Product Bulletin No.

: TDS-03-26
Release Top Drive Drilling Systems
October 20, 2003

Subject: Maintenance of Hydraulic Piston Accumulators

Product: All Varco Top Drive Drilling Systems

Affected
Assemblies: Accumulator (P/N’s 82674, 84601, 107060,110562, 110563, 110564 & 115290)

Objective: Advise Operators of Maintenance Requirements for Hydraulic Piston Accumulators

Problem: It has come to Varco’s attention that a general clarification of maintenance

requirements relating to hydraulic piston accumulators used on our Top Drive Drilling
Systems is required. Service manual documentation for the various Top Drive models
contain some of the basic maintenance information, however other information is
referenced in vendor instructions contained in some Varco Service Manuals as
supplemental material. The manner in which this information is organized varies
across all models of top drives.

Solution: The following sections relating to pre-charging and maintenance of accumulators will
be expanded in future service manuals.

2003 Varco All Rights Reserved TDS-03-26

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 Pre-charging the Piston Accumulator-

The following steps should be followed when pre-charging accumulators:

1) Use an inert gas such as nitrogen for pre-charging accumulators. Do not use
oxygen.

2) Before pre-charging, make certain:

a. The accumulator end caps are screwed flush into the accumulator body.
b. The gas valve is screwed in tight.
c. No oil remains trapped in the top of the accumulator.
d. The charging hose fitting on nitrogen charging kit is clean, as not to
introduce any contaminants to the accumulator when pre-charging.

Note: Depending on the size of the accumulator there are two possible types of gas
valves that may be found. Either the cored gas valve cartridge (ISO-4570-8V1;
Varco P/N 87979) or the heavy duty military poppet-type gas valve cartridge
(MS28889-2; Varco P/N 107060-GV1) may be supplied, as shown in Figure 1.

(ISO-4570-8V1) (MS28889-2)

Figure 1. Gas Valve Types

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 The recommended charging kit for accumulators is the Accumulator Charging
Assembly (P/N 114446-500) is shown in Figure 2 below. Note: T-handle shown in
View AA is used when charging cored type gas valve only.

Figure 2. Gas Charging Kit

3) Remove gas valve guard and gas valve cap.

4) Attach the charging hose to the nitrogen bottle and to the gas valve using the
following procedure:

If your accumulator has a cored gas valve cartridge follow Steps A through H.

Note: Use thread sealing and lubricating compound on the pipe threads of the
gauge.

a. Back gas chuck “T” stem completely out of the way out (CCW) before
attaching the charging assembly to accumulator gas valve. Caution: Make sure
not to loop or twist the hose, attach the swivel nut to the gas valve and tighten
(10-15 in-lbs).

b. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the
bleed valve.

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 c. Turn gas chuck “T” stem until the gauge starts showing the pressure in the
accumulator. Caution: Do not turn the “T” handle all the way down, as it will
damage the valve core.

d. Crack open nitrogen bottle valve and slowly fill accumulator. Shut off when the
gauge indicates the desired gas pressure.

e. Let the pre-charge set for 10-15 minutes, allowing the gas temperature to
stabilize. If gas pressure is exceeded, close nitrogen bottle valve, then slowly
open bleed valve (opposite the gas valve below the gauge). Caution: Do not
reduce pre-charge by depressing valve core with a foreign object. High
pressure will rupture rubber valve seat.

f. Before loosening the swivel nut, turn the gas chuck stem all the way out, then
open bleed valve.

g. To prevent the gas valve from turning, loosen swivel nut and remove the
assembly.

h. Replace the gas valve cap (torquing to 10-15 in-lbs.) and valve guard.

For heavy duty military poppet-type gas valve cartridges follow Steps I through P as
follows:

Note: Use thread sealing and lubricating compound on the pipe threads of the
gauge.

i. Back gas chuck “T” stem completely out of the way out (CCW) before
attaching the charging assembly to accumulator gas valve. Caution: Make sure
not to loop or twist the hose, attach the swivel nut to the gas valve and tighten
(10-15 in-lbs).

j. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the
bleed valve.

k. Hold the gas valve below the hex nut with one wrench while unscrewing hex
nut with a second wrench. This will open the poppet inside the gas valve.
Three (3) turns will fully open the valve.

l. Crack open nitrogen bottle valve and slowly fill accumulator. Shut off when the
gauge indicates the desired gas pressure.

m. Let the pre-charge set for 10-15 minutes, allowing the gas temperature to
stabilize. If gas pressure is exceeded, close nitrogen bottle valve, then slowly
open bleed valve (opposite the gas valve below the gauge). Caution: Do not
reduce pre-charge by depressing valve core with a foreign object. High
pressure will rupture rubber valve seat.

n. Tighten the hex nut with a wrench to internally close the poppet.

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 o. To prevent the gas valve from turning, loosen swivel nut and remove the
assembly.

p. Replace the gas valve cap (torquing to 10-15 in-lbs.) and valve guard.

Maintenance-

Periodic testing of the pre-charge pressure will detect whether O-ring wear is sufficient
to degrade sealing performance. There is currently no maintenance schedule for
verification of accumulator pre-charge, however to be consistent with the
manufacturer, Varco is recommending that pre-charge be checked one week after
initial equipment installation, and thereafter on a monthly basis.

If an accumulator will not maintain pre-charge pressure, contact your local Varco
Service Center to order seal kits shown in table below.

Troubleshooting-

Refer to the Troubleshooting section of your service manual for symptoms, probable
causes and remedies related to loss of accumulator pre-charge. This includes but is
not limited to operation of the alignment cylinder, IBOP valve Actuator,
counterbalance system, dolly retract systems, on-board hydraulic power units and
stand jump on your top drive.

Below is a table outlining piston accumulators currently used on Varco Top Drive
models. Also included is the applicable seal kit part number and pre-charge
pressures.

Accumulator P/N TDS Model Function Seal Kit Pre-Charge

(psig)
110563-1 TDS-9/11SA/11HP/10SA System 87605-1 800
110563-11 TDS-10SA System 87605-1 800
110562-1 TDS-9/10/11SA/11HP Counterbalance 30124575 900

110564 TDS-9/11SA IBOP Valve 30124576 800

84601-3 TDS-3S/4S/8SA/1000 Motor 87605 900

Alignment
115290 TDS-4S/8S Dolly Retract 115290-1 800
82674/-1 TDS-3/7 Retract 87605 1000
82674 TDS-3/4/3S/4S/6S/8S Counterbalance 87605 900

107060-2 IDS-1/3/4A Brake 107060-SK 600

(on-board hydraulics)
107060-3 IDS-1/3/4A Counterbalance 107060-SK *300 > PCC
(on-board hydraulics

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 *Note: Pressure at PCC set during initial installation. Refer to IDS-3 service manual.

Please contact your local Varco Service Center if you have any questions regarding this
product bulletin.

2003 Varco All Rights Reserved TDS-03-26

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