TDS-1000A TDS-1000A

SM01040
Top Drive System
Installation and
Commissioning
Manual
General Information
1
2
TDS1000A Top Drive System
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1
General Information
TDS1000A Top Drive System 2-3
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco

International, Inc., will not be held liable for errors in this

material, or for consequences arising from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information, and to advise
the reader to take specific action to protect personnel from potential injury or lethal
conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.
Note:
Caution:
Warning:
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts or establishing nomenclature, and may or
may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings
included with your Varco documentation.
i
The note symbol indicates that additional information is
provided about the current topics.
!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow instructions
explicitly. Extreme care should be taken when performing
operations or procedures preceded by this caution symbol.
The warning symbol indicates a definite risk of
equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant
property loss, or significant equipment damage.
1
General Information
2-4
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in Varco manuals are the recommended methods of performing
operations and maintenance.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on
the equipment, or those in the vicinity of the equipment, should be trained on rig safety,
tool operation, and maintenance to ensure their safety.
Contact the Varco Drilling Equipment training department for more information about
equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. Varco recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures or using tools not specifically recommended by Varco.
Replacing Components
o Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
o Replace failed or damaged components with Varco certified parts. Failure to do so
could result in equipment damage or injury to personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for
maintenance recommendations.
!
CAUTION: To avoid injury to personnel or equipment
damage, carefully observe requirements outlined in this
section.
!
CAUTION: Personnel should wear protective gear during
installation, maintenance, and certain operations.
!
CAUTION: Failure to conduct routine maintenance could
result in equipment damage or injury to personnel.
1
General Information
TDS1000A Top Drive System 2-5
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities, such
as water; or electrical, hydraulic or pneumatic power.
o Isolate energy sources before beginning work.
o Avoid performing maintenance or repairs while the equipment is in operation.
o Wear proper protective equipment during equipment installation, maintenance, or
repair.
Proper Use of Equipment
Varco equipment is designed for specific functions and applications, and should be used
only for its intended purpose.
Electrical Systems and Components
All electrical wiring, junction boxes, sensors, glands, and related equipment are designed
for the specific application, environment and particular zone where the equipment is
intended to be used.
o Before beginning work on this equipment, familiarize yourself with the electrical
schematics, as well as the equipment power and voltage requirements.
o When performing installation, maintenance, or repairs on the equipment, isolate all
power. Lock out switches and tag them to prevent injury.
o Prior to disconnecting wires, verify that all wires and terminals are properly labeled
to ensure proper reconnection.
Hydraulic Systems and Components
Hydraulic systems and components are designed for specific use in the drilling industry.
The hydraulic pressure for this equipment can be as high as 3,000 psi.
o Before beginning work on any portion of the hydraulic system, familiarize yourself
with the hydraulic and electrical schematics.
o Isolate, lock out, and tag the hydraulic and electrical power and controls.
o Take precautions when bleeding down residual system pressure, using bleed valves
or equivalent techniques.
o Properly discharge all system accumulators.
!
CAUTION: Read and follow the guidelines below before
installing equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
WARNING: Hydraulic fluids can be extremely hot
and under high pressure.
1
General Information
2-6
o Collect all residual hydraulic fluid in a container to prevent rig or environmental
contamination.
o Take precautions to prevent hydraulic oil from leaking into other open electrical or
mechanical components, such as junction boxes.
Pneumatic Systems and Components
Pneumatic systems and components are designed for specific use in the drilling industry.
The pneumatic pressure for this equipment can be as high as 150 psi.
o Prior to beginning work on any portion of the pneumatic system, familiarize yourself
with the pneumatic and electrical schematics.
o Isolate, lock out, and tag the pneumatic and electrical power and controls.
o Take precautions when bleeding down residual system pressure using bleed valves
or equivalent techniques.
o Properly discharge all system accumulators.
Water Cooling Systems and Components
Water cooling systems and components are designed for specific use in the drilling
industry. The water can reach temperatures high enough to cause scalding.
o Prior to beginning work on any portion of the cooling system familiarize yourself with
the plumbing and electrical schematics.
o Isolate, lock out, and tag the cooling water and electrical power and controls.
o Take precautions when bleeding down residual system pressure using bleed valves
or equivalent techniques.
o Collect all residual cooling water in a container to prevent rig or environmental
contamination if necessary.
o Take precautions to prevent cooling water from leaking into other open electrical or
mechanical components such as junction boxes.
General Safety
Equipment Motion Hazards
Some of the Varco equipment travels either horizontally, vertically on rails, or both.
WARNING: Avoid placing objects in or near the path of
motion for this equipment. Such interference could
cause personnel to be trapped or crushed by
equipment.
!
CAUTION: Keep the working envelope/zone of the
equipment free from personnel.
1
General Information
TDS1000A Top Drive System 2-7
When Replacing Components
During disassembly and reassembly of any equipment, verify all components such as
cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly.
Replace failed or damaged components with Varco certified parts. Failure to do so could
result in a hazard, equipment damage, or personal injury.
During Routine Maintenance
Equipment must be maintained on a regular basis. See the body of the service manual for
maintenance recommendations.
Visibility of Equipment Operation
Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not
block or impair the equipment operator's field of view. In cases where this is not possible,
the customer must install video cameras to ensure adequate visibility.
Proper Use of Equipment
Varco equipment is designed for specific functions and applications and should be used
only for the intended purpose.
!
CAUTION: Failure to conduct regular maintenance can
result in a hazard, equipment damage, or injury to
personnel.
!
CAUTION: Do not hoist personnel using this equipment.
Installation
1
2
TDS1000A Top Drive System
Long Term TDS Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Rig Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Regulatory Standards You Will Use . . . . . . . . . . . . . . . . . . . . . . 2-6
Tools You Must Provide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hardware Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Derrick Termination Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installing the Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
TDS and Retract Guide Dolly . . . . . . . . . . . . . . . . . . . . . . 2-8
Positioning the TDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Back Flange Rollers and Guide Rail Stops . . . . . . . . . . . . . . . . 2-10
Installing the Web Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Traveling Block and Counterbalance Kit . . . . . . . . . . . . . . . . . . 2-12
Installing or Removing the TDS Shims . . . . . . . . . . . . . . . . . . . 2-12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TDS Service Loop Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Preparing the Fluids Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Connecting the Fluids Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Preparing the Electrical Loop . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Connecting the Electrical Loop . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Connecting the Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Connecting the Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Terminating Electrical Connections . . . . . . . . . . . . . . . . . . . . . 2-17
PH-100 Pipehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Installing the IBOPs and Saver Sub . . . . . . . . . . . . . . . . . . . . . 2-18
Applying Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Actuator Shell and the Crank Assemblies . . . . . . . . . . . . . . . . . 2-19
Installing the Rotating Link Adapter . . . . . . . . . . . . . . . . . . . . . 2-19
Installing the Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Positioning the Pipehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Mud Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Connecting the Mud Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Attaching the S-Pipe to the Frame . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Removing the Exhaust Cover . . . . . . . . . . . . . . . . . . . . . 2-23
Motor Alignment System. . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installing the Bondura Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Lubricating the Bondura Bolt for the First Time . . . . . . . . . . . . . . . 2-25
Installation
1
2
Verification Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Pipehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Service Loops and Mud Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Post-Power Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Installing Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Adjusting the Motor Alignment Bar . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Commissioning Checkout Procedures . . . . . . . . . . . . . . . . . . . 2-30
Tightening the Bondura Bolt Again . . . . . . . . . . . . . . . . . . . . . . 2-31
Counterbalance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Using the System to Make Up and Break Out Pipe . . . . . . . . . 2-32
PH-100 Pipehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Breaking Out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Breaking Out the Lower IBOP Valve . . . . . . . . . . . . . . . . . . . . . 2-37
Making Up the Lower IBOP Valve . . . . . . . . . . . . . . . . . . . . . . . 2-37
Breaking Out the Upper IBOP Valve . . . . . . . . . . . . . . . . . . . . . 2-38
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
IBOP Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Torque Values for Load Carrying Components . . . 2-41
2
Installation
TDS1000A Top Drive System 2-3
Long Term TDS Storage
o Avoid wide variations in temperature and high humidity. The preferred environment
is clean and dry at 60F ambient.
If high humidity is unavoidable, 70F is recommended.
o All exposed unpainted metal surfaces are coated with a rust preventive at the
factory prior to shipment. However, check these surfaces periodically to be sure that
no corrosion is taking place.
The recommended rust preventive (slushing compound) for bare metal surfaces is
Kendall Grade 5 (GE-D6C6A1) or equivalent.
o During storage, lubricant drains from the top half of the roller bearings in the motor,
allowing corrosion on the exposed areas. To prevent corrosion, run the oil pump
(i.e., rotate the motor and gear train) periodically to distribute lubricant over the top
of the bearings.
Perform this at three-month intervals if the TDS is stored indoors, and at monthly
intervals if stored outdoors.
o Megger the drilling motor when placed into storage and at three-month intervals
thereafter (monthly, if stored outside). Keep a record of the readings, as a drop
between readings indicates an increase in moisture in the windings created by
inadequate storage protection.
If megger readings drop, bake the motor as soon as possible to restore proper
resistance and avoid further damage.
2
Installation
2-4
Pre-Installation Checklist
Rig Preparation
General
o Winches will be used for installing the TDS when drawworks and the traveling block
are not installed, functional or available.
o Rollers have been installed onto the traveling block.
o Derrick area is clear of obstructions, such as tugger lines and scaffolding.
o Block load pin has been inserted and retaining hardware permanently installed.
o Service loop brackets and clamps have been created so the service loops can be
attached to the derrick.
Guide Rails
o Guide rails and bracing are installed and inspected to conform to Varco specification
and installation tolerances as specified in this service manual and QA 00026.
o Guide rail stops are installed and can support the weight of the TDS-1000A and
dolly assembly.
Rigging
o Rigging of the long lines and other related rigging are inspected to ensure they will
not interfere with the TDS and other rig equipment.
o All rigging hardware is inspected and properly sized to accommodate the weights of
the tools to be installed in accordance with the following table:
!
CAUTION: The load block pins are instrumented load pins.
Do not force the pins by striking them with hammers.
Failure to follow this caution may result in damage to the
load pin instrumentation.
Tool Weights
Tool Weight
(lbs)
Weight
(kg)
Motor Frame and Dolly 52,000 23,587
PH-100 2045 928
2
Installation
TDS1000A Top Drive System 2-5
Pre-Installation Checklist
Rig Preparation
Electrical
o All electrical and electronic cabling is installed in the derrick at the correct locations
and heights per the TDS-1000A General Arrangement drawing. Make sure that the
cables have sufficient length to allow for termination in the derrick J-boxes.
o All electronics are installed up to the derrick junction box, per the General
Arrangement drawing.
Hydraulic
o Hydraulic and air stand pipes are installed in the derrick, per the TDS-1000A
General Arrangement drawing.
o The stand pipes are flushed clean and pressure tested.
Prior to attaching any Varco equipment to the derricks hydraulic plumbing, the
customer shall provide a materials test certification per DIN 50049, section 3,
certifying that the plumbing has been pickled, cleaned and flushed.
The customer must also ensure that the hydraulic fluid and system are at a
cleanliness level of IS0440615/12 or better, according to the following source:
Varcos SM00081, Hydraulic Fluid Cleanliness, and PC000112, Specification for
Fluid Cleanliness and for Cleaning and Flushing Hydraulic Lines.
Documentation You Will Need
o Electrical schematics for the Drillers console and Electrical loop
o TDS-1000A Product Documentation Package
o Commissioning checklists (see section titled "Commissioning" on page 2-30)
o Installation and commissioning FIPs: 3FIP00269, 3FIP00270
o TDS-1000A Top Drive System Service Manual Supplemental Material
o Vendor Documentation Package
o Design Specification DS00008 (Design Torque Standard)
o BJ Service and Installation Manual
o IBOP Service Manual
o RBS Service Manual
o Drilling Motor Service Manual
o Lock Wire DS Specification
o Package of drawings
o Specifications for your particular rig
2
Installation
2-6
Pre-Installation Checklist
Regulatory Standards You Will Use
o API Recommended Practice 85, Section 2 (inspection frequency)
o ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings
o ASTM E-709, Standard Recommended Practice for Magnetic Particle Inspection
o ASTM A-388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings
o Electrical Standards
o Electrical Documentation Standard
o Varcos SM00081, Hydraulic Fluid Cleanliness, and PC000112, Specification for
Fluid Cleanliness and for Cleaning and Flushing Hydraulic Lines.
o SM00981
o QA 00026
o DIN 50049, section 3
Tools You Must Provide
o Crimping pliers
o Wire strippers
o Hydraulic crimper for the power lugs with the correct dies for the cable
Hardware Kits
o Derrick Termination Kit
o Commissioning Spares Kit (see your Varco representative)
o Split Flange Kit
o Moisture Separation Kit
o Counterbalance Kit
2
Installation
TDS1000A Top Drive System 2-7
Derrick Termination Kit
Components
o TDS Derrick Power J-box
o Remote I/O J-box
o Pneumatic Filter/Regulatory Assembly
o Stand pipe fittings
o TDS service loop brackets
o Retract Control Plate Assembly
o Retract Dolly Service Loop Bracket
Installing the Kit
1. Mount the plate assembly at racking board height within 15 feet of the service loop
support bracket and four or five feet above the walk-around.
2. If a walk-around does not exist, construct a work platform to allow access to the
J-boxes.
3. Manufacture the appropriate brackets and clamps to attach the plate to the derrick
structure.
See the Derrick Termination drawings for more information.
i
NOTE: Remember to provide convenient access for wiring
and maintenance.
2
Installation
2-8
TDS and Retract Guide Dolly
Positioning the TDS
Procedure
1. Prepare the TDS and retract system to
be moved to the rig floor.
2. Ensure that the swing bolts between the
frame and retract dolly are locked and
secure to prevent the dolly from
extending during rig-up.
3. Using a crane that is sized to lift at least
53,000 lbs. total, attach one lift sling to
each corner of the TDS guide dolly.
4. Connect a winch to each of the two
upper lifting lugs on the TDS frame.
These winches and the rigging need to
be rated for at least 53,000 lbs. total.
5. Lift the TDS to the rig floor and position it
so the bail and top of the dolly frame are
directly under the TDS guide rails with
the main shaft in the direction of well
center.
Upper
Lifting Lugs
on Motor Frame
Lift Points on
Guide Dolly
4 places
Dolly Frame
Bail
Dolly Frame
Top
TDS Retract
Guide Dolly
Swing
Bolts
TDS-1000A
41,000 lb
Drill
Floor
TDS
Guide Rails
Well
C
L
Procedure
1. Prepare the TDS and retract system to
be moved to the rig floor.
2. Ensure that the swing bolts between the
frame and retract dolly are locked and
secure to prevent the dolly from
extending during rig-up.
3. Using a crane that is sized to lift at least
53,000 lbs. total, attach one lift sling to
each corner of the TDS guide dolly.
4. Connect a winch to each of the two
upper lifting lugs on the TDS frame.
These winches and the rigging need to
be rated for at least 53,000 lbs. total.
5. Lift the TDS to the rig floor and position
it so the bail and top of the dolly frame
are directly under the TDS guide rails
with the main shaft in the direction of
well center.
2
Installation
TDS1000A Top Drive System 2-9
TDS and Retract Guide Dolly
Preparing for Installation
Procedure
1. Connect two tuggers to the lower two
lifting lugs of the TDS frame.
Each tugger and its rigging must be able
to support 20,000 lbs.
2. Remove the upper web roller bracket
assembly from both sides of the guide
assembly.
CAUTION: Do not remove the lower roller
assemblies.
3. Remove the upper back right and left
flange roller assemblies from the guide
dolly.
CAUTION: Do not remove the front or lower
roller assemblies.
4. Remove the TDS guide rail stops.
!
!
Guide Rail
Stops
Upper Back Flange
Roller Assembly
2 places
Upper Web Roller
Bracket Assembly
2 places
Lower
Lifting Lug
2 places
Drill
Floor
TDS
Guide Rails
Well
C
L
Procedure
1. Connect two tuggers to the lower two
lifting lugs of the TDS frame.
Each tugger and its rigging must be
able to support 20,000 lbs.
2. Remove the upper web roller bracket
assembly from both sides of the guide
assembly.
CAUTION: Do not remove the lower
roller assemblies.
3. Remove the upper back right and left
flange roller assemblies from the
guide dolly.
CAUTION: Do not remove the front or
lower roller assemblies.
4. Remove the TDS guide rail stops.
!
!
2
Installation
2-10
TDS and Retract Guide Dolly
Back Flange Rollers and Guide Rail Stops
Procedure
1. Using winches and tuggers, hoist the
assembly to about 10 feet above the
floor.
2. Lower the tuggers while maintaining
the height of the winches until the TDS
is vertical.
CAUTION: Do not let the main shaft touch
the rig floor.
3. Position the TDS so the remaining set
of upper flange rollers touch the TDS
guide rails.
You may need additional tuggers to
stabilize the TDS and keep it vertical.
4. Install the back set of flange rollers.
This captures the guide rail between
the upper flange rollers.
5. Hoist the TDS, while carefully aligning
and placing the lower rollers onto the
guide rails.
6. Install the guide rail stops.
!
Guide Rail
Stops
2 places
Upper Flange
Rollers
2 places
Lower
Rollers
2 places
Back Set of
Flange Rollers
2 places
TDS
Guide Rails
2 places
Drill
Floor
TDS
Guide Rails
Well
C
L
Procedure
1. Using winches and tuggers, hoist the
assembly to about 10 feet above the
floor.
2. Lower the tuggers while maintaining
the height of the winches until the
TDS is vertical.

CAUTION: Do not let the main shaft
touch the rig floor.
3. Position the TDS so the remaining set
of upper flange rollers touch the TDS
guide rails.
You may need additional tuggers to
stabilize the TDS and keep it vertical.
4. Install the back set of flange rollers.
This captures the guide rail between
the upper flange rollers.
5. Hoist the TDS, while carefully
aligning and placing the lower
rollers onto the guide rails.
6. Install the guide rail stops.
!
2
Installation
TDS1000A Top Drive System 2-11
TDS and Retract Guide Dolly
Installing the Web Rollers
Procedure
1. Lower the TDS until the frame is just
above the guide rail stops.
2. Install the upper web rollers.
3. Lower the TDS until its weight rests on
the rail stops.
4. Remove the rigging from the TDS frame.
NOTE: When lowering the block,
monitor the weight indicator so the
dolly is not binding anywhere along
the path of travel.
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Guide Rail
Stops
2 places
Upper Web
Rollers
2 places
Drill
Floor
Well
C
L
Procedure
1. Lower the TDS until the frame is just
above the guide rail stops.
2. Install the upper web rollers.
3. Lower the TDS until its weight rests
on the rail stops.
4. Remove the rigging from the TDS
frame.
2
Installation
2-12
TDS and Retract Guide Dolly
Traveling Block and Counterbalance Kit
When the drawworks and TDS extend/retract systems are operational:
1. String up the traveling block.
2. Extend the TDS over well center.
3. Lower the block into position over the TDS.
4. Connect the Counterbalance Kit to the block.
Installing or Removing the TDS Shims
1. Measure the distance between the upper web rollers and inside of the TDS guide
rails at several points in the derrick.
2. Take the average of the measurements and shim the upper web rollers so the
nominal roller clearance is 0.18-inch.
3. Install (or remove) the shims to achieve alignment, then tighten and lockwire the
roller bolts.
4. After the shims are installed (or removed), hoist the block again and monitor the
weight indicator so the dolly isnt binding along the path of travel.
5. Place a tubular in the PS30.
6. Extend the TDS over well center.
7. Lower the TDS until its shaft almost touches the tubular.
8. Install roller shims to align the TDS with well center.
9. Tighten and lockwire the roller bolts.
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NOTE: When lowering the block, monitor the weight
indicator so the dolly is not binding anywhere along the
path of travel.
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NOTE: When hoisting the block, monitor the weight
indicator so the dolly is not binding anywhere along the
path of travel.
2
Installation
TDS1000A Top Drive System 2-13
Controls
1. Mount the drillers console so it is within easy reach or view of the driller during
operations.
2. Connect the wires as shown in the electrical schematics in the Engineering
drawings.
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NOTE: The throttle and torque limit controls are the
standard controls used for the independent rotary drive
table.
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NOTE: Appropriate cable glands are provided for the
electric cables.
Warning: If you choose to use control systems not
manufactured by Varco, 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 control systems.