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TDS-4S Top Drive Drilling System

Service Manual
SM00620-TOC
Rev. A

October 20, 1998

ii

TDS-4S Contents

Contents
Book 1 – Description
Preface/Manual conventions
Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6

Chapter 1 Introduction
General description .......................................................... 1-7

Chapter 2 Major component description
Motor housing assembly ................................................ 1-19 Drilling motor ......................................................... 1-20 Two speed transmission ........................................... 1-20 Integrated swivel bail and swivel washpipe ............... 1-22 Standard rotating head ............................................. 1-24 Powered rotating head ............................................. 1-26 Rotating head controls ....................................... 1-26 Cooling systems ............................................................. 1-28 Local blower ............................................................ 1-28 Closed loop .............................................................. 1-30 Remote blower ......................................................... 1-32 Guide dolly assemblies ................................................... 1-34 Motor alignment system ................................................ 1-37 Pipehandler .................................................................... 1-38 Link adapter ............................................................ 1-39 Safety valves (IBOP) ................................................ 1-40 Saver and crossover subs..................................... 1-40 Safety valve actuator ................................................. 1-40 Torque wrench ........................................................ 1-42

TDS-4S Contents

iii

October 20, 1998

Link tilt mechanisms ................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51 TDS Control System (TDCS) ....................................... 1-53 Varco Driller’s control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62

Chapter 3 Specifications
Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower * .................................................... 1-66 Derrick mounted remote blower * ..................... 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70

iv

TDS-4S Contents

................................. 2-23 Service loops ........................... 2-24 Electrical loop ................................................................................... 2-23 Wiring ..................... 2-7 Chapter 2 Installation Derrick electrical termination kit .......................................................... 2-23 Varco Driller’s Console (VDC)................................................................... 2-15 Water.............. 2-33 TDS-4S Contents v ..... 2-25 Air loop ............... 2-9 Wiring ........................................................................................................................ 2-6 Manual layout... 2-13 Plumbing ............................................................................. 2-9 Installation ................... 2-27 Chapter 3 Commissioning Checkout procedures .................................... 2-24 Installation ......................... 2-15 Air ..................................................................................................Book 2 – Installation and Commissioning Preface/Manual conventions Safety information ..................... 2-25 Fluids loop .............................................................................................................................................................................. 2-5 Directional references ................. 2-29 Long term TDS storage procedures.......................................................... 2-6 Chapter 1 Preparation Preinstallation checklist................................. 2-15 Hydraulic....................................................................................................................... 2-26 Retract loop ......................................................................................................................... 2-23 Throttle and torque limit controls ............................................................................................................... 2-21 Motor alignment cylinder system ........................ 2-22 Driller’s controls and instrumentation ........................ 2-16 Counterbalance system ... 2-15 Rig-up procedure ........................ 2-32 Returning the TDS to service after storage ........

......................... 3-21 Drilling ahead with triples ............................ 3-19 PH-60d .......................... 3-24 Drilling ahead on a semi ........ 3-34 vi TDS-4S Contents .......................... 3-12 Controls............... 3-8 Changing transmission speeds ........ 3-21 Drilling ahead with singles .............October 20................................................................... 1998 Book 3 – Operation Preface/Manual conventions Safety information ........ 3-11 Powered rotating head . 3-19 PH-85 ......................................................... 3-31 Running casing ............................................................... 3-32 Post jarring operations .......... 3-20 Drilling ahead ................................................... 3-7 Stalling the DC motor ..... 3-19 Torque values for load carrying components ........... 3-26 Tripping ............ 3-12 Safety valves (IBOP) ....................................................................................................... 3-14 Torque wrench ......................................... 3-9 Pipehandler operation ................................................................................. 3-11 Standard rotating head ........ 3-6 Chapter 1 Operating procedures Start-up procedure .... 3-16 Changing drill string sizes ............................................................................................................................. 3-12 ROTATING HEAD LEFT/RIGHT switch ............................................................................................................................................................... 3-12 AUTO STOP/FREE ROTATE switch .................................................................................................. 3-29 Well control procedures ..................................................... 3-28 Reaming out ............................................................................................................................. 3-32 Handling bottom hole assemblies ....... 3-6 Manual layout .................................................................. 3-5 Directional references .................................................

.. 4-13 Pipehandler ............. 4-16 Drive stem ............ 4-27 Oil capacity...........................................Book 4 – Maintenance and Troubleshooting Preface/Manual conventions Safety information ....................................................................................... 4-25 Other gearbox lubrication and maintenance considerations .......................................... 4-34 TDS-4S Contents vii .......... 4-28 Lubricating the DC motor ............ 4-12 Air exhaust muffler .............................................. 4-9 TDS swing out procedure .................................................... 4-18 Magnetic Particle Inspection (MPI) .... 4-14 Nondestructive Examination (NDE) ................... 4-21 Safety valve inspection procedures (IBOP) .................................. 4-23 Torque setting procedure ......................................................................................................................................... 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................................................................................................ 4-20 Ultrasonic Inspection ......... 4-9 DC drilling motor .............................................................................................................................................................................................................. 4-30 Lubricating the rotating head ................... 4-23 Gearbox ..................... 4-7 Directional references .................... 4-8 Chapter 1 Maintenance Inspection ....................... 4-21 Chapter 2 Lubrication Lubricating the motor and motor support bonnet assembly...................................................... 4-32 Lubricating the torque wrench ....................................... 4-14 Landing collar ................................ 4-29 Lubricating the washpipe and bonnet seal .................................. 4-27 Initial oil change period ....................................... 4-14 Visual inspection.......................................... 4-8 Manual layout................ 4-31 Lubricating the link adapter .... 4-33 Lubricating the master bushing ID wear guide ........................................................ 4-12 Motor alignment cylinder .............

.................. 4-71 Replacing the powered rotating head glyd rings ............ 4-97 viii TDS-4S Contents ............................ 4-62 Torque wrench disassembly . 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ................ 4-44 Lubricant specifications ...................................................................................................................... 4-82 Front jaw .................. 4-68 Replacing the standard rotating head glyd rings ....................... 4-82 Removing the motor assembly from the guide dolly......................................... 4-62 Pipehandler ......... 4-52 Adjusting the counterbalance system ................ 1998 Lubricating the safety valve actuator ............. 4-35 Lubricating the guide dolly assembly ..................................................................................................... 4-60 Assembly and disassembly ................................ 4-82 Upper safety valve (IBOP) .. 4-62 Replacing the torque wrench clamping piston seal . 4-95 Safety wiring tips .. 4-81 Removing the jaws ....................................................................................................................................................................................................................October 20..................................................................... 4-42 Lubrication schedule ................... 4-49 Adjusting the torque wrench ......................................................... 4-54 Precharging the counterbalance system ........... 4-92 Replacing the safety wiring ............................................................................................................................... 4-45 Chapter 3 Maintenance Adjustment procedures .................................................................... 4-82 Rear jaw ....................... 4-84 Installing the TDS motor pinion ............. 4-89 Closed loop cooling system assembly/disassembly .. 4-87 Local blower cooling system assembly/disassembly .......... 4-36 Lubricating the bail pins .......................................................................... 4-41 Lubricating the cooling system ............................................................. 4-81 Rear jaw ... 4-75 Replacing the standard or extended reach link tilt air actuator ........... 4-34 Lubricating the upper safety valve (IBOP) ................................................................... 4-82 Lower safety valve (IBOP) ............... 4-52 Adjusting the motor alignment cylinder system ........................ 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system .................................................... 4-77 Removing the tong dies . 4-81 Front jaw .....................................................

............ 4-101 Troubleshooting the transmission ............. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ................................... 4-102 Troubleshooting the oil pump ................................................. 4-110 Six-gang air valve assembly illustration ....................... 4-109 Troubleshooting the crown height indicator ............... 4-101 Troubleshooting the retract guide dolly ......... 4-101 Troubleshooting the motor air brake ......... 4-104 Troubleshooting the pipehandler .......................Chapter 4 Troubleshooting Troubleshooting the counterbalance .... 4-108 Troubleshooting the link tilt .......................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................ 4-111 Book 5 – TDS-4S Control System General description ..... 4-100 Troubleshooting the drilling motor and guide dolly .... 4-99 Troubleshooting the motor alignment cylinder ............... 4-106 Troubleshooting the safety valve actuator........................................... 4-103 Troubleshooting the cooling system .................................................................................................. 4-106 Troubleshooting the torque wrench ...... 5-7 TDS-4S Contents ix ...................

October 20. 1998 x TDS-4S Contents .

TDS-4S Top Drive Drilling System Description SM00620-1 .

October 20. 1998 1-2 TDS-4S Description .

. 1-40 Saver and crossover subs......................................................................................................... 1-38 Link adapter .......................................... 1-20 Two speed transmission ..... 1-28 Local blower ................................................................................................................................................ 1-28 Closed loop .... 1-40 Safety valve actuator ........... 1-48 Link tilt controls ............................................................ 1-51 TDS-4S Description 1-3 ........................... 1-45 Standard and extended reach pneumatic link tilt mechanisms ......................................................... 1-24 Powered rotating head ....... 1-32 Guide dolly assemblies ........................................................ 1-6 Chapter 1 Introduction General description ............... 1-26 Cooling systems ................................................ 1-22 Standard rotating head ...... 1-5 Directional references ................... 1-20 Integrated swivel bail and swivel washpipe ............................ 1-50 Counterbalance system . 1-26 Rotating head controls ................... 1-34 Motor alignment system ......... 1-42 Link tilt mechanisms.....................................Contents Preface/Manual conventions Safety information ............................................ 1-30 Remote blower ....................... 1-45 Hydraulic link tilt mechanism .................................................................... 1-39 Safety valves (IBOP) .................................................................................................................................................................................................................................................... 1-19 Drilling motor .... 1-48 Elevator links ....................................................................................................... 1-37 Pipehandler ............. 1-7 Chapter 2 Major component description Motor housing assembly .................................................................................................................................. 1-6 Manual layout.......................................................................................... 1-40 Torque wrench ..........................................

..............October 20............................................................................................. 1-57 Master bushing ID wear guide ......................... 1-70 1-4 TDS-4S Description ........................................................................ 1-69 Electrical equipment accessories ....................................................... 1998 TDS Control System (TDCS) ..................................................................................................... 1-53 Transfer control panel ............... 1-68 Fluid loop ........................... 1-67 Service loop kits ...................C....................................................... 1-59 Wireline adapter ............................. 1-68 Control loop ........ 1-58 Swiveling drill collar dolly ................................................ 1-68 Power loop (non-regulated areas) ....... 1-70 European standard zone 2 area-EExd ............................................................................................................................ 1-65 Main gearbox lube system ..E............ 1-65 Cooling systems .... 1-54 Purge control system ........................................... Division II -N.............. 1-66 Guide dollies ................. 1-54 Service loops ... 1-60 Crown height indicator ................................... 1-66 Closed loop ............................................................. 1-55 Derrick electrical termination kit . 1-56 Auxiliary equipment ............................................................. 1-66 Local blower * .......... 1-62 Chapter 3 Specifications Drilling motor ........ 1-66 Derrick mounted remote blower * ............................ .................... 1-67 Pipehandler ............. 1-70 API Class I........................................................................... 1-53 Varco Driller’s control and instrumentation Console (VDC) ......................................................................................

Preface Manual conventions Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information. See the examples below and pay close attention to these important advisories. inspecting. a warning. Avoid personnel injury and equipment damage by reading this manual and related documents before operating. TDS-4S Description 1-5 . n Indicates advisories involving a definite risk of injury to rig personnel. or servicing the equipment. z e Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. or a caution note. Indicates advisories involving a risk of equipment damage.

1998 Directional references References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S).October 20. standing behind the TDS-4S as it faces well center. 1-6 TDS-4S Description . Manual layout This binder contains several separate books that you can remove individually for convenience.

The TDS does not interfere with the existing conventional equipment. eliminating two thirds of the conventional single-pipe drilling connections. and a 45 ft. kelly. until the advent of top drive drilling systems.Chapter 1 Introduction General description Oil well drilling with a rotary table. and the running of casing as well as providing 90 ft. This manual describes the function and maintenance of the TDS-4S. which integrates the drill pipe connection handling and drive systems with the drilling swivel. This method of handling pipe and joint makeup remained unchanged. kelly was the industry standard for years. master bushing. TDS-4S Description 1-7 . The TDS (Figures 1-1 and 1-2) provides the rotating power of a conventional rotary table drive while eliminating the need to “pick up” the cumbersome swivel/kelly combination. rotation. Varco produces several Top Drive Drilling Systems (TDS) to rotate the drill string and allow adding entire 93 ft. apart from minor improvements such as kelly spinners. circulation. drawworks cathead. For decades. pipe tongs. kelly drive bushing. It allows tripping. drillers extended the drill string with the “making-a-single-connection” process using the rotary table. bowls. stands of pipe. and slips. back reaming capabilities to reduce the chance of stuck pipe.

Typical TDS-4S overall view 1-8 TDS-4S Description .October 20. 1998 Guide Dolly Assembly Motor Housing Assembly LO Pipehandler Assembly Figure 1-1.

... Motor Pinion Gear ... ........... . ......... .. .... ................... ........ .. . ... .. ... ......... ..... .... .. ........ .................. . Integrated Swivel Bail Counterbalance Cylinder (2) Gooseneck Air Brake Standard Washpipe Packing Motor Support Bonnet Swivel Bearing .. ........ .. ... . . ... ........... . .......... ... .... .......... .... .. ........ . .......... . ......... .. ... ... ........... . ....... . ..... ....... ...... ........ ........... ........... ..... ................. ........... ... ..... .. .... ............ ......... .. . .. . .. . ..... ........... ... ...... ...... ...... ..... ... ............. ...................... ........ ... ........ Connecting the TDS integrated swivel bail directly to the traveling block or motion compensator frame can eliminate the drilling hook and shorten the TDS working height further...... .. Upper Gearcase Low Gear (Engaged) ....... ....... ...... .......... ...................... ......... .......... ...... ....... .... ... .............. . .... ............ . ......... . .. ................................ .........The TDS integrated swivel bail connects directly to a drilling hook...... ......... ........... .... .. ... ... ... .. .......... . .. .... ............. . ................ ......... ..................... .... ....... ............... .......... ........ . ... ................... . .... .... . .................. . .. ... .. . .... . ..... .. ................ ... ...... ................ .. .. .... ......... .... ..... .. .... ........................ ............. . ........ ......... ...... .. .... ..... ..... . . .......... ........ ....................... .......... .......... .......... ... .. .. .. ....... ... .. ....... .............. ..... ... ................. ........... . . .. ....... .......... ..... ... ..... ........ ... ..... . .... ....... .. .. .... ............. . .............. .......... ... ....... . .. ............ . ........ TDS-4S motor and swivel housing assembly TDS-4S Description 1-9 .... .. ... . .... . ......... ........... ... .. ........... .... ........ ... ........ ........... .. ............. . . DC Drilling Motor ....... .................... ....... . ................ ..... ......... . . .. .............. .... .... .. .... ... ........... ..... ... . ... ................ .. .......... .... ........ . .. .... .... ..... ... Bull Gear ....... . .. ......... .......... .... ........................ .... ... .. ........ . ...... . ........... ............. .... . ..... .............. .................. ..... .................. ..... .......... .. .. ..... .. ...... ........... ........ .. ... ................... . .. .. .... ..... . .... ...... ... ... ...... ........... .. ......................... .......... ......... . .. ......... ... .. .............. High Gear (Disengaged) Rotating Head Main Shaft/Drive Stem Lower Gearcase Figure 1-2...... . .. ..... ..... ... ............ . . .......... . . ..... ... .......... .. . ........ .. ...... ... ... .. ................................................. ..... .......... .... . ........... ........ ...... . . . .... .... ... . ....... . .... ..... ... ...... ...... .. ... . . ........ ... ......... . ..... .... .... ....... ........ ... ..................... .. .... ... ............. ........... ..... ................ ........ .. ... . .................. ... .... ............ . . .... . ........ ... ..... .... ................ ........ . .......... ......... ........... ......... .. .. ..... ............. ............ . .. .......... .. ... ..... ... ..... . .... . ... ............. .... ..... . ........... ................ .. ............. ......... ....... .... .............. .. . ... ...... ......... .......... .... .... .... .. ........ . ............. . .............. .... ....... ... ...... ... .... ............. ....... .. ......... ............. ...... ...... ..... ..... .............. .................. .... ... .. ...... ... . .... ...... ..... ... ... ..... ......... ...... ..... . ........ ............ ... ..... . . ... ................ ............ ........ ....... ............. ........ ....... ..... ............ ...... ..... ... . .. . ........... ............... ..

The motor frame/guide dolly attaches to the motor housing assembly.October 20. The DC motor bolts to an upper assembly of the gearcase. The vertical rails react the motor torque during drilling operations and keeps the TDS positioned over wellcenter. The entire assembly moves vertically on two rails installed in the derrick. located next to the stem. 1-10 TDS-4S Description . 1998 The integrated drive stem functions as the main output shaft driving the drill string. rotates the stem. called the motor support bonnet. The electric drilling motor and transmission. The pipehandler assembly (Figures 1-3 and 1-4) can make or break drill pipe at any height in the derrick.

Rotating Head (Part of the Motor Housing Assembly) Torque Arrestor (4) Link Adapter (Also know as: Solid Body Elevator) (Landing Collar Inside on Main Shaft/Drive Stem) Pneumatic Link Tilt Upper IBOP Valve Actuator Splined Upper IBOP Valve Lower IBOP Valve (Inside Torque Tube) Torque Wrench 350-Ton 108 in. PH-85 pipehandler assembly TDS-4S Description 1-11 . Typical 650-Ton. Link (2) (Optional Varco Equipment) Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment) Figure 1-3.

650-Ton. 350-Ton Links (Optional Varco Equipment) Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment) Figure 1-4. PH-60d pipehandler assembly 1-12 TDS-4S Description . 1998 650-Ton Rotating Head (Part of Motor Housing Assembly) Torque Arrestor (4) Link Adapter (Also known as Solid Body Elevator) (Landing Collar Inside On Main Shaft/Drive Stem) Pneumatic Link Tilt Safety Valve Actuator Lower IBOP Valve (Inside Torque Tube) Splined Upper IBOP Valve Torque Wrench 108 in.October 20.

Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar Upper IBOP Valve Actuator Air Cylinder (2) Crank Assembly (2) Actuator Arm (2) Safety Valve Actuator Shell Upper IBOP Torque Tube Lower IBOP Saver Sub Drill Pipe Figure 1-5. Safety valves (IBOPs) and actuator assembly TDS-4S Description 1-13 . The driller can close the upper IBOP at any position in the derrick from the driller’s control console.Internal Blow Out Preventor (IBOP) valves connect to the end of the drive stem (Figure 1-5). A second. lower IBOP can be manually closed and sent downhole while controlling a kick.

1998 The drive stem passes through the link adapter. and optional cooling water services to the TDS. This directs the hoisting load through the drive stem. The Major component description chapter of this book describes each of these assemblies. The fluid service loop provides the hydraulic. the link adapter is pulled down onto the landing collar due to the added weight of the drill string.October 20. pneumatic power. 1-14 TDS-4S Description . motor housing assembly. When hoisting. A drill pipe elevator hangs from a pair of conventional links that attach to the link adapter. The electric service loops provide DC power and AC power/control. Actuating the link tilt swings the elevator out to facilitate picking up pipe. Subsequent books provide more information on the equipment specific to your rig configuration. The torque arrestors keep the link adapter above the landing collar on the drive stem when drilling (Figures 1-6. and swivel bail. 1-7 and 1-8).

650-Ton rotating head.Rotating Head (Part of Motor Housing Assembly) Link Adapter (Also known as Solid Body Elevator) Torque Arrestors (4) Figure 1-6. link adapter and torque arrestors TDS-4S Description 1-15 .

October 20. 650-Ton. 350-Ton Links (Optional Varco Equipment) Safety Valve Actuator Torque Wrench Lower IBOP Valve Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment) Saver Sub Figure 1-7. PH-85 pipehandler in relation to other TDS assemblies 1-16 TDS-4S Description . 1998 Pneumatic Link Tilt 650-Ton Rotating Head (Part of Motor Housing Assembly) 650-Ton Link Adapter (Also known as Solid Body Elevator) Torque Arrestor (4) Link Adapter Support Plate Upper IBOP Valve 108 in.

350-Ton Links (Optional Varco Equipment) Safety Valve Actuator Torque Wrench Lower IBOP Valve Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment) Saver Sub Figure 1-8. 650-Ton. PH-60d pipehandler in relation to other TDS assemblies TDS-4S Description 1-17 .Pneumatic Link Tilt 650-Ton Rotating Head (Part of Motor Housing Assembly) 650-Ton Link Adapter (Also known as Solid Body Elevator) Torque Arrestor (4) Link Adapter Support Plate Upper IBOP Valve 108 in.

October 20. 1998 1-18 TDS-4S Description .

Chapter 2 Major component description Motor housing assembly The motor housing assembly is composed of the following: t Drilling motor and brake t Two speed transmission t Rotating head t Integrated swivel and washpipe TDS-4S Description 1-19 .

2. full complement roller bearing on one end and a spherical roller bearing on the other end.October 20. 1-20 TDS-4S Description .100 hp DC drilling motor. 1998 Drilling motor The drilling motor on the TDS is a 1. Please refer to the specifications included later in this book for additional details.0 diametral pitch t High range compound gears – 27 tooth and 30 tooth t Low range compound gears – 23 tooth and 40 tooth t Motor pinion gears – 21 tooth t Geneva transmission shifter mechanism (Figure 1-9) t Main body and lower gearcase t Main shaft/drive stem t Bonnet t Swivel bearing The compound gears mount to their eccentric shafts with a tworow. It is remotely operated by a solenoid valve. the motor features a double-ended armature shaft and thrust bearings for vertical operation. Two speed transmission The two speed transmission consists of the following major components: t Bull gears – 96 tooth. There is an air brake on the motor to hold torque in the drill string to assist in directional work. Mechanically.

Transmission/geneva mechanism LO Shifter Input HI TDS-4S Description 1-21 .Rotating Head Assembly Shifter Input Shaft External HI / LO Indicator Compound Gear Shafts Bottom View Low Gear Eccentric Shaft (Disengaged) High Gear Eccentric Shaft (Engaged) Geneva Mechanism Top View Figure 1-9.

October 20. 1998 Lubrication to the bearings and gear meshes is force fed by an electrically driven gear pump externally mounted on the gearcase (Figure 1-10). it takes five turns of the input shaft to unlock both gear sets. After pushing inward on the male hex. fully ribbed for added heat dissipation. rotates the input shaft. rotate the disengaged gear set into full engagement. male hex at the bottom of the transmission case (Figure 1-9). A 1 in. 1-22 TDS-4S Description . the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. and locks both gears. It carries its own latching mechanism and provides the security of a double lock on the compound shafts. rotates. internally splined geneva slave. and lock both gear sets in their proper positions with positive stops in the locked position. A common geneva master sequentially unlocks. The two compound shafts (high and low) are supported on heavy trunnions between the main body and lower gearcase halves. Integrated swivel bail and swivel washpipe The integrated swivel bail is a bearing assembly that allows transfer of the rotating load to the lifting components (Figure 1-2). Each compound shaft carries a large. The swivel washpipe is a rotating seal that allows mud to flow to the rotating drill string. The transmission shifts gears by rotating two vertical compound gear eccentric shafts. An external indicator shows the gear range selection. The lower gearcase is a heavy duty steel casting. As the shafts rotate (less than one-half turn). rotate the engaged gear set to full disengagement. The master rotates using a reduction gear set with a vertical manual input shaft.

Lower Radial Shaft Bearing Motor Pinion Gears Side View Bull Gears Inlet Compound Shafts (Not Visible) Bull Gears Motor Pinion Gears LEGEND Pressure Tap Bottom View Fabricated Drilled Figure 1-10. Transmission lubrication system TDS-4S Description 1-23 .

The rotating head assembly consists of: t Stationary flange t Eight rotary glyd rings t Swivel block t Cam t Auto-return cylinder t Cam follower t Swivel block locking mechanism The hydraulic and air lines for the various pipehandler functions (air link tilt. The auto-return cylinder is hydraulically connected to the counterbalance manifold. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt. It features two hydraulic passages. etc. The fluids travel from the flange to the swivel block via sealed rotating passages. etc.) run from their respective solenoid valves to the stationary flange. torque wrench. There is also an auto-return cylinder mounted on the stationary flange.October 20. The glyd rings maintain the seal between the passages. The rod end of the cylinder connects to a cam follower assembly that tracks the cam mounted to the swivel block. three pneumatic passages. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block.500 psi). and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2. 1998 Standard rotating head The standard rotating head allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head (Figure 1-11).). The swivel block rotates relative to the flange without twisting or damaging any hoses. 1-24 TDS-4S Description .

Cam Stationary Flange Cam Follower Locking Lever Auto-Return Cylinder Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown) Figure 1-11. Standard 650-Ton rotating head assembly TDS-4S Description 1-25 .

1-26 TDS-4S Description .). The ROTATING HEAD LEFT/RIGHT switch rotates the rotating head.) run from their respective solenoid valves to the stationary flange.000 psi). The hydraulic motor assembly mounts to the swivel flange which engages a compound gear. driven by a pinion gear on the hydraulic motor shaft. The fluids travel from the flange to the swivel block via sealed rotating passages. five pneumatic passages. and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2. The glyd rings maintain the seal between the passages. and link tilt to the right or left (same direction as the drill string).October 20. etc. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt. etc. Two switches on the driller’s control panel control the hydraulic motor. It features three hydraulic passages. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. torque wrench. The swivel block rotates relative to the flange without twisting or damaging any hoses. The rotating head assembly consists of the following components: t Stationary flange t Eleven rotary glyd rings t Swivel block t Bull gear t Hydraulic motor assembly t Proximity sensor and adjustable targets The hydraulic and air lines for the various pipehandler functions (hydraulic link tilt. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. 1998 Powered rotating head The 10-port powered rotating head (Figure 1-12) allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head. pipe handler. The AUTO STOP/FREE ROTATE switch controls the powered rotating head operating mode. Rotating head controls The powered rotating head has two switches.

Stationary Flange Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly Bull Gear S1 A1 H1 PRESSU A1 S2 RE A5 H2 S2 A2 H3 A3 H2 S1 Figure 1-12. Powered rotating head assembly TDS-4S Description A2 H1 A3 H3 A5 A4 A4 1-27 .

3.450 rpm AC electrical motor directly drives the impeller in the blower housing. above the rig floor at the lowest point of the motor’s travel. An optional flexible duct connects the blower housing to the extended intake mounted on the traveling equipment. It receives air approximately 27 ft. 1-28 TDS-4S Description . These components hinder the egress of any air born sparks from the DC motor.October 20. An explosion-proof 20 hp. 1998 Cooling systems Local blower The local blower cooling system with an optional extended intake provides local cooling air to the drilling motor (Figure 1-13). Two spark arrestor assemblies are mounted on the exhaust ports of the upper gearcase.

Typical local blower cooling system TDS-4S Description 1-29 .Axial Fan 20 hp Blower Motor Locking Key Blower Housing Gasket Transmission Cooler Oil Fittings (2) Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket FLL-X Duct Connection Point Mounting Plate Blower Duct to AC Drilling Motor Spark Arrestor Figure 1-13.

The heat exchangers are built from Cupro-Nickel tubes and the headers are pressure tested to 250 psi. Ducting directs air out the motor exhaust port to the heat exchangers and back to the blower inlets.October 20. chilled fresh water or glycol) at 100 gpm at a maximum inlet temperature of 90°F. and a purge control system (refer to TDS Control System information provided later in this chapter) monitors system pressure to insure safe operation. The system requires a supply of liquid coolant (sea water.0 psig is also required to provide positive system pressure. Purge air at a rate of 70 scfm per motor at 1. 1998 Closed loop The closed loop cooling system (Figure 1-14) consists of two air/ water heat exchangers cooled by twin blowers driven by a double ended AC motor. 1-30 TDS-4S Description .

Typical closed loop cooling system TDS-4S Description 1-31 . Flex Connection (2) Blower Inlet (2) Water Connections DC to Motor Exhaust Port on Upper Gear Case Inspection Cover GE Drilling Motor Heat Exchanger (2) Figure 1-14.Dual Shaft 20 hp AC Blower Motor Blower Mount/ Brake Cover Blower Housing (2) Impeller (2) 8 in.

October 20. A pressure switch monitors the motor air inlet pressure to verify blower operation. Air is drawn in from outside the wind wall. The contacts of the pressure switch are usually wired into the SCR assignment logic for the drilling motor. 1998 Remote blower The remote blower motor cooling system consists of a motor and pressure blower mounted in the derrick at racking board level (Figure 1-15). 1-32 TDS-4S Description . and exits through spark arrestors attached to the air outlets of the motor. A moisture separator is attached to the blower inlet duct to prevent water from entering the motor. through a flexible duct into the top of the drilling motor.

Typical remote blower cooling system TDS-4S Description 1-33 .Air Inlet 40 hp Explosion Proof Electric Motor (AC) and Centrifugal Pressure Blower Wind Wall Racking Platform at Racking Board Level Rigid Cooling Duct Spark Arrestor Motor Dolly Assembly 86' Flex Air Duct Figure 1-15.

The standard guide dolly assembly consists of two frames connected by hinges on the pivot side and hold-down bolts on the other (Figure 1-16). Centralized lubrication manifolds provide roller lubrication. Non-swing retract guide dollies use hold-down bolts (swing bolts) on both sides (Figure 1-17).October 20. One frame attaches to the motor housing assembly and includes attachment points for the service loops and rotary hose. 1-34 TDS-4S Description . The other frame includes the guide rollers and remains in the guide rails during all normal operations. 1998 Guide dolly assemblies The guide dolly assembly transmits the drilling torque reaction to the guide rails keep the TDS positioned over wellcenter and can provide a method for setting the entire unit aside for maintenance or to allow rig operation without the TDS if necessary.

Motor Frame Guide Dolly Frame Hinge Pin (2) Hold-down Bolt (Swing Bolt) (2) Figure 1-16. Typical swing guide dolly assembly TDS-4S Description 1-35 .

Typical retract guide dolly assembly 1-36 TDS-4S Description .October 20.0" Figure 1-17. 1998 Upper Stabilizer Arm Motor Frame Guide Dolly Frame Retract Cylinder Lower Extend/Retract Arm LEGEND Intermediate Frame Extended Mode Retracted Mode 45.

hydraulic accumulator. It connects to an accumulator circuit located on the guide dolly. Motor alignment cylinder TDS-4S Description 1-37 . Motor Alignment Cylinder Shipping Brace Motor Frame Dolly (Ref) Figure 1-18. and related hardware. while allowing the motor housing assembly to float slightly about its trunnions. pressure reducing valve manifold. The accumulator is charged with nitrogen and maintained at a predetermined pressure setting by the alignment cylinder manifold. The duplex cylinder attaches between the bottom of the lower gearcase and the motor frame.Motor alignment system The motor alignment system consists of a duplex cylinder. Figure 1-18 shows the motor alignment cylinder installed in a typical motor frame. The duplex cylinder maintains a wellcenter orientation for the swivel stem when disconnected from the drill sting.

drilling pipe stands t Providing up to 85.000 ft lb torque) The pipehandler can be configured for various tool joint connections. It also incorporates a remote IBOP valve actuator and link tilt mechanism. the pipehandler is free to rotate 360°. 1998 Pipehandler The main components of the pipehandler include the following (Figures 1-3 and 1-4): t Link adapter t Safety valves (Upper and Lower IBOPs) t IBOP valve actuator t Torque wrench t Link tilt mechanism The pipehandler provides two basic functions for the TDS: t Tripping 93 ft. When not in use. emulating the action of a standard hook. When tripping or performing bottom hole operations.000 ft lb torque for makeup and break-out of connections at any height in the derrick (the PH-60d provides up to 60.October 20. the pipehandler remains stationary and free from the drill string passing through it. It includes a link adapter and a special-purpose Varco torque wrench assembly. 1-38 TDS-4S Description .

The torque arrestors contain compression springs capable of supporting any stand of drill pipe in the full up position. The drive stem is free to rotate inside the link adapter while drilling. working in conjunction with the torque arrestors.Link adapter The link adapter (solid body elevator) and the elevator links (Figures 1-7 and 1-8). transfer the hoisting loads to the drive stem. springs inside the torque arrestors compess to transfer the load to the drive stem by pulling the link adapter down onto the landing collar. The link adapter does not rotate with the drive stem because torque arrestors raise the link adapter up off the load supporting landing collar located on the drive stem. When hoisting loads. TDS-4S Description 1-39 . The link adapter rotates with the rotating head–which is required for tripping operations.

1-40 TDS-4S Description . e Saver subs are load bearing components in the TDS and must be inspected periodically along with other load bearing components. and parts information. The air cylinders are operated remotely by a solenoid valve controlled by an electrical switch at the VDC.October 20. The actuator arm connects to the valve actuator shell and moves the actuator shell up or down (Figure 1-19). Saver sub threads can be recut to a minimum shoulder-to-shoulder length of 5 in. A slot in the actuator shell engages the crank assemblies. maintenance. Refer to the Maintenance and Troubleshooting book for more information. The crossover sub converts the lower IBOP pin to a box connection for well control procedures with standard pipe. installation. operation. refer to the IBOP Service Manual. Saver and crossover subs Each pipehandler ships with two saver subs and one crossover sub. 1998 Safety valves (IBOP) The Varco pipehandler includes two Internal Blowout Preventor safety valves (IBOPs) to provide blowout prevention. Safety valve actuator The remotely operated upper IBOP valve actuator allows upper IBOP actuation at any height in the derrick. which opens or closes the IBOP. before the sub must be discarded. The upper IBOP actuator system consists of the following: t Two pneumatic air cylinders t Two actuator arms t Actuator shell t Two crank assemblies t Two pneumatic solenoid valves Double-acting air cylinders move the actuator arm. For detailed descriptions. Saver subs (Figures 1-7 and 1-8) are dual pin subs used to preserve the threads on the lower IBOP and provide a pin for the box end of the drill string.

Safety valve actuator system TDS-4S Description 1-41 .Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar Upper IBOP Valve Actuator Air Cylinder (2) Crank Assembly (2) Actuator Arm (2) Safety Valve Actuator Shell Upper IBOP Torque Tube Lower IBOP Saver Sub Drill Pipe Figure 1-19.

diameter clamping piston for gripping the box end of the drill pipe. The torque wrench assembly consists of the following components (Figures 1-20 and 1-21): t t t t t t t t t t t Hanger Torque tube Torque tube guide ring Two torque cylinders Two clamping jaws Two clamping pistons Control manifold Lift cylinder Two stop tubes Stabbing guide IBOP actuator cylinders and arms A hanger attached to the rotating head supports the torque wrench. another sequence valve automatically opens and directs pressure to the torque cylinders. One electrical push button on the VDC controls the entire torque wrench operation. The torque wrench has two torque cylinders connected to the torque tube.000 ft lb for PH-60d). The torque wrench can also make up or break out the saver sub or the lower IBOP.October 20. The driller then releases the button to allow the unit to automatically recycle to the ready position. The driller simply holds the button down until the connection is made or broken. The torque cylinders can rotate up to 25° while developing a maximum torque of 85. A two-position. A manually operated valve on the rear of the pipehandler selects either the make up or break out function. the torque wrench rises and engages the splines on the upper IBOP. The clamping jaw contains a 10 in.000 ft lb (60. After the clamping pressure develops. It then receives sequenced pressure to clamp the clamping piston on the box connection. On the lower section of the upper IBOP. 1-42 TDS-4S Description . 1998 Torque wrench The torque wrench provides a means for making and breaking out connections with the drive stem. air piloted hydraulic valve located on the counterbalance manifold controls the cycle. a female spline engages the mating male spline on the lower IBOP contained inside the torque tube. When actuated.

IBOP Actuator Hoses (Air) Hanger Torque Wrench Hoses (Hydraulic) IBOP Actuator Air Cylinders Lift Cylinder IBOP Actuator Arms Torque Tube Clamping Jaw (Inside Clamp Body) V a r c o Stop Tube (2) Control Manifold (Hidden) Stabbing Guide Torque Cylinder (2) Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible) Figure 1-20. PH-85 torque wrench assembly TDS-4S Description 1-43 .

October 20. PH-60d torque wrench assembly 1-44 TDS-4S Description . 1998 IBOP Actuator Hoses (Air) Hanger Torque Wrench Hoses (Hydraulic) Lift Cylinder IBOP Actuator Air Cylinders IBOP Actuator Arms Torque Tube Stop Tube (2) Clamping Jaws (Inside Clamp Body) Control Manifold (Hidden) Torque Cylinder (2) Stabbing Guide Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible) Figure 1-21.

TDS-4S Description 1-45 . A switch on the VDC controls a pneumatic solenoid valve that inflates an air spring within the lifting frame. tilting the links outward. A standard reach link tilt will extend links 52 in. Extended reach link tilt mechanisms have two air springs and extend 76 in. elevator links. This assembly consists of a pivoting lifting frame connected to the drilling elevator links with chains and clamps.Link tilt mechanisms Standard and extended reach pneumatic link tilt mechanisms The standard (Figure 1-22) and extended reach (Figure 1-23) link tilt assembly allows: t The elevators to move off of well center to pick up a stand in the mousehole. t The derrickman to handle pipe more easily. An adjustable intermediate stop mechanism provides clearance between the drill pipe elevator and the monkey board to assist the derrickman in racking operations. The link tilt assembly mounts on the front of the solid body elevator (link adapter). Both reaches are based on 108 in. Inflating the air spring pivots the frame upward.

October 20. 1998 Lifting Frame Intermediate Stop Air Actuator D/P Elevator Link Clamp Intermediate Stop Release Figure 1-22. Standard pneumatic link tilt mechanism 1-46 TDS-4S Description .

Lifting Frame Double Air Actuator Intermediate Stop Intermediate Stop Release D/P Elevator Link Clamp Figure 1-23. Extended reach pneumatic link tilt mechanism TDS-4S Description 1-47 .

The link tilt assembly mounts on the front of the link adapter (solid body elevator).October 20. During operation. from well center. and adding stands (available only on PH-85 models). The positions are RETRACT. 1-48 TDS-4S Description . the elevator backs away from well center. The link tilt uses dual hydraulic cylinders. based on 108 in. Full link tilt extension moves drill pipe approximately 78 in. 1998 Hydraulic link tilt mechanism The hydraulic link tilt assembly (Figure 1-24) provides lateral movement of the drill pipe elevator to a position above the mousehole or toward the monkeyboard. The link tilt also enables retracting the open drill pipe elevator from the drill pipe while drilling. HOLD This setting holds the position of the elevators extended or retracted. EXTEND This setting extends the elevator forward to the mousehole through wellcenter. and EXTEND. links. RETRACT In the RETRACT position. tripping. the operator can stop link tilt movement at any position and hold the supported load in place. Link tilt controls The link tilt is controlled by a four-position switch. A 1/2-second delay is programmed into the FLOAT function to allow the control switch to travel from the RETRACT position to the HOLD position without activating the FLOAT. HOLD. FLOAT FLOAT returns the elevators to well center from the retracted or extended position. FLOAT.

Hydraulic link tilt TDS-4S Description 1-49 .Passive Stop Assembly (2) Cylinder Assembly (2) Link Tilt Arm Figure 1-24.

. 1998 Elevator links Varco elevator links attach to the link adapter and support the drill pipe elevator.October 20. 350-Ton elevator links t 180 in. 350-Ton elevator links t 132 in. providing 120 in. 500-Ton elevator links (special long links for running casing. Elevator link options include: t 108 in. of clearance for cementing heads) 1-50 TDS-4S Description ...

It is a pre-adjusted system. The driller continues to lower the TDS until the saver sub touches the box of the new stand. The system (Figure 1-27) consists primarily of two hydraulic cylinders. the HPU is “on” when using the torque wrench for breaking out the top drive at the floor and is left on while making up the next stand. The system also incorporates a complete backup. The two accumulators. The hydraulic cylinder assemblies connect the integrated swivel bail and the traveling equipment (hook. becket. and two hydraulic accumulators. The counterbalance cylinders support the remainder of the TDS weight. It provides cushioned stroke similar to that provided by the hook. The driller then spins in and torques up the connection with the pipehandler assembly and is ready to drill ahead. block. hook adapter. constantly maintained at system pressure. of travel. The counterbalance system prevents damage to the threads of the saver sub and drill pipe by offsetting the weight of the top drive while stabbing into a connection. TDS-4S Description 1-51 . are always able to provide pressure to the counterbalance cylinders if the HPU is “off ” or non-operational for any reason.). etc.Counterbalance system The counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS. the counterbalance system supports all but about 800 lb of the weight of the top drive over a full 8 to 10 in. For normal operation. a counterbalance manifold. When adding a stand to the string during drilling operations. the driller takes a stand in the elevators and stabs it into the box in the rotary table. the HPU can be turned off and restarted again for breaking out the connection at the floor after drilling the stand down. When properly adjusted. Once drilling resumes. however. At this point. only about 800 lb load is on the saver sub/drill pipe connection. Note that the driller does not have to do anything extra to get the counterbalance system to function properly.

October 20.970 lb 18. Counterbalance system 1-52 TDS-4S Description .750 lb Typical System Weight Counterbalance Manifold 800 lb Weight on Threads Hydraulic Power Supply Rig Floor Fluids Service Loop Figure 1-27. 1998 Stabbing Mode: Top Drive Lowered Past Thread Contact Guide Dolly Assembly 18.970 lb Hydraulic Cylinders (2) Hydraulic Accumulators (2) 38.

A typical VDC also contains indicator lights for determining the status of: t The brake t The remotely controlled upper IBOP valve t The oil pump t Blower pressure loss t Cooling air temperature t The purge system(s) Optional controls and status indicator lights are available. The basic TDS control functions are: t Link tilt t Remotely controlled upper IBOP valve t Motor brake t Motor spin-torque control t Makeup torque limit t Transfer switch (TDS/ROT) The existing rotary table controls adjust motor speed.TDS Control System (TDCS) The TDS Control System (TDCS) provides the driller with a control console that operates all of the TDS functions. an RPM meter and various switches and indicator lights. torque and direction while drilling. TDS-4S Description 1-53 . Refer to Engineering Drawing 98952 for VDC configurations. The components of the TDCS include: t Varco Driller’s control and instrumentation Console (VDC) t Transfer control panel (TP) t Purge control system for closed loop cooling systems Varco Driller’s control and instrumentation Console (VDC) The Varco driller’s control and instrumentation Console (VDC) consists of a torque meter.

and TDS closed loop cooling system have separate purge systems. The transfer panel has a purge control system for use in a hazardous area (Zone 2 or Class 1. Purge control system The transfer panel. If the panel is in the SCR room. The Transfer control panel switches power between them. 2 hazardous areas. Div. All systems provide positive internal pressure to prevent hazardous gases from entering areas of potential ignition in Zone 2 or Class 1. Logic and alarm functions are connected to the TDS by programming the transfer panel’s Programmable Logic Controller (PLC) to operate the rig’s existing systems. Status lights on the VDC indicate to the driller correct purge pressure. Div. 1998 Transfer control panel The TDS operates from the same SCR as the rotary table. Pressure switches in the protection units monitor the pressure and provide an alarm signal in the event of purge pressure loss. the isolation unit can be set to shut down the TDS. the purge control unit purges the system for a specific time interval sufficient to remove any trapped hazardous gas. Similarly. VDC. loss of purge and system purging.October 20. New cables run from the TP to the rotary table motor and to the racking board junction boxes for the TDS. The DC power cables running from the SCR to the rotary table motor are disconnected from the rotary table and connect to the transfer panel. The panel is compatible with all currently installed SCR systems and is configured at installation for the SCR it will control. 2). the auxiliary AC components and the rig instrumentation interfaces for recording torque and speed of the TDS. such as spin-up and makeup speeds. a purge system is not required. 1-54 TDS-4S Description . are programmed into the PLC and are the same for all installations. the programmable controller. TDS interlocks and limits. If purge pressure loss alarms and indicators are ignored for a preset time interval. This electrical enclosure contains the DC contacts. Prior to starting an unpurged system.

The TDS can use optional dual electrical service loops in order to meet certain regulatory agency requirements for power cable current carrying capacity.Service loops The service loops transfer the required electric and fluid services between the derrick service standpipes and junction boxes. mounting flanges at each end. hydraulic and water lines (water lines included only on units with a closed loop cooling system). The power electrical loop contains four 646 MCM DC power cables. 20 AWG cables as required TDS-4S Description 1-55 . diameter hoses for purge supply 1 1/4 in. and the corresponding junction boxes and fluid connections located on the TDS. diameter hoses for cooling water (closed loop cooling systems only) 1 in. diameter hoses for hydraulic supplies (one is a spare) 1/2 in. and one containing air. The other electrical service loop contains a composite cable consisting of: t 26 14 AWG conductors for auxiliary features t 4 t 2 t 2 8 AWG conductors for blower motor 5 AWG conductors for series motor field supply 14 AWG shielded pairs for the RPM pickup signal The power and ground cables are spiral wound and potted inside a protective cover with 7 1/2 in. diameter hoses for retract cylinder supply and return Additional 7-conductor. The composit cable is pathed in its own smaller service loop. The fluids loop can consists of any combination of the following: t 3 t 2 t 1 t 2 t 2 t 3/4 in. There are two kinds of loops: one containing the electric cables. This allows for easy changeout of either the power loop or the composit loop in the event of a failure. one 2/0 AWG drilling motor ground cable. diameter hoses for air supply (one is a spare) 1 in.

1-56 TDS-4S Description . There are several J-box configurations. 1998 Derrick electrical termination kit This kit consists of all the necessary electrical junction boxes attached to a bulkhead mounting plate. which is then mounted in the derrick to connect the rig electric supplies to the service loop. Each configuration complies with specific electrical codes and regulatory agency requirements throughout the world. depending upon which electrical system is ordered.October 20.

Auxiliary equipment Auxiliary equipment is compatible with all TDS models. All of the equipment is selected or adapted for your specific rig. Below is a list of auxiliary equipment available: t Master bushing ID wear guide t Swiveling drill collar dolly t Wireline adapter t Crown height indicator t Driller’s recorder tranducer kit TDS-4S Description 1-57 .

1998 Master bushing ID wear guide The master bushing ID wear guide centers the rotating drill string and protects the master bushing while drilling ahead (Figure 1-26). The bushings can be changed out to accomodate different size drill pipe. Master bushing ID wear guide 1-58 TDS-4S Description . It hinges open for removal or when setting manual slips. Figure 1-26.October 20.

A Drill Pipe Elevator A 100 TON VARCO Drill Collar Dolly Perfection Links (36") .... The collars can be walked in or out with the elevator turning on the drill collar dolly. A shoulder elevator is suspended from the “perfection” links (or a second drill pipe elevator if lifting subs are used).. Square Shoulder Elevator Lifting Sub 37 in. which latches in the standard drill pipe elevator.. .Swiveling drill collar dolly The swiveling drill collar dolly (Figure 1-27) allows the drill collar elevators to turn freely when handling bottom hole assemblies.. 8 in. mounts on a bearing which allows it to swivel even under load. . Swiveling drill collar dolly TDS-4S Description 1-59 . The drill collar dolly’s upset. . . 91 in..... . Drill Collar View A-A Figure 1-27.

Typical Section through Sheave Figure 1-28.October 20.52 in. 42.1 in. It can be used with a lubricator held in the elevators by using 180 in. Typical PH-85 wireline adapter 1-60 TDS-4S Description . 26. casing elevator links. 23.0 in. 1998 Wireline adapter The wireline adapter (Figures 1-28 and 1-29) attaches to the pipehandler and prevents wireline from interfering and damaging pipe and TDS components.

Wire Rope Dia. or longerCustomer furnished) View A-A Figure 1-29. Sheave Elevator Links (180 in. Torque Wrench Guard (remove for installation) 20 in. Max. Dia.View A-A Top Drive Torque Wrench 9/16 in. longCustomer furnished) Lubricator Wireline Adapter installs in place of Torque Wrench Guard using existing Pins To Mud Manifold Elevator Links (180 in. Typical PH-60d wireline adapter TDS-4S Description 1-61 .

1-62 TDS-4S Description . The integral crown height indicator controls on the VDC are identical to the separate control box.October 20. The system contains four major subassemblies: t A metal target typically located on the Varco block dolly assembly t Two hinged sensor bracket assemblies located on the rear of the guide track t A sensor junction box located in the derrick near the above bracket assemblies t A crown height indicator control box. Two of the indicators display the position of the top of the traveling equipment relative to the crown. position. The red indicator illuminates when the traveling equipment is within five feet of the crown. or an integral control in the driller’s control and instrumentation console The Crown Height Indicator Control (CHIC) control box (Figure 1-30) contains three indicator lights and an electronic printed circuit board. 1998 Crown height indicator The crown height position indicator is a self-contained electronic instrument which determines the position of the traveling equipment with respect to the derrick crown. The yellow indicator on the CHIC control box illuminates when the top of the traveling equipment is within ten feet of the crown. The green indicator illuminates when correct DC system power is available. The third indicator displays system power status. When the traveling equipment is within two feet of the crown both indicators flash alternately. This indicator also contains a push-to-test button which simulates the 2 ft.

CROWN CLEARANCE 2 FEET WHEN FLASHING IBOP CLOSE BRAKE ON R 5 FEET IBOP CLOSE OPEN BRAKE OFF ON Y 10 FEET ACTIVE/TEST TORQ. WRENCH PUSH & PULL LINK TILT OFF ON G ACTIVE/TEST Purge Air out to Protection Unit VDC Independent Controls Figure 1-30. Typical CHIC control box TDS-4S Description 1-63 . WRENCH PUSH & PULL LINK TILT OFF ON G Integrated Controls IBOP CLOSE BRAKE ON CROWN CLEARANCE 2 FEET WHEN FLASHING Purge Air in IBOP CLOSE OPEN BRAKE OFF ON R 5 FEET Y 10 FEET TORQ.

1998 1-64 TDS-4S Description .October 20.

and oil level sight glass. Main gearbox lube system Provides lubrication to both the primary gear set and swivel bearing. Refer to the Operation book for details. TDS-4S Description 1-65 .Chapter 3 Specifications Drilling motor Horsepower: 1.100 Maximum stall time at full power is generally about 10 seconds. It includes explosion proof 5 hp AC motor/pump combination. pressure loss sensor. The TDS-4S main gearbox lube system holds approximately 20 gallons (refer to the Maintenance and Troubleshooting book for details on oil capacity and adding oil to the gearbox). filter/strainer.

200 cfm 40 hp 220/460 VAC. measured at rig floor 6 gpm 90°F 1-66 TDS-4S Description . 3-phase. for GE motor 50 gpm at 250 foot head. 60 Hz 3.000 BTU/Hr. 3-phase. 60 Hz 3.450 rpm 220. inlet temp 3.450 rpm Standard style.200 cfm 20 hp 220/460 VAC. Closed loop Flow Blower motor Typical voltage Speed Heat exchanger Cooling water supply Oil cooler Max. BASEEFA approved type available * These systems include an additional oil cooler/heat exchanger mounted on top of the gearcase on the TDS.450 rpm Standard style. 3-phase. 1998 Cooling systems Local blower * Flow Blower motor Typical voltage Speed Spark arrestors 3.200 cfm 20 hp 220/460 VAC.October 20. BASEEFA approved type available Derrick mounted remote blower * Flow Blower motor Typical voltage Speed Spark arrestors 3. 60 Hz 3.

39 or 48 in. side ASTM A-500/A-36 steel or equivalent Pipehandler Break-out torque Hydraulic pressure Hydraulic flow Air pressure PH-85 and PH-85H = 85.000 ft lb PH-60d = 60. W12x53 (land masts). 66 or 72 in. W14x90 6 in.000 ft lb 2. (Wellcenter to centerline of rails) Standard rail spacing (Centerline of rails) Recommended rail sizes Roller size Frame material 62.Guide dollies Standard rail setback 30.000 psi maximum 30 to 35 gpm 90 psi minimum TDS-4S Description 1-67 . flange and 6 in. or W14x74.

1998 Service loop kits Power loop (non-regulated areas) 646 mcm Standard length Diameter Power cable voltage Ground cable 4 (each) 86 ft. 5 guage 1 pair. ID SAE 100-R2 hose outer jacket 2. 14 guage twisted and shielded 2 conductor. 6 gauge twisted and shielded 1-68 TDS-4S Description .000 maximum (each) 2/0 conductor tinned copper ground Control composite loop 26 conductor. 8 guage 2 pair. 14 guage 4 conductor.October 20. (flange to flange) 5 in.

ID.000 psi 1 1/4 in. ID.000 psi 1/2 in. SAE 100-R9 3. ID. ID.500 psi 1 in. ID. SAE 100-R2 150 psi 1.625 psi 1 in. SAE 100-R2 150 psi 2.Fluid loop z Not all hoses are required for all configurations.000 psi Hydraulic pressure or return hose (3 total) Size Working pressure Maximum working pressure Purge air supply hose (2 each) Size Working pressure Maximum working pressure Water hose (2) Size Working pressure Maximum working pressure Retract hoses (2) Size Maximum working pressure TDS-4S Description 1-69 . Overall length of assembly Size Maximum working pressure Air supply hose (2 each) 86 ft. SAE 100-R2 3. (flange to flange) 3/4 in. SAE 100-R2 150 psi 3.

2 position 6 in..1. 110 volt VDC/instrument kit Torque meter RPM meter Various switches (0 . explosion proof 1/2 in.October 20. 1998 Electrical equipment accessories API Class I. Derrick J-boxes (2 each) Motor J-boxes (2 each) Solenoid valves (6 each) Pressure switches (2 each) Cast aluminum.E. 2 position 6 in.. Division II -N. 4-way.C. 220 volt 1-70 TDS-4S Description .350 rpm) European standard zone 2 area-EExd Derrick J-boxes (2 each) Motor J-boxes (2 each) Solenoid valves (6 each) Pressure switches (2 each) Stainless steel Stainless steel 1/2 in. of H2O sensor Motor space heaters (2 each) 2 . of H2O sensor Motor space heaters (2 each) 2 .500 Amps) (0 . explosion proof Cast aluminum.200 watt.200 watt. 4-way.

000 25.000 ft lb 10.500 CONTINUOUS 30.000 1.130 HP LIMIT TORQUE. 1991 A.130 HP LIMIT 50.TDS-4S TOP DRIVE DRILLING SYSTEM Drill Pipe Torque Vs.000 15.000 50. Speed GE 752 High Torque Series Motor 60. DURATION JUNE 3.000 58.000 120 0 0 50 100 150 200 250 300 190 RPM CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC.000 HIGH GEAR 20.000 40. TDS-4S Description 1-71 .000 ft lb 5.N.000 32.200 INTERMITTENT 1.000 160 RPM 37.200 INTERMITTENT 55.900 CONTINUOUS LOW GEAR 45.000 12.000 5. CONTINUOUS (ft lb) 35. MAX.

Speed GE 752 High Torque Shunt Motor 55.000 15. FEBRUARY 19.000 50.000 29.000 45.100 INTERMITTENT 45.000 HIGH GEAR 20. 1998 TDS-4S TOP DRIVE DRILLING SYSTEM Drill Pipe Torque Vs.000 130 RPM 0 0 50 100 150 200 250 300 205 RPM RPM CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC.000 32.October 20.500 CONTINUOUS 50. DURATION REDUCED FIELD AREA IS BASED ON A 30 AMPS FIELD.100 CONTINUOUS 25.000 REDUCED FIELD REQUIRED IN THIS AREA 10.000 INTERMITTENT 30. 1-72 TDS-4S Description . MAX. CONTINUOUS (ft lb) 35.000 5.1991 A.N.000 40.000 LOW GEAR TORQUE.

TDS-4S Top Drive Drilling System Installation and Commissioning SM00620-2 .

1998 2-2 TDS-4S Installation and Commissioning .October 20.

...................................................... 2-23 Varco Driller’s Console (VDC)........................................... 2-23 Throttle and torque limit controls .................... 2-22 Driller’s controls and instrumentation .............. 2-26 Retract loop .................................................. 2-25 Air loop ............................................................................................... 2-25 Fluids loop ............................................................................................................... 2-32 Returning the TDS to service after storage ....................................................... 2-15 Rig-up procedure ......................................................................... 2-15 Hydraulic..................... 2-24 Installation .............................. 2-29 Long term TDS storage procedures...... 2-6 Manual layout........ 2-15 Water........................................................................................................................................ 2-9 Wiring ............................................................................................ 2-5 Directional references ........................................................................................................................................ 2-33 TDS-4S Installation and Commissioning 2-3 ..................................................................................................... 2-23 Service loops .................... 2-27 Chapter 3 Commissioning Checkout procedures ...... 2-7 Chapter 2 Installation Derrick electrical termination kit ............................................................................................. 2-23 Wiring ..............Contents Preface/Manual conventions Safety information ....................................................................................................... 2-13 Plumbing .................................................. 2-16 Counterbalance system ........................ 2-21 Motor alignment cylinder system .................................... 2-6 Chapter 1 Preparation Preinstallation checklist............... 2-24 Electrical loop ...................... 2-15 Air ...... 2-9 Installation ....

October 20. 1998 2-4 TDS-4S Installation and Commissioning .

TDS-4S Installation and Commissioning 2-5 .Preface Manual conventions Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information. or a caution note. inspecting. a warning. z e Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Avoid personnel injury and equipment damage by reading this manual and related documents before operating. or servicing the equipment. See the examples below and pay close attention to these important advisories. Indicates advisories involving a risk of equipment damage. n Indicates advisories involving a definite risk of injury to rig personnel.

standing behind the TDS-4S as it faces well center. 2-6 TDS-4S Installation and Commissioning .October 20. 1998 Directional references References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S). Manual layout This binder contains several separate books that you can remove individually for convenience.

The transfer panel is installed. 5. flushed. and pressure tested. and 2-3). 2-2. Stops are ready for installation at the bottom of the rails. 2. 6. This includes: 1. 3. 4. TDS-4S Installation and Commissioning 2-7 . Rigging of the tong lines. Water piping is installed. Hydraulic and air standpipes are installed in the derrick. etc. and pressure tested as well for configurations with closed loop cooling systems. flushed clean. AC leads for blower motor. Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances (Figures 2-1.Chapter 1 Preparation Preinstallation checklist The following assumes that all preinstallation planning and rig-up has been accomplished prior to installation of the TDS. All electronics are installed up to the derrick junction box: DC power leads. and control/ alarm signals. are inspected to ensure that they will not foul with the TDS and other rig equipment.

1998 2-8 TDS-4S Installation and Commissioning .October 20.

Chapter 2 Installation Derrick electrical termination kit Installation Refer to Figures 2-1. Remember to provide convenient access for wiring and maintenance. Usually. 2-2. mounting the plate so that the J-box is four to five feet above the walk-around and near the service loop support bracket is adequate. then construct a work platform to allow access to the J-boxes. If a walk-around does not exist. Manufacture appropriate brackets and clamps to attach the plate to the derrick structure. TDS-4S Installation and Commissioning 2-9 . and 2-3 for typical mounting dimensions of the plate assembly. of the service loop support bracket. Mount it at racking board height within 15 ft.

of Floor C Well Center L TDS Back Guide Rails Operational Clearance Between Top Drive And Nearest Girt or Fastline Should Be 3 in. C Rail L Over Full Length C Rail L ± 3/8 in.October 20.3 0 0 1.3 3. Over Full Length ± 1/8 in. Rail Size Splice Dolly Clear Overhang Inches 10 ft. Within 25 ft.3 2. 39 x 66 48 x 62 30 x 72 30 x 72 W14 x 90 W14 x 90 W12 x 90 W14 x 90 3.5 Drill Floor C Well Center L Figure 2-1. for W14x74 Rails 6" Rail Stop Guide Dolly Config. Minimum Nearest Girt Splice Clearance Splice Plates or Bolts Are Not Permissible on Inside Surfaces of Beam Dolly Overhang Maximum Rail Support Spacing 16 ft.3 3. +0/-4 in. 1998 ± 1/4 in. for W12x53 Rails 25 ft. of Floor C Rail L C Rail L C Well Center L ± 3/8 in.6 0. Within 25 ft. General rail installation data 2-10 TDS-4S Installation and Commissioning . 6 in. Over Full Length ± 1/8 in.

6 in. 800 lb Load B 18. Sch 40 Pipe* 86 ft. Bolt (4 Places) 36. Service Loops 75 ft. Derrick services/general installation data TDS-4S Installation and Commissioning 2-11 . To Be 1 1/2 in. Must Support 4. 7 ft.0 in. Dia.0 in. Air and Water Standpipe Height and Service Loop Bracket Location 10 ft. Mud Hose Connection Service Loop Bracket** Existing Girt * 5500 lb Load View B-B 83 ft. Mud Hose Ref 36. +0/-4 in.000 lb Control Service Loop** B Electrical Service Loop** Fluids Service Loop** Hydraulic Air Standpipes Standpipes To Be 1 1/2 in. Motor J-Box ** Instrument J-Box ** Electrical Supply* Filter/Regulator Lubrication Assembly** 48.0 in.Clearance Hole For . Sch 40 Pipe* Sch 80 Pipe* Water Standpipes A To Be 2 in. Ref * Customer Supplied ** Varco Supplied Typical Equipment Stack-Up Figure 2-2.0 in. View A-A Typical Service Loop Termination A Gussets * 73 ft.75 in. Hydraulic.

91/101 in. 30 in.900 17. 1998 Motor Frame Setback Rails L P 9 ft.250 ft lb for TDS-8S.000 ft lb for TDS-7S and 62. TDS-6S.600 17.000 lb for a typical TDS-8S Rail Loading with TDS in Setback position Load P . 60. TDS-8S 7 ft.600 18.38. 3 in. x 72 in. 30 in. 48 in. General installation data 2-12 TDS-4S Installation and Commissioning . x 66 in.900 18. Load L .000 ft lb for TDS-4S.October 20.000 lb for a typical TDS-4S 52. TDS-3S 18. 34. TDS-3S 8 ft. TDS-8S 5450 5800 5000 3330 TDS-6S ---3780 TDS-7S 3090 3290 2840 -- Figure 2-3. x 62 in. TDS-4S. x 66 in. x 72 in.lb Rail Spacing 39 in.000 ft lb for TDS-6S. TDS-3S 10 ft. x 108 in.800 Rail Loading while Drilling . 48 in. x 62 in. TDS-3S 3450 3680 3170 -TDS-4S. TDS-8S 18.600 lb for a typical TDS-3S 48.lb Rail Spacing 39 in.000 lb for a typical TDS-7S 48.000 ft lb for TDS-3S. 3 in. 68.500 TDS-4S. TDS-4S. TDS-8S L P L Rail Stops L 42.

Typical cabling diagram TDS-4S Installation and Commissioning 2-13 #16AWG/10C . the hydraulic and water pumps and the drilling recorder. the TDS Varco Driller’s Console (VDC). the transfer panel. Derrick Power J-Box #6AWG/2C* Shunt Field #16AWG/10C #12AWG/20C #10AWG/4C #14AWG/2 Pr Shld #6AWG/2C* Shunt Field Derrick AC J-Box Service Loop Transfer Panel (4)646MCM* SCR Room #14AWG/2 Pr Shld #12AWG/3C #14AWG/2 Pr Shld #12AWG/3C #14AWG/37C #12AWG/20C #12AWG/20C #16AWG/10C #12AWG/20C Top Drive System #10AWG/4C E/P Torq AC Power E/P RPM #10AWG/4C #10AWG/4C #6AWG/4C #6AWG/4C #6AWG/2C* Existing Power Cables Rotary Table RBS Controls #12AWG/3C #16AWG/10C TDS Driller’s Console HYD Pump #1 HYD Pump #2 #16AWG/10C #16AWG/10C Existing Driller’s Console Water Pump #1 Water Pump #2 Figure 2-4. control cables are required between the service loop. In addition. the SCR. the SCR’s driller’s console.Wiring The electrical installation requires routing power to the transfer panel and then to the TDS through the service loops (Figure 2-4).

depending on options selected are: Cable 646MCM (4 Shunt) (8 Series) #6AWG/2C (Shunt only) Runs SCR room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary SCR Room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary AC Power to hydraulic pumps AC Power to water pumps AC Power to transfer panel Transfer panel to derrick J-box Transfer panel to existing driller’s console Transfer panel to derrick J-box Transfer panel to hydraulic pumps Transfer panel to water pumps Transfer panel to RBS unit Transfer panel to VDC RBS unit to VDC Transfer panel to VDC Transfer panel to derrick J-box Transfer panel to VDC Transfer panel to drilling recorder Transfer panel to SCR console Transfer panel to SCR room Hydraulic pumps to transfer panel Water pumps to transfer panel #6AWG/4C #10AWG/4C #12AWG/20C #12AWG/3C #14AWG/37C #14AWG/2PR SHLD #16AWG/10C Purge control system (not shown) #12AWG/3C Purge control unit to transfer panel Isolation unit to floor air control unit Transfer panel protection unit to isolation unit Purge control unit to transfer panel VDC protection unit to isolation unit Transfer panel to derrick J-box #16AWG/10C #14AWG/2PR SHLD Terminate the J-boxes per the electrical schematic. control and signal cables are not provided. 2-14 TDS-4S Installation and Commissioning .October 20. Follow applicable electrical codes during installation. Cable glands for the incoming power. 1998 The cable requirements. Cable glands are provided for the service loop cables.

NPT female pressure and fluid return for connection to the service loop. 2 in. Install shut-off valves at the drill floor or racking board level. black pipe lines (one pressure and one return) 1 1/2 or 2 in. The mating halves are preassembled on the service loop. Specifications for specific lines are described in the following sections. Install shut-off valves at the drill floor or racking board level. The air lines connect to the filtered and lubricated supply. dry air in the purge air system. Water The two cooling lines should be schedule 40. pipe. Install a shut-off valve at drill floor or racking board level. See the cooling system specifications for water supply requirements. NPT female for the purge line (if required) and 1/2 in. for the air line in order for the fluids service loop to match.Plumbing The plumbing connections should terminate near the service loop bracket. The derrick connections are reduced to 1 1/4 in. Hydraulic Hydraulic lines should be cleaned and pickled. z Do not connect purge air lines to the lubricator. The derrick connections are reduced to 1 in. TDS-4S Installation and Commissioning 2-15 . Only use clean. NPT female pressure and return for connection to the fluids service loop. pipe in the case of the purge supply for the TDS. 1 or 1 1/2 in. Air Air lines should be schedule 40. The derrick connections are reduced to 1 in. schedule 80 pipe.

000 lb combined. 4. 1. 5.) z On some configurations it may be necessary to remove the upper roller brackets from the dolly to allow the unit to engage the guide rails. Grease the OD liberally. Slide the link adapter onto the drive stem and support it up against the rotating head with adequate rigging and an air winch. Using four lift slings from the crane. and drive in the remaining roll pin. install the stops at the bottom of the guide rails and lower the TDS onto the stops. Use the installation procedure in the IBOP Service Manual to install the pipehandler assembly.October 20. Use the pipehandler to tighten the connection between the lower IBOP/saver sub assembly to the upper IBOP. Attach the lifting slings from the hook or block to the pad eyes located at the swivel end of the motor support bonnet and lift the TDS into the guide rails. long (equal length) and capable of lifting 40. 2. Wipe off excess grease. Slide the landing collar retainer onto the drive stem as shown in Figure 2-5. Once the TDS is fully engaged on the guide rails. 2-16 TDS-4S Installation and Commissioning . Install the O-ring in the uppermost groove on the stem. one attached at each corner of the guide dolly. Load the O-ring and remaining grooves with a waterproof grease. Be certain that the link tilt mounting bosses are opposite from the torque wrench mounting clevis on the rotating head. 1998 Rig-up procedure z Refer to the engineering drawings to install the TDS. 6. Place the split landing collar around the grooves of the drive stem. 3. The slings must be a minimum of 15 ft. 7. lift the TDS motor and dolly assembly to the V-door. (BOP stack lift slings are usually adequate.

Install the elevator links and drill pipe elevator. Connect the opposite end of the hose to the quick disconnect on the rotating head assembly. 9. lock washers and safety wire provided to install this assembly to the link adapter. Use the four bolts. Attach the link tilt clamps to the bails (U-bolts on the inside). slack in the chains. Installing the landing collar 8.O-Ring Roll Pin (4) Split Landing Collar (2) Drive Stem Safety Link (4) Figure 2-5. There should be about 1/2 in. TDS-4S Installation and Commissioning 2-17 .

Attach the S-tube to the swivel gooseneck and the side of the motor frame as follows: a. Make up the upper union just before clamping the S-tube to the side of the motor frame. Use the electrical schematic (refer to the engineering drawings) to make the connections. Position the 20° S-tube elbow on the bottom of the S-tube to adjust the hanging direction of mud hose. 12. Install pear links to ears on hook-block. measure the distance from the point of contact inside the pear link to the top of the mounting lug on the integrated swivel bail. Assemble remaining components and install per Figures 2-6 and 2-7. Route the hoses to the bulkhead and plug in the quick disconnects. When using chain. 11. or -0 in. Remove the exhaust duct shipping covers from the spark arrestors on the air exhaust duct at each side of the DC motor. c. b. Be certain that the cables are securely tied or clamped to the structure along their length. 2-18 TDS-4S Installation and Commissioning . d. Follow the stamped code numbers to confirm each type. 13. The tolerance is: +3 1/4 in. Subtract 37 1/4 in. Save the covers for use during future shipping or storage. 1998 10. Attach the service loops to the bracket on the TDS dolly frame. from the measurement in step b. Install the drill pipe rubber onto the S-tube aligned with the mounting saddle on the frame. and identify spares. use the following procedure to determine the chain length required: a. e. Install the counterbalance system as illustrated in Figure 2-6. Using the cable clamps provided on the motor support bonnet. d. c. route the electrical cables over the gear box and into the J-boxes. With the hook supporting the TDS. The front guard folds down for access to the Jboxes. Cut the chain to the length obtained in step c.October 20. b. Attach the mud hose to the bottom connection of the S-tube.

Typical counterbalance assembly TDS-4S Installation and Commissioning 2-19 .Pear Link Connecting Link Hydraulic Accumulator (Inside Motor Frame) Counterbalance Cylinder Assembly (2) Motor Frame and Guide Dolly Assembly Counterbalance Lug (Bolted to Bail) Integrated Swivel Bail Counterbalance Manifold (On Guide Dolly) Figure 2-6.

October 20, 1998

Loop Assembly

Guide Assembly

Cylinder Assembly

Hose Assemblies

Hydraulic Accumulator (Inside Dolly Tube) Swivel Bail

Counterbalance Operation Switch

Figure 2-7. Optional counterbalance assembly with parking system

n

Never operate the top drive with the exhaust duct covers attached to the spark arrestors on the air exhaust ducts. Doing so severely restricts air flow through the motor, causing overheating and potential damage. They can also fall off during operation and injure personnel working below. Attach the covers only during shipping and storage.

2-20

TDS-4S Installation and Commissioning

Counterbalance system
Figures 2-6 and 2-7 illustrates the installation arrangement for this system. Please see the Maintenance and Troubleshooting book for the adjustment procedures. This assembly is pre-charged when it is shipped by land or water transport. When this assembly is shipped by air freight, it must be pre-charged according to the instructions in the Maintenance and Troubleshooting book.

TDS-4S Installation and Commissioning

2-21

October 20, 1998

Motor alignment cylinder system
Figure 2-8 shows the motor alignment cylinder installed on a typical motor frame. The split shipping brace, shown exploded from the cylinder rod, is only removed after unit is fully installed. If the brace is removed before the hydraulic system is powered, the motor will tend to rotate on its trunnions. If the cylinder is removed for service, use the three bleed holes (located along the top of the cylinder barrel) to remove trapped air from the cylinder before operating the unit. Refer to the Maintenance and Troubleshooting book for the adjustment procedure.

Motor Alignment Cylinder

Shipping Brace

Motor Frame Dolly (Ref)

Figure 2-8. Motor alignment cylinder

2-22

TDS-4S Installation and Commissioning

Driller’s controls and instrumentation
The controls and instrumentation described in the following sections are, or must be, supplied for operation of the TDS system.

Varco Driller’s Console (VDC)
Mount the VDC within easy reach and in plain view of the driller while he is operating the drawworks brake and clutches. The gauges must be easily seen by the driller during drilling operations. Provide appropriate cable glands for the electric cables.

Throttle and torque limit controls
The throttle and torque limit controls are the standard controls used for the independent rotary drive table. If not using an independent rotary drive, then these controls must be added by the SCR manufacturer.

Wiring
Refer to the electrical schematics in the engineering drawings.

n

Customers who choose to use control systems not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel or damage to the system. Other systems must meet Varco requirements. Varco highly recommends the use of its system as it is specifically made for use with the TDS.

TDS-4S Installation and Commissioning

2-23

October 20, 1998

Service loops
Installation
Install the service loops as follows: 1. Fabricate the appropriate brackets and clamps to attach the service loop mounting bracket to the derrick structure. 2. Place the service loop derrick mounting bracket at the height specified on the derrick interface drawing provided in the engineering drawings. Locate the bracket on the side of the derrick adjacent to the hinges on the TDS and as far as practical toward the corner where the guide rail bracing is attached. The bracket must be located far enough from the corner to insure the loops do not catch under the guide rails during operations, but far enough back to provide clearance for tong lines, the stabbing board, tugger lines, etc. 3. Do not unpack the service loops from the shipping protective crate until they are ready to hang in the derrick. Lift the service loops onto the rig floor (still in the crates) and then remove them from the crates with the lifting eyes provided.

e

Use care in lifting gear rigging so as not to damage electrical conductors. Use lifting eyes only. Do not bend the service loops tighter than a three foot bend radius. Tighter bends damage the loops. 4. Attach a sling to the TDS end of the service loop and lift using the lifting eyes only. Allow enough room for the 86 ft. service loop to hang and untwist. 5. Use the lifting eyes to pull the derrick end of the loop through the V-door and attach it to the air tugger. Hoist this end of the loop into the derrick while slacking off at the crane end. Do not drag the loop on any sharp areas on the derrick. Disconnect the crane from the sling and continue hoisting the loop into the derrick. 6. Check that the derrick end of the loop is hanging toward the crown. Attach the derrick end to the derrick service loop bracket and hold in place with flange clamps (Figures 2-2).

2-24

TDS-4S Installation and Commissioning

2 Cut wires and cables to length and terminate them at the derrick end to attach them to the derrick J-boxes. wire strippers. Complete the terminations of the two loops as outlined in the following sections. Installation practices should comply with applicable electrical codes (i. Refer to the electrical schematic provided to ensure proper terminal block assignments. Use of any other type of oil (i. Terminal ends and lugs are supplied. z Use only 10 wt.) or synthetic additive will cause the seals in the air valves to swell and cease to function. hydraulic oil or non-detergent motor oil as a lubricant in the air system. be certain that the service stand pipes have been flushed free of any contamination. NEC. The hydraulic and air lines are identification stamped at both ends so they can be verified and connected properly. Electrical loop 1.. Before connecting the hoses from the service loop. Marvel Mystery Oil. The quick disconnects are arranged to connect only one way so that the hoses cannot be mixed up.. etc. and hydraulic crimper for the DC power lugs with the correct dies for the cable) must be provided by the installer.7. Connect the pre-terminated wire ends at the motor J-boxes using the appropriate glands. but proper assembly equipment (crimping pliers. An assortment of pipe fittings are supplied with the termination kit to attach the fluid service loop hoses to the top of the standpipes in the derrick (Figure 2-2).e. Fluids loop 1.). 2. TDS-4S Installation and Commissioning 2-25 . etc. Pick up the TDS end of the loops and attach them to the service loop bracket at the bottom of the motor frame. Plug the quick disconnects into the appropriate mating end on the TDS. 8.e.

from the mounting bracket. 2-26 TDS-4S Installation and Commissioning . noting the codes (i. H for hydraulic. etc. Connect the service loop to the standpipes. 1998 3. It may be necessary to make jumper hoses to reach the standpipes. attach the airlines from the air-operated elevators to the spare port S1 on the rotating head whenever possible.) to separate the hoses. A for air.. Install a pressure relief valve on the elevator and set at 200 psi.e. Port S2 is next to the hydraulic press port. Port S1 is located next to the hydraulic return port in the rotating head. Air loop To reduce the possibility of accidental opening of the air-operated elevator. z e The hoses in the fluids loop only extend 11 ft.October 20.

etc. 4. Uncrate the service loop. 1. Connect the retract service loop hydraulic and pneumatic hoses to the derrick standpipes. Marvel Mystery Oil. e Before connecting the hoses from the service loop. The electrical and fluids service loops attach to the derrick service loop mounting bracket. e Use only 10 wt. 3. of hose extending beyond the flange) and hoist to the retract system mounting bracket. 5. hydraulic oil or non-detergent motor oil as a lubricant in the air system.) or synthetic additive will cause the seals in the air valves to swell and cease to function. Use of any other type of oil (i. be certain that the standpipes have been flushed free of any contamination. Ensure that the service loop hangs straight in the derrick without any twists or kinks. the retract loop attaches to the retract system service loop bracket. Attach the service loop flange to the mounting bracket with the hardware provided. 2. attach the retract loop to the derrick mounting brackets as follows: z There are four separate service loops needed for a TDS with retractable dollies: two electrical loops. and a retract system loop. Lift the crate containing the retract system service loop onto the rig floor. a fluids loop.e. Attach an air winch to the lifting eyes on the derrick end (derrick end has 8 ft.Retract loop If your rig is equipped with a retract guide dolly. TDS-4S Installation and Commissioning 2-27 .

October 20. 1998 2-28 TDS-4S Installation and Commissioning .

6. Move the Make/Break valve located on the manifold at the back of the pipehandler torque wrench to the BREAK position. Check the function of switches and solenoids. Turn on the hydraulic and air power and check for leaks. 5. Be sure that it operates smoothly and the elevator reaches a joint in the mousehole. TDS-4S Installation and Commissioning 2-29 . Refer to the Maintenance and Troubleshooting book if a problem occurs. Turn on the hydraulic power supply and adjust the pressure reducing valve (also located on the torque wrench manifold) to the appropriate pressure for the lower IBOP connection. Adjust the intermediate stop so that the elevator clears the monkeyboard when actuated. 4. Turn on the electric power (driller’s controls only). Actuate the link tilt. Actuate the motor brake. 3. Repair as required. 8.Chapter 3 Commissioning Checkout procedures 1. There is a loud sound as the air escapes when the brake releases. 7. 2. There is an audible click when each solenoid is actuated.

22. 1998 9. 11. Verify that the stroke adjustment is correct and that no binding occurs. Verify that the indicator light on the VDC lights up when the IBOP valve is closed. refer to the Maintenance and Troubleshooting book for the adjustment procedure. 23. but be sure that it follows the proper sequence. 13. 21. Set a joint of drill pipe in the slips. Actuate the IBOP valve. 16. If necessary. Torque the connection between the upper and lower IBOP valves.October 20. 20. Make up the lower IBOP to the saver sub. 10. Return the Make/Break valve to the MAKE position. With the Hydraulic Power Unit (HPU) off. 12. Calibrate the Torque meter and RPM meter. 2-30 TDS-4S Installation and Commissioning . Use the procedure outlined in the Maintenance and Troubleshooting book to adjust the safety valve actuator mechanism. 19. Assign the TDS at the driller’s console and check that the blower operates. 17. not gas side). 15. Push and hold the makeup button on the VDC a sufficient number of times to make up the connection. 14. Reset pressure to the appropriate setting for drill pipe connections (you can preset the pressure with the Make/Break valve in the MAKE position). 18. Remove the split shipping brace (Figure 2-7) from the motor alignment cylinder. The torque wrench automatic sequence is adjusted at the factory. e It is extremely important to verify that the stroke adjustment is correct and that no binding occurs as the valve will fail prematurely (wash out) if it does not open and close fully. Advance the throttle and be sure that the motor is operating properly in both directions. bleed down the TDS accumulators (HYD SIDE. Open the two flow control valves 1-1/2 turns off their seats.

The pin and box should be in alignment.24. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with the drill pipe box. in the same direction the saver sub pin is to be moved. If you experience heavy drill pipe vibration. Turn off the HPU and bleed down the cylinder accumulator (open the needle valve on the back of the manifold). (more than 1/2 in. With a wrench tightened on the cylinder rod flats. of total cylinder stroke) close the flow controls to 3/4 turn off their seats. e. screw the rod into or out of the clevis. If adjustment is necessary. first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface. b. f. If motor movement becomes excessive due to continued vibration. The nominal position of the two cylinder flow control valves is 1-1/2 turn off their seats. Loosen the lock tab and jam nut on the cylinder clevis. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions until the integrated swivel bail contacts the motor support bonnet. Bring the TDS down as if stabbing the saver sub into the box. use the following procedure: a. TDS-4S Installation and Commissioning 2-31 . d. c. Secure the jam nut and lock tab.

Cover all openings to prevent water or dust from entering. 6. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent. 5. 2-32 TDS-4S Installation and Commissioning . preventing condensation. Keep a record of the readings. The preferred environment is clean and dry at 60°F ambient. however. Perform this at three month intervals if stored indoors. In order to counteract this. then replace the oil.October 20. Be sure to reseal the protective covering after connection. as a drop between readings indicates an increase in moisture in the windings created by inadequate storage protection. Leave enough space around the drilling motor to allow the machine to breathe. 70°F is recommended. and at one month intervals if stored outdoors. Avoid wide variations in temperature and high humidity. During storage. allowing corrosion to take place on the exposed areas. All exposed unpainted metal surfaces are coated with a rust preventive at the factory prior to shipment. 4. A cargo container is appropriate for indoor/outdoor storage. 2. If megger readings drop. If high humidity is unavoidable. lubricant drains from the top half of the roller bearings in the motor. Do not use silica gel or a dehydrating agent. run the oil pump and rotate motor to insure 100% coverage. Connect power to the space heaters at terminals 1 and 2 in the AC motor J-box (see electrical schematic in the back of this section for proper voltage). check these surfaces periodically to be sure that no corrosion is taking place. Palletize the main unit for indoor storage. The drilling motor is equipped with AC space heaters in order to keep the internal motor temperature above ambient. Varco recommends adding one gallon of Mobilarma 524 Rust Preventive prior to shutdown. 8. 3. rotate the motor and gear train periodically to distribute lubricant over the top of the bearings.000 VAC and 2 MOhm minimum) when placed into storage and at three month intervals thereafter (one month if stored outside). 7. Or drain the oil and mix with a rust preventive. 1998 Long term TDS storage procedures 1. Megger the drilling motor armature and field (static voltage of 1. bake the motor as soon as possible to restore proper resistance and avoid further damage.

Remove all rust preventive and any corrosion that may have taken place.000 volt megger. take note of the following: a. inspect and replace them as necessary prior to operation. Check the winding insulation continuity to ground with a 1. If the reading is less than two MOhms. Remove the brushes from holders. d. Blow out all dust and dirt that may have accumulated in the windings with clean. TDS-4S Installation and Commissioning 2-33 . c. Visually inspect for spring corrosion. Follow the procedure in the drilling motor service manual. b.Returning the TDS to service after storage Before placing the TDS back into service. Perform a complete system test and adjustment as detailed in the next section. verify the following items: 1. bake the winding until the moisture content is sufficiently reduced to produce an acceptable reading. To verify the condition of the motor. dry air. 2. taking special care with all load carrying components. sticking brushes and general defects. 3.

1998 2-34 TDS-4S Installation and Commissioning .October 20.

TDS-4S Top Drive Drilling System Operation SM00620-3 .

1998 3-2 TDS-4S Operation .October 20.

.............................................. 3-32 Handling bottom hole assemblies .................................................................................................................................. 3-32 Post jarring operations ........................ 3-11 Powered rotating head ................ 3-24 Drilling ahead on a semi .......................................................................................... 3-8 Changing transmission speeds ................................................................................................................................................................................................ 3-5 Directional references ............... 3-11 Standard rotating head ......... 3-6 Chapter 1 Operating procedures Start-up procedure ..................... 3-34 TDS-4S Operation 3-3 .......................................... 3-12 Controls......................................................... 3-21 Drilling ahead with singles .................................................... 3-19 PH-85 ................................................................ 3-21 Drilling ahead with triples ........ 3-14 Torque wrench .. 3-12 ROTATING HEAD LEFT/RIGHT switch ......... 3-20 Drilling ahead ........ 3-6 Manual layout............Contents Preface/Manual conventions Safety information .............................................. 3-7 Stalling the DC motor . 3-12 Safety valves (IBOP) ............................ 3-19 Torque values for load carrying components ............ 3-26 Tripping ............................ 3-12 AUTO STOP/FREE ROTATE switch . 3-28 Reaming out .................... 3-29 Well control procedures ...................................................................... 3-19 PH-60d .............. 3-9 Pipehandler operation ............................................................................................. 3-31 Running casing ........................................................................................................................................................................................................................... 3-16 Changing drill string sizes .......................

1998 3-4 TDS-4S Operation .October 20.

TDS-4S Operation 3-5 . inspecting. z e Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage.Preface Manual conventions Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information. a warning. Indicates advisories involving a risk of equipment damage. See the examples below and pay close attention to these important advisories. Avoid personnel injury and equipment damage by reading this manual and related documents before operating. n Indicates advisories involving a definite risk of injury to rig personnel. or a caution note. or servicing the equipment.

3-6 TDS-4S Operation . 1998 Directional references References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S).October 20. standing behind the TDS-4S as it faces well center. Manual layout This binder contains several separate books that you can remove individually for convenience.

4. Place the hydraulic power unit (HPU) switch in the PLC position. Assign a SCR. TDS-4S Operation 3-7 . 2. Place the top drive/rotary table (TDS/ROT) lockout switch in the TDS position. 6. 3. Place the water pumps switch in the PLC position.Chapter 1 Operating procedures Start-up procedure Use the following procedure to start up the TDS: 1. Place the motor space heater switch in the ON position. 5. Place the blower/oil pump switch in the AUTO position.

as the drill string slowly releases the wind-up torque. or parking brake. slip-releasing the wind-up torque in the drill string. reducing motor torque. 1998 Stalling the DC motor e The brake on the top end of the TDS drilling motor armature shaft is a static. Reduce the drill current. Turn the hand throttle off and reset the drill current to the normal operating position after the pipe unwinds completely. Varco recommends using the following procedure to safely release the torque in the string: 1. 2. It is not a running or dynamic brake. Release the parking brake. e Do not leave the top drive DC motor stalled in a high torque condition generally for more than 10 seconds (refer to the following table): Amps 280 470 670 820 Stall time (sec) 240 90 45 30 Amps 900 1000 1200 1400 Stall time (sec) 25 20 15 10 3-8 TDS-4S Operation . 3. nor is it capable of.October 20. Use the hand throttle to develop motor torque equal to the wind-up torque held by the parking brake. 4. Using the brake to slip-release the drill string wind-up torque causes the brake to heat up and can destroy the brake lining. When the TDS motor brake holds the down-hole torque. It is not intended to.

to rotate the input shaft. male hex. Refer to the Remote Gear Shifter Supplement for more information.Changing transmission speeds The transmission shifts gears by rotating two vertical compound gear eccentric shafts (Figure 3-1). located on the well side of the guide dolly lower cross members at the bottom of the transmission case. It allows the operator to change gears simply by turning a switch to select the desired gear. wrench to turn the 1 in. TDS-4S Operation 3-9 . rotate the engaged gear set to full disengagement. An optional remote gear shifter is available. It takes five turns of the input shaft to unlock both gear sets. rotate the disengaged gear set into full engagement and lock both gear sets in their proper positions with positive stops in the locked position. To change transmission speeds. the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. An external indicator shows the gear range selection. The two compound shafts (high and low) are supported between the main body and lower gear case halves on heavy trunnions. As the shafts rotate (less than onehalf turn). use a 1 in.

Transmission/geneva mechanism 3-10 TDS-4S Operation LO Shifter Input HI .October 20. 1998 Rotating Head Assembly Shifter Input Shaft External HI / LO Indicator Compound Gear Shafts Bottom View Low Gear Eccentric Shaft (Disengaged) High Gear Eccentric Shaft (Engaged) Geneva Mechanism Top View Figure 3-1.

manually rotate the swivel block to the desired position and release the locking lever. the ramp of the cam extends the return cylinder rod. When the cam follower is in this indented area. To operate the swivel block locking mechanism. Standard 650-Ton rotating head assembly TDS-4S Operation 3-11 . the return cylinder rod is fully retracted and hydraulic pressure inside the cylinder is at equilibrium. pulling the locking pin out of one of 24 locking slots in the cam.Pipehandler operation Standard rotating head The perimeter of the rotating head cam (Figure 3-2) has an indented area where the cam follower normally rests. With the locking lever in the vertical position. Cam Stationary Flange Cam Follower Locking Lever Auto-Return Cylinder Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown) Figure 3-2. unbalancing hydraulic pressure in the cylinder. setting the pin. When the swivel block and cam rotates to another position along with the drill string. the system automatically returns to its pre-selected (indented) position (equilibrium). pull down the locking lever. When the elevator is released.

3-12 TDS-4S Operation . Controls The powered rotating head is controlled by two switches. ROTATING HEAD LEFT/RIGHT switch This switch rotates the powered rotating head. or to a predesignated AUTO STOP position. Rotation only occurs when the switch is held in the RIGHT or LEFT position. In this mode. z The ROTATING HEAD function is only active when the LINK TILT switch is in the FLOAT position. The driller can rotate the swivel block and attached pipe handling equipment freely. In the AUTO STOP mode. then activated again. the rotating head rotates as described in the ROTATING LEFT/RIGHT section above. Rotation continues when the ROTATE switch returns to the center position. a proximity sensor automatically stops rotating head rotation. It provides ten hydraulic and pneumatic passages between the stationary swivel flange and the rotating swivel block and attached pipe handling equipment. pipe handler. The position can be set by locating a target in the bull gear on the rotating head. and link tilt to the right or left (same direction as the drill string). 1998 Powered rotating head The 10-port powered rotating head (Figure 3-3) functions as a hydraulic slip ring. AUTO STOP/FREE ROTATE switch This switch is in the AUTO STOP mode when the light is illuminated (on). The AUTO STOP function is independent of the direction of rotation. When the AUTO STOP/FREE ROTATE light is off.October 20. the FREE ROTATE mode is active. The powered rotating head is operated by controls on the driller’s console. to align with the proximity sensor mounted on the flange of the rotating head. Rotation stops when the switch returns to the center position.

Powered rotating head assembly A2 TDS-4S Operation H1 A3 H3 A5 A4 A4 3-13 .Stationary Flange Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly Bull Gear S1 A1 H1 PRESSU A1 S2 RE A5 H2 S2 A2 H3 A3 H2 S1 Figure 3-3.

z Closing the manually operated lower IBOP requires an Allen wrench. Operating the switch to the OPEN position retracts the cylinder rods. drawing the IBOP actuator shell downward-opening the upper IBOP. This upward movement causes the crank assemblies to rotate 90°. closing the upper IBOP. 3-14 TDS-4S Operation .October 20. 1998 Safety valves (IBOP) Operating the switch on the VDC to the IBOP CLOSED position causes the two actuator air cylinder rods to extend. moving the arms and the actuator shell body upward (Figure 3-4).

Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar Upper IBOP Valve Actuator Air Cylinder (2) Crank Assembly (2) Actuator Arm (2) Safety Valve Actuator Shell Upper IBOP Torque Tube Lower IBOP Saver Sub Drill Pipe Figure 3-4. Safety valve actuator system TDS-4S Operation 3-15 .

1998 Torque wrench The primary function of the TDS torque wrench is to breakout the drill string from the saver sub before making a connection. A two-position. Then another sequenced signal from the control manifold automatically directs pressure to the torque cylinders. raising the torque tube to engage the splines on the upper IBOP..000 ft lb on the PH-60d Pipehandler). air-piloted. The torque wrench has a control manifold with the following components (Figure 3-5): t Hydraulic pressure gauge t Control and sequencing valves t Hydraulic hose inlet and outlet Quick Disconnects (QDs) t Manual Make/Break directional valve The Make/Break valve controls the torque wrench operating direction (makeup/breakout) during operation.e. the driller simply operates the button again. When the driller actuates the torque wrench from the VDC. A push button switch on the VDC operates the hydraulic valve. and then releases the button to allow the torque wrench to automatically recycle to the ready position.October 20. The torque wench can also make connections if necessary (i. The driller holds the button down to makeup or breakout a connection. 3-16 TDS-4S Operation . the lifting cylinder rod retracts. when replacing the lower IBOP or saver sub. hydraulic valve located on the counterbalance manifold located on top of the TDS guide dolly controls the entire sequenced cycle described above. or while backreaming. The position of the Make/Break valve on the control manifold determines the direction that the torque tube rotates. A pressure reducing valve (PRV) on the control manifold allows presetting the makeup torque (this valve is bypassed when the torque wrench is in breakout mode). A sequenced signal from the control manifold then operates the clamping piston. If the torque developed on the first pass is insufficient. rotating the torque tube up to 25° while developing a maximum torque of 85.000 ft lb (65. or when adding a pup joint to the drill stem). clamping the jaws onto the drill string box connection.

Lbs.Manually switch the Make/Break valve on the torque wrench to the MAKE position to use the top drive torque wrench to make connections. Typical torque wrench control manifold TDS-4S Operation 3-17 . Make/Break Valve Recycle Sequence Valve Clamp Sequence Valve Torque Sequence Valve Torque Wrench Manifold BREAK Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE MAKE PRV 40 50 60 70 30 1000 1500 80 LIFT LOWER 20 500 2000 90 10 ® 0 2500 10 0 PSI Ft. This allows the driller to initiate automatic torque wrench sequences and repeat them until reaching the preset makeup torque. x1000 0 Torque Gauge 0 .2500 PSI Figure 3-5.

Varco also recommends checking the torque gauge on the pipehandler while making connections to make sure the torque wrench applies the correct amount of torque to the connection. Varco recommends that a second individual assist the driller when making connections with the torque wrench. Repeat the makeup sequence until the torque cylinders do not stroke more than one inch during the final sequence. which may require repeating the makeup sequence several times. Varco recommends that the driller operating the pipehandler verify that the torque cylinders do not stroke more than one inch on the last makeup cycle. 1998 n Failing to apply the correct amount of torque when using the torque wrench to makeup connections can result in equipment damage and injury to rig personnel. or finds it difficult to adjust set points. Verify the torque pressure regulating valve setting after every makeup sequence before releasing the makeup valve. repeat the sequence if uncertain.October 20. Stop and verify correct operation whenever the operator observes unsteady or inconsistent hydraulic pressure readings. The second person can verify that the torque wrench applies the correct torque to connections. Do not switch the Make/Break valve to BREAK until completing the makeup sequence. 3-18 TDS-4S Operation .

H.Changing drill string sizes PH-85 To operate the torque wrench using drill string sizes that are different from the size specified on your rig’s original configuration. jaw assemblies. installation drawing. saver subs. installation drawing.H. jaw assemblies. 78652-1 – Includes stabbing guide assembly. 78652-2 does not. while Part No. Refer to the following tables when ordering a drill string handling kit for a PH-85: Drill String Change-Over Kits 650 Ton PH-85 Pipehandling Original Part Number 95497-A-H-N-*-* 95497-A-J-N-*-* 95497-A-K-N-*-* 95497-B-K-N-*-* 95497-A-L-N-*-* Desired Tool Joint Connection NC 38 91873-650 91873-650 91873-651 91873-651 n/a NC 50 94731-650 94731-650 ––– ––– n/a 5 1/2 F. t Part No. By purchasing the latter. x 3 1/2 IF saver subs separately. drill string. ––– 94729-650 94729-651 94729-652 ––– 97219-651 n/a 2 7/8 F. install a separate drill string handling kit. install a separate drill string handling kit. TDS-4S Operation 3-19 . the user assumes responsibility for obtaining appropriate 6 5/8 reg. PH-60d To operate the torque wrench with a 3 1/2 in. *These designators do not affect kit choice. The following lists available kits for a PH-60d: t Part No. 78652-2 – Includes stabbing guide assembly.H. 94730-650 ––– 94730-651 94730-652 TBD 6 5/8 F. z Part No. 78652-1 includes 3 1/2 IF saver subs. Specifications for these are available from the factory or any Varco service center.

7 5/8 in.000 ft lb 84. API Reg. API Reg. API Reg.000 ft lb 75. Torque values for load carrying components Components Upper IBOP to main stem/main shaft Lower IBOP valve to upper safety valve Saver sub to lower IBOP valve Crossover sub to lower IBOP valve Upper IBOP valve to main stem/main shaft Lower IBOP valve to upper IBOP valve Saver sub to lower IBOP valve Crossover sub to lower IBOP valve ID 3 or 3 3/4 in.000 ft lb 46. 3 or 3 3/4 in.000 ft lb 60.000 ft lb 6 5/8 in.000 ft lb 66.000 ft lb 85.000 ft lb 63. Table 3-3 only includes components within the TDS. 9 in. Table 3-3. 9 in. 7 3/4 in. 3 or 3 3/4 in.000 ft lb 91. API Reg. Refer to the API charts for other components.000 ft lb 60. 7 5/8 in. 6 5/8 in. 6 5/8 in.000 ft lb 83.October 20. 1998 Torque values for load carrying components Proper makeup torque is critical to the function of drill stem components. 9 in. 3 or 3 3/4 in.000 ft lb 46. API Reg. 7 3/8 in.000 ft lb 60. 3 or 3 3/4 in. API Reg. 6 5/8 in. torque 50. 3 or 3 3/4 in. 7 5/8 in.000 ft lb 75. 7 3/8 in. 3 or 3 3/4 in. 7 3/4 in. 3 or 3 3/4 in. API Reg. torque Max. Connection OD Min. 3-20 TDS-4S Operation .000 ft lb 50.000 ft lb 91. API Reg. 7 5/8 in. 7 5/8 in.

Break out the drill pipe connection using the torque wrench on the pipehandler. Leave enough triples racked to handle anticipated bit life. 6. Drill down until the saver sub is within three feet of the rotary table.Drilling ahead Drilling ahead with triples Drilling ahead with triples is the common drilling mode for the TDS. there are two recommended methods of obtaining them. Stop the mud pumps. 4. The second method for obtaining triples is to make up triples in the mousehole while drilling ahead or during idle rig time. If triples do not currently exist. Circulate bottoms up as necessary. Stop the string rotation. 2. For safety reasons a pivoting mousehole is best because it can pivot to a vertical plane to simplify making connections. Switch the TDS motor from FORWARD to REVERSE. 3. Use the following procedure to drill ahead with triples (Figure 3-6): 1. drill pipe can be left racked and used to drill the next well. spin out of the box while hoisting the TDS with the drawworks (follow with the drawworks. 5. Close the IBOP. 9. 7. Using the TDS motor. One is to leave some triples racked in the derrick when tripping back in the hole and finish the trip with singles. do not lead). Pick up the string and set slips for a connection four feet off the rig floor. On skidding rigs drilling multiple well platforms. TDS-4S Operation 3-21 . There are various sources for triples. 8.

Drilling ahead with triples 3-22 TDS-4S Operation . 1998 Set slips on string Stop circulation Breakout connection using pipehandler and drilling motor (in reverse) Raise block Tilt link tilt to derrickman Pickup stand with elevator Stab bottom of stand onto string Lower block to stab motor into top of stand Spin in motor and stand Makeup both connections with motor Pull slips Start circulation Begin drilling 1 Link Tilt 2 3 4 5 Makeup Start Circulation Stop Circulation Stab Makeup Figure 3-6.October 20.

33. 18. Continue to slack off approximately two feet to stab the upper connection of the stand with the TDS. 13. Latch the backup tong on the box connection. Derrickman latches the elevator on the next stand. 25. 20. Retract the TDS away from the hole. TDS-4S Operation 3-23 . Hoist the pin off setback area and clear the box with the stand. 32. 26. Hoist the TDS to the racking board level to get the next stand. 14. Thoroughly dope the box connection in the rotary table. Start the mud pumps. 24. Unlatch the backup tong. 27. 15. 12. 29.10. Open the IBOP. 22. Pick up to pull the slips. 23. 19. The makeup torque is preset. do not follow). Open the drill pipe elevators. Stab the connection at the floor. 16. 11. Switch the TDS to SPIN IN mode. Drill ahead. 28. 17. Switch to DRILL mode. Switch to TORQUE and hold for approximately six seconds. Release the link tilt. 21. Switch the TDS motor from REVERSE to FORWARD. Stop the spin out mode. Slack off to allow connection to shoulder up (lead with the drawworks. 31. When the TDS is fully raised. Tilt the links. Verify full makeup to the correct value on the torque meter. 30. extend the TDS.

allowing the added single to enter the stabbing guide until the saver sub pin stabs into the box of the new joint. The link tilt feature makes drilling with singles safe and efficient by moving the elevators to the mousehole to pick up the singles. level (approximately). pull up to the 4 ft. 5. 4. 6. (i. Stab the connection at the floor and lower the TDS. Spin out the connection using the drilling motor. start the mud pumps and drill ahead. stop mud circulation. Lift the TDS. 3-24 TDS-4S Operation . Using a backup tong to react the torque. close the IBOP. The other is when making surveys every 30 ft. Pull the slips. when kicking off using a downhole mud motor).e. Break the connection between the saver sub and the drill pipe using the torque wrench in the pipehandler. 9. Pull the single out of the mousehole and as the pin clears the floor. deactivate the link tilt to allow the single to come to well center. 2. Drill down the existing single. and set the slips.October 20. 1998 Drilling ahead with singles Typically there are two situations requiring drilling ahead with singles. 3. Actuate the link tilt to bring the elevator over to the single in the mousehole and latch the elevator around the single. One is beginning operations on a new well where there are no triples made up and racked.. 7. opening the drill pipe elevators to allow them to pass over the box setting in the rotary table. spin up and torque the connection using the TDS motors in the TORQUE mode. Use the following procedure to drill ahead with singles (Figure 3-7): 1. 8.

Drilling ahead with singles TDS-4S Operation 3-25 .Set slips on string Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse) Tilt links to mousehole Latch drill pipe elevator around single Pickup single with elevator Release link tilt Stab bottom of single onto string Lower block to stab motor into top of single Spin in motor and single Makeup both connections with motor in torque mode Pull slips Open IBOP Start circulation Begin drilling 1 2 3 4 5 Makeup Open IBOP Close IBOP Link Tilt Stab Makeup Figure 3-7.

9. When making a connection. Stab the TDS into the upper end of the stand. there is no kelly to pull up. Stab the pin of the new stand into the string using the RBS stabbing head if so equipped. Pull the string up sufficiently off bottom. a torque backup device is required. Extend the RBS and adjust the height. The practical method for doing this is to pull up the pipe string until the bit is sufficiently off bottom. stand from the pipe rack in the same manner as on a fixed rig. 3. 7. spin in. 5. and the TDS motor can spin out the connection. The 54 ft. Raise the TDS to the racking platform and latch the elevator on a new stand. Breakout the TDS and spinout shaft using the drilling motor. Clamp the RBS tong on the elevated box of the drill string. 1998 Drilling ahead on a semi Derrick clearances are critical for drilling operations with the TDS on a floater. and make up both connections. 8. 3-26 TDS-4S Operation . Retract the RBS. you must be able to pull the bit off bottom enough to allow for vessel heave when making a connection. With the TDS. or use the lower racking arm. The TDS pipehandler can break out the drive shaft. Use the following procedure to drill ahead with triples on a semi (Figure 3-8): 1. kelly drilling pulls the bit off bottom far enough to account for vessel heave. Varco provides a simple. Pull the slips and drill ahead. above the floor. kelly must be pulled all the way up to add the next joint. remotely-operated Raised Backup System (RBS) which retracts out of the way when not in use.October 20. Because the pin connection of the new stand is about 15 ft. 2. Set the slips. as well as a means to assist stabbing. 6. The distance should equal the maximum expected heave. Then hoist the TDS into the derrick and add a new 90 ft. 4. 10. Drill the stand down until the elevator is to the floor. Therefore. and then set the slips.

Unlatch elevator Breakout/spinout with pipehandler and motor 1 2 3 4 5 Makeup Start Circulation Stop Circulation Makeup Figure 3-8.Drill down stand Stop circulation Pickup string 10 to 20 ft. Set slips Raise block Extend RBS and adjust height Pickup stand Stab stand using RBS to assist Spin in stand Makeup both connections with motor Pull slips Retract RBS Start circulation Begin drilling 90 ft. Drilling ahead with triples (floaters) TDS-4S Operation 3-27 .

1998 Tripping Perform tripping operations in the conventional manner. If a tight spot or key seat is encountered while tripping out of the hole. The hydraulic link tilt allows the elevator to also reach the mousehole. Use the link tilt feature to tilt the elevator to the derrickman so the derrickman can quickly latch it around the pipe.October 20. Establish circulation and rotation immediately to work the pipe through the tight spot. spin the drilling motor into the stand at any height in the derrick. The intermediate stop tilts out of the way to allow the elevator to reach the mousehole. 3-28 TDS-4S Operation . The air actuated link tilt has an intermediate stop which is adjustable to set the elevator at a convenient working distance from the monkeyboard.

Break out the drilling motor from the top of the stand using the pipehandler torque wrench. 7. With light slip loads. Stab the drilling motor into the box. 8. 3. Rack the stand back. 4. Use the following procedure to ream out of the hole (Figure 3-9): 1. 9. TDS-4S Operation 3-29 . stands in the derrick.Reaming out The TDS permits reaming out of an open hole to prevent pipe sticking and to reduce key seat formation. there are no singles to contend with). spin up and torque it with the drilling motor. Hoist the block while circulating and rotating the drilling motor until the third connection appears. 6. Lower the block and TDS to the floor.. 5. Stop circulation and rotation and set the slips. Hold a backup at the floor and spin out the drilling motor. Pick up the stand with the drill pipe elevator. Break out the stand at floor level. 2. without affecting racking functions associated with normal tripping (i. the pipehandler torque wrench can be used to torque the connection.e. Resume circulation and continue reaming out of the hole. and spin out using pipe spinners. The pipehandler torque wrench can break out 90 ft.

October 20. pull slips. hoist and rotate 1 Breakout 2 Hoist 3 4 Setback 5 Hoist and Rotate Breakout Figure 3-9. Reaming out 3-30 TDS-4S Operation . stop rotation and circulation Set slips on string Breakout connection using pipehandler and drilling motor (reverse) Breakout and spinout stand at floor Hoist free stand with elevator Setback stand using link tilt Lower block. stab motor into string Spin in motor and makeup connection with motor Start circulation. 1998 Hoist while circulating and rotating When 3rd connection surfaces.

Engage the top drive motor in reverse to spin out the connection. 2. 6. Install the appropriate crossover sub. Use the following TDS well control procedure in conjunction with standard IBOP well control procedures: 1. On indication of a kick. Remove the torque wrench vertical travel stops. 10. Manually close the lower IBOP valve. set the slips at the nearest connection and stab the TDS into the string. the remotely controlled IBOP valve is always in the string for immediate use as needed. Proceed with normal well control procedures.Well control procedures The TDS can stab into the string in any position in the derrick.* 4. 8. Spin up and torque the connection using the Spin/Torque control. 9. A 7/8 in. after setting the backup tong. check valve or circulation sub on top of the lower IBOP valve. Breakout the lower IBOP from the upper IBOP. hex wrench is included with the system to operate the upper valves if the remote actuator should fail. * Operation of the IBOP valves is the same as any standard valve. 7. 5. 3. or for checking that the valve is functioning correctly. Remotely close the upper IBOP valve. While drilling. Lower the string to the floor and reset the slips. TDS-4S Operation 3-31 .

use the swiveling drill collar dolly (Figure 3-10) to allow the elevators to turn freely. The drill collar dolly’s upset.) The collars can be walked in or out with the elevator turning on the drill collar dolly. Handling bottom hole assemblies For handling bottom hole assemblies.) must be used to allow clearance for the cementing head under the torque wrench in the pipehandler. If desired. Use longer bails (180 in. which latches in the standard drill pipe elevator.) to prevent the block dolly (if used) from contacting the TDS dolly. is mounted on a bearing allowing it to swivel even while it is under load. 3-32 TDS-4S Operation . Use the remotely controlled upper IBOP valve to start and stop the fluid flow. longer elevator links (180 in. 1998 Running casing For casing operations. Attach a short piece of hose to the saver sub in the pipehandler to fill the casing while lowering.October 20. run casing conventionally using the block and hook and swinging the TDS aside. A shoulder elevator is suspended from the “perfection” links (or a second drill pipe elevator if lifting subs are used.

. .. .. 91 in. .... ... . Drill Collar View A-A Figure 3-10. Swiveling drill collar dolly TDS-4S Operation 3-33 . 8 in. Square Shoulder Elevator Lifting Sub 37 in..A Drill Pipe Elevator A 100 TON VARCO Drill Collar Dolly Perfection Links (36") ..

looking for any wear that could cause a safety or operational risk. But the possibility of damage to a top drive during a jarring operation is considerable. Design Torque Standard (DS00008) to help ensure safe top drive operation. 1998 Post jarring operations e Jarring occurs on all drilling rigs. Design Torque Standard (DS00008) after performing any jarring operation while the top drive is in the drill string. It is not practical to recommend removing the top drive from the drill string during all jarring operations. The checklist draws attention to specific parts on major subassemblies. Use the Post Jarring Checklist (PI 93-1) and Design Specification. Use the Post Jarring Checklist (PI 93-1) and Design Specification. Consider removing the top drive from the drill string before performing prolonged jarring. Do not limit inspections to items on the checklist. It is imperative to exercise caution when using a top drive after a jarring operation. Note that the checklist includes recommended procedures. Safe operation of the TDS is the responsibility of the user and rig crew. 3-34 TDS-4S Operation .October 20. Inspection should be rigorous.

TDS-4S Top Drive Drilling System Maintenance and Troubleshooting SM00620-4 .

October 20. 1998 4-2 TDS-4S Maintenance and Troubleshooting .

......... 4-16 Drive stem ................... 4-20 Ultrasonic Inspection ... 4-18 Magnetic Particle Inspection (MPI) ............... 4-27 Initial oil change period .. 4-12 Motor alignment cylinder ......... 4-23 Gearbox ........................................................................................ 4-25 Other gearbox lubrication and maintenance considerations ... 4-14 Nondestructive Examination (NDE) ..................................... 4-21 Chapter 2 Lubrication Lubricating the motor and motor support bonnet assembly.............................. 4-14 Visual inspection.......................................................... 4-8 Chapter 1 Maintenance Inspection ....................................................................... 4-9 DC drilling motor ................................Contents Preface/Manual conventions Safety information ..................................................... 4-30 Lubricating the rotating head ................................. 4-34 TDS-4S Maintenance and Troubleshooting 4-3 ...................................................................................................................................................................................... 4-28 Lubricating the DC motor .......... 4-12 Air exhaust muffler ................................................................. 4-14 Landing collar ......... 4-29 Lubricating the washpipe and bonnet seal .............................................................. 4-31 Lubricating the link adapter .... 4-7 Directional references .............................................................................................. 4-23 Torque setting procedure ........................................... 4-27 Oil capacity.............................................. 4-32 Lubricating the torque wrench ............... 4-13 Pipehandler ............................... 4-8 Manual layout............................. 4-21 Safety valve inspection procedures (IBOP) .................................................................................................................................................. 4-33 Lubricating the master bushing ID wear guide ........................................... 4-12 Derrick termination kit air filter/regulator/ lubricators ................. 4-9 TDS swing out procedure ..........................

..................... 4-81 Removing the jaws .................. 4-54 Precharging the counterbalance system ....................................................................................................... 4-52 Adjusting the counterbalance system .............. 4-81 Rear jaw ............................. 4-77 Removing the tong dies ................. 4-44 Lubricant specifications .......................................................................................... 4-71 Replacing the powered rotating head glyd rings ............................................................................... 4-60 Assembly and disassembly .............. 4-62 Replacing the torque wrench clamping piston seal .......... 4-82 Upper safety valve (IBOP) ............................................... 1998 Lubricating the safety valve actuator . 4-87 Local blower cooling system assembly/disassembly .................................... 4-82 Rear jaw .......... 4-92 Replacing the safety wiring ........ 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................. 4-82 Removing the motor assembly from the guide dolly........ 4-84 Installing the TDS motor pinion .............................................. 4-82 Lower safety valve (IBOP) .................... 4-36 Lubricating the bail pins ..................... 4-41 Lubricating the cooling system ............................... 4-42 Lubrication schedule ........................................................... 4-81 Front jaw ............ 4-62 Torque wrench disassembly ........................ 4-34 Lubricating the upper safety valve (IBOP) ................................................................................... 4-95 Safety wiring tips ......................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ...................................................................................................................... 4-52 Adjusting the motor alignment cylinder system ..................................... 4-35 Lubricating the guide dolly assembly ......................................... 4-62 Pipehandler ............................................................................. 4-97 4-4 TDS-4S Maintenance and Troubleshooting ........................... 4-45 Chapter 3 Maintenance Adjustment procedures ................................................ 4-89 Closed loop cooling system assembly/disassembly ............................................................................................... 4-49 Adjusting the torque wrench ..... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet .. 4-82 Front jaw ..............October 20...................................................................... 4-68 Replacing the standard rotating head glyd rings ..

......... 4-104 Troubleshooting the pipehandler ........................ Refer to the GE Motor Service Manual........... 4-99 Troubleshooting the motor alignment cylinder .............................................................................. VDR00023 (included in VDP0001) for specific details such as: t Inspection and maintenance schedule t Recommended storage instructions drilling motors and generators t Removing motors or generators from storage TDS-4S Maintenance and Troubleshooting 4-5 .................. 4-101 Troubleshooting the transmission ..... 4-108 Troubleshooting the pipehandler at the counterbalance manifold ..... 4-101 Troubleshooting the motor air brake ...... 4-106 Troubleshooting the torque wrench ......... 4-101 Troubleshooting the retract guide dolly ................................................... 4-106 Troubleshooting the safety valve actuator............................ 4-109 Troubleshooting the crown height indicator ..... 4-108 Troubleshooting the link tilt .....Chapter 4 Troubleshooting Troubleshooting the counterbalance ..... 4-102 Troubleshooting the oil pump .................................................. 4-100 Troubleshooting the drilling motor and guide dolly .. 4-111 z This section contains some information regarding the GE motor..... 4-110 Six-gang air valve assembly illustration .............. 4-103 Troubleshooting the cooling system ......

1998 4-6 TDS-4S Maintenance and Troubleshooting .October 20.

n Indicates advisories involving a definite risk of injury to rig personnel.Preface Manual conventions Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information. or a caution note. See the examples below and pay close attention to these important advisories. TDS-4S Maintenance and Troubleshooting 4-7 . Indicates advisories involving a risk of equipment damage. inspecting. Avoid personnel injury and equipment damage by reading this manual and related documents before operating. z e Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. or servicing the equipment. a warning.

Manual layout This binder contains several separate books that you can remove individually for convenience. 4-8 TDS-4S Maintenance and Troubleshooting . standing behind the TDS-4S as it faces well center.October 20. 1998 Directional references References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S).

Lower the TDS guide dolly to the stop. If you have a retract system. maintenance. Use the following procedure to swing out the TDS only if your rig has a guide dolly with hinge pins (refer to the engineering drawings for information specific to your rig configuration): 1. Electrical. 2. Slowly lower the TDS until the elevator nears the rig floor. 4. TDS-4S Maintenance and Troubleshooting 4-9 . operate the switch on the VDC to retract the TDS. hydraulic. or to allow drilling operations requiring a kelly and rotary table. Remove the elevator and elevator links. running casing.Chapter 1 Maintenance Inspection TDS swing out procedure Varco top drives with swing-out guide dollies can be quickly swung aside on their own dolly frames for inspection. 3. and air supplies do not have to be disconnected.

Operate the air tuggers to slowly pull on the motor frame while unhooking the traveling block from the swivel bail. 9. n Unlatching the hook from the integrated swivel bail may cause the TDS motor assembly and/or the hook to lurch suddenly. 10. Detach the counterbalance system cylinders from the hook or block by unhooking the pear links from the ears on the hook or block. opposite the frame hinges. opposite the hinges. 12. it may be necessary to secure the traveling block frame to the guide dolly frame using chain and/or rope. Attach tugger lines to the TDS motor frame. Always keep adequate tension on the tailing lines to prevent sudden movement of these assemblies. Disconnect the mud hose from the TDS S-tube. Use tailing lines on the motor frame to control swing out.October 20. 13. 11. to assist in swinging out the TDS motor assembly. (The counterbalance manifold is located on the upper motor frame.) 6. When the traveling block is disconnected. 7. Disconnect the air intake hose. 4-10 TDS-4S Maintenance and Troubleshooting . 8. Unfasten the two swing-out bolts. Turn off the Hydraulic Power Unit (HPU) and bleed down hydraulic pressure by opening the needle valve on the counterbalance manifold. continue swinging out the TDS 180° and secure the motor assembly to the derrick with chain and/or rope. 1998 z On some rigs. 5. Unlatch the hook. holding the motor frame to the guide dolly.

8. perform the following procedure: 1. opposite the hinges. Retract the TDS and secure it. 7. Turn the HPU on and bleed air out of the system. 4. the swivel and/or the TDS motor assembly may suddenly lurch. Attach tugger lines to the TDS motor assembly. 6. Connect the air intake hose. Connect the mud hose to the S-tube. While swinging it back. 9. to aid in swinging back the TDS assembly. 5. Use tailing lines on the motor frame to control swing back. Release the chain and/or rope securing the TDS motor assembly to the derrick and slowly swing back the TDS motor assembly to the guide dolly. Hook the counterbalance system pear links onto the ears of the hook or block. Always keep adequate tension on tailing lines to prevent sudden movement of these assemblies. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the hinges. 3. latch the hook onto the swivel. TDS-4S Maintenance and Troubleshooting 4-11 . 2. Lower the guide dolly far enough to allow swinging the TDS back into place. n While latching the hook to the integrated swivel bail.To swing the TDS back in for operation after inspection or maintenance.

inspect all moving parts and check accumulator pressures on a weekly basis. It also holds pressure on the air brake. Motor alignment cylinder e The alignment cylinder is not intended to be used to align the pin with the box at the well bore. Air exhaust muffler Varco installs air exhaust mufflers on the exhaust ports of the multi-gang solenoid valve manifold for noise abatement. All such mufflers reduce noise and collect contaminants that can eventually restrict the air passage. Also. replace them immediately. It is adjustable to ensure that the mainshaft is straight at well center–to compensate for design tolerances in the guide rails and dolly. Check alignment cylinder operation weekly.October 20. and the dolly must fit within design tolerances. and guide dolly assembly for loose bolts and fittings daily. To work properly. If noise abatement is not an issue on the rig. 1998 DC drilling motor Thoroughly inspect the TDS. It is a device to counterbalance the offset weight of the DC motor and allow the system to accommodate external forces. 4-12 TDS-4S Maintenance and Troubleshooting . z The DC motor has a complete manufacturer’s service manual for your reference provided in the Vendor Documentation Package. Air passage constriction results in back pressure on all of the solenoid valves and erratic valve operation. replace the mufflers with simple pipe elbows. the guide rails must be properly located. Periodically remove the mufflers and clean or replace them. motor support bonnet. If any safety wire or cotter pins were removed to facilitate repairs.

z Varco supplies a filter/regulator/lubricator in the derrick installation kit and recommends installing it at the fingerboard level in the derrick. or valve and cylinder seals and O-ring extrusion at excessive pressures.Derrick termination kit air filter/ regulator/lubricators Top drives that rely on rig air to power link tilt. or improperly functioning components. upper IBOP. The air valves. cylinders and actuators for these functions require proper lubrication and moisture-free and particle contaminant-free air. brake. e Do not use fluids such as Marvel Mystery Oil. Swollen seals may result. Improperly adjusted regulators can cause poor device performance at reduced pressures. motor oil. injected by the lubricator and carried by the air. Clean and drain the filter weekly. Fill the lubricator with petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU at 100°F (ISO 32/34). or Dextron II in the lubricator. and torque wrench makeup/breakout sequence pilot signal functions require regular inspection. overall body. Moisture in the air can cause corrosion on internal cylinder surfaces. or inlet and outlet fittings. corroded. Adjust the pressure regulator outlet pressure to 100-120 psig monthly. reduces friction between moving parts and increases the life of seals in valves and actuators. TDS-4S Maintenance and Troubleshooting 4-13 . Inspect the entire filter/regulator/lubricator monthly for damage to the filter bowl. Replace any damaged. Particle contamination can damage the seals in moving parts and cause solenoid valves to stick. Oil.

replace them immediately. magnetic particle inspection. An indication of a possible problem is if the two intermediate stops are not adjusted equally (i. The capacity of the links equals the capacity of the weakest link.October 20. 4-14 TDS-4S Maintenance and Troubleshooting . Make sure the hinge pins are not loose due to excessive wear in the bore of the clamp clevis or a broken retaining bolt.e. x-ray examination. and other methods of nondestructive testing for metallurgical integrity. 1998 Pipehandler Thoroughly inspect the pipehandler for loose bolts and fittings daily. Inspect the hinge bolts daily to make sure they are not separating from the pipehandler.. dye penetrant examination. if the thread engagement differs between the two stops). Visual inspection Use calipers on a regular basis to measure the amount of wear on the elevator link eyes (Figure 4-1). Nondestructive Examination (NDE) Yearly (or after approximately 3. Failure to perform this inspection and/or component replacement can result in injury to rig personnel. n Inspect the link tilt intermediate stop and adjustment device for overall integrity weekly. Compare the measurements with the Wear Chart (Figure 4-1) to determine the current strength of the elevator links. If any safety wire or cotter pins were removed during repairs. z NDE inspection includes visual examination. ultrasonic inspection. Replace the components if there is excessive looseness of the threaded rod in the threaded hole of the pivot arm (Figures 4-24 and 4-25).000 operating hours). perform a Nondestructive Examination (NDE) of all critical load path items.

. 3 1/4 in.. 7 1/2 in. 350-Ton 5 in.. 500-Ton 6 in. The capacity of the set of links is determined by the weakest link. 7 1/4 in. measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity.. 4 5/8 in.... A Lower Eye (Elevator) Figure 4-1.... 5 3/4 in. To determine the strength of worn links....Forged Links Lower Upper Eye Eye Dimension Dimension A C B = 3 1/2 in. 2 3/8 in.. 2 3/4 in. 3 1/2 in.. 750-Ton 7 1/2 in.. . . .. . . 5 1/4 in. 500 420 325 250 A . 2 3/4 in. 5 1/2 in..Upper Eye (Hook) Wear Chart ... 7 1/4 in.. 6 3/4 in..... B B = 6 1/4 in.. B B = 4 1/2 in.. . Visual inspection of elevator links TDS-4S Maintenance and Troubleshooting 4-15 . 3 in.. 6 3/4 in... 2 3/16 in. 7 in. 4 13/16 in. 350 300 225 175 Capacity (per set) in Tons C C . 350 300 225 175 . 4 7/16 in. 7 in.. .. . 2 9/16 in.

3. Raise the solid body elevator to expose the landing collar retainer. Remove the IBOPs and pipehandler. 1998 Landing collar Disassemble and inspect the landing collar every six months. Slide the retainer off the drive stem. 6. or fatigue cracks on the inside or outside diameter of the landing collar halves t Evidence of drive stem contact with the solid body elevator t Evidence of inside bore wear on the solid body elevator indicating contact with the drive stem or landing collar retainer. damage. 7. Slide the retainer ring above the split landing collar halves. 4. Wear on the inside shoulder of the elevator should not exceed 1/8 in. or corrosion. Disconnect the top drive from the drill string. 2. Check for: t Grooves or other radial wear marks indicating that the bore of the solid body elevator is rubbing on the outside diameter of the landing collar retainer shell t Radial grooves on the inside diameter of the retainer shell t Missing tabs from the retainer shell t Wear or corrosion induced pitting on the retainer shell shoulder t Wear. inspect all landing collar parts for wear. Drive out one roll pin. 5. 8. corrosion. corrosion. t Evidence of wear. Remove the landing collar halves. Straighten the retainer tabs.October 20. or fatigue cracks on the safety links 4-16 TDS-4S Maintenance and Troubleshooting . Use the following procedure to disassemble the landing collar (Figure 2-5) for inspection: 1. After disassembly.

6. Use a hammer and drift to bend all 32 retainer tabs to secure the retainer shell. Reinstall the IBOPs and pipehandler. 7. 11. Place the landing collar halves on the drive stem with 15° taper closest to the top drive. 5. 8. 2. TDS-4S Maintenance and Troubleshooting 4-17 .Replace the appropriate part(s) if any of the above conditions exist. 10. Slide the retainer shell over the landing collar halves. Coat the retainer shell and drive stem with a generous amount of water resistant grease to prevent corrosion. Install one new roll pin and safety links on the split landing collar halves. Replace the existing O-ring in the retainer shell. 4. Slide the retainer onto the drive stem above the landing collar grooves. Use the following procedure to reassemble the landing collar: 1. Coat the landing collar halves with a generous amount of water resistant grease. Grease the inside diameter of the retainer shell. 9. Drive in the remaining roll pin. 3.

Use API Bulletin 5T1 to identify and define imperfections found during inspections.000 Diameter 7 5/8 API REG R. Pin 6.000 Diameter 7 5/8 API REG R. Section 2 for power swivels and power subs. Remove the drive stem/mainshaft from service if bore wear is greater than the dimensions shown in Figure 4-2.45 New) (1. Section 10.30 Minimum @ Landing Collar Grooves (2.45 New) (1. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections.30 Minimum @ Landing Collar Grooves (2.250-3 ACME-2G Left-hand Thread Figure 4-2. Measurement techniques are specified in API RP 7G. 650-Ton 1. Typical minimum bore wear dimensions (Refer to engineering drawings for exact dimensions) 4-18 TDS-4S Maintenance and Troubleshooting .00 Diameter (New) 9.70 New) 3. 1998 Drive stem Regularly inspect and measure the drive stem/main shaft for wear. Pin 7.N.75 Diameter (New) 9.70 New) 3.500-3 ACME-3G Left-hand Thread 750-Ton 1. Determine inspection frequency according to API Recommended Practice 8B.October 20.N.

20 1.25 1.50 1.30 1.00 Remaining Wall Thickness Under Pin Thread Relief Groove (Inches) Figure 4-3.35 1.55 1.00 Bore) Load (Lbs) 3100000 3000000 2900000 2800000 2700000 2600000 2500000 2400000 2300000 2200000 New Condition (3.65 1.Use the following API recommended guidelines (Figures 4-3) to determine the tensile load bearing capacities of the drive stem/ main shaft landing collar.45 1.15 1.60 1.10 1.95 4-19 .05 1.40 1. 750-Ton and 650-Ton drive stem/main shaft landing collar tensile dimensions TDS-4S Maintenance and Troubleshooting 0. 3800000 3700000 3600000 3500000 3400000 3300000 3200000 New Condition (3.75 1.82 Bore) 1.70 1.

The load carrying components are: t Drive stem/main shaft (lower portion) t Landing collar t Upper and lower IBOP t 350-Ton BNC drill pipe elevator t Link adapter t Saver.A. deep. and spacer subs t Power subs t Power swivels t Elevator links Details on MPI procedures are in the following publications: I. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. depending on the severity of operating conditions. 9th Edition Std. or every 3. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. Larger defects or any crack indications are cause for replacing the suspect component. Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components and load collar grooves to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Any indications found are a potential cause for replacing the suspect component.000 operating hours. crossover.October 20. After approximately five years. Recommended Practice for Magnetic Particle Inspection 4-20 TDS-4S Maintenance and Troubleshooting . or 15. Varco recommends performing a MPI of all load carrying components over their entire surface (including internal bores) to reveal any fatigue or crack indications. deep.C. Method for Magnetic Particle Inspection of Steel Forgings Std.000 operating hours. Larger defects or any crack indications are cause for replacing the suspect component. ASTM A-275 ASTM E-709 Drilling Manual. 1998 Magnetic Particle Inspection (MPI) Once a year.D.

Safety valve inspection procedures (IBOP) z Upper and lower IBOP valves. TDS-4S Maintenance and Troubleshooting 4-21 . These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis. are particularly susceptible to corrosion fatigue cracking. Any erosion reduces the loadcarrying capability of the part. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std.Ultrasonic Inspection In addition to the MPI. because of their internal grooves and shoulders. Any subsurface irregularity can also compromise a component’s integrity. Practice for Ultrasonic Examination of Heavy Steel Forgings. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611). Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter.

October 20. 1998 4-22 TDS-4S Maintenance and Troubleshooting .

2.500 operating hours or three months. (Refer to Oil capacity later in this chapter. This helps to distribute lubricant and prevents contaminant buildup.Chapter 2 Lubrication Lubricating the motor and motor support bonnet assembly Gearbox Check oil daily. Use the following procedure to maintain proper gear lubrication: 1. Shift all top drive two speed gearboxes from one gear to the other and back again at least once a week. TDS-4S Maintenance and Troubleshooting 4-23 . check to see that the oil level is at the middle of the sight glass located on the side of the main body. Remove the gear indicator lever assembly and the indicator gearcase cover.) Properly maintaining the TDS gear shifting mechanism increases the operational life of the top drive. whichever occurs first. With the motor off. Drain and refill the gearbox every 1.

If there are problems shifting from one gear to the other. damaged bearings.). Remove the 3 in.. If the torque is less than 65 ft lb. increase the torque if there are persistent problems. Clean. Turn the drive stem with chain tongs to make sure the gear mesh aligns properly. 4-24 TDS-4S Maintenance and Troubleshooting . 4.e. Inspect the gears for corrosion or damage. lubricate or replace components as required. Repack the inside area with grease every six months (refer to Figures 1-9 and 1-10 in the Description book). it indicates a larger problem (i. There is a “timing mark” on the gears to ensure correct orientation. 4. Eccentric shaft rotation direction is the same as the shifter input shaft when shifting into gear. etc. inspection plugs on the rear of the gearcase and make sure the compound gears are free to turn with the unit in neutral. use the following procedure to shift the gears: 1. If these marks are not visible when removing the gears. The factory setting of the clutch is 45 ft lb. However. 3.October 20. If the shift input mechanism slips when attempting to shift gears. Do not shear the bolts. Insert two 3/8 in. 2. then use the Torque setting procedure to adjust the clutch e Gearbox oil must be drained before removing clutch. 1998 3. If the gears cannot turn. use a torque wrench to check the torque of the shifter when the clutch begins to slip. contaminants in gears. Do not turn the DC motor while shifting gears. mark the gears before removal to ensure correct orientation when reinstalling them. bolts in the threaded holes on the bottom of the shafts while shifting the gears and use a bar to turn the shaft in the proper direction.

Torque setting procedure Use the following procedure to set the torque limit clutch to 45-50 ft lb: 1. 3. Remove the snap ring and locking plate. or to turn the nut counterclockwise to decrease the torque. Attach any torque indicator to the output stub (Figure 4-4). open end wrench to turn the nut clockwise to increase torque. 2. Replace the locking plate and snap ring. 6. Hold the body and determine the current torque setting. 4. Use a 5/8 in. TDS-4S Maintenance and Troubleshooting 4-25 . Check the resulting torque and repeat the above steps if more adjustment is necessary. 5.

.. : October 20..... ................. .... ... .. ............... ......................... ................ ........................................................ ........... ..... ....... ........... .. ................ ..... ....... ................................ .. ....... ......... . . ........ .......................... ..... . .................... ................. ........ .. Housing Gear Changer Gear Shaft Changer Torque Limiter (Clutch) Detail A Torque Limit Clutch Figure 4-4............................ ............. .................. ............... A Gear Subplate Lower Gearcase ........ ............................................ . ..... ... . . 1998 ... ....... .......n p o X ~ | Y _ ^ ] \ W z y x ` S c V b U a T ........................................................... ... Torque setting procedure 4-26 TDS-4S Maintenance and Troubleshooting ...........

Initial oil change period Drain and refill the gearbox after the first 500 operating hours or four weeks. One way to install sealed caps requires shop installation during top drive overhaul. The stud holds the cap on top of the gearcase and keeps contaminants away from the shaft.Other gearbox lubrication and maintenance considerations t Keep the bottom of the eccentric gear shafts clean and free of corrosion. whichever occurs first. It also adds a secondary seal between the oil in the gearbox and the DC motor cooling air path. depending on the model and configuration) when changing the oil. There are two ways to install sealed caps. There is a kit for field installation (P/N 97926). Remove and clean the oil pump suction strainer (or oil filter. Install sealed caps on the top of the shaft to correct the problem. Keep this area lightly lubricated with oil. t Contaminant build up or corrosion around the upper end of the eccentric shafts can cause persistent shifting problems. a sealing cap and a stud which threads into an existing tapped hole in the top of the eccentric shaft. paint or other contaminants. TDS-4S Maintenance and Troubleshooting 4-27 . It consists of a rubber gasket.

do not add any additional oil to the gearcase. add more oil until the level reaches the middle of the sight glass. Always fill the transmission to the middle of the sight glass. 1998 Oil capacity The TDS-4S holds approximately 10-20 gallons of oil. and the wetted surfaces inside the motor housing assembly (approximately 2-3 gallons). Fill the gearbox to the top of the sight glass (approximately 10-20 gallons). If the oil level is at. but oil capacities vary according to the type of cooling systems. Use the following procedure to fill the transmission for the first time on a new top drive: 1.October 20. Oil still remains in the rotating head cavity (approximately 1-2 gallons). The oil level should be near the middle of the sight glass. Removing the suction hose from the cover plate below the pinion shaft allows more oil to drain and also removes sediment that collects there. Removing the oil drain plug from the rotating head allows more oil to drain. the oil lube/pump/cooler system (approximately 1-2 gallons). 4-28 TDS-4S Maintenance and Troubleshooting . After installation and initial operation of the top drive. When draining oil from the drain plug at the bottom of the gearcase. only the 5-6 gallons of oil at the bottom of the gearcase actually drains. or above the middle of the sight glass. always fill the transmission to the middle of the sight glass. Operate the top drive 10-15 minutes and check the sight glass. 2. If the oil level is below the middle of the sight glass. 3. etc. installed.

Lubricate the commutator (brake) end bearing every 1. The lower armature bearing grease point on the G. e Excessive lubrication of electric motors can cause motor failure due to shorting or heat buildup from grease coming in contact with the field windings. TDS-4S Maintenance and Troubleshooting 4-29 .Lubricating the DC motor The upper motor armature bearings have grease points located on the brake adapter plate attached to the top of the motor. with two ounce by weight Shell Cyprina RA™.500 operating hours. or three months. or six months. Install grease fittings to lubricate and then remove the fittings and replace the plugs for operation. with two ounce by weight Shell Cyprina RA™. motor is at the end of a small diameter tube projecting toward the back of the tool.E. The grease points all have plugs or relief fittings installed during operation. Lubricate the pinion (transmission) end bearing every 750 operating hours.

October 20. 1998 Lubricating the washpipe and bonnet seal Apply grease daily to the washpipe grease fitting and the two bonnet seal fittings (located below the washpipe grease fitting) (Figure 4-5). Lubricating the washpipe and bonnet seal 4-30 TDS-4S Maintenance and Troubleshooting . Grease Fittings Wash Pipe Assembly Bonnet Figure 4-5.

Inspect for seal leakage weekly around the lower bearing retainer. Lubricating the standard rotating head Grease Fitting Grease Fittings Figure 4-7. Lubricating the powered rotating head TDS-4S Maintenance and Troubleshooting 4-31 . Grease Fittings Grease Fitting Grease Fittings Figure 4-6.Lubricating the rotating head Apply grease daily at the fittings (Figures 4-6 and 4-7).

Lubricating the link adapter 4-32 TDS-4S Maintenance and Troubleshooting . 1998 Lubricating the link adapter Apply grease to the link adapter fittings weekly as shown in Figure 4-8.October 20. 2 Grease Fittings on front. 2 Grease Fittings opposite. (4 places total) Figure 4-8.

Inspect the stabbing guide for excessive wear or cracks. Cylinder Pins and Arm Pins) Grease Fitting (6 on Optional Link Stop and Cylinder Assembly) Grease Fitting (1 each side of Torque Tube on Clevis Pin) Grease Fitting (8 on Bottom of Clamp) Figure 4-9. Grease Fitting (6 on IBOP Actuator Rollers.Lubricating the torque wrench Apply grease daily to the torque wrench fittings (Figure 4-9). Replace as necessary. Lubricating the PH-85 torque wrench TDS-4S Maintenance and Troubleshooting 4-33 .

Lubricate weekly. Check for worn components and operate the valve to verify correct adjustment weekly. Lubricating the master ID bushing wear guide Lubricating the safety valve actuator Apply grease daily to the fitting in the crank assemblies (Figure 411). Inspect the guide ring periodically for wear or damage and replace it as necessary.October 20. 1998 Lubricating the master bushing ID wear guide The master bushing ID wear guide has four fittings (Figure 4-10). Master Bushing Wear Guide Grease Fittings (4) Figure 4-10. 4-34 TDS-4S Maintenance and Troubleshooting .

Lubricating the upper safety valve (IBOP) Lubricate the upper IBOP valve weekly at the lubrication fittings located directly below the actuator cranks in the recessed counter bores (Figure 4-11). Refer to the IBOP Service Manual for complete IBOP lubrication instructions. Lubricating the IBOP TDS-4S Maintenance and Troubleshooting 4-35 . Open Position Actuator Shell Crank Arm Grease Port Grease Fitting Actuator Arm Groove Upper IBOP Valve Figure 4-11.

October 20, 1998

Lubricating the guide dolly assembly
Lubricate the 20 guide rollers every trip at the four manifolds (5 fittings each) located on each corner of the guide dolly (Figure 4-12). If your rig has a retract system, refer to the Retract Guide Dolly supplement. Check guide rollers weekly for cracks or excessive axial or radial play and replace as necessary. Lubricate the hinges (one place on each hinge) monthly. It is possible to over-grease (too much pressure, not volume) the guide rollers. This can push the plugs out. Visually inspect all of the guide rollers for evidence of grease extruding from the end(s) of the shaft. If you discover over-greasing, perform the following procedure: 1. Remove and disassemble the roller assembly. 2. Thoroughly clean and inspect all parts. 3. If the component parts are still serviceable, drill and tap the shaft end(s) for 1/8 in. NPT threads and install internal wrenching pipe plugs after thoroughly cleaning metal chips from the grease ports in the roller shaft. 4. Pre-grease roller bearings before reassembling and installing the rollers and shaft. 5. Re-grease roller bearings through grease lines to make sure lubricant is pumping through the roller bearings. Some grease should extrude between the rollers and roller shaft. 6. Replace unserviceable assemblies. 7. Improve plug retention on roller assemblies with intact sheet metal plugs by staking the edges of the port(s). To do this: a. Remove the roller or roller bracket assembly to improve accessibility. b. Use a hammer and chisel to stake the port edges.

4-36

TDS-4S Maintenance and Troubleshooting

A preferred method is to rework the roller assembly for drill and tap operation, but the staking method is also effective. At each bottom corner of the motor frame are the two grease points for the motor trunnions (Figure 4-13). Lubricate these weekly. Lubricate the washpipe packing daily with the mud pump off. Daily, with the hydraulic power on, check the filter gauge on the pressure filter to determine the condition of the filter element. Replace the element when a bypass condition is indicated.

e

Do not weld or torch cut on or near the motor frame without removing hydraulic accumulators.

TDS-4S Maintenance and Troubleshooting

4-37

October 20, 1998

Grease Fitting (20)

Grease Fittings

(TDS Removed for clarity) Non-Swing Guide Dolly

Grease Fittings

Figure 4-12. Lubricating the non-swing guide dolly assembly

4-38

TDS-4S Maintenance and Troubleshooting

Grease Fittings Grease Fitting (20)

Swing Guide Dolly

Grease Fitting

Grease Fitting

Grease Fittings

Figure 4-13. Lubricating the swing guide dolly assembly

TDS-4S Maintenance and Troubleshooting

4-39

October 20, 1998

Grease Fitting (28)

Grease Fittings

Retract Guide Dolly

(TDS Removed for clarity)

Grease Fittings

Figure 4-14. Lubricating the retract guide dolly assembly

4-40

TDS-4S Maintenance and Troubleshooting

Bail Bail Pin Bail Pin Grease Fitting Grease Fitting Figure 4-15. at the same time the dolly rollers are lubricated. one on each bail pin (Figure 4-15). Lubricating the bail pins TDS-4S Maintenance and Troubleshooting 4-41 .Lubricating the bail pins Lubricate the bail pins weekly. at the two fittings.

On rigs with closed loop cooling systems (Figure 4-17) also check the heat exchangers for water leakage weekly. Lubricating the local cooling system 4-42 TDS-4S Maintenance and Troubleshooting . and remove the access covers and operate the blower to remove dust buildup every 500 operating hours. 1998 Lubricating the cooling system Lubricate AC blower motors every three months (Figure 4-16).October 20. Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower Transmission Cooler Figure 4-16.

Lubricating the closed loop cooling system TDS-4S Maintenance and Troubleshooting 4-43 .Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower Motor Cooling Blower Heat Exchanger Heat Exchanger Figure 4-17.

1998 Lubrication schedule Frequency Daily Daily Daily Daily Daily Daily Daily Each trip Each trip Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly 750 hrs/90 days 1. 4-44 TDS-4S Maintenance and Troubleshooting . Monthly Monthly 3 months 3 months 3 months Location Bonnet seal Torque wrench (PH-85) Gearbox oil (check level) Rotating head Safety valve actuator cranks Hydraulic pressure filter † Wash pipe assembly BNC drill pipe elevator Guide dolly rollers (Retract ‡) Gearbox (shift gears) Dolly motor trunnions Air filter/regulator/lubricator † IBOP actuator arms Link adapter (650-Ton) Elevator support Master bushing wear guide Link tilt (check condition) Bail pins GE drilling motor pinion bearing GE drilling motor commutator bearing Motor frame/dolly hinges (Retract ‡) Cooling system cleaning AC blower motor Change gearbox oil Gear oil filter/suction strainer † Lubricant code* 1 1 2 1 1 – 1 1 1 1 – 1 1 1 1 1 3 3 1 – 1 2 – 4 – 2 1 1 Number of points 2 6 1 5 2 – 1 7 20 2 – 6 4 7 4 2 * See Table 4-1.October 20. hydraulic oil or non-detergent motor oil as a lubricant in the air control system. Recommended lubricants † Check condition and replace as necessary ‡ Refer to Retract Guide Dolly supplement e Use only 10-wt. Using any other type of oil or synthetic additive causes the seals in the air valves to swell and cease to function.500 hrs/6 mos.

The TDS transmission lubrication system is limited to pumping oils of a maximum of 9. Select lubrication for the TDS based on the minimum ambient temperature to be expected before the next oil change. and a minimum viscosity of 100 SUS at operating temperature. Keeping an effective film of oil on the gear mesh requires oil with an AGMA “extra pressure” rating. ISO 150 6EP. Varco recommends changing the oil every three months.Lubricant specifications TDS-4S transmissions operate under a combination of heavy and shock loads. the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. Varco recommends measuring the oil temperature with a contact thermometer. Varco top drives also operate under a wide variety of temperatures.000 SUS viscosity. Introducing an oil viscosity greater than required by the ambient temperature can: t Damage the gearbox due to reduced oil flow t Damage the oil pump because of excessive load All oils change viscosity with temperature and EP oil is no exception. ISO 68 4EP. ISO 320 Varco P/N See note below 56004-1 56004-BSC 56004-2 z For minimum temperatures below 20°F. The following tables will aid in your lubricant selection and keep your TDS-4S transmission operating properly: Minimum ambient temperature °F °C Below 20° 20° to 60° 45° to 85° Above 70° -6° -6 to 16° 7° to 30° 21° Oil type required See note below 2EP. Under these conditions oil tends to extrude out of the gear mesh. Measure on the pump discharge fitting on the TDS. TDS-4S Maintenance and Troubleshooting 4-45 . Under all but the most severe operating conditions.

If the oil temperature rises above 200°F. Recommended lubricants Lube Code and Description 1 2 General Purpose Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade Above -4°F (-20°C) MP grease Avi-Motive Lidok EP2 Below -4°F (-20°C) Avi-Motive W Lidok EP1 Above 70°F (21°C) Alpha LS-320 NL Gear 320 Spartan EP320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320 Gear Oil 45° to 85°F (7° to 30°C) Alpha -150 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 20° to 60°F (-6° to 16°C) Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Statoil Meropa 68 Carter EP 68 Gulf Crown EP32 Gulf Crown EP31 Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 1 - Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP 6EP 320 4EP 150 2EP 68 4-46 TDS-4S Maintenance and Troubleshooting .October 20. consult Varco engineering. Table 4-1. Varco recommends running the TDS at very light loads (less than 100 Amps) until the oil is above 20°F. 1998 If the oil temperature falls below 20°F. Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F. consult Varco engineering. If drilling conditions dictate oil temperatures below 20°F.

Table 4-1. Recommended lubricants (continued)
Lube Code and Description
3 4

Motor Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGL1 AGMA ISO Viscosity Grade All temperatures Cyprina RA -10˚ to 85˚C

Hydraulic Oil -15˚ to 75˚C Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 32

Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 1 46

TDS-4S Maintenance and Troubleshooting

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October 20, 1998

4-48

TDS-4S Maintenance and Troubleshooting

Chapter 3 Maintenance

Adjustment procedures
Adjusting the torque wrench
Use the following procedure to adjust the pipehandler torque wrench:

e

The pipehandler torque wrench is properly adjusted and tested in the factory before it is shipped. Perform the adjustment procedure after performing maintenance on the torque wrench or if the torque wrench does not function correctly. 1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight. Be sure to use the correct thread compound when making up.

z

When adjusting torque wrench manifold needle valves, loosen the locknut around the valve stem and use a 5/32 in. hex wrench to adjust the valve. After obtaining desired setting tighten locknut around valve stem.

TDS-4S Maintenance and Troubleshooting

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October 20, 1998

2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUE sequence valves on the torque wrench manifold fully in (Figure 4-18). 3. Fully back out the Pressure Reducing Valve (PRV), then screw in one turn. 4. Turn the LIFT/LOWER flow control valve fully in, and then back it out three turns. 5. Turn on the HPU. 6. If the torque cylinders are in their full clockwise position, set the Make/Break valve to MAKE. If they are in their full counterclockwise position, set Make/Break valve to BREAK. Note that torque cylinders should not move if the recycle sequence valve is fully in. 7. Slowly back out the RECYCLE sequence valve until torque cylinders just start to move, then screw out an additional full turn.

Make/Break Valve

Recycle Sequence Valve

Clamp Sequence Valve

Torque Sequence Valve

Torque Wrench Manifold

BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE

MAKE

PRV
40

50

60

70

30

1000

1500

80

LIFT LOWER

20

500

2000

90

10

®

0

2500

10

0

PSI Ft.Lbs.
x1000

0

Torque Gauge 0 - 2500 PSI

Figure 4-18. Torque wrench control manifold
4-50 TDS-4S Maintenance and Troubleshooting

8. Move the Make/Break valve to BREAK. Set the PRV to 750 psi. 9. Switch the lever between MAKE and BREAK to adjust the RECYCLE sequence valve until full rotation in each direction takes six to eight seconds. Tighten the locknut around the RECYCLE sequence valve adjustment screw. 10. Set the Make/Break valve to MAKE. 11. Depress and hold the torque wrench operating button on the VDC. The torque wrench should lift and the clamp jaws should remain retracted. 12. Slowly back out the CLAMP sequence valve until the clamp jaws just begin to clamp onto the tool joint. Screw out an additional half turn. Lock the CLAMP sequence valve adjustment screw in position by tightening the locknut. 13. Back out the TORQUE sequence valve until the torque cylinders just begin to stroke, then back out an additional half turn. Tighten the locknut around the TORQUE sequence valve adjustment screw. 14. Release the torque wrench operating button on the VDC. The torque wrench should start to unclamp and drop, then the torque cylinders should recycle. 15. If the torque cylinders recycle before the clamp cylinders retract, screw in the RECYCLE sequence valve until the torque cylinders do not move before clamp cylinders have fully retracted. Tighten the RECYCLE sequence valve adjustment screw locknut. 16. Cycle the torque wrench as many times as required to makeup the connection. 17. Set the Make/Break valve to BREAK. 18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub, without breaking out the saver sub or lower IBOP. 19. The torque wrench is ready for operation.

TDS-4S Maintenance and Troubleshooting

4-51

4-52 TDS-4S Maintenance and Troubleshooting . Tighten the fittings. A small amount of oil will leak around the adjusting stems after removing the caps. The pressure decreases and the cylinder rods begin extending. and disconnect the TDS from the drill string near the bottom of the rails. 4. 2. Crack both upper cylinder fittings and bleed air from system. Replace the caps on the valve adjustment stem. Remove the caps and loosen the lock nuts on the needle valve and PRV located on the counterbalance manifold (Figure 419).October 20. Using a hex wrench. Open the needle valve and let the stem circulate for two minutes. 1998 Adjusting the upper safety valve (IBOP) and safety valve actuator system Refer to the IBOP Service Manual for upper IBOP and safety valve actuator system adjustment procedures. 1. When the integrated swivel bail contacts the hook. Adjusting the counterbalance system Leave the HPU on during the entire adjustment procedure. Slowly back out the PRV. Allow the pressure to decrease an additional 25 psi and tighten the locknut. screw in the PRV until the cylinder retracts. It is not necessary to remove the front guard for access to the manifold. note the pressure on the gauge. but well off the stops. Close the needle valve. raising the TDS. 3.

Counterbalance manifold TDS-4S Maintenance and Troubleshooting 4-53 .Needle Valve (on opposite side) Upper Motor Frame Crossmember Pressure Reducing Valve Pressure Gauge Figure 4-19.

Open the two flow control valves located at the alignment cylinder supply return lines 1-1/2 turns off their seats. Close the needle valve. bleed down the alignment cylinder accumulator by opening the needle valve located at the alignment cylinder valve manifold (Figures 4-20 and 4-21).October 20. 5. 1998 Adjusting the motor alignment cylinder system Once the alignment cylinder is installed. With the HPU turned off. 2. Remove the split shipping brace from the motor alignment cylinder (Figure 4-22). use the following procedure to properly adjust the motor alignment before operating TDS systems that have a separate alignment cylinder accumulator and valve manifold. Turn on the HPU and allow the system to circulate for approximately two minutes. 1. 4-54 TDS-4S Maintenance and Troubleshooting . 3. 4.

Alignment Cylinder Lug (ref) Pressure Reducing Valve Needle Valve Motor Frame (ref) Alignment Cylinder Manifold Accumulator Bracket Gas Valve Figure 4-20. Typical motor alignment cylinder valve manifold TDS-4S Maintenance and Troubleshooting 4-55 .

October 20, 1998

Prefill Valve Assembly

Directional Control Valve (Operation Switch) Pressure Reducing Valve (PRV)

Needle Valve

Motor Frame (ref)

Alignment Cylinder Valve Manifold

Bracket Gas Valve Accumulator

Figure 4-21. Motor alignment cylinder valve manifold

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TDS-4S Maintenance and Troubleshooting

Motor Alignment Cylinder

Shipping Brace

Motor Frame Dolly (Ref)

Figure 4-22. Motor alignment cylinder

TDS-4S Maintenance and Troubleshooting

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October 20, 1998

z

The pressure setting is adjusted by screwing the PRV in or out with a hex wrench (Figure 4-19). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the PRV reduces pressure and moves the saver sub away from the rails (see additional notes at the end of this procedure). 6. Verify the correct pressure setting using the following procedure: a. With the HPU on, back down the pressure using the PRV until the saver sub begins to pivot away from the rails. Record this pressure. b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a “dead band” area. c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs. d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by two. The resulting pressure “dead band” provides equal pre-load in each direction – both toward and away from the rails. e. Record the pressure setting for future reference. 7. Set a joint of drill pipe in the slips. 8. Bring the top drive down as if stabbing the saver sub into the box. The pin and the box should be in alignment so that the OD of the pin clears the shoulder of the box. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box. b. Turn off the HPU and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame. c. Loosen the lock tab and jam nut on the cylinder clevis.

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TDS-4S Maintenance and Troubleshooting

d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4 in. of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2 3/8 ± 1/8 in. gland to rod threads when the system is properly aligned. e. Secure the jam nut and lock tab. f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2 in. of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats. g. Tighten the lock nuts and replace the caps on all valve stems.

z

If the alignment cylinder is removed for service, install the alignment cylinder replacement brace to support the motor housing assembly while continuing to operate the TDS. After reinstalling the alignment cylinder, use the three bleed holes (located along top of cylinder barrel) to remove air trapped in the cylinder. Rail spacing and setback from the centerline of the well must be held within recommended tolerances in order to maintain vertical alignment of the TDS.

TDS-4S Maintenance and Troubleshooting

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October 20, 1998

Precharging the counterbalance system
Please read these instructions completely before precharging, making note of the special cautions at the end of the section. 1. Use an inert gas such as nitrogen for precharging accumulators. If oil-pumped is not available, use dry, waterpumped nitrogen gas. 2. Before precharging, 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 end of the accumulator. 3. Remove the gas valve protector and the gas valve cap. 4. Attach the charging hose to the nitrogen bottle and to the gas valve using the following procedure: a. Use thread sealing and lubricating compound on the pipe threads of the gauge. b. Back the gas chuck stem completely out of the way before attaching the assembly to the accumulator gas valve. c. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the bleeder valve. d. Turn the gas chuck stem all of the way down, depressing the core in the accumulator gas valve. e. Only crack open the nitrogen bottle valve to slowly fill the accumulator. Shut it off when the gauge indicates 900 psi. f. If the 900 psi precharge pressure is exceeded, make sure the nitrogen bottle valve is closed, then open the bleeder valve (opposite the gas valve below the gauge) slightly, but only momentarily, to reduce pressure. g. Before loosening the swivel nut, turn the gas chuck stem out all of the way, then open the bleeder valve. h. Prevent the gas valve from turning, loosen swivel nut, and remove the assembly. 5. When precharging is complete, replace the cap on the gas valve and install the gas valve protector.

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TDS-4S Maintenance and Troubleshooting

Install new gas valve O-ring each time gas valve is removed. it warns of stored pressure whenever gas valve is being removed.e Do not loop or twist hose as it stiffens when gas pressure is released from nitrogen bottles. TDS-4S Maintenance and Troubleshooting 4-61 . Instead. slowly turn gas valve out until gas begins to escape through bleed hole drilled through threads of valve. Do not reduce accumulator precharge by depressing valve core (high pressure may rupture rubber valve seat). Never loosen the swivel nut attached to the gas valve in the accumulator without first backing the gas chuck stem all of the way out. This hole is a safety feature.

7. 10. Remove the bolts holding the frame onto the cast body and lift off. 11. Remove the pins holding the torque tube in place and remove. 4-24. 4. and remove the Make/Break manifold assembly. 2. 4-25. Pressurize the blind end of the clamping cylinder to remove the gland and piston. 3. Disconnect and label the remaining plumbing. 6. Disconnect the hard plumbing from the quick disconnects near the left torque cylinder. Remove the cylinder ring from the clamping piston bore. Remove the jaws.October 20. 1. hinge pins and outer body. see Figures 4-23. Remove the stabbing guide. 1998 Assembly and disassembly Pipehandler Torque wrench disassembly For PH-85. and 4-26. 8. Remove the guard. e Use care in this operation. 5. 9. Disconnect and label the hoses from the torque cylinders and remove the cylinders. For PH-60d. Remove the retaining bolts. 4-62 TDS-4S Maintenance and Troubleshooting . High pressure air can be explosive. see Figure 4-27.

PH-85 torque wrench assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-63 .Torque Tube V a r c o Torque Cylinders Figure 4-23.

October 20. PH-85 torque wrench assembly/disassembly 4-64 TDS-4S Maintenance and Troubleshooting . 1998 Clamping Jaws Body Clamp Cylinder Body Clamp Cylinder Pistons Stabbing Guide Figure 4-24.

Mounting Shaft Frame Safety Valve Actuating Cylinder (2) Vertical Positioning Cylinder Hanging Height Adjustment Guard Figure 4-25. PH-85 torque wrench assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-65 .

PH-85 torque wrench assembly/disassembly (optional link retractor) 4-66 TDS-4S Maintenance and Troubleshooting .October 20. 1998 Figure 4-26.

PH-60d torque wrench assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-67 .Frame Mounting Shaft Safety Valve Actuating Cylinders (2) Vertical Positing Cylinder Safety Valve Actuating Arm (2) Torque Tube Stabilizer Stop Tube Hanging Height Adjustment Shim Body Torque Tube Torque Cylinder (2) Guard Stabbing Guide Clamp Cylinder Body Clamping Jaws (2) Clamping Cylinder Piston Control Manifold Figure 27.

Replace all seals. Replacing the torque wrench clamping piston seal The following procedures require that the torque wrench be removed from the pipehandler. Pay close attention to the following points: 1. 2. 1998 Reassembly is accomplished in the reverse order of the above procedure. 2. 3 2 2 Disassembly P/N 72219 72220 72221 Description Piston seal Rod seal Rod wiper 1. Replacing the front and rear piston seals Parts required front and rear piston seal replacement: Qty.October 20. Take great care when installing the clamping piston and gland. 4-68 TDS-4S Maintenance and Troubleshooting . Vent the clamping cylinder as follows: disconnect the hydraulic lines to the clamp port and front unclamp port on the clamp body cylinder at the torque wrench manifold clamp and unclamp ports. If they are not closely aligned with the bore. Remove the slotted hex nut and cotter pin attaching the two halves of the stabbing guide together at the front and swing the guides out to each side. Use the following torque values: Cylinder rod end to cylinder rod* 944 ft lb Frame to clamp cylinder body 250 ft lb Stabbing guide to body 250 ft lb Die retainer screws 380 ft lb Body hinge pin retainer screws 150 ft lb Stabbing guide spring retainer screws 75 ft lb Jaw retaining screws 110 ft lb *The torque cylinder rod ends are threaded into the rods with locktite and cross pinned. they may become jammed and could be extremely difficult to remove. 3.

TDS-4S Maintenance and Troubleshooting 4-69 . 12. 4.3. Push in the cylinder gland from the rear cylinder head retainer ring and remove the ring with a screwdriver. Remove the jaw pins from the rear clamping jaw and remove the jaw. Be sure to remove the spacer from the piston rod slot. Remove and discard the piston seals. Attach the sliding hammer to the rear piston rod and carefully pull the piston until the cylinder gland can be removed. Assembly 1. 9. 6. Gently and evenly tap the piston into place until the rod appears beyond the front cylinder bore. Install a new piston seal in the front piston groove and lubricate with hydraulic fluid. 11. 2. 3. 7. Repair and clean as necessary. tap the front clamp piston from the front and remove it from the rear. rod seals. 4. 13. 8. Inspect the clamp cylinder bore thoroughly for dirt. Insert a new front rod seal and rod wiper in the clamp cylinder body and lubricate with clean hydraulic fluid. Remove the two screws holding the clamp clevis to the rear clamp cylinder piston. Insert the front piston into the clamp cylinder body with the two jaw spacer screw holes orientated vertically. Remove the pins holding the clamp body to the clamp clevis and remove the clamp clevis. and rod wipers. 10. Continue to pull until the piston comes out. Remove the front piston rod seal and rod wiper from the clamp cylinder body and discard. gouges. Remove the two screws holding the jaw spacer to the front clamp cylinder piston and remove the spacer and jaw spacer. and pitting. 5. Using a piece of wood or brass bar. burrs. nicks.

Install the piston seal in the outside groove. Insert the spacer and attach the clamp clevis to the rear cylinder rod with the two hex head cap screws and flat washers. Insert the rear piston into the clamp cylinder body with the two screws holes on the rod oriented to the horizontal position. 13. 11. Adjust orientation of the clamp clevis and attach to the clamp body using the two clevis pins and cotter pins. Gently tap piston into place until there is enough space between the piston face and retaining ring groove to insert cylinder gland and retainer ring. 4-70 TDS-4S Maintenance and Troubleshooting . 14. 18. 8. Tighten firmly and lockwire. Reinstall and adjust the torque wrench (refer to Adjusting the torque wrench earlier in this chapter). 15. 17. Install a new piston seal in the rear piston groove and lubricate with hydraulic fluid. 10. Push the gland past retainer groove and install the retainer ring. Attach the clamping jaw with the two jaw pins. 7. Tighten firmly and lockwire. 1998 5. 16 Swing the stabbing guide back into position and attach with the slotted nut and cotter pin. 9. Insert cylinder gland into the bore rod and piston seals first. Reconnect the hydraulic lines from the clamp body cylinder clamp port and front unclamp port at the torque wrench manifold clamp and unclamp ports. 12. Install the rod seal and rod wiper in the inside grooves of the cylinder gland. Lubricate all seals with hydraulic fluid.October 20. 6. Attach the rear clamping jaw spacer to the front piston rod using the spacer and two hex head cap screws and flat washers.

Replacing the standard rotating head glyd rings z Rotary glyd ring replacement is indicated when hydraulic oil is detected in the pipehandler air supply. 650-Ton rotating head assembly TDS-4S Maintenance and Troubleshooting 4-71 . Cam Stationary Flange Cam Follower Locking Lever Auto-Return Cylinder Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown) Figure 4-28. The following disassembly and assembly procedures assume that the TDS is swung out for maintenance in accordance with the TDS swing out procedures (refer to TDS swing out procedure in Chapter 1 of this book). Refer to Figures 4-28 and 4-29. An indication of oil contaminating the air supply would be an accumulation of oil in the link tilt air actuator (bag). when performing the following procedures.

Support the rotating block and remove the ten screws. Remove excluder cap gasket and replace with new gasket. 11. Place the rotating head stand.October 20. 8. Disconnect the IBOP actuator arms and hoses. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. Remove the torque arrestors. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 18. under the TDS and lower the TDS until the rotating head rests on the stand. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. Remove the pin attaching the hanger to the rotating block clevis. Push the cam follower away from the rotating block cam. and remove the torque wrench. 1998 Disassembly 1. Remove the rotating block and glyd rings. 4-72 TDS-4S Maintenance and Troubleshooting . 4. leaving the rotating head on the stand. 10. 19. Remove the cotter pin from the return cylinder clevis pin. Support the torque wrench. and one excluder cap gasket from Varco. 16. Order eight replacement glyd rings. 13. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. one flange gasket. built prior to disassembly. 5. 17. 6. link tilt and link adapter. 3. 7. Remove the flange nuts and lift the block. Remove the excluder cap and gasket. 12. 15. Remove the glyd rings from the rotating block and discard. two gearcase seals. 9. 2. Remove the hex-slotted nut and remove the clevis pin.

. .... . ..Cam Assembly Locking Handle Return Cylinder Return Cylinder Clevis Pin Return Cylinder Rod End Detail Hex Nut Cam Cotter Pin ..... Excluder Cap Gasket Ball Bearing C Stationary Flange Bull Gear Lip Seal Figure 4-29..... .......... .... ... .. ...... Cylinder Clevis Excluder Cap Detail Retainer Ring Ball Bearing Glyd Ring (8) Cam ... ...... Replacing the 650-Ton rotating head glyd rings TDS-4S Maintenance and Troubleshooting 4-73 . C .

1998 Assembly 1. 2. 7. carefully mate the rotating block to the stationary flange. Using a tugger or other support. 4. 6. Attach the return cylinder rod to the clevis with the clevis pin and install the slotted hex-head nut and cotter pin. 3. Place the excluder cap and gasket on the bottom of the rotating block. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. Reinstall the ten hex-head screws and torque to 250 ft lb. Reinstall the quick disconnect hydraulic fittings on the rotating block. 4-74 TDS-4S Maintenance and Troubleshooting . Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book. Safety wire the screws per standard safety wire procedures. 8.October 20. 5.

14. 5. 2. Place the rotating head stand. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 10. 4. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 11. leaving the rotating head on the stand. one flange gasket. 9. 7. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. Order eleven replacement glyd rings. 12. under the TDS and lower the TDS until the rotating head rests on the stand. Disassembly 1. two gearcase seals. Remove the flange nuts and lift the block. built prior to disassembly. 3. Remove the hydraulic motor assembly. Remove the torque arrestors. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. TDS-4S Maintenance and Troubleshooting 4-75 . 6. 8. and link adapter. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. link tilt. 13.Replacing the powered rotating head glyd rings Refer to the assembly drawings when performing the following procedures. Remove the hex-slotted nut and remove the clevis pin. Support the torque wrench. Remove the cotter pin from the return cylinder clevis pin. and remove the torque wrench. Remove the pin attaching the hanger to the rotating block clevis. Disconnect the IBOP actuator arms and hoses. and one excluder cap gasket from Varco.

Safety wire the screws per standard safety wire procedures. 1998 15. 2. 17. 4.October 20. Lubricate the eleven new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. Remove the rotating block and glyd rings. Remove excluder cap gasket and replace with new gasket. 7. Place the excluder cap and gasket on the bottom of the rotating block. Using a tugger or other support. 18. carefully mate the rotating block to the stationary flange. 3. Support the rotating block and remove the ten screws. Remove the glyd rings from the rotating block and discard. 16. 6. Reinstall the QD hydraulic fittings on the rotating block. 19. Remove the excluder cap and gasket. Reinstall the hydraulic motor assembly. 4-76 TDS-4S Maintenance and Troubleshooting . 5. Reinstall the ten hex-head screws and torque to 250 ft lb. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book. Assembly 1. 8.

Lift the lever or base off the air actuator sealing plate. 2. 3.Replacing the standard or extended reach link tilt air actuator The link tilt mechanism has two air actuators. Parts required: One air actuator (P/N 82353) 18 Button head cap screws (P/N 50186-10-01) Disassembly 1. Lower the link tilt to the floor with the air actuator to be replaced facing up. 4. pry the air actuator away from the screws. 8. 10. 6. TDS-4S Maintenance and Troubleshooting 4-77 . Remove the nuts and washers holding the sealing plate to the air actuator and remove the plate. Remove the safety wire from the four hex-head cap screws holding the air actuator sealing plate to the link tilt base or lever and remove the screws. Remove the cotter key and pin from one end of chain connecting the two sealing plates. 7. and rotate it 180° on the link tilt pivot pin and lay down. Using a pry bar or screwdriver. Use the following procedure to replace one air actuator (Figures 4-30 and 4-31). Disconnect the air hose from the rotating head rotating block to the link tilt assembly. Remove and discard the air actuator. 5. Remove any burrs or gouges on sealing surfaces of the hanger and sealing plates. attach the actuator to the hanger plate and remove the screws using a hex wrench. Support the link tilt and remove the two upper and two lower screws attaching the link tilt to the link adapter. 9.

Lock Washers (18) Air Actuator Base Hanger Plate Pressure Regulator Sealing Plate Bolt (4) Quick Exhaust Valve Lever Intermediate Stop (2) Connecting Chain Buttonhead Capscrew (18) Stop Pivot Arm Elevator Link (Ref) Stop Release Loop Figure 4-30. Standard reach link tilt assembly/disassembly 4-78 TDS-4S Maintenance and Troubleshooting . 1998 Lever Weldment Pivot Pin Sealing Plate (2) Nuts.October 20.

Lock Washers (18) Air Actuator (2) Sealing Plate Bolt (4) Pressure Regulator Base Hanger Plate Quick Exhaust Valve Lever Intermediate Stop (2) Connecting Chain Stop Pivot Arm Elevator Link (Ref) Stop Release Loop Figure 4-31. Extended reach link tilt assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-79 .Lever Weldment Pivot Pin Sealing Plate (2) Nuts.

Torque the nuts to the sealing plate at 80 ft lb. Attach the air actuator to the hanger plate with the 18 buttonhead cap screws. coat the bolt threads with locktite and fasten with the lockwashers and nuts provided. 11. Lift and rotate the link tilt lever or base to line up with the air actuator sealing plate. Reinstall the air actuator sealing plate. 10. These beads must be compressed equally to ensure a good air seal. Place a new actuator on the hanger plate. (See Caution above. Over-torquing may cause hex sockets to strip. e The air actuator has aluminum neck bead rings on both sealing surfaces. Reconnect the chain between the two sealing plates.October 20. This requires more than one tightening pass to accomplish. 6. 1998 Assembly 1. 4-80 TDS-4S Maintenance and Troubleshooting . 7. Attach with the four hex-head cap screws and torque to 250 ft lb.) 8. Torque the cap screws to the hanger plate at 80 ft lb. 9. 5. 2. Safety wire the four screws. Insert the 18 bolts into the neck ring of the air actuator. Coat the screw threads with locktite before installation. Reinstall and adjust the link tilt per the Installation and Commissioning book. 4.

remove the cotter pins from the retaining bolts and slotted nuts. Support the remaining retaining bolt while removing the slotted nut and upper die retainer. Remove the cotter pin from the retaining bolts and slotted nut. Remove the nuts securing the die retainer to the jaw. 5. Remove the tong dies from the jaw. 3. Support the retaining bolt while removing the slotted nut. TDS-4S Maintenance and Troubleshooting 4-81 . On the rear jaw. Remove the retaining bolt and lower die retainer. 3. 4.Removing the tong dies Front jaw 1. 6. Remove the die retainer from the jaw. 2. Remove the retaining bolt from the piston jaw. Remove the tong dies from the jaw. Rear jaw 1. 2. 4.

2. Lower safety valve (IBOP) Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures.October 20. Support the jaw and remove the socket-head cap screws and washers from the jaw assembly and the torque wrench body. Remove the front jaw assembly from the torque wrench body. Support the jaw assembly and remove the socket-head cap screws and washers from the jaw assembly and piston. 1998 Removing the jaws Front jaw 1. 3. Remove the rear jaw assembly from the piston. Upper safety valve (IBOP) Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures. Loosen the socket head cap screws securing the jaw assembly to the torque wrench body. Loosen the socket head cap screws securing the jaw assembly to the piston. Rear jaw 1. 4-82 TDS-4S Maintenance and Troubleshooting . 2. 3.

Make sure the transmission is in neutral. the drilling motor must be removed from the dolly. Take up the slack and remove the trunnion blocks that hold the transmission to the guide dolly frame. and sliding the housing off of the motor toward the gearcase 14. Remove any cooling ducts (heat exchanger. 3. Disconnect the wiring between the motor and motor support bonnet.e. 10. 8. Set the TDS down horizontally on a good flat surface. 13. 15. Set the TDS and motor support bonnet down on wooden chocks. 1. 4.000 lb). If service is required on the lower end (i. Hoist the transmission out of the guide dolly frame. 12. Disconnect all wiring and hoses between transmission and guide dolly frame. Remove the blower and brake assemblies. Reverse this procedure for reassembly. Use a suitable sling to support the weight of the TDS and motor support bonnet (approximately 10. 9. If so. Make sure none of the components protrude past the guide dolly roller brackets before setting the TDS down. lower bearings or seals). Lift the transmission off of the motor. air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. 6. etc. spark arrestor. upper drive stem bearing and seal. being careful not to damage components. Remove the four large motor bolts. 5. TDS-4S Maintenance and Troubleshooting 4-83 .) that interfere with removing the transmission from guide dolly frame. 2.Removing the motor assembly from the guide dolly You can perform some service procedures on top drives (i. block up the guide dolly accordingly. 11. angling the upper end slightly to clear the motor support bonnet. 7. gear set.e. Remove the dowel pins in the motor feet.

October 20. 4. slotted nuts and the rotating head. Remove the main body. 7. 6. Remove the brake for service. 1998 Disassembly/assembly of the drilling motor and motor support bonnet 1. Remove the upper bearing cover and grease seal (Figure 4-32). Carefully remove the bull gear. Do not remove the gear from the shaft unless you are replacing it. Remove the lower gearcase. Remove cotter pins. Remove the pinion seal and retaining ring. 8. carefully avoiding damage to the lower gearcase locator dowel pins. 5. On the opposite end of the motor. 4-84 TDS-4S Maintenance and Troubleshooting . 9. avoiding damage to the bearing surfaces or wear sleeves. Pressurize the air brake to hold the drive mechanism in place. 3. remove the magnetic pickup and brake cover. 2.

Drilling motor and motor support bonnet assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-85 .Main Body Air Brake Low Gear Assembly DC Drilling Motor Bull Gear High Gear Assembly Pinion Gear Manual Shifter Input Geneva Mechanism Shaft LO HI Oil Level Sight Glass Motor Pinion Seal Lower Gear Case Motor Alignment Cylinder Gear Selection Indicator Figure 4-32.

9. Blower: Clean any accumulation of dust from the ducting. replace it. 1998 Refer to the GE Electric Motor Manual for procedures to remove the pinion or hub on the armature shaft. Air brake: Check the brake for air leakage and the pads for wear. Seals: Always replace seals and gaskets when removed. 3. remove the appropriate valve and repair or replace. then operate the unit and correct any interference between the impeller and housing. The wear pattern should be even and symmetrical. Main shaft: Check fit to bull gear. and retaining threads. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gearcase are critical. 4-86 TDS-4S Maintenance and Troubleshooting . 7. 4.090 in. Replace the shaft if spline wear exceeds 0. Wear sleeves: These should be free of any imperfections on the sealing surface. If not. or to service the motor itself. Clean up any nicks or gouges prior to reassembly. 10. Main shaft: Check splines and tool joints for wear.October 20. and refer to the following torque chart for bolt tightening guidelines. Gear set: Check the teeth and splines for chips or heavy wear. 6. Once the unit has been disassembled. then rotate and listen for any roughness during rotation. wear sleeve surfaces. Replace all grease seals and O-rings. 8. Expect some small surface pitting. Bearings: Clean thoroughly in solvent. 2. inspect the following assemblies for any wear or damage that may be critical: 1. Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. 5. It is not cause for replacing the gear set. Air valve assembly: If any air-operated systems are malfunctioning.

Torque Chart Motor support/bonnet to main body Main body to motor support/bonnet Bull gear to hub Lower gearcase to main body Rotating head to lower gearcase Brake adapter ring to motor Brake to brake adapter plate Brake drum to hub Brake cover to brake 1100 ft lb 1100 ft lb 580 ft lb 250 ft lb 250 ft lb 250 ft lb 50 ft lb 250 ft lb 50 ft lb Installing the TDS motor pinion n Installing a pinion gear can be dangerous to personnel installing it as well as anyone witnessing the procedure. TDS-4S Maintenance and Troubleshooting 4-87 . Exercise caution at all times. Clean the motor shaft by hand and cover with a thin layer of Engineer’s Blue. lining up the reference marks. oil. 4. 2. trial mount the cold pinion gear on the motor shaft. Mark reference lines on the pinion and the shaft to ensure identical angular orientation each time. and/or grease from the pinion bore and shaft. There must be a minimum of 75% surface contact between the pinion and motor shaft. Firmly install the pinion on the motor shaft by hand. Dress the motor shaft/pinion very lightly with a fine emery cloth and repeat the “blueing” procedure if necessary until there is at least 75% surface contact between the pinion and motor shaft. 3. After thoroughly cleaning all blueing. Use the following procedure to install a TDS motor pinion: 1.

Heat the pinion gear to 360-385°F (182-196°C) for three hours in an oven. 12. Place the pinion gear assembly and fixture on the motor shaft. 7. advancement. 17. The pinion creeps up the shaft as it cools to the required position of 0. Remove the fixture from the pinion gear assembly.005 in. After heating for three hours. sandwiching the pinion gear in the fixture. Back off the adjusting screw until the gauge reads 0. 14. Gently tap the pinion gear assembly and fixture into place until the adjusting screw butts against the motor shaft. Complete the required documentation recording pinion advancement. Wait 2-3 minutes and back off the nuts holding the fixture in place.074 in. Make sure the fixture is clean and the “horse shoe” face and bar are parallel. Attach a calibrated dial indicator gauge to the fixture and set to zero. 10. 13. 11. fit the fixture and check final advancement. Place the fixture on the motor shaft with the “horse shoe” end against the inner face of the gear and the bar against the outer face of the gear. 16. Then lock the screw in place with a locknut. 8. When the pinion is fully cooled.0720. Adjust the adjusting screw to butt against the end of the motor shaft. 4-88 TDS-4S Maintenance and Troubleshooting . 15. 1998 5. e Do not put the fixture in the oven. 6.085 ± 0. 9. remove the pinion gear assembly and immediately attach the fixture. There may be some noise as the pinion gear cools.October 20. lining up the reference marks.

2. Remove the blower housing and inner plate assemblies as units from both sides.Local blower cooling system assembly/disassembly Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-33): 1. Do not separate the blower housing assemblies from the inner plates. Remove both blower impellers. 13. Unbolt the four bolts connecting the blower motor feet to the blower mount. Remove the electrical wires from the blower motor. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. Remove the eight bolts on each side connecting the ducts to the blower housing ducts. 6. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. 10. Remove the shaft seal assemblies from both sides. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. Remove the blower inlet ducts on both sides of the blower motor. 11. 5. 3. 7. 9. Lift the motor out. 8. 12. Remove the taper lock bushings from both blower impellers. Remove the four bolts connecting the blower mount to the brake cover. 4. TDS-4S Maintenance and Troubleshooting 4-89 .

October 20. Typical local blower cooling system assembly/disassembly 4-90 TDS-4S Maintenance and Troubleshooting . 1998 Axial Fan 20 hp Blower Motor Locking Key Blower Housing Gasket Transmission Cooler Oil Fittings (2) Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket FLL-X Duct Connection Point Mounting Plate Blower Duct to AC Drilling Motor Spark Arrestor Figure 4-33.

4. 6. 5. the cooling system assembly should line up perfectly on the TDS. Tighten and safetywire the retainer plates in place on both sides. 9. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. Connect the electrical wires to the blower motor. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 12. TDS-4S Maintenance and Troubleshooting 4-91 . Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. b. 2. Make sure the seals are centered. If the alignment holes were properly used. 3. Install shaft seal assemblies inside both blower housing assemblies. 11. 8. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. Install the impellers and taper lock bushings on both sides and safetywire the bolts. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Install wear sleeves on the blower motor shaft. Install and safetywire the four bolts connecting the blower mount to the brake cover. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Hoist the entire cooling system assembly onto the TDS. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 7. 10.Use the following procedure to install a new motor in the local cooling system: 1. Use two 3/8 in.

Remove the eight bolts on each side connecting the ducts to the blower housing ducts. Remove the electrical wires from the blower motor. 1998 Closed loop cooling system assembly/disassembly Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-34): 1. 6. 7. 4-92 TDS-4S Maintenance and Troubleshooting . 9.October 20. Remove the four bolts connecting the blower mount to the brake cover. Remove the shaft seal assemblies from both sides. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. Remove both blower impellers. 11. 13. Remove the blower housing and inner plate assemblies as units from both sides. Lift the motor out. 4. Do not separate the blower housing assemblies from the inner plates. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. Remove the taper lock bushings from both blower impellers. 8. 5. 3. 2. 12. Remove the blower inlet ducts on both sides of the blower motor. Unbolt the four bolts connecting the blower motor feet to the blower mount. 10.

Flex Connection (2) Blower Inlet (2) Water Connections DC to Motor Exhaust Port on Upper Gear Case Inspection Cover GE Drilling Motor Heat Exchanger (2) Figure 4-34.Dual Shaft 20 hp AC Blower Motor Blower Mount/ Brake Cover Blower Housing (2) Impeller (2) 8 in. Typical closed loop cooling system assembly/disassembly TDS-4S Maintenance and Troubleshooting 4-93 .

bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. the cooling system assembly should line up perfectly on the TDS. 6. Connect the electrical wires to the blower motor. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. Install and safetywire the four bolts connecting the blower mount to the brake cover. Make sure the seals are centered. Hoist the entire cooling system assembly onto the TDS. Install the impellers and taper lock bushings on both sides and safetywire the bolts. b. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 4. 5. Use two 3/8 in. Install shaft seal assemblies inside both blower housing assemblies. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. Install wear sleeves on the blower motor shaft. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a.October 20. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. 7. 8. Tighten and safetywire the retainer plates in place on both sides. 2. 10. 3. If the alignment holes were properly used. 4-94 TDS-4S Maintenance and Troubleshooting . 1998 Use the following procedure to install a new motor in the local cooling system: 1. 12. 11. 9. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a.

triangles. Squeeze the handles of the pliers together and unlock the round.g. perforated slider in the center of the pliers from the hook lock. Never overtorque or loosen a torqued fastener to align safety wire holes. use double-twist safety wiring. n n Limit single-twist wiring to the following: small screws located in closely spaced. 2. Use the size and type of safety wire required in the applicable specifications and drawings. 5. Do not reuse safety wire. closed geometrical patterns (e. 6. Squeeze the handles together with one hand and pull the slider toward the rear of the pliers with the other hand to lock the pliers. TDS-4S Maintenance and Troubleshooting 4-95 . n Torque fasteners before safety wiring any screw. or circles). or other fastener. rectangles. nut. To install safety wire: 1. or parts that are difficult to reach. Twist the safety wire by pulling the aluminum knob and twist the rod out from the pliers. Let the pliers spin free. Grip both safety wires in the jaw. Whenever possible. nuts. Return the knob and twist the rod by holding the pliers steady with one hand and pushing against the end of the knob the with other hand (step 4 in Figure 4-35). Open the jaws of the safety twist pliers. Repeat the previous twisting cycle. parts in electrical systems. bolts. 3.Replacing the safety wiring Use the following procedures to safety wire screws. or other fasteners where applicable. squares. plug.. 4.

After threading the safety wire through the hole in the fastener. 1 2 5 3 4 Figure 4-35.October 20. Make a pigtail of approximately 1 in. Safety wiring procedures 4-96 TDS-4S Maintenance and Troubleshooting . 1998 7. (25 mm) length (four twists minimum) at the end of the wiring and bend back or under to prevent it from becoming a snag. Twist four to five complete revolutions per inch of wire. pull the wire straight through without nicking the wire. 8.

If necessary. unless otherwise specified. or a 24 in. continue tightening within specified torque limits until a slot aligns with the hole. Position the safety wire so the pull exerted by the wire tightens the nut. Make twists tight. even. (610 mm) length of safety wire is usually the maximum. n When securing castellated nuts with safety wire. Safety wiring examples TDS-4S Maintenance and Troubleshooting 4-97 . let the wire leave the fastener in a clockwise direction t Twist the safety wire so the loop around the bolt or head has sufficient tension to keep it from slipping up and over the bolt head. For best results. with resulting slack in the safety wiring. tighten the nut to the low side of the selected torque range. As a guide. but do not stretch it or let kinks develop. bolts or screws that can be safety-wired together depends on the application. Figure 4-36. n Do not nick the wire with the edge of the hole in the fastener. t The number of nuts. a group of three. when safetywiring widely spaced bolts by the double-twist method. and as taut as possible without weakening the wire by overtwisting (Figure 4-36).Safety wiring tips t Pull the safety wire firmly.

1998 4-98 TDS-4S Maintenance and Troubleshooting .October 20.

Clean or replace. Cylinder rod seals leak. Adjust per adjustment procedure. Always start the Hydraulic Power Unit (HPU) first. then slowly close needle valve with HPU running. Tighten or replace as required. Replace seals. in rig down position. Probable cause Needle valve is not closed. Cylinder rods remain retracted (closed). Counterbalance control valve Return valve to drilling position. Dirty or defective PRV valve. run for 3-5 minutes. Clean or replace. Remedy See adjustment procedure and check needle valve. never start an empty system with the needle valve closed. TDS-4S Maintenance and Troubleshooting 4-99 . See adjustment procedure. Fittings or hoses leak. Dirty or stuck check valve. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals. e When activating or reactivating the counterbalance system. Pressure setting too high.Chapter 4 Troubleshooting Troubleshooting the counterbalance Symptom System does not hold pressure.

Fittings or hoses leak. Normal adjustment is 1 1/2 turns from full closed position on flow control valves.October 20. Alignment cylinder fluid flow not adequately throttled. Remedy Free trunnion pins as needed and lubricate area regularly. Dirty or defective PRV valve. motor dolly upright frame. Check Troubleshooting the counterbalance section of this book. 1998 Troubleshooting the motor alignment cylinder Symptom Alignment cylinder fails to move transmission at trunnion pivot points with recommended pressure setting. Loss of nitrogen precharge in Recharge accumulators as per the procedure in the Troubleshooting the accumulators located in counterbalance section of this book. Check to make sure that rotary is in center of floor and then check alignment of rails in relation to rotary. 4-100 TDS-4S Maintenance and Troubleshooting . See the adjustment procedure. from lack of lubrication. Possible problem with Counterbalance system hydraulic system works erratically or does not components. Alignment cylinder rod Adjust according to procedure. If there is excessive movement close to 3/4 turn from full closed position. See the adjustment procedure. Cylinder rod seals leak. Excessive motor movement. System does not hold pressure. Needle valve is not closed. adjustment too long or short. Clean or replace. See the adjustment procedure. Rails not properly aligned with centerline of well. work at all. Probable cause Transmission trunnion pins will not pivot in dolly support brackets. Alignment cylinder pressure too high or too low. Replace seals. Tighten or replace as required. Saver sub on TDS does not align with drill pipe.

repair with repair kit or replace valve. Clean or replace. TDS-4S Maintenance and Troubleshooting 4-101 .Troubleshooting the drilling motor and guide dolly Troubleshooting the motor air brake Symptom Brake does not hold. Lubricate. Brake does not release. Quick exhaust valve not functioning properly. Brake drum contaminated with grease or pads worn or burnt. Remedy Set the flow controls to attain desired retract speed. Check mechanical operation of solenoid valve. Solenoid valve sticking. Probable cause Flow control valves on the guide dolly are not properly set. Check electrical continuity. Check air supply lubricator. Probable cause Insufficient air supply. Check lubricator on air supply. Troubleshooting the retract guide dolly Symptom Guide dolly retracts too slow or too fast. Solenoid valve not shifting. Inspect and replace if necessary. Remedy Check air supply pressure. 90 psi minimum required.

Adjust oil level to recommended level in sight glass. Gearbox temperature is excessive. with such. Check discharge or pressure hoses at outlets to confirm circulation. Oil level too low or too high. Probable cause Lower gear case seals are dry or damaged.October 20. housing breather. Replace oil. Clogged oil suction screen. Incorrect lubricant used. Oil leaking from shaft Oil level too high. Check recommended lubricants chart and replace as needed. Remedy Apply grease to seal. If problem persists replace gearcase seals and bearing. Check recommended lubricants chart and replace as needed. 1998 Troubleshooting the transmission Symptom Oil leaking from lower seal. Oil is foaming. Incorrect lubricant used. Grease fitting daily. 4-102 TDS-4S Maintenance and Troubleshooting . Remove suction screen from oil pump. Check heat exchangers for air flow Clogged or dirty heat exchangers on unit equipped or water flow to ensure adequate heat transfer and dissipation. Adjust oil level per recommended specification.

Repair as needed. repair or replace as needed. Remedy Check electrical components to ensure power is available to motor. Inspect. Replace as needed. Verify proper rotation and correct if necessary. Check recommended lubricants chart to make sure proper viscosity of oil is used.Troubleshooting the oil pump Symptom OIL PUMP LOSS alarm is on. TDS-4S Maintenance and Troubleshooting 4-103 . Defective or improperly adjusted pressure switch. Incorrect motor rotation. Check relief valve on back of pump. Probable cause Motor is not running. repair or replace as needed. Failure of oil pump drive coupling. If unable to make oil pump work after checking all of the above. Check switch operation. Remove and clean suction screen making sure to properly seal screen cover when installing. Incorrect lubricant used. Check all connections and suction screen cover plate to ensure there are no air leaks on suction side of oil pump. Dirty or clogged oil pump suction screen. Repair or replace as needed. Oil pump cavitatingevidence of air bubbles in discharge lines. Faulty or worn oil pump. Repair or replace as needed. Install test gauge in discharge line and adjust to 10 psi.

Blower runs intermittently. Correct as needed. 4-104 TDS-4S Maintenance and Troubleshooting . Excessive air loss in blower motor shaft area. Clogged water or air passages Remove and clean passages as needed. Replace as needed. Faulty motor starter. 1998 Troubleshooting the cooling system Symptom Mechanical noise in blower. Locate and repair as needed.October 20. DC MOTOR OVERHEATING. wearing seals excessively. Check for dirt or trash between starter coil. in water cooled exchangers (closed loop cooling). Probable cause Loose impeller. Repair or replace as needed. Replace as needed. Faulty motor bearings. Worn or defective seal or wear sleeve. Remedy Reinstall impeller and hub and locktite screws. Verify blower rotation. Dirty or clogged spark arrestors (local or remote cooling systems). OVERTEMP alarm stays on with blower running. Repair or replace as needed. Faulty or loose wiring. Remove spark arrestors from motor and clean screens if screens are damaged with holes. Incorrect blower rotation. Correct blower mounting problem or faulty motor bearing and replace blower shaft seals. Loose or vibrating blower motor.

Remedy Check service manual for continuous Amp motor rating and adjust drilling program accordingly. Faulty temperature switch or Repair or replace as needed. Dirty or faulty water detector. Probable cause Continuous drilling Amps over recommended levels. Improper cooling water flow See the Installation and or incoming water temp too Commissioning book for recommended or required flow rates high (closed loop cooling). Check air intake on blower to ensure there are no restrictions. Check for leaks in heat exchanger. probe.Troubleshooting the cooling system (cont. and water temp. Ensure dry air is going into motor. Serious damage could occur to the motor if this is done. WATER DETECTOR alarm is on (closed loop system).) Symptom DC MOTOR OVERHEATING. Restricted air flow (local or remote cooling). OVERTEMP alarm stays on with blower running. Clean or replace as needed. Moisture in air inside DC motor. TDS-4S Maintenance and Troubleshooting 4-105 . Verify proper blower rotation. Check air purge line filters. e z DC motor should never be stalled for more than 5 seconds with over 300 Amps applied. Motor being stalled for over recommended periods of time. Do not readjust or raise heat range setting. Check and clean spark arrestors as needed.

Supply and return hoses are crossed. properly plugged together and flowing in both directions. Inspect valves for damaged seals or stuck spools. Torque wrench does not lift.October 20. z Die retainer and die retainer bolts damaged while breaking. should also have proper chamfer on both shoulders. Close needle valve (always with HPU running). Probable cause Valves in manifold out of adjustment. Replace if necessary. Valve cartridge replaced with wrong type. Sub machining. Locate and repair bypass as necessary. Reconnect hoses correctly. 4-106 TDS-4S Maintenance and Troubleshooting . 1998 Troubleshooting the pipehandler Troubleshooting the torque wrench Symptom Tool does not cycle properly. Listen for oil bypassing in pipehandler cylinders or manifold. When changing the Make/Break valve. Defective cartridge valve or PRV valve. Oil bypass in pipehandler hydraulic components. Improper component or component installation. Improper saver sub length or Saver sub length too long. make sure the valve is properly oriented when installed. Improperly connected Quick Check QDs to make sure they are Disconnects (QDs). Remedy Readjust. Needle valve in counterbalance manifold is open.

Make up saver sub per procedure described in the IBOP Service Manual. Tool goes up. Tong dies worn. hook both pipehandler hoses together and verify flow in both directions by activating switch with hydraulics on. clean and lubricate. remove pipehandler and break out with rig tongs at floor. check hydraulic pilot valve for stuck spool. Air pilot valve on counterbalance manifold stuck or and cycles. If air pilot valve is operable. Repair or replace. If saver sub is made up to recommended torque and continues to break out instead of drill pipe connection. If air supply is available remove end cap on pilot valve. Tong dies break or score drill pipe. Pilot valve dirty. TDS-4S Maintenance and Troubleshooting 4-107 . increase previous torque makeup by 10% to maximum torque recommended in the IBOP Service Manual (for original Varco OEM subs).Troubleshooting the torque wrench (cont. Connection overtorqued. but inoperative. Saver sub not made up properly. If saver sub or drill pipe will not break out using pipehandler. Hydraulic valve not shifting. Replace tong dies. Valves in manifold out of adjustment. Readjust per procedure. If QDs are properly connected. remains clamped on pipe when switch is released. Improperly connected quick disconnects. clamps. Saver sub breaks out instead of tool joint. If there is flow in only one direction. break out using rig tongs. check QDs.) Symptom Probable cause Remedy Remove air supply line to verify air supply when solenoid valve is activated.

Repair or replace rollers and roller brackets. Check actuator shell adjustment and crank assembly operation. Retracts past well center in float mode. Probable cause Internal parts worn out. Pressure setting on float valve too low. Adjust jam not on passive stop to position elevators over well center. Check spool mechanical operation and lubricate as needed.October 20. Retracts slowly. Worn cam rollers. Adjust pressure setting. brackets bent or out of adjustment. Passive stop not in right spot. Lubricate if needed. shimming as needed to maintain smooth operation. Passive stop not in right spot. Actuator out of adjustment. Improperly adjusted. Check spool mechanical operation. Excessive vibration or Actuator support roller wobble while rotating. Remedy Check electrical continuity. Readjust drag link. Check actuator cylinder adjustment (see procedure). Adjust pressure setting. shorten if necessary. Remedy Check for washouts or defective parts. Troubleshooting the link tilt Symptom Does not tilt. 1998 Troubleshooting the safety valve actuator Symptom Safety valve leaks. 4-108 TDS-4S Maintenance and Troubleshooting . Probable cause Solenoid valve not shifting. Repair as needed. does not make it back to well center. Adjust jam not on passive stop to position elevators over well center. Does not reach mousehole. Pressure setting on float valve too high. Check electrical continuity.

Clean as needed and lubricate. Crank assembly. Remedy Check all QDs to make sure that they are properly connected. Check oil lubricator to make sure valves are being lubricated. Air pilot valve sticking. Disconnect air line from solenoid to air pilot valve. There must be 90 psi minimum pressure. Repair or replace valve as needed. Check air supply. Repair as needed. Faulty or loose wiring. Remove the solenoid and valve. actuator Check crank assembly. Repair or replace valve as needed.Troubleshooting the pipehandler at the counterbalance manifold Symptom Pipehandler goes up and clamps when the HPU is turned on without pressing switch. the solenoid valve is stuck in the open position. If there is a constant air flow. adjustment. Probable cause Improperly connected QDs. Check actuator cylinder adjustment and adjust as needed. Check electrical continuity to switches and solenoids. IBOP valve does not fully Actuator cylinder out of open or close. z TDS-4S Maintenance and Troubleshooting 4-109 . actuator arms and cylinders. Check crank assembly retainer bolts to assure tightness. No air supply or air supply incorrect. Clean as needed. arms or cylinders sticking. remove end cover on air pilot valve and check spool to see if it is operating freely. Solenoid valves stuck in the open position or in center position. Crank assembly retainer bolts should be checked weekly to make sure they remain tight. Check solenoid valves to see if they are not stuck in the open position or in center position. also making sure that each half is intact and not coming apart and restricting fluid. Solenoid valve stuck or inoperative. If there is no constant air flow from air line. Check cam follower rollers on crank assembly and arms. Crank assembly retainer bolts loose. IBOP valve actuator remains either in closed or open position. Cam follower rollers sticking. Repair or replace valve as needed.

Check Expo purge system and input AC power. Yellow and red indicator constantly flash while traveling assembly is below ten feet. Failure of DC power supply. Replace electronic control module. Misadjusted lower sensor Check proximity switch alignment. 1998 Troubleshooting the crown height indicator Symptom Green power indicator does not illuminate. Malfunction of electronics control module. Replace proximity switch. Defective sensor cable between the sensor junction box and control electronics. Replace electronic control module. 4-110 TDS-4S Maintenance and Troubleshooting . Malfunction of electronics control module. Check voltages from upper proximity switch by measuring voltage between TB3 and TB2 for upper sensor at the sensor junction box. Check the mechanical operation of the upper sensor bracket assembly. Replace electronic control module necessary. Replace electronic control module. TEST indicator does not cause position indicators to flash or illuminate. Probable cause Remedy No AC power being applied. Defective sensor cable between sensor junction box and control electronics. Defective upper sensor bracket assemblies. bracket assembly.0 VDC indicates a working sensor when metal is detected. Defective upper proximity switches. Perform cable continuity tests.October 20. constantly illuminated while traveling assembly is below ten feet. Check internal circuit breaker on control electronic module for tripped condition. Internal AC breaker tripped. Defective lower sensor Check mechanical operation of sensor bracket assembly. Defective proximity switch. Perform cable continuity tests. Misadjusted lower sensor proximity switch. Check proximity switch alignment. Yellow indicator is proximity switch. A measurement of less than 2. Depressing the PUSH TO Malfunction of control electronics. Check AC power LED on control electronic module. Replace proximity switches as required.

Six-gang air valve assembly illustration Air Elevator Torque Wrench Brake IBOP Open Link Tilt IBOP Close TDS-4S Maintenance and Troubleshooting 4-111 .

October 20. 1998 4-112 TDS-4S Maintenance and Troubleshooting .

TDS-4S Top Drive Drilling System Control System SM00620-5 .

October 20. 1998 5-2 TDS-4S Control System .

........................................................................... 5-7 TDS-4S Control System 5-3 ................. 5-5 Maintenance and troubleshooting/ checkout procedures ..................Contents TDS-4S Control System General description .....

October 20. 1998 5-4 TDS-4S Control System .

The CEE typically contains the following components: t DC contactors t A programmable logic controller (PLC) t Auxiliary AC components t Rig instrumentation interfaces for recording TDS torque and speed TDS-4S Control System 5-5 . switches power from one to the other. located in a Central Electronics Enclosure (CEE). A transfer panel.TDS-4S Control System General description The Top Drive Drilling System (TDS) typically operates from the same SCR as the rotary table.

Logic and alarm functions are connected to the TDS via PLC programming so the TDS can operate existing rig systems. are programmed into the PLC and are the same for all installations. 5-6 TDS-4S Control System . a purge system is not required. the SCR runs the top drive only. The transfer panel is designed to be compatible with all presently installed SCR systems and is configured at installation for the specific SCR used on a rig. TDS interlocks and limits. such as spin-up and makeup speeds.October 20. 1998 In dedicated top drive SCR configurations. If the transfer panel is located in the SCR room. Also. The transfer panel features a purge control system so it can be located in hazardous areas.

Maintenance and troubleshooting/ checkout procedures The Varco top drive drilling control system (TDCS) is straightforward in its operation and relatively easy to service.) Verify and record. Frequency Each time the TDS is assigned. Refer to the following documentation for maintenance. Component mounting Blower mounting current Check fastener tightness. (A drop in the current may indicate restriction or blockage of the air intake. especially in vibration-prone areas. Periodic control system maintenance schedule Location Indicator lamps Heater High voltage connections Procedure Test using the lamp test switch on the driller’s console.) t Rig checklist t PLC manual t Card rack terminal specifications Table 1. troubleshooting and checkout information: t Periodic control system maintenance schedule (See Table 1 below. Check and record current. Monthly Monthly Monthly Monthly Monthly Drilling motor field current Seals and gaskets Weekly Monthly Every 3 months TDS-4S Control System 5-7 . Check operation with an Ohm meter. Check for integrity. Apply a light film of silicone lubricant to the transfer panel door. Check retaining bolt torque (needs to be 25 ft lb). Check for discolored or brittle insulation.

October 20. 1998 5-8 TDS-4S Control System .