Training Manual 10-Tds346-Pres 001

Training Solutions
Top Drive System

DC TDS 3, 4 and 6 Mechanical
Course
with Raised Back-up System
Document 1000158:8A/04
One Company … Unlimited Solutions

Training Solutions
Introduction

NOV Training Solutions Disclaimer
This manual was developed by National Oilwell Varco as a training

guide and while every effort was made to insure its accuracy, this
manual is only intended to be used as a training aid. Improvements in
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equipment including, but not limited to, design, engineering, materials,
production methods or customer specifications may necessitate
changes in the equipment that may result in inconsistencies between
the contents of this publication and the end product. National Oilwell
Varco reserves the right to make these changes without incurring any
liabilities or obligations beyond those stipulated in a signed purchase
contract with its customer. The images, photographs, charts,
diagrams, drawings, verbal contents and specifications contained
herein are not to be construed as giving rise to any warranty, and are
not to be regarded as approval or disapproval of any specific product or
practice on the part of National Oilwell Varco.

Technical Support
Rig Solutions
24/7 Support
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Technical Support Services
281.569.3050
houstonservicedept@nov.com

Course Outline
Introduction
Pre-test
Equipment Overview
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 At the end of this section the student will be able to: identify, label,
and describe the various parts of the DC top drive, compare the
components and uses of one particular model to the other, and
distinguish the differences between one particular model and the
other.
Equipment Operation
 At the end of this section the student will be able to: list the
procedures/sequences/processes needed to be taken when
operating the DC top drive, list the systems involved in the use of
the DC top drive, and explain the proper use of the DC top drive.

Course Outline (Continued)
Routine Maintenance
 At the end of this section the student will be able to: evaluate and
update existing maintenance schedules to fit the specified
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maintenance requirements, explain why such maintenance is
required, and recognize when repairs are needed.
Basic Troubleshooting and Hydraulics
 At the end of this section the student will be able to: recognize if a
problem exists, isolate the cause of the problem, and take steps to
rectify the situation.
Review/Summary
Post-test

Course Guidelines
 Be in class on time!
 You must be in class for the duration (only one ½ day excused
absence will be allowed,) participate and pass all applicable
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tests to receive your certificate of completion.
 Turn phones and beepers off while in class.
 Laptop computers will not be allowed in class.
 Only one conversation at a time.
 Respect others (no horse play).
 Wear personal protective equipment (PPE) while in the shop.
 Tobacco products of any kind may not be used within the

building. Smoking is only allowed in designated areas.

Wireless Internet Access
 Guest Access
 The receptionist will register a visitor with guest internet access
 The visitor must provide her with the following information:
 A valid email address; the email address becomes the visitors user name
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 A secure password
 The duration of their stay; the visitor will keep their user name and password for the
time specified
 NOV Employee Wireless Access
 The NOVTC students should have access to the employee wireless when they are given
their work computers
 For other employees (or if a student was not granted access) they must contact IT‟s help
desk at HelpDesk@nov.com or at (713) 346 7777.
 Within the help desk ticket the employee must specify their:
 Full Name
 Contact Number(s)
 IP address
 Request for the secure WEP Key to be entered on their computer to gain access to
the training wireless internet
One Company … Unlimited Solutions 9

Daily Agenda
 Class start time – 8:00 AM
 Pre-test (day 1)
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 Discussion
 Lunch break
 Discussion
 Dismissal – 4:00 PM

Class Participation
 You get out what you put in!
 Why are you here?
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 What do you want to learn?

Course Objectives
After completing this course, the student will be able to:

 Identify/compare and contrast the many parts of the DC top drive
and explain their various functions and uses
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 Explain the operation of the DC top drive
 Maintain the equipment
 Demonstrate basic troubleshooting techniques
This will be done through the facilitation of lecture, video, models,

graphics/diagrams/flow charts, demonstration, question and answer,
discussion, problem solving, group work, identification and simulation;
resulting in the student possessing adequate ability and skill needed to
operate and maintain the DC top drive.

Shop Safety
 Stay with the group on shop tours and exercises.
 Watch out for trip hazards.
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 This plant is a working manufacturing facility, so be
watchful of heavy equipment movement by overhead
cranes and forklifts. Moving equipment has priority, so
visitors must clear from any path of movement.
 PPE (safety hats, shoes, and eyewear) must be worn at
all times while in the shop facility.
 Smoking is only allowed in designated areas.

Safety Information
 This symbol indicates advisories for operational or

servicing procedures involving little or no risk of personnel
injury or equipment damage.
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 This symbol indicates advisories involving a risk of
equipment damage.
 This symbol indicates advisories involving a definite risk
of injury to rig personnel.

Advantages of Top Drives
 Ability to ream in or out in sloughing formations
 Minimizes stuck pipe, jarring, and lost wells
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 Higher average ROPs (drilling with stands)
 Reduced tool face reorientation times
 Improved well control while tripping (IBOP)
 More precise torque control on connections

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Equipment Overview

Objective
After completing the overview section of this course, the

student will be able to:
 Identify and label the various parts of the DC top drive
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 Describe the various parts of the DC top drive
 Distinguish the differences between each model
 Compare the components and uses of one particular

model to the other
This will be done through lecture, video, models,
graphics/diagrams/flow charts, demonstration, question and
answer/discussion, group work and identification.

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Equipment Overview
TDS 3S/H

TDS 3S/H Overview
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TDS 3S/H Overview
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Equipment Overview
TDS 4S/H

TDS 4S/H Overview
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Main Body Assembly
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Main Body Assembly
Single reduction transmission:

 Single speed gear reduction
ratio- 5.33:l
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 The main swivel thrust bearing
is housed in the main body.
 Electrically driven lubrication
pump

TDS 4S/H Main Body Assembly
Two speed transmission:

 Bull gears 96 tooth 2.0 diameter pitch
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 High range 5.08:1 27 tooth and 30 tooth
 Low range 7.95:1 23 tooth and 40 tooth
 Motor pinion gears 21 tooth
 Geneva mechanism

Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Description
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Main Body Assembly
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Equipment Overview
TDS 6S

TDS 6S Assembly
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Main Body Assembly
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Main Body Assembly
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Equipment Overview
Counterbalance System

Counterbalance Description – H Model
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Counterbalance Description – H Model
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Counterbalance Description – S Model
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Counterbalance Description
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Counterbalance Valve Assembly
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Equipment Overview
DC Motor

GE 752 DC Motor
 1,130 hp output Series
 1,100 hp output Shunt
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 Double-ended armature shafts
 Air brake

GE 752 DC Motor
Standard Motor Hi Torque Motor

Chamfer cut
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4 Cooling Ducts 6 Additional Cooling Ducts

GE 752 DC Motor
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GE 752 DC Motor
Motor connection to the differential

pressure switch and blower pressure
switch (positioned close to blower
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inlet of motor)
Connection for the low pressure side

of the differential pressure switch

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Equipment Overview
Motor Alignment

Motor Alignment System
 The alignment cylinder is NOT to be used to align the

saver sub with the box at the well center
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 It is used to counterbalance the offset weight of the
drilling motors.
 It is adjustable to ensure that the main shaft is straight at
the well center.

Alignment Cylinder
Adjustment
Valve
Pressure
Gauge
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Adjustment Valve

Motor Alignment Cylinder
Motor alignment system:

 Duplex cylinder
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 Hydraulic accumulator
 Pressure reducing valve

manifold

Motor Alignment
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Motor Alignment Manifold
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Equipment Overview
DC Motor Air Brake Assembly

DC Motor Air Brake
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DC Motor Air Brake
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DC Motor Air Brake
Brake Drum
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Brake Pads
Brake

DC Motor Air Brake
Brake Drum
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DC Motor Air Brake
Sprocket
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Equipment Overview
Blower Assembly

TDS 3S/H Blower Assembly
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TDS 3S/H Blower Assembly (Continued)
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TDS S – Blowers
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Local Blower Assembly
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Local Blower Assembly (Continued)
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Remote Blower Assembly
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Remote Blower Assembly (Continued)
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Closed Loop Assembly
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Closed Loop Assembly (Continued)
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Blower Sensors
 Blower pressure switch
 Differential pressure switch
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 LP connection
 HP connection
 „T‟ connection blower pressure

switch

TDS 4S/4H Sensors
Lubrication pump Sensors installed Switch connection

Oil pressure switch 6 psi rising Normally open
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Oil over-temp switch 160°F +/- 5% Normally closed

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Equipment Overview
PH-85

PH-85 Major Component Description
Pipe handler:
 Link adapter
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 Safety valves (upper and lower IBOPs)
 IBOP valve actuator
 Torque wrench
 Link-tilt mechanism

PH-85 Pipe Handler Specifications
Pipe handler:
 Hoisting capacity 750 tons
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 Break-out torque PH-85 = 85,000 ft-lb
 Hydraulic pressure 2,000 psi maximum
 Hydraulic flow 30 to 35 gpm
 Air pressure 90 psi minimum

PH-85 Pipe Handler Orientation
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PH-85 Pipe Handler
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PH-85 Pipe Handler (Continued)
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Hydraulic link-tilt mechanism:

 Retract
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 Float
 Hold
 Extend

Torque wrench:
 IBOP actuator air cylinders
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 IBOP actuator arms
 Clamping jaw
 Guide ring
 Two stop tubes
 Two torque cylinders

Torque wrench:
 Hanger
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 Lift cylinder
 Torque tube
 Stabbing guide
 Control manifold
 Clamping piston

PH-85 Pipe Handler Link Adapter
Link adapter:
 The link adapter and the
elevator links, working in
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conjunction with the torque
arrestors, transfer the hoisting
loads to the drive stem.

PH-85 Pipe Handler
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PH-85 Pipe Handler
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Pipe Handler Installation
Connections PH 85 / PH60
H1 to A on PH Manifold Hangs on
H2 to D on PH Manifold Rotating Head
A2 to IBOP Close
A1 to IBOP Open
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3/8” to 5/8”
Clearance Between
Torque Tube Splines
and IBOP Splines

PH-60 / PH-85 Pipe Handler
Safety valve actuator:

 Main shaft/drive stem
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 Two actuator arms
 Saver sub
 Landing collar
 Safety valve actuator shell
 Torque tube


 Two upper IBOP valve
actuator air cylinders
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 Lower IBOP
 Drill pipe
 Link adapter
 Two crank assemblies
 Upper IBOP

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Equipment Overview
PH-60

PH-60 Pipe Handler Specifications
Pipe handler:
 Hoisting capacity 500 tons
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 Break-out torque PH-60 =60,000 ft/lbs
 Hydraulic pressure 2,000 psi maximum
 Hydraulic flow rate 30-35 gpm
 Air pressure 90 psi

Pipe Handler Assembly
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Equipment Overview
IBOP Assembly

IBOP Assembly
Safety valves (IBOP):

 Provide blowout prevention
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Saver and crossover subs:
 Saver subs are dual pin.
 Both can be re-cut to a minimum shoulder to shoulder length of 5”.
 The crossover sub converts the lower IBOP pin to a box end.
 Saver subs are load bearing components in the TDS and must be
inspected periodically along with other load bearing components.
Refer to the Maintenance and Troubleshooting book for more
information.


 Main shaft/drive stem
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 Two actuator arms
 Saver sub
 Landing collar
 Safety valve actuator shell
 Torque tube

IBOP Assembly
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IBOP Assembly
Actuator
Crank
Lever
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Upper
IBOP
Actuator
Shell
Manual
Lower IBOP
Saver Sub
Cross over

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Equipment Overview
Pneumatic Link-Tilt

Pneumatic Link-Tilt Assembly
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Pneumatic Link-Tilt Assembly (Continued)
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Equipment Overview
Retract System

Major Component Description
Dual retract guide dolly system:

 Retracts the traveling equipment from well center
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 Provides pipe racking systems immediate access to well center
 Utilizes two dollies
 The retract dolly system includes:
 A block dolly assembly

 A motor dolly assembly
 A retract control system
 Both dolly assemblies include a frame, powered arm, non-powered
arm, a dolly (with rollers), and two hydraulic cylinders.

Retract System
Retract control system:

 Prior to each use of the dolly, clear the rails of any
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obstructions. Ensure that the area is clear of equipment
and/or debris before attempting to hoist, lower, extend,
or retract the system.

Retract Hydraulic Setup
Block Retract System Hydraulic Setup

Description NOV P/N Valve Type Adjustment Test Point
Slow speed 94539-3N Flow control To suit operation w/fast N/A
adjustment solenoid off
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Fast speed 91952 Flow restrictor To suit operation s/fast N/A
adjustment cover solenoid energized
Pilot pressure 94817-1BN PRV 300 PSIG T2
adjustment
Block dolly max 94522-2AN Relief valve 2500 PSID (*See note TB
pressure adjustment below)
TDS dolly max 94522-2AN Relief valve 500 PSID TT
pressure adjustment
Inlet pressure N/A N/A 2000 PSI at distribution T1
manifold
Accumulator 115290 Accumulator 800 PSI nitrogen At accumulator
precharge precharge charge port
*Note: This pressure will depend upon the inlet pressure available. If inlet is 2000 PSI, adjust to
read 2000 at T5 or T6 and then screw in adjustment another ½ turn.

TDS Retract Assembly
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TDS Retract Dolly
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TDS Swing Out Dolly Assembly
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Equipment Overview
Service Loop

Major Component Description
Service loops:
 Two electrical
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 One fluids and air
 Use only 10 wt. hydraulic oil or non-detergent motor oil as a

lubricant in the air system. Use of any other type of oil (i.e., Marvel
Mystery Oil, etc.) or synthetic additive will cause the seals in the air
valves to swell and cease to function.
 To reduce the possibility of accidental opening of the air-operated
elevator, attach the airlines from the air-operated elevators to the
spare port S1 on the rotating head whenever possible. Port S1 is
located next to the hydraulic return port in the rotating head. Port S2
is next to the hydraulic press port.

Service Loop Specifications
Service loop kits:

 Power cables (non-regulated areas):
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 646 mcm 4 (each)
 Standard length 86‟ (flange to flange)
 Diameter 5” ID SAE 100-R2 hose outer jacket
 Power cable voltage 2,000 maximum (each)
 Ground cable 2/0 conductor tinned copper ground

Fluids Loop
 Purge air supply hose (2 each):

 Size- 1 in. ID, SAE 100-R2
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 Working pressure: 150 psi
 Maximum working pressure: 2,000 psi
 Retract hoses (2):
 Size- 1 in. ID, SAE 100-R2
 Maximum working pressure: 3,000 psi

Service Loop
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Service Loop (Continued)
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Equipment Overview
Load Path

Primary Load Bearing Components
The primary load bearing components are:

 Drive stem/main shaft (lower portion)
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 Thrust bearing
 Gear box housing
 Upper / lower safety valves
 Saver subs / crossovers

Primary Load Path Components
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TDS S Drive Shaft
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TDS S Thrust Bearing
Motor
Housing
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Thrust
Bearing
Radial Bearing

TDS Stem and Thrust Bearing
Stem
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Thrust Bearing

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Equipment Overview
Secondary Loading Areas

Secondary Load Path Components
 Swivel bail
 Bail pins
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 Gear box housing
 Rotating head
 Link adapter
 Torque arrestors
 Hanging links
 Drill pipe elevator

Swivel and Bail Pin
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PH-85 Pipe Handler
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Pipe Handler
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Equipment Overview

PH-85 Clamp Assembly
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PH-85 Clamp Assembly
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PH-85 Pipe Handler Assembly
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Equipment Overview
Torque Arrestor

PH-85 Torque Arrestors Assembly
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PH-85 Torque Arrestor Assembly
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Torque Arrestor Assembly
(43.12)
(8.5 Minimum Stroke)
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Oil Plug 2 Outer Springs
2 Qts Oil 10W
Only Used On 500T
2 Inner Springs
Retaining Pin
Drain Plug

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Equipment Overview
Washpipe Assembly

Washpipe Assembly
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Washpipe Assembly
Stem Liner
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Washpipe assembly Poly Pack Seal

Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Equipment Operation

Objective
After completing the operations section of this course, the

 List the procedures/sequences/processes needed to be
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taken when operating the DC top drive
 List the systems involved in the use of the DC top drive
 Explain the proper use of the DC top drive
This will be done through simulation, lecture, video, models

answer, discussion, problem solving, group work,
identification, and homework resulting in a properly
functioning DC top drive.

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Equipment Operation
Top Drive System

TDS Operation
e Do not leave the top drive DC motor stalled in a high

torque condition for more than 7 seconds (refer to the
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following table):
Amps Stall time (sec) Amps Stall time (sec)

280 240 900 25
470 90 1000 20
670 45 1200 15
820 30 1400 7

TDS 4S Top Drive Drilling System
 Drill pipe torque vs.

speed for GE 752
High Torque Series
160 RPM
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motor
37,200 Intermittent  Continuous torque
1,130 HP
values are based on
32,500 Continuous
Limit 1250 armature amps.
 Intermittent torque
High Gear values are based on
stall at 1400 amps
with a 7 second
12,000 ft lb maximum duration.

58,200
Intermittent
50,900
1,130 HP speed for GE 752
Continuous Limit
High Torque Series
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motor
 Continuous torque
values are based on
1250 armature amps.
Low Gear values are based on
stall at 1400 amps
with a 7 second
maximum duration.
5,000 ft lb


speed for GE 752
High Torque Shunt
motor
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values are based on
32,000 Intermittent 1250 armature amps.
29,100 Continuous
Reduced Field  Intermittent torque
Required in
this Area values are based on
stall at 1400 amps
High Gear
with a 7 second
maximum duration.
 Reduced field area is
based on a 30 amp
205 RPM
field.


50,100 Intermittent speed for GE 752
High Torque Shunt
45,500 Continuous
motor
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values are based on
1250 armature amps.
values are based on
stall at 1400 amps
Low Gear
with a 7 second
maximum duration.
 Reduced field area is
based on a 30 amp
130 RPM
field.

TDS 3H Top Drive Drilling System

34,100 Intermittent
speed for GE 752
165 RPM
High Torque Shunt
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31,000 Continuous
motor
Reduced Field
Required in
values are based on
this Area 1250 armature amps.
values are based on
stall at 1400 amps
with a 7 second
maximum duration.
195 RPM

DC Motor Air Brake
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TDS Operation
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TDS Operation (Continued)
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Integrated Controls
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VDC Independent Controls
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Equipment Operation
Motor Alignment

Motor Alignment
Flow Control
Valves
Pressure
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Gauge
Alignment Cylinder

Motor Alignment Adjustment
 Turn off and bleed down HPU and alignment cylinder by

opening needle valve located at the alignment cylinder
valve manifold
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Motor Alignment
 Turn on HPU, circulate system

and close needle valve.
Flow Control  Open the flow control valves at
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Valves
the cylinder 1-1/2 turns off their
seat.

Motor Alignment
Verifying correct pressure settings:

1. HPU on, back down the PRV until saver sub pivots
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“away” from the rails. “Record pressure!!!”
2. Slowly “increase” pressure until the saver sub does not
move “toward” the rails. Cylinder should be in a “dead
band” area.
3. Slowly “increase” pressure until saver sub begins to
move “toward” the rails again. “Record pressure!!!”
4. “Add” the pressure readings and “divide by two.”
5. “Record the pressure setting for future reference.”

Motor Alignment
1. Set a joint of drill pipe in the slips.
2. Bring top drive to connection and check alignment with
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pin of top drive and box of drill pipe.
 If adjustment is necessary use the following procedure.

Motor Alignment
1. Measure how far and in what direction the pin must

move.
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2. Turn off the HPU and bleed down the alignment cylinder
accumulator.
3. Loosen the lock tab and jam nut on the cylinder clevis.
4. Using a wrench on the cylinder rod flats to screw the rod

into or out of the clevis, in the same direction the saver
sub pin needs to move.
5. Secure the jam nut and lock tab.

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Equipment Operation
Gear Changer

TDS 4 Gear Changers
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Remote Shifter
Manual Shifter

TDS 4 Geneva Gears
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Low High

TDS 4 Hi/Low Gears
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Low Gear High Gear

TDS 4 Gear Changers (Continued)
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Remote Gear Changer
Manual Gear Changer

Torque Limit Clutch
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Equipment Operation

 The counterbalance system prevents thread damage

during making up and breaking out connections.
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 The counterbalance system consists of the following
items:
 Two hydraulic cylinders
 Counterbalance manifold
 Two hydraulic accumulator

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Hydraulic Setup Counterbalance
Check the accumulators first.
The accumulators should be precharged to 900 PSI.

Nitrogen
bottle
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Accumulators are set
into each leg of the
TDS dolly.
Remove the plates and

install test kit for
shredder valve.

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

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Equipment Operation
Torque Wrench

Operations
Pipe handler operation:

 Functions as a hydraulic slip ring
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 Operated by controls on the driller‟s console
 Can rotate the swivel block and attached pipe handling

equipment freely to a pre-designated AUTO STOP
position
 The ROTATING HEAD function is only active when the
LINK-TILT switch is in the FLOAT position.

Operations
Torque wrench:
 Torque wrench control manifold consists of:
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 A hydraulic pressure gauge
 Control and sequencing valves
 Hydraulic hose inlet and outlet quick disconnects
 Manual make/break directional valve
 Controls make up/break out during operation
 A pressure reducing valve (PRV) on the control manifold which
allows presetting the make up torque
 This valve is bypassed when the torque wrench is in break out
mode.

Main Stem Torque Chart
Components ID Connection OD Min. torque Max. torque
Upper IBOP to main 3 or 3 ¾ in. 6 5/8 in. API Reg. 7 ¾ in. 50,000 ft-lb 63,000 ft-lb
stem/main shaft
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Lower IBOP valve to 3 or 3 ¾ in. 6 5/8 in. API Reg. 7 ¾ in. 50,000 ft-lb 60,000 ft-lb
upper safety valve
Saver sub to lower 3 or 3 ¾ in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft-lb 60,000 ft-lb
IBOP valve
Crossover sub to 3 or 3 ¾ in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft-lb 60,000 ft-lb
lower IBOP valve
Upper IBOP valve to 3 or 3 ¾ in. 7 5/8 in. API Reg. 9 in. 83,000 ft-lb 91,000 ft-lb
main stem/main shaft
Lower IBOP valve to 3 or 3 ¾ in. 7 5/8 in. API Reg. 9 in. 75,000 ft-lb 84,000 ft-lb
upper IBOP valve
Saver sub to lower 3 or 3 ¾ in. 7 5/8 in. API Reg. 7 5/8 in. 66,000 ft-lb 85,000 ft-lb
IBOP valve
Crossover sub to 3 or 3 ¾ in. 7 5/8 in. API Reg. 9 in. 75,000 ft-lb 91,000 ft-lb
lower IBOP valve

Torque Wrench
 Failing to apply the correct amount of torque when using the torque
wrench to makeup connections can result in equipment damage and
injury to rig personnel.
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 Do not switch the Make/Break valve to BREAK until completing the
makeup sequence (this may require repeating the makeup
sequence several times).
 Verify the torque pressure regulating valve setting after every
makeup sequence before releasing the makeup valve. Repeat the
makeup sequence until the torque cylinders do not stroke more than
one inch during the final sequence. Repeat the sequence if
uncertain. NOV recommends that the driller operating the pipe
handler verify that the torque cylinders do not stroke more than one
inch on the last makeup cycle.

Torque Wrench (Continued)
 NOV also recommends checking the torque gauge on the pipe

handler while making connections to make sure the torque wrench
applies the correct amount of torque to the connection.
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 Stop and verify correct operation whenever the operator observes
unsteady or inconsistent hydraulic pressure readings, or finds it
difficult to adjust set points.
 NOV recommends that a second individual assist the driller when
making connections with the torque wrench. The second person can
verify that the torque wrench applies the correct torque to
connections.

Maintenance Safety
Adjusting the torque wrench:

 The pipe handler torque wrench is properly adjusted and tested in
the factory before it is shipped. Perform the adjustment procedure
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after performing maintenance on the torque wrench or if the torque
wrench does not function correctly.
 Connect a pup joint or joint of drill pipe to the saver sub and make
up hand tight. Be sure to use the correct thread compound when
making up.
 When adjusting the torque wrench manifold needle valves, loosen
the locknut around the valve stem and use a 5/32 in. hex wrench to
adjust the valve. After obtaining the desired setting, tighten the
locknut around the valve stem.

Operations
Changing drill string sizes:

Drill String Change-Over Kits
750/650 Ton PH-85
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Pipe Handling Desired Tool Joint Connection
Original Part NC 38 NC 50 5 1/2 F.H. 6 5/8 F.H. 2 7/8 F.H.
Number
95497-A-H-N-*-* 91873- 94731-650 94730-650 --- ---
650
95497-A-J-N-*-* 91873- 94731-650 --- 94729-650 ---
650
95497-A-K-N-*-* 91873- --- 94730-651 94729-651 97219-651
651
95497-B-K-N-*-* 91873- --- 94730-652 94729-652 ---
651
95497-A-L-N-*-* n/a n/a TBD --- n/a
*These designators do not affect kit choice.

PH-85 Torque vs. Pressure
PSI Ft lb PSI Ft lb
100 4250 1100 46750
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200 8500 1200 51000
300 12750 1300 55250
400 17000 1400 59500
500 21250 1500 63750
600 25500 1600 68000
700 29750 1700 72250
800 34000 1800 76500
900 28250 1900 80750
1000 42500 2000 85000
Torque (ft lb) = Pressure (psi) x 42.5

Torque Values for Load Carrying Components
Components ID Connection OD Min. Torque Max. Torque
Upper safety valve to main 3 in. 6 5/8 in. API reg. 7 ¾ in. 50,000 ft lb 63,000 ft lb
stem / main shaft
Lower safety valve to upper 3 in. 6 5/8 in. API reg. 7 ¾ in. 50,000 ft lb 60,000 ft lb
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safety valve
Saver sub to lower upper 3 in. 6 5/8 in. API reg. 7 ¾ in. 46,000 ft lb 60,000 ft lb
safety valve
Crossover sub to lower 3 in. 6 5/8 in. API reg. 7 ¾ in. 46,000 ft lb 60,000 ft lb
safety valve
Upper safety valve to main 3 in. 7 5/8 in. API reg. 9 in. 83,000 ft lb 91,000 ft lb
stem / main shaft
Lower safety valve to upper 3 in. 7 5/8 in. API reg. 9 in. 75,000 ft lb 84,000 ft lb
safety valve
Saver sub to lower upper 3 in. 7 5/8 in. API reg. 7 ¾ in. 66,000 ft lb 85,000 ft lb
safety valve
Crossover sup to lower 3 in. 7 5/8 in. API reg. 9 in. 75,000 ft lb 91,000 ft lb
safety valve

Adjusting the Torque Wrench
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Pipe Handler Manifolds
 PH-60 manifold with booster kit
 PH-85 manifold
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 Both manifolds are set up the
same way and function in the
same manner.

 With the HPU off, screw the RECYCLE, CLAMP, and TORQUE
sequence valves on the torque wrench manifold fully in.
 Fully back out the pressure reducing valve (PRV), then screw in one
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turn.
 Turn the LIFT/LOWER flow control valve fully in, and then back it
out three turns.
 Turn on the HPU.
 If the torque cylinders are in their full clockwise position, set the
Make/Break valve to MAKE. If they are in their full counterclockwise
position, set Make/Break valve to BREAK. Note that the torque
cylinders should not move if the recycle sequence valve is fully in.

 Slowly back out the RECYCLE sequence valve until the torque
cylinders just start to move, then screw out an additional full turn.
 Move the Make/Break valve to BREAK. Set the PRV to 750 psi.
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 Switch the lever between MAKE and BREAK to adjust the
RECYCLE sequence valve until full rotation in each direction takes
six to eight seconds. Tighten the locknut around the RECYCLE
sequence valve adjustment screw.
 Set the Make/Break valve to MAKE.
 Depress and hold the torque wrench operating button on the VDC.
The torque wrench should lift and the clamp jaws should remain
retracted.

 Slowly back out the CLAMP sequence valve until the clamp jaws
just begin to clamp onto the tool joint. Screw out an additional half
turn. Lock the CLAMP sequence valve adjustment screw in position
by tightening the locknut.
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 Back out the TORQUE sequence valve until the torque cylinders just
begin to stroke, then back out an additional half turn. Tighten the
locknut around the TORQUE sequence valve adjustment screw.
 Release the torque wrench operating button on the VDC. The torque
wrench should start to unclamp and drop, then the torque cylinders
should recycle.
 If the torque cylinders recycle before the clamp cylinders retract,
screw in the RECYCLE sequence valve until the torque cylinders do
not move before the clamp cylinders have fully retracted. Tighten
the RECYCLE sequence valve adjustment screw locknut.

 Cycle the torque wrench as many times as required to

make up the connection.
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 Set the Make/Break valve to BREAK.
 Verify that the torque wrench correctly breaks out the drill
pipe from the saver sub without breaking out the saver
sub or lower IBOP.
 The torque wrench is ready for operation.

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Equipment Operation
Post Jarring

Operations
Post jarring operations:

 Jarring occurs on all drilling rigs. It is not practical to
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recommend removing the top drive from the drill string
during all jarring operations, but the possibility of damage
to a top drive during a jarring operation is considerable.
Consider removing the top drive from the drill string
before performing prolonged jarring. It is imperative to
exercise caution when using a top drive after a jarring
operation.

Before Jarring
A few preparations must be performed prior to jarring stuck pipe with the top drive. The purpose of the
pre-jarring inspection is to provide a record of the condition of the top drive prior to jarring and to restrain
all loose items that could fall free during jarring.
1. Ensure that the expected jarring load does not exceed the rating of the top drive and any other items
used for jarring. If the expected jarring load exceeds the top drive rating, the top drive must be
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moved off line (either in a side skid or removed from the track). Jarring would then be performed with
the kelly and swivel or using the hook and elevators.
2. Inspect all safety wires, lock nuts, etc. And replace as necessary.
3. Inspect the brackets and weld seams on the cooling system and motor frame.
4. Inspect the top of the gearbox, gooseneck support, and washpipe assembly.
5. Remove the elevator and elevator links, if possible, before jarring.
6. Remove the air supply to the air spring located under the grabs support. The air spring should then
be compressed.
7. Restrain the grabs from moving vertically using the grabs restraint. The grabs restraint protects both
the IBOP assembly and the grabs by keeping the grabs from bouncing during jarring operations.
8. Perform a function test of the various functions of the top drive. This will confirm the integrity of the
electrical connections, and also give an indication of hidden damages.
9. Inspect for fluid leaks and listen for air leaks or other unusual noises.

During Jarring
 During extended jarring operations, inspect the top drive

frequently per the chart in the non-destructive
examination document located in the operation and
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maintenance manual.
 Immediately correct all problems found before resuming
the jarring operations to prevent damage to the top drive.
 The frequency of inspection will depend on the intensity
and duration of the jarring process.

After Jarring
Re-inspect the top drive when jarring is complete.

1. Inspect the top drive per the chart in the non-destructive
examination document located in this manual.
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2. Inspect the weld seams on the cooling system and motor frame.
3. Inspect the gooseneck support by removing alternate bolts and

checking for cracks.
4. Inspect the solenoid junction box and motor junction box for
loosened items.
5. Check the transfer panel and top drive control console for loose
connections of electronic cards.
6. Inspect the service loop and mud line for loose connections.

Jarring Notice
Jarring stuck pipe is a serious situation. The top drive and the entire drill string
are severely stressed during this operation. Failure of any component can
occur. While National Oilwell Varco recognizes that jarring is a normal
operation when drilling, it is preferred that the top drive be removed from the
lineup during jarring. Although not available for all rig applications, removal of
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the top drive can be quickly and easily accomplished by utilizing the rotating
side skid system (if equipped).
The rotating side skid system is used for removing the top drive from its guide
tracks to a parallel storage skid, which is a side track/shipping skid
combination and is referred to as the side skid. By “rat holing” or placing the
top drive on the side skid, the guide tracks are open for other operations such
as lowering casing into the hole or jarring. This is an excellent time to perform
preventative maintenance on the top drive while the drill string is being
worked.
A good source of information about stuck pipe can be found in the book
entitled Drilling and Casing Operations written by J.A. “Jim” Short, published
by Pennwell Books, located in Tulsa, OK.

Post Jarring Checklist
Elevators
 Link block bolt assemblies secured
 Hinge pin retainer in place
 Latch pin retainer in place
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Pipe Handler
 Guard pin secured
 Bell guide bolts secured
 Hinge pin retainer bolts inspected
 Die retainer bolts secured
 Jaw retaining bolts tight
 Torque wrench mounting bolts secured
 Bolts on die spring covers secured
 Pins for die springs secured
 Lift cylinder pins secured
 Torque cylinder/torque tube secured
 Hanger nuts for IBOP cylinder secured
 Hanger pin for pipe handler/rotating head secured

Post Jarring Checklist (Continued)
IBOP Actuator
 Bolts for crank assembly secured
 Roller assembly bolts secured
 Actuator arm pins secured
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Dolly Assembly
 Bolts for dolly roller brackets secured
 Bolts for service loop clamp bars secured
 Bolts for s-pipe clamp secured
 Bolts for swivel link retainer plates secured
 Quill housing trunnion cap bolts secured
 Swing bolt pins/nuts secured
Motor/Quill Assembly
 Junction box mounting bolts secured
 Inspection junction box fleet
 Blower motor mounting feet bolts secured
 Heat exchanger mounting bolts secured
 Counterbalance cylinder pins secured
 Counterbalance shackles secured

Post Jarring Checklist (Continued)
Torque Arrestors
 All bolts for solid body elevator plate secured
 Torque arrestors/mounting pins at rotating head secured
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Link-Tilt
 Shackle secured
 Mounting bolts secured to solid body elevator
 Check mounting feet on link-tilt frame
 Stop adjustment pins or lock nuts secured
 Pivot pin secured
Gear Box
 Alignment cylinder pins secured
 Auto return cylinder pins secured
Cooling System
 Extended intake inlet mounting bolts
 Remote blower snorkel tube saddle bolts

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Routine Maintenance

Objective
After completing the maintenance section of this course, the

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 Evaluate and update existing maintenance schedules to
fit the specified maintenance requirements
 Explain why such maintenance is required
 Recognize when repairs are needed
This is done through lecture, video, models,

identification, simulation, and homework resulting in a clean
and functioning DC top drive.

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Routine Maintenance
DC Motor Air Brake

Air Brake Assembly
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Air Brake Assembly
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Air Brake Assembly (Airflex 16VC600)
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Air Brake Assembly
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Brake Pads
Brake Drum

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Routine Maintenance
Accumulator

Accumulator Charging Procedure
 Use an inert gas such as nitrogen for pre-charging the

accumulators. If oil-pumped gas is not available, use dry,
water-pumped nitrogen gas.
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 Before pre-charging, make certain that:
 The accumulator end caps are screwed flush into the
accumulator body
 The gas valve is screwed in tight
 No oil remains are trapped in the top end of the accumulator.
 Remove the gas valve protector and the gas valve cap.

 Attach the charging hose to the nitrogen bottle and to the

gas valve using the following procedure:
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 Thread sealing and lubricating compound on the gauge.
 Back the gas chuck stem completely out before attaching the
assembly to the accumulator gas valve.
 Wrench tighten the gas chuck swivel nut onto the gas valve.
Close the bleeder valve.
 Turn the gas chuck stem all of the way down, depressing the
core in the accumulator gas valve.
 Crack open the nitrogen bottle valve to slowly fill the
accumulator. Shut it off when the gauge indicates 900 psi.

 If the 900 psi pre-charge pressure is exceeded, make sure the

nitrogen bottle valve is closed, then slightly open the bleeder
valve (opposite the gas valve below the gauge)–but only
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momentarily–to reduce pressure.
 Before loosening the swivel nut, turn the gas chuck stem out all
of the way; then open the bleeder valve.
 Prevent the gas valve from turning, loosen the swivel nut, and
remove the assembly.
 When pre-charging is complete, replace the cap on the
gas valve and install the gas valve protector.

Accumulator Assembly
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Damaged piston Damaged
(side view) piston

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Routine Maintenance
Gear Shifter

TDS 4S Shifter Clutch Adjustment Procedure
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Shifter Assembly

Gear Shifter
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Output Stub

Gear Shifter
Gear shifting issues:

 Remove plate and gear stub to expose internal gears.
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 Turn the top drive with chain tongs to make sure the
gears mesh properly.
 DO NOT turn the top drive with the DC motor.

Gear Shifter (Continued)
 Insert two 3/8” bolts into the

threaded holes on the bottom
of the shafts while shifting the
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gears and use a bar to turn the
shaft in the proper direction.

Gear Shifter
 Attach a torque wrench to the indicator of the output stub.
 Hold the body and determine the current torque setting.
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 Remove the snap ring and locking plate.
 Use a 5/8” open end wrench to turn the nut clockwise to

increase torque or to turn the nut counterclockwise to
decrease the torque.
 Check the resulting torque and repeat if necessary.
 Replace the locking ring and snap ring.

Retract Sensor Adjustments
End of Stroke Sensor Fast Speed Target and Sensor
With the dolly extended to this position, locate the target

where the sensor indication is no longer achieved.
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With the dolly fully
extended, locate the
target where the
sensor is first
achieved.
With the dolly retracted to this position,

With the dolly fully retracted, locate locate the target where the sensor
the target where the sensor is first indication is no longer achieved.
achieved.

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Routine Maintenance
Inspection

Inspection
Nondestructive Examination (NDE):

 Yearly (or after approximately 3,000 operating hours),
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perform a nondestructive examination (NDE) of all critical
load path items.
 NDE inspection includes visual examination, dye
penetrating examination, magnetic particle inspection,
ultrasonic inspection, X-ray examination, and other
methods of nondestructive testing for metallurgical
integrity.

Inspection
Ultrasonic inspection:
 NOV also recommends performing an ultrasonic
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inspection to detect any erosion of the inside diameter.
 Any erosion reduces the load carrying capability of the
part. Any subsurface irregularity can also compromise a
component‟s integrity.
 Details on ultrasonic inspection procedures are in the
publication: ASTM A-388 Std. Practice for Ultrasonic
Examination of Heavy Steel Forgings.

Inspection
Magnetic particle inspection (MPI):

 Perform once a year, or every 3,000 operating hours.
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 Inspect exposed surfaces of all load carrying
components.
 After approximately five years, or 15,000 operating hours
(depending on the severity of operating conditions) NOV
recommends performing a MPI of all load carrying
components over their entire surface (including internal
bores) to reveal any fatigue or cracks.

Inspection
Landing collar:
 Disassemble and inspect the landing collar every six
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months.
 After disassembly, inspect all landing collar parts for
wear, damage or corrosion.

TDS S Landing Collar Inspection
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Drive Stem
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Tool Joint Locks
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Inspection
DC drilling motor:
 Thoroughly inspect the TDS, motor support bonnet, and
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guide dolly assembly for loose bolts and fittings daily. If
any safety wire or cotter pins were removed to facilitate
repairs, replace them immediately.

GE 752 DC Motor
1. Remove the commutator cover on the motor to inspect and ensure

all brushes are fully seated and their retaining springs are in place.
2. Check armature and field cables for signs of wear or damage and
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ensure all tails are sitting clear of both the motor and the shop floor.
3. Select the 1000V range on the megger and check that the battery is
okay.
4. Connect one lead from the megger to the motor frame ensuring a
good connection. Connect the other lead to one of the armature
cables. Press the test pushbutton on the megger and note the
value.
5. Repeat step 4, but this time move lead from the armature cable to
the armature cable screen and note the value.
6. Repeat steps 4 and 5, but this time use one of the field cables and
note values.

GE 752 DC Motor (Continued)
7. Connect one lead from the armature cable and the other from the
field cable. Press the test button on megger and note the value.
8. Armature to ground/screen megger reading:
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 This should give a reading somewhere in the region of 500M Ohms
to 50M Ohms. When new, this should be expected to be reasonably
high. The lowest reading that the motor should be operated at is 0.5M
Ohms. Once the motor is electrically energized, this should rise. If the
megger reading is lower than 0.5M Ohms, the motor should be
heated up before use, as most SCR systems will fault below this level
and there is also a possibility of damage to the motor.
9. Field to ground/screen megger reading:
 This reading should be about 500M Ohms. If this reading is lower,
the motor should be heated to bring the value higher.

GE 752 DC Motor
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Bonnet Isolation Bearing
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Upper Bearing Seal
Grease Fitting

Washpipe Inspection
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Washpipe Inspection
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Washpipe Inspection
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Washpipe Inspection
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TDS S Models
 Adjust the upper bearing shims

so that the end of play or axial
movement of main shaft is
.001 to .003 in maximum.
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Inspection
Motor alignment cylinder:

 Check alignment cylinder operation weekly.
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 Check the moving parts.
 Check accumulator pressures on a weekly basis.
 The alignment cylinder is not intended to be used to align the pin

with the box at the well bore. It is a device to counterbalance the
offset weight of the DC motor and allow the system to accommodate
external forces. It is adjustable to ensure that the main shaft is
straight at well center (to compensate for design tolerances in the
guide rails and dolly). To work properly, the guide rails must be
properly located, and the dolly must fit within design tolerances.

Alignment Cylinder
 Set the rod extension and

bleed air as follows:
 adjust the clevis to indicated
Gauge dimension on the rod end (do not
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bend the lock tab)
 open both flow controls
 orient cylinder with side shown up
 fill rod ports with hydraulic oil
through the inlet (bleeding all air
out of the first and third bleed
ports)
Inlet
 pressurize until the rod retracts
fully
 fill the piston port with hydraulic
Initial start-up
measurement is oil (bleeding all air out of the
not final second bleed port).

Alignment Cylinder
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Inspection
Derrick termination kit: air filter/regulator/lubricators:

 NOV supplies a filter/regulator/lubricator in the derrick installation kit
and recommends installing it at the fingerboard level in the derrick.
Improperly adjusted regulators can cause poor device performance
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at reduced pressures, or valve and cylinder seals and O-ring
extrusion at excessive pressures.
 Inspect the entire filter/regulator/lubricator monthly for damage to
the filter bowl, overall body, or inlet and outlet fittings. Replace any
damaged, corroded, or improperly functioning components.
 Adjust the pressure regulator outlet pressure to 100-120 psig
monthly. Clean and drain the filter weekly. Fill the lubricator with
petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU
at 100°F (ISO 32/34).
 Do not use fluids such as Marvel Mystery Oil, motor oil, or Dextron II
in the lubricator. Swollen seals may result.

Inspection
Pipe handler:
 Inspect for loose bolts and fittings daily.
 If there are any safety wire or cotter pins missing or damaged,
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replace them immediately.
 Inspect the hinge bolts daily.
 Make sure the hinge pins are not loose due to excessive wear.
 Inspect the link-tilt intermediate stop and adjustment device for
overall integrity weekly. Replace the components if there is
excessive looseness of the threaded rod in the threaded hole of the
pivot arm. An indication of a possible problem is if the two
intermediate stops are not adjusted equally. Failure to perform this
inspection and/or component replacement can result in injury to rig
personnel.

TDS 4S/H PH-85 Pipe Handler
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TDS 3S/H PH-60 Pipe Handler
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Rotating Head Inspection
10-port powered rotating head:

 Transfers pneumatic and hydraulic pressure from
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stationary ports to rotating ports on the rotating head.
 Three hydraulic passages
 Five pneumatic passages
 Two spare passages
 All are rated at 2,000 psi

Rotating Head (Continued)
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Powered Rotating Head
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Rotating Head Drive
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Hydraulic Drive Motor Drive Hydraulic Manifold

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Routine Maintenance
Lubrication

Washpipe Lubrication
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Washpipe Assembly
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Bail Pin Lubrication
 Lubricate the bail pins weekly.
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Blower Motor Lubrication
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Torque Arrestor Lubrication
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Master Bushing Lubrication
Lubricating the elevator supports

and master bushing wear guide:
 Apply grease to the seven
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fittings on the elevator support
weekly.
 Master bushing wear guide
has four fittings; apply weekly.
 Inspect the guide ring
periodically for wear or
damage and replace it as
necessary.

Torque Wrench Lubrication
Lubricating the torque wrench:

 Apply grease daily to the
torque wrench fittings.
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 Inspect the stabbing guide for
excessive wear or cracks.
 Replace as necessary.

IBOP Lubrication
Lubricating the safety valve actuator:

 Apply grease to the fitting in the crank assembly daily.
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 Check for worn components.
 Operate the valve to verify correct adjustment weekly.

IBOP Lubrication
Lubricating the upper safety

valve (IBOP):
 Lubricate the upper IBOP
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weekly at the lubrication
fittings located directly
below the actuator cranks
in the recessed counter
bores.

Guide Dolly Lubrication
Lubricating the guide dolly

assembly:
 Lubricate the 20 guide rollers
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weekly.
 Lubricate the eight retract arm
pivot points weekly.
 Lubricate the four retract
cylinder pivot points weekly.
 Do not weld, torch, cut on, or
get near the motor frame
without removing the hydraulic
accumulators.

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DC Motor Lubrication
Lubricating the DC motor:

 Plugs need to be removed and grease fittings installed.
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 Lubricate the pinion (transmission) end bearing every 750 hours
(or three months) with 2 ounce by weight Shell Cyprina RA™.
 Lubricate the commutator (brake) end bearing every 1,500 hours
(or six months) with 2 ounce by weight Shell Cyprina RA™.
 Excessive lubrication of electric motors can cause motor
failure due to shorting or heat buildup from grease coming
in contact with the field windings.

Lubricant Specifications
Minimum Ambient Temperature

°F °C Oil type required NOV P/N
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Below 20° -6° See note below See note below
20° to 60° -6° to 16° 2EP, ISO 68 56004-1
45° to 85° 7° to 30° 4EP, ISO 150 56004-BSC
Above 70° 21° 6EP, ISO 320 56004-2
For minimum temperatures below 20°F, the TDS must be warmed up by rotating at a
very light load (less than 200 amps) and at very slow speeds (less than 50 rpm) until
the oil temperature climbs above 20°F.

Lubrication Schedule
Frequency Location Lubricant Number of

code* points
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Daily Bonnet seal 1 2
Daily Torque Wrench (PH-85) 1 6
Daily Gearbox oil (check level) 2 1
Daily Rotating head 1 5
Daily Safety valve actuator cranks 1 2
Daily Hydraulic pressure filter † - -
Daily Washpipe assembly 1 1
Each trip Drill pipe elevator 1 7
Each trip Guide dolly rollers (Retract ‡) 1 20


code* points
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Weekly Gearbox (shift gears) - -
Weekly Dolly motor trunnions 1 2
Weekly Air filter/regulator/lubricator † - -
Weekly IBOP actuator arms 1 6
Weekly Link adapter (650-Ton) 1 4
Weekly Elevator support 1 7
Weekly Master bushing wear guide 1 4
Weekly Link tilt (check condition) - -
Weekly Bail pins 1 2


code* points
Monthly Motor frame/dolly hinges 1 4
(Retract ‡)
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Monthly Cooling system cleaning - -
3 months AC blower motor 1 2
3 months Change gearbox oil 2 1
3 months Gear oil filter/suction strainer † - 1
750 hours/90 days GE drilling motor pinion 3 -
bearing
1,500 hours/6 months GE drilling motor commutator 3 -
bearing
*See Recommended †Check condition and replace ‡Refer to Retract Guide
Lubricants as necessary Dolly supplement
Use only 10-wt. hydraulic oil or non-detergent motor oil as a lubricant in the air control system. Using any other type of
oil or synthetic additive causes the seals in the air valves to swell and cease to function.

Recommended Lubricants
Lube Code and Description
General Purpose Grease Gear Oil

Ambient Above -4°F Below -4°F Above 70°F 45° to 85°F 20° to 60°F
Temperature Range (-20°C) -20°C) (21°C) (7° to 30°C) (-6° to 16°C)
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Castrol MP grease --- Alpha LS-320 Alpha 150 Alpha LS-68
Chevron Avi-Motive Avi-Motive W NL Gear 320 NL Gear 150 NL Gear 68
Exxon Lidok EP2 Lidok EP1 Spartan EP320 Spartan EP150 Spartan EP68
Gulf Gulf Crown EP32 Gulf Crown EP31 EP Lube HD320 EP Lube HD150 EP Lube HD68
Mobil Mobilux EP2 Mobilux EP1 MobilGear 632 MobilGear 629 MobilGear 626
Shell Alvania EP2 Alvania EP1 Omala 320 Omala 150 Omala 68
Statoil Uniway EP2N Uniway EP1N Loadway EP320 Loadway EP150 Loadway EP68
Texaco Multifak EP2 Multifak EP1 Meropa 320 Meropa 150 Meropa 68
Total Multis EP2 Multis EP1 Carter EP 320 Carter EP 150 Carter EP 68
Union Unoba EP2 Unoba EP1 Extra Duty Extra Duty Extra Duty
NL6EP NL4EP NL2EP
NGLI 2 1 --- --- ---
AGMA --- --- 6EP 4EP 2EP
ISO Viscosity Grade --- --- 320 150 68

Recommended Lubricants
Motor Grease Hydraulic Oil

Ambient All 14° to 185°F 5° to 167°F
Temperature Range Temperatures (-10° to 85°C) (-15° to 75°C)
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Castrol N/R Hyspin AWS-46 Hyspin AWS-32
Chevron Black Pearl AW Hyd Oil 46 AW Hyd Oil 32
Exxon N/R Nuto H46 Nuto H32
Gulf N/R Harmony 46AW Harmony 32AW
Mobil N/R DTE 25 DTE 24
Shell N/R Tellus 46 Tellus 32
Statoil N/R Hydraway HMA 46 Hydraway HMA 32
Texaco N/R Rando Oil HD46 Rando Oil HD32
Total N/R Azolla ZS 46 Azolla ZS 32
Union N/R Unax AW46 Unax AW32
NGLI 2 --- ---
AGMA --- --- ---
ISO Viscosity Grade --- 46 32

TDS Lubrication – Oil Pump
Electric Motor
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Coupling
Discharge Pump
Suction

Force Feed Lubrication System
Unless otherwise specified:

5 hp motor rotary gear pump  Apply anti-seize compound to
(TDS 4S/6S) 2 hp motor rotary gear all threads.
pump 2S (TDS 3H/3S/4H)
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 Lock wire all adapter cap
screws.
1” NPT port in
Pump assembly 2 places
outlet pressure-
100 psi dead
head max
Relief valve-
16 Gal/min @ remove cap to
1725 rpm adjust.
Apply anti-seize compound
to both shafts.

Configurations
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Dash no. Description
BSC 5hp 460vac, 60hz 3 phase motor
-1 5hp 575vac, 60hz 3 phase motor
-2 5hp 575vac, 60hz 3 phase motor, with anti-condensation
heaters (42w)
-3 5hp 380vac, 50hz 3 phase motor

Gear Box Lubrication
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Gear Box Lubrication (Continued)
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TDS 3/3H
Check Screen Mesh
Breather
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Suction
Lower
Bearing
Flow
Indicator
Spray Nozzle
Low Lube Oil

Pressure Switch

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Legend
Orifice Filter Orifice Spray Nozzle

Gear Box Lubrication (Continued)
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Legend
Orifice Filter Orifice Spray Nozzle

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Spray Nozzle Tips

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Spray Nozzle

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TDS Gear Box Lubrication
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Thrust Bearing

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Basic Troubleshooting

Objective
After completing the troubleshooting section of this course,

the student will be able to:
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 Recognize if a problem exists
 Isolate the cause of the problem
 Take steps to rectify the situation
This is done through lecture, video, models,

identification and simulation; resulting in a working and
functioning DC top drive.

Technical Support
Rig Solutions
24/7 Support
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Technical Support Services
281.569.3050
houstonservicedept@nov.com

Hydraulics Disclaimer
In order to have a basic understanding of how the hydraulic

system works within a top drive, it is imperative that all other
systems are understood. The hydraulics system marries all
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of the systems in the top drive to give an overall
representation of how they work together to make the top
drive function. Because the majority of the DC top drive
troubleshooting guidelines are within the hydraulic system,
and it is beneficial to learn this system last, the following
sub-sections of this troubleshooting section deal mainly with
hydraulics.

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General Hydraulic Symbols

Hydraulic System and Components
 Hydraulic systems and components are designed for

specific use in the drilling industry. The hydraulic pressure
for this equipment can be as high as 2,500 psi.
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 Before beginning work on any portion of the hydraulic
system, familiarize yourself with the hydraulic and
electrical schematics.
 Isolate, lock out, and tag the hydraulic and electrical
power and controls.
 Take precautions when bleeding down residual system
pressure, using bleed valves or equivalent techniques.

Solenoid Operated Valves
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Manual Valve
3 Position 4 Way Valve

Manual Shift
Detent
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Pumps
Fixed Displacement
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Variable Displacement

Pressure Relief Valves
Standard Valve
Ventable Relief Valve
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Differential Unloading Valve

Pressure Relief Valve in Operation
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Directional Control Valve in Operation
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Directional Control Valve in Operation
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Pressure Reducing Valve
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Pressure Reducing/Relieving Valve
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Check Valve
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Check Valve in Operation
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Check Valves
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Cavity Plug
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3

Internal Plug
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Non Adjustable Flow Control Valves
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Non Adjustable Orifice
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Counterbalance Valves
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Logic Cartridge
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With Metering

Disconnect Coupling
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Non Bypass Filter
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Filter with Bypass
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Manual Shutoff Valve
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Optional Handle
Directional

Thermostat
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Bi-metallic
Strip

Pressure Switch
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2 Position
Normally Closed
Normally Open

Heat Exchanger
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Hydro-Pneumatic Accumulator
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Hydraulic Motor (Bi-Directional)
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Hydraulic Cylinder
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Bore
Stroke
Rod Diameter

Cylinder in Operation
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Tank (Reservoir)
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Test Point
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TDS Hydraulic Components
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System Hydraulics

Pneumatic Manifold
 IBOP closed
 Link-tilt
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 IBOP open
 Brake
 Torque
 Air elevator

Torque Wrench Schematic
Directional control
valve on Pilot valve on
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Torque wrench
solenoid on

Air Manifold Schematic
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Link-Tilt On Schematic
Link-tilt
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solenoid on
Pressure
regulator
Quick release
valve

IBOP Close Schematic
IBOP close-
IBOP open- on
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off
Shuttle valve
Pressure switch
at 75 psi
30 psi set pressure light indicator
regulator
Quick disconnect
Quick relief
(not shown)

IBOP Open Schematic
Before the 30 sec. timer expires
IBOP open- IBOP close-

off
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on
Shuttle valve
Pressure switch
at 75 psi
30psi set pressure light indicator
regulator
Quick disconnect
Quick relief
(not shown)

IBOP Open Schematic
After the 30 sec. timer expires
IBOP open- IBOP close-

off off
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Shuttle valve
Pressure switch
at 75 psi
30 psi set pressure light indicator
regulator
Quick disconnect
Quick relief
(not shown)

Brake On Schematic
Brake solenoid
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Quick relief valve

Brake Operation
Air Exhaust
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Brake
Brake Off
On

Air Elevator Schematic
Air elevator
solenoid on
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Alignment Schematic
Hydraulic
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Power Unit
2000 psi

Alignment Schematic
Hydraulic
Power Unit
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2000 psi

Alignment Adjustment
 Flow control valves
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 1 ½ turns off of seats during
normal drilling operations
 3/4 turn off of seats for heavy
drilling or excessive
movement

Hydraulic Solenoid Manifold
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Counterbalance Manifold
Pilot Operated
Solenoid Valve
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Needle Valve
Pressure
Reducing Valve
Pressure
Gauge

Counterbalance Circuit
Power Supply
2000 PSI
Accumulators Counterbalance Cylinders
Nitrogen
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Hydraulic Manifold
C
Relief Valve
Filter Pilot to open
check valve
P
PRV G
Check Valve
Needle Valve
COUNTERBALANCE MANIFOLD

Link-Tilt Schematic
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S2 Float 150 psi S1 Links Extend
Retract 1000 psi

Torque Wrench Schematic
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Retract System
Retract control system:

 Accumulators
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 Flow divider
 Solenoids
 J-box
 Hydraulic valves
 Bypass valve

Retract Schematic
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Retract Schematic (Continued)
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Appendix

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RBS-3/3i Raised Back-up System

General Description
 The Raised Back-up System allows operators to make

off-bottom drilling connections when using a top drive
system.
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 Using an RBS is typically required for TDS drilling
operations on all floating rigs such as semisubmersibles
or drill ships, and can be specified for bottom supported
or land rigs where off-bottom connections are desirable.

General Description
 The RBS is installed behind the TDS guide rails with the
lower part of the RBS frame located approximately 10 ½‟
above the drill floor.
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 It has integral lift cylinders with a 10‟ stroke to position the
clamping jaws for making connections approximately 11 ½‟
to 21 ½‟ off the drill floor.
 The RBS-3 clamping jaws and supporting framework are
designed to provide back up torque of up to 40,000 ft lbs.
 The RBS-3i clamping jaws and supporting framework are
designed to provide back up torque of up to 60,000 ft lbs.

RBS in Operation
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General Description
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Theory of Operation
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Major Components
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Stabbing Head Assembly
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Tong Arm Assembly
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Tong Arm (New)
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Rail Assembly
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Lift Cylinder Assembly
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Hydraulic Control System
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Hydraulic Control System (Continued)
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Hydraulic Cylinder Locations
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Electrical Control System
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Unlatch/Lift/Deploy Electrical
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Unlatch/Lift/Deploy Hydraulics
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Unclamp/Lower/Store Latch Hydraulics
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Clamp Electrical
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Clamp Hydraulics
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Stab/Grab Electrical
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Grab Hydraulics
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Stab Hydraulics
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Maintenance – Inspection
 Conduct a general visual inspection before each trip.

Check for:
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 Bent or broken hydraulic tubing and fittings
 Broken lockwires
 Loose bolts
 Signs of corrosion
 Check condition of cam rollers during lubrication.
 Check the hydraulic filter indicator on the bulkhead

assembly.

Maintenance – Lubrication
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Maintenance – Lubrication (Continued)
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Maintenance – Hydraulic Filter
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Replacing Tong Dies
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Stabbing Head Alignment
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Troubleshooting
Failed or damaged hardware or a faulty hydraulic system cause most

RBS problems.
Failed or damaged hardware is readily apparent during a visual
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inspection. Failed or damaged hardware can also cause a malfunction
traceable to a particular system or component. Fixing a hardware
problem involves finding the worn or damaged component and
repairing or replacing it.
A failed hydraulic system, unless caused by a clogged filter, defective
seal(s), or insufficient pressure, usually requires some analysis by a
person with hydraulic system experience who is familiar with a current
schematic of the hydraulic system.
The troubleshooting tables on the following pages describe correction
procedures in the remedy column of the tables. If rig personnel cannot
isolate and fix a particular problem, contact the nearest NOV Field
Service Office.

Troubleshooting Guide
Symptom Probable cause Remedy
Control switches do not The RBS ON/OFF switch is Turn the switch ON.
operate. OFF.
The circuit breaker to RBS Reset the circuit breaker.
is OFF.
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The wiring to RBS Check the wiring and
bulkhead assembly is replace or repair as
defective. necessary.
RBS movement is slow or The hydraulic filter is Check the filter on the
erratic. clogged. bulkhead assembly and
replace.
The hydraulic pressure Make sure the HPU output
from the HPU is too low. is 2000 psi and adjust it as
required.
Make sure there are no
kinks or obstructions in the
hoses from the HPU.
The flow control valves are Adjust as necessary.
out of adjustment.

Troubleshooting Guide (Continued)

The tong jaws are slipping Using 3 ½” pipe Adjust the tong jaws for 3
on the pipe. ½” pipe.
The tong jaw dies are Replace the tong jaw dies.
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excessively worn.
The hydraulic pressure Make sure the HPU output
from the HPU is too low. is 2000 psi and adjust it as
required.
The pin does not stab into There is low tension on the Adjust the stabbing head
the box. stabbing head. tension.
The stabbing head is out of Adjust the head alignment.
alignment.
The stabbing head fails to The stabbing head is out of Adjust the stabbing head.
grab pipe. adjustment.
One or both stabbing head Replace the springs and
compression springs are readjust the stabbing head.
broken.


The RBS is unable to move There is an obstruction Check for an obstruction
to the storage position. between the RBS and the and clear as necessary.
guide rails.
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There is no hydraulic Check the tilt cylinder hose
pressure to the tilt cylinder. for kinks and obstructions.
The tilt cylinder directional Clean or replace the
valve is plugged or directional valve as
inoperative. required.
The RBS cannot maintain There is a hydraulic leak in Check the lift circuit for
vertical position when the the lift circuit. leaks and repair as
RAISE (DEPLOY)/LOWER necessary.
(STORE) switch is The raise/lower directional Check the directional valve
released. valve is not closing. for debris. Clean or replace
as necessary.
The dual over-center valve Clean or replace the over-
is leaking. center valve.


Indicator light does not Electric wiring not properly Check wiring against the
operate properly. installed. schematic.
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Broken wire Check for a broken wire.
Switch on tilt cylinder is Verify that the switch
loose. functions properly. Adjust
as necessary.
Safety latch does not Electric wiring or hydraulic Check wiring and plumbing
operate properly. system not properly against the schematics.
installed.
There is a broken wire or Check for broken wire or
hydraulic line. hydraulic lines.
Limit switches on the tilt Verify that the switches
and latch cylinders are function properly. Adjust as
loose. necessary.

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Glossary of Terms

Glossary of Terms
AC (alternating current): a current that flows in one direction in a circuit and then reverses
its direction.
API (American Petroleum Institute): a trade organization that represents the interest of the
oil and gas industry. It presents publications concerning recommended practices, standards,
and other industry related information.
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CHIC (crown height indicator control) box: a box that contains three indicator lights and
an electronic printed circuit board. The lights display the position of the top of the traveling
equipment relative to the crown as well as the system power status.
DC (direct current): continuous current of electric charge.
GPM: gallons per minute.
HPU: hydraulic pressure unit (also referred to as hydraulic power unit).
IBOP (internal blowout preventer): a valve that is installed into the drill stem. It prevents a
blowout from happening inside the stem by allowing mud to be pumped in while not allowing
any flow back up the stem.
ID (inside diameter): diameter of the added circle of an internal gear.
MPI (Magnetic Particle Inspection): a method for the detection of defects in iron-
containing materials. It is done by applying a magnetic field or DC current through a
particular material. The area of defect will have a greater magnetic resistance than that of
the material around it.

Glossary of Terms (Continued)
Pilot-to-close check valve: when the pilot port is pressurized the pilot piston will hold the
check valve closed.
PLC (programmable logic controller): a device used to control some other device that
governs the operation of a system or process.
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PRV (pressure reducing valve): a valve that lowers the pressure of a fluids flow through it.
Psi (pounds per square inch): a unit of pressure. Psi is the pressure resulting from a one
pound-force applied to an area of one square inch.
NDE (nondestructive examination): includes visual examination, dye penetrating
examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and
other methods of nondestructive testing for metallurgical integrity.
NPT (National Pipe Thread): a United States standard for tapered threads used to join
fittings and pipes.
Ohm: unit of electrical resistance.
PH (pipe handler): used to assist the derrick man and driller to move pipe on the drill floor.
Pilot-to-open check valve: pilot piston will hold the check valve open when the pilot port is
pressurized.

Glossary of Terms (Continued)
ROP (rates of penetration): a measure of speed at which the bit drills into formations,
usually expressed in minutes per foot or feet per hour.
RPM (revolutions per minute): a unit of frequency. It is the number of complete rotations
in one minute around a fixed axis.
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SCR (silicon-controlled rectifier): a semiconductor device (a rectifier) that controls current
flow by changing alternating current to direct current by means of a silicon control gate.
SSU (Saybolt Second Universal): a unit for measuring the viscosity of lighter lubricating
oils and petroleum products.
TW: torque wrench.
VDC (Varco driller’s console): the standard driller‟s console used on the A/C top drive.
V-ICIS (Varco integrated controls and instrumentation system): master control system
on the rig that sends signals to a main PLC which transfers data to the various pieces of
equipment on the rig to control them. The driller has a set of controls (touch screen and
joystick) that s/he can use to send these signals.
WC: water column.

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Training Solutions

Top Drive System

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This manual was developed by National Oilwell Varco as a training

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 Laptop computers will not be allowed in class.

 Only one conversation at a time.

 Respect others (no horse play).

 Wear personal protective equipment (PPE) while in the shop.

 Tobacco products of any kind may not be used within the

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 Class start time – 8:00 AM

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 You get out what you put in!

 Why are you here?

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After completing this course, the student will be able to:

 Maintain the equipment

 Demonstrate basic troubleshooting techniques

This will be done through the facilitation of lecture, video, models,

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 Stay with the group on shop tours and exercises.

 Watch out for trip hazards.

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 This symbol indicates advisories for operational or

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 Ability to ream in or out in sloughing formations

 Minimizes stuck pipe, jarring, and lost wells

 Reduced tool face reorientation times

 Improved well control while tripping (IBOP)

 More precise torque control on connections

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After completing the overview section of this course, the

 Distinguish the differences between each model

 Compare the components and uses of one particular

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Single reduction transmission:

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Two speed transmission:

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