testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FSA
General Information
Varco
General Information
Description
The Foxhole® Slip Assembly, referred to herein as the FSA, is a remote-controlled slip
assembly that sits on top of the Foxhole®, recessed so that the top of the FSA is flush
with the drill floor when in the stored position. The FSA is used for making up stands off
1
line. A permanent (customer supplied) platform provides a stable base on which the
FSA rests. (See the Foxhole® Slip Assembly drawing for a recommended example of the
platform.)
The FSA accommodates 3 1/2 to 14 in. tubulars by applying one of three different slip
sets.
This assembly can be used whether or not the Foxhole® contains an automatic hoist
assembly.
FSA 1-3
General Information
Major components
The FSA consists of the Foxhole® Slip Assembly and a pneumatic control plate
assembly, which the customer installs in the derrick. The control plate is supplied with
1 electrical and pneumatic power, as required. The customer also supplies two 1/2 in.
pneumatic lines from the control plate assembly to the FSA.
On shipment, the FSA accommodates tubulars from 5 to 9 3/4 in. outside diameter
(OD). Additional slip sets are available for handling tubulars from 3 1/2 to 8 1/4 in. and
from 9 5/8 to 14 in. OD.
The FSA consists of the following items:
Foxhole® Slip Assembly

Leveling beam and guide rods
Pipe centralizer guide
Slip and hanger assemblies
Pneumatic cylinders
Hose assemblies
Cover plate
Control plate assembly
Release regulator
Supply regulator
Solenoid control valve
Lubricator
Check valve
Mounting plate
1-4 Varco
General Information
Major components
Safety Bar (2) Plate 1
Supply Regulator
Lubricator
Release Regulator
Pipe Centralizer Guide Check Valve

Solenoid
Valve
Pneumatic Cylinder (3) Leveling Beam Guide Rod (3)
Leveling Beam
Hose Connections
with Quick Disconnects (QDs)
Body
Slip Assembly (6)
FSA 1-5
General Information
Leveling beam, guide rods, and

pneumatic cylinders
1 The slip assemblies connect to the leveling beam by slip hanger brackets. The leveling
beam is supported by three pneumatic cylinders and guided by three guide rods. When
the leveling beam is lowered, the slip assemblies are centralized to grip the tubular
correctly.
1-6 Varco
General Information
Leveling beam, guide rods, and

pneumatic cylinders
1
Guide Pneumatic
Rod Cylinder
Pneumatic
Cylinder Guide
Rod
Guide
Rod Pneumatic
Cylinder
Pneumatic
Cylinder Guide
Rod
Drill Floor
Leveling
Beam
Body
FSA 1-7
General Information
Slip and hanger assemblies

Three sets of slip and hanger assemblies enable the FSA to accommodate the following
tubular ranges:
1
3 1/2 to 8 1/4 in.
5 to 9 3/4 in.
9 5/8 to 14 in.
The air-operated slip assembly grips or releases the tubular in the Foxhole® during
stand building. Six roller-equipped slips are arranged in 60° increments around the
circumference of the FSA. The rollers move up and down on guide plates as the slips
are raised or lowered. These rollers require no lubrication. The slip and hanger
assembly consists of two slip hangers joined by extension springs, which attach to the
slip assembly by means of a slip bracket, hanger, and cotter pins. The extension springs
connecting the two slip hangers allow the slips to retract and set, when the leveling
beam is raised. The slips remain retracted when raised, regardless of platform or vessel
motion.
Accommodating various tubular sizes

The slip and hanger assemblies attach to the leveling beam with the hanger bracket pin.
To accommodate various tubular sizes, remove the slip and hanger assemblies and
replace with the desired size. (See Changing out the slip assemblies on page 12.)
1-8 Varco
General Information
Hanger Bracket Pin

1
and Retainer
Leveling Beam
Slip Hanger
Bracket
Slip Hangers
Slip and Hanger Assembly

Extension
Spring
Hanger Pins (4)

and
Cotter Pins(8)
Roller
Slip Assembly
(Shown in open position, Body

simplified for clarity)
FSA 1-9
General Information
Operation overview
Operator controls
1 A two-position detent switch located on the driller’s control panel allows the operator to
raise and set the slips within the FSA.
Operating considerations
The FSA should be used only when building stands off line.
When operating the FSA, always set the slips before making up or breaking out
connections.
The FSA is not designed to provide back up torque for making or breaking out
connections. This tool is intended only to support vertical tubular loads. Connections
must be backed up independently to avoid damage to the FSA and/or dropped pipe.
i
Under light loads, it is normal that not all six slip assemblies contact the outside diameter
(OD) of the tubular. This is not a cause for concern.
i
FSA set up
Before each use, set up the FSA as follows:
1. Install the proper slip assemblies for the size of tubular being used.
2. Verify that the lubricator on the control plate assembly is full.
3. Adjust the pneumatic supply pressure to the maximum, using the supply regulator
on the control plate assembly.
4. Adjust the release regulator on the control plate assembly to the minimum
required to raise the leveling beam.
Setting the release pressure too high could cause the pipe to release.
5. Cycle the FSA 5 to 10 times to insure proper lubrication of the cylinders before
allowing it to support weight.
1-10 Varco
General Information
Operation overview
Operational sequences
This section describes general operational sequences of the FSA. 1
General tool sequence
The operational sequence is as follows:
1. Using pipe-handling equipment, lower a tubular into the FSA.
2. Set the control switch to CLOSE. This lowers the slips, so that the Foxhole® Slip
grips the stand in the Foxhole®.
3.
Building stands
The following sequence describes how to build double and triple stands using the FSA.
1. Open the slips.
2. Lower the first tubular into the Foxhole® to the appropriate connection height.
3. Set the slips to grip the tubular.
4. Release the pipe-handling equipment after verifying that the slips have taken the
load.
5. Present a second tubular over the Foxhole® and make the connection to the
required torque (using separate back-up).
6. Using pipe-handling equipment, latch onto the double, open the slips, and hoist.
!
When raising the load, set the control switch to OPEN only after the tubular begins hoisting.
Repeat the process once more for building a triple.
FSA 1-11
General Information
Operation overview
Changing out the slip assemblies
1 To accommodate various tubular sizes, you must change out the slip and hanger
assemblies and replace with the correct size.
Before you start, attach a lifting sling to the slip hanger to be removed.
1. Remove the hanger bracket retainer and pin.
2. Slide the slip and hanger assembly out of the FSA.
3. Repeat steps 1 and 2 for the other five hanger and slip assemblies.
4. Install the different size hanger and slip assembly.
5. Replace the hanger bracket pin and retainer.
6. Repeat steps 4 and 5 for the other five hanger and slip assemblies.
1-12 Varco
General Information
Operation overview
Lifting Sling Hanger Bracket Pin

and Retainer
Slip Hanger Bracket
Remove the Hanger Bracket Pin

and Retainer
to Remove Slip Assemblies
from FSA
Slip and
Hanger Assembly
Slip Assembly
FSA 1-13
General Information
Installation considerations
Installing the FSA involves the following:
1 1. Preparing the Foxhole®

2. Installing the FSA and connecting the control system.
3. Function testing the FSA
Preparing the Foxhole ®

The FSA sits on top of the Foxhole®. Two 1 1/2 in. guide pins (Varco supplied) position
the FSA in the proper location.
Installing the FSA

To install the FSA:
Position the FSA above the Foxhole®.

1. Connect the air lines. (See the pneumatic schematic in the Technical Drawing
book.)
2. Lower the FSA onto the guide pins.
The FSA is held in position by its own weight. The guide pins assure the FSA is in the
appropriate location to avoid fouling or damaging the air supply hoses.
Connecting the control system

See the Foxhole® Slips Installation Kit drawing for mounting instructions, and the
Foxhole® Slips Interconnect Diagram located on the Installation Kit drawing in the
Technical Drawing Package to connect the control system as follows:
1. Attach the control valve plate assembly to the rig structure.
2. Connect the rig air supply to the 1/2 in. NPT ball valve located on the control valve
plate assembly.
3. Connect the rig electrical supply to the J-box located on the control valve plate
assembly.
4. Connect the control valve plate assembly to the FSA with customer-supplied 1/2
in. air hoses.
5. Open the inlet ball valve adjacent to the supply filter/regulator assembly.
6. Set the supply filter/regulator to 90 psi.
7. Set the release regulator to the minimum required to raise the leveling beam.
1-14 Varco
General Information
Installation considerations
Function testing
To function test the FSA: 1
1. Make sure the air hose and QDs are firmly attached.
2. Turn on the power to the FSA.
3. Cycle the FSA control switch to OPEN and CLOSE several times.
4. Verify that the FSA is operating correctly in relation to the operator switch position,
i.e., the FSA is in the up position when the switch is in the raised (OPEN) position;
the FSA is in the down position when the switch is in the “slips set” (CLOSED)
position.
5. Verify that it takes at least 1 1/2 seconds for the slips to raise.
6. If the slips raise up too fast in step 5, reduce the available pressure at the release
regulator on the control panel assembly. Repeat step 5.
FSA 1-15
General Information
1-16 Varco
Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Physical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 1
Performance specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pneumatic specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
FSA
Specifications
Varco
Specifications
Specifications
Physical specifications
Size: Height (Retracted) 29.0 in. (737 mm)
(Extended) 46.0 in. (1,168 mm)
Diameter 36 in. (914 mm)

2
Travel Leveling beam 17 in. (432 mm)
Weight 2,600 lb (1179 kg)
Performance specifications
Tubular range Diameter 3 1/2 to 14 in. in three ranges:
•3 1/2 t0 8 1/4 in.
(Three sets of slips are
required to cover the full
•5 to 9 3/4 in.
tubular range.) •9 5/8 to 14 in.
Load capacity Safe working load (SWL) 22,000 lb (9988kg)
Electrical specifications
The air solenoid requires a 24 VDC control signal.
Pneumatic specifications
90 psi (6.1 BAR) minimum
FSA 2-3
Specifications
2-4 Varco
Maintenance
General maintenance practices . . . . . . . . . . . . . . . . . . . 3-3

Equipment maintenance records . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Inspection procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Inspecting load-carrying components . . . . . . . . . . . . . . . . . . . . . 3-4
Lubrication procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
2
FSA
Maintenance
Varco
Maintenance
General maintenance practices
Equipment maintenance records

i
components. See the supplier manuals for maintenance
procedures and schedules for the vendor equipment.
3
Safety precautions
this manual.

Do not attempt any adjustments while the machine is

moving.

warnings before performing maintenance procedures.
FSA 3-3
Maintenance
Inspection procedures
warrant more frequent inspection intervals. Perform the maintenance procedures
indicated, as warranted by the inspection.
Inspecting load-carrying components

deterioration. If you detect any excessive wear and tear on any component, replace the
component.
3 installation manager and by local regulatory requirements.
3-4 Varco
Maintenance
Inspection procedures
Air Cylinders (3) Guide Rod Seals (3)
Fasteners
Guide Pins (24)
Extention Springs (12)

Main Body
Slip Assembly
Circular Buttons (36)
Cotter Pins (30)
FSA 3-5
Maintenance
Lubrication procedures
!
Failure to maintain adequate lubrication could result in
equipment damage.
!
Failure to thoroughly clean grease fittings before applying
3 grease can cause foreign matter to be injected into the
fitting, causing equipment damage.
Recommended lubricants
Recommended hydraulic fluids
Manufacturer -15° to 75° C -10° to 85° C

(5° to 167° F) (14° to 185° F)
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity 32 46
Grade
3-6 Varco
Maintenance
Recommended lubricants
Recommended general purpose lubricants

Castrol - MP Grease

3
Mobil Mobilux EP1 Mobilux EP2
Viscosity Index
NGLI 1 2
FSA 3-7
Maintenance
When in use, lubricate the following components every three or four days.
1. Extend the FSA to expose internal components.

2. Lubricate the leveling beam guide rods (3) by wiping the rods down and applying
fresh waterproof grease.
3. Fill the lubricator on the control panel using SAE 10 mineral-based oil.
3-8 Varco
Troubleshooting
Troubleshooting fault symptoms . . . . . . . . . . . . . . . . . . 4-3

Running diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Helpful documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
FSA
Troubleshooting
Varco
Troubleshooting
Troubleshooting fault symptoms

Electrical components
Pneumatic components
this chapter.
i
causes, and which components to check as the most likely
candidates causing the fault.
Running diagnostics
Diagnostics is a valuable troubleshooting tool. Use the instructions contained in the
4
V-ICIS Users Manual to run diagnostics.
Helpful documents
The Technical Drawings Package contains assembly drawings for component locations,
and electrical and pneumatic schemetic diagrams for signal tracing.
FSA 4-3
Troubleshooting
Troubleshooting


Slips fail to open or close No 24 VAC to pneumatic Turn on electrical power.
without a tubular solenoid.
Improper air supply to the FSA Supply proper air pressure.
Leaky air cylinder or air lines. Check air cylinders and air lines.Repair or
4 replace as necessary.
Binding caused by bent or Check guide rods and air cylinders. Repair
damaged guide rod or air or replace as necessary.
cylinder.
Slips fail to open while Excessive weight on the FSA Reduce weight to the safe working load
gripping a tubular (SWL) of 22,000 lb (9988 kg).
Improper air supply to the FSA Supply proper air pressure.
Leaky air cylinder or air lines. Check air cylinders and air lines.Repair or
replace as necessary.
Binding caused by bent or Check guide rods and air cylinders. Repair
damaged guide rod or air or replace as necessary.
cylinder.
4-4 Varco
Glossary
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
1
FSA
Glossary
Varco
Glossary
Definitions
The following are definitions of the acronyms, abbreviations, and terminologies that may
be used in this manual. Standard acronyms and abbreviations, such as vac, vdc, in., ft-
lb, etc., and industry-standard terminologies are not listed.
FSA - Foxhole® Slip Assembly

QD - QuickDisconnect connector on pneumatic hoses/lines
SWL - Safe Working Load.
TDP - Technical Drawing Package
FSA 5-3
Glossary
5-4 Varco
This document contains proprietary
information, and such information REVISIONS
may not be disclosed to others for any Letter DESCRIPTION Prepared Checked Approved Date
purpose nor used for manufacturing
purposes without written permission R. Mooers T. Montgomery T. 1/14/03
from VARCO INTERNATIONAL INC. - RELEASE Montgomery
A See DCN Mar.Garcia R. Mooers R. Mooers 12-4-03
30171934 – 1 RECOMMENDED COMMISSIONING SPARES
30171934 – 2 RECOMMENDED OPERATIONAL SPARES
30171934 – 3 - *** RECOMMENDED INSURANCE SPARES

SEE NOTE 1
NOTES:
1. ADDITION OF A SUFFIX TO THE INSURANCE SPARES LIST NUMBER

INDICATES THE CERTIFYING AUTHORITY THAT APPLIES TO THE HYDRAULIC
CYLINDERS.
-ABS FOR AMERICAN BUREAU OF SHIPS

-DNV FOR DET NORSKE VERITAS
-LLD FOR LLOYD’S REGISTER
EXAMPLE:
30171934-3-ABS SPECIFIES THE COMMISSIONING SPARES FOR AN ABS PRS-
8i.
IF THE CERTIFYING AUTHORITY NOT APPLICABLE, USE –DNV.
2. ADD CERTIFYING AUTHORITY DESIGNATION TO SPECIFY THE NOTED

HYDRAULIC CYLINDER.
EXAMPLE:
ITEM 13, 131827-ABS CYLINDER ASSEMBLY FOR AN ABS PRS-8i.
3. THE 30171934 - 3 - *** INSURANCE SPARES ARE THOSE PARTS THAT MAY
NOT BE STOCKED IN HOUSE AND HAVE LONG DELIVERY LEAD TIMES.
APPLICATION TITLE Mechanical Spare

Parts List PRS-8i
Next Assy Product DATE
FINAL PRS-8i Prepared R. Mooers 1/14/03 Document No.
Checked T. Montgomery 30171934
Project Engr. T. Montgomery Size A Scale N/A
Group Mgr. N/A SHEET _1_ of 5
Item Part No Description Commissioning Operational Insurance Part No. Description Probability Lead
-1 -2 -3 of Failure Time
1 2633 Insert, Die 6 131690 Lift Jaw Asy High Short

2 83450 Spring, Die 4 131690 Lift Jaw Asy Low Short
3 88909 Carrier, Die 2 131690 Lift Jaw Asy Low Short
4 88962 Keeper, Insert 2 131690 Lift Jaw Asy Low Short
5 96388 Sensor, Proximity -15mm 1 1 131962 Compensator Asy High Short
6 115889 Seal, Lip 1 131936 Driveshaft Assy. Med Med
7 115890 Seal, Lip 1 131936 Driveshaft Assy. Med Med
8 115960 Bearing, Tapered Roller 2 131936 Driveshaft Assy. Med Long
9 118648 Sleeve, Carrier 4 131690 Lift Jaw Asy Low Long
10 116920-325 Retaining Ring 1 131936 Driveshaft Assy. Med Long
11 119974-1 Roller 2 131690 Lift Jaw Asy Low Long
12 128944 Brake, Universal Input 1 131936 Driveshaft Assy. Med Med
13 131827-XXX Cylinder Assy, Hydraulic -Grip Arm 1 131690 Lift Jaw Asy Med Long
SEE NOTE 2
13a 131827-SK1 Seal Kit 1 131827-LLD Cyl. Assy. Hyd.-Grip Arm. Med Short
13b 131827-RK1 Repair Kit (Includes Rod Bearing) 1 131827-LLD Cyl. Assy. Hyd.-Grip Arm. Med Short
14 131828 Cylinder Assy, Hydraulic -Roller 1 131690 Lift Jaw Asy Low Long
Arm
14a 131828-SK1 Seal Kit 1 131828 Cyl. Assy. Hyd.-Roller Med Short
Arm.
14b 131828-RK1 Repair Kit (Includes Rod Bearing) 1 131828 Cyl. Assy. Hyd.-Roller Med Short
Arm.
15 131829 Cylinder Assy, Hydraulic -Claw 1 131690 Lift Jaw Asy Low Long
15a 131829-SK1 Seal Kit 1 131829 Cyl. Assy. Hyd. Claw Med Short
15b 131829-RK1 Repair Kit (Includes Rod Bearing) 1 131829 Cyl. Assy. Hyd. Claw Med Short
16 30131846 Gearbox, Planetary -Slew 1 131936 Driveshaft Assy. Med Long
17 131900 Motor, Travel and Hoist 1 131936 Driveshaft Assy. Med Long
18 131901 Motor, Slew 1 131936 Driveshaft Assy. Med Long
19 131912-XXX Cylinder, Arm Extension 1 131687 Column Assembly Low Long
SEE NOTE 2
19a 131912-SK1 Seal Kit 1 131912-LLD Cylinder, Arm Extension Med Short
19b 131912-RK1 Repair Kit (Includes Rod Bearing) 1 131912-LLD Cylinder, Arm Extension Med Short
20 131913-XXX Cylinder, Jaw Alignment 1 131936 Driveshaft Assy. Low Long
SEE NOTE 2
20a 131913-SK1 Seal Kit 1 131913 Cylinder, Jaw Alignment Med Short
20b 131913-RK1 Repair Kit (Includes Rod Bearing) 1 131913 Cylinder, Jaw Alignment Med Short
21 131916 Gearbox, Planetary -Travel 1st 1 131936 Driveshaft Assy. Low Long
Stage
22 131931 Gearbox, Hoisting -First Stage 1 131936 Driveshaft Assy. Low Long
30171934 PRS-8i Mechanical Spare Parts Rev. A Page 2 of 5
23 131932 Gearbox, Hoisting -Second Stage 1 131936 Driveshaft Assy. Low Long
24
25 30131953 Seal, V-Ring 1 131936 Driveshaft Assy. Low Long
26 30131960 Cylinder, Hydraulic 1 131962 Compensator Asy Low Long
26a 108894-LG13 Rod Seal & Gland Kit 1 131960 Cylinder Hydraulic Med Short
26b 108894-LP20 Piston Seal Kit 1 131960 Cylinder Hydraulic Med Short
26c 108894-B20 Body Seal Kit 1 131960 Cylinder Hydraulic Med Short
27 131971 Bearing, Drive Shaft Dampener 2 131936 Driveshaft Assy. Low Long
28
29 131993 Cylinder, Hydraulic -1-1/2 Bore X 1 131692 Claw Assembly Med Long
4.38 Stroke
29a 108894-R10 Rod Seal Kit 1 131993 Cylinder, Claw Med Short
29b 108894-P15 Piston Seal Kit 1 131993 Cylinder, Claw Med Short
29c 108994-B15 Body Seal Kit 1 131993 Cylinder, Claw Med Short
30
31
32 119001-04 Roller, Cam Follower 2 131693, Lower Drive Assy., Upper Med Long
131850 & Drive & Column Assembly
131687
33
34
35 119001-06 Roller, Thrust 4 131693 Lower Drive Assy. Med Long
36 119002-03 Roller, Side 1 1 131689 Carriage Assembly Med Long
37 119002-04 Roller, Side 2 131850 Upper Carriage Med Long
38 131838-1 Gearbox, Planetary -Lower Travel 1 131693 Lower Drive Assy. Low Long
38a 131838-2 Gearbox, Planetary -Upper Travel 1 131850 Upper Carriage Low Long
39 30156245- Transducer, Linear 1 1 131936 Driveshaft Assy. Med Long
0305
40 30156245- Transducer, Linear 1 1 131936 Driveshaft Assy. Med Long
0765
41 131999 Wiper, Piston Rod 1 131692 Claw Assembly Med Long
42 132000 Seal, Piston Rod 1 131692 Claw Assembly Med Long
43 132001 Seal, Piston 1 131692 Claw Assembly Med Long
44 132002 Wear Strip, Piston Rod 2 131692 Claw Assembly Med Long
45 132003 Wear Strip, Piston 2 131692 Claw Assembly Med Long
46 112554-D2 Valve Directional Control 2 Pos. 2 2 131968 & Mfd Inlet Filter & Mfd Lr. Med Long
131967 Arm
47 92537-E-216 Element, Filter 1 4 131968 Manifold Inlet Filter High Short
48 92537-SK Seal Kit 1 1 131968 Manifold Inlet Filter High Short
49 112554-J2 Valve Directional Control 3 Pos. 2 4 131967 & Mfd. Lower & Upper Arm Med Long
131965
50 109858-IDN Reducing Valve, Direct 2 2 131967 & Mfd. Lower & Upper Arm Med Short
131965
51 123235-PC1 Reducing Valve, Proportional 1 1 131966 & Valve Lower & Upper Arm Med Long
131964
52 131670-AK22 Seal Kit 4 4 131966 & Valve Lower & Upper Arm Med Short
131964
53 107631-2AN Valve, Sequence 2 2 131966 & Valve Lower & Upper Arm Med Short
131964
54 131733-2N Element, Filter 2 2 131966 & Valve Lower & Upper Arm Med Short
131964
55 30152691- Service Loop Upper 1 131694 Upper Arm/Mech Inst. Kit Med Med
501
56 30132069- Lower Power Service Loop 1 131694 Lower Arm/Mech. Inst. Kit Med Med
501
57 30152692- Lower N.I.S. Service Loop 1 131694 Lower Arm/Mech. Inst. Kit Med Med
501
58 30151272 Assembly, Encoder Adapter 1 131687 Column Assembly High Long
59 30155842 Encoder 1 1 132128 Assembly, Encoder High Long
Adapter
60 131942 Bearing, Idler 4 132128 Assembly, Encoder Med Short
Adapter
61 30131600 Timing Belt 2 132128 Assembly, Encoder Med Short
Adapter
62 132088 Kit, Journal & Bearing 2 132093 Drive Shaft Assembly Med Short
63 118834- Bearing, Sheave 1 131689 & Carriage & Column Med Med
RBSC 131687 Assemblies
64 108894-P32 Piston Seal Kit 1 131990 Claw Piston Med Short
65 118844-56-64 Bushing 2 131687 Column Assenbly Med Short

66 118844-40-36 Bushing 4 131687 Column Assenbly Med Short
67 118836-40-60 Thrust Washer 8 131687 Column Assenbly Med Short
68 118844-36-36 Bushing 2 131690 & Assembly, Lift Jaw & Med Short
131692 Assembly, Claw

70 118844-24-32 Bushing 2 131690 Assembly, Lift Jaw Med Short
73 118836-20-36 Thrust Washer 6 131692 Assembly, Claw Med Short
74 131893-48 Rack, Gear 2 131684 & Upper and Lower Track Low Long
131695 Assemblies
75 131840 Locking Device 1 131850 & Upper Drive Carriage and Low Long
131693 Lower Drive
76 51300-250-B O-Ring 1 131915 Parallel Gearbox Low Med
79 132007 Seal, Lip 1 131915 Parallel Gearbox Low Med
83 131920 Bearing, Input 1 131915 Parallel Gearbox Low Long
84 131921 Bearing, Roller 1 131915 Parallel Gearbox Low Long
85 131923 Bearing, Output 1 131915 Parallel Gearbox Low Long
86 30131928 Shaft, Input 1 131915 Parallel Gearbox Low Long
87 30131929 Shaft, Output 1 131915 Parallel Gearbox Low Long
88 131930 Chain, Gearbox 1 131915 Parallel Gearbox Low Long
89 131845 Bearing, Turntable 1 131693 Lower Drive Assy Low Long
90 30131839 Pinion, Drive 1 131693 Lower Drive Assy Med Long
91 30131842 Seal, V-ring 4 131693 Lower Drive Assy Low Med
92 131837 Bushing 4 131693 Lower Drive Assy Med Med
93 131847 Gear, Pinion -Rotation 1 131687 Column Assembly Low Long

PRS-8i (MTC)
ELECTRICAL SPARES LIST
GENERIC
NOTES:
1. 30177849-1 Recommended Commissioning Spares
2. 30177849-2 Recommended Operational Spares
3. 30177849-3 Recommended Insurance Spares
COPYRIGHT © VARCO INTERNATIONAL, INC 2005

ALL RIGHTS RESERVED
THIS DOCUMENT MAY NOT BE COPIED OR REPRODUCED IN ANY WAY
WITHOUT THE WRITTEN CONSENT OF VARCO. VARCO OWNS ALL
RIGHTS TO THIS WORK AND INTENDS TO ENFORCE ITS RIGHTS
UNDER THE COPYRIGHT LAWS AS A PUBLISHED WORK. TITLE
CURRENT INITIAL ELECTRICAL SPARES LIST
DRAWN
M. MARONEY M. MARONEY PRS-8i (MTC), GENERIC
CHECKED
D. SUMMERS D. SUMMERS
SIZE DWG NO REV
APPVD
D. SUMMERS D. SUMMERS A 30177849 A
DATE NONE 1 OF 3
10/31/07 6/01/05 SCALE WT LBS SHEET
DCF0045
(REV A)
-1 -2 -3
Recom. Recom. Recom.
Commission Operational Insurance Where Description
Part No. Description Spare Spare Spare Used Where Used
94635-35 Isolator Switch, 2-Pole - 1 - 30177661 VFD Assembly

94635-136 System Start / Reset - - 1 30177661 VFD Assembly
141556-6 Fan 1 30177661 VFD Assembly
141556-7 Filter 1 30177661 VFD Assembly
123577-1 Relay 24VDC DPDT 5A @ - 1 - 30177661 VFD Assembly
250VAC
123577-5 Relay 24VDC 4 Pole 3A 1 30177661 VFD Assembly
116054-2 Fuse 10A - 1 - 30177661 VFD Assembly
94635-115 Hammond Transformer, - - 1 30177661 VFD Assembly
240/480: 120/240 VAC
3.0kVA
123377-18 Solid State Circuit Breaker - - 1 30177661 VFD Assembly
300A (Set to 175A)
30157674-250 Contactor 250A - - 1 30177661 VFD Assembly
116054-37-14 Output Reactor (11kW - - 1 30177661 VFD Assembly
Motor)
116054-37-15 Output Reactor (17kW - - 1 30177661 VFD Assembly
Motor)
116054-E100-5 Snubber 250VAC - - 1 30177661 VFD Assembly
116054-DC110-11 SS Outdoor Brake Resistor - - 1 30177661 VFD Assembly
4.0 ohm P20 100kW
116054-DC110-4 Brake Chopper P20 100Kw - - 1 30177661 VFD Assembly
116054-DC110-1 Rectifier 110kw - - 1 30177661 VFD Assembly
122627-75 Front Connector, Screw 1 - 1 30177661 VFD Assembly
Terminal, 40 Pins
116054-DC-8 OP1S Operator Control - - 1 30177661 VFD Assembly
Panel
116054-37-13 Drive, 37kW - - 1 30177661 VFD Assembly
116054-S100-5 Profibus Communications 1 - 1 30177661 VFD Assembly
Board
116054-S100-6 Simolink Communications 1 - 1 30177661 VFD Assembly
Board
94635-131 Motor Thermistor Protection - - 1 30177661 VFD Assembly
Unit 240 VAC Supply
116054-55-10 Fuse 200A (INC 2 Spare) 2 2 - 30177661 VFD Assembly
116054-55-9 Fuse 160A 2 4 - 30177661 VFD Assembly
123377-1 Circuit Breaker Double Pole - - 1 30177661 VFD Assembly
480 VAC 4A
480 VAC 1A
480 VAC 5A
480 VAC 8A
480 VAC 2A
122627-74 Digital Output Module (32 1 - 1 30177661 VFD Assembly
Channel), SM322
94638-33 Power Supply 24VDC@20A - - 1 30177661 VFD Assembly
122627-73 Digital Input Module (32 1 - 1 30177661 VFD Assembly
Channel), SM321
SIZE DWG NO REV
A 30177849 A
SCALE NONE WT LBS SHEET 2 OF 3
DCF0045
(REV A)
118910-7 Phoenix Relay, 24V (E-Stop) - 1 - 30175349 Derrick Rem Pow. J-Box
-1 -2 -3
Recom. Recom. Recom.
Commission Operational Insurance Where Description
Part No. Description Spare Spare Spare Used Where Used
114054-3110 Thermostat, 24-230VAC/24- - - 1 30175349 Derrick Rem Pow. J-Box

60 VDC
114054-3107 Rittal, Heater Electric - - 1 30175349 Derrick Rem Pow. J-Box
122627-02 Siemens Power Supply, 10A, - - 1 30175349 Derrick Rem Pow. J-Box
Sitop
122627-01 Siemens Power Supply, 5A, - - 1 30175349 Derrick Rem Pow. J-Box
Sitop
122627-27 Front I/O Connector, 20 pin - - 1 30175349 Derrick Rem Pow. J-Box
122627-91 RS-485 Repeater - 1 1 30175349 Derrick Rem Pow. J-Box
122627-59 8DI/DO Module SM323 1 - 1 30175349 Derrick Rem Pow. J-Box
122627-112 Siemens, Optical Link 1 - 1 30175349 Derrick Rem Pow. J-Box
Module/G12
122627-92 Profibus Bus Connector 1 2 - 30175349 Derrick Rem Pow. J-Box
30180836-3 Bartec Profibus Coupler - 1 1 30158472 Upper Arm Rem I/O J-

Box
140244 Profibus, 16 x Digital Output 1 - 1 30175459/ Upper Arm Rem / Tail.
Module (N.I.S) 30158472 Arm Rem I/O J-Box
140698 Profibus, 16 x Digital Input 1 - 1 30175459 Tail. Arm Rem I/O J-Box
Module (I.S.)
30180836-3 Bartec Profibus Coupler - 1 1 30175459 Tail. Arm Rem I/O J-Box
30156246 Profibus Proportional 1 - 1 30158227 Tailing Arm Electronic

Solenoid Driver Driver J-Box
122627-34 Simatic S5/S7 Profibus - - 1 30158227 Tailing Arm Electronic
Connector Driver J-Box
131900 17kW Motor - - 1 30157884 PRS-8i Tool

131901 11kW Motor - - 1 30157884 PRS-8i Tool
112554-D2 Hydraulic Solenoid Valve 1 2 - 30157884 PRS-8i Tool
123235-PC1 Proportional Solenoid 1 1 - 30157884 PRS-8i Tool
83095 Pressure Switch 1 1 - 30157884 PRS-8i Tool
30156245-0765 Linear Transducer Lower 1 1 - 30157884 PRS-8i Tool
Arm
30155842 Abs. Encoder Profibus 1 2 - 30157884 PRS-8i Tool
84882-2 Proximity Sensor 1 2 - 30157884 PRS-8i Tool
96388 Proximity Sensor 1 2 - 30157884 PRS-8i Tool
30156245-0305 Linear Transducer Lower 1 1 - 30157884 PRS-8i Tool
Jaw
112554-J2 Hydraulic Solenoid Valve 2 4 - 30157884 PRS-8i Tool
SIZE DWG NO REV
A 30177849 A
SCALE NONE WT LBS SHEET 3 OF 3
DCF0045
(REV A)
MECHANICAL SPARES KIT
FOXHOLE SLIP ASSEMBLY
NOTES
1. RECOMMENDED COMMISSIONING SPARES, 30175005-1
RECOMMENDED OPERATIONAL SPARES, 30175005-2
RECOMMENDED INSURANCE SPARES, 30175005-3
2. INSURANCE SPARES ARE THOSE PARTS THAT MAY NOT BE STOCKED AND HAVE LONG DELVERY LEAD
TIMES
DCF00019 (REV B )
THIRD ANGLE CRITICAL LOAD CERTIFICATION
COMMISSIONING OPERATIONAL
PROJECTION PART FLAGS TRACEABILITY PATH ITEM REQUIRED SPARE PART INSURANCE
UNLESS OTHERWISE SPECIFIED THIS DOCUMENT CONTAINS PROPRIETARY

INTERPRET DIMENSIONS & INFORMATION, AND SUCH INFORMATION MAY NOT BE
TOLERANCES PER ANSI Y14.5 & DISCLOSED TO OTHERS FOR ANY PURPOSE NOR USED FOR
ABBREVIATIONS PER ANSI Y1.1 MANUFACTUING PURPOSES WITHOUT WRITTEN
.X +.1 CAN BE *TORCH CUT PERMISSOIN FROM VARCO INTERNATIONAL, INC.
.XX +.030 .XXX +.010
ANGULAR TOLERANCE +0 30’ TITLE
SURFACE FINISHES
MACHINED *TORCH CUT KIT, SPARES, FOXHOLE SLIP
250 MAX 1000 MAX ASSEMBLY -SAKHALIN
FSA
DIMENSIONS ARE IN INCHES DRAWING NO.
NEXT ASSY PRODUCT SIZE REVISION
DO NOT SCALE DOCUMENT
30175005 -
A
T. MONTGOMERY SCALE WEIGHT LB SHEET OF
- DA. YENZER DA. YENZER 7/16/04
1/1 N/A 1 3
LTR PREPARED CHECKED APPROVED DATE
Item Part Description -1 -2 -3 Where
Recommended Recommended Recommended
Number Used
Commission Spares Operational Insurance
Spares Spares
Mechanical Components
1 11883 Filter-Regulator 1 96403-6 Control Plate Assy.
2 11883-3 Gauge, Pressure, Pneumatic 1 1 96403-6 Control Plate Assy.
3 88549 Regulator 1 96403-6 Control Plate Assy.
4 105955-800-B Valve, Check 1 1 96403-6 Control Plate Assy.
5 56408-24-C Pin, Clevis 2 6 128027 Foxhole Slip Assy
6 120963 Rod, Leveling Beam 1 128027 Foxhole Slip Assy
7 121157 Seal, Spring Loaded 3 128027 Foxhole Slip Assy
8 141641 Pin, Hanger Bracket 2 6 128027 Foxhole Slip Assy
9 30121461 Pin , Retainer 2 6 128027 Foxhole Slip Assy
Note: Items 10 thru 16 are sufficient to re-build one slip

hanger assembly.
10 120966 Pin, Hanger 4 128027 Foxhole Slip Assy
11 51435-12 Pin, Cotter 4 128027 Foxhole Slip Assy
12 120962 Slip Hanger 2 128027 Foxhole Slip Assy
13 121457 Spring, Extension 2 128027 Foxhole Slip Assy
14 121524 Bushing, Flanged 8 128027 Foxhole Slip Assy
15 120967 Bracket, Slip Hanger 1 128027 Foxhole Slip Assy
16 128035 Bracket, Slip 1 128027 Foxhole Slip Assy
17 120964 Cylinder, Pneumatic 1 120960 Foxhole Slip Assy
18 114382-NG13 Seal Kit, Gland 3 120964 Foxhole Slip Assy
19 114382-NP32 Seal Kit, Piston 3 120964 Foxhole Slip Assy
20 114382-NR13 Seal Kit, Rod 3 120964 Foxhole Slip Assy
30175005 Rev. - Spares Kit, Foxhole Slip Assembly 2 OF 3

Item Part Description -1 -2 -3 Where
Recommended Recommended Recommended
Number Used
Commission Spares Operational Insurance
Spares Spares
21 118844-32-32 Bushing, Fiberglide, 2.00 ID x 2.00 6 120964 Foxhole Slip Assy
22 2630 Button, Circular 12 72 128028 Slip Assemblies
23 128030 Slip Body, 9-5/8 to 14 1 128028 Slip Assemblies
24 128031 Slip Body, 5 to 9-3/4 1 128028 Slip Assemblies
25 30156173 Slip Body, 2-3/8 to 6-5/8 1 128028 Slip Assemblies
30175005 Rev. - Spares Kit, Foxhole Slip Assembly 3 OF 3


may not be disclosed to others for any REV DESCRIPTION Prepared Checked Approved Date
purposes without written permission - INITIAL RELEASE J. JENSEN WALLIHAN WALLIHAN 8/30/02
from VARCO INTERNATIONAL INC.
PRS-8i
COMMISSIONING
PROCEDURE
APPLICATION PRS-8I
COMMISSIONING
Next Assy Product PROCEDURE DATE
30153853 PRS-8i Prepared By: J. JENSEN 8/30/02 Document No.
30153402 PRS-8i Checked By: B. WALLIHAN 8/30/02 3FIP00248
Approved By: B. WALLIHAN 8/30/02 Size A Scale: NONE
Page 1 of 14
SCOPE:
This procedure defines the commissioning tests for a fully installed PRS-8i.
SECTION 1 – GENERAL INSPECTION

___1.1 Check mechanical connections on the tool and in the derrick are
satisfactory. Specifically, note pneumatic and hydraulic service loop connections are
free of leaks and routed to minimize potential damage.
___1.2 Check electrical connections on the tool and in the derrick are satisfactory.
Specifically, note glands and J-box terminations are secure, and verify service loops are
routed to minimize potential damage.
___1.3 Check the fingerboard and operational area is clear of cables, ropes, debris
or other equipment that might be damaged by or fouled in the PRS-8i. Resolve any
deficiencies prior to operation.
___1.4 Verify that all appropriate electrical loop checks have been performed.
___1.5 All auxiliary piping shall be cleaned, passivated and hydrostatically tested,
according to customer requirements.
___1.6 Inspect the auxiliary piping installations and check for adequate pipe
hangers, completeness, welding quality and system tightness.
___1.7 Disconnect the motor conductors at the Control System (CS) and megger
each conductor with respect to ground. Each conductor should have at least 5 mega-
ohms resistance. Megger between phase A & B, A & C, and B & C to insure a good
circuit. This resistance should be near zero (0). Reconnect conductors to proper
terminals.
PRS-8I
COMMISSIONING REV: -
PROCEDURE
Document No. 3FIP00248 Page 2 of 14
___1.8 Disconnect each Positive Temperature Coefficient (PTC) amplifier

conductors in the CS panel. Verify the resistance between each PTC is approximately
250 ohms. Reconnect to proper terminals.
___1.9 Verify that the motor heaters are operational by measuring the voltage
across the terminals in Tailing Arm Junction Box EJB 310 to verify 230 VAC present.
Lift one of the conductors from the motor side of the terminals in EJB 310 and measure
the resistance across the heater. Resistance should be 1.5k ohms:
Lower Drive
Hoist A
Hoist B
Rotate
___1.10 Check for proper operation of each proximity switch by passing a metallic
object across the face of the sensor and verifying operation of the input status of the
indicator lights on associated remote I/O modules.
___1.11 From the Network Monitor Applet on a laptop computer, verify that the
network is operational and that each node is active.
___1.12 With the VFD’s deactivated and the hydraulic power off, use the Monitor
Applet on a laptop computer to verify all chair functions are operating properly.
___1.13 From the Monitor Applet on a laptop computer, verify that there is a
position count value being received from each of the four rotary absolute encoders.
___1.14 From the Monitor Applet on a laptop computer, verify that there is a
position count value being received from the each jaw and arm position transducer.
PRS-8I
PROCEDURE
SECTION 2 – INITIAL CONFIGURATION
Verify services are provided to the tool, including electric, hydraulic, and pneumatic
power.
At least two stands (triples) of 5-1/2” and 6-5/8” drill pipe and two stands of drill collar
are needed to complete this procedure as written. Note differences in actual tubular
used.
• PRS-8i arms fully retracted, not holding pipe.

• Fingerboard “From/To” area setup, and a stand located in the “active” slot.
• Automated Roughneck on, taught at well center, and at the home position. (See
Automated Roughneck manual)
PRS-8I
PROCEDURE
SECTION 3– OVERALL RACKER OPERATION
_____3.1 – Overall Function Test
1) Operate Hoist Jaw and Lower Claw:
Hoist Jaw (Upper Arm):
The PRS-8i comes standard with hoist jaw capable of handling 2 7/8” to 9 ¾ inch
OD tubulars.
Open and close the grip jaw. Verify grip jaw accommodates the 2 7/8 to 9 ¾ inch
OD tubular range. Verify proper alignment and smooth operation of this function.
Open and close the roller jaw. Verify roller jaw accommodates the 2 7/8 to 9 ¾
inch OD tubular range. Verify proper alignment and smooth operation.
Open and close the claws. Verify closed inside diameter is greater than 9 ¾”.
Lower Arm Claw:
Actuate the claw latches and tilting functions. Verify that the claw’s opening
accommodates the 2 7/8” to 9 ¾” OD tubular range. Verify proper alignment and
smooth operation. Verify the claw tilting function is between a horizontal position
and 40 degrees.
2) Extend/Retract Hoist Arm and Lower Arm:
With no payload in the hoist jaw, extend and retract both the hoist arm and lower
arm over their entire range. Verify proper alignment and smooth operation of
function and stroke.
PRS-8I
PROCEDURE
3) Hoisting & Lowering:
With no payload in the hoist jaw, hoist and lower the hoist carriage over its range.
Verify proper alignment and smooth operation of function and stroke. Verify
hoist stroke is clear of all derrick interference throughout its entire range
4) Slew/Rotate the Column:
With no payload in the hoist jaw and both arms fully retracted, slew the lower
drive rotation gearbox through its entire range. Verify proper alignment and
smooth operation of function and slew stroke.
5) Traverse the Column:
With no payload, drive the column from the forward most possible point of the
lower drive tracks to the rear most possible. Verify proper alignment and smooth
operation of this function. Verify there is no derrick interference.
PRS-8I
PROCEDURE
_____3.2 – Static Proof Load Test
Static Proof Load testing of the PRS-8i will be accomplished by lifting a load
“platform” and the hoist jaw will be situated at a distance equal to the max
operational arm reach permitted with the maximum operational payload (144
inches as measured from center of column rotation to center of jaw/tubular). Use
a 9 ¾” to 9 ½” DC simulator suspended in the hoist jaw and connected to the load
platform. The load test will be performed at 3 hoist carriage elevations relative to
the rig floor: near the lowest position, near the carriage mid-stroke and near the
highest position. In each case the load will be held for 2 minutes to validate the
structural integrity of the PRS-8i. Static proof load to be applied to PRS-8i
system is 1.25 x max operational load (22,000 lbs) = 27,500 lbs.
Lowest Carriage Position:
Load the hoist jaw/hoist arm assembly with static proof load. Hold this load for 2
minutes. Remove the load.
Mid Column Carriage Position:
Highest Carriage Position:
PRS-8I
PROCEDURE
_____3.3 – Abnormal/Extreme Condition Test
The purpose of this test is to demonstrate that the redundant load path system will
hold the full rated load with one hoist path active. This will be done
demonstrating its static ability to hold the full 22,000 lbs. rated load on one load
path and demonstrate the ability to stop the full rated load of 22,000 lbs. when
lowering at a slow speed. For safety, this test should be performed at well center
with the elevators attached to the stand of drill collar.
3.3.1) Static Load Test
With the rated load of 22,000 lbs. suspended from the grip jaw, with both motors
active, raise the load approximately 4” clear of rig floor. With the power unit
running, manually hydraulically release one of the hoist brakes by depressing the
manual valve override corresponding to that brake. Verify that one wire rope goes
slack and that the load is held clear of the floor by the other hoist path.
3.3.2) Dynamic Testing
Hoist the full load of 22,000 lbs. approximately 3’ clear of rig floor. While
lowering at slow speed of approximately 2”/second, manually depress the manual
valve override corresponding to one of the brake circuits. While manually
maintaining this valve depressed, move the hoist/lower joystick to its center
position to stop downward motion. Verify that the load stops moving and is clear
of the rig floor.
PRS-8I
PROCEDURE
_____3.4 – Building Stands with PRS-8i and Installed Handling Equipment
On the HMI screen, select the Building Stands Mode, Pipe for the following
procedure.
Using the Mousehole, PLS-3, and Automated Roughneck, build a double of drill
pipe at the mousehole.
Once the double is built, use the PRS-8i to raise the double out of the mousehole.
Position the PRS-8i so the jaws “bite” about 1/3 of the way from the top of the
double. Move the double clear of the mousehole.
Stab the third joint into the mousehole. Using the PRS-8i, stab the double on top
of the third joint, and make up the connection using the automated roughneck.
Using the PRS-8i, remove the stand from the mousehole and rack it back to an
appropriate fingerboard location.
Repeat this procedure for 5 ½” & 6 5/8” drill pipe and with 8” & 9 ¾” drill collar.
PRS-8I
PROCEDURE
____ 3.5 –Tripping Stands of Drill Pipe
On the HMI screen, select the Tripping Mode, Pipe for the following procedures:
With a single or stand of appropriate size of drill pipe suspended in the rotary
table, demonstrated a trip in and a trip out sequence by:
Moving a stand of each size of drill pipe and drill collar available from its
position in the fingerboard to well center
Stab, make up the connection with the AR4500
Hand off to the elevator and move the PRS-8i to a stand-by position.
Move the PRS-8i back to well center
Close the upper and lower pipe guides, break the connection with the AR4500
Return the stand to the fingerboard.
PRS-8I
PROCEDURE
Section 4 – SETBACK AREA ACCESSIBILITY
___ 4.1 – Slot Access Check
Ensure all latches in the slots nearest and furthest from well center on both sides
of the fingerboards are up.
While holding a stand of drill pipe, move the PRS-8i to the slot furthest away
from well center. Extend the stand to the furthest row. Ensure the stand will fit
into the slot, and extend fully without interference.
While holding a stand of drill pipe, move the PRS-8i to the slot nearest well
center. Extend the stand to the furthest row. Ensure the stand will fit in to the slot,
and extend fully without interference.
Check that the maximum size tubular fits into each fingerboard slot as designed
including collar slots. Perform the check on the other side fingerboard.
PRS-8I
PROCEDURE
Section 5 – RECOVERY FROM ABNORMAL CONDITIONS
__ 5.1 Loss of Electrical Power and Recovery
With the PRS-8i holding pipe ~ 1” off the drill floor and fingerboards on, power
down the PRS-8i including the control SBC, and fingerboard control towers.
Maintain the power shut for five (5) minutes.
Restore power to the control PC, fingerboards, and the tool itself.
Confirm that the fingerboard latches return to their prior position before power
was shut off.
Turn the PRS on. Push the open jaw pushbutton. Verify jaws do not open. Push
the jaws close button. Verify the PRS-8i will move.
__ 5.2 Loss of Hydraulic Power and Recovery
Hoist a stand of drill pipe a short distance off the deck. Fingerboard latches
should remain closed around the stand of pipe.
Remove hydraulic power to the PRS-8i (shut the supply isolation valve). Ensure
the stand remains in the jaw without dropping. Maintain hydraulics off for five
(5) minutes. (NOTE: This is not intended as proof load test for the PRS-8i.)
Restore hydraulics to the PRS-8i. Ensure the stand remains in the jaw without
dropping.
PRS-8I
PROCEDURE
SECTION 6 - EMERGENCY STOP VERIFICATION
NOTE: The following steps shall be conducted with the jaws empty; i.e. holding no
tubular.
___6.1 Using the X-Y override, Move the PRS-8i so that slew and arms move
simultaneously. While holding the joystick, push AD's or Driller's
Emergency Stop button. Verify that movement stops.
6.2 Hoist Carriage using the Carriage joystick button. While holding joystick
in Hoist Carriage position, push AD's or Driller's Emergency Stop button.
Verify that motion stops.
6.3 Lower Carriage using the Carriage joystick button. While holding joystick
in Lower Carriage position, push AD's or Driller's Emergency Stop button.
Verify that motion stops.
___6.4 Using the Traverse Override, drive to Well Center using joystick. While
holding joystick in Drive to Well Center position, push AD’s or Driller’s
emergency Stop button. Verify that motion stops.
___6.5 Using the Traverse Override. drive to Setback using joystick. While
holding joystick in Drive to Setback position, push AD’s or Driller’s
emergency Stop button. Verify that motion stops.
___6.6 During any of the above Emergency Stop Actuations, ensure all
fingerboard latches move to the latched position. Ensure latches return to
their original position following restoration from the E-Stop condition.
PRS-8I
PROCEDURE
COMPLETION ACKNOWLEDGMENT
The undersigned representatives hereby acknowledge that all checkout and testing work, as
listed herein, has been successfully completed. This acknowledgment is sufficient for the
initiation of equipment warranty coverage pursuant to Varco’s standard terms and conditions
of sale, and for approval for payment of any invoices for equipment, effective from the date
listed below. This acknowledgment in no way relieves Varco of its responsibility for the
equipment and workmanship with respect to this equipment.
Varco Representative:
Customer Representative(s):
Date:
Customer: Project:
Maersk Giant
Reference: Drawing Title:

Software Specification
Mechanical Installation
Electrical Installation
Precommissioning Procedure, PRS-8i
Installation Procedure, PRS-8i
Other (Specify ___________________)
PRS-8I
PROCEDURE
may not be disclosed to others for any
purpose nor used for manufacturing Letter DESCRIPTION Prepared Checked Approved Date
purposes without written permission
from VARCO INTERNATIONAL INC. B See DCN T. Montgomery D. Yenzer D. Yenzer 10/8/04
FUNCTIONAL DESIGN
DESCRIPTION
PRS-8i
APPLICATION TITLE DATE

Functional Design Varco Drilling
Description
PRS-8i
Equipment
Next Assy Product A Varco Company
PRS-8i Prepared: K. Marx 7/11/03 Document No. 3PS00091B
Checked: R. Mooers 7/11/03 Size A Scale N/A
Approved: J. Kauffman 7/11/03 SHEET 1 of 14
1. Introduction
The PRS-8i pipe handling system is a column type dynamic machine, designed and built for
adaptation to a customer’s fixed installation or floating drilling rig derrick and drill floor design.
The PRS-8i is a full function tripping and stand building machine, capable of performing riser and
casing tailing functions with the lower tailing arm.
The PRS-8i consists of a vertical column assembly, which traverses the rig floor between pipe
setback areas, supported and driven at the rig floor by a guide and drive track arrangement. The
column is guided and driven at the upper level by a similar track incorporated into the diving board
assembly supported by customer supplied derrick mounting structure. Timing between the top and
bottom, keeping the column vertical, is achieved by a common drive shaft powering upper & lower
drive pinions engaging their respective racks. The unit incorporates two extendible arms for
hoisting and guiding tubulars.
Extending or retracting the arms, hoisting or lowering the upper arm and rotating the column
performs pipe handling operations between well center and the setback area. Extending or
retracting the arms, hoisting or lowering the upper arm, and driving the column laterally to or from
well center performs handling operations within the setback area.
The PRS-8i has the capability to “Tail” casing from a distance away from the well center to the
well center and holds the casing in alignment for stabbing. A riser or casing tool is adapted to the
existing claw on the lower tailing arm. The casing handling tools are configured with adjustable
links and rollers to adapt required sizes.
The fingerboard comprises a series of horizontally extending fingers arranged at 90 degrees to the
column’s direction of travel. Individual pneumatic powered latches locate and secure each stand
separately.
All hoses and control cables associated with all PRS-8i functions are routed from derrick
termination plate located at approximately 35’ above the rig floor to the rotating and traversing
column assembly via flexible service loops connected to the derrick at the termination plate level
and to the back of the column. The hoist carriage and it’s lifting arm functions on the column are
supplied by service loops hanging from the derrick at approximately 75’ above the rig floor. All
devices associated with the drive and positioning of the unit are contained in the vertical column
assembly. Customer is responsible for providing safe work platform access to all derrick mounted
junction boxes.
The PRS-8i functions are controlled remotely from the driller’s or assistant driller’s chair in the
DCR operator’s control station. The unit will have a certified lifting capacity of 10,000 kg (22,000
lbs). The fingerboard will be designed to hold a selection of drill pipe and collars as required by the
customer and is designed for each rig application to withstand the maximum derrick allowable
loads with drill pipe in the setback.
2. Description
2.1 Major components
The PRS-8i consists of a vertical column assembly that traverses the rig floor between well center
and pipe setback area to support tripping operations. The column rides on a lower drive assembly,
which guides and drives the column along a drive track mounted on the rig floor. The upper end of
the column is guided on a similar track, which is pinned at one end to customer supplied derrick
Varco Drilling Equipment TITLE Functional Design Description PRS-8i Rev B
A Varco Company
Document No. 3 P S 0 0 0 9 1 SHEET 2 of 14
mounting structures. The lower drive assembly turns a shaft in the center of the column that has
gears on each end to engage into their respective drive track. Drive timing between the lower and
upper portion of the column is achieved through this drive shaft, keeping the column vertically
aligned. The PRS-8i uses the upper arm assembly and upper carriage assembly for hoisting and a
fixed elevation lower tailing arm assembly for guiding tubular stands and singles.
Pipe handling operations between well center and the setback area, and within the setback area are
performed by extending or retracting the arms, hoisting or lowering the upper arm, rotating the
column and driving the column laterally to or from well center.
2.1.1 Vertical Column

The PRS-8i column assembly is a single assembly and carries the upper hoisting arm and lower
tailing arm and claw. The column section is a trapezoid section with the arm’s carriage rollers
directly contacting the column plates.
The column assembly is connected to the lower drive assembly at the rig floor and attached to the
upper drive through the use of a vertically sliding arrangement to compensate for slight dimensional
variations within the rig. All vertical loads and slewing moments are reacted exclusively by the
lower drive assembly to the rig floor structure. The upper drive, guided in the upper track and
mounted to the rig structure at approximately the 88’ elevation, transfers only horizontal loads to the
derrick. The horizontal loads originate from the static geometry and the dynamic motions of the
machine itself.
Motive power for the upper and lower drives consists of upper and lower gearboxes affixed to the
respective drive carriages. Pinion gears attached to the gearboxes engages their racks in the diving
board or floor track. Power from the column mounted traverse drive motor is transferred to the upper
and lower gearboxes via a rigid drive shaft mounted inside the column structure and attached to the
upper and lower gear boxes via a telescoping universal jointed jack shaft assembly. The traversing
drive motor is mounted on the column, under the hoist motors and transfers power to the rigid drive
shaft through a parallel shaft transfer box.
2.1.2 Hoisting Arm

The upper hoisting arm and its gripper jaw assembly carry the complete vertical load of the tubular
being handled as well as the lateral loads acting on the tubular. The jaw normally grips tubulars
approximately 35’ below the upper box connection of a nominal 93 foot stand. It uses hardened
inserts hydraulically and mechanically actuated against the OD of the tubular for lifting. The jaw
assembly includes hydraulically actuated roller jaws that close on the tubular before the grip jaws,
centralizing the pipe with respect to the grip jaws, the grip jaw assembly and an encircling claw
assembly. The claw assembly is used to capture a drill floor supported stand to allow vertical
repositioning of the hoist arm. The jaw assembly will be provided with attachment points for stand
building and casing running tools as required by the customer configuration. An optional kit is
provided for handling high chrome tubulars. The kit includes stainless steel centering rollers for the
roller jaw, and smooth stainless steel inserts for the grip jaw.
Dual path hoist motors located at the lower end of the column section move the PRS-8i hoist arm.
The PRS-8i hoist arm extend mechanism is a simple hydraulically actuated arm attached to a hoist
carriage riding along the column. The grip jaw assembly is attached to the hoist arm. The vertical
alignment of the grip jaw is maintained through the full extension of the hoist arm by use of an

A Varco Company
active hydraulic compensating system. Height changes in the PRS-8i caused by the swing of the
hoist arm are compensated through the use of compensating cylinders mounted in series with the
hoisting cylinders. As the arm is extended or retracted, hydraulic fluid is exchanged between the arm
extension cylinder and the compensating cylinders so that as the arm extends or retracts, the
compensating cylinder either lowers or raises the hoist carriage to maintain a horizontal motion of
the grip jaw. Height changes of the PRS-8i hoist arm are compensated through active synchronized
motion between the hoist arm extension and the hoist motors.
Protective shrouds are provided on both carriages of the lower arm to prevent snagging of local
equipment.
2.1.3 Hoisting System

Hoisting of the PRS-8i upper arm assembly is done with two hydraulic cylinders mounted in series
with the compensating cylinders described above and grounded to the top of the column. These
cylinders use absolute encoder feed back for positive, accurate positioning. The hoist is proportional
hydraulic controlled and includes all necessary safety valves to prevent load dropping incase of
hydraulic system failure.
The hoisting means of the PRS-8i consists of spooling and unspooling wire rope from reels direct
coupled to the gearbox output shafts mounted near the bottom of the column. Each wire rope is
reeved around an idler sheave located at the top of the main column section, through another sheave
on the sheave carriage and anchored back at the top of the column. The reels have grooved cores for
controlled placement of the spooled cable. This hoisting arrangement provides two independent load
paths, each of which can hold the hoisting loads at a substantial factor of safety. The hoists are
powered by two variable speed electric motors. Each motor utilizes a spring applied, hydraulically
released safety brake for positive load holding position during extended off periods.
The PRS-8i uses weight-compensating cylinders at each hoisting wire rope attachment to the
column. The cylinders counterbalance the weight of the hoist arm and carriage assembly to limit the
axial load put on a connection when stabbing at well center or setting down in the setback.
Additionally, the compensating cylinders are used to assure the safe transfer of live load by sensing
when weight is removed from the hoist arm.
The PRS-8i hoisting system Safe Working Load (SWL) is 10,000 kg (22,000 Lbs). The maximum
upper arm extension at SWL is 120 inches. Further extension is achieved at a reduced SWL per
section 3.5. The PRS-8i hoist utilizes dynamic resistance braking through the variable speed motors
for deceleration when lowering the working load and spring set, hydraulically released fail-safe
brakes for holding the load stationary.
2.1.4 Lower Arm

The extend/retract motions of the upper and lower arms are not mechanically connected and can be
independently operated when required. Synchronization of the upper and lower arm motions is
achieved by electronically controlling their respective horizontal displacements and velocities with a
motion controller located in the Control Module enclosure.
The lower arm incorporates the claw assembly, which encircles and guides the lower end of the
tubular being handled, but supports none of the tubular weight. A remotely operated, pneumatically
positioned roller is provided to accurately position various tubular diameters within the upper claw
for accurate stabbing.

A Varco Company
Unlike the hoisting arm, the lower tailing arm does not have any hoisting capacity. It consists of an
arm of similar geometry as the hoisting arm pivotally attached to the lower column and to the claw.
Vertical alignment of the claw is achieved with a active hydraulic cylinder arrangement. The lower
arm is hydraulically actuated and includes the necessary safety valves to maintain safety in case of
hydraulic system failure.
2.1.5 PRS-8i Fingerboard

The PRS-8i fingerboard is designed for a customer’s specific setback requirements. It consists of
two or more welded structures mounted to the sides of the derrick. The structures have a series of
“Fingers” welded to the back mounting plate and extend laterally toward the well centerline. For
dynamic applications, individual remotely controlled air operated latches are positioned along the
length of each finger and are used for holding each stand in place. The adjacent finger in one
direction and the latch in the other hold each stand.
The PRS-8i fingerboard is to be designed for each application. Some rows of tubulars may need to
be laid down for extreme (survival) conditions as they are typically designed for maximum
operational loads.
2.1.6 PRS-8i Stow Position

On floating rig applications, there is an operational envelope with certain maximum vessel motions
allowed. When weather conditions deteriorate, approaching these conditions, operations must be
suspended. The PRS-8i, being a column design of pipe handling system, is susceptible to damage
from extreme vessel motions. In order to prevent damage, the PRS-8i has a “Stowed” position. In
this condition, the operator is required to move the PRS-8i to its outer most position and manually
engage the stowage locks.
The stowage locks are manually operated and require rig personnel to engage manual locking
devices to secure the lower drive assembly to the rig floor and the upper drive to the upper track.
Customer is responsible to provide access to these locations.
2.1.7 Safety
The PRS-8i hoist carriage is hoisted by two wire ropes, each with an independent motor, gearbox
and drum. Each wire rope assembly is capable of hoisting and lowering the hoist carriage without
assistance from the other wire rope assembly. The grip jaw is capable of holding the maximum
working load. During all operations that do not require the grip jaw to be open (i.e. operations
involving the stand rotating), the stand is gripped with both grip jaw and the roller jaw.
2.2 Control System

2.2.1 Control Module
The control system consists of an industrialized Control Module with embedded motion control. All
communication with the PRS-8i is via a Profibus DP bus operating at 1.5 MHz. The tool uses
onboard remote I/O modules for communicating the control system.
2.2.2 Control Station

The operator interface / control station can be provided via a Varco Operator Control Console or an
HMI interface such as VICIS. Command signal communication from the operators control station to
the tool controller will be Profibus DP. When the VOCC is switched on, the PRS-8i can only be

A Varco Company
controlled from the VOCC. When V-ICIS is present, the PRS-8i can be controlled from either the
driller’s chair or the assistant driller’s chair.
2.2.3 Drive Systems

PRS-8i traverse, rotation and carriage hoist A and B are electrically powered using Variable
Frequency Drives (VFDs). The PRS-8i upper and lower arm extend / retract circuits and jaw angle
circuits are powered using a proportional electro-hydraulic solenoid valves. The PRS-8i grip, roller
and guide jaws, and handling tool circuits are powered using standard electro-hydraulic solenoid
valves.
3 Design Data
3.1 Environmental Design Specifications
• Operating
• Wind: 65 knots, applied from any direction.
• Minimum Design Temperature (MDT) -20o C
• Minimum non-operating temp -40ºC
• Maximum Design Temperature 45o C
• Ice Thickness (Max on all Horizontal Projected Surfaces) None
• Marine Environment
3.2 Size:
• Total Traversing Weight 42,000 Lbs [19050 kg]
(Column, Upper & Lower Arms, Upper & Lower Drive Assemblies)
• Total Stationary Weight 8,000 Lbs [3629 kg]
( Diving board, Floor Tracks)
• Operating Envelope Footprint 30 Inches [762 mm]
(Max. Radius of column assy, rear, right & left sides)
3.3 Travel (Operational):

• Hoisting Arm
• Reach, Max from CL Column to CL Tubular 144 Inches [3658 mm]
• Reach, Min. From CL Column to CL Tubular 24.5 Inches [622 mm]
• Min. Swing Rad. (To End of Jaw) 31 Inches [787 mm]
• Rotation 225 o
• Hoist Stroke. Max From Floor 64’ 6” Feet [19660 mm]
• Hoist Stroke. Min From Floor 12’ 6” Feet [3810 mm]
• Lower Arm
• Reach, Max From CL Column to CL Tubular 144 Inches [3658 mm]
• Reach, Min From CL Column to CL Tubular 24.5 Inches [622 mm]
• Min. Swing Rad. (To End of Claw) 31 inches [787 mm]
• Rotation 225 o
• Hoist None
• Claw Level Above Rig Floor 20 Feet Retracted [6096 mm]
15 Feet Extended [4572 mm]
3.4 Speeds:
• Arm In/Out (Average), Drill Pipe 2 Ft/Sec [0.6 m/s]

A Varco Company
• Hoist, Drill Pipe 2 Ft/Sec [0.6 m/s]

• Slew, Drill Pipe 30o /Sec
• Traverse Travel, Drill Pipe 2 Ft/Sec [0.6 m/s] Max
• Arm In/Out (Average), Drill Collar .8 Ft/Sec [.24 m/s]
• Hoist, Drill Collar .6 Ft/Sec [.18 m/s]
• Slew, Drill Collar 12o/Sec
• Traverse Travel, Drill Collar .8 Ft/Sec [.24 m/s] Max
3.5 Capacities:
• Drill Pipe Size Range 3 ½” to 6 5/8” [89 to 168 mm]
• Drill Collar Size 9 ¾” [248 mm] Max.
• Hoist Capacity @ 120 inch Arm Extension (SWL) 22,000 Lbs [9980 kg]
• Hoist Capacity @ 144 inch Arm Extension (SWL) 16,000 Lbs [7260 kg]
3.6 Hydraulic Flow Requirements

• 60 GPM [227 l/min] at 2500 PSI [172 barg], Closed Centered.
3.7 Fail-safe Brake Specifications (Braking Torque)

• Hoist (PRS-8i) 265 Lb-ft [360 N-m]
• Slew 265 Lb-ft [360 N-m]
• Traverse 265 Lb-ft [360 N-m]
4. Design Codes and Verification

The PRS-8i operates above the drill floor, across the entire general area. The area immediately
around well center (1.5m radius) is a zone 1 area, the rest of the drill-floor is classified as a zone 2
area. The zone 2 area extends up to the top of the drill-floor wind-wall. The PRS-8i is designed to
operate in a zone 1 hazardous area. All electrical equipment mounted on the PRS-8i tool is certified
for zone 1.
• Tool Area Classification - All electrical equipment mounted on the PRS is certified for zone one.
The PRS extends up to the 87’ level and is suitable for both hazardous areas and safe areas.
• Remote I/O J-Box Area Classification - The OLM/Power Supply/Remote I/O J-box, to which the
tool drag-chain cables are run, is mounted at the 87’ level which is in a safe area. This J-box
contains an OLM, a remote digital I/O device and a power supply, which must be located in a
safe area.
• Hydraulic Manifold - The hydraulic manifold is located close to the Remote I/O J-box in a safe
area. The hydraulic manifold equipment is certified for zone two.
• Operator Control Station Area Classification - The operator control station is located on the drill-
floor close to the driller’s cab in a zone two area. The operators control station is certified for
zone two.
4.1 Relevant Codes and Standards

• “Rules for Certification - Lifting Appliances” DnV, (1989)
• “Code for Lifting Appliances in a Marine Environment” Lloyd’s Register of Shipping, (1987)
• “Specifications for Structural Steel Building - Allowable Stress Design and Plastic Design”,
AISC, (June 1, 1989)
• Varco Dynamic Design Loading Specification

A Varco Company
4.2 Design Verification

Not applicable.
5. Design Philosophy
5.1 General Approach
The design is intended to provide semi-automatic, remote controlled pipe handling operations. The
design utilizes experience gained from existing pipe racking machines in operation. Structural
components of the PRS-8i are design to withstand the static, dynamic and fatigue loads likely to be
imposed during it’s life time. The design and analysis of structural components are performed using
design safety factors and methods specified in the DnV specification “Rules For Certification of
Lifting Appliances”. Loading criteria is defined in the “Varco Dynamic Design Loading
Specification”. When applicable, more stringent environmental loading is taken from the customer’s
specifications.
5.2 Design Life

The design life of the PRS-8i system is 400,000 drill pipe and 24,000 drill collar cycles over a 30
year operating life. A cycle is defined as moving one stand from the setback area to the well center,
or from the well center to the setback area. These cycle values correspond to an average drilling
program consisting of 10,000 ft wells, tripping every 2-days with 3-stands of drill collars in the
string. On parts where fatigue damage is likely to occur, such as pinions and racks, the stresses will
be shown to be below the fatigue limit under operational load conditions. A lubrication and
maintenance program, combined with routine change out of wear components like bearings for
motors and gears, will maintain the unit in peak operational condition for its design life.
5.3 Material & Component Selection

5.3.1 Mechanical Construction
All materials used in the fabrication are Varco standard design and suppliers.
Surface protection for the equipment is per project approved Varco Paint Specification
VPS 00001.
All material selection decisions are based on fitness to the application as defined above,
availability, manufacturability, serviceability, cost, and standardization with respect to other
Varco products. In addition, the following will be considered:
Structural components - chosen on basis of strength, durability, and resistance to stress. Material
to be selected from family of existing Varco Material Specifications to the extent practicable,
with Charpy impact testing and tracability appropriate to the application and customer
specification.
Pressure containing components (e.g. hoses, accumulators, cylinders): to be commercially

available with appropriate service ratings.
Fasteners, fittings - Materials are resistant to the environment, through either sacrificial coating
scheme or other environmentally resistant properties.
Non-metallic seals - commercial seals, chosen on basis of chemical and environmental

resistance, and long service life.

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5.3.2 Electrical Construction

Electrical System / Components
Reference “Electrical Standards” design specification 3DS00079 and “Electrical Documentation
Standards” DS00072 .
Control Panel & Electrical System

The PRS 8i electrical design has taken into account the Zone 1 hazardous area classification of
the drilling rig installation. Electrical and control system designs have been chosen to
satisfactorily meet or exceed the conditions for safe operation within the respectively classed
areas. Equipment selections are made which meet the required temperature extremes, i.g. -40
deg C. Should items of equipment not be available for this extreme, heaters will be provided to
maintain the equipment within its operating temperature range. Standard components will be
used as practicable.
The PRS 8i utilizes (IEC / CENELEC) Ex electrical components and is constructed according to
IEC standards for marine applications. All hazardous area equipment is certified for Zone 1. All
hardware is rated for IP 56 min and –40 to 45ºC.
The PRS-8i control will be provided by one (1) control module in the Multi Tool Controller
which is housed in an IP 44 Rittal stand-alone enclosure and is designed to be located in a non-
hazardous area i.e. Drill Floor LIR. The Multi Tool Controller is a generic controller which can
control up to seven (7) individual tools independently of each other. The Multi Tool Controller
#1 houses several Varco Single Board Computer (SBC) Controllers with other associated
hardware, one of which is dedicated to controlling the PRS-8i, the SBC includes all necessary
software to control the PRS-8i, programmed sequential control and operational interlocks for
both operator and tool safety. The SBC system is based on Profibus DP serial communications
running at 1.5 Mbaud for tool field equipment where remote I/O technology minimizes derrick
and tool cabling and provides the flexibility to utilize smart type sensors / devices. Profibus DP
is a recognized industry standard method of serial communications, which utilizes a RS 485
hardware platform. Field communications will be via copper and fiber, which provides
redundancy and also noise immunity. The Control Module (CM) receives inputs from various
electrical sensors, encoders, operator interfaces, and other devices mounted on the tool or
operators station. Command inputs to the CM from the operator’s station result in outputs to
drive the tool. The CM provides interlock control of various tool functions monitors sensor and
encoder feedbacks. In general, the system of programmed interlocks provides a safety net to
help prevent inadvertent damage.
MTC’s will be supplied by V-ICIS. See V-ICIS FDD for more details.
Emergency Stop:
All individual E-Stop circuits are hardwired back to the derrick remote I/O enclosure. These E-
Stop signals are connected in series in the derrick remote I/O enclosure, and if all healthy a
signal is made available for external purpose, “E-Stop healthy”. These signals are monitored by
the E-Stop Control System for diagnostic purpose and to inform operators of E-Stop status for
each tool. Any activation of any E-Stop switch will disable all Varco Supplied tools. The E-Stop
Control System also receives E-Stop signals from the drillers chair and the assistant drillers chair
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and will determine depending on ownership if the PRS-8i performs a Hard Stop or Soft Stop, a
Hard Stop being the application of the main brake.
PRS Control System Diagnostic:
The PRS-8i Single Board Computer is provided with a comprehensive set of built in diagnostic
features. Some examples of which are Setup, Alarm & Event Viewer and Administration
capabilities. The diagnostic screens can also be accessed from any Web Browser on a laptop or
HMI connected to the controller, no special software is required.
Note: Varco to provide standard design screens. There is no requirement for customer specified,
project specific screens.
PRS 8i Variable Frequency Drive System:
The Variable Frequency Drive (VFD) requires a 3 phase 50 Hz, 400 VAC, 175 Amps supply,
and is used to control / power the AC motors on the PRS 8i. The VFD assembly is housed in an
IP44 Rittal type enclosure, which is also designed for a safe area installation. In addition to the
above enclosure the system is provided with a dynamic braking resistor used to dissipate drive
energy during axis deceleration or when the hoist carriage is lowering. System rated for 45 Deg
C ambient. Both the VFD and braking resistors will be located in the Varco supplied LIR on the
drill floor, which is part of the DCDA module.
The system comprises of a 3 phase circuit breaker / isolator which feeds 3 phase power to a
common AC to DC rectifier via a RFI filter and a 5 % Impedance Line Reactor. System
Harmonics are generally below 5% but are subject to the power system upstream. A detailed
analysis of the upstream power system should be done during the design stage. The rectifier
supplies a common DC bus, which sits at approximately 600 VDC but is dependant on the 3-
phase supply. Four Siemens 6SE70 DC to PWM AC Master Drives are connected to the DC bus
via appropriately sized fuse disconnects. A Dynamic Brake Chopper connected to a 4 ohm
Dynamic Brake Resistor (mounted external to the drive enclosure) is also connected to the
common DC Bus via a fuse disconnect to dissipate excess DC Bus energy during any operation
which causes regeneration such as decelerating or lowering the hoist carriage. When the DC bus
elevates to a preset threshold the IGBT in the Chopper fires and connects the resistor to the bus
dissipating the excess energy in the form of heat via the resistor.
The following VFD’s are connected to the following axis motors via a motor reactor, which are
provided to minimize the effects of reflection caused by impedance mismatching and protect the
motor insulation.
Drive 1 - 37 kW Hoist Drive A Hoist Motor A - 17

kW
Drive 2 - 37 kW Hoist Drive B Hoist Motor B - 17
kW
Drive 3 - 37 kW Slew Slew Motor - 11
kW
Drive 4 - 37 kW Lower Drive Lower Drive Motor - 17
kW
Each drive is configured / paramertized for it application with a custom developed set of
parameters which Varco has developed to optimize the tools performance, these parameter are

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downloaded into the drive via a serial link upon commissioning, the drive is then auto tuned to
maximize the drives / equipment performance. If at any time during the life of the equipment the
drive has to be replaced the parameters can simply be down loaded and the drive tuned. Each
drive has it own built in diagnostics for a multitude of Alarms and Faults which are displayed on
the operator panel on the front of the drive package and are also transmitted to the controller for
Alarm / Fault monitoring / indication to the operator. The drives are configured to operate in a
open loop configuration and therefore have eliminated the need for encoder feedback to the
VFD. The axis brake, which is mechanically coupled to the axis drive train, is controlled from
the VFD control circuit, the brake is mechanically spring applied and hydraulically released by a
pressure pilot signal from an electric solenoid controlled from the drive, on activation of the
drive the VFD builds up sufficient torque in the motor to hold the load and then releases the
brake, when de activating the axis the brake is applied at a minimal low speed command to
ensure that the load is held. Both transactions between brake to motor and from motor to brake
appear seamlessly to the operator and ensure the optimum operation of the equipment.
Communications between the PRS Controller and the PRS VFD’s is done via a Profibus DP
serial link. Each VFD is fitted with a Profibus communications card called a CBP 2, the Profibus
is daisy chained between drives in a common node to node configuration. This link between the
two systems is fiber, which provides redundancy and noise immunity, the internal enclosure
Profibus wiring is copper. Typical interface includes the following handshake of signals between
each controller and each drive:
From Controller to VSD From VSD to Controller

Assign Drive (Stop / Start) Drive Available
Drive Run Drive Running
Speed Command Actual Speed
Torque Command Actual Torque
Direction Drive Status / Alarms / Faults
5.4 Control System

The Control Module (CM) receives inputs from various electrical sensors, encoders, operator
interfaces, and other devices mounted on the tool or operators station. Command inputs to the CM
from the operator’s station result in outputs to drive the tool. The CM provides interlock control of
various tool functions, monitors sensor and encoder feedbacks. In general, the system of
programmed interlocks provides a safety net to help prevent inadvertent damage, and are not relied
on as a primary operating system. The operator is ultimately responsible for safe operation.
5.5 Failure Modes

In general, the PRS-8i mechanical, electrical, and hydraulic systems are designed to provide the least
obstructive or destructive failure mode. In general, electrical devices are chosen to assure failsafe
mode in order to force the operator to make a decision before proceeding further.
Hydraulic systems are fitted with solenoid operated and load-holding valves as applicable to assure
safe handling of loads in the event of failure.
6. Functions & Operations

6.1 General Operation
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General operation of the PRS is defined as semi-automatic, where the assistant driller is in constant
control of the PRS through use of a single joystick. The joystick is spring return to center / off for
safety. The PRS moves through pre-programmed paths that are configured during initial setup, and
may be modified later using the calibration mode. The operator provides speed and direction along
the path with the joystick. While in a primary operation mode, the operator does not control the
individual axis of movement of the PRS.
There are five primary modes of operation, which are configured during initial set up of the system.
These modes can be changed at any time but the proper precautions must be taken to ensure that the
system hardware is also properly configured.
• Tripping – This mode is used to trip tubulars in and out of the hole and into and out of the
fingerboard.
• Building Stands – This mode is used to build stands in the Foxhole® and rack them back into
the fingerboard. It is also used to grab stands from the fingerboard and break them down in the
Foxhole®.
• Singles – This mode is used to grab singles off of the conveyor and to take them to well center.
It is also used to grab singles at well center and to lay them down at the conveyor.
• Riser Tailing – This mode is conjunction with a special tool attached to the upper jaw. The PRS
will tail the riser from the conveyor to well center.
• Parking – This mode is used to park the PRS in a safe position in the derrick for rig movements
and hazardous weather.
Additionally there are three override modes to facilitate non-standard operations that might require
overriding the normal control of the PRS.
• X-Y Override – Operator controls the position of the jaw with limited interlocks, column is
frozen relative to the rig. The PRS jaw will move in the direction the joystick is pushed. ZMS is
still active while in this mode.
• Traverse Override – Operator controls the position of the column with limited interlocks, jaw is
frozen relative to the column. The PRS column will move in the direction the joystick is pushed.
ZMS is still active while in this mode.
• Maintenance Mode – All axis of movement are controlled individually by the operator with no
interlocks. This mode is activated through a locked key switch located in the control system
cabinet. This mode may be used in emergency situations or for maintenance or troubleshooting.
Maintenance purposes include calibration of sensors and actuators used by the PRS, or
modification to the positional data used by the PRS in its path movements.
6.2 Changing Modes

Modes of operation are configured during initial system set up. These modes require that hardware
configurations match the selection to ensure proper operation of the equipment.
• Tripping – Used anytime through operator control touch screen. Configured through initial set
up screen.
• Building Stands – Used anytime through operator control touch screen. Configured through
initial set up screen.
• Singles – Used anytime through operator control touch screen. Configured through initial set up
screen.
• Riser Tailing – Used anytime through operator control touch screen. Configured through initial
set up screen.

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• Parking – Used anytime through operator control touch screen. Configured through initial set up
screen.
Override modes can be selected at any time through use of override push buttons on the operator
control screen and the key switch located in the control cabinet.
• X-Y Override – Used anytime through operator control touch screen.
• Traverse Override – Used anytime through operator control touch screen.
• Maintenance Mode – Used anytime through key switch in control cabinet.
6.3 Interlocks
A general list of interlocks follows, although these are not necessarily the only factors that will stop
the PRS from moving. The PRS will automatically stop when it has reached a preset destination, or
when operator interaction is required without displaying an interlock message. A message for the
appropriate situation will be displayed. However, this does not constitute an interlock condition.
• ZMS Interlock – PRS is attempting to move into a ZMS zone that is occupied by another piece
of equipment or the derrick.
• Jaw Holding Weight Interlock – The operator is attempting to open the grip jaw while the PRS is
still supporting the weight of the stand.
• Fingerboard Interlock – The operator is attempting to remove the PRS from the fingerboard
before the latch has been activated, or the operator is attempting to remove the stand from the
fingerboard without unlatching the stand.
• Pipe Setdown Interlock – The operator is attempting to move the PRS while it is gripped on a
stand that is setdown on the floor.
• Foxhole® Interlock – The operator is attempting to hoist a tubular from the Foxhole® without
opening the Foxhole®.
Some events must be alarmed because these events will stop operation of the PRS-8i. A general list
of alarm messages follows:
• Motor PTC fault (1 for each motor) – Motor Temperature Exceeded.
• Encoder Failure Detected (1 for each Encoder) – Control System has detected an encoder failure.
• VFD Fault (1 for each VFD) – VFD has faulted out, error code will be displayed.
• Loss of Air Pressure – Insufficient air pressure available to fingerboard.
• Loss of Hydraulic Pressure – Insufficient hydraulic pressure available to PRS.
• Loss of communication to tool mounted remote I/O devices.
• Loss of Communication to ZMS
• Loss of Communication to Fingerboard Controller
Other event messages are simply displayed to the operator for information and ease of operation
purposes. These messages generally do not stop or affect operation, but may have an effect on
operational decisions made by the operator. A general list of event messages follows:
• PRS On / Off
• Maintenance Mode Active – The key switch in the control cabinet has been activated.
• X-Y Override Active – X-Y Override is being used by operator.
• Traverse Override Active – Traverse Override is being used by operator.
• Maximum Load Limit – Load being held is at or near maximum load limit
6.4 Configuration

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Configuration Access available with base level system. These screens can be made available to the
operator but it is advised that these screens would not be necessary during normal operation. These
screens also require advanced knowledge of system hardware, software and configuration.
• Tripping – Configured through initial set up screen, available only in set up / configuration
mode.
• Building Stands – Configured through initial set up screen, available only in set up /
configuration mode.
• Singles – Configured through initial set up screen, available only in set up / configuration mode.
• Riser Tailing – Configured through initial set up screen, available only in set up / configuration
mode.
• Parking – Configured through initial set up screen, available only in set up / configuration mode.
6.5 Modification Facilities

Modification of some operational values and parameters of the PRS-8i are available. These screens
can be used to configure destinations / positions and operational characteristics of the PRS-8i.
• Rig Positions – Allows operator to set and control the destinations and paths the PRS follows
during its normal modes of operation.
• Encoder Calibration – Allows operator to calibrate the absolute encoders used on the PRS when
they are replaced.
• Proportional hydraulic valve calibration – Allows the operator to calibrate the proportional
hydraulic valves used on the PRS.

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may not be disclosed to others for any Letter DESCRIPTION Prepared Checked Approved Date
purposes without written permission
from VARCO INTERNATIONAL INC. A See DCN 4/12/02
FUNCTIONAL DESIGN
DESCRIPTION
FSA
APPLICATION TITLE DATE

Functional Design
Description
FSA
Next Assy Product
FSA Prepared: 11/00/01 Document No. 3PS00063

Checked: 11/00/01 Size A Scale N/A
Approved: 11/00/01 SHEET 1 of 6
1. Introduction
The Foxhole® Slip Assembly (FSA) is Varco System’s latest answer to the challenging demands of
offshore drilling. It is a remotely operated slip to assist with off line stand building. It is designed to
accommodate tubular diameters from 2-3/8” to 20” and has a safe working load capacity of 13,600 kg
(30,000 lbs). It sits on top of the Foxhole and flush with the rig floor when not in use. It is secured to
the rig structure enabling it to vertically retain tubulars when making up or breaking out. Its scope also
includes a pneumatic control plate assembly consisting of air filter, pressure regular, lubricator, solenoid
valve and J-box.
2. Description
2.1 Major components
• Body - The Body is the main component of the assembly, which interfaces with the Foxhole and
to which the other components mount. Its main feature is the 6 sets radially arranged slip guides,
with a slip angle of 11°.
• Leveling beam - This is the moving element of the assembly. It attaches to the Body with 3
guide rods and is raised and lowered with 3 pneumatic cylinders. Slip assemblies connect to the
leveling beam through hanger brackets and are raised and lowered by the beam.
• Hanger Brackets - Six Hanger Brackets install in slots in the Leveling Beam and support the slip
assemblies. The brackets are designed for quick change of the slips to a different size.
• Slip assemblies - Six slip assemblies hang from the Leveling Beam. Each assembly has a pair of
rollers which ride on the slip guides as they are raised and lowered by the Leveling Beam. Slip
assembly sizes are: 2-3/8” to 6-1/2”, 5” to 9-3/4”, 9-5/8” to 14”, 16” to 20.
• Pipe centralizer guide - This keeps the tubular centralized in the center of the Foxhole® Slip
Assembly. A cover plate installs on the pipe guide and Cover protects the assembly when not is
use and removes a trip hazard.
• Control panel. - The control panel installs remote from the FSA and controls the air supply to the
pneumatic cylinders.
The following safety features are included in the FSA design:

• Safety cover - When not in use, the FSA has a cover to prevent a trip hazard.
• Loss of air – The FSA will automatically close / set.
2.2 Control System

2.2.1 Control Module
There is no dedicated control system for the FSA, it is usually connected to the AUX controller
which consists of an industrialized Control Module. All communication with the AUX controller is
via Ethernet or a Profibus DP bus operating at 1.5 MHz. The tool uses remote I/O modules for
communicating the control system.
2.2.2 Control Station

The operator interface / control station can be provided via a Varco Operator Control Console or an
HMI interface such as VICIS. Command signal communication from the operators control station to
the tool controller will be Profibus DP and / or Ethernet. When the VOCC is switched on, the FSA
can only be controlled from the VOCC. When V-ICIS is present, the FSA can be controlled from
either the driller’s chair or the assistant driller’s chair.
2.2.3 Drive Systems

The FSA is powered using a standard electro-pneumatic solenoid valve.
TITLE Functional Design Description FSA Rev A
3 Design Data
3.1 Specifications
• Tubular diameter 2 3/8 in. to 20 in.
• Tubular length 10 ft. to 50 ft
• Tubular Weight 13,600 kg (30,000 lbs)
• Cycle time 20 seconds to locate and hold tubulars,
5 seconds to release.
Live Load – The FSA has a maximum load rating of 13,600 kg (30,000 lbs).
Slip Sets – The FSA must be manually configured with the proper slip set for the size range of
tubular being handled.
Back up torque – The FSA can provide only minimal back up torque. It can provide backup for
spinning and shouldering, but cannot provide backup for making or breaking connections.
3.2 Environmental
Operating Ocean Wet Towage Location Move
Wind: 20 m/sec 51.5 m/sec 36 m/sec
Temperature: -20°C to +40°C -20°C to +40°C -20°C to +40°C
Pitch/Roll amplitude None +15° +10°
Pitch/Roll period n/a 15 sec 15 sec
Heave n/a n/a n/a
Heave period n/a n/a n/a
Center of rotation n/a 30 m 15 m
Note: Ocean Wet Tow and Location Move are non-operational conditions.
4. Design Codes and Verification

The FSA operates above the drill floor at the foxhole. The area immediately around foxhole is a
zone 2 area, the rest of the drill-floor, with exception to the well center area, (a 1.5m radius
immediately around the well center), is classified as a zone 2 area. The zone 2 area extends up to the
top of the drill-floor wind-wall. The FSA is designed to operate in a zone 2 hazardous area. All
electrical equipment mounted on the FSA tool is certified for zone 2.
4.1 Relevant Codes and Standards

• “Rules for Certification - Lifting Appliances” DnV, (1989)
• “Code for Lifting Appliances in a Marine Environment” Lloyd’s Register of Shipping, (1987)
• “Specifications for Structural Steel Building - Allowable Stress Design and Plastic Design”,
AISC, (June 1, 1989)
• Varco Dynamic Design Loading Specification
4.2 Design Verification

Design is subject to third party verification by a recognized certifying authority, usually designated
by customer requirements.

5. Design Philosophy
5.1 General Approach
The design is intended to provide semi-automatic, remote controlled holding and releasing of drill
pipe, drill collar and casing singles during stand building and breaking operations. The design
utilizes experience gained from existing foxhole slip assemblies in operation. Structural components
of the FSA are design to withstand the static, dynamic and fatigue loads likely to be imposed during
it’s life time. The design and analysis of structural components are performed using design safety
factors and methods specified in the DnV specification “Rules For Certification of Lifting
Appliances”. Loading criteria is defined in the “Varco Dynamic Design Loading Specification”.
When applicable, more stringent environmental loading is taken from the customer’s specifications.
5.2 Design Life

The design life of the FSA system is 100,000 open / close cycles over a 20 year operating life. These
cycle values correspond to an average drilling program consisting of 10,000 ft wells, tripping every
2-days with 3-stands of drill collars in the string. On parts where fatigue damage is likely to occur,
the stresses will be shown to be below the fatigue limit under operational load conditions. A
lubrication and maintenance program, combined with routine change out of wear components like
bearings for motors and gears, will maintain the unit in peak operational condition for its design life.
5.3 Material & Component Selection

All material selection decisions are based on fitness to the application as defined above, availability,
manufacturability, serviceability, cost, and standardization with respect to other Varco products. In
addition, the following will be considered:
Structural components - chosen on basis of strength, durability, and resistance to stress. Material to
be selected from family of existing Varco Material Specifications to the extent practicable, with
tractability appropriate to the application
Pressure containing components (e.g. hoses, accumulators, cylinders): to be commercially available

with appropriate service ratings.
Fasteners, fittings - Materials are resistant to the environment, through either sacrificial coating
scheme or other environmentally resistant properties.
Non-metallic seals - commercial seals, chosen on basis of chemical and environmental resistance,
and long service life.
Electrical System / Components - Reference “Electrical Standards” design specification 3DS00079

and “Electrical Documentation Standards” DS00072
Control Panel & Electrical System

The FSA utilizes (IEC / CENELEC) Ex electrical components and is constructed according to
IEC standards for marine applications. All hazardous area equipment is certified for zone 1,
exterior mounted safe area equipment is all designed for a marine application .All hardware is
rated for IP 56 min and –20 0 C to +45 0 C. The control system is housed in a IP 44 Rittal
enclosure and is designed to be located in a non-hazardous area. The control system is based on
a Varco Control Module and includes all necessary software to control the tool, programmed
sequential control and operational interlocks for both operator and tool safety. The Control
Module system is based on Profibus DP serial communications for tool field equipment where
the remote I/O technology minimizes derrick and tool cabling and provides the flexibility to
utilize smart type sensors / devices. Control Module peer-to-peer communications and interface
to a higher level network for operator control is accomplished via Ethernet communications and
Profibus DP. Enclosure: 600mm wide x 600mm deep x 2100mm high
The AUX control system has four connections to other electrical systems.
• Power supply: The control system requires a 220vac single-phase power supply @ 5A. This
supply is used by the control system for all power with the exception of the single board
computer, which is on a separate UPS power supply.
• UPS power supply: The control system requires a 220vac single-phase UPS power supply @ 1A.
This supply is used only for the single board computer.
• Ethernet data connection: Data transfer is provided to other systems is via a Cat 5 copper
Ethernet cable, which can be run from control system to control system, and possibly to another
network. All Varco equipment controllers have similar data connections and may be connected
via redundant fiber optic link when required. This provides data communications between Varco
control systems and to/from a higher level network if necessary.
• Emergency Stop: All individual E-Stop circuits are hardwired back to the control system. These
E-Stop signals are connected in series in the control system enclosure, and if they are all healthy
a signal is made available for external purpose, E-Stop healthy. These signals are generally
monitored by a supervisor system for diagnostic purpose and to inform operators of E-Stop
status for each tool. Additionally, there is a contact on the control system power isolator switch,
which, if the control system is isolated for maintenance, sends the E-Stop circuit healthy,
allowing other associated control systems to operate normally.
The FSA design takes into account the hazardous area classification of a particular drilling
operation. Electrical and control system designs will be chosen that satisfactorily meet or exceed the
conditions for safe operation within the respectively classed areas. Rig floor level systems may be
subject to more stringent levels of classification than derrick mounted systems. Standard
components will be used as practicable.
5.4 Control System

The Control Module (CM) receives inputs from various electrical sensors, encoders, operator
interfaces, and other devices mounted on the tool or operators station. Command inputs to the CM
from the operator’s station result in outputs to drive the tool. The CM provides interlock control of
various tool functions monitors sensor and encoder feedbacks. In general, the system of
programmed interlocks provides a safety net to help prevent inadvertent damage, and are not relied
on as a primary operating system. The operator is ultimately responsible for safe operation.
5.5 Failure Modes

In general, the FSA mechanical, electrical, and hydraulic systems are designed to provide the least
obstructive or destructive failure mode. In general, electrical devices are chosen to assure failsafe
mode in order to force the operator to make a decision before proceeding further.
Hydraulic systems are fitted with solenoid operated and load-holding valves as applicable to assure
safe handling of loads in the event of failure.
6. Functions & Operations

6.1 General Operation

General operation of the FSA is defined as manual, where operator is in constant control of the FSA
through use of the VOCC or HMI screen and / or some other controls. The primary function of the
Foxhole® Slip Assembly is to support tubulars in the Foxhole during stand making operations. The
assembly opens to load/unload tubulars and closes to set the slips. The slip sets must be manually
changed in order to support tubulars larger or smaller than their specified range. The following
mechanical functions are used to operate the machine(s):
• Foxhole Open – Opens the Foxhole Slip Assembly.
• Foxhole Close – Closes the Foxhole Slip Assembly.
6.2 Changing Modes

Modes of operation may be changed anytime during operation, however, interlocks will be enforced
to prevent damage to the equipment.
• FSA Open – Used anytime through operator discrete control or touch screen.
• FSA Close – Used anytime through operator discrete control or touch screen
6.3 Interlocks
There are no interlocks currently programmed for operation of the FSA.
6.4 Configuration
There are no base level services or parameters configurable for the FSA.
6.5 Modification Facilities

There are no modification facilities for the FSA.

Technical Drawing Package
PRS-8i
SBM
Lonestar
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

D844000005-GEN-001 Customer Configuration
ADDITIONAL CODE SDRL CODE TOTAL PGS
This document contains proprietary and confidential information
which is the property of National Oilwell Varco, L.P., its affiliates or
REMARKS subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
Reproduction, in whole or in part, or use of this design or
MAIN TAG NUMBER DISCIPLINE
distribution of this information to others is not permitted without the RIG SOLUTIONS
express written consent of NOV. This document is to be returned to 12950 West Little York
CLIENT PO NUMBER NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
represented herein is the copyrighted property of NOV.
CLIENT DOCUMENT NUMBER © National Oilwell Varco
DOCUMENT NUMBER REV

Client Document Number
D811000367-DOS-001 01
www.nov.com
D811000461-GEN-001/01
Document number D811000367-DOS-001

Revision 01
Page 2
REVISION HISTORY
01 06.03.2008 First Issue J. Kellstrom K. Schmidt B. LeVay

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

01 First issue
www.nov.com
D811000461-GEN-001/01

Revision 01
Page 3
TECHNICAL DRAWING PACKAGE

This document provides a list of drawings for the PRS-8i. The actual drawings are arranged in
the binder in numerical order.
Drawings by Assembly
General
Customer Configuration..................................................................................................D844000005
General Arrangement, PRS-8i........................................................................................D721000153
General Arrangement, Foxhole Slip Assembly..............................................................D721000101
Hydraulic Schematic………………………...........................................................................30157732
Block Diagram.................................................................................................................D801000264
Interconnect Diagram......................................................................................................D801000266
Hazardous Equipment Index……………........................................................................D801000270
I/O Map……………….....................................................................................................D801000268
Cable Schedule...............................................................................................................D801000267
Network Diagram Topology……………..........................................................................D801000269
VFD Lineup Assembly, PRS-8I………….......................................................................M801000051
Pneumatic Schematic, Foxhole Slip Assembly…………........................................................122499
Pipe Racking System

Column Assembly………………………………………………………………....................30175136
Counterbalance Manifold Assembly...........................................................................131969
Manifold Assembly, Lower Arm..................................................................................131967
Valve Assembly, Arm……………………………………………………………............ 131964
Compensator Assembly……………………………………..........................................131962
Parallel Gearbox Assembly……………………………………………………………...131915
Roller Housing Assembly………………………………………………………….......... 131869
Claw Assembly………………………………………………………..............................131692
J-Box Assembly, I.S. Carriage………………………………………………………...130900-4
J-Box Assembly, IS/NIS Remote I/O…………………………………………..........30175459
Carriage Assembly, Hoist………………………………………………………..........30175137
J-Box, Tailing Arm Power……………………………………………………………….30156596
Drive Shaft Assembly………………………………………………...........................30151860
Encoder Adapter…………………………………………………...............................30151272
Manifold Assembly, Hoist Arm……………………………………………….............30158097
Manifold Assembly, Handling Tools……………………………………………….....30154737
www.nov.com
D811000461-GEN-001/01

Revision 01
Page 4
Lift Jaw Assembly…………………………………………………………………....…131690-2

Upper Track Assembly………………...............................................................................30172830
Carriage Assembly………………...............................................................................131850
Floor Track Assembly……………………....................................................................M844000341
Lower Drive Assembly…………….......................................................................................131693
Kits PRS-8i
Installation Kit………………………………………………………………………………….M844000072
Foxhole Slip Assembly

Installation Kit, 14”………………………...........................................................................121765-500
Foxhole Slip Assembly……………...................................................................................120960-2
Slip and hanger Assembly, 9-5/8” to 14”……………………...................................121654-2
Slip and hanger Assembly, 3-1/2” to 8-1/4”……………………...............................121654-3
Control Plate Assembly…………........................................................................................96403-6
Handling Tools
Elevator Positioner Assembly………………………………………………...........................30157748
Elevator Assembly, 9 -3/4”………………………………………………….....................30175828-501
Adapter Kit, 5-1/2” Drillpipe for 9-3/4” Elevator…………………………………………............123757
Adapter Kit, 9-1/2” Drill Collar for 9-3/4” Elevator……………………………………………....122378
Adapter Kit, 8” DC for 9-3/4” Elevator……………..................................................................125163
www.nov.com
D811000461-GEN-001/01

Revision 01
Page 5
Drawings in Numerical Order

Control Plate Assembly…………...........................................................................................96403-6
Foxhole Slip Assembly…………….......................................................................................120960-2
Slip and hanger Assembly, 9-5/8” to 14”……………………................................................121654-2
Slip and hanger Assembly, 3-1/2” to 8-1/4”……………………............................................121654-3
Installation Kit, 14”………………………...........................................................................121765-500
Adapter Kit, 9-1/2” Drill Collar for 9-3/4” Elevator……………………………………………....122378
Pneumatic Schematic, Foxhole Slip Assembly…………........................................................122499
Adapter Kit, 5-1/2” Drillpipe for 9-3/4” Elevator…………………………………………............123757
Adapter Kit, 8” DC for 9-3/4” Elevator……………..................................................................125163
J-Box Assembly, I.S. Carriage………………………………………………………................130900-4
Lift Jaw Assembly………………………………………………………………….................…131690-2
Claw Assembly………………………………………………………...........................................131692
Lower Drive Assembly……………..........................................................................................131693
Carriage Assembly………………............................................................................................131850
Roller Housing Assembly…………………………………………………………....................... 131869
Parallel Gearbox Assembly……………………………………………………………................ 131915
Compensator Assembly…………………………………….......................................................131962
Valve Assembly, Arm……………………………………………………………..........................131964
Manifold Assembly, Lower Arm...............................................................................................131967
Counterbalance Manifold Assembly........................................................................................131969
Encoder Adapter…………………………………………………............................................30151272
Drive Shaft Assembly………………………………………………........................................30151860
Manifold Assembly, Handling Tools………………………………………………..................30154737
J-Box, Tailing Arm Power………………………………………………………………........... 30156596
Hydraulic Schematic………………………...........................................................................30157732
Elevator Positioner Assembly………………………………………………...........................30157748
Manifold Assembly, Hoist Arm………………………………………………..........................30158097
Upper Track Assembly………………..................................................................................30172830
Column Assembly………………………………………………………………....................... 30175136
Carriage Assembly, Hoist……………………………………………………….......................30175137
J-Box Assembly, IS/NIS Remote I/O………………………………………….......................30175459
Elevator Assembly, 9 -3/4”………………………………………………….....................30175828-501
Installation Kit……………....................................................................................................30179609
General Arrangement, Foxhole Slip Assembly..............................................................D721000101
www.nov.com
D811000461-GEN-001/01

Revision 01
Page 6
General Arrangement, PRS-8i........................................................................................D721000153

Block Diagram.................................................................................................................D801000264
Interconnect Diagram......................................................................................................D801000266
Cable Schedule...............................................................................................................D801000267
I/O Map……………….....................................................................................................D801000268
Network Diagram Topology……………..........................................................................D801000269
Hazardous Equipment Index……………........................................................................D801000270
Customer Configuration..................................................................................................D844000005
VFD Lineup Assembly, PRS-8I………….......................................................................M801000051
Installation Kit………………………………………………………………………………….M844000072
Floor Track Assembly…………………….......................................................................M844000341
www.nov.com
D811000461-GEN-001/01

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Item Quantity Part Number Description

1 1 SM00969 Service Manual, PRS-8i

NEXT ASSY PRODUCT

CURRENT INITIAL SBM, LONESTAR

© Copyright 2003 Varco International, Inc.

Information in this manual is subject to change without notice.

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

The warning symbol indicates a definite risk of

General System Safety Practices

 Isolate all energy sources before beginning work.

Proper Use of Equipment

PRS-8i Pipe Racking System

Upper Inlet Upper Arm Assembly

Lower Inlet Vertical Column

Floor Track Claw Assembly

Lower Drive Assembly Lower Arm Assembly

PRS-8i Pipe Racking System

Driveshaft components synchronize movement of

Upper Upper Drive

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

90∞ Gearbox 90∞ Gearbox

PRS-8i Pipe Racking System

Remote Output Upper Arm

Lift Jaw Assembly

View from rear

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

View from Rear

View from Front

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

Pressure Valve Control

PRS-8i Pipe Racking System

The SBC (Single Board Computer) section processes

6EP1 333-1SL11 6EP1 333-1SL11

Terminal TBPS1+ TBPS1- TBPS2+ TBPS2-

Digital I/O Modules

PRS-8i Pipe Racking System

a motor, the VFD sends a modulated output to drive the motors. It

also sends a brake release signal to release the brake.

SS Outdoor Brake Resistor VDF Section

Power MR1 MR2 MR3 MR4

6EP1 336-1SH01 SHORT

TBN200 TBN201 TBN202

Circuit Breakers Transformer Line

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

PRS-8i Pipe Racking System

5 1/2" Drill 6 1/2" Drill

Pneumatic Pressure Switch Terminal Blocks

DERRICKMAN RACKER UNLATCH LATCH ACTIVATE

Pressure Air Outlet

Pneumatic Schematic Doubles Latch

Controls and Indicators

Fingerboard Control Station 1

SECTION SLOT BOUNDARIES

Isolate all energy sources before beginning work.