TDH-250 – Top Drive System

User Manual

Customer References
Customer: PT Pertamina Drilling Services Indonesia
Rig / Hull: PDSI #16.2/NT 45-M
Tag Number: N/A

National Oilwell Varco References:

SO Number / Project Number: 293814
Document Number: 16645318-MAN
Revision: 01
Volume: 1 of 1

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 Document Number 16645318-MAN
Revision 01
Page 2

REVISION HISTORY

01 12.08.2016 For Information C. Shugart C. Klevies P. Williams

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

01 Initial Release

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 Bill of Material

Item Quantity Part Number Description

1 1 11043316-MAN Service Manual, Top Drive

2 1 16560911-MAN Service Manual, Hydraulic Power Unit
3 1 16645318-DOS Technical Drawing Package
4 1 16645318-SPL Spare Parts List, Mechanical
5 1 16645301-SPL Spare Parts List, Electrical
6 1 16645329-SPL Spare Parts List, TDH-250 Hydraulic Power Unit
7 1 16645337-SPL Mechanical Spares, Hose Reel
8 1 ASP00019 Safety Wiring Procedure
9 1 DS00008 Design Torque Standard
10 1 D811000719-PRO-001 Recommended Lubricant and Fluids
11 1 SM00081 Hydraulic Fluid Cleanliness
12 1 D811001337-DAS-001 NOV Service Center Directory

NEXT ASSY PRODUCT

16567184-GEN TDH-250
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 TITLE USER MANUAL
copyrighted property of NOV. © National Oilwell Varco
PT Pertamina Drilling, Indonesia
CURRENT INITIAL Rig: PDSI 16.2/NT45-M
TDH-250 Top Drive System, Serial No. TD-140-C
DRAWN T. Harmon SCALE: WT LBS: SIZE: SHT:
CHECKED J. Rhone AV 1 OF 1
DWG NO.: REV:
APPVD P. Williams
16645318-IDX 01
DATE 05/19/2016
D811000457-GEN-001/04
 FINAL DOCUMENTATION
TDH-250 - Top Drive System

Chapter 1.0
Service Manual, TDH-250

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 Service Manual
TDH-250 Drilling System

Reference Reference Description

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 National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
11000 Corporate Centre Drive
others is not permitted without the express written consent of
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
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
Document Number Rev.

11043316-MAN 01

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Revision History

01 01.12.2015 First Issue H Gomez A Jones JL Rhone

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Change Description
Revision Change Description

01 First Issue
 Table of Contents
Chapter 1: General Information ....................................................... 1
Overview.................................................................................................................................. 1
Intended Audience ....................................................................................................................................... 1
Disclaimer.................................................................................................................................................... 1
Conventions............................................................................................................................. 2
Advisories .................................................................................................................................................... 2
Illustrations ............................................................................................................................................ 3
Safety Requirements ............................................................................................................... 3
Proper Use ................................................................................................................................................... 3
Safe Lifting .................................................................................................................................................. 3
Personnel Training ....................................................................................................................................... 4
Recommended Tools .................................................................................................................................... 4
General System Safety Practices ............................................................................................................... 4
Replacing Components ................................................................................................................................ 4
Routine Maintenance .................................................................................................................................. 4
Equipment Disposal ............................................................................................................... 5
Service Centers ........................................................................................................................ 5

Chapter 2: Description ....................................................................... 7

Introduction ............................................................................................................................ 7
Major Assemblies and Components ..................................................................................... 7
Swivel Assembly ......................................................................................................................................... 9
Pipe Handler Assembly ............................................................................................................................. 10
Upper Housing Assembly.......................................................................................................................... 13
Rotating Link Adapter Assembly .............................................................................................................. 14
S-pipe Assembly ........................................................................................................................................ 15
Dolly Assembly ......................................................................................................................................... 16
Onboard Electrical Assembly .................................................................................................................... 17
Onboard Hydraulic Assembly ................................................................................................................... 18
Bail and Counterbalance Assemblies ........................................................................................................ 19
Rig Interface ......................................................................................................................... 20
Control Umbilical Assembly (Service Loop) ............................................................................................ 20

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 Table of Contents
Transport Skid ........................................................................................................................................... 21
Rig Interface Kit ........................................................................................................................................ 21
Cable Tender Assembly ............................................................................................................................ 22
Hydraulic Power Unit .......................................................................................................... 23
Hose Reel ............................................................................................................................... 24
Control System ..................................................................................................................... 25
Specifications ........................................................................................................................ 26
Performance Curve .............................................................................................................. 28

Chapter 3: Installation .................................................................... 29

Introduction .......................................................................................................................... 29
Precautions ............................................................................................................................ 29
Reference Documentation ................................................................................................... 30
Preparing the Site ................................................................................................................. 30
Preinstallation ....................................................................................................................... 34
Rigging ...................................................................................................................................................... 34
Mechanical ................................................................................................................................................ 34
Hydraulic ................................................................................................................................................... 35
Electrical .................................................................................................................................................... 35
Unpacking and Handling the Top Drive Assembly .......................................................... 36
Perform the Initial Inspection .................................................................................................................... 36
Position the Hydraulic Power Unit and Hose Reel ................................................................................... 37
Installation Procedures ........................................................................................................ 38
Prepare the Top Drive Assembly .............................................................................................................. 39
Identify Guide Beam Sections ................................................................................................................... 39
Install the Guide Beam Sections to the Mast ............................................................................................. 40
Connect the Service Loop to the Top Drive .............................................................................................. 57
Connect Cables and Hoses to the HPU ..................................................................................................... 57
Hydraulic System Pre-check ..................................................................................................................... 57
Pay out the Hose Reel................................................................................................................................ 57
Inspect the Motor Rotation ........................................................................................................................ 58
Install the Elevator Links........................................................................................................................... 59
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 Table of Contents
Install the Counterbalance Cylinders ......................................................................................................... 61
Adjust the Counterbalance Cylinders ........................................................................................................ 61
Commissioning the Top Drive Assembly ........................................................................... 62
Initial Checkout ......................................................................................................................................... 62
Hydraulic System Checkout ...................................................................................................................... 63

Chapter 4: Operations ..................................................................... 65

Operation .............................................................................................................................. 65
Introduction .......................................................................................................................... 65
Pre-operation Guidelines ..................................................................................................... 66
Preparing the TDH-250 ....................................................................................................... 66
Pre-startup ............................................................................................................................ 67
Checking the Top Drive Mechanical Components............................................................................ 67
Checking the Top Drive Electrical System ........................................................................................ 67
Checking the Top Drive Hydraulics System ............................................................................................. 68
Checking / Adjusting the Counterbalance Valve Pressure ............................................................... 68
Checking the Top Drive System Controls ................................................................................................. 68
Starting the TDH-250 in Cold Weather ...................................................................... 69
Operator System Controls ................................................................................................... 70
Stateless Driller’s Control Console ........................................................................................................... 70
Control Console .................................................................................................................... 71
Front Panel................................................................................................................................................. 71
Internal Components ................................................................................................................................. 72
Controls ..................................................................................................................................................... 73
Interlock Conditions ............................................................................................................ 84
Interlock Rules for Zero Throttle ......................................................................................................... 84
Operating the Top Drive Modes ......................................................................................... 86
Top Drive Modes ..................................................................................................................................... 86
Spin Mode ................................................................................................................................................. 87
Torque Mode ............................................................................................................................................. 88
Operating the Link Tilt ....................................................................................................... 89
Basic Operation .................................................................................................................... 90
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 Table of Contents
Drilling Ahead with Single Drill Pipe ....................................................................................................... 91
Back Reaming ........................................................................................................................................... 92
Tripping in and Tripping Out .................................................................................................................... 93
Running Casing ......................................................................................................................................... 94
Releasing Downhole Torque ..................................................................................................................... 94
Operating the Torque Wrench ........................................................................................... 95
Servicing the Tool Joint Connections ................................................................................. 96
Breaking Connections ............................................................................................................................... 97
Making Connections .................................................................................................................................. 97
Making up the Dual-Valve IBOP Connections ......................................................................................... 98
Breaking out the Dual-Valve IBOP Connections ...................................................................................... 98
Making up the Saver Sub ........................................................................................................................ 100
Breaking out the Saver Sub ..................................................................................................................... 100
Post Jarring Option ............................................................................................................ 102

Chapter 5: Maintenance................................................................ 103

Introduction ........................................................................................................................ 103
Precautions .......................................................................................................................... 104
Reference Documents ......................................................................................................... 105
Regulatory Standards........................................................................................................ 105
Installing or Removing Safety Wire ............................................................................... 105
Maintaining Equipment Maintenance Records............................................................ 105
Inspection & Lubrication Schedules ................................................................................ 106
Secondary Retention ................................................................................................................................ 106
General Greasing Procedures .................................................................................................................. 106
Rig Interface Inspection & Lubrication Schedule ................................................................................... 107
Top Drive Inspection & Lubrication Schedule ....................................................................................... 109
Inspecting the Hang-off Assembly .................................................................................... 114
Inspecting the Guide Beam Joints .................................................................................... 115
Inspecting the Main Tieback ............................................................................................. 116
Inspecting the Intermediate Tieback................................................................................ 117

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 Table of Contents
Inspecting the Top Drive Dolly ......................................................................................... 118
Swivel Assembly Index....................................................................................................... 119
Pipe Handler Assembly Index ........................................................................................... 120
Inspecting the Gearbox Lubrication System ................................................................... 121
Removing the Lubrication Pump Assembly............................................................................................ 121
Inspecting the Lubrication Pump Assembly............................................................................................ 121
Reassembling the Lubrication Pump Assembly ...................................................................................... 123
Inspecting the Oil Level Sight Gauge ..................................................................................................... 123
Adding Gear Oil to the Gearbox ............................................................................................................. 123
Inspecting the Internal Lubrication Flow ................................................................................................ 125
Inspecting the Washpipe Assembly .................................................................................. 126
Removing the Washpipe.......................................................................................................................... 126
Disassembling the Washpipe ................................................................................................................... 126
Repacking the Washpipe ......................................................................................................................... 127
Reassembling the Washpipe .................................................................................................................... 127
Inspecting the Stem Endplay............................................................................................. 129
Inspecting the Bonnet Assembly ....................................................................................... 130
Inspecting the Stem Liner ................................................................................................. 131
Inspecting the S-pipe Assembly ........................................................................................ 132
Inspecting the Bail Assembly ............................................................................................ 133
Inspecting the Encoder ...................................................................................................... 134
Inspecting the Brake Assembly ......................................................................................... 134
Changing the Brake Pads......................................................................................................................... 135
Inspecting the Gearbox Assembly .................................................................................... 136
Inspecting the Gear Backlash .................................................................................................................. 136
Inspecting the Repositioner Assembly ............................................................................. 138
Inspecting the Lock Assembly........................................................................................... 139
Inspecting the Slip Ring Upper Housing Assembly ........................................................ 140
Inspecting the Rotating Link Adapter ............................................................................. 141
Inspecting the Load Collar ................................................................................................ 142
Inspecting the Link Tilt Assembly .................................................................................... 143
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 Table of Contents
Inspecting the Elevator Links ........................................................................................... 144
Inspecting the IBOP Yoke Actuator................................................................................. 145
Inspecting the Clamp Assembly ........................................................................................ 146
Changing the Tong Dies..................................................................................................... 147
Disassembling the Tong Dies .................................................................................................................. 147
Replacing the Tong Dies ......................................................................................................................... 148
Inspecting the Stabilizer .................................................................................................... 148
Inspecting the Tool Joint Locks ........................................................................................ 149
Inspecting the IBOP ........................................................................................................... 150
Inspecting the Hydraulic System ...................................................................................... 151
Inspecting the Control Console ......................................................................................... 151
Top Drive Daily Lubrication ............................................................................................. 152
Top Drive Weekly Lubrication ......................................................................................... 153
Storage Procedure .............................................................................................................. 154
Storing the Equipment ............................................................................................................................. 154
Cleaning the Equipment .......................................................................................................................... 154
Returning the Equipment to Service ................................................................................ 155

Chapter 6: Troubleshooting.......................................................... 157

Introduction ........................................................................................................................ 157
Safety Precautions .............................................................................................................. 157
Troubleshooting Guidelines .............................................................................................. 158
Determining the Nature of the Problem .......................................................................... 159
Identifying Troubleshooting Categories .......................................................................... 159
Mechanical Components ......................................................................................................................... 159
Hydraulic System and Components ........................................................................................................ 159
Controls and Electrical System and Components ................................................................................... 159
Lubrication and Cooling System Components ........................................................................................ 160
Troubleshooting Tables ..................................................................................................... 160
Troubleshooting the Mechanical Components ........................................................................................ 160
Gearbox Lubrication ................................................................................................................................ 163
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Troubleshooting the Lubrication System ................................................................................................ 164
Washpipe Assembly ................................................................................................................................ 165
Troubleshooting the Motor Performance and the Motor Brakes ............................................................. 166
Troubleshooting the Motor Brake Schematic.......................................................................................... 167
Troubleshooting the Main Motor Schematic ........................................................................................... 168
Pipe Handler ............................................................................................................................................ 169
Clamp Assembly ..................................................................................................................................... 169
Troubleshooting the Clamp Assembly – Schematic ............................................................................... 170
Link Tilt Cylinders and RLA System ...................................................................................................... 171
Troubleshooting the RLA Lock Cylinder – Schematic ........................................................................... 172
Troubleshooting the Link Tilt System – Schematic ................................................................................ 173
Troubleshooting the RLA Rotate – Schematic ........................................................................................ 174
Troubleshooting the IBOP ....................................................................................................................... 175
Troubleshooting the Counterbalance System .......................................................................................... 176
Troubleshooting the Top Drive Operations ............................................................................................. 176

Appendix - Hydraulic Symbols...................................................... 177

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 List of Figures
Figure 2-1 : Top Drive Assembly .................................................................................................................... 8
Figure 2-2 : Swivel Assembly .......................................................................................................................... 9
Figure 2-3 : Pipehandler Assembly ................................................................................................................ 11
Figure 2-4 : Upper Housing Assembly .......................................................................................................... 13
Figure 2-5 : Link Adapter Assembly.............................................................................................................. 14
Figure 2-6 : S-Pipe Assembly ........................................................................................................................ 15
Figure 2-7 : Dolly Assembly .......................................................................................................................... 16
Figure 2-8 : Onboard Electrical Assembly ..................................................................................................... 17
Figure 2-9 : Onboard Hydraulic Assembly .................................................................................................... 18
Figure 2-10 : Bail and Counterbalance Assemblies ....................................................................................... 19
Figure 2-11 : Control Umbilical Assembly .................................................................................................... 20
Figure 2-12 : Transport Skid .......................................................................................................................... 21
Figure 2-13 : Cable Tender Assembly ........................................................................................................... 22
Figure 2-14 : Hydraulic Power Unit ............................................................................................................... 23
Figure 2-15 : Hose Reel Assembly ................................................................................................................ 24
Figure 2-16 : Control Console Interface ........................................................................................................ 25
Figure 2-17 : Performance Curve ................................................................................................................... 28
Figure 3-1 : Collapsed Rig Layout ................................................................................................................. 31
Figure 3-2 : Raised Rig Layout ...................................................................................................................... 32
Figure 3-3 : Top Drive Label ......................................................................................................................... 37
Figure 3-4 : Top Guide Beam Section ........................................................................................................... 40
Figure 3-5 : Attaching Carriage Sling to the Hook ........................................................................................ 41
Figure 3-6 : Moving Guide Beam Sections .................................................................................................... 42
Figure 3-7 : Hooking the First Guide Beam Section ...................................................................................... 43
Figure 3-8 : Hoisting the First Guide Beam Section ...................................................................................... 44
Figure 3-9 : Stabbing and Pinning the First Guide Beam Section ................................................................. 45
Figure 3-10 : Completing Guide Beam Section Installation .......................................................................... 46
Figure 3-11 : Hoisting and Attaching the Guide Beam .................................................................................. 47
Figure 3-12 : Removing the Hoist Carriage ................................................................................................... 48
Figure 3-13 : Moving the Top Drive to the Rig Floor ................................................................................... 49
Figure 3-14 : Attaching the Top Drive to the Hook ....................................................................................... 50
Figure 3-15 : Lifting the Top Drive in to the Rig........................................................................................... 51
Figure 3-16 : Connecting the Top Drive to the Guide Beam ......................................................................... 52
Figure 3-17 : Bottom Intermediate Section Warning Label ........................................................................... 53
Figure 3-18 : Attaching the Torque Tieback .................................................................................................. 54
Figure 3-19 : Pinning the Top Drive to the Guide Beam ............................................................................... 55
Figure 3-20 : Raising the Top Drive Assembly ............................................................................................. 56
Figure 3-21 : Motor Rotation ......................................................................................................................... 58
Figure 3-22 : Installing Elevator Links .......................................................................................................... 60
Figure 3-23 : Installing Counterbalance ......................................................................................................... 61
Figure 3-24 : Hydraulic System Checkout ..................................................................................................... 63
Figure 4-1: Front Panel (Door Closed) .......................................................................................................... 71
Figure 4-2: Front View with Door Open ........................................................................................................ 72
Figure 4-3: Common Alarms ......................................................................................................................... 73
Figure 4-4: TDS Emergency Stop and On Buttons ........................................................................................ 74
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Figure 4-5: TDS Rotational Direction and Operations Mode Button ............................................................ 75
Figure 4-6: Pipe handler Controls .................................................................................................................. 77
Figure 4-7: Torque and Rotation Speed Meter ............................................................................................... 79
Figure 4-8: IBOP Controls ............................................................................................................................. 81
Figure 4-9: Dolly Controls and Engine Stop Button ...................................................................................... 82
Figure 4-10: Typical Link and Elevator Position ........................................................................................... 89
Figure 4-11: Drilling Ahead with Single Drill Pipe ....................................................................................... 91
Figure 4-12: Back Reaming ........................................................................................................................... 92
Figure 4-13: IBOP Clamp and Stack Position ............................................................................................... 96
Figure 4-14: Breaking out the dual-ball IBOP ............................................................................................... 99
Figure 5-1: Inspecting the Hang-off Assembly ............................................................................................ 114
Figure 5-2: Inspecting the Guide Beam Joints ............................................................................................. 115
Figure 5-3: Inspecting the Main Tieback .................................................................................................... 116
Figure 5-4: Inspecting the Intermediate Tieback ........................................................................................ 117
Figure 5-5: Inspecting the Top Drive Dolly ................................................................................................ 118
Figure 5-6: Swivel Assembly Index ............................................................................................................ 119
Figure 5-7: Pipe Handler Assembly Index .................................................................................................. 120
Figure 5-8: Inspecting the Lubrication Pump Assembly ............................................................................ 122
Figure 5-9: Inspecting the Gearbox Lubrication System ............................................................................. 124
Figure 5-10: Inspecting the Internal Lubrication Flow ............................................................................... 125
Figure 5-11: Washpipe Bore Tool ............................................................................................................... 126
Figure 5-12: Inspecting the Washpipe Assembly ....................................................................................... 128
Figure 5-13: Inspecting the Stem Endplay .................................................................................................. 129
Figure 5-14: Inspecting the Bonnet Assembly ............................................................................................ 130
Figure 5-15: Inspecting the Stem Liner....................................................................................................... 131
Figure 5-16: Inspecting the S-pipe Assembly ............................................................................................. 132
Figure 5-17: Inspecting the Bail Assembly ................................................................................................. 133
Figure 5-18: Inspecting the Brake Assembly .............................................................................................. 134
Figure 5-19: Changing the Brake Pads ....................................................................................................... 135
Figure 5-20: Inspecting the Gear Backlash ................................................................................................. 136
Figure 5-21: Inspecting the Gearbox Assembly .......................................................................................... 137
Figure 5-22: Inspecting the Repositioner Assembly ................................................................................... 138
Figure 5-23: Inspecting the Lock Assembly ............................................................................................... 139
Figure 5-24: Inspecting the Slip Ring Upper Housing Assembly ............................................................... 140
Figure 5-25: Inspecting the Rotating Link Adapter .................................................................................... 141
Figure 5-26: Inspecting the Load Collar ..................................................................................................... 142
Figure 5-27: Inspecting the Link Tilt Assembly ......................................................................................... 143
Figure 5-28: Inspecting the Elevator Links ................................................................................................. 144
Figure 5-29: Inspecting the IBOP Yoke Actuator ....................................................................................... 145
Figure 5-30: Inspecting the Clamp Assembly ............................................................................................. 146
Figure 5-31: Changing the Tong Dies ......................................................................................................... 147
Figure 5-32: Inspecting the Stabilizer ......................................................................................................... 148
Figure 5-33: Inspecting the Tool Joint Locks ............................................................................................. 149
Figure 5-34: Inspecting the IBOP ............................................................................................................... 150
Figure 5-35: Inspecting the Control Console .............................................................................................. 151

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Figure 5-36: Top Drive Daily Lubrication .................................................................................................. 152
Figure 5-37: Top Drive Weekly Lubrication .............................................................................................. 153
Figure 6-1: Lubrication System .................................................................................................................... 164
Figure 6-2: Motor Brake Schematic ............................................................................................................. 167
Figure 6-3: Main Motor Schematic .............................................................................................................. 168
Figure 6-4: Clamp Assembly Schematic ...................................................................................................... 170
Figure 6-5: RLA Lock Cylinder Schematic ................................................................................................. 172
Figure 6-6: Link Tilt System Schematic ...................................................................................................... 173
Figure 6-7: RLA Rotate Schematic .............................................................................................................. 174
Figure 6-8: IBOP Actuator Schematic ......................................................................................................... 175

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 List of Tables

Table 2-1: System Specifications………………………………………………………………………….26

Table 2-2: Performance Specifications…………………………………………………………………….28
Table 4-1: Identifying Programmed Interlock Conditions…………………………………………………85
Table 5-1: Wear Limits for Washpipe Spacers ........................................................................................... 126
Table 5-2: Wear Limits for Washpipe Packing Nuts .................................................................................. 127
Table 6-1: Troubleshooting the Swivel Assembly ....................................................................................... 161
Table 6-2: Troubleshooting the Gearbox Lubrication.................................................................................. 163
Table 6-3: Troubleshooting the Washpipe Assembly .................................................................................. 165
Table 6-4: Troubleshooting the Motor Performance and the Motor Brakes ................................................ 166
Table 6-5: Troubleshooting the Clamp Assembly ....................................................................................... 169
Table 6-6: Troubleshooting the Link Tilt Cylinders and RLA System ........................................................ 171
Table 6-7: Troubleshooting Motor Brakes ................................................................................................... 176
Table 6-8: Troubleshooting the Top Drive Operations ................................................................................ 176

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Overview
This service manual is part of the National Oilwell Varco® (NOV) documentation package for your
NOV equipment. Along with a description of the equipment, the service manual contains
information for the installation, operation, maintenance, and troubleshooting of the equipment.

Intended Audience
This manual is intended for use by field engineering as well as installation, operation, and
maintenance personnel. The procedures within this manual should never be performed by
untrained individuals.
Reference: For more information about training, see the Safety Requirements section (in this
chapter).

Disclaimer
While every reasonable effort has been made to ensure the accuracy of the information contained
herein, NOV makes no representations or warranties as to the accuracy or completeness of the
information. NOV reserves the right to revise this manual at any time without the obligation to notify
any person or organization.
NOV shall not be liable for any damages arising from the use of this manual. It is the responsibility
of the owner/operator to ensure safe usage and operation of the equipment. All operators must be
properly trained before they handle or operate the equipment.
The illustrations in this manual may not be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

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Conventions
This section of the chapter describes the service manual conventions.

Advisories
The graphical symbols within this manual indicate advisories that provide the user (intended
audience) with additional information about a topic or inform the user of the potential or definite
risks to personnel or equipment and the necessary action the user should or should not take to
avoid the risks. The following lists the symbols and an explanation of each:

Note
The note symbol indicates details or additional information that may be useful
for better understanding the related topic.

Caution
This symbol indicates a potential risk of injury to personnel or damage to
! equipment. Failure to follow instructions explicitly and use extreme care when
performing operations and procedures could result in injury to personnel,
damage to equipment, or rig downtime.

Warning
WA
ARN
NI N G
The warning symbol indicates a definite risk of equipment
damage or danger to personnel. Failure to follow safe work
procedures could result in serious or fatal injury to
personnel, significant equipment damage, or extended rig
downtime.

Hot Surface
This symbol indicates the presence of a potentially hot surface or component.
Failure to allow the hot surface or component to cool before touching it could
result in bodily injury.

Pinch Point
The pinch point symbol indicates the potential for part of the body becoming
caught or pinched between two objects. Failure to avoid pinch point areas
while the equipment is operating or use extreme care around the pinch points
could result in serious or fatal bodily injury.

Electrostatic Discharge
This symbol indicates the potential for electrostatic discharge (ESD). Always
remove static electricity prior to working on ESD sensitive components or in
flammable environments. Failure to do so could result in ESD:
• Damaging or destroying sensitive electronic components
• Setting off explosions or fires in flammable environments
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 Illustrations
The illustrations (figures) provide a graphical representation of equipment components or
screenshots for use in identifying parts or establishing nomenclature. These illustrations may not
be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

Safety Requirements
NOV equipment is installed and operated in a controlled drilling-rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
in the manuals are the recommended methods for performing installation, operations,
maintenance, and troubleshooting.

To avoid injury to personnel or damage to equipment, carefully observe the

! requirements outlined in this section.

Proper Use
NOV equipment is designed for specific functions and applications and, therefore, should be used
only for its intended purposes.

Safe Lifting
Operators and maintenance personnel should be properly trained in safe lifting procedures and in
the inspection of material handling equipment and lifting components. When lifting and handling
NOV equipment or components, always:
• Follow all federal, state, and local rules, industry and company standards, and rig-specific safety
guidelines.
• Use approved safe lifting procedures and safe methods.

Safe lifting recommendations provided in this manual do not take precedence

over local safety rules and regulations, OSHA regulations, or instructions issued
by the manufacturers of rig hoisting equipment and other tools on the rig.

WA
AR N I NG
Lifting equipment improperly creates a hazardous working
environment. To avoid lifting hazards, lift equipment only
with material handling equipment rated for the expected
load and from the designated lift points. Failure to follow
safe lifting guidelines may result in serious or fatal injury to
personnel, significant damage to equipment, and extended
rig downtime.

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 Personnel Training
To ensure their safety, all personnel performing installation, operations, maintenance, or repair
procedures on or in the vicinity of the equipment should be trained in rig safety and equipment
operation and maintenance.
Reference: For more information about personnel training, contact the NOV training department.

Recommended Tools
When an operation requires a specific tool recommended by the manufacturer, the use of that tool
should be enforced, and the tool should be used in a manner that:
• Follows the procedures for the operation
• Safeguards personnel and equipment

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
cooling water or electrical, hydraulic, or pneumatic utilities.

Before installing, operating, or troubleshooting equipment or performing

! maintenance, read and follow these guidelines to avoid endangering exposed
persons or damaging the equipment:
• Isolate energy sources before beginning work.
• Avoid performing maintenance or repairs while the equipment is in
operation.
• Wear proper protective equipment during equipment installation,
operations, maintenance, and repair.

Replacing Components
When replacing components:
• Verify that components such as cables and hoses are tagged and labeled during assembly and
disassembly of equipment to ensure correct installment.
• Replace failed or damaged components with original manufacturer-certified components.

Failure to replace failed or damaged components could result in injury to

! personnel or damage to equipment.

Routine Maintenance
Equipment must be routinely maintained.

Failure to conduct routine maintenance could result in injury to personnel or

! damage to equipment.

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Equipment Disposal
The equipment owner is responsible for disassembling and removing the equipment at the end of
the equipment’s useful operating life. It is also the equipment owner’s responsibility to conform to
applicable regulatory policies and standards, as well as recycling guidelines, when removing the
equipment and when disassembling equipment components and disposing of fluids and
consumable spare parts after scheduled and unscheduled equipment maintenance.

Service Centers
For a directory of NOV service centers, see Service Center Directory, document number
D811001337-DAS-001 in the NOV documentation package.
This link provides after-hours and 24-hour contact information for emergencies or equipment
issues requiring an immediate response from NOV service personnel:
www.nov.com/contact_us/24hr_EmergencyList.asp.

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Introduction
The National Oilwell Varco TDH-250 is a hydraulically driven top drive that contains all modern features in a
compact package. Three variable displacement hydraulic motors allow the TDH-250 to produce 23,000 ft-lbs
of torque with a maximum stem speed of 225 RPM. It can make and break pipe connections with
43,250 ft-lbs of torque and will support a 250 ton drill string.

This chapter covers the following sections:

• Major Assemblies and Components
• Rig Interface
• Hydraulic Power Unit
• Hose Reel
• Control System
• Specifications
• Performance Curve

Major Assemblies and Components

This section describes the major assemblies and components of the TDH-250. The TDH-250 provides
optimal power in a compact package and can be used in both land-based and offshore drilling operations.
For detailed top drive capability information, see the Specifications section on page 25.

This manual covers one version of the TDH-250, although there are other
variations of the Top Drive available. For information regarding the other
versions or features of the TDH-250, please contact an NOV representative.

The top drive assembly is comprised of the following:

• Swivel Assembly
• Pipe Handler Assembly
• Upper Housing Assembly
• Rotating Link Adapter Assembly
• S-pipe Assembly
• Dolly Assembly
• Onboard Electrical Assembly
• Onboard Hydraulic Assembly
• Bail and Counterbalance Assemblies

Figure 2-1 shows an orientation view of the top drive assembly.

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 Figure 2-1 : Top Drive Assembly

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 2 Description

Swivel Assembly
The swivel assembly, Figure 2-2, of the TDH-250 contains all of the components necessary to assemble
the gearbox/transmission, motor assemblies, brake system, and lubrication system. The gearbox holds
gear oil that is dispensed as lubrication to the gears and bearings of the main assembly. It has three
hydraulic motors on top of the gearbox cover that deliver torque to the gear set.
An encoder is attached to the gearbox cover. It produces a signal of pulses for each revolution of the main
shaft. This signal is sent through to the single-board computer (SBC). The SBC calculates the actual drill
stem speed by dividing the main shaft speed by the gear ratio of the transmission.
Reference: For specific information about the Encoder, refer to the TDP.

Figure 2-2 : Swivel Assembly

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 The swivel assembly consists of the following major systems and components:
• Gearbox Housing
• Washpipe
• Braking System
• Lubrication System

Gearbox Housing
The gearbox contains the bearings, shafts, and gears of the top drive. It transmits the torque needed for
drill string operations and also supports the weight of the drill string. The inspection window plate is located
on the driller’s side of the gearbox and is used to access the inside of the gearbox.

Washpipe
The washpipe connects the rotating top drive drill stem to the stationary gooseneck and is rated to 5,000
psi pressure. The washpipe must have free movement in vertical and lateral directions. Restrictions in
either direction can reduce operating time.

Braking System
The TDH-250 uses a disc braking system which is mounted on top of the gearbox cover under the driller’s
side motor. This system is equipped with 35,000 ft-lb of static braking capacity. The braking system
prevents the top drive from rotating while downhole operations are performed.

Lubrication System
The lubrication system supplies lube oil to the bearings and gears within the gearbox. Sprayer
nozzles mounted inside of the gearbox evenly distribute lube oil to each gear mesh while orifices
feed a steady supply of oil to each bearing.

Pipe Handler Assembly

The pipe handler,

Figure 2-3, provides functions for making and breaking drill string tool joints with the top drive. The
clamping mechanism can be positioned to provide backup support for removal and installation of a saver
sub and dual-ball internal blowout preventer (IBOP) valves.
This pipe handler assembly consists of:
• Dual-Ball IBOP Valve
• Saver Sub
• External Clamps
• Torque Arrestor
• Stabbing Guide
• Back-up Clamp

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 2 Description

Figure 2-3 : Pipehandler Assembly

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 Dual-Ball IBOP Valve
The IBOP system is a series of components used to contain or prevent a downhole pressure kick
from venting into the atmosphere through the inside of the drill pipe. It also provides the coupling
hardware between the drive stem of the top drive and the drill string. The IBOP has a dual ball
valve design that is connected directly to the main shaft.
The dual ball valve contains a remotely operated upper actuator valve and manually operated
lower actuator valve. If the selected upper IBOP valve fails or requires service, the lower IBOP
valve can enable the drilling operation to continue until the IBOP assembly can be removed for
maintenance.
Reference: For detailed maintenance procedures on the dual ball IBOP valve assembly, see the
Maintenance chapter in this manual.

The valve should never be used as a meter or be partially opened to restrict

! the flow of drilling fluid. Doing this could cause damage to the equipment.

Saver Sub
The saver sub is a component used to save the IBOP valve's shoulder and threads by absorbing
the wear due to repeated makeup and breakout of drill pipe. A variety of saver subs are available
according to the size of the tool joints being used and the casing sizes being used downhole.

External Clamps
External clamps provide torsional resistance and prevent unwanted tightening or loosening of the
threaded stem connections while making or breaking pipe connections. The external clamps fit
around the connection seam to provide torsional resistance at these locations. The patented split
inner-ring design of the Ringfeder™ external clamps enable quick installation of the clamps and
securing the clamps through several bolt connections.

Torque Arrestor
The torque arrestor frame hangs from the rotating link adapter, and is used during pipe
connection procedures. When making and breaking connections, torque is transferred from the
clamp to the gearbox by the torque arrestor.

Stabbing Guide
The stabbing guide is on the bottom of the pipe handler clamp. The cone shape of the stabbing
guide helps direct pipe into the clamp assembly.

Back-up Clamp
The back-up clamp utilizes a hydraulic piston to press dies in to the box end of a connection joint.
The top drive can spin in to or out of this box joint to make or break a connection.

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 2 Description

Upper Housing Assembly

This housing assembly is a customized configuration that includes the following components:
• Slip ring
• Rotate manifold (controls the fluid for the hydraulic motor)
• Repositioner gear
• Rotating link adapter (RLA) lock
• Hydraulic motor
• Hydraulic cylinder
The upper housing assembly directs the flow of hydraulic fluid from the main functions manifold,

Figure 2-4, through the upper slip ring ports. The fluid then flows through the internal slip ring ports and is
channeled out to the link adapter hydraulic ports, Figure 2-5. This process enables the control of the
hydraulic components below the RLA. The rotate manifold provides hydraulic fluid to the hydraulic motor,
which enables rotation of the repositioner gear.

Figure 2-4 : Upper Housing Assembly

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 Rotating Link Adapter Assembly
The RLA assembly consists of the following components, Figure 2-5:
• Link tilt
• Clamp
• Stabbing guide
• Link adapter
• Load collar
• Hydraulic link adapter ports
• Torque arrestor
• Links
The rotating link adapter assembly houses the slip ring assembly and carries the drill string load. It also
provides support for the torque arrestor.

Figure 2-5 : Link Adapter Assembly

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 2 Description

S-pipe Assembly
The S-pipe assembly consists of the following components,Figure 2-6:
• Bonnet
• Goooseneck
• S-pipe
The S-pipe assembly routes mud flow through the swivel assembly into the main shaft. This assembly is
located on the right-front side of the top drive.

Figure 2-6 : S-Pipe Assembly

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 Dolly Assembly
The dolly assembly,

Figure 2-7, attached to the gearbox housing, enables the top drive assembly to travel along the guide
beam. The dolly assembly is designed to support the weight of the top drive during shipping and will also
transmit torque to the guide beam and derrick.
The dolly assembly includes these components:
• Bogie Rollers
• Cam Followers
• Frame

Figure 2-7 : Dolly Assembly

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 2 Description

Onboard Electrical Assembly

The onboard electrical assembly,

Figure 2-8, has two stainless steel junction boxes (J-boxes). The top drive J-box is mounted to
the rear driller’s side gearbox fin and the solenoid J-box is mounted to the rear off-driller’s side
gearbox fin. The J-boxes join the electrical cables from the service loop to the electrical
components on the top drive.
The onboard electrical assembly contains:
• J-boxes
• Pressure Transmitters
• Pressure Switch

Figure 2-8 : Onboard Electrical Assembly

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 Onboard Hydraulic Assembly
The onboard hydraulic assembly,Figure 2-9, contains a hydraulic manifold assembly that
distributes fluid to each component, as well as a hose/fitting kit and an auxiliary manifold kit that
powers the counterbalance and lubrication systems.
The onboard hydraulic assembly contains:
• Manifold assembly
• Counterbalance and lubrication manifold assembly
• Hose and fitting kit

Figure 2-9 : Onboard Hydraulic Assembly

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 2 Description

Bail and Counterbalance Assemblies

The bail assembly connects the top drive assembly,

Figure 2-10, to the hook block. It includes bail pin bushings that act as a wearable interface between the
bail and bail pins. The counterbalance assembly floats the weight of the top drive to aid in making-up and
breaking-out drill pipe or casing connections. It helps to protect the pipe threads from damage while
making-up or breaking-up out of a connection.

Figure 2-10 : Bail and Counterbalance Assemblies

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Rig Interface
The following components make up the TDH-250 rig interface:
• Control Umbilical Assembly
• Transport Skid
• Rig Interface Kit
• Cable Tender Assembly

Control Umbilical Assembly (Service Loop)

The TDH-250 requires a control umbilical assembly (service loop) to carry hydraulics, controls, and
electrical power to the drilling system. The service loop for the top drive contains a solenoid valve cable
and an instrumentation cable, as well as hydraulic hoses for hydraulic fluid supply and drain lines. It is
spooled around a Hose Reel, which is the link between the HPU/Rig and the Top Drive. The service loop
assembly consists of the following cables and hoses:
• Solenoid valve cable (1)
• Instrumentation cable (1)
• Hydraulic hoses (5)
Reference: For rig-specific service loop connections, refer to the engineering drawings provided in
the TDP.

Figure 2-11 : Control Umbilical Assembly

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 2 Description

Transport Skid
The top drive assembly ships on a transport skid, which is used to stabilize the assembly during
transport. In addition, the skid serves as the lower track section when attached to the guide track
in the derrick. It utilizes the Rig Installation Kit to rigidly fix itself against the derrick. Figure 2-12
shows the lifting points where the TDH-250 can be lifted safely to avoid possible injuries to
personnel or damage to the equipment.

Figure 2-12 : Transport Skid

Rig Interface Kit

The top drive assembly is secured to the mast using the Rig Interface Kit. This kit includes all the structural
components and hardware used to fix the bottom guide beam section against the derrick.

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 Cable Tender Assembly
The umbilical assembly is securely hung in the derrick by the Cable Tender Assembly,Figure 2-13. This
assembly keeps the umbilical assembly from laying on the drill floor and enables the hoses and cables to
articulate as the top drive moves within the mast.

Figure 2-13 : Cable Tender Assembly

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 2 Description

Hydraulic Power Unit

The TDH-250 receives its hydraulic supply from a Hydraulic Power Unit (HPU),
Figure 2-14, that typically utilizes a diesel engine to pump hydraulic fluid through a closed circuit, although
electric versions are possible. The diesel engine (or electric motor) will produce up to 850 horsepower while
turning the variable displacement pump to power the drilling motors. An onboard electric motor supplies
power to all of the hydraulic top drive functions such as pipehandler clamping, counterbalance, and link tilt.

Figure 2-14 : Hydraulic Power Unit

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Hose Reel
The hose reel,
Figure 2-15, is a spooling system that organizes and contains the top drive hoses and cables. When the
top drive is installed in a mast, the hose reel will pay out enough hose and cable to safely run the top drive
up and down the mast. During shipping, the cables and hoses are reeled in and locked in place.

Figure 2-15 : Hose Reel Assembly

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 2 Description

Control System
Although there are many different ways to provide control, the TDH-250 is typically controlled with a
stainless steel control console mounted atop the drill floor and directly connected to the Hydraulic Power
Unit. This console,
Figure 2-16, contains hand activated buttons and knobs that control the various functions of the top drive
and HPU.

Figure 2-16 : Control Console Interface

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Specifications
This section covers specifications for the TDH-250 system.

Table 2-1. System specifications

Component Description Measurement

General Weight 13,360 lb

Height w/o links 14 ft-5 in.

Output torque (continuous) 23,000 ft-lb

Tool torque (intermittent and 43,250 ft-lb

stall)

Maximum speed 225 rpm

(at full power)

Hoisting capacity
Top drive 250 ton API-8C, PSL-1

Load path Single

Temperature rating -20°C to +45°C

Gooseneck entry 5,000 psi/ 2-3/4 in. ID

Gooseneck access hole Diameter: 2-1/4 in.

Circulation passage 2-3/4 in.

S-pipe pressure rating 5,000 psi

Washpipe pressure rating 5,000 psi

Mud hose connection 4 in. FIG 1502

Mud system pressure 5,000 psi

Pipe handler assembly Stem connection NC50

Link tilt position with 96 in.
(2,438 mm) links
• Up to 56 in. elevator position for singles from
mousehole V-door
• Up to -31in. when delivering stands to and from
the derrick operator
• -72 in. over drill position

Table continues on next page

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 2 Description

Table 2-1. System specifications (continued)

Component Description Measurement

Drilling motor Type Bosch Rexroth A6V (3 x 215cc)

Max speed at full disp. 2900 rpm

Max input flow 165 GPM @ 6525 psi

Brakes Type Hydraulic caliper-disc brakes

35,000 ft-lb static capacity

Gear case Type Single-speed, double-reduction, helical gear

Gear ratio 18.67:1

Transmission lube Pressure fed, filtered, and cooled

Hydraulic system Pressure 3,000 psi

Flow 20 gpm

Oil type Mineral-based hydraulic oil

IBOP Dual ball 6-5/8 in. (168 mm) API NC50 box to box

ID 2-1/2 in. (64 mm)

Pressure 10,000 psi (689 bar)

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Performance Curve
The following table and graph,
Figure 2-17, represent the performance curve for the TDH-250:

Table 2-2. Performance specifications

Performance parameter Specification

Maximum drilling torque 23,000 ft-lb

Drilling torque at 100 rpm 23,000 ft-lb

Makeup/breakout torque 43,250 ft-lb

Maximum drill pipe rpm 225 rpm

Maximum continuous input power Approximately 600 bhp (at HPU)

Figure 2-17 : Performance Curve

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 Before installing or removing the equipment or any of its components, ensure that you have
! read and understand the content in the General Information chapter as well as the
applicable installation advisories and procedures in this chapter.

Introduction
This manual covers one version of the TDH-250, although there are other
! variations of the Top Drive available. For information regarding the other
versions or features of the TDH-250, please contact an NOV representative.

The following sections are covered in the chapter:

• Precautions
• Reference Documentation
• Preparing the Site
• Preinstallation
• Unpacking and Handling the Top Drive Assembly
• Installation Procedures
• Commissioning the Top Drive Assembly

Precautions
There are several hazards that exist when installing the TDH-250 drilling system. Avoiding such hazards
and employing safety measures helps to prevent serious injury to personnel or damage to the equipment.
When installing the equipment, including the mast at the rig site, personnel should be aware of potential
hazards such as:
• Being struck by falling equipment and tools
• Being struck by swinging equipment
• Getting entangled in lines while the mast is rising
• Falling off the rig
• Falling or tripping during the rig-up or rig-down process

Before installing the top drive assembly and traveling block:

• Review the engineering drawings in the Technical Drawing Package (TDP), which provides rig-
specific installation details.
• Read and acknowledge all precaution information.
• Verify the mast area is clear of obstructions such as guy anchors, tugger lines, and
scaffoldings, and ensure the rigging equipment, rig, and associated components will not
interfere with the installation of the system.
• Verify the mast is horizontal with the traveling block directly over well center when installing the
equipment.
• Ensure all mast brackets, braces, and retaining hardware are installed and secured.
• Verify the mast weight capacities to avoid over loading.
• Verify the rigging equipment, lifting tools, and hardware are inspected and properly sized to
accommodate the system’s weight.

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Reference Documentation
Ensure the following reference documents are available for additional information when needed:
• Technical Drawing Package
• Mast Rig-Up Procedure
• Hydraulic Fluid Cleanliness (SM00080 Rev C)
• Design Torque Standard (DS00008)
• User manual

Preparing the Site

The TDP will need to be used as reference documentation for the following
section.

The following equipment is required for preparing the site:

• Two lifting cranes with the lifting capacity specifications for the TDH-250.
Reference: For the lifting capacity for equipment weights, see the Specifications section in the
Description chapter.
• Tugger lines
• Endless lifting slings and shackles rated for lifting specifications
• Forklift
• Appropriate lubrication fluids such as grease and gear oil
Reference: For guidelines for choosing the appropriate lubrication for the system and ambient
temperatures, see the Recommended Lubricants Guide, D811000719-MAN.
Reference: The drawworks assembly on the rig may also be used during the Installation procedures.
Preparing the site for installing the TDH-250 drilling system requires special considerations.
Information in this section is provided to show the general layout and positioning of the drilling
system components, Figure 3-1 and Figure 3-2.

Installation procedures will vary from site to site. This section is a general
outline for rig-up installation and will vary depending on other rig-up factors.

Reference: For the installation procedures and drawings specific to the operating rig, see the Technical
Drawing Package.

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 Figure 3-1 : Collapsed Rig Layout

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 Figure 3-2 : Raised Rig Layout

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 The TDH-250 assembly interfaces with the mast hoisting equipment and hydraulic power unit.
Rig-up may require mast and power unit modifications when installing the top drive assembly skid
in the rig.
The rig interface package (custom or generic) provides all the necessary hardware and
components to install, connect, and secure the top drive assembly and skid in the mast. Although
many installation layout arrangements are possible, critical preparation and installation planning
must be performed before installing the TDH-250.
The location of the service loop and mud hose is an important installation consideration for the pipe
setback functions. Proper location of these components reduces risk of wear or damage to the
service loop and mud hose.
Other important installation considerations include the location of:
• The floor and mast accessories
• The drawworks fastline
• The mud stand pipe extension
• The system controls console
• The hose reel
• The hydraulic power unit

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Preinstallation
This section contains checklist items that should be performed during preinstallation planning and
the rig-up stage. The checklist is categorized by the following equipment systems:
• Rigging
• Mechanical
• Hydraulic
• Electrical

Rigging
The TDH-250 requires two lifting cranes that can support the weight of the top drive and
shipping skid. The lifting cranes should be on-site and be ready to hoist the equipment to the
installation location.

Other handling equipment may include drawworks and tugger lines.

Follow these guidelines when preparing to install the TDH-250:

• Ensure that all mast permanent brackets, braces, and retaining hardware are installed.
• Ensure that all the rigging equipment is inspected and will not interfere with the top drive
assembly or associated equipment.
• All the rigging hardware should be inspected and properly sized to accommodate the
weights of the components that will be handled.
Reference: For detailed information on equipment weights and additional capacity
information, see the Specifications section in the Description chapter.
• Ensure that the interface components and hardware that supports the guide rail, top drive assembly, and
skid are located on site as described in the general arrangement drawing and service loop engineering
drawings included in the TDP.

Mechanical
Perform the following mechanical checks before installation:
• Check the customer configuration drawing for any retrofit or upgrade kits, and ensure that
all required retrofits and upgrades have been installed.
• Ensure that the mast area is clear of obstructions such as tugger lines and scaffolding.
• Ensure that the top drive assembly is positioned over well center.
• Ensure that all mast modifications for the rig interface hardware are complete.
• Ensure the drill floor clearance is checked and adjusted according to specifications.
Reference: For the drilling system layout for the TDH-250, see Figure 3-2.
• Ensure that the service loop cable tender assembly is installed securely in the mast and that all nuts and
bolts used for retention measures are secured with lockwire.

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 • Ensure that the control and power systems are positioned and installed in locations that are accessible,
and that they conform to all requirements as specified in the general arrangement drawing
• Ensure that the control and power system components are properly grounded.
• Ensure that the mast structure and all lines will not interfere with the top drive assembly
when it is hoisted or lowered.

Hydraulic
Perform the following hydraulic checks before installation:
• Ensure that the hydraulic stand pipes are installed in the mast and meet the required
height specifications as described in the general arrangement drawing in the
Technical Drawing Package..
• If the stand pipes have not been properly flushed clean and pressure tested, complete the
necessary procedures to clean and test the pipes.
Reference: For the stand pipe cleaning and testing procedures, see the corresponding
vendor manual.

Hydraulic fluid cleanliness should meet the ISO4406 18/15 or better

standards.

Electrical
All electrical components and electronic cabling should be installed in the mast at the correct
locations and heights as described in the general arrangement drawing in the Technical Drawing
Package.
• Ensure that the cables have sufficient length to allow for termination at the top drive and
solenoid J-boxes.
Reference: For additional information on J-box installations, see the Technical Drawing Package.

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Unpacking and Handling the Top Drive Assembly

The Technical Drawing Package will need to be used as reference

documentation for the following section.

Once the equipment arrives at the rig site and rig preparation is completed, unpack and verify that
all assembly components are included in the shipment package.
Reference: For detailed information on equipment inventory, see the user manual in the Technical
Drawing Package. Unpack the components of the TDH-250 Drilling System as follows:

• Remove all binding tie downs used to ship or transport the top drive assembly and
associated components.
• Remove all the protective covering from the equipment.
• Remove the crating (if applicable) from the equipment.
• With a rag, clean the top drive assembly and associated components of any nonessential oil or
grease used as protective coating for shipment or storage.
Before beginning the installation procedures, complete the following tasks:
• Perform the Initial Inspection
• Position the Hydraulic Power Unit and Hose Reel

Perform the Initial Inspection

After unpacking the TDH-250, inspect the equipment as follows:
• Use the shipping documents, drawings, and customer configuration to inventory all components, parts,
and identification plates, Figure 3-3.
• If a component or part is missing or incorrect, notify the NOV service center immediately.
• Inspect all components and parts for damage or corrosion.
• If any components appear damaged, notify the equipment carrier and NOV service personnel immediately.
• If any retention hardware is missing, notify the NOV service center immediately.

WA
AR N I NG
All retention hardware (screws, washers, nuts, cotter pins,
and safety wire) must be installed as described in the
procedures and in the Technical Drawing Package.
Installing the equipment with missing retention hardware
could result in serious or fatal injury to personnel or
significant equipment damage.

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 Figure 3-3 : Top Drive Label

Position the Hydraulic Power Unit and Hose Reel

The TDH-250 requires a hydraulic power unit for the top drive assembly control and power.
When positioning the hydraulic power unit and hose reel, ensure the equipment is positioned:
• At the off driller’s side.
• As close to the mast as possible to minimize service loop lengths.
• Safely away from direct sources of heat, such as exhaust from diesel engines.
• To allow accessibility from all sides.

WA
AR N I NG
Ensure all H2S (hydrogen sulfide) is kept away from the
hydraulic power unit. Failure to adhere to this warning may
result in serious injury or death to personnel.

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Installation Procedures
Only experienced personnel should perform top drive assembly installation
! activities. Personnel should be qualified and must adhere to operating
procedures. Failure to do so may result in injury to personnel or damage to the
equipment.

The following reference documents are needed during the following installation procedures:
• Technical Drawing Package
• SM00080 Rev C, Hydraulic Fluid Cleanliness
• DS00008, Design Torque Standard
• User Manual

The following tools are required to complete the installation procedures:

• Endless lifting slings with the lifting capacity specifications for the TDH-250
• Two cranes
• Fork lift
• Tugger lines
Once the mast is in position, complete these tasks in the order listed:
• Prepare the Top Drive Assembly
• Identify Guide Beam Sections
• Install the Guide Beam Sections to the Mast
• Connect the Service Loop to the Top Drive
• Connect Cables and Hoses to the HPU
• Hydraulic System Pre-check
• Pay out the Hose Reel
• Inspect the Motor Rotation
• Install the Elevator Links
• Install the Counterbalance Cylinders
• Adjust the Counterbalance Cylinders

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 Prepare the Top Drive Assembly
After the top drive assembly shipping skid has been positioned underneath the mast, complete the
following steps to prepare the top drive assembly for installation:
1. Manually remove the two pins holding the shipping bracket to the pipe handler at the end of the
top drive assembly, Figure 2-12.
2. Using a wrench, remove the two bolts holding the U-bolts on the bail, then manually remove
the U-bolts from the shipping skid.

Identify Guide Beam Sections

Thoroughly review the Guide Beam Kit engineering drawing in the TDP prior to beginning the guide beam
installation procedure. The guide beam sections must be installed in the correct order. Failure to install
them in the correct order may result in a guide beam section falling to the rig floor.
The bottom hinge joint on the bottom intermediate guide beam section is specifically designed to be
connected to the upper hinge joint on the top drive shipping skid/guide beam section. The bottom
intermediate guide beam section has a warning label identifying where it connects to the top drive shipping
skid/guide beam section.

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 Install the Guide Beam Sections to the Mast

Figure 3-4 : Top Guide Beam Section

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 Figure 3-5 : Attaching Carriage Sling to the Hook

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 Figure 3-6 : Moving Guide Beam Sections

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 Figure 3-7 : Hooking the First Guide Beam Section

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 Figure 3-8 : Hoisting the First Guide Beam Section

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 Figure 3-9 : Stabbing and Pinning the First Guide Beam Section

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 Figure 3-10 : Completing Guide Beam Section Installation

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 Figure 3-11 : Hoisting and Attaching the Guide Beam

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 Figure 3-12 : Removing the Hoist Carriage

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 Figure 3-13 : Moving the Top Drive to the Rig Floor

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 Figure 3-14 : Attaching the Top Drive to the Hook

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 Figure 3-15 : Lifting the Top Drive in to the Rig

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 Figure 3-16 : Connecting the Top Drive to the Guide Beam

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 Figure 3-17 : Bottom Intermediate Section Warning Label

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 Figure 3-18 : Attaching the Torque Tieback

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 Figure 3-19 : Pinning the Top Drive to the Guide Beam

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 Figure 3-20 : Raising the Top Drive Assembly

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 Connect the Service Loop to the Top Drive
After installing the Top Drive, complete the following steps:
1. Inspect all receptacle connectors and quick disconnects, then clean each with a cloth.
2. Attach quick service loop receptacles and quick disconnects to mating ends on top drive.
3. Ensure the receptacles and quick disconnects are secure.

Connect Cables and Hoses to the HPU

Before installing the cables and hoses:
1. Inspect all receptacle connectors and quick disconnects, then clean each with a cloth.
2. Attach quick service loop receptacles and quick disconnects to mating ends on HPU.
3. With the isolation circuit breaker turned off, connect the power cables.
Reference: For cable installation instructions, see the electrical schematic provided in the TDP.
4. Install lockwire on all connector bolts and nuts as necessary.

Hydraulic System Pre-check

Before operating any hydraulic functions
1. Inspect fluid filters to ensure pop-up dirt alarms are not raised.
2. Ensure all hoses and fittings are tightly secured and connected.
3. With system power on, carefully inspect all hoses and fittings for leakage.

Pay out the Hose Reel

To pay the hose reel out for drilling operations:
1. Connect the jumper hoses from the pressure and return of the auxiliary service loop bulkhead on the
HPU to the Hose Reel Operation bulkhead on the corner of the hose reel.
2. Turn on the functions pump.
3. Remove locking pin from the drum intended to be paid out.
4. Ensure there are NO cables or hoses connected to the internal drum bulkhead before movement.
5. Attach a rope or strap to the ends of all hoses and walk the hose ends out while paying out the proper
drum (using the control levers).
6. Once at the proper length, reinstall the necessary drum locking pin to prevent the drums from
inadvertently rotating.
7. Repeat steps 2-6 for the second drum.
8. Pay out high pressure hoses an extra 10-20 feet from desired length for operation, then unstrap the high
pressure jumpers from the hose reel and carefully reel in the high pressure drum. This will reel in the
extra length of the service loop hoses while paying out the jumper hoses.
9. Connect the high pressure jumper hose ends to the HPU bulkhead.
10. Turn off functions pump and disconnect the auxiliary jumper hoses.
11. Reconnect all hoses to respective locations on top drive function bulkhead inside drums and behind the
guard doors.
12. Connect service loop hoses to top drive and secure the hoses in the saddle to prevent inadvertent
moving during top drive operations.

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 Inspect the Motor Rotation
To ensure the motors are rotating properly after the mast is raised:
1. Select FORWARD or REVERSE on the control console.
2. Ensure that the rotation direction of the drill stem corresponds with the chosen Direction option
and Figure 3-21.
• If the rotation direction is incorrect on any component, contact an NOV representative.
• If the rotation is correct on all components, proceed to the
following section.
3. Ensure the lube flow is correct. This may require removing a sprayer nozzle to check for flow.
Note: Be sure to correctly reinstall the sprayer nozzle using proper secondary retention.

Figure 3-21 : Motor Rotation

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 Install the Elevator Links
Complete the following steps:
1. Using the control console, Figure 2-16, rotate the RLA either the CW or CCW until the link
catch is positioned under the front guard, Figure 3-22.

WA
ARN
NI N G
The elevator links can weigh up to 2,400 lb (1,100 kg) and
can fall if handled improperly. Failure to follow safe work
procedures could result in serious or fatal injury to
personnel, significant equipment damage, or extended rig
downtime

2. Lubricate the elevator link eyes with pipe dope.

3. Using the endless sling and lifting crane or tugger line, lift the elevator link, with the small eye
towards the rig floor, onto the link catch.
4. Secure the link catch with locking pin and fasteners.
5. Secure the elevator link to the link tilt lever with the link clamp and clevis pin.
6. Once the first elevator link is secured, use the control console to rotate the RLA 180°
CW or CCW.
7. Repeat steps 3 through 5 to install the other elevator link.
8. Install the elevator.
9. Reference: For the elevator installation steps, see the corresponding vendor manual.

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 Figure 3-22 : Installing Elevator Links

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 Install the Counterbalance Cylinders
To install the counterbalance cylinders, Figure 3-23:
1. Ensure hydraulic power is on.
2. Turn the MVR valve on the counterbalance manifold clockwise to extend the cylinders.
3. Install the counterbalance pear links onto the hook block using the cotter and locking pins on
each side of the top drive.
4. Turn the MVR valve on the counterbalance manifold counter-clockwise to retract the cylinders.

Adjust the Counterbalance Cylinders

If the counterbalance cylinders need to be adjusted after installation, complete the following steps:
1. Dump the pressure in the cylinders.
2. Manually extend the cylinders.
3. Adjust the PCC valve on top of the cylinder manifold clockwise so the top drive begins to lift.
4. Once the top of the bail is touching the upper hook surface, turn the PCC valve
1/4-turn counterclockwise so the top drive is “floating.”
5. Turn the top drive power off.

Figure 3-23 : Installing Counterbalance

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Commissioning the Top Drive Assembly
Complete the following commissioning tasks before operating the top drive assembly:
• Initial Checkout
• Hydraulic System Checkout

Initial Checkout
Complete the following before operating the top drive assembly for the first time:
1. Bleed the air from the hydraulic system.
2. Lubricate all grease points.
Reference: For the lubrication points, see the Maintenance chapter.
3. Repair or replace any loose or missing connectors or QD’s.
4. Lockwire all connector nuts.
5. Remove any obstructions along the guide track.
6. Turn on the hydraulic power unit.

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 Hydraulic System Checkout
Complete the following before operating the top drive assembly for the first time:
1. Ensure that the counterbalance cylinders are connected.
2. Ensure that the pipehandler clamp is unclamped.
3. Ensure the system power is off.
4. Ensure the red, pop-up dirt alarm on the hydraulic filter is not raised.
Reference: If the dirt alarm is raised, there is dirt in the hydraulic filter. To remove the dirt
from the filter, see the corresponding vendor manual for cleaning/replacement directions.

Figure 3-24 : Hydraulic System Checkout

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Operation
Before operating the equipment, ensure that you have read and understand the content in the
General Information chapter as well as the applicable operating advisories and procedures in this
chapter.

Introduction
The NOV TDH-250 Top Drive System is intended for supplying rotary power for drilling operations.
This chapter covers operating procedures for drilling as well as inserting pipe or tubing into well.

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Pre-operation Guidelines

Failure to follow safe work procedures and adhere to

precautions in this chapter could result in serious or fatal
injury to personnel, significant damage to the equipment,
or extended rig downtime.

Before operating the TDH-250:

 Acknowledge and obey all warning and cautionary plaques installed on the equipment.
 Always inspect the equipment prior to use for proper operating condition.
 Ensure that the plaques on the equipment remain clean and legible.
 Inspect the equipment to ensure that it meets safe operating requirements.
Reference: For detailed information on inspecting the equipment, see the following sections:
– Top Drive Inspection and Lubrication system in the Maintenance chapter.
– Secondary Retention Checklist in the Maintenance chapter.
 Ensure that no other rig activities can cause hazards while operating the equipment.
 Prior to starting an operation, always check the operator control console indicators by pressing
the "Lamp Test" button. Make sure all indicator lamps illuminate.
 Ensure that the top drive assembly travels freely throughout the mast structure without
interference from associated components.
 Ensure that the top drive assembly is not making any abnormal noises.
Reference: If the assembly is making any questionable noises, contact a NOV representative.
 Ensure that all hydraulic service loops are connected correctly, secured, and not leaking.
 Ensure that all electrical and control service loops are connected correctly and secured.
 Ensure the personnel operating the TDH-250 top drive system are properly trained.
Reference: For guidelines and procedures for resolving issues found when preparing to operate
the top drive assembly, see applicable information provided in the Troubleshooting chapter.
Preparing the TDH-250

When preparing to start a top drive for the first time or

restarting one that has been returned from maintenance
service or storage, perform all required inspection and
lubrication checks. Failure to adhere to this warning could
result in injury to personnel, significant equipment
damage, and extended rig downtime.

Reference: For the detailed information on inspecting and lubricating the TDH-250, see top drive
inspection and lubrication system in the Maintenance chapter.

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Pre-startup

Always conduct pre-startup checks with all power sources

turned off. Failure to adhere to this warning could result in
serious or fatal injury to personnel, significant equipment
damage, or extended rig downtime

To prevent safety hazards, identify and resolve all issues before starting or restarting the equipment.
Complete the following tasks:
 Checking the Top Drive Mechanical Components
 Checking the Top Drive Electrical System
 Checking the Top Drive Hydraulic System Controls
o Checking / Adjusting the Counterbalance Valve Pressure
 Checking the Top Drive System Controls

Checking the Top Drive Mechanical Components

Ensure that:
 The gear oil level in the gearbox is filled to required levels.
 The washpipe packing assembly is lubricated as required.
Reference: For detailed information on the washpipe lubrication, see top drive inspection and lubrication
system in the Maintenance chapter.
 Top drive fasteners (nuts and bolts) are tightened and lockwired where applicable.
 The guide dolly is unlocked.

Checking the Top Drive Electrical System

Ensure that:
 The power and control cables are free of abrasions, pinches, kinks, cracks, exposed wiring, and
excessive bends or twists.
 The cable connectors are damage-free and tight.
 The junction boxes (J-box) hardware is tight and that no hardware is missing.
 The J-boxes are free of moisture.
 The J-boxes interior are free of contamination and the front J-box cover seal is damage-free.
 All screws on the cover are tight and secured (lockwired).
 All termination connections are correct, tight, and properly secured.
 All electrical and control service loops are connected correctly and secured in place.
Reference: For more information on resolving issues found while checking the electrical system
for the top drive assembly, see the Troubleshooting chapter in this manual.

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 Checking the Top Drive Hydraulics System

Always check the hydraulic drain line connection prior to

starting the equipment. Failure to connect the drain line to
the top drive or to identify an improper drain line
connection at the hydraulic motor could result in serious or
fatal injury to personnel, significant equipment damage, or
extended rig downtime.
Ensure that:
 The operating pressure is correct.
 The counterbalance pressure setting is correct.
 Reference: For additional information on adjusting the pressure settings, see related section
below.
 Hydraulic fluid levels are filled to requirements.
 The oil sight gauge is clean and oil level measurements can be seen.
 The hydraulic filter is clean and in good condition.
 The hydraulic system hoses are free of abrasions, pinches, kinks, bends, twists, and wear.
 The dirt popup alarm is functioning.
 The hydraulic service loops are connected correctly, secured, and no hoses are leaking.
Reference: For more information on resolving issues found while checking the hydraulic system,
see the Troubleshooting chapter in this manual or the HPU standalone manual.

Checking / Adjusting the Counterbalance Valve

Pressure
Reference: To check and adjust the counterbalance cylinder, see the section titled “Adjusting the
Counterbalance Cylinders” section in the Installation Chapter

Checking the Top Drive System Controls

Ensure that the top drive system controls function as designed.

Reference: For a description of the system controls and their functions, see the section titled
Operator’s System Controls in this chapter.

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Starting the TDH-250 in Cold Weather

Check gear lubricants and grease properties to ensure

adequate performance for ambient temperatures. Failure
to do so could result in damage to the equipment and
extensive rig downtime.
Reference: For information on recommended lubricants
suitable for use in cold weather, see the Recommended
Lubricants document.

Starting the top drive system may be possible at temperatures 16° C (30° F) above the pour point of
the fluid. If the air temperature falls below that range, the fluids will need to be replaced with a fluid
suitable for the colder environment. For Recommended Lubricant Guide, see D811000719-MAN.

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Operator System Controls
Stateless Driller’s Control Console
A stateless NOV Driller’s Control Console is typically used to operate the TDH-250 Top Drive.
Some top drive installations may also include an Amphion™ Human-Machine Interface (HMI)
system, in addition to the driller’s control console. In this chapter, the controls on the driller’s
control console are provided to explain top drive operations. All the operator controls described are
replicated in the Amphion HMI.

The control console provides the control circuitry for the TDH-250 top drive and pipe handler
functions. The console enclosure also contains Intrinsically Safe (I.S.) barrier components that
support Zone 2 certification.

Control commands from the console are processed through a single-board computer (SBC). The
SBC controls the actions of the cooling system, the solenoid valves, the brakes, IBOP functions,
switches and sensors. The SBC also monitors all component sensors and switches, and acts as a
safety interlock to prevent inadvertent tool operation. Additionally, the SBC notifies the driller of
the operational status of the top drive and diagnoses abnormal operating conditions.

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Control Console
Front Panel
Figure 4-1 below shows the front panel for a typical NOV Driller’s Control Console for the TDH-
250.

Figure 4-1: Front Panel (Door Closed)

For Reference Only. The illustrations in this supplement

show a typical control console panel layout. Depending on
the top drive system options, the layout of the console
controls may vary. Refer to the engineering drawings in the
Technical Drawing Package (TDP) for the rig-specific
console layout for the equipment order.

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 Internal Components
Figure 4-2 below shows the internal components with the front panel opened for a typical NOV
Driller’s Control Console for the TDH-250.

Figure 4-2: Front View with Door Open

For Reference Only. Refer to the engineering drawings in

the Technical Drawing Package (TDP) for the rig-specific
console wiring diagrams and other details.

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 Controls
Controls: Common Alarm

Figure 4-3: Common Alarms

 Lamp Test - When the button is pressed and held for two seconds, the
console indicators are tested. When the button is pressed and held for four
seconds, the TORQUE and RPM meters go to full scale for a meter test.

 Lube - Indicator flashes when oil pressure loss is detected.

 Hydraulic - Indicator flashes when hydraulic system pressure loss is

detected.

 Engine – Indicator light flashes when a low oil pressure, or fuel pressure,
low cooling pressure, or low voltage is detected.

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 Controls: Top Drive

Figure 4-4: TDS Emergency Stop and On Buttons

 TDS ON - Pushing this illuminated button enables top drive operation from the Driller’s
Control Console. When the green indicator is illuminated, the operator has control of the top
drive from the console, the lubrication pump and cooling system are turned on, and the
hydraulic supply is ready for top drive operation.

 EMERGENCY TDS STOP - The Emergency Stop button is hard-wired to the HPU. When
pressed, the:
 HPU slows down the shaft speed and then shuts off
 power to the top drive shuts off
 hydraulic supply shuts off
 motor brakes are applied

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 Controls: Top Drive

Figure 4-5: TDS Rotational Direction and Operations Mode Button

 DIRECTION – There are three buttons in this console area.

 FWD – When pushed, the rotational direction of the top drive is set to forward (clockwise),
the lubrication pump starts, and rotation ramps up to the RPM setpoint. The green indicator
illuminates when the top drive is assigned to rotate clockwise (forward).
 UNWIND – When pushed, the top drive is de-assigned and rotation gradually slows down
until stop.
 REV – When pushed, the rotational direction of the top drive is set to reverse
(counterclockwise), the lubrication pump starts, and rotation ramps up to the RPM setpoint.
The green indicator illuminates when the top drive is assigned to rotate counter-clockwise
(reverse).

 MODE – There are two illuminated buttons in this console area.

 SPIN mode – When pushed, the green indicator illuminates to show that the top drive is in
SPIN mode. This mode is used for shouldering up pipe while making up connections. When
in this mode, the RPM and torque settings are fixed at standard SPIN mode rotational speed
and torque values.

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  TORQUE mode – When pushed and held, the green indicator illuminates to show that the
top drive is in TORQUE mode. This mode is used for making up and breaking out
connections. When this mode is selected in the FORWARD direction, RPM is fixed and
torque gradually ramps up to the makeup torque setpoint. When this mode is selected in the
REVERSE direction, RPM is fixed and torque gradually ramps up to the maximum torque
of the top drive, or until the connection is broken, whichever happens first.

Note: There is no specific button for Drill mode, however to operate in DRILL mode,
deactivate both the SPIN mode and the TORQUE mode by pushing the SPIN and TORQUE
mode button until the indicator lights are off.

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 Controls: Pipe Handler

Figure 4-6: Pipe handler Controls

 LINK TILT FLOAT – When pressed, the elevator links float to the center position. When the
elevator links are in float mode, the green indicator illuminates and the pipe handler can be
rotated.

 DRILL / TILT – This is a three-position momentary switch.

 When switched to DRILL, the elevator links tilt to the Drilldown position. This position
allows the top drive to continue operating close to the drill floor.
 When switched to TILT, the elevator links will extend until the operator releases the tilt
switch.
 When the switch is in the center position, the elevator links are held in the current position.
 Any time the switch is released, tilt motion stops immediately

 RLA CCW / CW – Turning this three-position momentary switch to the right rotates the RLA
clockwise. Turning the switch to the left rotates the RLA counterclockwise. When released, the
spring-centered switch returns to the off position (center) and the RLA stops.

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  RLA LOCK – When this push button is pressed, it locks the RLA in a position and enables the
top drive to react to the pipe when making and breaking connection.

 TW CLAMP – When this button is pressed and held:

 the RLA jogs until it locks into position
 the pipe handler locking mechanism locks the pipe handler in place
 the torque wrench clamp engages

Once engaged, the clamp is used to make up and break out connections.
 The clamp is used to make up connections when the top drive is in TORQUE mode and
when the FORWARD direction is selected. The torque will gradually ramp up to the
MAKEUP torque limit setpoint.
 The clamp is used to break out connections when the top drive is in TORQUE mode and
when the REVERSE direction is selected. The torque will gradually ramp up to the max
break-out torque limit.
 The clamp disengages when the TW Clamp button is released.

 ELEVATORS –The elevators indicator illuminate when the elevator has closed on a pipe only
on a BX elevators (if equipped)

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 Controls: Torque and Rotation Speed Meter

 TORQUE – This is a three position switch for

setting the allowable torque. The torque limit is
adjusted by turning the switch to either the INC
(increase) or DEC (decrease) position and
observing the ft-lb of torque displayed on the
TORQUE meter.

 TORQUE SET – This three-position

momentary switch allows the operator to set
Drill and Make torque set points. Turning the
switch to DRILL and then turning the Torque
switch to either DEC or INC sets the Drill
torque. Turning the switch to MAKE and then
turning the Torque switch to DEC or INC sets
the makeup torque in the FORWARD direction.
This switch automatically returns to the center
position (off) when released.

 THROTTLE – This is a three position switch

controlling the speed of the drilling motor when
in DRILL mode. The drilling speed is adjusted
by turning the switch to the INC (increase) or
DEC (decrease) position while observing the
RPM value displayed on the Top Drive RPM Figure 4-7: Torque and Rotation Speed Meter
meter.

 ZERO THROTTLE / ENGINE IDLE –

When pushed while the top drive is rotating, it
drops the top drive throttle to zero, when pushed
again, it will set the diesel engine to idle speed
which is about 900 RPM.
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  TORQUE meter – Shows the drill pipe torque
in ft-lb (x 1000) increments from 0 to 50,000 ft-
lb. The torque limit is set by the TORQUE
switch below the meter.

 RPM meter – Shows the rotational speed of the top drive from 0 to 300 RPM. Rotational speed
is controlled using the Throttle switch below the meter.

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 Controls: IBOP

Figure 4-8: IBOP Controls

 IBOP – The IBOP area has a yellow indicator and a switch. The yellow indicator is illuminated
when the IBOP is closed. Turning the switch will open or close the IBOP.

 Brake – There are two controls in this console area:

 Auto – When pressed, the green indicator on this button illuminates to show that the motor
brakes are in AUTO mode. In this mode, the brakes are automatically released when a speed
command is sent to the VFD (in FWD or REV mode). The brakes are automatically set
when the speed command is removed (OFF mode).
 On / Off – The red indicator on this button lights whenever the motor brakes have been
applied and are engaged (ON). This indicator lights any time the brake is set, regardless of
whether or not the button has been pressed. When this button is pressed once, the brakes are
set and the light comes on. When pressed again, the light goes out to show the brakes have
been released.

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 Controls: Dolly & Engine Stop

Figure 4-9: Dolly Controls and Engine Stop Button

 Dolly – The dolly area has a three-position momentary switch. The switch is used to extend the
dolly or retract the dolly to the guide beam (if equipped)
 The retracted light shows that the Dolly is in the retracted position.
 Engine Stop – This button is used to stop the engine.

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 Setting the Output Torque Limits
Defining Torque Limits
This task is performed using the Drillers Control Console system.

Defining Drill Torque Limit

To define drill torque limits, complete the following steps:

1. Turn the Torque Set switch to the Drill position to display the drill torque limit on the Torque meter.
2. Turn the Torque switch to the DEC or INC position to decrease or Increase the torque value
respectively.
3. Once the desired Torque value is displayed on the Torque meter, release the Torque switch back
to the center position to set the torque value

Defining Makeup Torque Limit

The following procedure describes how to define the makeup torque limits:

1. Turn the Torque Set switch to the Make position to display the Make torque limit on the Torque
meter.
2. Turn the Torque switch to the DEC or INC position to decrease or Increase the torque value
respectively.
3. Once the desired Torque value is displayed on the Torque meter, release the Torque switch back
to the center position to set the torque value

Defining a Throttle Speed Limit

The Throttle Speed meter is located to the right of the Torque meter.

The top drive system must be turned off before setting spin parameters .
Failure to follow this caution could lead to equipment damage.

1. Turn the top drive assembly off by pushing the TDS ON button. The green indicator light should
turn off.
2. After turning off the top drive system, turn the Throttle switch clockwise to increase the throttle
speed or counter clockwise to decrease the speed.
3. The Speed will be displayed on the Speed meter. Once the desired speed is reached, return the
throttle switch back to the center position.

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Interlock Conditions
To enhance safety of rig personnel and reduce risk of damage to the TDH-250, several components on the
top drive will not operate under certain interlock conditions that are programmed in the system software
controls. Resolve issues to continue operating the top drive.

Any interlock condition must be resolved to continue

operating the top drive system. Failure to do so could result in
serious or fatal injury to personnel, significant equipment
damage, or extended rig down time

Interlock Rules for Zero Throttle

If the throttle is not in the zero position and is switched from the Spin or Torque modes to Drill mode, the
top drive will not respond to a throttle command. If the throttle is not in the zero throttle position, then a zero
speed command is sent to the top drive.
However, there are several other interlocks that will override these settings to allow a zero speed command.
The following are the interlock overrides for the top drive:
• When switching to the Drill mode from the Spin or Torque modes, the top drive throttle must be
in the Zero Throttle position and the clamp mode must be active.
• When switching to the Drill mode from the Spin or Torque modes with the top drive throttle in
the Zero Throttle position, a zero speed signal is automatically sent to the top drive and the
automatic command is reset after five seconds.
• If the IBOP is in the process of opening or closing, a zero speed command is sent to the top
drive.
• If the clamp assembly is not released, a zero speed command is sent to the top drive.

describes interlock conditions by component,

Table 4-1 (Identifying programmed interlock conditions)
the operating condition, and the programmed interlock that occurs under the operating condition.

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 Table 4-1: Identifying programmed interlock conditions

Component Operating Condition Interlock Condition

Clamp assembly The top drive is in An interlock is set to open the

drill mode. clamp assembly and to prevent a
clamp or torque engagement on
the drill shaft.

The links are titled or not in float. An interlock is set to prevent the
clamp jaws from engaging.

The brake is applied. An interlock is set to prevent the

clamp jaws from engaging.

Torque Wrench Clamp is An interlock is set to prevent the

activated RLA from rotating clockwise and
counterclockwise.

Brake If the drill shaft is spinning at 50 An interlock is set to slow down the
rpm or higher, and the brake speed of the drill shaft to
button is pressed on, the brake approximately 10 rpm before the
will not engage at this rpm. brake will engage.

Rotate Direction If the drill shaft is spinning at 50 An interlock is set to prevent

rpm or higher and the rotate changing drill direction at high drill
direction is changed either from speed until the speed is reduced.
forward to reverse or vice-versa,
the shaft will not change
direction.

Top Drive RLA Link tilt is not in float position. An interlock is set to prevent the
RLA from rotating when the link tilt
is not in float position.

IBOP Drill shaft is rotating. An interlock is set to prevent the

IBOP changing from opened to
close or from closed to open
unintentionally. The IBOP actuator
will not operate if the drill shaft is
rotating.

There may be additional zone management system interlocks based on where the drilling
equipment is positioned. These interlocks may impact the operation of the top drive.

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Operating the Top Drive Modes
The top drive has two modes of operation separately from the standard drill-ready state.
Top Drive Modes
 Spin Mode
 Torque Mode
Before applying or changing modes, verify the following conditions:
 Ensure that the IBOP is not in the process of opening or closing.

Reference: Check the IBOP selector switch on the operator console, ensure it is in the
"center" position. Make sure the IBOP yellow indicator lamp is not illuminated.

 Ensure the link tilt is in a float position

Reference: Check the link tilt float selector on the operator console, ensure it is set to the
"center" position. Make sure the link tilt float green indicator lamp is illuminate.

 Ensure the brake is set to the "off" position

Reference: Check the brake selector button on the operator console, ensure the brake red
indicator lamp is not illuminated.
 Ensure that the top drive RPM throttle is set at the Zero Throttle position.

Reference: For more information on zero throttle positions, see the section titled Interlock
Rules for Zero Throttle.
 Ensure that the torque limit is defined.
Reference: For more information on defining torque limit, see the section titled Defining
Torque Limits.

The maximum makeup torque limit is 40,000 ft-lb (54,232 N-m).

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 Spin Mode
The spin mode applies a fixed RPM (normally 50 RPM) and torque limit to the top drive for spinning in or out
a drill pipe connection. During a spin in operation, the spin mode will shoulder up pipe while making up
connections. When the pipe shoulders up, the system slows the top drive speed as it approaches the spin
torque set value and prevents it from stopping abruptly with too much force.

While the top drive is in the spin or torque mode, the clamp is activated.

Important: The following components will not function when the top drive is in the spin mode:
 Link tilt
 Elevator
 Brake
 IBOP

This section covers the following procedures:

 Activating the Spin Mode
 Deactivating the Spin Mode

Activating the Spin Mode

To activate the spin mode, complete the following steps:
1. Select the top drive direction (Forward or Reverse) to orient the tool for spinning in or spinning out
connections.
– If the direction is set to the forward mode, the function will be a spin-in operation.
– If the direction is set to the reverse mode, the function will be a spin-out operation.

2. Press and hold the SPIN mode button to run the top drive at the user-defined spin speed and spin torque
set points.
Result: The Spin mode button backlight is green when the spin mode is active. The top drive can perform
either a spin-in or a spin-out operation based on the set direction, speed, and torque value.

Deactivating the Spin Mode

To deactivate the spin mode, press the Spin button again to send a notification signal to system controls to
deactivate the spin mode.

No backlight on the spin mode button means that the spin mode has
been deactivated.

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 Torque Mode
The torque mode is used to make-up drill pipe connections with a defined makeup torque value limit.
During a make-up torque operation, when the Forward direction mode is selected, the speed of the top drive
is fixed and the torque gradually ramps up to the makeup torque set value limit.
During a breakout operation, when the Reverse direction is selected, the speed is fixed and the torque
gradually ramps up to the max break-out torque limit or until the connection is broken, whichever happens
first.
When the top drive is in the Torque mode, the following components will not function:
 Link tilt
 Elevator
 Brake
 IBOP
This section covers the following procedures:
 Activating the Torque Mode

 Deactivating the Torque Mode

Activating the Torque Mode

To activate the torque mode function, complete the following steps:
1. Select the top drive direction (Forward or Reverse) to orient the direction of the top drive make-up or
break-out operation.

If the direction is set to the Forward mode, the function will be a make-up
operation. If the direction is set to the Reverse mode, the function will be a
breakout operation.

2. Press and hold the Torque Mode button to run the top drive using the user-defined makeup torque set
point.
3. Release the Torque button to return to the Spin mode.

The green lamp illuminates to indicate that the top drive torque mode is
active and can perform either a make-up or break-out operation based on
the set direction, speed, and torque value.

Deactivating the Torque Mode

To deactivate the torque mode, simply release the Torque Mode button. This will either activate the Spin
mode (if previously activated) or revert back to the Drill-ready state with both Torque and Spin mode
deactivated.

No backlight on the torque mode button means that the Torque mode has
been deactivated.

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Operating the Link Tilt
The link tilt can be extended or retracted to user defined position. Below are typical extend and
retract position for link tilt, however there are no locking mechanism to lock the links in any
position.

Figure 4-10: Typical Link and Elevator Position

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Basic Operation
This section contains the following procedures that describe the basic operation of the TDH-250:
 Drilling Ahead with Single Drill Pipe
 Back Reaming
 Tripping in and Tripping Out
 Running Casing
 Releasing Downhole Torque

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 Drilling Ahead with Single Drill Pipe
The following illustration Drilling Ahead with Single Drill Pipe displays the procedure tasks for
drilling ahead with a single drill pipe:

Figure 4-11: Drilling Ahead with Single Drill Pipe

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 Back Reaming
The TDH-250 allows reaming out an open hole to prevent the drill pipe from sticking without affecting racking
functions associated with normal tripping. Back reaming allows the top drive and backup clamp to break out
93 ft (28 m) stands in the mast as shown in

Figure 4-12.

Figure 4-12: Back Reaming

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 Tripping in and Tripping Out
Refer to the following tasks during operation:
 Tripping In the Top Drive
 Tripping Out the Top Drive

Tripping In the Top Drive

To perform a tripping-in procedure, complete the following steps:
1. Set the slips on the string.
2. Unlatch the elevator and hoist the top drive until the elevator clears the box.
3. Actuate the link tilt to bring the elevator over to the joint in the mousehole funnel, lower the
top drive and latch the elevator around the single.
4. Pull the single out of the mousehole and as the pin clears the floor, release the link tilt to
allow the single to come to well center.
5. Lower the single and stab the connection at the floor.
6. Spin in and torque the connection at the floor level.
7. Pick up the string with the elevator and release the slips.
8. Lower the string until the joint is at the makeup height.
9. Repeat steps 1 through 8 until the tripping-in operation is completed.

Tripping Out the Top Drive

If a tight spot or key seat is encountered while tripping out of the hole, the drilling motor may be spun
into the joint at any height in the mast to work the pipe through the tight spot.
To perform a tripping out procedure, complete the following steps:
1. Stop circulation and rotation, and set the slips on the string.
2. Break out and spin out the joint from the top drive saver sub using the top drive motor and
the backup clamp in the pipe handler.
3. Latch the drill pipe elevator around the string, if the elevator is not latched.
4. Pick up the drill pipe string with the elevator and release the slips.
5. Hoist the string until the next connection appears and then set the slips on the string.
6. Break out and spin out the connection at the floor level.
7. Pick up the joint with the elevator.
8. Actuate the link tilt and lower the joint into the mousehole funnels and then release the
elevator and float link tilt back to well center. At this point, the pipe handling system will
remove the joint from the mousehole funnels and pass the pipe over to its location freeing up
the location to receive another joint of pipe.
9. Lower the top drive and latch the elevator around the string.
10. Repeat steps 4 through 10 until the tripping out operation is completed.

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 Running Casing
Use longer elevator links to allow clearance for the cementing head under the gripper in the pipe
handler. By attaching a short piece of hose to the saver sub, the casing can be filled while being
lowered. This is achieved by using the upper IBOP valve to start and stop the fluid flow.

Releasing Downhole Torque

The TDH-250 includes an automatic function that releases (unwinds) downhole torque. To release
downhole torque, set the TDS Direction to UNWIND. The top drive will send a speed command to
unwind the torque at a controlled rate. When the torque has been reduced to a level below the set
threshold, the top drive will stop rotating.

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Operating the Torque Wrench
The torque wrench is used to make-up or break-out tubular connections. When the torque mode is activated,
the clamp assembly grips the lower segment of the connection and the drive stem provides the counter
torque rotation for a make-up or break-out operation.
To operate the torque wrench, complete the following steps:
1. Press the Forward or the Reverse direction to makeup or break out the drill pipe connection.

The backlight illuminates for the Forward or Reverse selection.

 If the TDH direction is set to forward, then the operation will be a makeup operation
 If the TDH direction is set to reverse, then the operation will be a breakout operation
 Also while in torque mode, this mode operates the torque wrench clamp function. To unclamp,
you must select and assign drill mode.
2. Press the Torque button in the Mode panel to activate the torque wrench.
Result: The clamp assembly grips the lower segment of the connection.
References:
 For information on using operating modes, see the section titled Operating the Top Drive Modes.
 For procedures on setting the drill or makeup torque values, see the section titled Setting the
Output Torque Limits.

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Servicing the Tool Joint Connections
The top drive assembly is placed in a service mode position when preparing to perform a break-out or make-
up procedure of the IBOP and saver sub tool joint connections.

The IBOP crank (two places, one each side of the IBOP component) is used to open or close the
IBOP, whichever is required. When lifting the clamp, use the lifting points beneath the clamp
assembly as shown in Figure 4-13.

Figure 4-13: IBOP Clamp and Stack Position

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 Breaking Connections
The following procedure details how to perform a breakout sequence for breaking out tool joint
(drill pipe) connections.

Before beginning break out procedures for breaking out the connections, verify clamp
assembly grabs are fully open:

Complete the following steps to break out a connection:

1. Throttle the top drive to zero RPM speed.
2. Select Reverse direction, Link Tilt Float and Torque mode to breakout the connection.
3. When the connection is fully broken, select spin mode.
4. Press the Spin mode to spin out the connection.
5. After the connection fully spins out, select Spin mode again to deactivate and stop the spinning
operation.

Making Connections
The following procedure details how to perform a breakout sequence for breaking out tool joint
(drill pipe) connections.

Before beginning make up procedures for making up the connections, verify the following:

 The clamp assembly grabs are fully opened.

 The torque has been set.

Complete the following steps to make up a connection:

1. Throttle the top drive to zero rpm speed.

2. Select Forward direction and Spin mode to spin in the connection.

Result:
The clamp assembly will centralize and grip on the lower segment connection. The top drive
will then spin in the connection. After the connection fully spins in, push the Spin mode button
to deactivate and stop the spinning operation.

3. Select Link Tilt Float, RLA Lock, TW Clamp and Torque mode (push and hold) to make up
the connection.
Once the connection is fully made up to the set Torque, release the Torque mode button to
deactivate and stop the Torque operation. Push the RLA lock button again to deactivate and
release the RLA.
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 Making up the Dual-Valve IBOP Connections
This section describes how to make up the dual-valve IBOP component.

To make up the Dual-Valve IBOP, complete the following steps:

1. Place the Dual-Valve IBOP on the floor under the clamp cylinder so that the clamp cylinder can
be stabbed over it (a pup joint may be used to support it). Lower the clamp cylinder so that the
Dual-Valve IBOP comes through the clamp cylinder

2. Tighten the safety pins raise the clamp cylinder along with the Dual-Valve IBOP while rotating
the drive stem clockwise to engage the threads. Once the drive stem and the Dual-Valve IBOP
start to spin together, stop the motor, switch to FORWARD and SPIN and press and hold the
TW CLAMP button to pressurize the clamp cylinder

3. Spin in the Dual-Valve IBOP

4. Press and hold the TORQUE button on the control console and apply the desired torque to make
up the connection

5. Release the TW CLAMP button to unclamp. Lower the clamp cylinder and the tool joint lock
until the clamp cylinder positioning slot lines up with the second hole on the torque arrestor and
then insert the pin.

6. Place the tool joint lock at the joint.

7. Install the mounting bolt on the tool joint lock.

Breaking out the Dual-Valve IBOP Connections

This section describes how to break out the dual-valve IBOP component.

To breakout the dual-valve IBOP, complete the following steps:

8. Ensure that the saver sub has been removed from the dual valve IBOP component.
9. Unscrew the bolts mounted on the tool joint lock.
10. Slide the tool joint lock down until it rests on the clamp cylinder body.
11. Raise the clamp cylinder and the tool joint lock until the clamp cylinder positioning slot lines up
with the second hole on the torque arrestor and then insert the pin.

12. Press the Reverse button in the direction panel of the control console
13. Press and hold the TW Clamp button to pressurize the clamp cylinder.
14. Press and hold the Torque button on the control console to break out the connection
15. When the connection breaks out, release the Torque button and press the Spin button.
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 16. Allow the motor to spin until the dual ball IBOP connection is broken.
17. Remove the safety pin and lower the clamp cylinder along with the dual ball IBOP.
18. Unclamp the IBOP valve by releasing the Clamp button in the Torque Wrench system controls
panel.

Figure 4-14: Breaking out the dual-ball IBOP

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 Making up the Saver Sub
To make-up the saver sub, complete these steps:
1. Insert the saver sub into the dual-valve IBOP valve by:
a. Raising the clamp cylinder until the IBOP valve is exposed below the stabbing
guide.
b. Lowering the clamp cylinder until the correct clamp position lines up with the
hole.
c. Inserting the clamp positioning pin.
d. Manually support the saver sub and stab into the bottom of the IBOP.
e. Spin the saver sub manually until it engages the threads of the IBOP.
2. Press the Forward button on the control console panel.
3. Press the TW Clamp button and hold to pressurize the clamp cylinder to the clamp on
the saver sub.
4. Press and hold the Torque Mode button on the control console panel.
5. Release the Torque button to unclamp and then lower the clamp cylinder all the way to
its lowest position.
6. Position the tool joint lock correctly and tighten the bolts.

Breaking out the Saver Sub

To break out the saver sub, complete these steps:
1. Loosen the tool joint lock between the saver sub and the Dual-Valve IBOP valve by
unscrewing all the bolts.
2. Raise the clamp cylinder until the clamp cylinder positioning slot lines up with the first
hole on the torque arrestor. Insert the safety pin through the clamp cylinder and torque
arrestor.
3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by
pressing and holding the TW CLAMP button.
4. Switch the drilling motor to REVERSE to break out the connection.

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 5. Once the connection is broken out, switch to SPIN and allow the motor to spin until the
saver sub and the Dual-Valve IBOP valve separate. Remove the safety pin. Lower the
clamp cylinder with the saver sub. The saver sub is ready for removal.
6. Unclamp the saver sub by releasing the TW CLAMP button.

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Post Jarring Option
Jarring causes severe vibration and shock loads to the top drive. This occurs on all drilling rig types. The top
drive operator must exercise care and caution when using a top drive after jarring or hard drilling.

If a prolonged jarring drilling operation is anticipated, consider removing the top drive from the drill
string

Prior to jarring or hard drilling operations, verify that all current

secondary retention fasteners have been installed and properly
maintained. Review all related product information bulletins
(PIBs), if any, for secondary retention upgrade information.
Failure to install and maintain secondary retention fasteners may
result in falling objects while jarring or hard drilling operations.
Falling objects can damage rig equipment and cause severe
injury or death to rig personnel.

Safe operation of the top drive is clearly the responsibility of the user and the rig crew. In an effort to assist
the user, NOV prepared a post-jarring checklist. A PIB was issued that includes the inspection
recommendations after hard or severe drilling.
Reference: For detailed information on the post-jarring checklist, refer to the PIB TDS-93-1, Rev C. If this
bulletin is not included in the equipment shipping package, contact the NOV Service Center.

Always follow the Preinstallation procedures in the Installation chapter and then follow
with the post-jarring inspection after jarring or hard drilling operations. Always check all
fasteners for tightness and inspect all components for excessive wear or damage. Failure to
follow these cautions could result in damage to the equipment.

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 Before performing maintenance on the equipment, ensure that you have read and understand
the content in the General Information chapter as well as the applicable maintenance advisories
and procedures in this chapter.

Introduction
As with most machinery, the longevity of equipment is directly related to performing recommended
maintenance procedures at recommended scheduled intervals. These procedures may be modified to
account for specific operating goals and conditions and may include selecting suitable lubricants and other
fluids that enhance operating ranges. Compliance with maintenance procedures described in this chapter
promotes optimum performance, minimum equipment wear or failure, and reduced risk of rig downtime.
In general, inspect all hoses and connections weekly, and inspect pins and bushings monthly. The
equipment owner is responsible for conforming to applicable regulatory policies, standards, and recycling
guidelines when removing equipment, dismantling components, disposing of fluids, and disposing of
consumable spare parts during and after maintenance.
Important: More frequent service intervals are required if the equipment is operated under abnormal
conditions such as maximum loads, corrosive or dusty atmospheres, or extreme temperatures.
Reference: Procedures in this chapter are related only to NOV components. For the inspections,
maintenance schedules, and procedures related to the original equipment manufacturer (OEM) parts,
see the appropriate vendor-supplied documentation included in the equipment shipping package.

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Precautions
Prior to performing any inspection, lubrication, or replacement procedures, turn the equipment
off, isolate all energy sources, and lockout all energy sources. Failure to do so could result in
serious or fatal injury to personnel, equipment damage, or rig downtime.
Complete all appropriate job safety analysis (JSA), permits, and crew safety briefings immediately prior
to each maintenance activity or session. If, at any point during the maintenance session, the planned
activities change for any reason, review the job safety requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all appropriate personal safety equipment is in good condition
and used when necessary.
Before performing any maintenance procedures, carefully read, understand, and adhere to the following
precautions. Failure to comply with precautions in this chapter may result in injury to personnel, damage
to equipment, or rig downtime.
 Never check for hydraulic leaks with your hands. Oil under pressure that may be escaping from a hole
can be nearly invisible and can penetrate the skin causing serious injury or death if not diagnosed and
treated immediately. Always check for leaks with a piece of wood or cardboard.
 Do not perform any maintenance procedures on the equipment while it is moving.
 Maintain awareness of pinch point hazards where body parts can get caught between moving and
stationary parts of the equipment. If possible, avoid these areas when performing maintenance on the
equipment.
 Wear personal protective equipment (PPE) when performing maintenance including eye protection,
gloves, hard hat, and protective footwear.
 Tag the system controls as "out of service."
 Inspect the system prior to each use and repair or replace defective components immediately.
 Be familiar with the hydraulic schematics as well as the equipment flow and pressure requirements.
 If draining fluids is necessary, properly discard used fluids.
 Drain the fluid by carefully opening the fluid lines, and drain the oil in a container to avoid floor spills.
Fluid spills on the rig floor presents slip and fall hazards to personnel. All drained fluids need
to be properly collected and discarded according to regulated standards. Failure to follow this
caution could result in injury to personnel.
 Do not remove any hydraulic components or parts until pressure has been relieved.
 Before changing lines, connections, filters, or fittings allow the hydraulic system to cool.
 Observe and obey all warning and caution labels and placards on the equipment.
 Clean or replace all equipment plaques so that they are readable.
 Clean the equipment of accumulated mud or debris.
 When replacing threaded fasteners, always ensure they are similar and that all bolts, hex nuts,
washers, and secondary retention devices (cotter pins and lockwire) are intact and secured per OEM
specifications.
 When performing maintenance on the equipment at heights, the potential for personal injury or injury to
personnel from dropped objects exists. Adhering to the recommended guidelines in the secondary
retention and prevention of dropped objects documents will greatly reduce the risk of falling objects from
installed equipment and prevent injury to personnel working on the rig floor.

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Reference Documents
When performing maintenance procedures on the TDH-250, refer to the following documents included in
the equipment user manual if needed:
 Technical drawing package (TDP)
 Electrical interconnects and hydraulic schematics in the TDP
 Design Torque Standard (DS00008)
 Recommended Lubricants Guide (D811000719-MAN)
 Safety Wiring Procedure (ASP00019)
 Design Guideline, Secondary Retention and Prevention of Dropped Objects (D411000342-SPC-001)

Regulatory Standards
The following documents contain standards that regulate practices for performing certain complex
inspections or examinations of rig drilling equipment. They provide rules and regulations that enforce
standards and best practices and prove beneficial in preventing unnecessary cost due to equipment
damage and unscheduled rig downtime. In addition, these documents include standards that govern
proper safety practices when servicing the equipment.
 ASTM A 275, Standard Practice for Magnetic Particle Examination (MPE) of Steel Forgings
 ASTM E 709, Standard Guide for Magnetic Particle Testing
 ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings
 API RP 8B, Recommended Practice for Procedures for Inspections, Maintenance, Repair, and Re-
manufacture of Hoisting Equipment
 API Spec 8C, Specification for Drilling and Production Hoisting Equipment (PSL 1 and PSL 2)
 IADC, Drilling Manual

Installing or Removing Safety Wire

Some procedures in this chapter require removing safety wire (lockwire) from or reinstalling it onto
component fasteners when disassembling or reassembling the top drive components.
Reference: For lockwire installation procedures, refer to the Safety Wiring Procedure (ASP00019) in
the equipment user manual.

Maintaining Equipment Maintenance Records

NOV recommends keeping records of all maintenance procedures performed on the TDH-250. These
records may contain the action taken, the date that the action was completed, a brief description of the
action, and the name or initials of the technician who performed the action.
Maintaining a record-keeping process can prove valuable for fault finding and problem-solving should a
technical problem arise. Accurate maintenance records can be used to show compliance with required
maintenance practices and intervals. Maintenance records are an essential element of a well-managed
maintenance program. NOV does not provide customers with record-keeping materials; however,
customers are encouraged to create and record performed maintenance activities.

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Inspection & Lubrication Schedules
Prior to performing any inspection, lubrication, or replacement procedures, turn the equipment
off, isolate all energy sources, and lockout all energy sources. Failure to do so could result in
serious or fatal injury to personnel, equipment damage, or rig downtime.
The inspection intervals specified in this chapter only address normal conditions. Observe these
intervals; however extreme conditions, such as operating in dusty or corrosive environments, or extreme
temperatures, require more frequent inspection intervals.
Aside from the intervals described in this section, additional equipment inspections need to be
performed at the following times:
 Immediately before the equipment is put into use, either after initial installation or after reinstallation.
 After a substantial repair has been made.
When performing regularly scheduled maintenance procedures, inspect all load-carrying components
for corrosion, fatigue, or any other types of deterioration. Examine the equipment components with
visual aides such as lenses, fiberscopes, cameras, flashlights, and mirrors to determine the surface
conditions that may not be observed by the naked eye.
If any wear or damage is detected on any component, disassemble the component for a closer
inspection and repair or replace components.

Secondary Retention
To prevent safety hazards that may involve dropped or falling objects from the equipment; inspect to
ensure that components are properly secured.
Reference: For detailed information on securing the secondary retention of equipment components,
refer to the Design Guideline, Secondary Retention and Prevention of Dropped Objects
(D411000342-SPC-001) document included in the equipment shipping package.
The secondary retention inspection should be performed daily with the following items being checked:
 Inspect the top drive system for loose, broken, or missing hardware (nuts and bolts), and replace if
necessary.
 Check lockwire to ensure that it is not loose or broken, and replace if necessary.

General Greasing Procedures

Do not over-grease components. Over-greasing a fitting can cause a bearing seal to blow out.
Over-greased components may also drip, creating a slip hazard.
The TDH-250 contains numerous grease fittings for lubricating critical areas. Normally these grease
fittings should be charged with 1-to-3 pumps of general purpose extreme pressure (EP) grease. After
pumping, the grease should be observed weeping out of the component. This ensures that old grease is
purged and that the component is completely lubricated.
The lubrication intervals specified in this chapter only address normal conditions. Observe these
intervals; however extreme conditions, such as operating in dusty or corrosive environments, or extreme
temperatures, require more frequent lubrication intervals.

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 Rig Interface Inspection & Lubrication Schedule
Prior to performing any inspection or lubrication, make sure to read and understand the
warnings in the section titled “Precautions”. Failure to do so could result in serious or fatal
injury to personnel, equipment damage, or rig downtime.
Note: The rig interface inspection and lubrication schedule is identical between a mobile rig and a
standard rig, unless otherwise specified in parenthesis.
Daily Inspection Page Number

 Check for missing guide beam lynch pins and retainer pins at each joint section 115
 Check top drive alignment over well center 116

 Check for missing detention pins on the top drive dolly locking plates 118

 Check for missing lockwire and cotter pins, typically everywhere

Weekly Inspection & Lubrication Page Number

 Check guide beam joint bushings for wear 115

 Check torque post for weld cracks (mobile)

 Check chain yokes for weld cracks (mobile)

 Check torque post fasteners for tightness (mobile)

 Check hang-off bracket for weld cracks (standard) 114

 Check hang-off tieback for weld cracks (standard) 114

 Check intermediate tieback for weld cracks (standard) 117

 Check main tieback for weld cracks (standard) 116

 Check hang-off tieback fasteners for tightness (standard) 114

 Check intermediate tieback fasteners for tightness (standard) 117

 Check main tieback fasteners for tightness (standard) 116

 Check all dolly cam followers for wear or damage 118

 Grease all dolly cam followers (16 places) 153, 118

Monthly Inspection & Lubrication Page Number

 Check crown padeye(s) for weld cracks 114
 Check shackle and hang-off link bore for wear 114

 Check hang-off chains for wear (mobile)

 Check guide beam joints for weld cracks 115

 Check guide beam joint pins for wear 115

 Brush guide beam track (rolling surfaces) with grease 115

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 Yearly Inspection Page Number
 Check torque post connection for wear (mobile)
 Check main tieback connection for wear (standard) 116

 Check all dolly bogeys for wear or damage 118

 Perform MPI on all guide beam joints 115

5 Year Inspection Page Number

 Perform overhaul by NOV service center

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 Top Drive Inspection & Lubrication Schedule
Prior to performing any inspection or lubrication, make sure to read and understand the
warnings in the section titled “Precautions”. Failure to do so could result in serious or fatal
injury to personnel, equipment damage, or rig downtime.
Daily Inspection & Lubrication Page Number
 Swivel Assembly 119
 Check for missing lockwire and cotter pins, typically everywhere

 Check for loose or broken parts and leaks, typically everywhere

 Check for damaged hoses and fittings, typically everywhere

 Check electrical cables for abrasion, pinches, and kinks, typically everywhere
 Check washpipe assembly for leaks 128

 Check gooseneck and mud-hose connection for leaks 132

 Check gear oil level and filter condition 124

 Grease washpipe seals (1 place, twice daily, see manufacturer manual for details) 152, 128

 Grease bonnet seals (1 place) 152, 130

 Grease brake shaft seals (1 place) 152

 Pipe Handler Assembly 120
 Check for missing lockwire and cotter pins, typically everywhere

 Check for loose or broken parts and leaks, typically everywhere

 Check for damaged hoses and fittings, typically everywhere

 Check electrical cables for abrasion, pinches, and kinks, typically everywhere
 Check clamp tong dies for wear 147

 Check clamp cylinder for leaks 146

 Check tool joint locks for tightness 149

 Check load collar for tightness 142

 Check IBOP valve for proper operation 150

 Grease link tilt cylinder pins (2 places) 152

 Grease IBOP cylinder pins (2 places) 152

 Grease IBOP cam followers (2 places) 152

 Grease IBOP crank arms (2 places) 152

 Brush the IBOP actuator shell with grease (all around) 152
 Grease front and rear stabilizer bushings (4 places) 152

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 Weekly Inspection & Lubrication Page Number

 Swivel Assembly 119

 Check counterbalance cylinders for leaks 133

 Check functions manifold assembly for leaks

 Check heat exchanger for leaks

 Check lubrication manifold for leaks

 Check HP manifold for leaks

 Check counterbalance manifold for leaks

 Grease the bail pins (2 places) 153, 133
 Pipe Handler Assembly 120
 Check rotate manifold for leaks

 Check clamp cylinder manifold for leaks

 Check slip ring upper housing assembly for leaks 140

 Check stabbing guide and arm guides for wear or damage 146

 Check front and rear stabilizer bushings for wear 146

 Check link tilt clamps for position and tightness 144

 Check link tilt cylinders for leaks 143

 Check IBOP actuator cylinder for leaks 145

 Check IBOP cam followers for wear or excessive play 145

 Check IBOP crank for damage 150

 Check rotating link adapter lock cylinder for leaks 139

 Check rotating link adapter repositioner gear and pinion for corrosive wear 138

 Check clamp cylinder gate hinge pin for wear 146

 Grease torque arrestor tube (4 places) 153

 Brush the elevator link eyes with grease (4 places) 153

 Grease repositioner bearing (1 place) 153

 Brush the repositioner gear with grease (all around) 153

 Grease stabilizer springs (2 places) 153

 Grease clamp cylinder gate pins (6 places) 153

 Grease link tilt stop positioner pin (1 place) 153

 Grease IBOP valve (1 place, 10 pumps, see manufacturer’s manual for details) 153

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 Monthly Inspection Page Number

 Swivel Assembly 119

st
 Replace gear oil and filter element (only after 1 month of initial break-in) 124
 Check flow of gear oil in the gearbox while the lube pump is on 125
 Check brake pads for wear 134

 Check counterbalance cylinder pins for wear 133

 Check junction boxes for water ingression or contamination

 Check the control console for water ingression or contamination 151

 Check the control console fasteners for tightness 151

 Pipe Handler Assembly 120
 Check elevator link eyes for wear 144
 Check link adapter ears (saddle area) for wear 141

 Check link tilt ball joints for wear 144

 Check link tilt cylinder pins and bushings for wear 143

 Check link tilt crank pin for wear 143

 Check IBOP actuator cylinder pins and bushings for wear 145

 Check IBOP actuator yoke pin and bushing for wear 145

 Check torque arrestor pins and bushings for wear 145

 Check clamp cylinder bushings for wear 146

3 Month Inspection Page Number

 Swivel Assembly 119

 Replace gear oil filter element 124

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 6 Month Inspection Page Number

 Swivel Assembly 119

 Check gear teeth for pitting and corrosive wear 136
 Check primary and secondary gear set backlash 136
 Check s-pipe for pitting, corrosion, or erosion 132

 Pressure test s-pipe to rated working pressure 132

 Check stem liner for erosion 131

 Check washpipe assembly for wear or damage 128

 Check umbrella for wear or damage 130

 Replace gear oil (and filter element) 124

 Perform gear oil analysis 124

 Check visually all primary load carrying components for cracks or fatigue
 Replace all grease fittings, typically everywhere 152, 153
 Pipe Handler Assembly 120
 Check visually all primary load carrying components for cracks or fatigue

 Replace all grease fittings, typically everywhere 152, 153

 Check front stabilizer springs for damage 148

Yearly Inspection Page Number

 Swivel Assembly 119
 Check hydraulic motors for wear or damage (see manufacturer manual for details)
 Replace bonnet oil seals 130

 Check stem endplay for axial movement 129

 Check gearbox lube pump assembly for wear or damage 122

 Check bail, bushings, and bail pins for wear 133

 Pipe Handler Assembly 120
 Check load collar for wear 142
 Perform MPI on load collar contact area 142

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 5 Year Inspection Page Number

 Swivel Assembly 119

 Perform overhaul by NOV service center
 Perform MPI on all load carrying components
 Check all gears and pinions for wear or damage 137

 Check all bearings for wear or damage 137

 Check all shafts for pitting, grooves, and chipping 137

 Pipe Handler Assembly 120
 Perform overhaul by NOV service center

 Perform MPI on all load carrying components

 Check all gears and pinions for wear or damage 138

 Check repositioner bearing for wear or damage

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Inspecting the Hang-off Assembly

Figure 5-1: Inspecting the Hang-off Assembly

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Inspecting the Guide Beam Joints

Figure 5-2: Inspecting the Guide Beam Joints

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Inspecting the Main Tieback

Figure 5-3: Inspecting the Main Tieback

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Inspecting the Intermediate Tieback

Figure 5-4: Inspecting the Intermediate Tieback

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Inspecting the Top Drive Dolly

Figure 5-5: Inspecting the Top Drive Dolly

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Swivel Assembly Index

Figure 5-6: Swivel Assembly Index

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Pipe Handler Assembly Index

Figure 5-7: Pipe Handler Assembly Index

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Inspecting the Gearbox Lubrication System
Before inspecting the gearbox lubrication system, complete the following steps:
1. While the top drive is running, listen for any unusual or abnormal noises.
2. If abnormal noises are heard coming from the gearbox, turn it off and troubleshoot to find the source.
3. Check the oil sight gauge with the equipment turned off and let the oil in the gearbox settle for at least
45 minutes.
4. Check the oil level.
5. Inspect the oil filter by checking the pop-up dirt alarm.
6. Perform an oil analysis, such that, the oil viscosity should be adjusted base on the expected ambient
conditions for the next six months.

Removing the Lubrication Pump Assembly

Remove the lubrication pump assembly from the gearbox to inspect it for wear or damage. The following
procedure describes how to remove and inspect the gearbox lubrication pump:
1. Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly.
2. Remove the lockwire and unscrew the fasteners that mount the pump adapter plate to the gearbox.
3. Disengage the pump adapter plate from the gearbox.

Inspecting the Lubrication Pump Assembly

Disassemble the gearbox lubrication pump as described in this section (Figure 5-8). Inspect for wear or
damage. Repair or replace worn or damaged components.
1. Remove the lockwire and unscrew the fasteners that mount the hydraulic motor to the adapter plate.
2. Remove the motor gasket from the adapter plate and inspect for wear or damage.
3. Remove and replace the o-ring on the adapter plate.
4. Disassemble the mechanical pump components and inspect for wear or damage.
5. Remove and replace the gear housing body seals (upper and lower).
6. Disassemble the spline adapter and housing components as shown. For instructions on disassembling
the spline adapter, lube pump, and housing components, refer to the pump vendor service instruction
found in the equipment shipping package or TDP.
7. Inspect the pump assembly components, especially the gears.
A good practice is to always replace o-rings during each inspection process. Worn o-rings can
result in extensive equipment repairs or extended rig downtime.

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 Figure 5-8: Inspecting the Lubrication Pump Assembly

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 Reassembling the Lubrication Pump Assembly
After servicing the gearbox lubrication pump assembly, reassemble the component. Complete the
following steps:
1. Insert a new body seal into the gear housing, followed by the first thrust plate, roller bearings, and the
pump cover.
2. Coat the new body seal with the recommended adhesive and install on top of the gear housing
component.
3. Insert the driven and idler gears, thrust plate, roller bearings, and the motor/pump adapter into the gear
housing.
4. Fasten the assembled components to the adapter plate. Coat with anti-seize and torque to
specification.
5. Lubricate a new o-ring and install on the bottom of the adapter plate.
6. Fasten and lockwire the adapter plate to the gearbox. Coat with anti-seize and torque to specification.
7. Install the motor gasket, then fasten the hydraulic motor on the adapter plate. Coat with anti-seize and
torque to specification. Add lockwire for secondary retention.

Inspecting the Oil Level Sight Gauge

Check the oil level and condition while the top drive motor is cold, in order to get an accurate
measurement. Failure to adhere to this caution may result in damage to the equipment.

To inspect the oil level (Figure 5-9), complete these steps:

1. Turn off the equipment.
2. Wait at least 45 minutes before checking the oil level to allow the oil to settle in the top drive gearbox.
3. Check the oil sight gauge to see if the oil level has settled between the maximum and minimum
requirements (or the visual extent of the sight glass).
4. If the oil level has settled below the minimum requirement (bottom of sight glass), add oil up to the
maximum requirement (top of sight glass).

Adding Gear Oil to the Gearbox

Use every precaution to keep the gear oil clean. Always clean the fill connections thoroughly
prior to adding oil and replace the lubrication filter element any time the oil is changed. Do not
mix different gear oil grades, nor mix with any additives.
To add gear oil to the lubrication system (Figure 5-9), complete these steps:
1. Check the oil level prior to adding oil. Do not mistake the tan colored foam for the dark brown oil.
2. Make sure the equipment is turned off.
3. The area must be wiped clean prior to adding gear oil.
4. Add oil until the level reaches the top of the sight glass.
5. Replace the fill plug.
6. Run the top drive until the transmission is warm, then repeat the process until the oil level is within the
operating limits.

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 Figure 5-9: Inspecting the Gearbox Lubrication System

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 Inspecting the Internal Lubrication Flow
If gear oil temperatures consistently exceed the operating limit, contact NOV service center.
To inspect the internal lubrication flow (Figure 5-10), complete the following steps and replace
components as necessary:

Before opening any gearbox seals, allow the gear oil to cool to a safe temperature. Failure to
do so could result in serious or fatal injury to personnel.

1. Remove the lockwire and unscrew the fasteners of the inspection window cover.
2. Remove the inspection window cover and gasket.
3. While the lube pump is operating, check the flow of oil spraying at the gear mesh nozzle.
4. Check for oil running through each motor bearing.
5. Replace the gasket and reinstall the inspection window cover.

Figure 5-10: Inspecting the Internal Lubrication Flow

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Inspecting the Washpipe Assembly
This section provides procedures for removing, repacking, and reassembling the washpipe assembly.
When preparing to replace the washpipe packing, disassemble and inspect all washpipe components
for excessive wear, corrosion, or washout. Replace worn or damaged components. Replace the packing
set and all o-rings. These parts are not serviceable and must be replaced.
The upper packing nut has left-handed threads and the lower packing nut has right-handed
threads.

Performing maintenance on the washpipe requires a 3-inch washpipe bore tool, as shown in Figure
5-11, and a hammer. These tools are recommended for proper loosening or tightening of washpipe
components.

Figure 5-11: Washpipe Bore Tool

When loosening or tightening washpipe components, only use the recommended tools and
strike only the tool where designated. Failure to adhere to this caution may result in damage to
the equipment and extended rig downtime.

Removing the Washpipe

To remove the washpipe assembly, complete the following steps:
1. Loosen all of the packing nut retainer screws.
2. Strike the lower packing nut in a counter-clockwise direction until it turns freely, and back it completely
off the upper stem. It may be necessary to fix the stem in order to keep the lower packing nut from
turning while loosening.
3. Strike the upper packing nut in a clockwise direction until it turns freely, and back it completely off the
gooseneck.
4. Compress the packing nuts to the length of the washpipe and remove the assembly as a single unit
from the top drive and place it on a suitable workbench.
Disassembling the Washpipe
To disassemble and inspect the washpipe, complete the following steps and replace components as
necessary:
1. Press the washpipe out of the lower packing nut. Remove and discard all the oil seals.
2. Press the washpipe out of the upper packing nut. Remove and discard all the oil seals.
3. Thoroughly clean and inspect all parts for excessive wear, corrosion, washout, and leaks.
4. Inspect the middle and lower spacers, and the lantern ring for wear. Ensure they meet the required ID
ranges in Table 5-1 using a caliper measuring device.

Table 5-1: Wear Limits for Washpipe Spacers

Component Proper ID Service Limit ID
Lantern Ring 3.512 in. to 3.516 in. 3.521 in.
Middle Spacer 3.512 in. to 3.516 in. 3.521 in.
Lower Spacer 3.512 in. to 3.517 in. 3.522 in
5. Inspect the packing nuts for wear. Ensure they meet the required ID ranges in Table 5-2 using a caliper
measuring device.

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 Table 5-2: Wear Limits for Washpipe Packing Nuts
Component Proper ID Service Limit ID
Upper Packing Nut 3.532 in. to 3.540 in. 3.545 in.
Lower Packing Nut 3.512 in. to 3.516 in. 3.521 in.

Reference: For additional information on the NOV standard washpipe, see the Washpipe Assembly
Service Manual (SM01053).

Repacking the Washpipe

To repack the washpipe assembly, complete the following steps:
1. With the upper and lower packing nuts facing up (threaded end up), assemble new packing seals and
spacers into the packing box.
2. Hand pack all four seals with multipurpose grease, being careful not to grease the outside diameter of
the spacers.

Reassembling the Washpipe

To reassemble the washpipe,
Figure 5-12, complete the following steps:
1. Install packing seals in the following order:
a. Insert the upper packing seal into the upper packing ring (packing seal lip facing outward).
b. Insert the upper packing ring and packing seal into the packing nut.
c. Insert the lower packing seals, one each, into the lower rings (packing seal lip facing outward).
2. Insert the lower rings with packing seals into the lower packing nut in the following order:
a. Lantern packing ring
b. Middle packing ring
c. Lower packing ring
3. Turn the upper packing nut on its side and then insert the washpipe into the upper packing nut
(threaded end).
4. Position the hex end of the washpipe into the hex configuration of the upper packing nut.
5. Turn the lower packing nut on its side and install the lower packing nut onto the washpipe (unthreaded
end).
6. Press the lower packing nut until its flush with the bottom end of the washpipe.
7. Install new upper and lower o-rings using grease to hold them in place.
8. Install and hand tighten the lower and upper packing nuts to the main shaft and gooseneck (apply pipe
dope to the threads) and then tighten as specified.
9. Turn on the mud pumps and check for leaks.
10. If the washpipe assembly leaks, try tightening the packing nuts.
Reference: If the washpipe assembly continues to leak after ensuring that all the packing nuts have
been tightened, see Troubleshooting chapter in this manual.

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 Figure 5-12: Inspecting the Washpipe Assembly

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Inspecting the Stem Endplay
For every washpipe change-out, inspect the stem endplay (Figure 5-13) by completing the following
steps:
1. Remove the washpipe assembly.
2. Check the stem axial movement by applying an upward force on the main shaft and measuring the
movement with a dial indicator.
3. If the axial movement is not .001 to .003 in., remove the bonnet. Adjust the shim set, re-install the
bonnet, and measure until the axial float is achieved.

Figure 5-13: Inspecting the Stem Endplay

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Inspecting the Bonnet Assembly
To inspect the bonnet assembly (Figure 5-14), complete the following steps and replace components as
necessary:
1. Remove the lockwire and unscrew the fasteners at the base of the bonnet.
2. Remove the umbrella and inspect for wear.
3. Remove the retainer ring and inspect for wear.
4. Remove and replace both oil seals.
5. Remove the shims and inspect for damage. Typically discard and replace if plastic.
The shims are prone to damage during operation and disassembly. Use caution when working
with the shims. Failure to follow these cautions could result in damage to the equipment.

6. Inspect the upper stem bearing for damage.

Figure 5-14: Inspecting the Bonnet Assembly

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Inspecting the Stem Liner
To inspect the stem liner (Figure 5-15), complete the following steps and replace components as
necessary:
1. Remove the washpipe assembly.
2. Check the upper surface of the liner for erosion caused by leaking seals. The upper surface of the liner
must be flat and smooth. Replace liner and polypack seal if erosion is evident.
3. Grease the polypack seal and clean the stem bore before reinstalling.
4. Make sure the o-ring of the polypack seal is facing down when installed on the liner.

Figure 5-15: Inspecting the Stem Liner

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Inspecting the S-pipe Assembly
To inspect the s-pipe assembly, complete the following steps and replace components as necessary:
1. Support and secure the mud hose with a sling.
2. Unscrew the hammer nuts of the mud hose and gooseneck connection.
3. Remove the lockwire and unscrew the fasteners on the s-pipe clamping bracket.
4. Unscrew the hammer nut of the elbow connection.
5. Clean the bore of the s-pipe and inspect for visible signs of pitting, corrosion, or erosion.
Use a flashlight and mirror to visually inspect the bore of the s-pipe. A bore scope is best for
inspection, if available.

6. Remove and perform an ultrasonic inspection on the s-pipe if visual inspection indicates erosion or
corrosion. No indications shall be deeper than .125 in.
7. Check the condition of the seals.
8. Apply pipe dope to the threads before re-installing.
9. Perform a pressure test on the s-pipe to achieve the rated working pressure of 5,000 psi.
Reference: For detailed information on the pressure test, refer to the Factory Acceptance Testing
procedure included in the equipment shipping package or Technical Drawing Package.

Figure 5-16: Inspecting the S-pipe Assembly

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Inspecting the Bail Assembly
To inspect the bail assembly (Figure 5-17), complete the following steps and replace components as
necessary:
1. Remove the lockwire and fasteners on each bail pin retainer.
2. Remove the bail pin retainers and bail pins.
3. Slowly and securely, pull the bail out of the gearbox pockets.
4. Check the bail contact areas for wear or damage.
5. Check the bushings and bail pins for wear or damage. Replace if:
a. Bushing inner diameter is more than 3.400 in
b. Bail pin outer diameter is less than 3.160 in
6. Perform MPI on load path components during the 5 year overhaul.

Figure 5-17: Inspecting the Bail Assembly

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Inspecting the Encoder
The encoder should not be disassembled unless there is a problem, and then, only by skilled personnel.
To inspect the encoder, complete the following steps:
1. Check that the encoder is not subjected to extreme shock or vibration.
2. Check the encoder cable for abrasion, pinches, and kinks.

Inspecting the Brake Assembly

To inspect the brake assembly (Figure 5-18), complete the following steps and replace components as
necessary:
1. Remove the lockwire and fasteners on each caliper bracket that mount to the motor brake housing.
2. Check the brake pads for wear, and replace pads if worn below .08 in. minimum thickness.
3. Re-install the brake calipers and use feelers to determine the gap above and below the rotor disc.
4. If the gap is uneven, adjust the mounting bolts on the calipers to achieve an equal gap.
5. Check the hydraulic brake lines for leaks.
6. Check the rotor disc for grooves, corrosion, or wear.

Figure 5-18: Inspecting the Brake Assembly

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 Changing the Brake Pads
To change the brake pads (Figure 5-19), complete the following steps:
1. Ensure the equipment is turned off and the hydraulic pressure is bled from the lines.
2. The top drive shall not be connected to the drill string during this procedure and must be allowed to
rotate freely.
3. Remove the lockwire and fasteners on each caliper bracket that mount to the motor brake housing.
4. For each brake caliper, complete the following steps:
a. Remove the (4) guide pins and (4) return spring screws.
b. Replace (2) brake pads.
c. Re-install the guide pins and return spring screws.
d. Tighten the guide pins to 59 ft-lb (80 Nm) of torque.
e. Tighten the return spring screws to 70 ft-lb (95 Nm) of torque.
Air was removed from the braking system after the top drive was manufactured. However
when a brake caliper is removed, air can get back into the system. In order to achieve full
braking potential, always bleed the air from the system each time a hydraulic line to the brake
caliper is opened.
5. Set each brake caliper to clamp on a plate slightly thinner than the rotor disc.
6. Bleed air from the relief valve at the top of each brake caliper.
7. Re-install the brake calipers in the motor brake housing and hand tighten the fasteners.
8. Set the brake on. The calipers will self-align.
9. Fully tighten the mounting fasteners to the recommended torque.

Figure 5-19: Changing the Brake Pads

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Inspecting the Gearbox Assembly
To access the gearbox components, the gearbox must be completely disassembled, which is
a major overhaul procedure. It is recommended to only inspect gearbox components at that
time.
Use a lint-free cloth to clean the external surfaces of the equipment to prevent dust and dirt from
entering the bearings during inspection. To inspect the gearbox assembly (Figure 5-21), complete the
following steps and replace components as necessary:
1. Every 6 months, check for visual signs of fatigue on all load path components.
2. Every 5 year overhaul, disassemble the gearbox.
3. Test a sample of the lubricant for metal shavings or contamination.
4. Check the exposed surfaces of each component for corrosion or damage. Remove any corrosion with
abrasive paper.
5. Check the gear teeth of each component for pitting and corrosive wear.
6. Check the bearing racers for cracks or heat (discoloration).
7. Check each shaft for pitting, grooves, and chipping.
8. Perform MPI on load path components during the 5 year overhaul.

Inspecting the Gear Backlash

To inspect the gear backlash (Figure 5-20), complete the following steps and replace components as
necessary:
1. Remove the lube pump adapter plate and the window inspection cover to check the primary and
secondary gear set backlash.
2. Run a piece of solid wire solder through the primary and secondary gear meshes and measure the
thickness of the two flat spots made by the gear teeth surfaces with a micrometer.
3. If the primary gear mesh backlash exceeds .030 in. or the secondary gear mesh backlash exceeds
.040 in., then excessive gear wear or bearing failure may be indicated and a NOV service center
should be contacted.
4. Check the gear teeth for signs of pitting or corrosive wear at the same time the backlash is checked.
5. Record the backlash data for future reference.

Figure 5-20: Inspecting the Gear Backlash

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 Figure 5-21: Inspecting the Gearbox Assembly

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Inspecting the Repositioner Assembly
To inspect the repositioner assembly (Figure 5-22), complete the following steps and replace
components as necessary:
1. Remove the lockwire and unscrew the fasteners from the pinion gear guard.
2. Remove the lockwire and unscrew the fasteners that mount the pinion retainer to the repositioner
pinion.
3. Remove the lockwire and unscrew the fasteners that mount the hydraulic motor in the motor adapter.
4. Remove the lockwire and unscrew the fasteners that mount the rotate motor manifold to the hydraulic
motor.
5. Remove the lockwire and unscrew the fasteners that mount the motor adapter to the slip ring upper
housing.
6. Check the repositioner pinion and repositioner gear for corrosive wear or pitting.
7. Check the motor adapter, hydraulic motor, and manifold for wear or damage.
8. To reassemble, follow reverse order of disassembly.
9. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention.

Figure 5-22: Inspecting the Repositioner Assembly

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Inspecting the Lock Assembly
To inspect the lock assembly (Figure 5-23), complete the following steps and replace components as
necessary:
1. Decouple the proximity sensor and place in safe area. Check the cable for kinks or abrasion.
2. Remove the lockwire and unscrew the fasteners that mount the guard to the lock gear housing.
3. Remove the lockwire and unscrew the fasteners that mount the actuator bracket to the lock gear
housing.
4. Remove the pivot pin and spiral pin from the brake link to decouple the lock cylinder from the lock gear.
5. Remove the lockwire and unscrew the fasteners that mount the lock cylinder to the actuator bracket.
6. Remove the lockwire and unscrew the fasteners that mount the lock gear housing to the slip ring upper
housing.
7. Check the locking gear for corrosive wear or pitting.
8. Check the locking cylinder clevis, pins, brake link, guard, and housing for wear or damage.
9. To reassemble, follow reverse order of disassembly.
10. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention.

Figure 5-23: Inspecting the Lock Assembly

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Inspecting the Slip Ring Upper Housing Assembly
Disassemble the slip ring upper housing assembly only if there is a problem. To inspect the slip ring
upper housing assembly (Figure 5-24), complete the following steps and replace components as
necessary:
1. Disconnect the hydraulic lines and cap all connections.
2. Remove the saver sub, IBOP, and elevator links.
3. Remove the lockwire and unscrew the fasteners that mount the retainer to the split load collar. Remove
the split load collar.
4. Lower the top drive on a support structure. However, always keep the top drive supported by hoist.
5. Remove the lockwire and unscrew the fasteners that mount the slip ring upper housing to the gearbox.
6. Raise the top drive slowly to separate the rotating link adapter from the gearbox. Carefully pull the stem
out of the slip ring upper housing.
7. Remove the hydraulic fittings from the slip ring hub.
8. Remove the lockwire and unscrew the fasteners that mount both anti-rotational pins to the slip ring
upper housing.
9. Remove the retainer ring from the sleeve.
10. Carefully pull the slip ring hub off the sleeve.
11. Remove, discard, and replace the oil seal energizers, oil seal rings, and thrust ring.
12. Inspect the slip ring hub, sleeve, and anti-rotational pins for wear or damage.
13. To reassemble, follow reverse order of disassembly.
14. Pressure test each port to 1000 psi and inspect for leaks.
15. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention.

Figure 5-24: Inspecting the Slip Ring Upper Housing Assembly

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Inspecting the Rotating Link Adapter
Disassemble the rotating link adapter only if there is a problem. To inspect the rotating link adapter
(Figure 5-25), complete the following steps and replace components as necessary:
1. Remove the fasteners that secure each Belleville washer stack-up, and inspect for damage.
2. Remove the lockwire and unscrew the fasteners that mount the repositioner gear adapter.
3. Carefully pull the repositioner gear adapter away and remove the load compensator pins and bushings.
4. Inspect the load compensator pins and bushings for wear or damage.
5. Inspect the rotating link adapter ears (saddle area) for wear or damage.
6. Perform MPI during the 5 year overhaul.
7. To reassemble, follow reverse order of disassembly.
8. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention.

Figure 5-25: Inspecting the Rotating Link Adapter

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Inspecting the Load Collar
To inspect the load collar (Figure 5-26), complete the following steps and replace components as
necessary:
1. When unloaded, check for a gap between the load collar and rotating link adapter.
2. Check the load collar fasteners for tightness.
3. Check the load collar and stem contact area for wear.
4. Perform MPI on the contact area on a yearly basis and during the 5 year overhaul.

Figure 5-26: Inspecting the Load Collar

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Inspecting the Link Tilt Assembly
To inspect the link tilt assembly (Figure 5-27), complete the following steps and replace components as
necessary:
1. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections.
2. Check the link tilt crank and cylinder pins and bushings for wear or damage.
3. Check the link tilt cylinders for leaks.

Figure 5-27: Inspecting the Link Tilt Assembly

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Inspecting the Elevator Links
To inspect the elevator links (Figure 5-28), complete the following steps and replace components as
necessary:
1. Remove the elevator.
2. Rotate the link adapter such that the elevator links are at the front and back of the top drive.
3. Secure the elevator link with a sling. Unfasten the catch link bolt and unpin the clamp bracket.
4. Hoist the elevator link away from the top drive. Rotate and repeat the procedure for the other link.
5. Check each elevator link eye for wear or damage.
6. Check each link tilt clamp for position and tightness.
7. Check each link tilt ball joint for wear or damage.
8. Perform MPI during the 5 year overhaul.

Figure 5-28: Inspecting the Elevator Links

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Inspecting the IBOP Yoke Actuator
To inspect the IBOP yoke actuator (Figure 5-29), complete the following steps and replace components
as necessary:
1. Remove one gate hinge pin, open the gate, and pull back the clamp assembly.
2. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all connections.
3. Check the yoke, torque arrestor, and cylinder pins and bushings for wear or damage.
4. Check the IBOP actuator cylinder for leaks.
5. Check the IBOP cam followers for wear or excessive play.

Figure 5-29: Inspecting the IBOP Yoke Actuator

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Inspecting the Clamp Assembly
To inspect the clamp assembly (Figure 5-30), complete the following steps and replace components as
necessary:
1. Remove one gate hinge pin, open the gate, and pull back the clamp assembly.
2. Check the tong dies for excessive wear.
3. Check the front and rear stabilizer bushings for wear or damage.
4. Check the gate hinge pins, stabbing guide, and arm guides for wear or damage.
5. Check the clamp cylinder bushings for wear or damage.
6. Check the clamp cylinder body for leaks.

Figure 5-30: Inspecting the Clamp Assembly

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Changing the Tong Dies
Performing this procedure may require more than one individual to complete. One person will
have to perform the task and the other person should assist by support objects that may fall.
Do not stand directly beneath the clamp.
This section provides procedures for removing and changing the clamp tong dies. For more information
on this topic, see engineering drawing for stabbing guide component in the TDP.
Important: Before beginning any maintenance procedure on the clamp tong dies, complete the following:
1. Place a cover over the wellbore to prevent any dropped objects from falling downhole.
2. Lower the top drive until the stabbing guide is eye level.

Disassembling the Tong Dies

To remove the tong dies (Figure 5-31), complete the following steps:
1. Retract the clamp cylinder to the fully unclamped position and turn the equipment completely off.
2. Remove the lockwire and unscrew the fasteners that mount one of the hinge pin retainer plates to the
stabbing guide.
3. Remove the clevis pin and hinge pin from the clamp cylinder gate. Allow the clamp cylinder gate to
swing out.
4. Clean the area around the dies and unscrew the fasteners that mount both of jaw assemblies.
5. Unscrew the retaining bolts that mount the die retainers and remove the dies from each jaw assembly.

Figure 5-31: Changing the Tong Dies

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 Replacing the Tong Dies
To replace the tong dies, complete the following steps:
1. Check each jaw for dirt or debris and clear with a wire brush if necessary.
2. When surfaces of the jaws are completely clean, liberally apply anti-seize to all mating surfaces.
3. Slide the new dies into each jaw.
4. To reassemble, follow reverse order of disassembly.
5. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention. Torque the retaining bolts to 138-152 ft-lb (187-206 Nm).

Inspecting the Stabilizer

To inspect the stabilizer (Figure 5-32), complete the following steps and replace components as
necessary:
1. Unscrew the fasteners that mount the front stabilizer on the clamp cylinder gate.
2. Remove the front stabilizer and inspect the bushing for wear or damage.
3. Check the compression springs for wear or deformation.
4. Remove the lockwire and unscrew the fasteners that mount the rear stabilizer on the clamp cylinder
body.
5. Remove the rear stabilizer and inspect the bushing for wear or damage.
6. To reassemble, follow reverse order of disassembly.
7. Apply anti-seize compound and torque all fasteners to specification. Add lockwire for secondary
retention.

Figure 5-32: Inspecting the Stabilizer

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Inspecting the Tool Joint Locks
To inspect the tool joint locks (Figure 5-33), complete the following steps and replace components as
necessary:
1. Remove the lockwire and slowly unscrew each fastener ¼ turn at the joint. Avoid tilting and jamming the
collars.
Do not remove the screws completely at this time; otherwise the collars may spring off. This
may result in damage to the equipment. After removing any locking screws, replace them with
new ones. Do not reuse locking screws.
2. Clean any corrosion or dirt that has collected adjacent to the tool joint lock.
3. Carefully loosen the screws and remove the tool joint lock from the shaft assembly.
4. Lubricate the locking screw threads, the screw head bearing area, and the tapers of the inner rings with
molybdenum disulfide grease, such as Molykote GN paste.
5. Lightly file the shaft assembly free of high spots (such as tong grooves), and clean the shaft assembly
surfaces free of grease, oil, and pipe dope.
6. Slide the tool joint lock along the shaft assembly into position and torque to establish a slight contact.
Never tighten locking screws before the tool joint is positioned in the correct location. Failure
to do so will prevent the tool joint lock from sliding freely.

7. Torque the fasteners per DS00008 specification and Figure 5-33. Add lockwire for secondary retention.

Figure 5-33: Inspecting the Tool Joint Locks

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Inspecting the IBOP
To inspect the IBOP and saver sub, Figure 5-34, complete the following steps and replace components
as necessary:
1. Check IBOP valve for loose hardware.
2. Check IBOP crank for damage and lubrication.
3. Check IBOP valve for correct operation.
4. Perform MPI during the 5 year overhaul.

Figure 5-34: Inspecting the IBOP

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Inspecting the Hydraulic System
To inspect the hydraulic system, complete the following steps and replace components as necessary:
Hydraulic fluid escaping under pressure can penetrate the skin, causing serious injury. Avoid
injury by turning the equipment completely off and relieving pressure before disconnecting
hydraulic lines. Always search for hydraulic leaks with a piece of cardboard or wood. Do not
use your bare hands. If a hydraulic fluid injury occurs, get immediate medical attention. Do
not tighten hydraulic fittings while they are under pressure.
1. Check the hydraulic system weekly for leaks at fittings and hoses. Check for kinked, crushed, or stiff
hoses and corroded fittings. In addition, tighten or replace any leaking connections, and clean up any
dirt build-up on hydraulic components.
2. Check the hydraulic manifold solenoid valves for leaks or loose fittings and bolts.
3. Check the hydraulic cylinders for leaks or loose fittings. Verify each cylinder rod and clevis is secure.

Inspecting the Control Console

To inspect the control console (Figure 5-35), complete the following steps and replace components as
necessary:
Inspect the control console on a routine basis. Failure to conduct routine inspections and
maintenance may result in equipment damage or injury to personnel.

1. Test using the Common Alarm / Lamp Test button on the console, each time the top drive is assigned.
2. Check the fasteners for tightness, especially in vibration prone areas.
3. Check the seals and gaskets for water ingression or contamination.
4. Apply a light film of silicone lubricant at the seams, every 3 months.

Figure 5-35: Inspecting the Control Console

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Top Drive Daily Lubrication

Figure 5-36: Top Drive Daily Lubrication

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Top Drive Weekly Lubrication

Figure 5-37: Top Drive Weekly Lubrication

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Storage Procedure
When preparing to store the equipment for long periods of time, complete these initial steps:
1. Turn the equipment off and bleed all lines of hydraulic pressure and fluid. Cap all open ports.
2. If storing the equipment in a vertical orientation, drain and refill the gearbox to a full level with an AGMA
appropriate EP gear oil with a rust inhibitor, or equivalent.
Reference: For detailed lubrication information, see the Recommended Lubricants Guide (D811000719-
MAN), included in the equipment user manual.
3. If storing the equipment in a horizontal orientation, ensure the gear oil will not spill through the breather.
Drain the gear oil if necessary, and coat the inside components with a grease type rust inhibitor.
4. Remove the washpipe from the top drive and disassemble the packing rings.
5. Clean and coat the washpipe assembly with rust inhibitor and store components separately.
6. Grease and install thread protectors on all exposed threads on the washpipe, gooseneck, and stem.

Storing the Equipment

When storing the equipment, follow these guidelines:
 Store the top drive and auxiliary components under a cover.
 Store indoors.
 Store away from blowing dust, salt spray, and sources of vibration.
 Avoid storing in areas where rapid temperature changes occur since this type of environment produces
condensation, which is potentially harmful to the equipment.
 Store the top drive in a vertical orientation if possible. Otherwise use the shipping skid.
 Use racks or pallets for all other parts of the top drive to ensure that they are stored off the ground or
concrete.
 Perform these monthly tasks:
o Rotate all rolling elements and raceways to prevent etching or staining.
o Coat all exposed metal surfaces and moving parts with rush inhibitor.
o Remove all covers and guards to gain access to underlying parts if necessary.
o Grease all pins and joints.
o Check each junction box and add/replace desiccant packs.
o Clean the exterior of the equipment to remove any dirt or mud.
o Remove any rust then coat the area with red oxide or rich primer.

Cleaning the Equipment

To clean the equipment, follow these guidelines:
 For steam cleaning, limit the steam to painted surfaces only. Otherwise, ensure the unpainted surfaces
are thoroughly dried and retreated with a rust inhibitor.
 Avoid getting steam or water into the gearbox chamber, hydraulic system, bearing housings, and
bushings.
 Avoid using diesel-based cleaners of any kind when cleaning junction boxes, hoses, and electrical
items.

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Returning the Equipment to Service
To return the equipment to service after storage, complete the following steps and replace components
as necessary:
1. Remove all protective covers, wrappings, and desiccant packs.
2. Inspect the equipment for corrosion or damage and make repairs as necessary.
3. Drain and flush the oil, and remove all rust inhibitors.
4. Change all filters and clean all strainers.
5. Check all rubber and elastomer parts, such as hoses and seals.
6. Reinstall the washpipe assembly, which was stored separately.
7. Fill the gear oil to the appropriate level and then perform your typical inspection and lubrication
procedures as described in this chapter.
Before the equipment can return to service, perform a thorough inspection to verify all top drive systems
are functioning properly.
Allow adequate run time for this procedure. Start the top drive slowly with no load for two
hours to assess for any hidden damage or faulty operation.

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Introduction
This chapter identifies general troubleshooting issues and provides probable causes along with possible
solutions for troubleshooting problems encountered when operating or maintaining the TDH-250 Hydraulic
Top Drive. It provides guidelines to inspect and troubleshoot the mechanical, hydraulic, and electrical
components and circuits for the top drive system and control system.

Before troubleshooting the equipment, ensure that the servicemen have read
and understand the content in the General Information chapter as well as the
content in this chapter.

There is no way to anticipate every issue that may be encountered. If the issue cannot be resolved using the
troubleshooting instructions, contact a NOV Service Center. A list of NOV Service Centers is provided in the
equipment User Manual.

The top drive's control system has interlocks that prevent movement of
components when system is not operable. An equipment interlock will cause the
top drive to become unresponsive. This is normal and is required to protect
equipment and rig personnel.

Safety Precautions
The following precautions must be met prior handling any equipment.

All troubleshooting recommendations provided in this chapter are superseded by

the procedures and methods approved for use at the location where the
equipment is installed and commissioned.

Ensure all hydraulic lines are isolated and the reservoir ball valves are closed
prior to any troubleshooting work is performed on the top drive system.

When hoisting or lowering or operating the top drive system, ensure all personnel
and equipment are clear of the operating area. Failure to follow this warning may
result in injury to personnel or damage to equipment.

During operation, surfaces may become hot enough to

cause bodily injury. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.

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Troubleshooting Guidelines
NOV top drive hydraulic and electrical systems use standard components and follow industry-
standard design practices. For the hydraulic or electrical systems to function (produce flow at all
times and pressure when a load is present), the following basic operating conditions must be present
at all times:

 Ensure the top drive is properly installed and positioned in the mast. If troubleshooting top drive
system in the yard prior to field installation, make sure the top drive is secured and its drill shaft
is lifted clear from the floor.

 Ensure that all hoses and quick disconnects are properly connected at the remote control console
and the HP manifold.

 Ensure that the lubrication system is running and rotating in the correct direction.

 Verify the fluid cleanliness of the top drive.

 Select and use the proper lubricant for the applicable ambient temperature range to ensure
proper hydraulic system performance. Reference: For recommended lubricants and hydraulic
fluids for NOV drilling equipment, see the Recommended Lubricants Guide (D811000719-
PRO) in the TDP.

 The hydraulic and electric circuits must be correctly connected.

 The cables and hoses must be positioned properly and unobstructed.

Ensure all electrical and hydraulic lines and valves are isolated
before any work is started on top drive hydraulics. Failure to
follow safe working procedures could result in serious or fatal
injury to personnel, significant equipment damage, and rig
downtime.

 Check the output of the lubrication system (the top drive must be upright).

Lubrication oil pressure is critical to the performance and proper operation

of the top drive. The oil pressure must be carefully monitored and
maintained. Failure to adhere to this caution may result in damage to the
equipment.

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  Check the flow and pressure of the NOV hydraulic power unit (HPU) or customer-supplied
hydraulic power supply.

 Check the lubrication system filter for dirt pop-up indicator.

Reference: If the pop-up indicator is raised, there is dirt in the hydraulic filter and the filter
element needs to be changed. See the corresponding vendor manual for the procedure.

Use caution when checking the components in the next step. High pressure pinhole leaks can
cause injury or death to personnel.

 Check whether hydraulic fluid leaks are visible at hydraulic components, hoses, and quick-
disconnect couplings.

 Ensure the Maintenance chapter of this manual is available during the troubleshooting
guidelines.

Determining the Nature of the Problem

When troubleshooting the top drive, determine the nature of the problem using the troubleshooting
tables, detailed theory of operation for components, and diagnostic procedures. Potential component
failures for most top drives fall into the following four categories:

 Mechanical System components

 Hydraulic System components

 Electrical System components

 Lubrication and Cooling System components

Identifying Troubleshooting Categories

Mechanical Components
Mechanical problems are usually related to damaged or worn parts of the mechanical assembly. Vibrations
in mechanical systems are often signals that there may be a problem within a component. Other factors that
can contribute to mechanical problems is the lack of periodic preventive maintenance that must be provided
and performed to the assembly.

Hydraulic System and Components

Hydraulic circuit and component problems are usually related to faulty valves, hydraulic actuators,
contamination, fluid leakage, or damage not related to maladjusted hydraulic circuit components. Changes to
adjustments should only be made after eliminating all other possible causes.
Refer to the hydraulic schematic for the TDH-250 to aid in troubleshooting the hydraulic system.

Controls and Electrical System and Components

Electrical system and component problems are usually related to faulty discrete control switches, electrical
supply voltage, and or improper interconnection wiring. Refer to the Interlock Conditions section in the
Operation chapter for different conditions that could affect operation.

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 Lubrication and Cooling System Components
Lubrication and cooling system problems are usually related to contamination, faulty discrete control
switches, faulty valves and dirty filters. Making changes to the flow rate, system pressure, or other
adjustments should only be completed after eliminating all other possible causes.

Make sure to have the hydraulic, electrical, and lubrication engineering

schematics available before troubleshooting system problems. These schematics
are located in the Technical Drawing Package (TDP).

Troubleshooting Tables
This section list tables for troubleshooting different components of the top drive.
One of the major factors that contribute to failures is the lack of periodic
preventive maintenance. Periodic inspections and equipment maintenance must
be completed to ensure proper operation.

Tables do not necessarily cover all possible issues that may arise while
operating the top drive, but they list typical issues, the probable causes,
and methods of remedying the problems.

Determine the nature of the problem using the troubleshooting tables, theory of
operation information for components, and diagnostic procedures.

Troubleshooting the Mechanical Components

This section provides guidelines to follow and offers diagnostic methods to
troubleshoot mechanical components from the top drive assembly. Each section
provides an explanation of common troubleshooting tools and their uses to
identify system faults. Diagnoses are to be done in a series of tests, component
replacement, and actions that will allow the system back into an operating
condition.

The main areas that consistently need to identify equipment malfunctions and
problem solving are:

 Swivel Assembly
 Gearbox Lubrication
 Washpipe Assembly
 Motor Brakes
 Motor Performance
 Pipe Handler Assembly
 Clamp Assembly
 Link Tilt Cylinders & Rotating Link Adapter
 IBOP
 Counterbalance System
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 Swivel Assembly
The following table details how to troubleshoot components assembled to the swivel assembly. The
gearbox lubrication and the washpipe assembly are common areas that may influence failure in the
tool assembly from operating correctly. The tables may contribute to the aid in troubleshooting
several incidents that may be categorized in certain areas of fault.

The information is categorized as follows:

 Issue
 Probable Cause(s)
 Possible Solution(s)
Table 6-1: Troubleshooting the Swivel Assembly
Issue Probable cause Possible Solution
The gearbox oil The lubricant level in the Fill the gearbox to the proper level
temperature exceeds gearbox is low.  Refer to the “Recommended
95oC (200oF). Lubricant and Fluid” section located
in this manual.

 The lubricant does not Drain and clean the gearbox.

meet specification or is
contaminated.
 There may be
excessive foaming in
the gearbox. Metal
shavings or mud/water
may appear in oil.
Replace lubricant with
recommended oil.
 Refer to the "Recommended
Lubricants and Fluids" section
located in this manual.

The top drive may be Refer to the “Recommend

operating at high speed or Lubricants and Fluids” section
high torque in a high located in this manual for
ambient temperature recommended oil for high ambient
environment. temperature.

The top drive may be Replace the faulty bearing and

operating with a faulty galled gear set.
bearing or galled gear teeth
inside the gearbox.

The gear oil lubricant The oil seals may be worn Replace the oil seals.
is leaking from the or damaged.
upper and lower ends
of swivel.

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 Hydraulic oil is The motor oil seals may be  Inspect each hydraulic motor
leaking from a motor. worn or damaged. and replace the worn or
damaged seals.
 Drain and clean the gearbox,
replace lubricant with the
recommended oil.

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 Gearbox Lubrication
The following table contains malfunctions that may arise during operations. The faults are listed
accordingly to the individual functions of the gearbox.
Table 6-2: Troubleshooting the Gearbox Lubrication
Issue
The oil is leaking from the
lower bearing cover.
The oil is leaking from the
bonnet.
The gearbox oil temperature is
less than minimum
temperature specified in the
“Recommended Lubricants
and Fluid section”.
The lube alarm is on.
Water or mud appears in the
oil.
The oil has excessive foam.
Metal shavings may appear in
the oil.
The oil flow is restricted.
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Probable cause
The oil seals may be worn or
damaged.
The oil seals may be worn or
damaged.
The oil level is too low or too high.
Incorrect lubricant is used.
The gears or bearings may be
damaged.
 The oil level is too low.
 The oil is overheated.
The oil pressure switch is out of
adjustment.
The gear spray nozzle is missing.
There may be excessive oil
viscosity.
Faulty (intermittent operation) or
failed oil pump hydraulic motor.
Fails to operate.
A plugs is missing or damaged.
The bonnet seals are worn.
There may be water in oil.
 Excessively viscous oil.
 Cold oil.
The gears or bearings may be worn
or damaged.
The oil pump may be damaged.
Foreign particles may be blocking
the orifice or nozzle spray.
Possible Solution
Replace the seals.
Replace the seals.
Adjust the oil level to the middle of the sight
glass.
Check the recommended lubricants chart and
replace as needed.
Repair and replace as needed.
Adjust the oil level to the middle of the sight
glass.
Adjust the switch.
Replace the spray nozzle.
Lower the oil viscosity.
Replace the pump and/or motor.
Check hydraulic supply to hydraulic motor.
Replace missing or damaged plug. Flush and
replace oil
Replace the seals. Flush and replace oil.
Replace the oil.
Lower the oil viscosity.
Replace the gears or bearings. Flush and replace
oil
Replace the oil pump. Flush and replace oil
Clean the orifice or spray nozzle.
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 Troubleshooting the Lubrication System
The following illustration provides the gearbox lubrication system schematic used to determine the
issues in the troubleshooting guidelines.

Figure 6-1: Lubrication System

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 Washpipe Assembly
The following table contains malfunctions that may arise during operations. The faults are listed
according to the individual functions of the washpipe assembly.
Table 6-3: Troubleshooting the Washpipe Assembly
Issue
The washpipe assembly is
leaking drilling fluid.
There is leakage between the
washpipe and the lower
packing nut.
There is leakage between the
lower packing nut and the
threads.
There is leakage between the
washpipe and the upper
packing nut.
There is leakage at the threads
between washpipe nut (upper
packing nut) and the
gooseneck.
There is leakage at the grease
fitting.
Excessive vertical and lateral
washpipe movement.
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Probable cause
The washpipe is worn or damaged.
The washpipe has worn or damaged
components.
Packing failure or packing is
improperly seated.
The lower O-ring has failed.
The packing is improperly seated or
packing has failed.
The upper O-ring has failed.
The grease fitting has failed.
Excessive stem axial movement.
Possible Solution
1. Disassemble and inspect for corrosion and
deterioration of the washpipe
2. If washpipe shows signs of wear, noted by
scoring or washpipe surface wearing away,
it should be replaced.
1. Disassemble and inspect all the
components for wear, corrosion, pitting,
and washout.
2. Replace all worn or damaged components
on the reassembly of the washpipe.
1. Disassemble and inspect the components.
2. Replace worn or damaged components on
reassembly of the washpipe.
1. Remove the washpipe assembly and
replace the O-ring.
2. Inspect the stem liner. The sealing surface
area of the stem liner should be smooth
and flat. Repair or replace the stem liner as
required.
1. Disassemble and inspect the components.
2. Replace worn or damaged components on
the reassembly of the washpipe.
1. Remove the washpipe assembly and
replace the O-ring.
2. Inspect the gooseneck liner. The sealing
surface area of the gooseneck liner should
be smooth and flat. Repair or replace the
gooseneck liner as required.
Inspect the spring tension in the ball of the
grease fitting. If the ball is not properly
tensioned, replace the grease fitting. If in doubt,
replace the grease fitting.
Remove washpipe packing assembly and check
stem with dial indicator for excessive end play
clearance. Repair and reset end play as required.
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 Troubleshooting the Motor Performance and the
Motor Brakes
Table 6-4: Troubleshooting the Motor Performance and the Motor Brakes
Issue Probable cause Possible Solution
Brake does not release. Directional valve is stuck. Test the valve and replace if necessary.

Brake releases but still drags. Check valve is blocked or tube is Replace the check valve or tube as required.
pinched.
Mechanical problem with brakes. Repair brake mechanism.

Brakes do not engage or slip. Hydraulic oil on brake pads. Check for hydraulic leaks and repair.

Pressure is not 2,000 psi or does not Reducing valve is plugged or needs to be
rise crisply to 2000 psi. adjusted or replaced.

Directional valve (DV1) is stuck Replace valve or check electrical signal.

(check pressure at A1).
Check valve (CV1) is blocked. Replace the check valve.

Delay in brakes actuating after Hydraulic oil is contaminated. Replace hydraulic oil.
console switch is turned on.
Pressure reducing valve is faulty. Replace valve.

Main Shaft rotating too Low or no pressure to the Motor Check port AX on the main manifold to ensure
slowly. (Motor Performance displacement pilot signal port X on the pilot signal is no less than 500 PSI. Ensure
issue) the motor. the pilot line to the motor is free of kinks that
may impede the pressure.

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 Troubleshooting the Motor Brake Schematic
The following illustration provides the motor brake schematic for reference and troubleshooting.

Figure 6-2: Motor Brake Schematic

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 Troubleshooting the Main Motor Schematic
The following illustration provides the Main Shaft Motor schematic for reference and
troubleshooting.

Figure 6-3: Main Motor Schematic

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 Pipe Handler
The following tables provide guidelines to follow when troubleshooting the pipe handler’s
mechanical components. This section addresses the mechanical faults from the clamp assembly and
link tilt cylinders. The malfunctions that occur during operations are to be identified from the tables
and should provide possible solutions needed to overhaul the system, assuming all electrical
components are functioning properly.

Clamp Assembly
The following table contains malfunctions that may arise during operations. The faults are listed
according to the individual functions of the clamp assembly.

Table 6-5: Troubleshooting the Clamp Assembly

Issue Probable cause Possible Solution
The clamp cylinder does not There is no pressure or reduced Test the pressure ports, adjust, and repair as
actuate. pressure at the cylinder. required.

The cylinder is damaged. Inspect the cylinder, and repair or replace.

Mud and debris may be built-up Wash the mud and debris out.
behind die heads.

Clamp circuit pressure is too low.
To provide high pressure to the clamp circuit,
ensure that pressure reading at port B8 on Main
Functions Manifold Assembly and port VP on
the Clamp Cylinder Manifold Assembly both
read 2,000 psi

 If pressure readings are significantly lower,

The stem is stuck and will not
rotate.
 The stabilizer bushings are
loose, worn, or damaged.
 Stabilizers lacking grease.
inspect and repair the plumbing or/and the
clamp cylinder.
 Replace the bushings as required.
 Grease stabilizer bushings

The clamp is difficult to lift. The clamp body has seized against Grease the torque arrestor
the torque arrestor.
The clamp’s thread compensator is Check the thread compensator’s spring posts and
not working. springs.

The clamp is damaging tool The dies may worn. Replace the dies.
joints.
The clamp stab-in position is Check the height of the clamp. Reset the clamp
improperly positioned. position.

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 Troubleshooting the Clamp Assembly –
Schematic
The following illustration provides the Clamp Assembly schematic for reference and
troubleshooting.

Figure 6-4: Clamp Assembly Schematic

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 Link Tilt Cylinders and RLA System
The following table contains malfunctions that may arise during operations. The faults are listed
according to the functions of the link tilt cylinders and RLA system.

Table 6-6: Troubleshooting the Link Tilt Cylinders and RLA System
Issue Probable cause Possible Solution
The drill pipe elevator does The link clamps are incorrectly Readjust the link clamps.
not reach the derrickman’s adjusted.
position.

RLA will not rotate 

The RLA lock cylinder does
not engage or disengaged.
 Abnormal pressure change
indicates plumbing or RLA lock
cylinder is faulty.
 RLA lock gear is stuck.
Repair plumbing or RLA lock cylinder.
Reference: For the maintenance instructions,
see the applicable vendor documentation.
Grease gear teeth.

The links drifting. The pressure at B4 has decayed to a Inspect and replace the DV4 valve if damaged.
low (return) pressure.

The cylinder seal has failed. Replace the seal.

The load holding relief valves are Adjust or replace the load holding relief valve.
out of adjustment, stuck open, or
contaminated

The drill pipe elevator does Use the manual override button on  Test the solenoid and connectors.
not float back to the center the SV4 valve. If the link tilts, the  Test the hydraulic system.
position. problem is electrical. If the links do
not tilt, the problem is hydraulic.

The link tilt does not tilt. The solenoid valve is not shifting.  Check the electrical continuity.
 Replace solenoids.

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 Troubleshooting the RLA Lock Cylinder – Schematic
The following illustration provides the RLA Lock Cylinder schematic for reference and
troubleshooting.

Figure 6-5: RLA Lock Cylinder Schematic

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 Troubleshooting the Link Tilt System – Schematic
The following illustration provides the Link Tilt System schematic for reference and
troubleshooting.

Figure 6-6: Link Tilt System Schematic

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 Troubleshooting the RLA Rotate – Schematic
The following illustration provides RLA Rotate schematic for reference and troubleshooting.

Figure 6-7: RLA Rotate Schematic

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 Troubleshooting the IBOP
The following illustration provides the IBOP schematic for reference and troubleshooting.

Figure 6-8: IBOP Actuator Schematic

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 Troubleshooting the Counterbalance System
Table 6-7: Troubleshooting Motor Brakes
Issue Probable cause Possible Solution
Counterbalance system does The counterbalance cylinder is Inspect the cylinder and repair or replace seal.
not function. damaged and the seal leaks.
No hydraulic pressure Ensure there is system pressure to the
counterbalance circuit. Test port P2 on the Rig
Up manifold assembly and verify it is the same
as system pressure.

The PCC valve is not operating. Ensure PCC valve is set properly, and replace if
damaged.
Reference: Hydraulic schematic for setting
value.

Troubleshooting the Top Drive Operations

The following table contains malfunctions that may arise during operations. The faults are listed
accordingly to the functions of the top drive.

Table 6-8: Troubleshooting the Top Drive Operations

Issue Probable cause Possible Solution
There is no rotation and no The correct top drive mode is not Switch to the correct top drive mode.
torque. selected for top drive operation.
Make sure the DRILL torque is not at zero.

The drill or makeup torque limits Set the drill torque limit to the proper setpoint.
have not been set for the proper Set the makeup torque limit to the proper
limits of the current drilling setpoint.
operation.

The brake has not been released. Set the Brake switch to OFF to release the
brake.

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 The following pages provide descriptions for hydraulic symbols used in the hydraulic schematic
diagrams.

Figure A-1: Hydraulic Symbols (1 of 3)

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 Figure A-2: Hydraulic Symbols (2 of 3)
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 Figure A-3: Hydraulic Symbols (3 of 3)
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 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 2.0
Service Manual, Hydraulic Power
Unit

www.nov.com
 SERVICE MANUAL

TDH-250
HYDRAULIC POWER UNIT

REFERENCE REFERENCE DESCRIPTION

TDH-250 HPU USER MANUAL
This document contains proprietary and confidential National Oilwell Varco
information which belongs to National-Oilwell Varco, L.P., its 11000 Corporate Centre Dr.
affiliates or subsidiaries (all collectively referred to hereinafter Houston, TX 77041
as "NOV"). It is loaned for limited purposes only and remains Phone 281-854-0427
the property of NOV. Reproduction, in whole or in part, or use Fax 281-854-0508
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 and in any
event 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

DOCUMENT NUMBER REV

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REVISION HISTORY

02 17-AUG-2016 SEE EN JL RHONE P WILLIAMS P WILLIAMS

01 12-04-2015 New Release B. STARNES H. GOMEZ J. RHONE
Rev Date (mm.dd.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

01 First issue
02 Update to more generic

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Chapter 1: General Information ................................................................. 1
Overview .................................................................................................................... 1
Intended Audience ......................................................................................................................... 1
Disclaimer ...................................................................................................................................... 1
Conventions .............................................................................................................. 1
Advisories ...................................................................................................................................... 1
Illustrations..................................................................................................................................... 2
Safety Requirements ................................................................................................ 2
Proper Use..................................................................................................................................... 2
Safe Lifting ..................................................................................................................................... 2
Personnel Training ......................................................................................................................... 3
Recommended Tools ..................................................................................................................... 3
General System Safety Practices .................................................................................................. 3
Replacing Components.................................................................................................................. 3
Routine Maintenance ..................................................................................................................... 3
Equipment Disposal .................................................................................................. 4
Service Centers ......................................................................................................... 4
Chapter 2: Description ................................................................................ 5
Introduction ............................................................................................................... 5
Description ................................................................................................................ 5
Layout ........................................................................................................................ 5
Chapter 3: Installation................................................................................. 9
Preparation for Use ................................................................................................... 9
Unpacking and Checking ............................................................................................................... 9
Storage .......................................................................................................................................... 9
Installation ................................................................................................................. 9
Locating Power Unit ....................................................................................................................... 9
Reservoir Inspection ...................................................................................................................... 9
Diesel Engine Operation ................................................................................................................ 9
Start-Up Procedure ...................................................................................................................... 10
Chapter 4: Maintenance ............................................................................ 13
Special Tools ........................................................................................................... 13
Recommended Spare Parts.................................................................................... 13
HPU General Maintenance Schedule..................................................................... 13
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 HPU Component Maintenance Suggestions ........................................................ 14
Preventative Maintenance Suggestions................................................................ 15
Maintaining Proper Oil Temperature ..................................................................... 15
Measuring Oil Temperature .................................................................................... 15
Look, Smell and Feel .............................................................................................. 15
Preventative Measures ........................................................................................... 16
Filter Replacement Specifications ......................................................................... 16
Diesel Engine Maintenance .................................................................................... 16
Chapter 5: Troubleshooting ..................................................................... 17
Introduction ............................................................................................................. 17
Safety Precautions .................................................................................................. 17
Troubleshooting Guidelines................................................................................... 18
Determining the Nature of Problem ....................................................................... 18
Identifying Troubleshooting Categories ............................................................... 19
Mechanical Components ............................................................................................................. 19
Hydraulic System and Components ............................................................................................. 19
Electrical System and Components ............................................................................................. 19
Cooling System Components ...................................................................................................... 19
Troubleshooting the Hydraulic System ................................................................ 20
Chapter 6: Fluid Requirements ................................................................ 25
Hydraulic Fluid Requirements ............................................................................... 25
Hydraulic Fluid Recommendations .............................................................................................. 25
Hydraulic Fluid Cleanliness.......................................................................................................... 25
Filters ........................................................................................................................................... 25
Inspection .................................................................................................................................... 25
Appendix - Drawing References .............................................................. 27

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Figure 2-1 Overall HPU Layout ............................................................................................................ 5
Figure 2-2 Overall HPU Layout ............................................................................................................ 6
Figure 2-3 Overall HPU Layout ............................................................................................................ 6
Figure 2-4 Overall HPU Layout ............................................................................................................ 7
Figure 3-1 Location of main pump case drain port ............................................................................. 11
Figure 3-2 Location of functions pump case drain port ...................................................................... 11
Figure 3-3 Location of suction line ball valve ..................................................................................... 12
Figure 3-4 Depiction of reservoir level gauge..................................................................................... 12

Table 3-1 HPU Startup Procedure ..................................................................................................... 10

Table 4-1 HPU Maintenance Schedule .............................................................................................. 13
Table 4-2 Individual Component Maintenance ................................................................................... 14
Table 4-3 Filter Element Replacement Part Numbers ........................................................................ 16
Table 5-1 Troubleshooting the Hydraulic System .............................................................................. 21

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Overview
This service manual is part of the National Oilwell Varco® (NOV) documentation package for your NOV
equipment. Along with a description of the equipment, the service manual contains information for the installation,
operation, maintenance, and troubleshooting of the equipment.

Intended Audience
This manual is intended for use by field engineering as well as installation, operation, and maintenance
personnel. The procedures within this manual should never be performed by untrained individuals.
Reference: For more information about training, see the Safety Requirements section (in this chapter).

Disclaimer
While every reasonable effort has been made to ensure the accuracy of the information contained herein, NOV
makes no representations or warranties as to the accuracy or completeness of the information. NOV reserves the
right to revise this manual at any time without the obligation to notify any person or organization.
NOV shall not be liable for any damages arising from the use of this manual. It is the responsibility of the
owner/operator to ensure safe usage and operation of the equipment. All operators must be properly trained
before they handle or operate the equipment.
The illustrations in this manual may not be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

Conventions
This section of the chapter describes the service manual conventions.

Advisories
The graphical symbols within this manual indicate advisories that provide the user (intended audience) with
additional information about a topic or inform the user of the potential or definite risks to personnel or equipment
and the necessary action the user should or should not take to avoid the risks. The following lists the symbols and
an explanation of each:

Note
The note symbol indicates details or additional information that may be useful for
better understanding the related topic.

Caution
This symbol indicates a potential risk of injury to personnel or damage to
! equipment. Failure to follow instructions explicitly and use extreme care when
performing operations and procedures could result in injury to personnel, damage
to equipment, or rig downtime.

Warning
WA
ARN
NING

The warning symbol indicates a definite risk of equipment

damage or danger to personnel. Failure to follow safe work
procedures could result in serious or fatal injury to personnel,
significant equipment damage, or extended rig downtime.

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 Hot Surface
This symbol indicates the presence of a potentially hot surface or component.
Failure to allow the hot surface or component to cool before touching it could
result in bodily injury.

Pinch Point
The pinch point symbol indicates the potential for part of the body becoming
caught or pinched between two objects. Failure to avoid pinch point areas while
the equipment is operating or use extreme care around the pinch points could
result in serious or fatal bodily injury.
Electrostatic Discharge
This symbol indicates the potential for electrostatic discharge (ESD). Always
remove static electricity prior to working on ESD sensitive components or in
flammable environments. Failure to do so could result in ESD:
• Damaging or destroying sensitive electronic components
• Setting off explosions or fires in flammable environments

Illustrations
The illustrations (figures) provide a graphical representation of equipment components or screenshots for use in
identifying parts or establishing nomenclature. These illustrations may not be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

Safety Requirements
NOV equipment is installed and operated in a controlled drilling-rig environment involving hazardous situations.
Proper maintenance is important for safe and reliable operation. Procedures in the manuals are the
recommended methods for performing installation, operations, maintenance, and troubleshooting.

To avoid injury to personnel or damage to equipment, carefully observe the requirements

! outlined in this section.

Proper Use
NOV equipment is designed for specific functions and applications and, therefore, should be used only for its
intended purposes.

Safe Lifting
Operators and maintenance personnel should be properly trained in safe lifting procedures and in the inspection
of material handling equipment and lifting components. When lifting and handling NOV equipment or components,
always:
• Follow all federal, state, and local rules, industry and company standards, and rig-specific safety
guidelines.
• Use approved safe lifting procedures and safe methods.

Safe lifting recommendations provided in this manual do not take precedence

over local safety rules and regulations, OSHA regulations, or instructions issued
by the manufacturers of rig hoisting equipment and other tools on the rig.

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 WA
ARNING

Lifting equipment improperly creates a hazardous working

environment. To avoid lifting hazards, lift equipment only with
material handling equipment rated for the expected load and
from the designated lift points. Failure to follow safe lifting
guidelines may result in serious or fatal injury to personnel,
significant damage to equipment, and extended rig downtime.

Personnel Training
To ensure their safety, all personnel performing installation, operations, maintenance, or repair procedures on or
in the vicinity of the equipment should be trained in rig safety and equipment operation and maintenance.
Reference: For more information about personnel training, contact the NOV training department.

Recommended Tools
When an operation requires a specific tool recommended by the manufacturer, the use of that tool should be
enforced, and the tool should be used in a manner that:
• Follows the procedures for the operation
• Safeguards personnel and equipment

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as cooling water or
electrical, hydraulic, or pneumatic utilities.

Before installing, operating, or troubleshooting equipment or performing

! maintenance, read and follow these guidelines to avoid endangering exposed
persons or damaging the equipment:
• Isolate energy sources before beginning work.
• Avoid performing maintenance or repairs while the equipment is in
operation.
• Wear proper protective equipment during equipment installation,
operations, maintenance, and repair.

Replacing Components
When replacing components:
• Verify that components such as cables and hoses are tagged and labeled during assembly and
disassembly of equipment to ensure correct installment.
• Replace failed or damaged components with original manufacturer-certified components.
Failure to replace failed or damaged components could result in injury to
! personnel or damage to equipment.

Routine Maintenance
Equipment must be routinely maintained.
Failure to conduct routine maintenance could result in injury to personnel or
! damage to equipment.

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Equipment Disposal
The equipment owner is responsible for disassembling and removing the equipment at the end of the equipment’s
useful operating life. It is also the equipment owner’s responsibility to conform to applicable regulatory policies
and standards, as well as recycling guidelines, when removing the equipment and when disassembling
equipment components and disposing of fluids and consumable spare parts after scheduled and unscheduled
equipment maintenance.

Service Centers
For a directory of NOV service centers, see Service Center Directory, document number D811001337-DAS-001
in the NOV documentation package.
This link provides after-hours and 24-hour contact information for emergencies or equipment issues requiring an
immediate response from NOV service personnel: www.nov.com/contact_us/24hr_EmergencyList.asp.

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Introduction
This manual provides descriptive information, operation and maintenance instructions for the TDH-250 Hydraulic
Power Unit (HPU) manufactured by National Oilwell Varco. Any additional information may be obtained from the
NOV Engineering Dept. by referencing the unit's model number and serial number stamped on the reservoir
nameplate, referencing the Technical Drawing package or by contacting your authorized NOV representative.
Some of the information in this manual may not apply to your power unit.

Description
The TDH-250 Hydraulic Power Unit is a combined open loop/closed loop system designed to power the TDH-250
Top Drive in drilling operations. It utilizes a high horsepower diesel engine to drive a main pump which delivers
high pressure (5000 PSI) flow to the Top Drive motors. Two secondary pumps mounted on an electric motor
deliver medium pressure flow to operate various functions on the HPU and Top Drive. The fluid is stored in a 300
gallon reservoir and is conditioned through various filters found on the HPU and Top Drive. Two onboard heat
exchangers cycle on and off to keep the fluid at an appropriate operating temperature.

Layout
The following figures show the location of the primary components on the hydraulic power unit. Reference Figures
Figure 2-1 Overall HPU LayoutFigure 2-1, Figure 2-2, Figure 2-3 and Figure 2-4 for locating these components.
Refer to hydraulic schematic for corresponding function within the circuit. For complete detail

Figure 2-1 Overall HPU Layout

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 Figure 2-2 Overall HPU Layout

Figure 2-3 Overall HPU Layout

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 Figure 2-4 Overall HPU Layout

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Preparation for Use
It is imperative that personnel involved in the installation, service, and operation of the
! power unit be familiar with how the equipment is to be used, the limitations of the system
and its components, and have knowledge of good hydraulic practices in terms of safety,
installation, and maintenance.

Unpacking and Checking

Carefully check for damage that may have occurred to the HPU in transit. Report all damage immediately to the
carrier and send a copy to the vendor. All open ports on the Power Unit were plugged at the factory to prevent the
entry of contamination. These plugs must not be removed until just before piping connections are made to the
unit.

Storage
If the Power Unit is not going to be installed immediately, it should be stored indoors, covered with plastic sheet,
and all open ports plugged. If long term storage is expected (6 months or more) we recommend filling the
reservoir completely with clean hydraulic fluid to prevent the entry of moisture.

Installation
Locating Power Unit
The HPU must be located in a safe area with the diesel engine radiator fan facing away from the rig.

Warning
One of the key requirements for good service and long life from a hydraulic system is cleanliness. Since it has
been our experience that most dirt infiltrates a hydraulic system during installation, we recommend the following
rules be adhered to:
 All open ports on the power unit, cylinders, etc. must remain plugged with tape or plastic plugs until just
before the hydraulic connections are made.
 All interconnecting tubing, pipe, or hose should be clean, and free of rust, scale and dirt. The ends of all
connectors should be plugged until just before they are to be installed in the system.
 All openings in the reservoir such as the filler breather or access end covers must remain
closed during installation.
 If Teflon tape or pipe dope is used, be sure it doesn't extend beyond the first thread of the pipe fitting.

Reservoir Inspection
The reservoir has been thoroughly cleaned at NOV prior to shipping. It is suggested, however, to remove the
reservoir access covers and re-inspect the tank for cleanliness.

Diesel Engine Operation

See attached user manual for CAT C18 Diesel Engine for operation procedures before running hydraulic power
unit.

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 Start-Up Procedure
Prime main pump by filling pump through case drain port with hydraulic fluid until pump is full
1
(Figure 3-1).
Prime functions pump by filling through case drain port with hydraulic fluid until pump is full
2
(Figure 3-2).
3 Walk around unit and ensure that no leaks are present.

4 Open suction line ball valve (single or set of 3, depending on configuration) (Figure 3-3).
Fill reservoir using ISO Viscosity Rating 46 hydraulic oil until level reaches “SERVICE LOOP HOSE
5 VOLUME STORAGE” reading on reservoir oil gauge (Figure 3-4). Oil should be filtered through a 10
micron filter before entering the reservoir to ensure cleanliness.
Observe all hydraulic lines to ensure that no leaks are present. If a leak is located, take corrective
6
action immediately.
Verify that diesel engine oil is at proper level on engine dip stick and top off with oil if necessary as
7
specified by engine manufacturer.

8 Verify that diesel engine coolant is full and top off if needed as specified by engine manufacturer.

Verify that diesel engine AdBlue (also known as DEF or Urea per ISO 22241 or DIN 70070) is full
9 and top off as needed (Only on diesel engines with exhaust gas after-treatment systems – may not
exist on your unit).
10 User must supply 480VAC/95 Amp power and connect to HPU power junction box.

11 Connect diesel fuel tank lines to engine and pressurize fuel lines to purge air out of fuel system.

12 Verify again that no visible leaks of any kind are present in the system.

13 Turn system on and set to idle speed.

Check that A and B pressure readings on gauge panel are approximately equal to charge pressure
14 reading (less than 400 PSI). If either A or B line pressure readings are significantly above charge
pressure, turn off system immediately and take corrective action.
With the system at idle, visually check for any leaks present in the system.
15 CAUTION: Under no circumstances attempt to locate leaks using your hands with the system under
pressure. Doing so could result in hydraulic fluid injection into skin causing serious injury.
Allow system to idle while monitoring pressure gauges, filters, connections and hydraulic lines. If any
16
filter indicators are tripped and in bypass, turn system off and replace filter elements immediately.

17 Shut down hydraulic power unit and fill hydraulic reservoir as needed.

Connect HPU to top drive service loop ensuring that all connections are properly coupled and
18
torqued.

19 Turn system on and set to idle.

Closely monitor reservoir level to ensure that level does not drop below “LOW” mark while connected
20
to top drive (Figure 3-4).

21 Perform final visual check of system to ensure no leaks exist and then shut off entire system.

Table 3-1 HPU Startup Procedure

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 Figure 3-1 Location of main pump case drain port

Figure 3-2 Location of functions pump case drain port

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 Figure 3-3 Location of suction line ball valve

Figure 3-4 Depiction of reservoir level gauge

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Special Tools
All normal service and maintenance on standard power units can be accomplished with standard hand tools. No
special tools are required.

Recommended Spare Parts

Refer to document Spare Parts List on customer configuration for list of spare parts utilized on this hydraulic
power unit.

HPU General Maintenance Schedule

FREQUENCY PROCEDURE TYPE
Check diesel engine oil level. Add oil if necessary Engine Oil (Per manufacturer)
Check hydraulic oil reservoir level. Add oil if
Hydraulic Oil
necessary.
Check all filters for tripped indicators. Replace
DAILY Manufacturer recommended filter
filter element if necessary (Table 4-3 Filter
element
Element Replacement Part Numbers).
Check for any signs of leaking hydraulic oil or
engine fluids.
Must meet existing pressure rating
Check hoses for wear. Replace any hose with
and hose size and be crimped with
excessive visual wear.
WEEKLY proper fitting.
Check diesel engine radiator coolant level. Add Engine manufacturer’s
fluid as necessary. recommended fluid.
Change diesel engine oil and filter per
Engine Oil (Per manufacturer)
manufacturer's recommendation.
Lubricate electric motor as recommended by
manufacturer.
QUARTERLY
Check filter elements for signs of failure. Replace
as needed.
Visually inspect hydraulic oil to ensure good
condition (Table 4-3).
Drain hydraulic oil and refill with fresh oil. Note:
YEARLY May need to be replaced sooner based on Hydraulic Oil
hydraulic oil analysis.
Table 4-1 HPU Maintenance Schedule

! NOTICE
When adding oil, types and brands of oil should not be intermixed because of possible incompatibility.

! NOTICE
High operating temperatures increase the lubricant’s rate of oxidation and shorten its effective life.
When average operating temperatures are very high, more frequent oil changes may be required.

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HPU Component Maintenance Suggestions

Maintain oil level at all times. The oil should be checked after the first 100 hours
Reservoirs and verify that the class of oil meet the requirements of the pump being used.
Change the oil every 1000 to 2000 hours depending on the application and
operation environment.

It is important to maintain sufficient oil in the air breather, of the same grade as
the hydraulic oil in the system. Clean the air breather and refill it with oil every
Air Breather
month, more often if environmental conditions require it. Additionally, as filtering
systems are improved, inadequate air breathers can become the major source of
contamination.

The key to good filtration is filter maintenance. A machine may be equipped with
the best filters available and they may be positioned in the system where they do
the most good; but, if the filters are not taken care of and cleaned when dirty, the
Filters money spent for the filters and their installation has been wasted. A filter which
gets dirty after one day of service and is cleaned 29 days later gives 29 days of
non-filtered fluid. A filter can be no better than the maintenance afforded it.
Replacement filter elements must exactly match manufacturer specifications to
ensure that proper conditioning of the fluid is performed.

Follow your pump manufacturer’s instructions regarding periodic checks and

maintenance.
Obtaining the maximum service life and performance of hydraulic pumps requires
the following:

Top quality oil condition. Oil must be filtered, cooled, clean, and free of
water. Oil condition is the most critical factor in pump life.
Pumps
No cavitation. Air bubbles entrained in the pump suction collapse violently,
causing erosion of metallic surfaces.

Proper alignment and rotation. Shaft alignment must be checked with a dial
indicator any time the motor or pump has been removed and replaced. Check
alignment and rotation before re-coupling. Repack the coupling with grease
as needed. Also, periodically re-torque the mounting bolts of the pump and
motor, to avoid misalignment, excessive wear, and noise.

When trouble-shooting valve problems, look for the most common system
problems: contamination and oil condition. Dirt or foreign matter in the system
Valves may hold check and relief valves open or prevent directional valve spools from
shifting. Excessive heat in the oil may cause valve bodies to warp and bind the
spools, or carbonization of the oil may cause stiction in spools.
Table 4-2 Individual Component Maintenance

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Preventative Maintenance Suggestions
 Inspect filter elements that have been removed from the system for signs of failure which may
indicate that the service interval should be shortened and of impending system problems.
 Do not return any fluid which has leaked out back to the system.
 Always keep the supply of fresh fluid covered tightly.
 Use clean containers, hoses and funnels when filling the reservoir. Use of a filter cart when adding oil is
highly recommended.
 Use common sense precautions to prevent entry of dirt into components that have been temporarily
removed from the circuit.
 Make sure that all clean-out holes, filler caps, and breather cap filters on the reservoir are properly
fastened.
 Do not run the system unless all normally provided filtration devices are in place.
 Make certain that the fluid used in the system is of a type recommended by the manufacturers of
the system or components.

Maintaining Proper Oil Temperature

Hot oil in a hydraulic system is one of the primary causes of poor operation, component failure and downtime.
The oil in your hydraulic system was designed for operation within a specified temperature range. You may be
able to run it at hotter temperatures for short periods of time, intermittently, without degradation. If you run
continuously with overheated oil, however, your equipment will operate poorly, and eventually key components
will fail and damage your machine.

Measuring Oil Temperature

Use the thermometer mounted on the hydraulic oil reservoir to verify system oil temperature. The temperature at
the reservoir should never exceed a maximum of 190°F. Always take an oil temperature reading at the reservoir,
not at a component or any of the piping.

Look, Smell and Feel

Checking oil temperature periodically is good preventative maintenance. So too is the practice of periodically
siphoning an oil sample from the reservoir and comparing it with a sample of clean, new oil. Oil that has been
running too hot will look darker and feel thinner than new oil. It will also smell burned. It will likely contain more
contaminants because hot oil leads to accelerated wear of component parts.

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Preventative Measures
How can you keep your equipment's hydraulic system from running too hot?
 Be prompt about removing, checking and repairing or replacing valves, pumps or other components that
are running hot.
 Keep your equipment clean. A thick layer of dirt acts as insulation. It will prevent the hydraulic system
from getting rid of heat.
 On hot days and in hot climates, check and change the oil more frequently. Be sure to use an oil
recommended for hot-weather operation by the equipment manufacturer or oil supplier.
 Check heat exchangers for proper operation and fan rotation.

Filter Replacement Specifications

Table 4-3 lists the replacement filter element part numbers for each filter used on the TDH-250 Hydraulic Power
Unit. For the unit to perform and operate properly, these specific filter elements must be used.

FILTER NOV FILTER ELEMENT PART NO. QUANTITY

Filter 1 (FL1) – High Pressure 11025814-002 2
Filter 2 (FL2) – Medium Pressure M851008036-E210 2
Filter 3 (FL3) – Medium Pressure M851008036-E210 1
Filter 4 (FL4) – Medium Pressure P851000398-E210 1
Table 4-3 Filter Element Replacement Part Numbers

Diesel Engine Maintenance

See user manual for CAT C18 Diesel Engine (SEBU7899-03).

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Introduction
This chapter describes general troubleshooting issues and provides probable causes and their possible solutions
when operating or maintaining the TDH-250 Hydraulic Power Unit. It provides guidelines to inspect and
troubleshoot the mechanical and hydraulic components for the Hydraulic Power Unit.

Before troubleshooting the equipment, ensure that the servicemen have read
and understand the content in the General Information chapter as well as the
content in this chapter.

There is no way to anticipate every issue that may be encountered. If the issue cannot be resolved using the
troubleshooting instructions, contact an NOV Service Center. A list of NOV Service Centers is provided in the
equipment User Manual.

Safety Precautions
The following precautions must be met prior to handling any equipment.

All troubleshooting recommendations provided in this chapter are

superseded by the procedures and methods approved for use at the location
where the equipment is installed and commissioned.

Ensure all hydraulic lines are isolated and the reservoir ball valves are closed
prior to any troubleshooting work is performed on the HPU.

During operation, surfaces may become hot enough to cause bodily

injury. To reduce the risk of injury from a hot component, allow the
surface to cool before touching.

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Troubleshooting Guidelines
NOV hydraulic power units use standard components and follow industry-standard design practices. For the
hydraulic systems to function (produce flow at all times and pressure when a load is present), the following basic
operating conditions must be present at all times:
 Ensure that all hoses and quick disconnects are properly connected at the remote control console and
hydraulic motor manifold hook-up.
 Ensure that the hydraulic pumps are running and rotating in the correct direction.
 Verify the fluid cleanliness of the HPU.
 The hydraulic and electric circuits must be correctly connected.
 The cables and hoses must positioned properly and unobstructed.

Ensure all electrical and hydraulic lines and valves are isolated before any work is started on top drive hydraulics.
Failure to follow safe work procedures could result in serious or fatal injury to personnel, significant equipment
damage, and rig downtime.

 Check the hydraulic system charge pressure output.

Lubrication oil pressure is critical to the performance and proper operation of
the top drive. The oil pressure must be carefully monitored and maintained.
Failure to adhere to this caution may result in damage to the equipment.
 Check the flow and pressure of the hydraulic power unit (HPU).
 Check the system filters for dirt pop-up indicators.
 If the pop-up indicator is raised, check and replace filter element as needed.

Use caution when checking the components in the next step. High pressure
pinhole leaks can cause serious injury. Failure to adhere to this caution may
result in injury to the personnel.

 Check whether hydraulic fluid leaks are visible at hydraulic components, hoses, and quick-disconnect
couplings.
 Ensure the Maintenance chapter of this manual is available during the troubleshooting guidelines.

Determining the Nature of Problem

When troubleshooting the HPU, determine the nature of the problem using the troubleshooting tables, detailed
theory of operation information for components, and diagnostic procedures. Potential component failure for the
HPU falls into the following categories:
 Mechanical System components
 Hydraulic System components
 Electrical System components

18 16560911-MAN
Revision 02
Identifying Troubleshooting Categories
Potential HPU failure typically falls into one or more of the following categories.

Mechanical Components
Mechanical problems are usually related to damaged or worn parts of the mechanical assembly. Vibrations and
abnormal noises in mechanical systems are often signals that there may be a problem within a component. Other
factors that can contribute to mechanical problems are the lack of periodic preventive maintenance, schedules,
and services that must be provided and performed to the assembly.

Hydraulic System and Components

Hydraulic circuit and component problems are usually related to faulty valves, hydraulic actuators, contamination,
fluid leakage, or damage not related to improperly adjusted hydraulic circuit components. Changes to component
adjustments should only be made after eliminating all other possible causes.

Electrical System and Components

Electrical system and component problems are usually related to faulty discrete control switches, electrical supply
voltage, and or improper interconnection wiring.

Cooling System Components

Cooling system problems are usually related to contamination, faulty discrete control switches, faulty valves and
dirty filters. Making changes to the flow rate, system pressure, or other adjustments should only be completed
after eliminating all other possible causes and after contacting a National Oilwell Varco service representative.

Make sure to have the hydraulic and electrical engineering schematics

available before troubleshooting system problems. These schematics are
located in the Technical Drawing Package (TDP).

16560911-MAN
Revision 02
19
 Troubleshooting the Hydraulic System

Ensure all hydraulic lines and valves are isolated before any work is
carried out on the hydraulics. Failure to follow safe work procedures
could result in serious or fatal injury to personnel, significant
equipment damage, and extended rig downtime.

The main areas of the hydraulic power unit that commonly require troubleshooting are:
 Hydraulic System
 Pump Case Drains
 Diesel Engine

The hydraulic circuit is powered by a diesel engine driven variable displacement axial piston pump, which
produces a constant flow of oil in a closed loop hydraulic circuit.

The variable displacement pump is designed to convert an input torque into hydraulic power. The high pressure
fluid is ported out from the pump to provide power to the top drive system. The pump’s displacement control valve
controls the output torque for a given input in either direction. The main ports of the pump are connected by
hydraulic lines to the main ports of the hydraulic motors.

The hydraulic pump can fail due to heat, contamination, overpressure or wear.

There are pressure gauges in the system to help determine if the pump is functioning correctly. In some
cases it may be helpful to add flow meters temporarily to determine if the system is functioning correctly
or if there is excessive case drain flow indicating a failing pump. The pumps are not considered to be
repairable and new pumps should be a part of the standard spares package.

It is important to use the recommended hydraulic oils and the correct

viscosities of oil for the environmental conditions being experienced.

20 16560911-MAN
Revision 02
 The following table contains malfunctions that may arise during operations. The faults are listed accordingly to the
individual functions of the hydraulic system.
Table 5-1. Troubleshooting the Hydraulic System
Probable
Issue
Cause/Symptom
There is loss of charge
pressure (pump in neutral).
There is loss of charge
pressure (pump in stroke)
The hydraulic oil is
overheating.
There is high back pressure
at the tank. The tank
temperature is high 88°C
(Temperature gauge reads
in excess of 190°F)
There is no system
pressure.
16560911-MAN
Revision 02
There is no charge pressure
indicated on the gauge.
High (10Hg or higher vacuum
gauge reading)
There is low charge pressure
when operating at full rpm.
The temperature gauge reading
is excess of 88°C (190°F).
The return filter is dirty.
The aerated hydraulic oil (air in
oil) is detected by milky
appearance.
Ambient air temperature is too
high.
The system relief valves are not
unloading.
The pump is failing/leaking
internally and creating heat.
The pump rotation is incorrect.
The Coupling has failed.
Table 5-1 Troubleshooting the Hydraulic System
Possible Solution
 Check for a defective gauge.
 Inspect the charge pump, repair or
replace.
 Check to ensure ball valve is open
Defective hydraulic pump or motor:
1. Close the ball valve in the high
pressure line.
2. If charge pressure is normal the motor
is defective.
3. Repair or replace the motor.
4. If the charge pressure is not normal it
indicates a defective pump.
5. Repair or replace the pump.
Aerated hydraulic oil (air in oil) detected by
milky appearance:
 Check the charge pump suction
connections.
 Check the oil level in the reservoir.
Replace the filter.
 Check the charge pump suction
connections.
 Tighten as necessary.
 Check the oil level in the reservoir.
 Fill as necessary.
 Reduce the duty cycle.
 Check the air flow through the heat
exchanger.
 Clean as necessary.
 Verify the pressure settings of the
charge-pressure relief valve and high-
pressure relief valve.
 Replace as necessary.
 Check the pump's flow and pressures.
 Replace the pump as necessary.
Ensure the correct rotation.
Inspect and replace the parts as necessary.
21
 Table 5-1. Troubleshooting the Hydraulic System (continued)
Probable
Issue Possible Solution
Cause/Symptom
There is no system Relief valve venting.
pressure.
Worn pump: test pump according to
manufacturer’s recommendation.
Open valve in system.
Relief valve setting not high enough.
The system pressure is The relief valve has failed or is
high. out of adjustment.
The filter is clogged or dirty.
The main pump pressure
compensator is set too high
The hydraulic system is The relief valves RV1 and RV2
overheating. are out of adjustment.
The unloading valve is not
working.
The counterbalance mode valve
is left in shut down position too
long and the pressure bleeds
down.
There is no precharge in the
system accumulator.
The hydraulic components The system pressure is down.
do not operate.
The piston pump is not working.
The flexible coupling is damaged.
The pressure at the valve is too
low.
The pumps are rotating in the
wrong direction.
The motors are rotating in the
wrong direction.
The suction valve is closed.
The oil level in reservoir is low.
22
Check all venting relief valves to be sure
vent is being blocked. Remove piping at
relief valve and insert plug to test relief
valve.
Replace pump.
Locate and repair.
Adjust relief valve to meet required
operating pressure. Contact NOV service
representative as needed.
Inspect and adjust or replace as necessary.
Replace the filter element.
Pressure compensator setting needs to be
adjusted
Test the pressures and adjust, or repair as
required.
Test and adjust valve or replace unloading
valve.
Check the system pressure.
Charge the system accumulator.
First make sure the RIG-UP SHUTDOWN
valve is in the correct position. Test the
pumps and motors. Test the relief valve
pressures. Adjust as required. Check for
leaks, loose fittings, loose cylinders, worn
hoses, fluid levels, and seals.
Replace the piston pump.
Replace the flexible coupling.
Adjust the pressure at the valve.
Verify prime mover is rotating in correct
direction and fix as needed.
Inspect hydraulic connections and verify
hoses are connected to correct ports.
Open the suction valve.
Fill the hydraulic reservoir and check for
leaks in system.
Table continues on next page
16560911-MAN
Revision 02
 Table 5-1. Troubleshooting the Hydraulic System (continued)
Probable
Issue Possible Solution
Cause/Symptom
The pump is not delivering Suction passage blocked.
fluid Suction line loose or disconnected.
Fluid viscosity too heavy.
The pump is noisy Air bubbles in intake fluid.
Pump cavitating due to low fluid
level.
Reservoir breather clogged.
Partially clogged intake line.
Suction line loose.
Leaks in other piping subject to
suction.
Note: A connection that will not leak
fluid under pressure may leak air
under suction.
The oil level in reservoir is low.
16560911-MAN
Revision 02
Clean.
Correct.
Heat fluid using in-tank heater. Verify
proper hydraulic fluid. See manufacturer’s
recommendations.
Return lines must be well below fluid level
and baffled from pump intake.
Fill reservoir to proper level.
Clean breather, check size and replace if too
small.
Clean.
Tighten, replace gasket or “O” ring as
required.
Tighten, replace gasket or “O” ring as
required.
Test by pouring hydraulic fluid over
connection while under suction and note
change in pump’s noise or flow of fluid into
connection.
Fill the hydraulic reservoir and check for
leaks in system.
23
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24 16560911-MAN
Revision 02
Hydraulic Fluid Requirements
NOV recommends anti-wear (AW) hydraulic fluid of the proper viscosity grade. AW hydraulic fluid is typically
mineral-based and contains anti-wear additives, along with rust and oxidation inhibitors. The hydraulic oil viscosity
should be adjusted based on expected ambient conditions, refer to the recommended hydraulic fluid tables for
specific hydraulic fluids for start-up and operating in non-arctic and arctic environments.

Hydraulic Fluid Recommendations

For recommended lubricants and hydraulic fluids for NOV drilling equipment, see the Recommended Lubricants
Guide (D811000719-PRO) in the Technical Drawing Package.

Hydraulic Fluid Cleanliness

In order to ensure reliable operation, hydraulic fluid must be maintained at a minimum particle count (cleanliness)
level that meets or exceeds an ISO 4406 rating of 17/15/12 (NAS Class 6 or better). Refer to the following NOV
documents for specific instructions about maintaining hydraulic fluid cleanliness:
 FIP00121 – Specification for Fluid Cleanliness and for Cleaning and Flushing Hydraulic Lines
 SM00081 – Hydraulic Fluid Cleanliness Supplement
 Do not mix different types of fluids. Do not mix the same type of fluid from different manufacturers.
 Maintain a clean, sludge-free oil of proper viscosity.

Filters
 Filters should always be replaced when changing hydraulic fluid. Refer to the Maintenance chapter (in the
NOV equipment User Manual) for filter descriptions and details. Replace filters every three (3) months or
whenever the indicators show that changing is required.

Inspection
 Check the hydraulic fluid level daily. Keep the hydraulic reservoir full at all times. The oil level should be
visible in the sight gauge.
 Inspect for leaks daily.
 Perform hydraulic system oil analysis once every six (6) months.

16560911-MAN
Revision 02
25
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26 16560911-MAN
Revision 02
 Hydraulic Power Unit Assembly Drawing – See Customer Configuration
Hydraulic Power Unit Schematic – See Customer Configuration
Spare Parts List for HPU – See Customer Configuration
Recommended Lubricants Guide - D811000719-PRO

16560911-MAN
Revision 02
27
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 3.0
Technical Drawing Package

www.nov.com
 Technical Drawing Package

TDH-250 Top Drive System

With Hydraulic Power Unit

Top Drive Serial Number: TD-140-C

HPU Serial Number: HPU-112-C
Hose Reel Serial Number: HR-111-C

PT Pertamina Drilling, Indonesia

Rig Name: PDSI 16.2/NT45-M

RIG/PLANT
REFERENCE REFERENCE DESCRIPTION
16567184-GEN Customer Configuration
ADDITIONAL CODE SDRL CODE TOTAL PGS
This document contains proprietary and confidential information
REMARKS 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. National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the RIG SOLUTIONS
CLIENT PO NUMBER express written consent of NOV. This document is to be returned to 11000 Corporate Centre Drive
NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
CLIENT DOCUMENT NUMBER represented herein is the copyrighted property of NOV.
© National Oilwell Varco

Client Document Number DOCUMENT NUMBER REV

16645318-DOS 01

www.nov.com

D811000461-GEN-001/04
 Document number 16645318-DOS
Revision 01
Page 2

REVISION HISTORY

01 01/07/2016 First Issue T. Harmon J. Rhone P. Williams

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

01 First issue

www.nov.com

D811000461-GEN-001/04
 Document number 16645318-DOS
Revision 01
Page 3

TECHNICAL DRAWING PACKAGE

This document provides a list of drawings for the TDH-250 Top Drive System. The actual
drawings are arranged in the binder by assembly order.

Drawings by Assembly

TDH-250 Top Drive

Customer Configuration ............................................................................................ 16567184-GEN
General Arrangement ...................................................................................... 16646559-GAD-DOS

Top Drive System and Rig Interface Drawing Assembly

Swivel Assembly, Part Number 16593460-001 ........................................................ 16593460-DOS
Lube Assembly, Part Number 16609592-001 .................................................... 16609592-DOS
Lube Pump Assembly, Part Number 10386317-001 ............................. M624000304-DOS-001
Spray Nozzle Head Assembly, Part Number 10473453-001................. M624000326-DOS-001
Spray Nozzle Head Assembly, Part Number 10360781-001................... 220288/005-DOS-001
H.P. Hydraulic Assembly, Part Number 16600369-001..................................... 16600369-DOS
Manifold Header Assembly.......................................................................... 10731713-DOS
Manifold Bracket Assembly ......................................................................... 10732744-DOS
Washpipe Assembly, Hex Lock Design, Part Number 10452132-001 ........... 218111/007-DOS
Gooseneck Assembly, Part Number 10386260-001 ............................. M624000256-DOS-001
Encoder Assembly, Part Number 10473465-001 .................................. M624000335-DOS-001
Onboard Hydraulics Kit, Part Number 10386319-002 (-501) ....................... M624000305-DOS-001
Hydraulic Manifold Assembly, Part Number 16631783-001 .............................. 16631783-DOS
Rig-Up Manifold Assembly ................................................................................. 11042766-DOS
Hose and Fitting Kit, Part Number 16628709-001 ............................................. 16628709-DOS
Extended Dolly Assembly, Part Number 16648030-001 .......................................... 16648030-DOS
Carriage Cylinder Assembly, Part Number 10456731-001................................ 30180149-DOS
Upper Housing / Link Adapter, Part Number 10386233-002 (-501) ............. M624000239-DOS-001
Pipe Handler Assembly, Part Number 10386234-001 ................................. M624000240-DOS-001
Torque Arrestor Assembly, Part Number 10386311-001 ...................... M624000298-DOS-001
Clamp Cylinder Assembly, Part Number 10479829-001 ................ M614001826-DOS-001
Manifold Assembly, Part Number 10480763-001 ..................... M614002346-DOS-001
Jaw Assembly, NC50 ......................................................................................... 16525886-DOS
Stabbing Guide Assembly, Part Number 10479483-001 ....................... M614003512-DOS-001
Clamp Assembly, Link, Part Number 10473455-001............................. M624000328-DOS-001
S-Pipe Assembly, Part Number 10386301-001 ........................................... M624000290-DOS-001

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D811000461-GEN-001/04
 Document number 16645318-DOS
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Top Drive System and Rig Interface (Continued) Drawing Assembly

Bail Assembly, Part Number 10386253-001 ................................................ M624000253-DOS-001
Thread Compensation Assembly, Part Number 10386238-001 .................. M624000243-DOS-001
Chain Counterbalance Assembly, Part Number 10473522-001 ............ M624000374-DOS-001
Cylinder Assembly, Counterbalance, Part Number 10358563-001 ....................... 122023-DOS
Cylinder Assembly, Counterbalance, Part Number 10448819-001 ....................... 122024-DOS
Onboard Electrical Kit, Part Number 10386321-002 .................................... M624000307-DOS-001
Top Drive Junction Box Assembly ..................................................................... 16504962-DOS
Transport Assembly, Part Number 10386323-002 ....................................... M624000309-DOS-001
Guide Track Assembly, Part Number 10386222-004................................... M624000228-DOS-001
Guard Assembly ....................................................................................................... 16619139-DOS
Rig Interface Installation Kit, Part Number 10386224-001 ........................... M621000229-DOS-001
Service Loop Cable Tender Assembly, Part Number 10361111-001 ................... 221496/006-DOS

Top Drive Control System

Hydraulic Power Unit Assembly, Part Number 16592908-001 ................................ 16592908-DOS
Pump / Motor Assembly, Part Number 10737385-002 ...................................... 10737385-DOS
Manifold Assembly, Part Number 16623861-002 .............................................. 16623861-DOS
Filter Assembly................................................................................................... 10952943-DOS
SBC Control Panel Assembly ............................................................................ 16509119-DOS
Power Junction Box Assembly ........................................................................... 16593106-DOS
Reservoir Assembly ........................................................................................... 16610700-DOS
Hose Kit .............................................................................................................. 16633292-DOS
Main Pump Support Kit, Part Number 11337775-002 ....................................... 11337775-DOS
Pump Support Kit ............................................................................................... 11314952-DOS
Control Console ........................................................................................................ 16593189-DOS
Hose Reel / Hoses Assembly, Part Number 11024480-002 .................................... 11024480-DOS
Hose Reel Assembly, Part Number 10936630-001 ........................................... 10936630-DOS
Hose Kit, Part Number 11017095-001 ........................................................ 11017095-DOS
Manifold Assembly, Left Motor, Part Number 11016774-003 ..................... 11016774-DOS
Manifold Assembly, Right Motor, Part Number 11016774-004 ................... 11016774-DOS
Cable Kit, Control Console ....................................................................................... 16646088-DOS
Cable Kit, Hydraulic Power Unit ............................................................................... 16667126-DOS

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D811000461-GEN-001/04
 Document number 16645318-DOS
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Page 5

Schematics
Hydraulic Schematic, TDH-250 Top Drive ......................................................16633294-SCH-DOS
Hydraulic Schematic, Hydraulic Power Unit .....................................................16598058-SCH-DOS
Hydraulic Schematic, Hose Reel ......................................................................11028080-SCH-DOS
Block Diagram ................................................................................................... 16645341-DIA-DOS
Interconnect Diagram ........................................................................................ 16645340-DIA-DOS

Note: Either the assembly part number or drawing assembly number

may appear in the drawing bill of material.

www.nov.com

D811000461-GEN-001/04
 Document number 16645318-DOS
Revision 01

TDH-250 Top Drive

General Information

www.nov.com
This document contains proprietary information, and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from National Oilwell Varco, LLC.
REVISIONS
LTR DESCRIPTION PREPARED / DATE CHECKED/ DATE APVD / DATE
01 INITIAL RELEASE J.L. RHONE 26-MAY-16 P.W. WILLIAMS 26-MAY-16 P.W.WILLIAMS 26-MAY-16
03 UPDATE…SEE EN FORM J.L. RHONE 29-JUN-16 P.W. WILLIAMS 29-JUN-16 P.W.WILLIAMS 29-JUN-16

STANDARD ORDER INFORMATION QUALITY REQUIREMENTS

SHIPMENT DATE: 6/2016 CERTIFICATION: NONE
PRE-SHIP: None DATA BOOK: NONE
RIG TYPE: Land
INSTALLATION LOCATION: Indonesia
OPERATION LOCATION: Indonesia
RELATED CONFIGS: N/A CONTACT NOTES
SALES ORDER #: 293814 CUSTOMER: PT Pertamina Drilling Services
QUOTE # & REV: 230982-2 Fax: +62 21 2956 3148
SPARES QUOTE #: N/A Phone: +62 21 2936 0730
PO #: 4500157838 PROJECT MANAGER: Douglas Kidd
TOP DRIVE SERIAL #: TD-140-C SYSTEM INTEGRATION: N/A
HPU SERIAL #: HPU-112-C CONTRACTS: Rachele Mulcahy
HOSE REEL SERIAL #: HR-111-C SALES: Dean Muttom
ENGINEERING JOB #: 10459 RESPONSIBLE ENGINEER: Paul Williams
ELECTRICAL ENGINEER: Danny Sohn
SOFTWARE ENGINEER: Charlie Patek

APPLICATION NOTES:
1) TDH-250 Hydraulic Top Drive System
2) Extend Dolly

REVISION
Sheet 1 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

"" INITIAL UNDEFINED PART NUMBERS: REFERENCE ONLY

REVISION
Sheet 2 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

TOP DRIVE SYSTEM

16567184-001 1 DRILLING SYSTEM, TDH-250
16567184-002 1 DRILLING UNIT, TDH-250
16593460-001 1 SWIVEL ASSEMBLY Service Loop Loc: RIGHT
M624000239-501 1 UPPER HOUSING/LINK ADAPTER
M624000305-501 1 KIT, ONBOARD HYDRAULICS
16648030-001 1 DOLLY ASSEMBLY, EXTEND Setback: 23”
M624000240 1 PIPE HANDLER ASSEMBLY, TDH-250 Connection: NC50
M624000290 1 S-PIPE ASSEMBLY Location: Right Mud Connection: Female, 4” FIG 1002
Pressure Rating: 5000 PSI
M624000253 1 BAIL PACKAGE, Bail Length: 62.5”
M624000243 1 THREAD COMPENSATION ASSEMBLY Attachment: TO HOOK
M624000307-501 1 KIT, ONBOARD ELECTRICAL
M624000309-500 1 SHIPPING PACKAGE Setback: 23”

RIG INTERFACE
M624000229 1 INSTALLATION KIT, RIG INTERFACE Rig Type: LAND

REVISION
Sheet 3 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

TOP DRIVE CONTROL SYSTEM

16592908-001 1 ASSEMBLY, TDH-250 HPU Service Loop Length: 200’
16593189-001 1 CONTROL CONSOLE (SHP Engineering)
16646088-001 1 CABLE KIT, TOP DRIVE (SHP Engineering)
16667126-001 1 CABLE KIT, HPU (SHP Engineering)
11024480-002 1 HOSE REEL/HOSES ASSEMBLY
10936630-001 REF HOSE REEL ASSEMBLY
218360/013-201-200-001 REF CONTROL UMBILICAL ASSY, HYD/ELEC HYD Service Loop Length: 200’ ELEC Service Loop Length: 200’
11000904-005 REF HIGH PRESSURE HOSE ASSY W/MALE END Service Loop Length: 200’
11000904-008 REF HIGH PRESSURE HOSE ASSY W/FEMALE END Service Loop Length: 200’

ACCESSORIES / SPECIAL ITEMS

M624000228-501-103 1 GUIDE BEAM ASSEMBLY
16363Y1108-BSC 1 LINKS, WELDLESS 250 TON (SET) Length: 108”
16623821-001 1 CANOPY ASSEMBLY, HPU

SPARES
218111/007 2 WASHPIPE ASSEMBLY
220841/005 10 WASHPIPE
M611005764 2 IBOP VALVE
M614005193 2 ACTUATOR, SHELL
M624000241 4 SAVER SUB, NC50 X NC50
REVISION
Sheet 4 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

10680099-003 2 SAVER SUB, NC50 X NC38

10893883-002 2 MAIN PUMP, HPU
10520555-001 1 CONTROL CABLE, 37C
P854000077 3 MOTOR, HYDRAULIC
M851008036-E210 60 FILTER, HPU, RETURN HEADER & ACCUMULATOR
P851000398-E210 30 FILTER, HPU, CASE DRAIN
16634344-003 20 FILTER, WATER SEPARATOR & FUEL, DIESEL ENGINE
16634344-002 20 FILTER, OIL, DIESEL ENGINE
10737385-002 1 PUMP/MOTOR (50Hz) ASSEMBLY
10470792-001 4 CRANK, ACTUATOR

MANUALS, CERTIFICATION, AND DOCUMENTATION

16645318-001 1 USER’S MANUAL (ELECTRONIC COPY)

REVISION
Sheet 5 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

REFERENCE DRAWINGS
16646559-GAD REF GENERAL ARRANGEMENT, TDH-250
16633294-SCH REF SCHEMATIC, HYDRAULIC, TOP DRIVE, TDH-250
16598058-SCH REF SCHEMATIC, HYDRAULIC, HPU, TDH-250
11028080-SCH REF SCHEMATIC, HYDRAULIC, HOSE REEL, TDH-250
TS00162-SPC REF TEST SPECIFICATION, HYDROSTATIC PRESSURE & POST MPI (GOOSENECK/S-PIPE)
TS00168-SPC REF TEST SPECIFICATION, MAG PARTICLE INSPECTION
TS00419-SPC REF POST FUNCTION TEST, HYDRAULIC FLUID CLEANLINESS
TS00167-SPC REF PULL TEST, 250 TON LINKS
PS-3070 REF GOOSENECK SUPPORT ALIGNMENT
D621000381-PRO-001 REF HYDROSTATIC PRESSURE TEST, ROTATING LINK ADAPTER ASSEMBLY
11030226-REP REF ASSEMBLY INSPECTION REPORT
10915110-PRO REF TRACEABILITY WORKSHEET
16504962-001 REF TOP DRIVE J-BOX (INTEGRAL TO M624000307-501) (SHP Engineering)
16645341-DIA REF BLOCK DIAGRAM (SHP Engineering)
16645340-DIA REF SYSTEM INTERCONNECT DIAGRAM (SHP Engineering)
16648189-IDX REF CABLE SCHEDULE
16648190-IDX REF HAZARDOUS AREA INDEX
16648191-IDX REF I/O MAP
10934263-SPC REF FINAL INSPECTION REPORT
11023828-SPC REF TEST SPECIFICATION, MOTOR HOUSING
D621002413-PRO-001 REF FUNCTION TEST W/LABVIEW
16645318-SPL REF MECHANICAL SPARES, TOP DRIVE
16645337-SPL REF MECHANICAL SPARES, HOSE REEL
16645301-SPL REF ELECTRICAL SPARES, TOP DRIVE
16645329-SPL REF SPARES, HPU
16567184-PLN REF QUALITY PLAN
REVISION
Sheet 6 of 7 Customer:
DOCUMENT NUMBER
PT Pertamina
Drilling
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
PART NUMBER QTY DESCRIPTION
S/O -001 -002

16653488-PRO REF FUNCTION TEST, EXTEND DOLLY

16657751-PRO REF FAT, TDH-250 SYSTEM

REVISION
Sheet 7 of 7 Customer: PT Pertamina Drilling
DOCUMENT NUMBER
CUSTOMER Services Indonesia
CONFIGURATION 16567184-GEN 03 Rig: PDSI 16.2/NT45-M
Equipment: TDH-250
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 2:07 PM 6/29/2016
 Document number 16645318-DOS
Revision 01

Top Drive System

And Rig Interface

www.nov.com
R-C 3/8"
M

3/4" M
3/4" M

C5D

BUNA N 90 DURO
BUNA N 90 DURO
BUNA N 90 DURO
BUNA N 90 DURO
BUNA N 90 DURO
9/16" - 18 X 1/4" TUBE STEEL W/ O-RING BOSS
7/16" - 20 UNF X 1/4" TUBE STEEL
1/4" - 18 X 1/4" TUBE X LONG 90 DEG. EXT.
7/16" -20 UNF X 1/4" TUBE STEEL
7/16" - 20 UNF X 1/4" TUBE STEEL

.437-20 UNF

1 OF 4

DOS
DOS
DOS
DOS
 9/16" - 18 UNF STEEL
1" BLACK
1-5/16" M.I. 150# BLACK
3/4" - 16 X 3/4" TUBE X 90 DEG.
1/4" MORB X 3/8" MJIC X 90 DEG.
S 1-1/16" - 12 X 3/4" TUBE X 90 DEG.
9/16" - 18 X 1/4" TUBE
S 1/4" - 18 X 1/2" TUBE
3/4" - 16 X 3/4" TUBE
1-5/8" - 12 X 3/4" TUBE
1-1/2" NPT X 3/4" TUBE
1-1/16 - 12 UNC
3/4" - 14 LOCK-OUT

R-C

C5D

3/8" - 16 X 1" LG.

M
S

1 OF 2

DOS
DOS
 5/8" MORB X 3/4" MJIC

1/2" ZINC PLATED

1-1/16" -12 X 3/4" TUBE

P MOTOR WITHOUT CASE DRAIN

DOS
DOS
 1 OF 2
DOS
DOS
 , 1-5/16" -12 UNF X 1" TUBE
1-1/4"
1"
1/2"
3/4"

, 9/16" UNF
, 1.06" - 12 UNF STEEL
1.312" - 12 UNF STEEL, HEX W/O-RING
S

UNION WITH O-RING BOSS/37, 1-5/16" - 12 MALE

UNION WITH O-RING BOSS/37, 1-1/16" -12 MALE
UNION WITH O-RING BOSS/37, 1-5/8" -12 MALE
, 1-1/4"

1 OF 1

DOS
DOS
 WASHPIPE ASSEMBLY
SEE NOTES
HEX LOCK DESIGN
1 1

218111-007-DOS A
M

1 OF 1

DOS
 , 1/4" TUBE
, 1/4" TUBE X 90 DEG.

DOS
DOS
DOS
 (PCM)
(SV1, SV2, SV3, SV4, SV5, SV6, SV8, SV9)
(SV7)
(FCP)
(CVT)
(CVD)
(CVC)
(PCC)
(PCX, PC5, PC8)
(FLX)
(RVL)
(CV1, CV5)
(DV2, DV4, DV8)
(DV1, DV3, DV5, DV6)
(DV9)
(CB3A, CB3B)
(CC3A, CC3B)
(LC5)
(CB7A, CB7B)
(CV8)
(CVT)
(DV7)

(SV1, SV2, SV3, SV4, SV5, SV6, SV8, SV9)

(SV1, SV2, SV3, SV4, SV5, SV6, SV8, SV9)
(SV1, SV2, SV3, SV4, SV5, SV6, SV8, SV9)

TDH-250 MAIN FUNCTIONS

150
MANIFOLD ASSEMBLY
1 8
16631783-DOS 01
DOS
DOS
DOS
DOS
DOS
DOS
DOS
 1/2" STEEL
3/4" - 16 UNF X 1/2" TUBE
1" TUBE OD
1/2" TUBE OD
3/4" TUBE OD

PLUG W/ .091 DIA. ORFICE, 1/8" - 27

, 3/4 - 16 X 3/4" TUBE
CONNECTOR, O-RING BOSS/37, 3/4 - 16 X 1/2" TUBE
, 1-1/16 -12 X 1/2" TUBE
, 1-5/16 -12 X 1" TUBE
7/16" UNC

1 OF 1
DOS
 DEG., 3/4" - 16 UNF

, 7/16" - 20 UNF X 90 DEG,

S , 7/16" 20 UNF

, 3/4" - 16 UNF

S , 9/16" - 20 UNF

, 3/8" TUBE X 1/4" PT

3/4" - 16 UNF FEMALE HOSE

, 9/16" - 18 UNF HOSE FITTING

7/16" - 20 UNF FEMALE HOSE

9/16" - 18 UNF, STRAIGHT THREAD

DOS
DOS
DOS
DOS
DOS
DOS
 C

-C , 3/8" X 1/2" STAINLESS STEEL

ELBOW, 1/2"TUBE X 1/2" HOSE ID X 45 DEG SWIVEL FEMALE
HOSE FITTING, 1/2" TUBE X 1/2" HOSE ID FEMALE STEEL

HOSE FITTING, 1/2" TUBE X 1/2" HOSE ID STEEL FEMALE

TEE W/ O-RING BOSS, 1/2" TUBE X 3/4" - 16
ELBOW W/ O-RING BOSS, 1/2" MORB X 1/2" MJIC

TYPE DP4

C5D
C

TYPE DP4
TYPE DP4

C
C 3/4" - 10 UNC X 3" LG.

M
M

M
M

DOS
DOS
 1/2"
1/4"
DEG., 1/4"
1/4"

CAPSCREW, 5/16" - 18 X 2" LG. GR 5 ZINC PLATED DRILLED HEX HEAD

1 OF 1

30180149-DOS B
 1/2"
S CONNECTOR, 9/16" -10 X 1/2" TUBE STEEL

3/8"

, 9/16" -18 X 3/8" TUBE STEEL

6-MORB X 10-MJIC
, 1/8"-27

CAPSCREW, 1/2" - 13 X 1-3/4" LG. 12 POINT DRILLED HEAD

DOS
DOS
DOS
DOS
DOS
M624000239-DOS-001
 1/8"

, 9/16" - 18 X 3/8" TUBE STEEL

6-MORB X 6-MJIC X 90 DEG.

1" - 14 UNS

X 45 DEG.

1-3/8" BORE X 3/4" LONG

, 1-1/2" BORE X 1-1/2" LONG

1" BORE X 1-1/4" LONG

DOS
DOS
DOS
DOS
DOS
FT.

2" BORE X 2" LONG

1-3/8" BORE X 1" LONG
1" BORE X 1" LONG
1" BORE X 3/4" LONG

1 OF 3

DOS
DOS
DOS
dos
, 3/4" - 16 UNF
, 9/16" - 18 UNF
, 7/16" - 20 UNF
, 5/16" - 24 UNF

dos
DOS
 , 3/8" - 16

, 1/8" X 1" LG. STAINLESS STEEL

, 3/4" ZINC PLATED
, 1/2" ZINC PLATED
, 3/8" ZINC PLATED
, 5/8" NARROW ZINC PLATED
, 1/2" - 13 ZINC PLATED
, 3/4" - 10 X 2" LG. GR 5 DRLD.
,1/2" - 13 X 1-5/8" LG. GR 5 DRLD.
, 5/8"-16 x 1" LG. GD 5 DRLD.

dos
dos
 2 1
REV DESCRIPTION OF CHANGE MADE CHKD DATE APPD
NOTES:

1. TAG WITH NOV PN "M624000328".

2. TORQUE FASTENERS (ITEMS 4) PER

NOV SPEC DS00008 AT INSTALLATION. 2

B B

4 51810-C-H NUT, HEX HD 5/8-11 SELF LOCKING 4

4 50910-C WASHER, REG SPG LOCK 5/8" 3
2 117078 U-BOLT, LINK TILT, 250 TON 2
A 1 M624000327 CLAMP WELDMENT, LINK 1 A
QTY PART NUMBER DESCRIPTION MATERIAL ITEM
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
PRODUCT: TDS-250 TOLERANCES ARE: INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
END ITEM: X.X ±.1 ANGLES ±.50 DEG REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
X.XX ±.03 FRACTIONS ±1/16
NEXT ASSY: M624000240 NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF TITLE:
X.XXX ±.010 BREAK EDGES .02/.03 THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
SIMILAR TO: DO NOT SCALE DRAWING
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
CLAMP ASSEMBLY, LINK
WT LBS: 17 CURRENT INITIAL
FINISH DRAWN D. MORENO III
USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
IS THE COPYRIGHTED PROPERTY OF NOV.
TDS-250
B
UNLESS OTHERWISE SPECIFIED CHECKED J. RHONE SCALE: PROJECTION: SIZE: SHT:
TOL < ±.06 TOL > ±.06 RIG SOLUTIONS 1:2 1 OF 1
APPVD B. ZAHN DWG NO. REV:
DOS
250 1000 MECHANICAL ENGINEERING
DATE 10/19/10 M624000328-ASM-001 01
DRAWN IN SW
2 1 RS-MECH_B-TPL-001
 REV DESCRIPTION OF CHANGE MADE CHKD DATE APPD
JLR RIP RIP

REF GOOSENECK
M624000256

REF SEAL RING

91923
REF BONNET
M624000255

56-1/2"
1 REF

REF UPPER COVER

M624000252

12-1/4"
24" REF
REF
NOTES:

1. ITEM(S) NOT SHOWN.

2 4X
4X 2. APPLY ANTI-SEIZE AND TORQUE ALL FASTENERS
3 PER DS00008 AND SECURE WITH LOCKWIRE (ITEM #5).
4 1 2
3. THIS IS A CRITICAL COMPONENT OF A PRODUCT
WHOSE DESIGN, MATERIALS AND MANUFACTURING
PROCEDURES MUST COMPLY WITH THE
REQUIREMENTS OF API SPECIFICATION 8C, PSL 1.
WHEN SPECIFIED ON THE PURCHASE ORDER,
FINAL APPROVAL OF THIS EQUIPMENT WILL
REQUIRE AN INDEPENDENT REVIEW OF THE DESIGN
BY A CERTIFYING AUTHORITY, IN PLANT SURVEYS
BY A CERTIFYING AUTHORITY AND FINAL DATA BOOK
REVIEW AND APPROVAL BY THE CERTIFYING
AUTHORITY SPECIFIED BY NATIONAL OILWELL VARCO.
IF A CERTIFYING AUTHORITY IS NOT SPECIFIED, A
VENDOR MUST CONTACT NATIONAL OILWELL VARCO
FOR CLARIFICATION OF THE SPECIFIC REQUIREMENTS.

4. TRACEABILITY REQUIRED.

02 4 1 M624000409 S-PIPE EXTENSION, 22.5 DEG 6

1 2 3' Z6001 LOCK WIRE, 302 SST .051" DIA 5
2 4 50008-26-C5D SCREW, DR HD HEX HD CAP 1/2-13 X 3-1/4" LG 4
4 50908-C WASHER, REG SPRING LOCK 3
1 M624000287 CLAMP BRACKET, S-PIPE 2
4 1 M624000289 WELDMENT, S-PIPE 1
QTY PART NUMBER DESCRIPTION MATERIAL ITEM

X.X ±.1 ANGLES ±.50 DEG

X.XX ±.03 FRACTIONS ±1/32
X.XXX ±.010 BREAK EDGES .02/.03

DOS
 REV DESCRIPTION OF CHANGE MADECHKD DATE APPD
NOTE: 02.1
02.1 REMOVED NOTE 4
PM JR 18-Jan-11 PWW
1. ALL DIMENSIONS ARE FOR REFERENCE. 02.2 REMOVED ITEMS 3 & 4

2. TAG WITH PART NO. "M624000253" AND REVISION.

3. CENTER AND PRESS FIT BUSHINGS.

A 2
62-1/2"
79-1/2"
7-1/2"

2X 21/32" 1 63/64"
1-3/4" 3/8" A

3-1/4"

SECTION A-A
SCALE 1 : 4
2X R21/32" 9-1/2" 8"
1-5/8"

1-1/2"
2-7/8" 26-1/8" 2-7/8"

02.2

2 M624000248 BUSHING, BAIL PIN 2

1 M624000246 BAIL, TDS-250 1
QTY PART NUMBER DESCRIPTION MATERIAL ITEM

X.X ±.1 ANGLES ±.50 DEG

X.XX ±.03 FRACTIONS ±1/16
X.XXX ±.010 BREAK EDGES .02/.03

DOS
, -8MORB X -12MJIC X 90 DEG.

DOS
 2 1
REV DESCRIPTION OF CHANGE MADE CHKD DATE APPD
NOTE:

TAG PART NO. "M624000374" AND REVISION.

13.30

B B

31.91

1 M624000373 LINK, PEAR SHAPE 3

3 P764000107-03 SHACKLE, CHAIN 2
A 1 P764000135 CHAIN, STRAIGHT LINK (8 LINKS) 1 A
QTY PART NUMBER DESCRIPTION MATERIAL ITEM
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
PRODUCT: INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
TOLERANCES ARE:
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
END ITEM: X.X ±.1 ANGLES ±.50 DEG REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
X.XX ±.03 FRACTIONS ±1/16
NEXT ASSY: NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF TITLE:
X.XXX ±.010 BREAK EDGES .02/.03 THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
SIMILAR TO: DO NOT SCALE DRAWING
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
ASSEMBLY, CHAIN
WT LBS: 20 CURRENT INITIAL
FINISH DRAWN D. GILMORE
USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
IS THE COPYRIGHTED PROPERTY OF NOV.
COUNTERBALANCE, TDS-250
B
UNLESS OTHERWISE SPECIFIED SCALE: PROJECTION: SIZE: SHT:
CHECKED B. ZAHN 1 1
TOL < ±.06 TOL > ±.06 RIG SOLUTIONS 1:4 OF
APPVD P. WILLIAMS
DOS
MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE 12/16/10 M624000374-ASM-001 01
DRAWN IN SW
2 1 RS-MECH_B-TPL-001
S 1/4" - 18 NPT X 7/16" - 20 UNF

1/2" PT X 3/8" TUBE X 90 DEG. STEEL

5000 PSI

DOS
M624000307-DOS-001
DOS
DOS
DOS
DOS
DOS
DOS
DOS
R-C

DOS
 1 OF 1

221496/006-DOS B
 Document number 16645318-DOS
Revision 01

Top Drive
Control System

www.nov.com
DOS
 2 5
16592908-DOS 01
DOS
DOS
DOS
 , 7/8" -14
, 1-1/16" - 12
, 1-5/8" - 12
, 3/4" CODE 61
, 1" CODE 61
, 1-1/4" CODE 61
, 2-1/2" CODE 61
NO. 4 X 1/2" LG.

7/16"

CAPSCREW, 7/16" - 14 X 4-1/2" LG. SOCKET HEAD

CAPSCREW, 1/2" - 13 X 1-1/4" LG. GR 5 HEX HEAD
CAPSCREW, 1/2" - 13 X 1-1/2" LG. GR 5 HEX HEAD
CAPSCREW, 5/8" - 11 X 2" LG. GR 5 HEX HEAD

PLUG W/ O-RING, 1-1/16" - 12 UNF STRAIGHT THREAD

DOS
DOS
 FL1 / FL2
LA1
LA1
LA2
LA2
DFD
LA2 / DFD D
RCV
PCD
LAR
RVA / RVB
HEF
CV1
CVL / CVS
CV2
CA2
DV3
RVF

MANIFOLD ASSEMBLY
990
TDH-250 HPU
1 6
16623861-DOS 03
DOS
DOS
DOS
DOS
DOS
DOS
HYDRAULIC RESERVOIR ASSEMBLY
HPU, TDH-250
1 1
16610700-DOS 02
DOS
DOS
DOS
DOS
DOS
DOS
 1/2" REG. LOCK
1/2" FLAT
1-1/4" - 7 UNC STD. HEX
1-1/4" - 7 UNC X 5" LG. HEX HEAD CAP
1/2" - 13 UNC X 1-1/2" LG. DRILLED HEX HEAD CAP

MAIN PUMP SUPPORT KIT

11337775-DOS 02
WASHER, 1/2" REG. ZINC PLATED SPRING LOCK
NUT, 3/4" - 10 UNC ZINC PLATED STEEL HEX JAM
CAPSCREW, 3/4" - 10 UNC X 3-1/4" LG. HEX HEAD
CAPSCREW, 1/2" - 13 UNC X 1-1/4" LG. DRILLED HEX HEAD

PUMP SUPPORT KIT

11314952-DOS 02
DOS
 .924 I.D. X .116 W.
.458 I.D. X .078 W.
.644 I.D. X .087 W.

5/16"
1" X 3/4"
3/8" TUBE X 7/16"- 20 UNF
3/4" TUBE X 1-1/16" - 12 UNF
S 1/2 TUBE X 7/8" -14
S 3/4" TUBE X 1-1/16" - 12 UNF
3/8" TUBE X 9/16" - 18 UNF
S 1/2" TUBE X 3/4" - 16 UNF
3/8" TUBE X 9/16" - 18 UNF
S 3/4" TUBE X 1-1/16" -12 UNF
1/2" TUBE X 3/4" - 16 UNF
5/8" STEEL
, 3/8" - 16, FOR 2-1/2" PIPE
3/8" X 3/4" LG. STAINLESS STEEL

C
C 3/8" -16 UNC
N-C
G.
C
-C
C , 3/8" - 16, FOR 1-1/2" PIPE C5D
C ,3/8" - 16, FOR 1-1/4" PIPE 1-1/4" BULKHEAD
C , 3/8" - 16, FOR 1" PIPE 1" MSAE X 1" MJIC

OA

S 3/4" MSAE X 3/4" MJIC

3-3/4" LG.

ZINC PLATED
ZINC PLATED

DOS
DOS
DOS
DOS
DOS
DOS
DOS
DOS
DOS
DOS
DOS
, 1/2" TUBE X 5/8" - 18 UNF
3/8" TUBE X 9/16" - 18 UNF

3/8" TUBE X 9/16" - 18

1/2" TUBE X 3/4" - 16

9/16" - 18 UNF STEEL

DOS
DOS
 Document number 16645318-DOS
Revision 01

Schematics

www.nov.com
11028080-SCH-DOS
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 4.0
Spare Parts List, Mechanical

www.nov.com
 MECHANICAL SPARES LIST
TDH-250
PT PERTAMINA DRILLING
PDSI 16.2/NT45-M

NOTES:
1. 16645318-1 Recommended Commissioning Spares
2. 16645318-2 Recommended Operational Spares
3. 16645318-3 Recommended Insurance Spares
4. Configuration 16567184-GEN

NEXT ASSY PRODUCT

16567184-001 TDH-250
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 TITLE Mechanical Spare Parts List
copyrighted property of NOV. © National Oilwell Varco
PT Pertamina Drilling, Indonesia
CURRENT INITIAL Rig: PDSI 16.2/NT45-M
TDH-250 Top Drive, Serial Number: TD-140-C
DRAWN T. Harmon SCALE: WT LBS: SIZE: SHT:
CHECKED J. Rhone AV 1 OF 7
DWG NO.: REV:
APPVD P. Williams
16645318-SPL 01
DATE 05/24/2016
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

JAW ASSEMBLY, 85786

16401-2 DIE 8 8 16 85786 Jaw Assembly
76406 DIE RETAINER 4 4 8 85786 Jaw Assembly

COUNTERBALANCE CYLINDER, 120105

108894-P32 PISTON SEAL 1 1 2 120105 Counterbalance Cyl.
108894-B32 BODY SEAL 1 1 2 120105 Counterbalance Cyl.
108894-G13 ROD SEAL 1 1 2 120105 Counterbalance Cyl.

COUNTERBALANCE CYLINDER ASSEMBLY, 122023

120105 CYLINDER - - 1 122023 CB Cylinder Assy.
51300-214B O-RING 1 1 2 122023 CB Cylinder Assy.
94522-21N PRESSURE RELIEF VALVE 1 1 2 122023 CB Cylinder Assy.

COUNTERBALANCE CYLINDER ASSEMBLY, 122024

120105 CYLINDER - - 1 122024 CB Cylinder Assy.

WASHPIPE ASSEMBLY, 218111/007

72355/005 PACKING SET 1 2 2 218111/007 Washpipe Assembly
568243/050 O-RING 2 2 2 218111/007 Washpipe Assembly

LOCK CYLINDER ASSEMBLY, 218220/007

53600-50 RETAINING RING 2 2 4 218220/007 Lock Cylinder Assy.
78025993 GLAND KIT 1 1 2 218220/007 Lock Cylinder Assy.
78025992 ROD SEAL KIT 1 1 2 218220/007 Lock Cylinder Assy.
218220-012 PISTON SEAL KIT 1 1 2 218220/007 Lock Cylinder Assy.

HYDRAULIC ROTATE MOTOR, 218233/005

96073-1 MOTOR SEAL KIT 1 1 2 218233/005 Hyd. Rotate Motor
96073-3 SHAFT SEAL KIT 1 1 2 218233/005 Hyd. Rotate Motor

CONTROL UMBILICAL, 218360/013-201-200-001

10520555-001 ELECTRICAL CABLE ASSY. 218360/013-201-
- - 1 Control Umbilical
200-001
16501936-001 ELECTRICAL CABLE ASSY. 218360/013-201-
- - 1 Control Umbilical
200-001
59335P3602400 HOSE ASSEMBLY 218360/013-201-
- - 1 Control Umbilical
200-001
59355P3502400 HOSE ASSEMBLY 218360/013-201-
- - 1 Control Umbilical
200-001
59335P2902400 HOSE ASSEMBLY 218360/013-201-
- - 1 Control Umbilical
200-001

SCALE: WT LBS: SIZE: SHT:

AV 2 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

SPRAY NOZZLE ASSEMBLY, 220288/005

568210/010 O-RING 2 2 4 220288/005 Spray Nozzle Assy.

CABLE TENDER ASSEMBLY, 221496/006

216681/005 SHACKLE - - 2 221496/006 Cable Tender Assy.
216007/008 PIN - - 1 221496/006 Cable Tender Assy.
217539/006 WIRE ROPE - - 1 221496/006 Cable Tender Assy.
HIGH PRESSURE HOSE ASSEMBLY, 11000904-005 & 11000904-008
216090/009-100 HIGH PRESSURE HOSE ASSY 11000904-005 &
- - 1 HP Hose Assembly
11000904-008

RIG-UP MANIFOLD ASSEMBLY, 11042766-001

30176409-4XN LOGIC VALVE 1 1 2 11042766-001 Rig-Up Manifold Assy
P851004324-LRN DIRECTIONAL VALVE 1 1 2 11042766-001 Rig-Up Manifold Assy
94522-IDN PRESSURE RELIEF VALVE 1 1 2 11042766-001 Rig-Up Manifold Assy
94539-IN FLOW CONTROL CARTRIDGE 1 1 2 11042766-001 Rig-Up Manifold Assy

SWIVEL ASSEMBLY, 16593460-001

M624000259 POLYPAK SEAL - 2 4 16593460-001 Swivel Assembly
2230058 FILTER BREATHER - 1 1 16593460-001 Swivel Assembly
10688121-001 INSPECTION COVER GASKET 1 1 2 16593460-001 Swivel Assembly
10688210-001 LUBE LEVEL COVER GASKET 1 1 2 16593460-001 Swivel Assembly
M624000264 COVER PLATE GASKET - 1 1 16593460-001 Swivel Assembly
M624000278 OIL SEAL - 6 12 16593460-001 Swivel Assembly
221221/005 OIL SEAL - 1 2 16593460-001 Swivel Assembly
221208/005-501 OIL SEAL - 2 4 16593460-001 Swivel Assembly
221220/005 OIL SEAL - 1 2 16593460-001 Swivel Assembly
51300-249-B MOTOR ADAPTER O-RING - 2 4 16593460-001 Swivel Assembly
51300-276-B BONNET O-RING - 1 2 16593460-001 Swivel Assembly
51300-253-B BRAKE ADAPTER O-RING - 1 2 16593460-001 Swivel Assembly
51300-261-B INT. COVER O-RING - 1 2 16593460-001 Swivel Assembly
51300-275-B LOWER COVER O-RING - 1 2 16593460-001 Swivel Assembly
P764000095-073-S UPPER RETAINING RING - - 1 16593460-001 Swivel Assembly
221219/005 LOWER RETAINING RING - - 1 16593460-001 Swivel Assembly
221480/005 BEARING, MAIN THRUST - - 1 16593460-001 Swivel Assembly
221216/005 BEARING, LOWER STEM - - 1 16593460-001 Swivel Assembly
M624000233 BEARING, UPPER STEM - - 1 16593460-001 Swivel Assembly
M624000230 BEARING, INPUT LOWER - - 3 16593460-001 Swivel Assembly
M624000231 BEARING, INPUT UPPER - - 3 16593460-001 Swivel Assembly
219687/005 BEARING, SECONDARY - - 1 16593460-001 Swivel Assembly
M624000232 BEARING, SECNDRY UPPER - - 1 16593460-001 Swivel Assembly
P854000077 MOTOR, HYDRAULIC - - 3 16593460-001 Swivel Assembly
M624000275 SHIM SET, UPPER - 1 1 16593460-001 Swivel Assembly
M624000272 SHIM SET, INPUT - 1 1 16593460-001 Swivel Assembly
M624000274 SHIM SET, INPUT - 2 2 16593460-001 Swivel Assembly
SCALE: WT LBS: SIZE: SHT:
AV 3 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

SWIVEL ASSEMBLY, 16593460-001 (continued)

M624000273 SHIM SET, SECONDARY - 1 1 16593460-001 Swivel Assembly
10799945-001 LUBE LEVEL GAUGE - 1 2 16593460-001 Swivel Assembly

HP HYDRAULIC ASSEMBLY, 16600369-001

10745706-044 H.P. HOSE ASSEMBLY - 2 2 16600369-001 HP Hydraulic Assy.
10745706-048 H.P. HOSE ASSEMBLY - 1 1 16600369-001 HP Hydraulic Assy.
51307-222 O-RING 6 12 12 16600369-001 HP Hydraulic Assy.
M854000305-20M20 QUICK DISCONNECT - - 1 16600369-001 HP Hydraulic Assy.
M854000305-12M12 QUICK DISCONNECT - - 1 16600369-001 HP Hydraulic Assy.
M854000305-16M16 QUICK DISCONNECT - - 1 16600369-001 HP Hydraulic Assy.
10745706-040 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.
10745706-032 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.
10745764-060 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.
10745764-056 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.
10745706-048 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.
10745706-044 HP HOSE ASSEMBLY 1 1 2 16600369-001 HP Hydraulic Assy.

LUBRICATION MANIFOLD ASSEMBLY, 16609592-001

M614002301 HEAT EXCHANGER - 1 1 16609592-001 Lubrication Assy.
P854000100-100-150 LUBE TEMP. SENSOR 1 1 1 16609592-001 Lubrication Assy.

HYDRAULIC MANIFOLD ASSEMBLY, 16631783-001

M854000360 MODIFIED VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
30182400-A PRESS. REDUCING VALVE 7 7 14 16631783-001 Hyd. Manifold Assy.
M854000320-12-N30 CHECK VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
94536-14N CHECK VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
109858-2AN PRESS. REDUCING VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
109858-1BN PRESS. REDUCING VALVE 3 3 6 16631783-001 Hyd. Manifold Assy.
131733-2N FILTER 1 1 2 16631783-001 Hyd. Manifold Assy.
93547-1B75N CHECK VALVE 2 2 4 16631783-001 Hyd. Manifold Assy.
30183123-1XN DIRECTIONAL VALVE 3 3 6 16631783-001 Hyd. Manifold Assy.
30176410-1YN DIRECTIONAL VALVE 4 4 8 16631783-001 Hyd. Manifold Assy.
30176110-1CN DIRECTIONAL VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
94518-13HN COUNTERBALANCE VALVE 2 2 4 16631783-001 Hyd. Manifold Assy.
P854000031-17ZN COUNTERBALANCE VALVE 2 2 4 16631783-001 Hyd. Manifold Assy.
117851-1KHN LOGIC VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
93548-1530N CHECK VALVE 1 1 2 16631783-001 Hyd. Manifold Assy.
M854000319-16 CHECK VALVE CARRIER 1 1 2 16631783-001 Hyd. Manifold Assy.
30182400-PN ACTUATION PIN 16 16 32 16631783-001 Hyd. Manifold Assy.
30182400-RR O-RING 16 16 32 16631783-001 Hyd. Manifold Assy.
30179443-PC4 VALVE, PROPORTIONAL 1 1 2 16631783-001 Hyd. Manifold Assy.
P851002886-B VALVE, SOLENOID 2 4 4 16631783-001 Hyd. Manifold Assy.
94536-230N VALVE, CHECK 1 2 2 16631783-001 Hyd. Manifold Assy.

SCALE: WT LBS: SIZE: SHT:

AV 4 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

CABLE KIT, 16646088-001

10636739-001 CABLE ASSY, PROFIBUS - - 1 16646088-001 Cable Kit
10636753-001 CABLE ASSY, CONSOLE POWER - - 1 16646088-001 Cable Kit

EXTENDED DOLLY ASSEMBLY, 16648030-001

M624000338-03 3” CAM FOLLOWER - - 16 16648030-001 Dolly Assembly
30172475-32-32 BUSHING, GARLOCK - 4 4 16648030-001 Dolly Assembly
M624000338-05 5” CAM FOLLOWER - - 4 16648030-001 Dolly Assembly
M624000350-500 BOGIE ROLLER - - 4 16648030-001 Dolly Assembly
M624000349 BOGIE PIVOT PIN - 4 8 16648030-001 Dolly Assembly
M624000401 BEARING - 8 16 16648030-001 Dolly Assembly
30178290 PIN - 6 12 16648030-001 Dolly Assembly
30178291 PIN - 2 4 16648030-001 Dolly Assembly
30172475-22-22 BUSHING, GARLOCK - 2 2 16648030-001 Dolly Assembly
M614000189 PIN - 4 8 16648030-001 Dolly Assembly
30172475-22-28 BUSHING, GARLOCK - 2 4 16648030-001 Dolly Assembly
30172475-22-16 BUSHING, GARLOCK - 4 8 16648030-001 Dolly Assembly
10941136-001 SENSOR, PROXIMITY 2 2 2 16648030-001 Dolly Assembly
10526432-001 CABLE 2 2 2 16648030-001 Dolly Assembly

LUBE FILTER ASSEMBLY, 30156633-MECH

30156633-1 20 MICRON ELEMENT 1 1 3 30156633-MECH Lube Filter Assy.
30156633-3 MECHANICAL DIRT ALARM - - 1 30156633-MECH Lube Filter Assy.
30156633-10 O-RING - 1 3 30156633-MECH Lube Filter Assy.
30156633-2 60 PSI BYPASS - - 1 30156633-MECH Lube Filter Assy.
30146633-13 COMPRESSION SPRING - 1 2 30156633-MECH Lube Filter Assy.

DISC BRAKE ASSEMBLY, 30178838

30178838-RK PAD REPLACEMENT KIT - 2 2 30178838 Disc Brake Assy.
30178838-SK SEAL KIT - 2 2 30178838 Disc Brake Assy.

CARRIAGE CYLINDER ASSEMBLY, 30180149

94518-13AN-OBS C.B. VALVE CARTRIDGE - 4 4 30180149 Carriage Cylinder Assy.
108894-G17 ROD SEALS & BRONZE GLAND 2 4 4 30180149 Carriage Cylinder Assy.
108894-P32 PISTON SEAL KIT 2 4 4 30180149 Carriage Cylinder Assy.

IBOP VALVE ASSEMBLY, M611005764

M611005764-001 REPAIR KIT, COMPLETE 1 1 2 M611005764 IBOP Valve Assy.
M611005764-002 REPAIR KIT, SOFT SEALS 1 1 2 M611005764 IBOP Valve Assy.

CLAMP ASSEMBLY, M614001826-501

72219 PISTON SEAL 2 2 4 M614001826-501 Clamp Assembly
72220 ROD SEAL 1 1 2 M614001826-501 Clamp Assembly

SCALE: WT LBS: SIZE: SHT:

AV 5 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

CLAMP ASSEMBLY, M614001826-501 (continued)

M614002346 CYLINDER MANIFOLD ASSY. - - 1 M614001826-501 Clamp Assembly
11085 O-RING 1 1 2 M614001826-501 Clamp Assembly
30178854-05 SPLIT RING 2 2 4 M614001826-501 Clamp Assembly
72221 WIPER ROD 1 1 2 M614001826-501 Clamp Assembly
79179 SPRING 2 2 4 M614001826-501 Clamp Assembly

CLAMP CYLINDER MANIFOLD, M614002346

51300-210-B O-RING 2 2 4 M614002346 Clamp Cyl. Manifold

GUIDE BEAM ASSEMBLY, M624000228-501-103

M621002163 PIN, RETAINER 1 1 1 M624000228-501-103 Guide Beam Assy.
M624000390 PIN, RETAINER 3 3 5 M624000228-501-103 Guide Beam Assy.
117496-1 RETAINER, LOCKING 3 3 6 M624000228-501-103 Guide Beam Assy.

UPPER HOUSING / LINK ADAPTER ASSEMBLY, M624000239-501

10941136-001 PROXIMITY SENSOR 1 1 1 M624000239-501 Link Adapter Assy.
218237/005 LOCK GEAR - - 1 M624000239-501 Link Adapter Assy.
218220/007 LOCK CYLINDER - - 1 M624000239-501 Link Adapter Assy.
218233/005 HYDRAULIC ROTATE MOTOR - - 1 M624000239-501 Link Adapter Assy.
M854000356 ROTATE MOTOR MANIFOLD - - 1 M624000239-501 Link Adapter Assy.
218221/005 SLIP RING ASSEMBLY - - 1 M624000239-501 Link Adapter Assy.
51300-110-B O-RING - 12 12 M624000239-501 Link Adapter Assy.
M624000316 HARDENED WASHER - - 4 M624000239-501 Link Adapter Assy.
P764000097-221-C-C BELLEVILLE WASHER - - 92 M624000239-501 Link Adapter Assy.
10941360-001 PROXIMITY SWITCH CABLE 1 1 1 M624000239-501 Link Adapter Assy.

PIPE HANDLER ASSEMBLY, M624000240

P854000096 HYDRAULIC TILT CYLINDER - - 2 M624000240 Pipe Handler Assy.
85786 CLAMP JAW ASSEMBLY - - 2 M624000240 Pipe Handler Assy.
M624000241 SPLIT RING 1 1 2 M624000240 Pipe Handler Assy.
30178854-05 SUB SAVER 2 2 4 M624000240 Pipe Handler Assy.
M611005764 IBOP 1 1 2 M624000240 Pipe Handler Assy.

THREAD COMPENSATION ASSEMBLY, M624000243

M624000374 CHAIN ASSEMBLY - - 1 M624000243 THREAD COMP. ASSY.

BAIL PACKAGE, M624000253

M624000248 BUSHING - 2 4 M624000253 Bail Package

GOOSENECK ASSEMBLY, M624000256

91923 LIP SEAL RING 2 2 4 M624000256 Gooseneck Assembly

SCALE: WT LBS: SIZE: SHT:

AV 6 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

TORQUE ARRESTOR ASSEMBLY, M624000298

125594-502 HYDRAULIC CYLINDER - 1 1 M624000298 Torq. Arrestor Assy.
30157308 COMPRESSION SPRING 2 2 4 M624000298 Torq. Arrestor Assy.
71847 CAM FOLLOWER - 2 4 M624000298 Torq. Arrestor Assy.

LUBE PUMP ASSEMBLY, M624000304

P614000093 HYDRAULIC MOTOR - - 1 M624000304 LUBE PUMP ASSY.
71033 MOTOR GASKET - 1 1 M624000304 LUBE PUMP ASSY.
109567-G20 P50 PUMP GEAR SET - - 1 M624000304 LUBE PUMP ASSY.
109567-S PUMP BODY SEAL - 2 2 M624000304 LUBE PUMP ASSY.

ONBOARD ELECTRICAL KIT, M624000307-501

10509458-001 6000 PSI TRANSMITTER 2 2 4 M624000307-501 Onboard Elec. Kit
2302070186 500 PSI TRANSMITTER 2 2 4 M624000307-501 Onboard Elec. Kit
30151891-X3D PRESSURE SWITCH 1 1 2 M624000307-501 Onboard Elec. Kit
56625-1.5-03 3C CABLE - - 40 M624000307-501 Onboard Elec. Kit
M624000383 CABLE ASSEMBLY - 1 2 M624000307-501 Onboard Elec. Kit

SPRAY NOZZLE ASSEMBLY, M624000326

51300-116-B O-RING 1 1 2 M624000326 Spray Nozzle Assy.

ENCODER ASSEMBLY, M624000335

10515072-001 INCREMENTAL ENCODER - 1 1 M624000335 Encoder Assembly
56625-1.5-07 ENCODER ASSEMBLY CABLE 1 1 1 M624000335 Encoder Assembly
M624000336 JM CLIPPER OIL SEAL - 1 1 M624000335 Encoder Assembly
51300-243-B O-RING - 1 1 M624000335 Encoder Assembly

S-PIPE EXTENSION, M624000409

654672 SEAL RING 1 1 2 M624000409 S-Pipe Extension

ROTATE MOTOR MANIFOLD, M854000356

P854000107-1VT322 RELIEF VALVE 2 2 4 M854000356 Rotate Motor Manifold
220339/006 FLOW CONTROL VALVE 1 1 2 M854000356 Rotate Motor Manifold

LINK TILT CYLINDER, P854000096

P854000096-3 SEAL KIT 2 2 4 P854000096 Link Tilt Cylinder

SCALE: WT LBS: SIZE: SHT:

AV 7 of 7
DWG NO.: REV:
16645318-SPL 01
D811000567-GEN-001/03
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 5.0
Spare Parts List, Electrical

www.nov.com
 ELECTRICAL SPARES LIST

TDH-250
PERTAMINA #1

NOTES:
1. 16645301-SPL-1 Recommended Commissioning Spares
2. 16645301-SPL-2 Recommended Operational Spares
3. 16645301-SPL-3 Recommended Insurance Spares
4. See Customer Configuration 16567184-001

NEXT ASSY PRODUCT

TDH-150
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 TITLE
copyrighted property of NOV. © National Oilwell Varco

CURRENT INITIAL TOP DRIVE TDH-250

DRAWN D. SOHN D. SOHN SCALE: WT LBS: SIZE: SHT:
CHECKED L. GARCIA L. GARCIA AV 1 OF 3
DWG NO.: REV:
APPVD D. SOHN D. SOHN
16645301-SPL 02
DATE 6/6/2016 5/25/16
D811000567-GEN-001/03
 -1 -2 -3

Commission Operational Insurance Where Description

Part Number Description Spare Spare Spare Used Where Used

SBC Control Panel 16509119-001

10066792-001 PWR SPLY- 24V/10A, 1 1
10064178-086 PLC-WAGO PROFIBUS DP/V1 1 1
10064178-040 WAGO 4 CH DI MODULE, DC 24V 1 1 1
10064178-053 PLC-2DO;24V DC 2A 2. 1 2 2
10064178-008 PLC-2PT,ANALOG INPUT,4-20MA 1 2 2
10064178-024 PLC-WAGO 2- ANALOG OUT 1 1 1
10064178-072 PLC-MOD,FIELD SIDE AC/DC 0-230 1 1 1
10064178-096 PLC-MOD;PWR SPLY/FUSE;24VDC 2 2 2
10064178-032 PLC-MOD ENCODER 1 1 1
10064194-029 FUSE-6A,125VAC,5 X 20MM MDLY 1 1
10571514-001 REMOTE SPD CONTRL CAT ENG 1 1
10064185-013 PL- 24V AC/DC;30.5MM;GREEN LED 1 1
10482149-001 AMPLIFIER, SOLENOID VALVE 1 1
10043807-001 RLY-PLC 24VDC;SPDT;6A@250VAC 1 1 1
10066482-001 RLY- 24VAC/DC,5NO,2NC CONT 1 1
10066030-001 SBC-CONTROLLER ASSY; 1 1
10068310-001 PWR SPLY-FOR CX1020 SBC 1 1
10068309-001 CARD-APPLICOM;DP1 1 1 1
10065613-001 BOOT COVER-CAT 5 LUG BOOT 2 2
10064185-013 PL- 24V AC/DC;30.5MM;GREEN LED
10066781-001 TB-KNIFE DISCONNECT BLOCK 5 5
10066917-001 CB- 20AT,2P, 480V C, 6KIC, 1 1
10541475-001 FUSE-0.5A,250VAC,5X20MM,GDC 2 5 5
10066675-001 FUSE-HOLDER 6.2MM,BLACK 2 2
10064178-104 PLC-MODULE;FILTER 1 1
10064178-103 PLC-MOD;FILTER 24VDC FIELD 1 1 1
10066978-001 SUPPRESSOR-SURGEW/FILTER 1 1

Control Console 16593189-001

10064178-086 PLC-WAGO PROFIBUS DP/V1 1 1
10064178-104 PLC-MODULE;FILTER 24 1 1
10064178-072 PLC-MOD,FIELD SIDE AC/DC 0-230 1 1
10064178-040 WAGO 4 CH DI MODULE, DC 24V 1 2
10064178-064 0 PC-DIGITAL OUTPUT,4DO,24VDC 1 2
10379378-003 PLC- 2-OTPT ANALOG 4-20MA 1 1
10064178-034 PLC-MOD,ENCODER MOD,32 BIT, 1 1
10064178-096 PLC-MOD;PWR SPLY/FUSE;24VDC 1 1
10042793-001 PLC, CONN, PROFIBUS 1 1

SCALE: WT LBS: SIZE: SHT:

AV 2 of 3
DWG NO.: REV:
10848673-SPL 02
D811000567-GEN-001/03
 -1 -2 -3

Commission Operational Insurance Where Description

Part Number Description Spare Spare Spare Used Where Used

10064194-029 FUSE-6A,125VAC,5 X 20MM MDLY 1 1 2

10047251-001 BARRIER-IS;1X24VDC/ IS OUT 1
10043663-001 ISOLATOR-GALVANIC;1 CH AO 4-20 1
10043304-001 HORN-BEKA;IS;EEx ia IIC T4; 1
10551018-001 BRACKET, HEATER 1
10548948-001 HEATER- 100W; 24VDC 1
10566900-001 THERMOSTAT, ON-10C, 10A 1
10670721-001 CONN-RECP,7M#12AWG,PANEL 1
10536592-001 CONN-RECP,7M#12AWG,PANEL 1
16645338-001 METER ASSY, 5", SCALE 1
10690957-001 METER ASSY,5", UL CERT, 1
10055017-001 OPERATOR,PB,4 LABELS,RED,GRN, 1 1 2
10044536-001 SW-CONT BLK SW MODULE,2 NO 1 1 4
10044540-001 SW-SEL,3POS,SPR RETURN CENT 1 1 5
10066997-001 LENS-EEX D;RED;OFFSHORE 1 1 2
10044544-001 PL- 24VDC;RED LED;NO LENS;ATEX 1 1 2
10066451-001 LENS-EEX D;YELLOW;OFFSHORE 1 1 1
10066581-001 LAMP-LED;YELLOW 1 1 1
10066582-001 PB-ILLUM;ACTUATOR;GRN 1 1 3
10066583-001 PB-MOD;W/TERM;GRN;1NO FOR 1 1 3
10066579-001 PB-ILLUM;ACTUATOR;RED 1 1 2
10066580-001 PB-MODULE;W/TERM;RED;1NO FOR 1 1 2
10044537-001 PB-EMER.STOP;MAINT CONT 1 1 1
10044543-001 SW-CONTACT BLK SW 1 1 1
10050243-001 KNOB-S/S;ROTARY TORQUE 1 1 2
10048305-001 ENCODER-INCREM;5VDC;EExd; 1 1 2

TDH-250 POWER J-BOX 16593106-001

10051297-001 CB-20A ,3P,TRIP CURVE C,6KA 1 1
10045083-001 CB- 10AT,2P,480Y/277VAC,6KIC 1 1
10510594-001 CB- 20AT,2P, 480V C, 6KIC 1 1
10433008-001 CONTR-SIZE 3,60HP 1 1
10514334-001 BREAKER,100AF,3P,THERMAL-MAG 1 1
10573873-001 MOTOR STARTER PROTECTOR 1 1

SCALE: WT LBS: SIZE: SHT:

AV 3 of 3
DWG NO.: REV:
10848673-SPL 02
D811000567-GEN-001/03
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 6.0
Spare Parts List, TDH-250 HPU

www.nov.com
 MECHANICAL SPARES LIST
TDH-250 HYDRAULIC POWER UNIT
PT PERTAMINA DRILLING
PDSI 16.2/NT45-M

NOTES:
1. 16645329-1 Recommended Commissioning Spares
2. 16645329-2 Recommended Operational Spares
3. 16645329-3 Recommended Insurance Spares
4. Configuration 16567184-GEN

NEXT ASSY PRODUCT

16567184-001 TDH-250
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 TITLE Mechanical Spare Parts List
copyrighted property of NOV. © National Oilwell Varco

CURRENT INITIAL PT Pertamina Drilling, Indonesia

TDH-250 HPU, Serial Number: HPU-112-C
DRAWN T. Harmon
SCALE: WT LBS: SIZE: SHT:
CHECKED J. Rhone AV 1 OF 3
DWG NO.: REV:
APPVD P. Williams
16645329-SPL 01
DATE 05/19/2016
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

PUMP/MOTOR ASSEMBLY, 10737385-002

10514221-001 OILGEAR PUMP - - 1 10737385-002 Pump/Motor

10514216-001 CHECK VALVE 1 1 2 10737385-002 Pump/Motor
10514214-001 RELIEF VALVE 1 1 2 10737385-002 Pump/Motor
10742696-001 DOUBLE VANE PUMP - - 1 10737385-002 Pump/Motor
51300-222-B O-RING 2 2 4 10737385-002 Pump/Motor

MAIN PUMP, 10893883-002

10893883-003 SEAL KIT, P30 PUMP 2 2 4 10893883-002 Main Pump
10893883-004 SHAFT & BEARING KIT, P30 2 2 4 10893883-002 Main Pump
10742706-002 SEAL KIT, AUXILIARY PUMP 2 2 4 10893883-002 Main Pump

FILTER ASSEMBLY, 10952943-001

M851008036-E210 ELEMENT, FILTER 2 2 4 10952943-001 Filter Assembly

51300-244-B O-RING 4 4 8 10952943-001 Filter Assembly
51300-228-B O-RING 4 4 8 10952943-001 Filter Assembly

HYDRAULIC POWER UNIT ASSEMBLY, 16592908-001

10893883-002 MAIN PUMP - - 1 16592908-001 HPU Assembly
M851008036-E210 ELEMENT, FILTER 1 2 2 16592908-001 HPU Assembly
51300-244-B O-RING 2 2 4 16592908-001 HPU Assembly
P851000398-E210 ELEMENT, FILTER 1 2 2 16592908-001 HPU Assembly
2302070122 RELIEF VALVE 1 1 2 16592908-001 HPU Assembly
7026B012 PRESSURE REDUCING VALVE 1 1 2 16592908-001 HPU Assembly
16600501-001 CHECK VALVE 1 1 2 16592908-001 HPU Assembly
10509458-001 TRANSMITTER - 3 3 16592908-001 HPU Assembly
P854000100-100-200 TEMPERATURE TRANSMITTER - 2 2 16592908-001 HPU Assembly
M854000305-16M16 QUICK DISCONNECT - - 1 16592908-001 HPU Assembly
M854000305-12M12 QUICK DISCONNECT - - 1 16592908-001 HPU Assembly
M854000305-20M20 QUICK DISCONNECT - - 1 16592908-001 HPU Assembly
16634344-003 FILTER, WATER SEP/FUEL,DIESEL 1 2 2 16592908-001 HPU Assembly
16634344-002 FILTER, OIL, DIESEL 2 4 4 16592908-001 HPU Assembly
16653398-001 GASKET, ENGINE TO FLANGE 1 2 2 16592908-001 HPU Assembly
16653399-001 GASKET, FLANGE TO MUFFLER 1 2 2 16592908-001 HPU Assembly

RESERVOIR ASSEMBLY, 16610700-001

10894092-001 TEMPERATURE TRANSDUCER - - 1 16610700-001 Reservoir Assembly
4509-0098-02 BALL VALVE, ¾” - 1 1 16610700-001 Reservoir Assembly
10519235-007 PRESSURE GAUGE - 1 1 16610700-001 Reservoir Assembly
10519235-012 PRESSURE GAUGE - 2 2 16610700-001 Reservoir Assembly
10519235-010 PRESSURE GAUGE - 1 1 16610700-001 Reservoir Assembly
10520881-001 BALL VALVE, 2-1/2” - 1 1 16610700-001 Reservoir Assembly

SCALE: WT LBS: SIZE: SHT:

AV 2 OF 3
DWG NO.: REV:

16645329-SPL 01
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

10633688-001 BALL VALVE, 2” - 1 1 16610700-001 Reservoir Assembly

16603376-001 BALL VALVE, 1-1/2” - 1 1 16610700-001 Reservoir Assembly
10618996-002 ELEMENT, FILTER BREATHER 1 2 2 16610700-001 Reservoir Assembly
4504-0170-04 CONDUIT BODY - - 2 16610700-001 Reservoir Assembly
4510-0051-03 TEMP/LEVEL SWITCH 2 2 16610700-001 Reservoir Assembly

MAIN MANIFOLD, 16623861-002

11025814-002 ELEMENT, HI PRESS FILTER 2 4 8 16623861-002 Main Maniold
P851000399-D2 DIRECTIONAL SOLENOID 1 1 2 16623861-002 Main Maniold
P851000400-RV5-V PROPORTIONAL VALVE 1 1 2 16623861-002 Main Maniold
P851000401-PC1 PROPORTIONAL VALVE 1 1 2 16623861-002 Main Maniold
94522-44N-5500 RELIEF VALVE 2 2 4 16623861-002 Main Maniold
94534-ICLN LOGIC VALVE 1 1 2 16623861-002 Main Maniold
94536-34N CHECK VALVE 1 1 2 16623861-002 Main Maniold
94536-430N CHECK VALVE 2 2 4 16623861-002 Main Maniold
94536-4U4N CHECK VALVE 1 1 2 16623861-002 Main Maniold
112802-10 CHECK VALVE 1 1 2 16623861-002 Main Maniold
10654740-001 DIRECTONAL VALVE 1 1 2 16623861-002 Main Maniold
11321167-001 PILOT OPERATED VALVE 1 1 2 16623861-002 Main Maniold
51300-012-B O-RING 4 4 8 16623861-002 Main Maniold
51300-219-B O-RING 1 1 2 16623861-002 Main Maniold
51300-228-B O-RING 2 2 4 16623861-002 Main Maniold
11321942-604 O-RING, PLUG 11 11 22 16623861-002 Main Maniold
11321942-606 O-RING, PLUG 10 10 20 16623861-002 Main Maniold
11321942-612 O-RING, PLUG 2 2 4 16623861-002 Main Maniold
11321942-616 O-RING, PLUG 16 16 32 16623861-002 Main Maniold
11321942-620 O-RING, PLUG 20 20 40 16623861-002 Main Maniold

SCALE: WT LBS: SIZE: SHT:

AV 3 OF 3
DWG NO.: REV:

16645329-SPL 01
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 7.0
Mechanical Spares, Hose Reel

www.nov.com
 MECHANICAL SPARES LIST
TDH-250 HOSE REEL
PT PERTAMINA DRILLING
PDSI 16.2/NT45-M

NOTES:
1. 16645337-1 Recommended Commissioning Spares
2. 16645337-2 Recommended Operational Spares
3. 16645337-3 Recommended Insurance Spares
4. Configuration 16567184-GEN

NEXT ASSY PRODUCT

16567184-001 TDH-250
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 TITLE Mechanical Spare Parts List
copyrighted property of NOV. © National Oilwell Varco

CURRENT INITIAL PT Pertamina Drilling, Indonesia

TDH-250 Hose Reel, Serial Number: HR-111-C
DRAWN T. Harmon
SCALE: WT LBS: SIZE: SHT:
CHECKED J. Rhone AV 1 OF 2
DWG NO.: REV:
APPVD P. Williams
16645337-SPL 01
DATE 05/19/2016
 -1 -2 -3

Commission Operation Insurance Where Description

Part Number Description Spares Spares Spares Used Where Used

HOSE REEL ASSEMBLY, 10936630-001

10979951-001 BUSHING, SHAFT - 2 4 10936630-001 Hose Reel Assy
10984493-001 BUSHING, SHAFT - 2 4 10936630-001 Hose Reel Assy
51307-008 O-RING, BULKHEAD 4 4 8 10936630-001 Hose Reel Assy
51307-012 O-RING, BULKHEAD 1 1 2 10936630-001 Hose Reel Assy
51307-006 O-RING, BULKHEAD 2 2 4 10936630-001 Hose Reel Assy
M854000305-12M12 Q/D Male -12 - - 1 10936630-001 Hose Reel Assy
M854000305-16M16 Q/D Male -16 - - 1 10936630-001 Hose Reel Assy
M854000305-20M20 Q/D Male -20 - - 1 10936630-001 Hose Reel Assy
10964369-001 SPROCKET 11T - - 1 10936630-001 Hose Reel Assy
10964372-001 SPROCKET 80T - - 1 10936630-001 Hose Reel Assy
10956205-001 SPACER SET - 1 1 10936630-001 Hose Reel Assy
10956205-002 SPACER SET - 1 1 10936630-001 Hose Reel Assy
10971953-001 SPROCKET KEEPER 1 2 2 10936630-001 Hose Reel Assy
218311/005-096 DRIVE CHAIN - 2 2 10936630-001 Hose Reel Assy

HYDRAULIC MOTOR, 10964452-009

10964452-009 MOTOR - - 1 10936630-001 Hose Reel Assy
10964452-012 KEY 1 1 1 10964452-009 HYDRAULIC MOTOR
10964452-013 O-RING 1 2 2 10964452-009 HYDRAULIC MOTOR
10381002-003 SEAL KIT 1 1 1 10964452-009 HYDRAULIC MOTOR

DIRECTIONAL VALVE ASSEMBLY, 10969867-001

10969867-001 VALVE, DIRECTIONAL - - 1 10936630-001 Hose Reel Assy
10969867-002 SEAL KIT, VALVE 1 2 1 10969867-001 VALVE ASSY
10969867-003 LEVER 1 1 2 10969867-001 VALVE ASSY
10969867-004 PRES. LIMITING VALVE INSERT - - 2 10969867-001 VALVE ASSY
10969867-005 SEAL KIT, ANCILLARY 1 2 1 10969867-001 VALVE ASSY
10969867-006 SHUTTLE VALVE - - 2 10969867-001 VALVE ASSY
10969867-007 INFLOW CONTROLLER - - 1 10969867-001 VALVE ASSY
10969867-008 LHT 30 - - 2 10969867-001 VALVE ASSY

MANIFOLD ASSEMBLY, LEFT MOTOR, 11016774-001

11001939-001 MANIFOLD, LEFT - - 1 10936630-001 Motor Assembly
P851004323-1HN SEQUENCE VALVE 1 1 2 10936630-001 Manifold, Motor

MANIFOLD ASSEMBLY, RIGHT MOTOR, 11016774-002

11001939-002 MANIFOLD, RIGHT - - 1 10936630-001 Motor Assembly
P851004323-1HN SEQUENCE VALVE 1 1 2 10936630-001 Manifold, Motor

CODE 62 FLANGE KIT, 56536-32

51307-228 O-RING 4 8 8 56536-32 Flange Kit

SCALE: WT LBS: SIZE: SHT:

AV 2 OF 2
DWG NO.: REV:
16645337-SPL 01
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 8.0
Safety Wiring Procedure

www.nov.com
 PROCEDURE

THE USE OF AND APPLICATION OF

SAFETY WIRE FOR SECONDARY
RETENTION

National Oilwell Varco

This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited Rig Solutions
RIG/PLANT
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 11000 Corporate Centre Dr.
distribution of this information to others is not permitted without the
ADDITIONAL CODE SDRL CODE TOTAL PGS
express written consent of National Oilwell Varco. This document is Houston TX 77041 USA
to be returned to National Oilwell Varco upon request and in any Phone +1 (281) 854-0647
REMARKS event upon completion of the use for which it was loaned. Fax +1 (281) 854-0508
 National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE
DOCUMENT NUMBER REV

CLIENT PO NUMBER
ASP00019 A
CLIENT DOCUMENT NUMBER

Client Document Number

 Document number ASP00019
Revision A
Page 2

REVISION HISTORY

A 15/04/2011 SEE ECN C. SILVA T. GORMSEN T. GORMSEN

- 10/03/1995 First Issue KTK K DAW JES
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

- First Issue
A SEE ECN
 Document number ASP00019
Revision A
Page 3

TABLE OF CONTENTS

1  SCOPE.............................................................................................................................. 3 
2  APPLICABLE DOCUMENTS ........................................................................................... 4 
3  REQUIREMENTS ............................................................................................................. 4 
3.1  MATERIAL AND SIZE ............................................................................................ 4 
3.2  GENERAL REQUIREMENTS ................................................................................. 5 
3.3  LOCK-WIRING METHODS .................................................................................... 6 
3.4  OTHER APPLICATIONS ........................................................................................ 7 
3.5  ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8 
4  QA PROVISIONS.............................................................................................................. 9 
5  NOTES .............................................................................................................................. 9 

1 SCOPE
 Document number ASP00019
Revision A
Page 4

This procedure establishes the method for the selection and application of safety wire.
Lock wiring is the application of wire to prevent relative movement of structure or other
critical components subject to vibration, tension, torque, etc.

This procedure is intended to help eliminate the risk of dropped objects in

components or parts manufactured.

Bolts, Nuts and Screws are the common type of fasteners used on NOV
equipment. They need to be locked (secondary retention) against loss of torque / pre-
tension.

Use of safety wire to prevent rotation of fasteners is a safe and primarily

recommended secondary retention method for fasteners. It is the most preferred
method because it not only prevents fasteners from loosening but also keeps them from
falling in case of primary retention failure (bolt head Breaks off) and effectively prevents
dropped objects.

Note that the secondary retention will work only if the primary retention method is
properly in place, i.e. bolts and screws are tightened and torqued as per specifications,
and there is no play between the mating elements. Secondary retention methods aim in
preventing any compromise in primary retention, loss of pre-tension in assembled
fasteners, loosening and backing out.

Definitions:

Secondary Retention – The means of effectively retaining a fastener/joining component

such that the operating loads do not compromise the integrity of the primary fastening
component.

2 APPLICABLE DOCUMENTS

DS00008-DES DESIGN TORQUE STANDARDS

Machinery’s Handbook 27th Edition

3 REQUIREMENTS

3.1 MATERIAL AND SIZE

3.1.1 Material
Lock wire must be aircraft quality stainless steel 302/304 condition A.

3.1.2 Lock-wire sizes

 Document number ASP00019
Revision A
Page 5

a. 0.5080 mm (0.020 inch) diameter

b. 0.8128 mm (0.032 inch) diameter NOV P/N Z6000.8
c. 1.1938 mm (0.047 inch) diameter NOV P/N Z6000.9
d. 1.2950 mm (0.051 inch) diameter NOV P/N Z6001
e. 3.1750 mm (0.125 inch) diameter NOV P/N Z6002

3.2 GENERAL REQUIREMENTS

3.2.1 Safety wire shall be new upon each application.

3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension
when the part tends to loosen.

3.2.3 The lockwire should always be installed and twisted so that the loop around the
head stays down and does not tend to come up over bolt head and leave a slack loop.

3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not
over stressed.

3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns
for .052 wire. More twists will over stress the wire and cause fatigue and breakage.

3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This
pigtail shall be bent back or under to prevent it from becoming a snag.

3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply:

a) No more than three (3) bolts may be tied together.

b) Bolt heads may be tied as shown only when the female thread receiver is
captive.(see figure 1)
c) Lockwire must fill a minimum of 50% of the drilled hole provided for the
use of lockwire.
d) Diameter of lockwire is determined by the thread size of the fastener to be
lockwired.
1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020
inch) wire.
2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm
(0.032 inch) wire.
3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR
1.295mm (0.051) wire.

The larger wire may be used in smaller bolts in cases of convenience, but smaller
wire must not be used in larger fastener sizes.
 Do
ocument number ASP00
0019
Re
evision A
Pa
age 6

Figure 1: Safety Wire / Lo

ock Wire

3.3 LOC
CK-WIRING
G METHOD
DS

3.3.1
1 The method involve es threadin ng a wire through ho oles in the fastener tto lock it
against being rotated
r loos
se. The wirre is twisted d before be
eing threadded and is locked to
nextt bolt. Safetty wire shou
uld be place ed in and aaround bolt head to ma aintain the pre-load.
The use of saffety wire tie es is illustra
ated in figu re 1 above
e. The illusttrations asssume the
use of right-hannd threaded d fasteners.

2 The doub
3.3.2 ble-twist me
ethod:
The doub
ble-twist meethod of lock-wiring sshall be use
ed as the common m
method of
lock--wiring.

CAUUTION: scre ews in clos

sely spaced d geometricc which seccure hydrau ulic or air se
eals, hold
hydrraulic press
sure, or use
ed in criticall areas of cclutch mechhanism should use dou uble twist
methhod of lock--wiring. Ma
ake sure tha at the wire iis so installled that it ccan easily b be broken
when required in an emerg gency situa ation.

3.3.3
3 Lock-wirin
ng widely spaced multtiple groupss by the dou uble twist m
method.
a) When
W the multiple
m faste
eners are ffrom 4-6 incches apart,, three (3) ffasteners
shhall be the e maximum m number in a serie es that ca an be safe ety wired
to
ogether.
b) When
W the multiple
m fas
steners are
e spaced m more than 6 inches a apart, the
multiple
m fasttener applic
cation speccified in Figure 1 shall not be useed unless
tie
e points are e provided on adjacennt parts to sshorten thee span of th
he wire to
le
ess than 6 inches.
c) One
O end of the safety wire shall be inserte ed through one set off lockwire
holes in the e head of the bolt. Th he other en nd of the ssafety wire shall be
ooped around the bolt head in the
lo e tighteningg direction.
 Do
ocument number ASP00
0019
Re
evision A
Pa
age 7

d) The
T strands, while taut, shall be tw wisted until the twisted
d part is jusst short of
th
he nearest hole in the next bolt. TThe twistedd portion shhall be within 1/8” of
th
he holes in each bolt as
a shown in n figure 1 abbove.
e) After
A wiring the last bo
olt, the wiree shall be ttwisted to fform a pigtail of 2-4
tw
wists. The excess
e wire
e shall be cut off. The e pigtail sh
hall be bentt back or
under the paart to prevent it from beecoming a snag.

3.3.4
4 Single wirre method:
The sing gle wire method may y be used in a closelly spaced, closed geo ometrical
patte
ern (triangle
e, square, circle,
c n an electriical system
etc.)) on parts in m, and in pla
aces that
would make th he single-mmethod more advisab ble as show wn in figurre 2 below. Closely
spacced shall bee considere
ed a maximum of two iinches betw ween cente ers. Maximuum length
of wire shall no
ot exceed 244” in total le
ength.

Figure 2: Safety
S Wire / L
Lock Wire Sing
gle

3.4 OTH
HER APPLIICATIONS
 Do
ocument number ASP00
0019
Re
evision A
Pa
age 8

3.4.1
1 Hollow he
ead bolts arre safety wiired in the m
manner pre
escribed forr regular bo
olts.

3.4.2
2 Drain plug
gs and coccks may be wired to a bolt, nut, oor other parrt having a free lock
hole in accorda
ance with th
he general instructionss contained herein.

3.4.3
3 External snap rings s may be loocked if ne
ecessary in
n accordancce with the
e general
locking principle
es containe
ed herein.

3.4.4
4 Internal snap rings shall
s never be lockwire
ed.

3.4.5
5 Bolts an
nd hardwa
are may be
b wired u
using SAFE
E-T-Cable. Follow p
procedure
D744000087-PPRO-001.

Safee-T-Cable®® can be used similar tot Safety/L ock wire to

o secure Fa asteners. Th
he safety
cable installatio
on proceduure is show wn in Figu ure. The safety cable e comes in n pre-cut
lengths with stuubs on one
e end. Afterr sewing through the h holes in the
e fasteners they are
tighttened and crimped
c using a ferrule
e cartridge and crimpin
ng tool.

They y are more convenientt to use andd take onlyy a fraction of the time to secure ffasteners
as compared
c to
o safety wirre as no wire twisting is required
d. However additional tools like
ferru
ule cartridge
e and crimping tool are required d. For addittional inform
mation refer Safe-T-
Cable® (websitte http://wwww.dmctools s.com/Cata alog/safe_t__cable.htm)).

Figure 3: Safety Cab

ble Installation
n Procedure

3.5 USTRATION OF TYPIICAL LOCK

ILLU K-WIRE AP
PPLICATIO
ON
 Do
ocument number ASP00
0019
Re
evision A
Pa
age 9

4 QA PR
ROVISIONS
S

5 S
NOTES
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 9.0
Design Torque Standard

www.nov.com
 DS00008

Design Specification
Design Torque Standard

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS

TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. 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 NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT INITIAL Design Torque Standard
DRAWN
B. Levay A. Vargas
CHECKED
N. West B. Levay SIZE DWG NO REV
APPVD
T. Mongomery JB A DS00008 G
DATE
2/13/15 11.13.1992 SCALE NONE WT LBS SHEET 1 OF 16
DCF0045 (REV B)
 NOTES

1. Unless noted, all values are based on light machine oil or anti-seize lubricated bolts (not high
pressure lubes).
2. NOV does not recommend assembling bolts dry.
3. Proof strength is 92% of minimum yield strength.
4. Torque values given represent 70% and 80% of proof strength.
5. Clamp force is based on 75% of proof strength.
6. These torque values are to be followed unless otherwise specified.
7. If torqueing into aluminum, contact engineering for appropriate torque value.
8. After torqueing fasteners, identify by marking head. Follow with lockwire per ASP00019 for all
drilled head fasteners.
9. Equations used to generate the values in this document:
Clamp Force= (.75)(Proof Strength)(Thread Area)
Torque= (Screw Diameter)(Clamp Force)(k)
k= .0160min / .0176max for light oil or Loctite
k= .0120min / .0132max for anti-seize
10. For fastener grades not listed in the following tables, use the equations in note 9, or use the
table that most closely matches the screw’s proof strength (see note 3).

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 2 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,000 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI PROOF STRENGTH = 74,000 PSI
COARSE THREAD SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 5.2 5.8 1,312 8.1 8.9 2,027
5/16 – 18 10.8 11.9 2,162 16.7 18.4 3,341
3/8 – 16 19.2 21.1 3,197 30 33 4,941
7/16 – 14 31 34 4,385 47 52 6,777
1/2 – 13 47 52 5,853 72 80 9,046
9/16 – 12 68 74 7,508 104 115 11,603
5/8 – 11 93 103 9,323 144 158 14,408
3/4 – 10 165 182 13,778 256 281 21,293
7/8 – 9 160 176 11,435 412 454 29,453
1–8 240 264 14,999 618 680 38,633
1 1/8 – 7 340 374 18,884 762 838 42,347
1 1/4 – 7 480 528 23,983 1,076 1,183 53,780 7
1 3/8 – 6 626 689 28,463 1,404 1,545 63,825 7
1 1/2 – 6 835 918 34,774 1,871 2,059 77,978 7

FINE THREAD SERIES – UNF

1/4 – 28 6.0 6.6 1,502 9.3 10.2 2,321
5/16 – 24 12.0 13.2 2,393 18.5 20.3 3,698
3/8 – 24 21.7 23.9 3,622 34 37 5,597
7/16 – 20 34 38 4,896 53 58 7,567
1/2 – 20 53 58 6,596 82 90 10,194
9/16 – 18 75 83 8,374 116 128 12,941
5/8 – 18 106 116 10,560 163 180 16,320
3/4 – 16 185 203 15,386 285 314 23,779
7/8 – 14 176 194 12,598 454 500 32,449
1 – 14 (UNS) 269 296 16,805 693 762 43,286
1 1/8 – 12 381 419 21,186 855 941 47,508 7
1 1/4 – 12 531 584 26,557 1,191 1,310 59,552 7
1 3/8 – 12 716 788 32,546 1,606 1,766 72,983 7
1 1/2 – 12 939 1,033 39,130 2,106 2,316 87,746 7

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 3 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 8 EXTREME STRENGTH
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 120,000 PSI PROOF STRENGTH = 136,000 PSI

COARSE THREAD SERIES - UNC

Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 11.4 12.6 2,862 13.0 14.3 3,244
5/16 – 18 23.6 25.9 4,716 27 29 5,345
3/8 – 16 42 46 6,975 47 52 7,905
7/16 – 14 67 74 9,567 76 83 10,843
1/2 – 13 102 112 12,771 116 127 14,474
9/16 – 12 147 162 16,380 167 184 18,564
5/8 – 11 203 224 20,340 231 254 23,052
3/4 – 10 361 397 30,060 409 450 34,068
7/8 – 9 582 640 41,580 660 726 47,124
1–8 873 960 54,540 7 989 1,088 61,812 7
1 1/8 – 7 1,236 1,360 68,670 7 1,401 1,541 77,826 7
1 1/4 – 7 1,744 1,919 87,210 7 1,977 2,174 98,838 7
1 3/8 – 6 2,277 2,505 103,500 7 2,581 2,839 117,300 7
1 1/2 – 6 3,035 3,338 126,450 7 3,439 3,783 143,310 7

FINE THREAD SERIES – UNF

1/4 – 28 13.1 14.4 3,276 14.9 16.3 3,713
5/16 – 24 26 29 5,220 30 33 5,916
3/8 – 24 47 52 7,902 54 59 8,956
7/16 – 20 75 82 10,683 85 93 12,107
1/2 – 20 115 127 14,391 130 144 16,310
9/16 – 18 164 181 18,270 186 205 20,706
5/8 – 18 230 253 23,040 261 287 26,112
3/4 – 16 403 443 33,570 457 502 38,046
7/8 – 14 641 705 45,810 7 727 800 51,918 7
1 – 14 (UNS) 978 1,076 61,110 7 1,108 1,219 69,258 7
1 1/8 – 12 1,387 1,525 77,040 7 1,572 1,729 87,312 7
1 1/4 – 12 1,931 2,125 96,570 7 2,189 2,408 109,446 7
1 3/8 – 12 2,604 2,864 118,350 7 2,951 3,246 134,130 7
1 1/2 – 12 3,415 3,756 142,290 7 3,870 4,257 161,262 7

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 4 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
300 SERIES / 18-8 STAINLESS STAINLESS ASTM F593U
TENSILE STRENGTH = 70,000 PSI TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 27,600 PSI PROOF STRENGTH = 95,000 PSI
(YIELD = 30,000 PSI)

COARSE THREAD SERIES - UNC

Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 2.6 2.9 658 9.1 10.0 2,266
5/16 – 18 5.4 6.0 1,085 18.7 20.5 3,734
3/8 – 16 9.6 10.6 1,604 33 36 5,522
7/16 – 14 15 17 2,200 53 58 7,574
1/2 – 13 23 26 2,937 81 89 10,110
9/16 – 12 34 37 3,767 117 128 12,968
5/8 – 11 47 51 4,678 161 177 16,103
3/4 – 10 83 91 6,914 286 314 23,798
7/8 – 9 134 147 9,563 461 507 32,918
1–8 201 221 12,544 691 760 43,178
1 1/8 – 7 284 313 15,794 979 1,076 54,364 7
1 1/4 – 7 401 441 20,058 1,381 1,519 69,041 7
1 3/8 – 6 524 576 23,805 1,803 1,983 81,938 7
1 1/2 – 6 698 768 29,084 2,403 2,643 100,106 7

FINE THREAD SERIES – UNF

1/4 – 28 3.0 3.3 753 10.4 11.4 2,594
5/16 – 24 6.0 6.6 1,201 20.7 22.7 4,133
3/8 – 24 10.9 12.0 1,817 38 41 6,256
7/16 – 20 17 19 2,457 59 65 8,457
1/2 – 20 26 29 3,310 91 100 11,393
9/16 – 18 38 42 4,202 130 143 14,464
5/8 – 18 53 58 5,299 182 201 18,240
3/4 – 16 93 102 7,721 319 351 26,576
7/8 – 14 148 162 10,536 508 559 36,266
1 – 14 (UNS) 225 247 14,055 774 851 48,379 7
1 1/8 – 12 319 351 17,719 1,098 1,208 60,990 7
1 1/4 – 12 444 489 22,211 1,529 1,682 76,451 7
1 3/8 – 12 599 659 27,221 2,061 2,267 93,694 7
1 1/2 – 12 785 864 32,727 7 2,704 2,974 112,646 7

F593
U

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 5 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,00 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI PROOF STRENGTH = 74,000 PSI
COARSE THREAD SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 3.9 4.3 1,312 6.1 6.7 2,027
5/16 – 18 8.1 8.9 2,162 12.5 13.8 3,341
3/8 – 16 14.4 15.8 3,197 22.2 24.5 4,941
7/16 – 14 23.0 25.3 4,385 36 39 6,777
1/2 – 13 35 39 5,853 54 60 9,046
9/16 – 12 51 56 7,508 78 86 11,603
5/8 – 11 70 77 9,323 108 119 14,408
3/4 – 10 124 136 13,778 192 211 21,293
7/8 – 9 120 132 11,435 309 340 29,453
1–8 180 198 14,999 464 510 38,633
1 1/8 – 7 255 280 18,884 572 629 42,347
1 1/4 – 7 360 396 23,983 807 887 53,780 7
1 3/8 – 6 470 517 28,463 1,053 1,158 63,825 7
1 1/2 – 6 626 689 34,774 1,404 1,544 77,978 7

FINE THREAD SERIES – UNF

1/4 – 28 4.5 5.0 1,502 7.0 7.7 2,321
5/16 – 24 9.0 9.9 2,393 13.9 15.3 3,698
3/8 – 24 16.3 17.9 3,622 25.2 27.7 5,597
7/16 – 20 26 28 4,896 40 44 7,567
1/2 – 20 40 44 6,596 61 67 10,194
9/16 – 18 57 62 8,374 87 96 12,941
5/8 – 18 79 87 10,560 122 135 16,320
3/4 – 16 138 152 15,386 214 235 23,779
7/8 – 14 132 146 12,598 341 375 32,449
1 – 14 (UNS) 202 222 16,805 519 571 43,286
1 1/8 – 12 286 315 21,186 641 705 47,508 7
1 1/4 – 12 398 438 26,557 893 983 59,552 7
1 3/8 – 12 537 591 32,546 1,204 1,325 72,983 7
1 1/2 – 12 704 775 39,130 1,579 1,737 87,746 7

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 6 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 120,000 PSI PROOF STRENGTH = 136,000 PSI

COARSE THREAD SERIES - UNC

Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 8.6 9.5 2,860 9.7 10.7 3,240
5/16 – 18 17.8 19.7 3,720 20.0 22.0 5,340
3/8 – 16 32 35 7,000 36 39 7,920
7/16 – 14 50 55 9,550 57 63 10,850
1/2 – 13 78 87 12,750 87 96 14,450
9/16 – 12 107 118 16,100 125 138 18,500
5/8 – 11 157 173 20,350 173 190 23,000
3/4 – 10 271 299 30,100 307 337 34,000
7/8 – 9 428 473 41,600 495 544 47,000 7
1–8 641 709 54,500 7 742 816 61,700 7
1 1/8 – 7 912 1,008 68,700 7 1,051 1,156 77,800 7
1 1/4 – 7 1,297 1,433 87,200 7 1,483 1,631 98,700 7
1 3/8 – 6 1,696 1,874 104,000 7 1,935 2,129 117,800 7
1 1/2 – 6 2,252 2,489 126,500 7 2,580 2,838 143,200 7

FINE THREAD SERIES – UNF

1/4 – 28 10 11 3,280 11.1 12.3 3,713
5/16 – 24 17.8 19.7 5,220 22.2 24.4 5,916
3/8 – 24 36 39 7,900 40 44 8,956
7/16 – 20 57 63 10,700 64 70 12,107
1/2 – 20 86 95 14,400 98 108 16,310
9/16 – 18 121 134 18,250 140 154 20,706
5/8 – 18 171 189 23,000 196 215 26,112
3/4 – 16 299 331 33,600 342 377 38,046
7/8 – 14 470 520 45,800 7 545 600 51,918 7
1 – 14 (UNS) 713 788 59,700 7 831 914 69,258 7
1 1/8 – 12 1,026 1,134 77,000 7 1,179 1,297 87,312 7
1 1/4 – 12 1,425 1,575 96,600 7 1,642 1,806 109,446 7
1 3/8 – 12 1,938 2,142 11,840 7 2,213 2,434 134,130 7
1 1/2 – 12 2,537 2,804 142,200 7 2,903 3,193 161,262 7

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 7 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
300 SERIES / 18-8 STAINLESS STAINLESS ASTM F593U
TENSILE STRENGTH = 70,000 PSI TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 27,600 PSI PROOF STRENGTH = 95,000 PSI
(YIELD = 30,000 PSI)

COARSE THREAD SERIES - UNC

Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 10.5 11.6 658 6.8 7.5 2,266
5/16 – 18 17.4 19.1 1,085 14.0 15.4 3,734
3/8 – 16 25.7 28.2 1,604 24.8 27.3 5,522
7/16 – 14 35 39 2,200 40 44 7,574
1/2 – 13 47 52 2,937 61 67 10,110
9/16 – 12 60 66 3,767 88 96 12,968
5/8 – 11 75 82 4,678 121 133 16,103
3/4 – 10 111 122 6,914 214 236 23,798
7/8 – 9 153 168 9,563 346 380 32,918
1–8 201 221 12,544 518 570 43,178
1 1/8 – 7 253 278 15,794 734 807 54,364 7
1 1/4 – 7 321 353 20,058 1,036 1,139 69,041 7
1 3/8 – 6 381 419 23,805 1,352 1,487 81,938 7
1 1/2 – 6 465 512 29,084 1,802 1,982 100,106 7

FINE THREAD SERIES – UNF

1/4 – 28 12.1 13.3 753 7.8 8.7 2,594
5/16 – 24 19.2 21.1 1,201 15.7 17.3 4,133
3/8 – 24 29.1 32.0 1,817 28 31 6,256
7/16 – 20 39 43 2,457 44 49 8,457
1/2 – 20 53 58 3,310 68 75 11,393
9/16 – 18 67 74 4,202 97 107 14,464
5/8 – 18 85 93 5,299 135 150 18,240
3/4 – 16 124 136 7,721 237 261 26,576
7/8 – 14 169 185 10,536 377 417 36,266
1 – 14 (UNS) 225 247 14,055 561 620 48,379 7
1 1/8 – 12 284 312 17,719 815 901 60,990 7
1 1/4 – 12 355 391 22,211 1,135 1,254 76,451 7
1 3/8 – 12 436 479 27,221 1,530 1,691 93,694 7
1 1/2 – 12 524 576 32,727 7 2,006 2,218 112,646 7

F593
U

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 8 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 0.4 0.4 191 1.0 1.1 509
M3.5 - .6 0.6 0.6 257 1.5 1.7 686
M4 - .7 0.8 0.9 333 2.2 2.5 888
M5 - .8 1.7 1.9 539 4.5 5.0 1,437
M6 - 1 2.9 3.2 763 7.7 8.5 2,033
M8 - 1.25 7.0 7.7 1,388 18.7 20.5 3,703
M10 - 1.5 13.9 15.2 2,200 37 41 5,868
M12 - 1.75 24.2 26.6 3,198 64 71 8,528
M14 - 2 38 42 4,363 103 113 11,634
M16 - 2 60 66 5,956 160 176 15,883
M18 – 2.5 83 91 7,284 220 242 19,423
M20 – 2.5 117 129 9,294 312 343 24,785
M22 – 2.5 159 175 11,495 425 467 30,653
M24 - 3 202 223 13,392 540 594 35,711
M27 – 3 296 326 17,413 790 869 46,434
M30 - 3.5 402 442 21,282 1,072 1,180 56,753 7
M33 – 3.5 547 602 26,328 1,459 1,605 70,208 7
M36 – 3.5 703 773 30,994 1,874 2,062 82,651 7
M39 - 4 910 1,001 37,026 2,426 2,668 98,736 7
M42 - 4.5 1,124 1,237 42,489 2,998 3,297 113,304 7
M48 - 5 1,678 1,846 55,510 7 4,475 4,923 148,003 7
M56 - 5.5 2,663 2,929 75,494 7 7,102 7,812 201,316 7

4.6 8.8

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 9 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
PROOF STRENGTH = 830 MPa PROOF STRENGTH = 970 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 1.3 1.5 704 1.6 1.7 823
M3.5 - .6 2.1 2.3 949 2.4 2.7 1,109
M4 - .7 3.1 3.4 1,229 3.6 4.0 1,436
M5 - .8 6.3 6.9 1,987 7.3 8.0 2,322
M6 - 1 10.6 11.7 2,813 12.4 13.7 3,287
M8 - 1.25 26 28 5,122 30 33 5,986
M10 - 1.5 51 56 8,117 60 66 9,486
M12 - 1.75 89 98 11,797 104 115 13,787
M14 - 2 142 156 16,094 166 182 18,808
M16 - 2 221 244 21,971 259 285 25,677
M18 – 2.5 305 335 26,869 356 392 31,401
M20 – 2.5 432 475 34,286 505 555 40,069
M22 – 2.5 588 646 42,403 687 755 49,555 7
M24 – 3 747 822 49,400 7 873 960 57,733 7
M27 – 3 1,092 1,202 64,234 7 1,277 1,404 75,069 7
M30 - 3.5 1,484 1,632 78,508 7 1,734 1,907 91,751 7
M33 – 3.5 2,019 2,221 97,121 7 2,359 2,595 113,503 7
M36 – 4 2,593 2,852 114,334 7 3,030 3,333 133,619 7
M39 – 4 3,355 3,691 136,585 7 3,921 4,314 159,623 7
M42 - 4.5 4,147 4,561 156,737 7 4,846 5,331 183,174 7
M48 - 5 6,190 6,810 204,737 7 7,235 7,958 239,271 7
M56 – 5.5 9,824 10,806 278,488 7 11,481 12,629 325,461 7

10.9
12.9

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 10 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 0.3 0.3 191 0.7 0.8 509
M3.5 - .6 0.4 0.5 257 1.1 1.2 686
M4 - .7 0.6 0.7 333 1.7 1.8 888
M5 - .8 1.3 1.4 539 3.4 3.7 1,437
M6 - 1 2.2 2.4 763 5.8 6.3 2,033
M8 - 1.25 5.2 5.8 1,388 14.0 15.4 3,703
M10 - 1.5 10.4 11.4 2,200 28 30 5,868
M12 - 1.75 18.1 19.9 3,198 48 53 8,528
M14 - 2 29 32 4,363 77 85 11,634
M16 - 2 45 50 5,956 120 132 15,883
M18 – 2.5 62 68 7,284 165 182 19,423
M20 – 2.5 88 97 9,294 234 258 24,785
M22 – 2.5 119 131 11,495 319 350 30,653
M24 - 3 152 167 13,392 405 445 35,711
M27 – 3 222 244 17,413 592 652 46,434
M30 - 3.5 302 332 21,282 804 885 56,753 7
M33 – 3.5 410 452 26,328 1,095 1,204 70,208 7
M36 – 3.5 527 580 30,994 1,406 1,546 82,651 7
M39 - 4 682 750 37,026 1,819 2,001 98,736 7
M42 - 4.5 843 927 42,489 2,248 2,473 113,304 7
M48 - 5 1,259 1,384 55,510 7 3,356 3,692 148,003 7
M56 - 5.5 1,997 2,197 75,494 7 5,326 5,859 201,316 7

4.6 8.8

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 11 OF 16
DCF0045 (REV B)
 TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
PROOF STRENGTH = 830 MPa PROOF STRENGTH = 970 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 1.0 1.1 704 1.2 1.3 823
M3.5 - .6 1.6 1.7 949 1.8 2.0 1,109
M4 - .7 2.3 2.6 1,229 2.7 3.0 1,436
M5 - .8 4.7 5.2 1,987 5.5 6.0 2,322
M6 - 1 8.0 8.8 2,813 9.3 10.3 3,287
M8 - 1.25 19.4 21.3 5,122 22.6 24.9 5,986
M10 - 1.5 38 42 8,117 45 49 9,486
M12 - 1.75 67 74 11,797 78 86 13,787
M14 - 2 106 117 16,094 124 137 18,808
M16 - 2 166 183 21,971 194 214 25,677
M18 – 2.5 228 251 26,869 267 294 31,401
M20 – 2.5 324 356 34,286 379 416 40,069
M22 – 2.5 441 485 42,403 515 567 49,555 7
M24 – 3 560 616 49,400 7 655 720 57,733 7
M27 – 3 819 901 64,234 7 958 1,053 75,069 7
M30 - 3.5 1,113 1,224 78,508 7 1,300 1,430 91,751 7
M33 – 3.5 1,514 1,666 97,121 7 1,770 1,947 113,503 7
M36 – 4 1,945 2,139 114,334 7 2,273 2,500 133,619 7
M39 – 4 2,517 2,768 136,585 7 2,941 3,235 159,623 7
M42 - 4.5 3,110 3,421 156,737 7 3,635 3,998 183,174 7
M48 - 5 4,643 5,107 204,737 7 5,426 5,969 239,271 7
M56 – 5.5 7,368 8,105 278,488 7 8,611 9,472 325,461 7

10.9
12.9

The following tables specify torque values for fasteners used

with Nord-Lock washers.

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 12 OF 16
DCF0045 (REV B)
 NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.2 540 1.2 540
NL4 M4 .7 3.0 944 2.7 944
NL5 M5 .8 5.8 1,529 5.2 1,529
NL6 M6 1.0 10 2,181 9.1 2,181
NL8 M8 1.25 24 4,047 22 4,047
NL10 M10 1.5 47 6,295 43 6,295
NL12 M12 1.75 82 8,992 74 8,992
NL14 M14 2.0 129 12,364 117 12,364
NL16 M16 2.0 197 16,861 177 16,861
NL18 M18 2.5 276 20,682 249 20,682
NL20 M20 2.5 385 26,527 348 26,527
NL22 M22 2.5 525 32,822 474 32,822
NL24 M24 3.0 664 37,993 599 37,993
NL27 M27 3.0 968 49,683 873 49,683
NL30 M30 3.5 1,322 60,474 1,192 60,474
NL33 M33 3.5 1,779 74,861 1,600 74,861
NL36 M36 4.0 2,295 88,125 2,067 88,125
NL39 M39 4.0 2,960 105,211 2,663 105,211
NL42 M42 4.5 3,663 120,947 3,297 120,947

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 10.9

Oil Graphite
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.7 719 1.5 764
NL4 M4 .7 3.9 1,259 3.5 1,326
NL5 M5 .8 7.8 2,046 6.7 2,158
NL6 M6 1.0 14 2,900 12 3,057
NL8 M8 1.25 33 5,171 29 5,620
NL10 M10 1.5 64 8,318 56 8,768
NL12 M12 1.75 110 12,140 95 12,814
NL14 M14 2.0 175 16,636 151 17,535
NL16 M16 2.0 268 22,481 230 23,830
NL18 M18 2.5 375 27,651 323 29,225
NL20 M20 2.5 524 35,070 451 37,093
NL22 M22 2.5 714 43,613 613 46,086
NL24 M24 3.0 903 50,582 776 53,505
NL27 M27 3.0 1,318 66,094 1,128 69,691
NL30 M30 3.5 1,798 80,482 1,542 84,978
NL33 M33 3.5 2,422 99,590 2,068 105,211
NL36 M36 4.0 3,125 117,350 2,673 123,870
NL39 M39 4.0 4,030 140,281 3,440 148,149
NL42 M42 4.5 4,988 160,963 4,262 170,180
SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 13 OF 16
DCF0045 (REV B)
 NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 12.9
Oil Graphite
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.9 877 1.6 922
NL4 M4 .7 4.4 1,506 3.8 1,596
NL5 M5 .8 8.7 2,450 7.4 2,585
NL6 M6 1.0 15 3,462 13 3,664
NL8 M8 1.25 36 6,295 31 6,744
NL10 M10 1.5 72 9,892 61 10,566
NL12 M12 1.75 123 14,613 105 15,287
NL14 M14 2.0 196 20,008 167 21,132
NL16 M16 2.0 298 26,977 252 28,551
NL18 M18 2.5 419 33,272 355 35,070
NL20 M20 2.5 585 42,264 494 44,512
NL22 M22 2.5 797 52,380 670 55,303
NL24 M24 3.0 1,009 60,698 850 64,295
NL27 M27 3.0 1,470 79,133 1,235 83,629
NL30 M30 3.5 2,005 96,668 1,688 102,063
NL33 M33 3.5 2,699 119,598 2,265 126,343
NL36 M36 4.0 3,483 140,730 2,927 148,823
NL39 M39 4.0 4,490 168,157 3,763 177,599
NL42 M42 4.5 5,560 193,336 4,666 204,126

NORD-LOCK Stainless Steel with Stainless Steel Bolt A4

A4-70 w/ Graphite Lube A4-80 w/ Graphite Lube
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 0.9 337 1.2 450
NL4 M4 .7 1.9 585 2.6 764
NL5 M5 .8 3.7 922 5.1 1,236
NL6 M6 1.0 7 1,326 9 1,754
NL8 M8 1.25 16 2,473 21 3,147
NL10 M10 1.5 32 3,822 41 5,171
NL12 M12 1.75 54 5,620 72 7,419
NL14 M14 2.0 85 7,644 114 10,116
NL16 M16 2.0 130 10,341 174 13,713
NL18 M18 2.5 183 12,589 244 16,861
NL20 M20 2.5 256 16,186 341 21,357
NL22 M22 2.5 349 20,008 465 26,527
NL24 M24 3.0 441 23,155 588 30,799
NL27 M27 3.0 643 30,124 858 40,241
NL30 M30 3.5 877 36,869 1,170 49,233
NL33 M33 3.5 1,182 45,636 1,576 60,698
NL36 M36 4.0 1,525 53,729 2,034 71,714
NL39 M39 4.0 1,968 64,071 2,624 85,652
NL42 M42 4.5 2,435 73,737 3,247 98,241
SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 14 OF 16
DCF0045 (REV B)
 NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5
Oil Graphite
Washer Bolt Pitch Torque Clamp Torque Clamp
Size Size (TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.1 550 1.0 550
NL3.5 #6 32 1.4 630 1.3 630
NL4 #8 32 2.7 970 2.4 970
NL5 #10 24 3.9 1,200 3.5 1,200
NL1/4” ¼ 20 9.1 2,200 8.3 2,200
NL8 5/16 18 18 3,600 16 3,600
NL3/8” 3/8 16 30 5,400 28 5,400
NL11 7/16 14 47 7,300 42 7,300
NL1/2” ½ 13 73 9,800 66 9,800
NL14 9/16 12 104 12,600 94 12,600
NL16 5/8 11 145 15,600 131 15,600
NL3/4” ¾ 10 254 23,100 230 23,100
NL22 7/8 9 408 31,900 369 31,900
NL 1” 1 8 617 41,800 557 41,800
NL30 1 1/8 7 771 46,400 697 46,400
NL33 1¼ 7 1075 58,900 969 58,900
NL36 1 3/8 6 1410 70,200 1,270 70,200
NL39 1½ 6 1860 85,500 1,670 85,500

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 8

Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.5 740 1.3 780
NL3.5 #6 32 1.9 840 1.7 890
NL4 #8 32 3.5 1,300 3.1 1,400
NL5 #10 24 5.1 1,600 4.6 1,700
NL1/4” ¼ 20 12 2,900 11 3,100
NL8 5/16 18 24 4,900 21 5,100
NL3/8” 3/8 16 41 7,200 36 7,600
NL11 7/16 14 64 9,800 56 10,400
NL1/2” ½ 13 99 13,100 86 13,900
NL14 9/16 12 138 16,800 122 17,800
NL16 5/8 11 197 20,900 171 22,100
NL3/4” ¾ 10 346 30,900 299 32,700
NL22 7/8 9 556 42,700 479 45,100
NL 1” 1 8 840 56,000 724 59,200
NL30 1 1/8 7 1,190 70,600 1,030 74,500
NL33 1¼ 7 1,660 89,600 1,430 94,600
NL36 1 3/8 6 2,180 107,000 1,880 113,000
NL39 1½ 6 2,870 130,000 2,470 137,000

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 15 OF 16
DCF0045 (REV B)
 NORD-LOCK Stainless Steel with ASTM A574 Bolt
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.7 870 1.6 910
NL3.5 #6 32 2.2 990 2.0 1,050
NL4 #8 32 3.8 1,500 3.7 1,600
NL5 #10 24 5.8 1,900 5.5 2,000
NL1/4” ¼ 20 13 3,400 12 3,700
NL8 5/16 18 26 5,700 23 6,000
NL3/8” 3/8 16 45 8,400 39 8,900
NL11 7/16 14 70 11,500 60 12,200
NL1/2” ½ 13 109 15,400 93 16,300
NL14 9/16 12 148 19,800 141 20,900
NL16 5/8 11 216 24,600 184 26,000
NL3/4” ¾ 10 378 36,400 321 38,400
NL22 7/8 9 607 50,200 514 53,000
NL 1” 1 8 916 65,900 776 69,600
NL30 1 1/8 7 1,300 83,000 1100 87,700
NL33 1¼ 7 1,810 105,000 1530 111,000
NL36 1 3/8 6 2,380 126,000 2020 133,000
NL39 1½ 6 3,140 153,000 2640 161,000

NORD-LOCK Stainless Steel with ASTM F593 Bolt

Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(TPI) (ftlb) (lb) (ftlb) (lb)
NL3 #5 40 - - - -
NL3.5 #6 32 - - - -
NL4 #8 32 - - - -
NL5 #10 24 - - - -
NL1/4” ¼ 20 5.2 1,300 5.2 1,300
NL8 5/16 18 10.3 2,200 10.3 2,200
NL3/8” 3/8 16 18 3,300 18 3,300
NL11 7/16 14 28 4,500 28 4,500
NL1/2” ½ 13 43 6,000 43 6,000
NL14 9/16 12 61 7,700 61 7,700
NL16 5/8 11 85 9,500 85 9,500
NL3/4” ¾ 10 104 9,800 104 9,800
NL22 7/8 9 166 13,500 166 13,500
NL 1” 1 8 251 17,700 251 17,700
NL30 1 1/8 7 356 22,300 356 22,300
NL33 1¼ 7 497 28,300 497 28,300
NL36 1 3/8 6 653 33,800 653 33,800
NL39 1½ 6 859 41,100 859 41,100

SIZE DWG NO REV

A DS00008 G
SCALE NONE WT LBS SHEET 16 OF 16
DCF0045 (REV B)
 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 10.0
Recommended Lubricants and
Fluids

www.nov.com
 Recommended
Lubricants Guide
This guide is not all-inclusive. It is only intended to cover
the recommended lubricants for the product lines and
models specified within the guide.

Reference Reference Description

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
National Oilwell Varco
part, or use of this design or distribution of this information to RIG SOLUTIONS
others is not permitted without the express written consent of 11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or
upon completion of the use for which it was loaned. This Houston, TX 77041
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
Document Number Rev.

D811000719-PRO-001 06

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 Form D811001123-GEN-001/07

Revision History

06 23.04.2014 Engineering Update A. Donovan S. Blanco S. Williams

05 15.08.2012 Engineering Update B. Dominguez S. Sobreira R. Luher

04 21.02.2012 Engineering Update B. Dominguez B. Levay B. Levay

03 30.11.2009 Engineering Update B. Dominguez P. Williams P. Williams

02 09.14.2009 Publication update B. Dominguez P. Williams P. Williams

01 10.01.2008 First Issue TCD BMD BDW

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

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 Form D811001123-GEN-001/07

Change Description

Revision Change Description

1. Changed equipment reference to cover page.

2. Added temperature range reference to hydraulic fluids and gear lubricant pour point advisories to
page 1.
3. Changed and added frequency of fluid changes for hydraulic fluids and gear lubricants to pages 4
and 8.
4. Changed Non-Arctic Service heading to Non-Arctic Service Fluids to page 6.
5. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Non-Arctic Service Fluid table
to page 6.
6. Changed Arctic Service heading to Arctic Service Fluids to page 7.
7. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Arctic Service Fluid table to
page 7.
8. Added “SUS” viscosities to best choice supreme grade arctic service hydraulic fluids to
page 7.
9. Added “SUS” viscosities to alternative supreme grade arctic service hydraulic fluids to page
02
7.
10. Changed gearbox reference and added cross-reference information to operating temperature table
for draining of gear oil to page 8.
11. Added “Conventional” reference to washpipe lubricant recommendation section to page 10.
12. Removed "AC" reference to page 10.
13. Removed grease brand example to page 11.
14. Added External Pinion and Gear Sets section with recommended grease information tables to page
9 and 10.
15. Changed “Viscosity” cell title to “Kinematic Viscosity” cell title in Lubricants and Fluids Reference
Chart to pages 14 and 15.
16. Added "External Pinion and Gear Sets" component lubricant reference to page 15.
17. Removed "AC" reference from drilling motor bearings to page 15.
18. Changed all primary temperature degrees to Celsius and changed all reference temperature
degrees to Fahrenheit.

1. Added caution note and contact information note to page 2.

03
2. Removed oil additive recommendation note to page 15.

1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12.
2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13.
3. Moved Air Lubricator Misting Oil section from page 13 to page 17.
04
4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled:
Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16.
5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.

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 Form D811001123-GEN-001/07

Change Description (continued)

Revision Change Description

1. Corrected cross-reference page information on page 9 to refer to the table on page 10.
2. Placed ambient temperature minus symbol in front of 9 Celsius on column one, row two of
Recommended Gear Oil for the Transmission Gearbox Table (page 10).
3. Placed ambient temperature minus symbol in front of 4 Celsius on column one, row three of
05 Recommended Gear Oil for the Transmission Gearbox Table (page 10).
4. Changed ambient temperature -10 Celsius to -9 Celsius on column two, row three of Recommended
Gear Oil for the Transmission Gearbox Table (page 10).
5. Corrected inverted primary (Celsius) and reference (Fahrenheit) temperature degree call-outs to
column two, row four of Recommended Gear Oil for the Transmission Gearbox Table (page 10).

1. Updated the document to the latest Technical Publications template

2. Updated the title to “Recommend Lubricants Guide”
3. Removed the NOV product lines from the cover
4. Updated the overall text and tables to reflect the current information for the various products (whole
guide)
5. Updated the Introduction section (page 1)
6. Created the Hydraulic Fluid Quick Reference table (page 4)
7. Added a note explaining the top drive lubrication in the Gear Oil section (page 5)
8. Updated the gear oil grade tables to differentiate between the PS Series, TDS-150, and TDH-150 top
drive and the TDS, TDX, and IDS top drive product lines (pages 4 and 5)
06 9. Updated the lubricants and fluids reference tables by combining the relevant information for each
component and placed them at the end of their corresponding sections (pages 2 through 14)
10. Added the Below -6°C (21°F) procedure to the gear oil grade tables and lubricants and fluids
reference tables (pages 7 through 9)
11. Added the recommended procedures column to Table 1-5 and 1-6 (page 7 and 8)
12. Added Recommended Gear Oil for Top Drive, and Iron Roughneck and Pipe Racking sections (page
8 and 9)
13. Created the Gear Oil Quick Reference table (page 10)
14. Added the Landing Collar subsection to the External Pinion and Gear Set (page 12)
15. Added the Grease Quick Reference table (page 14)
16. Deleted the Wire Rope Lubricant section (page 15)

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 Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fluid Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Top Drive Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Iron Roughneck and Pipe Racking Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gear Oil Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IBOP/Kelly Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Handling-Ring/Repositioner/RLA Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crowned Tooth Gear Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Landing Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grease Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Lubricator Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Table of Contents

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ii D811000719-PRO-001
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 List of Tables

Table 1-1. Approved product lines and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Table 1-2. Recommended hydraulic fluids for non-arctic conditions:
-12 to 52°C (10 to 125°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Table 1-3. Recommended hydraulic fluids for arctic conditions:
-40 to 17°C (-40 to 63°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Table 1-4. Recommended hydraulic fluids (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . .5
Table 1-5. Recommended gear oil grades
(PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives) . . . . . . . . . . .7
Table 1-6. Recommended gear oil grades and procedures
[TDS (except for TDS-150), TDX, and IDS top drive series] . . . . . . . . . . . . . . . . . . . . .8
Table 1-7. Recommended gear oil grades
(ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck,
ST-160 Iron Roughneck, and STV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Table 1-8. Gear oil specifications (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Table 1-9. Recommended grease for washpipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 1-10. Recommended grease for crowned tooth gear coupling . . . . . . . . . . . . . . . . . . . . . .12
Table 1-11. General recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Table 1-12. Recommended grease for various components (quick reference table) . . . . . . . . . . .14
Table 1-13. Recommended misting oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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 List of Tables

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iv D811000719-PRO-001
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 Recommended Lubricants Guide

If the operating equipment service manual contains a Recommended Lubricants

section, please disregard this guide and adhere to the section.
Reason: This is a general guide; a Recommended Lubricants section within the
service manual is specific to that particular equipment.

Introduction
This guide contains the recommended lubricants to be used on the approved product lines and
models listed in table 1-1.
Reference: If the operating equipment is not listed in this table, see the equipment vendor
documentation or contact an NOV representative.

Table 1-1. Approved product lines and models

Product line Models

Fingerboard All

Hydraulic Cathead HC-26EV

Hydraulic Power Unit (HPU) HP-45Q

Iron Roughneck AR Series, ST-80 Series, ST-100, ST-120, and ST-160

Pipe Racking Systems (PRS) Standard Transfer Vehicle (STV)

Power Rotating Bail Adapter (PRBA) All

Power Rotating Hook Adapter (PRHA) All

Rotary Table and Swivel All

IDS-1, IDS-3, IDS-4A, IDS-350P, IDS-350PE, IDS-

Top Drive System (TDS)/
Integrated Drilling System (IDS)
350P+, PS and PS2 Series, TD-500PAC, TDS-150,
TDH-150, TDS-3, TDS-3H, TDS-4, TDS-4S, TDS-4H,
TDS-5, TDS-6S, TDS-8SA, TDS-9SA, TDS-10SA, 
TDS-10SH, TDS-10SRR, TDS-11SA, TDS-11SH,
TDS-1000, TDX-1000, and TDX-1250

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 Recommended Lubricants Guide Introduction

Before equipment operation, it is essential to determine the grade and quality of lubricant
appropriate for the minimum ambient temperature of operation. To determine if this guide is
applicable, refer to the General Recommendations section in this guide.
This guide provides recommendations for selecting the appropriate grade and quality of the
following lubricants:
• Hydraulic Fluid
• Gear Oil
• Grease
• Air Lubricator Misting Oil

Consult engineering for lubrication requirements in extreme conditions, such as:

• Extreme service temperature
• Extreme pressure
• Emergency lubrication

General Recommendations
Adhere to the lubrication product information and instructions listed in/on:
• The design notes on the assembly drawing in the technical drawing package
• The nameplate on the equipment
• The documentation of the original equipment manufacturer (OEM)
If there is no information for selecting the appropriate lubricant for the NOV equipment provided,
refer to the NOV recommendations provided in this guide.
This guide lists the specifications or required qualities, not particular brand names, of the
recommended lubricants for the equipment. If none of the recommended lubricants have the
correct properties for the ambient and operating temperature ranges at your location, contact an
NOV service center for instructions.
Reference: For application and maintenance information, see the OEM documentation or NOV
service manual.
If the application and maintenance information is not available, contact your NOV representative.

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 Recommended Lubricants Guide

Hydraulic Fluid
An anti-wear (AW) hydraulic fluid of the proper viscosity grade is recommended for the hydraulic
system.

The AW hydraulic fluid is typically mineral-based and contains AW additives

along with rust and oxidation inhibitors.

Selecting the appropriate fluid viscosity grade to operate a typical hydraulic system involves the
consideration of the following interdependent variables:
• The starting viscosity at the minimum ambient temperature
• Verification that:
– The pour point temperature of hydraulic fluid will be at least 17°C (30°F) lower than the
expected minimum ambient temperature.
– The hydraulic fluid pours freely at the minimum operating temperature.

Operating the equipment in cold temperatures requires hydraulic fluid with a

viscosity that allows the oil to flow freely and transmit power. If the ambient
temperature approaches the hydraulic fluid pour point, a heater may be used
to get the fluid flowing for proper lubrication of the component.

• Maximum expected operating temperature limits

• Permissible and optimum viscosity range for the component
– Minimum viscosity at maximum ambient temperature and in severe duty-cycle operation
– Maximum viscosity at cold start
Use table 1-2 and table 1-3 as a general guide for selecting the hydraulic fluids for equipment
operation in non-arctic or arctic conditions, respectively.

Table 1-2. Recommended hydraulic fluids for non-arctic conditions: 

-12 to 52°C (10 to 125°F)

Choice Parameter Unit

Kinematic viscosity 6.9 cSt @ 100°C (49 SUS @ 210°F)

Minimum viscosity index 105

Best
Pour point -30°C (-22°F)

ISO viscosity grade 46

Kinematic viscosity 6.9 cSt @ 100°C (49 SUS @ 210°F)

Minimum viscosity index 100

Alternative
Pour point -37°C (-35°F)

ISO viscosity grade 46

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 Recommended Lubricants Guide Hydraulic Fluid

Table 1-3. Recommended hydraulic fluids for arctic conditions: 

-40 to 17°C (-40 to 63°F)

Choice Parameter Unit

Kinematic viscosity 5.5 cSt @ 100°C (44 SUS @ 210°F)

Minimum viscosity index 377

Best
Pour point -60°C (-76°F)

ISO/ASTM viscosity grade 15

Kinematic viscosity 3.72 cSt @ 100°C (39 SUS @ 210°F)

Minimum viscosity index 140

Alternative 1
Pour point -42°C (-44°F)

ISO viscosity grade 15

Kinematic viscosity 6.4 cSt @ 100°C (47.5 SUS @ 210°F)

Minimum viscosity index 155

Alternative 2
Pour point -50°C (-58°F)

ISO viscosity grade 32

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 Hydraulic Fluid Quick Reference Table
Use table 1-4 as a quick reference table for selecting the recommended hydraulic fluids information presented in this section.

Table 1-4. Recommended hydraulic fluids (quick reference table)

ASTM/

Revision 06
Kinematic Viscosity
Component Environment Lube Type ISO-VG/ NLGI AGMA Pour Point
Viscosity Index
SAE

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Hydraulic Fluid

D811000719-PRO-001
6.9 cSt @ 100°C
Hydraulic Oil1 Grade 46 --- --- 105 -30°C (-22°F)
-12°C to 52°C (49 SUS @ 210°F)
(-10°F to 125°F)
Hydraulic 6.9 cSt @ 100°C
Grade 46 --- --- 100 (min.) -37°C (-35°F)
Transmission Oil (49 SUS @ 210°F)

-30°C to 17°C 6.4 cSt @ 100°C

Typical (-22°F to 63°F) Hydraulic Oil2 Grade 32 --- --- 155 -50°C (-58°F)
(47.5 SUS @ 210°F)
hydraulic
systems -30°C to 17°C) Grade 7.5 cSt @ 100°C
(-22°F to 63°F) AT Fluid --- --- 172 -48°C (-54°F)
10W (51 SUS @ 210°F)

3.72 cSt @ 100°C

Hydraulic Oil3 Grade 15 --- --- 140 -42°C (-44°F)
-40°C to 0°C (39 SUS @ 210°F)
(-40°F to 32°F)
5.5 cSt @ 100°C
Hydraulic Oil Grade 15 --- --- 377 -60°C (-76°F)
(44 SUS @ 210°F)

1 Must be premium grade with anti-rust and anti-wear additives

2
Must be premium shear stable high VI, anti-wear hydraulic oil
3 Must be supreme grade high shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives
Recommended Lubricants Guide

5
 Recommended Lubricants Guide

Gear Oil
This section is a general guide for selecting the gear oil used on the top drive, iron roughneck, and
pipe racking systems only.
Reference: If the gearbox is not part of a top drive, iron roughneck, or pipe racking system, see the
equipment vendor documentation or contact an NOV representative.
Always use an extreme pressure (EP) gear oil when working with gearboxes.

The EP gear oils are typically mineral oils that contain sulfur-phosphorous
additives. Most EP gear oils meet the American Gear Manufacturers
Association (AGMA) extreme pressure-performance requirements.

The proper grade and type of gear oil is selected by viscosity.

Reference: For the brand or trade name of the lubricant for the applicable viscosity range, consult
the lubricant suppliers.

Using oil with a greater viscosity than required can damage:

! • The gearbox, as a result of reduced oil flow.
• The oil pump, as a result of excessive load.

The pour point temperature of the oil should be at least 6°C (10°F) lower than the expected
minimum ambient temperature. The gear oil must pour freely at its minimum operating
temperature.

Operating the equipment in low temperatures requires gear oil with a

viscosity:
• High enough to carry the load.
• Low enough to allow the oil to circulate.

At start-up, the oil should flow freely and not cause high torque. If the ambient temperature
approaches the gear oil pour point, a heater may be used to get the fluid flowing and to ensure
proper lubrication of components.
This section will cover the following:
• Recommended Top Drive Gear Oil
• Recommended Iron Roughneck and Pipe Racking Gear Oil

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Gear Oil Recommended Lubricants Guide

Recommended Top Drive Gear Oil

Use table 1-5 as a general guide for selecting the recommended gear oil grades used for the
following top drive models:
• PS and PS2 Series
• TD-500PAC
• TDS-150
• TDH-150

Table 1-5. Recommended gear oil grades 

(PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives)

Ambient temperature Minimum gear oil

Recommended gear oil grade
range operating temperature

10 to 52°C
16°C (60°F) AGMA no. 7 EP, ISO VG 460
(50 to 125°F)

-9 to 16°C
4°C (40°F) AGMA no. 6 EP, ISO VG 320
(15 to 60°F)

-29 to -4°C
-23°C (-9°F) AGMA no. 4 EP, ISO VG 150
(-20 to 25°F)

-46 to -18°C
-40°C (-40°F) Synthetic AGMA no. 3 EP, ISO VG 100
(-50 to 0°F)

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 Recommended Lubricants Guide Gear Oil
Recommended Top Drive Gear Oil

Use table 1-6 as a general guide for selecting the recommended gear oil grades and procedures
used for the following top drive models:
• TDS series (excluding TDS-150; see table 1-5)
• TDX series
• IDS series

Table 1-6. Recommended gear oil grades and procedures 

[TDS (except for TDS-150), TDX, and IDS top drive series]

Ambient temperature range Recommended gear oil grade Recommended procedures

Above 21°C --
AGMA no. 6 EP, ISO VG 320
(Above 70°F)

7 to 30°C --
AGMA no. 4 EP, ISO VG 150
(45 to 86°F)

-6 to 16°C Synthetic AGMA no. 3 EP,  If using AGMA no. 2 EP

(21 to 61°F) ISO VG 100
If synthetic AGMA no. 3 EP,
ISO VG 100 is unavailable, use
AGMA no. 2 EP (mineral base
oil), ISO VG 68.
(mineral base oil), ISO VG 68,
the oil must be changed every
1,000 operating hours or every
four months.

Below -6°C See recommended procedures The oil temperature will need to
(Below 21°F) be raised above -6°C (21°F)
by completing the following
steps:
1. Warm the top drive up by
rotating at a very light load
and very slow speeds until the
oil temperature is raised to 
-6°C (21°F).
2. If specific instructions are
needed for warming up the
top drive, contact your local
NOV service center.
Once the oil temperature has
been raised above -6°C (21°F),
refer to the -6 to 16°C ambient
temperature range row in this
table.

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Gear Oil Recommended Lubricants Guide

Recommended Iron Roughneck and Pipe Racking

Gear Oil
Use table 1-7 as a general guide for selecting the recommended gear oil grades used for the
following iron roughneck and pipe racking models:
• ST-80 Series
• ST-120
• ST-160
• STV
Table 1-7. Recommended gear oil grades
(ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck, 
ST-160 Iron Roughneck, and STV)

Ambient temperature range Recommended gear oil grade

Above 21°C
AGMA no. 6 EP, ISO VG 320
(Above 70°F)

7 to 30°C
AGMA no. 4 EP, ISO VG 150
(45 to 86°F)

-6 to 16°C
AGMA no. 2 EP, ISO VG 68
(21 to 61°F)

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 Gear Oil Quick Reference Table
Use table 1-8 as a quick reference table for selecting the gear oil specifications used for the top drive, iron roughneck, and pipe racking systems
listed in this section.

10
Table 1-8. Gear oil specifications (quick reference table)

ASTM/ Kinematic Viscosity

Lube Type NLGI AGMA Pour Point1
ISO-VG/SAE Viscosity1 Index1

30.3 cSt @ 100°C

EP Gear Oil Grade 460 --- #7 EP 95 -7°C (20°F)
(150 SUS @ 210°F)

24.0 cSt @ 100°C

EP Gear Oil Grade 320 --- #6 EP 95 -18°C (0°F)
(120 SUS @ 210°F)

EP Gear Oil 14.5 cSt @ 100°C

Grade 150 --- #4 EP 95 -23°C (-10°F)
(78.1 SUS @ 210°F)

8.8 cSt @ 100°C

EP Gear Oil Grade 68 --- #2 EP 102 -20°C (-4°F)
(55.5 SUS @ 210°F)

#3 EP &  14.4 cSt @ 100°C

Synthetic Gear Oil
Recommended Lubricants Guide

Grade 100 --- 149 -46°C (-50°F)

#3 S (77.1 SUS @ 210°F)

1 Values are for reference only, and may vary slightly depending on manufacturer

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 Recommended Lubricants Guide

Grease
This section will cover the recommended grease for the general preventive maintenance for the
following components.
• Washpipe Assembly
• Motor Bearings
• IBOP/Kelly Valve Actuator
• External Pinion and Gear Set
For all other components requiring grease lubrication, see the General Grease Lubrication
subsection.

Washpipe Assembly
For general preventative maintenance of the washpipe assembly, use table 1-9 as a general guide
for selecting the washpipe grease for moderate operating conditions or extreme operating
conditions, such as high speed, pressure, or fluid temperature.

Table 1-9. Recommended grease for washpipe assembly

Moderate operating conditions Extreme operating conditions

NLGI grade 2 NLGI grade 3

Non-soap based moly grease Non-soap based moly grease

NOV part number 7806084 NOV part number 7806663

Motor Bearings
Some motors are equipped with greased bearings, which must be lubricated at manufacturer-
recommended intervals.

Always use the recommended lubrication product specified by the original

! equipment manufacturer.

Generally, the drilling motors and blower motors are vendor-supplied equipment; therefore, the
motor housing may have a nameplate attached to it that provides the recommended lubrication
product, amount to use, and lubrication intervals.
Reference: If there is no nameplate, see the vendor documentation in the owner’s manual. If no
vendor documentation is supplied, contact an NOV representative.

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 Recommended Lubricants Guide Grease

IBOP/Kelly Valve Actuator

IBOP and Kelly valve actuators may be vendor-supplied equipment.

Always use the recommended lubrication product specified by the original

! equipment manufacturer. Using the incorrect lubrication product can cause
damage to the equipment.

Reference: If the actuator assembly does not have a nameplate that lists the recommended
grease, see the vendor documentation in the owner’s manual.
If the vendor documentation does not list the recommended grease, use grease with properties
that meet the NLGI grade 1.5 specifications.

External Pinion and Gear Set

This subsection covers the recommended greasing procedures for the following components:
• Handling-Ring/Repositioner/RLA Pinion and Gear Set
• Crowned Tooth Gear Coupling
• Landing Collar

Handling-Ring/Repositioner/RLA Pinion and Gear Set

For all environmental conditions, coat the gear teeth with an extreme pressure lubricant, such as
NOV Copper Top (Jet-Lube Kopr-Kote®) or equivalent.

Crowned Tooth Gear Coupling

Use table 1-10 as a general guide for selecting the grease for moderate or extreme operating
conditions, such as normal or high speed and torque:

Table 1-10. Recommended grease for 

crowned tooth gear coupling

Operating conditions NLGI grade

Moderate 1

Extreme 2

Landing Collar
For all environmental conditions, coat the landing collar halves, main shaft grooves, and inside
diameter of the retainer ring with a generous amount of NLGI Grade 2 Jet-Lube Arctic™ Extreme
Service Grease, a Calcium 12- Hydroxystearate grease with exceptional resistance to salt water
spray and wash-down.

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Grease Recommended Lubricants Guide

General Grease Lubrication

For all other components not specified in the Grease section, use EP, lithium-based, general-
purpose grease. Use table 1-11 as a general guide for selecting the appropriate NLGI grade.

Table 1-11. General recommended grease

Ambient temperature range NLGI grade

0°C (32°F) and below 1

Above -20°C (-4°F) 2

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 Grease Quick Reference Table
Use table 1-12 as a quick reference table for selecting the recommended grease information presented in this section.

Table 1-12. Recommended grease for various components (quick reference table)

14
ASTM/
Kinematic Viscosity
Component Environment Lube Type ISO-VG/ NLGI AGMA Pour Point
Viscosity Index
SAE

Moderate Operating
Primrose Plus # 327 --- #2 --- --- --- ---
Conventional Conditions
Washpipe Packing
Grease Extreme Operating
Primrose Plus # 327 C --- #3 --- --- --- ---
Conditions

Drilling Motor
All EP Grease1 #2 --- --- --- ---
Bearings

Blower Motor
All EP Grease1 #2 --- --- --- ---
Bearings

Above -20°C (-4°F) EP Grease2 --- #2 --- --- --- ---

General Grease
Bearings 0°C (32°F) 
Recommended Lubricants Guide

EP Grease2 --- #1 --- --- --- ---

and below

IBOP/Kelly Valve Metalon 

All --- #1.5 --- --- --- ---
Actuator Hi-Tech 1.5 Grease3

External Pinion and

Gear Sets, and
Elevator and Main All EP Grease4 --- -- --- --- --- ---
Links Contact
Surfaces

Calcium 12-
Landing Collar All --- -- --- --- --- ---
Hydroxystearate5

1
Polyurea-based grease or as specified by the motor manufacturer
2
Lithium base, general-purpose, extreme pressure grease
3
Use the product specified by the original equipment manufacturer
4
For example: Jet-Lube Kopr-Kote or NOV Copper Top
5 Use Jet-Lube Arctic™ Extreme Service Grease or equivalent

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 Recommended Lubricants Guide

Air Lubricator Misting Oil

Along with table 1-13, it is recommended that the misting oils for the air lubricator have the
following properties:
• Turbine-quality lubricant
• Long life
• Rust and oxidation-inhibited

Table 1-13. Recommended misting oil

Parameter Unit

Kinematic viscosity1 29-35 cSt @ 40°C (136-165 SUS @ 100°F)

Viscosity Index1 100-104

ISO viscosity grade 32

1
Values are for reference only, and may vary slightly depending on manufacturer

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16 D811000719-PRO-001
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 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 11.0
Hydraulic Fluid Cleanliness

www.nov.com
Hydraulic
Fluid
Cleanliness

Supplement
SM00081 Rev. C
October 26, 2000

Copyright 2000, 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.

Product names mentioned in this publication may be

trademarks or registered trademarks of their respective
holders and are hereby acknowledged.

ii Hydraulic Fluid Cleanliness SM00081-C

 Contents
Supplement

Hydraulic Fluid Cleanliness

Scope .................................................................................................................... 5
Hydraulic Fluid Cleanliness ................................................................................. 6
Hydraulic fluid ............................................................................................... 6
Hydraulic Fluid Contamination ............................................................................ 7
Solid contamination ....................................................................................... 7
Classes of contamination ......................................................................... 7
Measuring the contamination of a system ............................................... 9
Taking samples .................................................................................. 9
Analyzing the samples .......................................................................... 10
Cleanliness during installation ........................................................................... 11
Service loops ................................................................................................ 11
Hydraulic pipe cleaning ............................................................................... 11
Reference documents: ........................................................................... 11
Pipe cleaning (carbon steel): ................................................................. 11
Pipe cleaning (stainless steel) ................................................................ 13

SM00081-C Contents iii

October 26, 2000

iv Hydraulic Fluid Cleanliness SM00081-C

 Supplement
Hydraulic Fluid
Cleanliness

Scope
The purpose of this document is to provide guidance to the installers and users of
Varco’s hydraulically powered equipment and to ensure that each piece of equipment
performs as intended. Prior to connecting Varco equipment to a hydraulic system, the
piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to
minimize hydraulic fluid contamination. The following paragraph defines the
hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to
maintain these cleanliness levels could result in premature equipment damage and
nullification of the equipment warranty.

This document outlines fluid cleanliness measurement and analysis criteria and also
describes procedures for filtering and cleaning a hydraulic system.

Each final assembly item from Varco will be function tested with clean hydraulic fluid
maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid
cleanliness levels will be recorded on Test Specification document (TS00419) for each
piece of equipment prior to shipment.

SM00081-C Hydraulic Fluid Cleanliness 5

October 26, 2000

Hydraulic Fluid Cleanliness

Hydraulic fluid
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO
4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning
of Varco equipment. After initial system operation, Varco recommends that the
hydraulic supply system be capable of continuously maintaining this level of
cleanliness or better to assure that fluid contamination is not a factor in any component
failure during the desired useful life of the hydraulic powered equipment. The final
level of acceptable cleanliness prior to equipment hook up must be determined by a
hydraulic fluid sample and should be analyzed by a qualified laboratory.

6 Hydraulic Fluid Cleanliness SM00081-C

 Hydraulic Fluid Contamination

Hydraulic Fluid Contamination

Solid contamination
When determining contamination of hydraulic fluids, you must consider the size and
quantity of the solid particle contamination within a representative fluid sample. The
contamination of hydraulic fluids by solid particles is covered by a number of different
classification systems:

❏ ISO DIS 4406

❏ MIL STD 1246 A
❏ NAS 1638
❏ SAE 749 D
❏ CETOP RP 70 H

CLASSES OF CONTAMINATION
The various classes of contamination define the quantity of particles of a certain size in
a 100 ml sample of fluid.

A classification is determined by counting and sizing the contaminating solid particles.

The classification is performed either under a microscope, or by using an electronic
particle counter. The electronic counter method is more objective than using the
microscope.

Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the
contamination can only be ascertained by weight, i.e., by gravimetric analysis.
However, with this method, the individual dirt particles cannot be classified.

SM00081-C Hydraulic Fluid Cleanliness 7

October 26, 2000

ISO DIS Particles ACFTD Mil STD NAS 1638 SAE 749 D
4406 per ml solids 1246 A (1967) (1963)
or >10 µm content (1967)
Cetop RP mg/L
70 H
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 300 8 5
16/13 140 1 7 4
15/12 70 6 3
Acceptable range for Varco equipment

Acceptable range for Varco equipment

14/12 40 200
14/11 35 5 2
13/10 14 0.1 4 1
12/9 9 3 0
18/8 5 2
10/8 3 100
10/7 2.3 1
10/6 1.4 0.01
9/6 1.2 0
8/5 0.6 00
7/5 0.3 50
6/3 0.14 0.001
5/2 0.04

Figure 1. Comparison of contamination classifications

8 Hydraulic Fluid Cleanliness SM00081-C

 Comparison of contamination classifications

MEASURING THE CONTAMINATION OF A SYSTEM

Solid particle contamination is measured by taking a sample of fluid from the output of
the hydraulic supply system at a location just prior to the Varco equipment and
analyzing it.

The analysis can reveal the following:

❏ Solid particle contamination of fluid delivered by suppliers

❏ Effectiveness of the system filters
❏ Flushing time when commissioning a system
❏ State of the system and any possible damage to components when making regular
checks

Taking samples

Take a sample from a moving fluid (known as dynamic sampling)

Sampling point: Take the sample within a system that is operating and which contains
turbulent flow. (See ISO 4021.)

Since obtaining a fluid sample can be an input for contamination the following general
measures should be utilized when taking a fluid sample.

❏ Utilize continuous flow monitoring equipment that records a cleanliness level over
a period of time whenever possible.
❏ Take a sample of the circulating fluid of a system that is at operating conditions and
temperature. All fluid samples shall be taken from a system test-port fitting using
a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish
a leak point as a fluid source for fluid contamination sampling.
❏ Before attaching the sampling device, carefully flush out the device and clean the
system test-port fitting.
❏ Open sampling device and allow approximately 2 liters of fluid to flow through the
test port prior to sampling the fluid.
❏ Without shutting the test port, open and fill the sterile sampling bottle by holding
it in the continuous fluid stream. Cap and seal the test bottle.
❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit
location.

e Only properly trained personnel should be allowed to take the fluid samples. Errors in
sampling procedures can greatly affect contamination classes below ISO 18/IS.

SM00081-C Hydraulic Fluid Cleanliness 9

October 26, 2000

ANALYZING THE SAMPLES

Analyzing the fluid samples involves using a microscope to make a quick estimate of
the amount of solid particle contamination. From this assessment, you can roughly
assess the state of the system.

To avoid errors in sampling, conduct particle counting off site. Do not allow rig
personnel to attempt to check the samples at the time of sampling. Send the samples to
an appropriate institute for testing.

Usually, samples are analyzed by means of an electronic particle counter. These

particle counters are employed by major users of hydraulics, manufacturers of
hydraulic filters, and by various institutions. Since testing by an outside source may not
be easily accessible from a rig, you can make a quick assessment of the fluid samples
on the spot by using the assessment test charts in this document.

z Mobile laboratory services can also perform the measurements for customers.

10 Hydraulic Fluid Cleanliness SM00081-C

 Cleanliness during installation

Cleanliness during installation

Service loops
Varco service loops are blown clean in the factory and capped prior to shipment. They
are not flushed. All service loops and hoses should be flushed as part of the overall
hydraulic system prior to connecting Varco equipment.

Hydraulic pipe cleaning

z Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The
following processes are examples of pickling, cleaning, and flushing procedures for
cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and
are provided for information and reference only. Varco is typically not responsible for
any part of the pickling, cleaning, or flushing process of derrick and rig floor piping.

The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe
(carbon or stainless), the condition of the pipe (pickled or not pickled), the types and
levels of contamination, the types and temperatures of the pickling and flushing
solutions in use, and the type of flushing equipment.

REFERENCE DOCUMENTS:
❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and
purification of petroleum fluid hydraulic system.

PIPE CLEANING (CARBON STEEL):

Obtain the following chemicals:

Hydrochloric acid - 35% commercial grade

Alkaline cleaner, KD-500

Potable water - Unless otherwise specified

Passivator - iron phosphate, KO-30

Inhibitor - Rodine 214 for HCL

SM00081-C Hydraulic Fluid Cleanliness 11

October 26, 2000

Degrease

Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish
or other tough soils should be sandblasted prior to pickling.

Rinse

Rinse carbon steel pipe with potable water until all alkaline cleaner is removed.

Acid pickle

Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at
ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed.
Rinse with potable water until all alkaline cleaner is removed.

Rinse

Rinse the pipe with potable water until the water reaches a neutral PH (7.0).

Flush

Begin flushing the piping with the hydraulic power unit until the desired state of
cleanliness is met.

12 Hydraulic Fluid Cleanliness SM00081-C

 Cleanliness during installation

PIPE CLEANING (STAINLESS STEEL)

Use the following recommended procedure for cleaning stainless steel pipe:

Obtain the following chemicals:

Nitric acid - 42% technical grade

Hydrofluoric acid - 35% technical grade

Alkaline cleaner, KD-500

Potable water - unless otherwise specified

Degrease

Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present.

Rinse

Rinse pipe with portable water until all alkaline cleaner is removed.

Acid pickle

Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at
ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed.

Rinse

Rinse the pipe with potable water until the water reaches a neutral PH.

Passivate

Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for
approximately one-half the time used in acid pickling.

Rinse

Rinse with potable water until the PH of the effluent equals the pH of the influent.

Dry

Dry with oil-free air until all visible traces of moisture are removed.

Final inspection

Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to
hooking up equipment pump clean hydraulic fluid through the plumbing and measure
the contamination of the system per this specification. Additional flushing and cleaning
may be required if contamination levels do not meet the requirements of this
specification.

SM00081-C Hydraulic Fluid Cleanliness 13

 FINAL DOCUMENTATION
TDH-250 – Top Drive System

Chapter 12.0
Service Center Directory

www.nov.com
 National Oilwell Varco
Service Center Directory

Reference Reference Description

This document contains proprietary and confidential National Oilwell Varco

information which is the property of National Oilwell Varco, RIG SOLUTIONS
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only 11000 Corporate Centre Drive
and remains the property of NOV. Reproduction, in whole Houston, TX 77041
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
Document Number Rev.

D811001337-DAS-001 06

www.nov.com
Form D811001123-GEN-001/06
 D811001337-DAS-001
Revision 06

Revision History
06 12.03.2015 Operations update V. Mulhern T. Harmon T. Harmon

05 10.09.2014 Operations update V. Mulhern T. Harmon T. Harmon

04 12.11.2011 Operations update T. Drake S. Sobreira T. Harmon

03 18.01.2011 Operations update T. Drake T. Harmon T. Harmon

02 02.10.2009 Operations update T. Drake T. Harmon P. Williams

01 08.09.2009 First Issue T. Drake T. Harmon P. Williams

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Change Description
Revision Change Description

01 First Issue

02 • Moved Cairo office under North Africa heading.

• Changed address information for India office.

03 • Removed outdated Louisiana contact information.

• Added the new Louisiana service and repair center contact information.

04 • Updated/added Brazil, Canada, Colombia, UK contact information (page 3 through page 7).
• Added North Dakota contact information (page 4).
• Updated the contact information for the China office (page 6).
• Added addresses and contact information for Singapore and India (page 6).
• Updated contact information for NOV Dubai and NOV Abu Dhabi. (page 8).

05 • Updated format.
• Updated Colombia contact information (page 3).
• Added Peru contact information (page 4).

06 • Added contact information for Angola (page 8) and South Africa (page 8) locations.
• Changed Middle East heading to Middle East and Africa (page 8).

www.nov.com
 Service Center Directory SC

The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx

Americas

Brazil
National Oilwell Varco do Brasil
Rodovia Amaral Peixoto, s/n KM164,5 - n° 8.500
Imboassica – Macaé – RJ – Brazil
CEP 27925-290
+55 22 2773 0600 (reception)
+55 22 9882 7591 (after hours)
+55 22 9702 8866 (drilling equipment)
+55 22 9974 7056 (PCE / MoComp equipment)
+55 22 9894 6608 (lifting and handling equipment)
+55 22 2773 0635 (repair shop)
+55 22 2773 0675 (inside sales)
+55 22 2123 2452 (tech college)

Canada
NOV Rig Solutions Aftermarket Service, Repair and Rentals (Leduc)
Varco Canada ULC CO 009
6621 – 45 Street
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712 (main)
NOV Rig Solutions Spares (Edmonton)
Varco Canada ULC CO 009
7127 – 56 Ave
Edmonton, Alberta, Canada
T6B 3L2
+1 780 801 1800 (main)
+1 780 619 5579 (24 hour on-call)

Colombia
NOV Rental and Service (Bogotá)
National Oilwell Varco de Colombia
Rig Solutions-Top Drive
DDS-Dynamic Drilling Solutions
Centro Empresarial Metropolitano Km 3.4 Costado Norte vía Siberia
Bodega 15 – Modulo 1 Bogotá - Colombia
Main (571) 743 2258
Mobile +571 3168758748
Mobile +571 3102385722

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SC Service Center Directory Americas

Peru
NOV Rental and Service
National Oilwell Varco Peru
Rig Solutions-Top Drive
DDS Dynamic Drilling Solutions
Avenida Rivera Navarrete, San Isidro 501 Of.502 Lima, Perú
Office +511 2191160 - 180
Mobile +51 958572058
Mobile 3102385722

USA
Colorado
NOV Service and Repair (Colorado)
420 South Ash St.
Fruita, CO 81521
+1 970 858 4522
+1 281 569 3050 (after hours)

Louisiana
NOV Service and Repair (Covington)
73765 Penn Mill Rd.
Covington, LA 70435
+1 985 892 8216 (direct)
+1 800 722 4425 (toll free)
(Cranes: AmClyde, Unit, OS National, Dreco, Kingpost)
+1 985 871 8609 (service)
+1 985 871 8603 (parts
NOV Service and Repair Center (New Iberia)
5212 Highway 90 Service Road West
New Iberia, Louisiana 70560
(All NOV spare parts; legacy Shaffer, Varco, and NOI equipment)
+1 337 374 1400

Minnesota
NOV Service (St. Paul)
240 East Plato Blvd.
St. Paul, Minnesota 55107
(lifting and handling equipment)
+1 651 293 4745 (service) 
+1 651 293 4776 (service)
+1 651 293 4600 (parts)
+1 651 293 4603 (parts)

North Dakota
NOV Service, Repair, and Spare Parts
3201 1st Avenue W.
Williston, ND 58801
+1 307 473 8888
+1 281 569 3050 (after hours)

4 D811001337-DAS-001
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Americas Service Center Directory SC
USA

Oklahoma
NOV Service and Repair (Oklahoma City)
7713 North West 3rd St.
Oklahoma City, Oklahoma 73127
+1 405 495 1000
+1 281 569 3050 (after hours)

Pennsylvania
NOV Service (Pittsburgh)
1349 Saw Mill Run Blvd.
Pittsburgh, Pennsylvania 15226
+1 412 884 1027
+1 281 569 3050 (after hours)

Texas
NOV Service and Repair (Alice)
2351 Energy Avenue
Alice, Texas 78380
+1 361 668 4154
+1 281 569 3050 (after hours)
NOV Service and Repair (Houston)
5100 North Sam Houston Parkway West
Houston, Texas 77086
+1 281 569 3050 (24/7 technical support)
+1 281 569 3051 (eHawk remote support)

Wyoming
NOV Service and Repair (Casper)
1080 North Robertson Road
Casper, Wyoming 82601
+1 307 473 8888
+1 281 569 3050 (after hours)

Venezuela
NOV Rental and Service (Maturin, Monagas)
Varco International de Venezuela
Top Drive Rental and Service
+58 291 651 6489
+58 414 394 2784 (mobile)
+58 291 651 4384 (fax)

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Asia

China
NOV Service
18th Floor, Raffles City Beijing Office Tower
No. 1, Dongzhimen South Street, Dongcheng District
Beijing 100007 P. R. China
+86 139 0121 9392
+86 800 810 5109 (24/7 technical support)

India
NOV Service and Repair
R-619, TTC Industrial Area
Rabale, MIDC
Navi Mumbai – 400 701
Maharashtra, India
+91 22 3916 9700
+91 982 009 1322
+91 983 349 6154 (after hours)
NOV Machining Centre (Pressure Control)
11A/2 (NP) Sidco Industrial Estate
Ambattur
Chennai, Tamil Nadu, India 600098
+91 44 4285 8074
+91 95 0008 4149 (after hours)

Singapore
NOV Service and Repair
29 Tuas Bay Drive
Singapore 637429
+65 6594 1000
+65 6594 1222 (24/7 technical support)
NOV Machining Centre (Pressure Control)
22 Jalan Terusan
Singapore 619299
+65 6265 1900
+65 9128 2545 (after hours)

Europe

France
NOV Service
+33 24 068 3600
+33 24 068 3611
+33 24 068 3600 (after hours)
+33 677 790 943 (after hours)

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Norway
NOV Service (Asker)
Blakstadmarka 26
1386 Asker – Norway
+47 6400 5000
+47 6400 5001 (after hours)
NOV Service (Kristiansand)
Skibaasen 2
4636 Kristiansand – Norway
+47 3819 2000
+47 3819 2482 (after hours)
NOV Service (Molde)
Granfjaera 24
6415 Molde – Norway
+47 7120 2020
+47 9169 9664 (after hours)
NOV Repair (Stavanger)
Dusavik Base
Notberget 46
4029 Stavanger – Norway
+47 5781 8181
NOV Service (Stavanger)
Lagerveien 8
4069 Stavanger – Norway
+47 5181 8181
+47 4140 0041 (after hours)
+47 9511 8181 (24/7 eHawk remote support)

Russia
NOV Service and Support
Russia, 119071, Moscow
Leninsky prosp., 15A, 7th floor
+7 495 287 2601 (direct)
+7 495 981 3470 (fax)
+7 985 410 5272 (mobile)

UK
NOV Service and Repair (Aberdeen/Montrose)
Forties Road
Montrose
Scotland
DD10 9ET
+44 1674 677222
UK after hours, on-call contacts
+44 (0) 7711 415 485 (mechanical)
+44 (0) 7711 415 484 (electrical)
+44 (0) 7739 170 079 (repair workshop)
+44 (0) 7713 643 012 (spare parts)
+44 (0) 7770 325 333 (distribution)
+44 (0) 7801 078 092 (IMO/MD Totco)
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Middle East and Africa

Angola
NOV Service and Repair (Angola)
Sonils Oil Service Center
Luanda, Angola
+244 923 426620

Algeria
NOV Service (Algeria)
Overseas Equipment Service Africa
BP 852 Zone Industrielle Algerie
Hassi Messaoud Ouargla
Algeria 30500
+213 29 73 1236
+213 29 75 4105 (fax)

Egypt
NOV Service and Repair (Badr City)
IMPEC (Sea Harvest Company)
Part B, 47 Acer Area
Badr City, Cairo, Egypt
+20 2 231 08001
+20 2 231 08002
+20 2 231 08003 (fax)

Saudi Arabia
NOV Service and Repair (Dammam)
P. O. Box 20754, Al-Khobar 31952
Al Khobar, Saudi Arabia
Gate No. 2, Makkah Street (opposite of Saudi Electricity Company)
Dammam Second Industrial City
Dammam, Saudi Arabia
+966 3 835 3061
+966 3 830 2453 (fax)

South Africa
NOV Service and Repair (Port Elizabeth)
Kendle Street
Neave Township
Port Elizabeth, South Africa
+27 41 451 2416
+27 41 405 1605 (24/7 Technical Support)

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UAE
NOV Service and Repair (Abu Dhabi)
Varco Al Mansoori Services LLC
P. O. Box 27011
Abu Dhabi, United Arab Emirates
+971 2 555 2668
+971 2 554 2280 (fax)
+971 2 554 0012 (fax)
+971 50 811 6083 (after hours service)
+971 50 617 1235 (after hours workshop)
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, United Arab Emirates
+971 4 883 8776
+971 4 883 8795 (fax)
+971 56 686 2184 (after hours service on-call)

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