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Sm00620b (User Manual TDS4SA)
Sm00620b (User Manual TDS4SA)
SM00620
Revision B
March 8, 2001
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 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
Book 2 – Installation and Commissioning
Preface/Manual conventions
Safety information ........................................................... 2-5
Directional references ...................................................... 2-6
Manual layout.................................................................. 2-6
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Counterbalance system .................................................. 2-21
Motor alignment cylinder system ................................... 2-22
Driller’s controls and instrumentation ........................... 2-23
Varco Driller’s Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
TDS-4S Contents v
March 8, 2001
Book 3 – Operation
Preface/Manual conventions
Safety information ........................................................... 3-5
Directional references ...................................................... 3-6
Manual layout .................................................................. 3-6
vi TDS-4S Contents
Book 4 – Maintenance and Troubleshooting
Preface/Manual conventions
Safety information ........................................................... 4-7
Directional references ...................................................... 4-8
Manual layout.................................................................. 4-8
Chapter 1 Maintenance
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
Replacing the standard rotating head
glyd rings ........................................................... 4-71
Replacing the powered rotating head
glyd rings ........................................................... 4-75
Replacing the standard or extended reach
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
Removing the motor assembly
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97
TDS-4S Contents ix
March 8, 2001
x TDS-4S Contents
TDS-4S
Top Drive
Drilling
System
Description
SM00620-1
Rev. B
March 8, 2001
Chapter 1 Introduction
General description .......................................................... 1-7
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
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, or a caution note. See the examples
below and pay close attention to these important advisories.
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), 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.
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45
ft. kelly was the industry standard for years. For decades, drillers
extended the drill string with the “making-a-single-connection”
process using the rotary table, kelly, pipe tongs, drawworks
cathead, master bushing, bowls, and slips. This method of
handling pipe and joint makeup remained unchanged, apart from
minor improvements such as kelly spinners, until the advent of
top drive drilling systems.
Varco produces several Top Drive Drilling Systems (TDS) to
rotate the drill string and allow adding entire 93 ft. stands of pipe,
eliminating two thirds of the conventional single-pipe drilling
connections. 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.
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. The TDS
does not interfere with the existing conventional equipment. It
allows tripping, circulation, rotation, and the running of casing as
well as providing 90 ft. back reaming capabilities to reduce the
chance of stuck pipe.
Guide Dolly
Assembly
Motor Housing
Assembly
LO
Pipehandler Assembly
Gooseneck
Air Brake
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High Gear
(Disengaged)
Rotating Head
Lower Gearcase
Main Shaft/Drive Stem
Link Adapter
Torque Arrestor (4) (Also know as: Solid Body Elevator)
(Landing Collar Inside
on Main Shaft/Drive Stem)
Hydraulic/Pneumatic
Link Tilt
Upper IBOP
Valve Actuator
Splined Upper
IBOP Valve
Lower IBOP Valve
(Inside Torque Tube)
Torque Wrench
Manually or
Remotely Operated
Drill Pipe Elevator
(Optional Varco Equipment)
Link Adapter
(Also known as
Solid Body Elevator)
(Landing Collar Inside
On Main Shaft/Drive Stem)
Splined Upper
IBOP Valve
Torque Wrench
108 in.
350-Ton Links
(Optional Varco Equipment)
Manually or Remotely
Operated Drill Pipe Elevator
(Optional Varco Equipment)
Main Shaft/
Drive Stem
Link Adapter
(Also known as
Solid Body Elevator)
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
The drive stem passes through the link adapter. The torque
arrestors keep the link adapter above the landing collar on the
drive stem when drilling (Figures 1-6, 1-7 and 1-8). When
hoisting, the link adapter is pulled down onto the landing collar
due to the added weight of the drill string. This directs the
hoisting load through the drive stem, motor housing assembly,
and swivel bail.
The fluid service loop provides the hydraulic, pneumatic power,
and optional cooling water services to the TDS. The electric
service loops provide DC power and AC power/control.
A drill pipe elevator hangs from a pair of conventional links that
attach to the link adapter. Actuating the link tilt swings the
elevator out to facilitate picking up pipe.
The Major component description chapter of this book describes
each of these assemblies. Subsequent books provide more
information on the equipment specific to your rig configuration.
Link Adapter
(Also known as
Solid Body Elevator)
Torque
Arrestors (4)
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors
650/500-Ton
Hydraulic/Pneumatic Link Tilt Rotating Head
(Part of
Motor Housing
Assembly)
650/500-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor
650-Ton: (4)
500-Ton: (2)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton Safety Valve
Links Actuator
(Optional
Varco Equipment)
Torque Wrench
Lower
IBOP Valve
650-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor (4)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton
Safety Valve
Links
Actuator
(Optional
Varco Torque Wrench
Equipment)
Lower
IBOP Valve
Drilling motor
The drilling motor on the TDS is a 1,100 hp DC drilling motor.
Mechanically, the motor features a double-ended armature shaft
and thrust bearings for vertical operation.
There is an air brake on the motor to hold torque in the drill
string to assist in directional work. It is remotely operated by a
solenoid valve. Please refer to the specifications included later in
this book for additional details.
Shifter
Input Shaft
HI LO
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
Top View
Side View
Bull
Gears
Bull Gears
Motor Pinion
Gears
LEGEND
Pressure Tap
Fabricated
Bottom View Drilled
❏ Stationary flange
❏ Eight rotary glyd rings
❏ Swivel block
❏ Cam
❏ Auto-return cylinder
❏ Cam follower
❏ Swivel block locking mechanism
The hydraulic and air lines for the various pipehandler functions
(air link tilt, torque wrench, etc.) run from their respective
solenoid valves to the stationary flange. The fluids travel from the
flange to the swivel block via sealed rotating passages. The glyd
rings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to the
corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the gearcase with the drive stem running through the center.
There is also an auto-return cylinder mounted on the stationary
flange. The auto-return cylinder is hydraulically connected to the
counterbalance manifold. The rod end of the cylinder connects to
a cam follower assembly that tracks the cam mounted to the
swivel block.
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8) Swivel Block
❏ Stationary flange
❏ Eleven rotary glyd rings
❏ Swivel block
❏ Bull gear
❏ Hydraulic motor assembly
❏ Proximity sensor and adjustable targets
The hydraulic and air lines for the various pipehandler functions
(hydraulic link tilt, torque wrench, etc.) run from their respective
solenoid valves to the stationary flange. The fluids travel from the
flange to the swivel block via sealed rotating passages. The glyd
rings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to the
corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the gearcase with the drive stem running through the center.
The hydraulic motor assembly mounts to the swivel flange which
engages a compound gear, driven by a pinion gear on the
hydraulic motor shaft. Two switches on the driller’s control panel
control the hydraulic motor.
Rotary Glyd
Ring (11)
Torque Arrestor
Hanger
Bull Gear
Swivel Block
Hydraulic Motor
Assembly
H1
S1
A1
RE
A3
PRESSU
H1
H3
A2
S2
A5
A4
H2
S2
A4
A1
A5
A2
H3
A3
H2 S1
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). It
receives air approximately 27 ft. above the rig floor at the lowest
point of the motor’s travel.
An explosion-proof 20 hp, 3,450 rpm AC electrical motor
directly drives the impeller in the blower housing. An optional
flexible duct connects the blower housing to the extended intake
mounted on the traveling equipment.
Two spark arrestor assemblies are mounted on the exhaust ports
of the upper gearcase. These components hinder the egress of any
air born sparks from the DC motor.
Locking Key
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
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. Ducting directs air out the motor exhaust port
to the heat exchangers and back to the blower inlets. The heat
exchangers are built from Cupro-Nickel tubes and the headers are
pressure tested to 250 psi.
The system requires a supply of liquid coolant (sea water, chilled
fresh water or glycol) at 100 gpm at a maximum inlet
temperature of 90°F.
Purge air at a rate of 70 scfm per motor at 1.0 psig is also required
to provide positive system pressure, and a purge control system
(refer to TDS Control System information provided later in this
chapter) monitors system pressure to insure safe operation.
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
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). Air is drawn in from outside the wind wall,
through a flexible duct into the top of the drilling motor, and
exits through spark arrestors attached to the air outlets of the
motor.
A pressure switch monitors the motor air inlet pressure to verify
blower operation. The contacts of the pressure switch are usually
wired into the SCR assignment logic for the drilling motor.
A moisture separator is attached to the blower inlet duct to
prevent water from entering the motor.
40 hp Explosion Proof
Electric Motor (AC)
and Centrifugal
Pressure Blower
Wind Wall
Racking Platform
at Racking Board Level
Spark Arrestor
Hold-down Bolt
(Swing Bolt) (2)
Guide Dolly
Frame
Retract
Cylinder
Lower
Extend/Retract
Arm
LEGEND
Intermediate
Extended Mode
Frame Retracted Mode
45.0"
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
Pipehandler
The main components of the pipehandler include the following
(Figures 1-3 and 1-4):
❏ Link adapter
❏ Safety valves (Upper and Lower IBOPs)
❏ IBOP valve actuator
❏ Torque wrench
❏ Link tilt mechanism
e Saver subs are load bearing components in the TDS and must be
inspected periodically along with other load bearing components.
Refer to the Maintenance and Troubleshooting book for more
information.
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Torque wrench
The torque wrench provides a means for making and breaking
out connections with the drive stem.
The torque wrench assembly consists of the following
components (Figures 1-20 and 1-21):
❏ 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. The torque wrench has two torque cylinders connected
to the torque tube.
The clamping jaw contains a 10 in. diameter clamping piston for
gripping the box end of the drill pipe. On the lower section of the
upper IBOP, a female spline engages the mating male spline on
the lower IBOP contained inside the torque tube.
When actuated, the torque wrench rises and engages the splines
on the upper IBOP. It then receives sequenced pressure to clamp
the clamping piston on the box connection. After the clamping
pressure develops, another sequence valve automatically opens
and directs pressure to the torque cylinders. The torque cylinders
can rotate up to 25° while developing a maximum torque of
85,000 ft lb (60,000 ft lb for PH-60d).
One electrical push button on the VDC controls the entire torque
wrench operation. The driller simply holds the button down until
the connection is made or broken. The driller then releases the
button to allow the unit to automatically recycle to the ready
position. A two-position, air piloted hydraulic valve located on
the counterbalance manifold controls the cycle.
The torque wrench can also make up or break out the saver sub
or the lower IBOP. A manually operated valve on the rear of the
pipehandler selects either the make up or break out function.
1-42 TDS-4S Description
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
IBOP Actuator
Air Cylinders
Lift Cylinder
IBOP
Actuator Arms
Torque Tube
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator
Air Cylinders
IBOP
Actuator Arms
Torque Tube
Clamping Jaws
(Inside Clamp Body) Control Manifold
(Hidden)
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
Lifting Frame
Intermediate
Stop
Air
Actuator
D/P Elevator
Link Clamp
Intermediate
Stop Release
Double Air
Actuator
D/P Elevator
Intermediate Link Clamp
Stop
Intermediate
Stop Release
RETRACT
In the RETRACT position, the elevator backs away from well
center.
FLOAT
FLOAT returns the elevators to well center from the retracted or
extended position. 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
This setting holds the position of the elevators extended or
retracted.
EXTEND
This setting extends the elevator forward to the mousehole
through wellcenter.
Passive
Stop
Assembly
(2)
Cylinder
Assembly
(2)
Link
Tilt Arm
Hydraulic
Link Tilt with
Intermediate Stop
Intermediate Stop
Stop Adjuster
Elevator links
Varco elevator links attach to the link adapter and support the
drill pipe elevator. Elevator link options include:
Stabbing Mode:
Top Drive Lowered Past Thread Contact
Guide Dolly
Assembly
18,970 lb 18,970 lb
Hydraulic
Cylinders (2)
Hydraulic
Accumulators (2)
38,750 lb
Typical System Weight
Counterbalance
Manifold
810 lb
Weight on Threads
Hydraulic Fluids
Power Supply Service Loop
Rig Floor
❏ Link tilt
❏ Remotely controlled upper IBOP valve
❏ Motor brake
❏ Motor spin-torque control
❏ Makeup torque limit
❏ Transfer switch (TDS/ROT)
The existing rotary table controls adjust motor speed, torque and
direction while drilling. A typical VDC also contains indicator
lights for determining the status of:
❏ The brake
❏ The remotely controlled upper IBOP valve
❏ The oil pump
❏ Blower pressure loss
❏ Cooling air temperature
❏ The purge system(s)
Optional controls and status indicator lights are available. Refer
to Engineering Drawing 98952 for VDC configurations.
Drill Pipe
Elevator
Drill Collar
Dolly
A
100 TON
VARCO
Perfection
Links (36")
;;
;;; ;;
;;; ;;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
Drill
8 in. Collar
View A-A
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. It can be used with a lubricator held
in the elevators by using 180 in. casing elevator links.
42.52 in.
26.0 in.
23.1 in.
20 in. Dia.
Sheave
Elevator Links
(180 in. long-
Customer furnished)
Lubricator
Elevator Links
(180 in. or longer-
Customer furnished)
View A-A
R
5 FEET
IBOP BRAKE
CLOSE OPEN OFF ON
Y
10 FEET
TORQ. WRENCH LINK TILT
ACTIVE/TEST PUSH & PULL OFF ON
Integrated Controls
Purge Air in R
5 FEET
IBOP BRAKE
CLOSE OPEN OFF ON
Y
10 FEET
ACTIVE/TEST
VDC
Independent
Controls
Drilling motor
Horsepower: 1,100
Maximum stall time at full power is generally about 10 seconds.
Refer to the Operation book for details.
Cooling systems
Local blower *
Flow 3,200 cfm
Blower motor 20 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Spark arrestors Standard style, BASEEFA
approved type available
Closed loop
Flow 3,200 cfm
Blower motor 20 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Heat exchanger 220,000 BTU/Hr.
for GE motor
Cooling water supply 50 gpm at 250 foot head,
measured at rig floor
Oil cooler 6 gpm
Max. inlet temp 90°F
Pipehandler
Break-out torque PH-85 and PH-85H = 85,000 ft lb
PH-60d = 60,000 ft lb
Hydraulic pressure 2,000 psi maximum
Hydraulic flow 30 to 35 gpm
Air pressure 90 psi minimum
60,000
58,200
INTERMITTENT
55,000
1,130 HP LIMIT
50,000 50,900
CONTINUOUS
LOW GEAR
45,000
37,200 INTERMITTENT
TORQUE, CONTINUOUS (ft lb)
1,130 HP LIMIT
35,000
32,500 CONTINUOUS
30,000
25,000
HIGH GEAR
20,000
15,000
12,000 ft lb
10,000
5,000 ft lb
5,000
120 190
0
0 50 100 150 200 250 300
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS
INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS
WITH A 7 SEC. MAX. DURATION
JUNE 3, 1991 A.N.
55,000
50,000 50,100
INTERMITTENT
45,000 45,500
CONTINUOUS LOW GEAR
40,000
TORQUE, CONTINUOUS (ft lb)
35,000
32,000 INTERMITTENT
30,000
29,100 CONTINUOUS
HIGH GEAR
25,000
20,000
Reduced Field
Required in this Area
15,000
10,000
5,000
130 RPM 205 RPM
0
0 50 100 150 200 250 300
RPM
Continuous Torque Values are based on 1250 Armature Amps.
Intermittent Torque Values are based on stall at 1400 Amps with a 7 second maximum duration.
Reduced Field area is based on a 30 Amps Field.
Installation and
Commissioning
SM00620-2
October 20, 1998
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Counterbalance system .................................................. 2-21
Motor alignment cylinder system ................................... 2-22
Driller’s controls and instrumentation ........................... 2-23
Varco Driller’s Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
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, or a caution note. See the examples
below and pay close attention to these important advisories.
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), 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.
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up
has been accomplished prior to installation of the TDS. This
includes:
1. Guide rails and bracing are installed and inspected to
conform to Varco specification and installation tolerances
(Figures 2-1, 2-2, and 2-3).
2. Stops are ready for installation at the bottom of the rails.
3. Hydraulic and air standpipes are installed in the derrick,
flushed clean, and pressure tested. Water piping is installed,
flushed, and pressure tested as well for configurations with
closed loop cooling systems.
4. All electronics are installed up to the derrick junction box:
DC power leads, AC leads for blower motor, and control/
alarm signals.
5. The transfer panel is installed.
6. Rigging of the tong lines, etc. are inspected to ensure that
they will not foul with the TDS and other rig equipment.
Installation
Refer to Figures 2-1, 2-2, and 2-3 for typical mounting
dimensions of the plate assembly. Mount it at racking board
height within 15 ft. of the service loop support bracket.
Remember to provide convenient access for wiring and
maintenance.
Usually, 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. If a walk-around does not exist, then construct a
work platform to allow access to the J-boxes. Manufacture
appropriate brackets and clamps to attach the plate to the derrick
structure.
± 1/4 in.
Over Full Length CL Rail
CL Rail ± 3/8 in. Over Full Length
± 1/8 in. Within 25 ft. of Floor
CL Rail CL Rail
C
L Well Center
± 3/8 in. Over Full Length
± 1/8 in. Within 25 ft. of Floor
C
L Well Center
TDS Back
Operational Clearance Between Top Drive
And Nearest Girt or Fastline Should Be 3 in. Minimum
Guide Rails
Nearest Girt
Splice
Clearance Splice Plates
or Bolts Are
Not Permissible
on Inside
Surfaces
of Beam
Dolly Overhang
Drill Floor
CL Well Center
Electrical Supply*
48.0 in.
Filter/Regulator
Lubrication Assembly** 800 lb Load
B
18.0 in.
Must Support
4,000 lb
Control Service Loop**
B Electrical Service Loop**
Gussets *
75 ft.
Mud
Hose
Ref
Service Loop
73 ft. Mud Hose Bracket**
Connection
Existing Girt *
5500 lb Load
View B-B
83 ft. Hydraulic, Air and Water
Standpipe Height and
Service Loop Bracket Location
10 ft. 6 in.
+0/-4 in. 7 ft. Ref * Customer Supplied
** Varco Supplied
Typical Equipment Stack-Up
Motor Frame
Setback
Rails
L
P
L
9 ft. 3 in. TDS-3S
10 ft. 3 in. TDS-4S,
TDS-8S 7 ft. TDS-3S
8 ft. TDS-4S,
TDS-6S, TDS-8S
P
L
Rail Stops
L
42,600 lb for a typical TDS-3S
48,000 lb for a typical TDS-4S
52,000 lb for a typical TDS-7S
48,000 lb for a typical TDS-8S
Derrick
Power
J-Box
#6AWG/2C*
#12AWG/20C
Shunt Field Derrick
#10AWG/4C
#16AWG/10C #14AWG/2 Pr Shld AC
Transfer Panel J-Box
#6AWG/2C*
Shunt Field
Service Loop
(4)646MCM*
Top
SCR
Drive
Room
System
#14AWG/2 Pr Shld
#14AWG/2 Pr Shld
#14AWG/37C
#12AWG/20C
#12AWG/20C
#16AWG/10C
#12AWG/20C
#12AWG/3C
#12AWG/3C
#10AWG/4C
E/P
Torq #6AWG/2C*
Existing
Power
AC Rotary
Cables
Power Table
RBS
E/P Controls
RPM
#12AWG/3C
#10AWG/4C
#10AWG/4C
#6AWG/4C
#6AWG/4C
#16AWG/10C
#16AWG/10C
TDS Existing
Driller’s Console Driller’s Console
HYD HYD
Pump Pump Water Water
#1 #2 Pump Pump
#1 #2
#16AWG/10C
#16AWG/10C
Hydraulic
Hydraulic lines should be cleaned and pickled, black pipe lines
(one pressure and one return) 1 1/2 or 2 in. schedule 80 pipe.
Install shut-off valves at the drill floor or racking board level. The
derrick connections are reduced to 1 in. NPT female pressure and
fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of
the purge supply for the TDS. Install a shut-off valve at drill floor
or racking board level. The air lines connect to the filtered and
lubricated supply. The derrick connections are reduced to 1 in.
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.
z Do not connect purge air lines to the lubricator. Only use clean,
dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2 in. pipe. Install
shut-off valves at the drill floor or racking board level. See the
cooling system specifications for water supply requirements. The
derrick connections are reduced to 1 1/4 in. NPT female pressure
and return for connection to the fluids service loop.
Rig-up procedure
Split Landing
Collar (2)
Drive Stem
8. Use the four bolts, lock washers and safety wire provided to
install this assembly to the link adapter. Connect the opposite
end of the hose to the quick disconnect on the rotating head
assembly.
9. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). There
should be about 1/2 in. slack in the chains.
Connecting
Link
Hydraulic
Accumulator
(Inside Motor Frame)
Motor Frame
and Guide Dolly
Counterbalance Assembly
Cylinder Assembly
(2)
Counterbalance
Counterbalance Lug Manifold
(Bolted to Bail) (On Guide Dolly)
Integrated
Swivel Bail
Loop Assembly
Guide Assembly
Cylinder Assembly
Hose Assemblies
Hydraulic Accumulator
(Inside Dolly Tube)
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.
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
Wiring
Refer to the electrical schematics in the engineering drawings.
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.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematic
provided to ensure proper terminal block assignments.
2 Cut wires and cables to length and terminate them at the
derrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assembly
equipment (crimping pliers, wire strippers, and hydraulic crimper
for the DC power lugs with the correct dies for the cable) must be
provided by the installer. Installation practices should comply
with applicable electrical codes (i.e., NEC, etc.).
Fluids loop
1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of any
contamination.
z The hoses in the fluids loop only extend 11 ft. from the
mounting bracket. It may be necessary to make jumper hoses to
reach the standpipes.
Air loop
z There are four separate service loops needed for a TDS with
retractable dollies: two electrical loops, a fluids loop, and a retract
system loop. The electrical and fluids service loops attach to the
derrick service loop mounting bracket, the retract loop attaches to
the retract system service loop bracket.
1. Lift the crate containing the retract system service loop onto
the rig floor.
2. Uncrate the service loop.
3. Attach an air winch to the lifting eyes on the derrick end
(derrick end has 8 ft. of hose extending beyond the flange)
and hoist to the retract system mounting bracket.
4. Attach the service loop flange to the mounting bracket with
the hardware provided. Ensure that the service loop hangs
straight in the derrick without any twists or kinks.
e Before connecting the hoses from the service loop, be certain that the
standpipes have been flushed free of any contamination.
Checkout procedures
1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (driller’s controls only).
3. Check the function of switches and solenoids. There is an
audible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and the
elevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears the
monkeyboard when actuated. Refer to the Maintenance and
Troubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the air
escapes when the brake releases.
7. Move the Make/Break valve located on the manifold at the back
of the pipehandler torque wrench to the BREAK position.
8. 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.
16. Verify that the indicator light on the VDC lights up when the
IBOP valve is closed.
17. Assign the TDS at the driller’s console and check that the
blower operates.
18. Advance the throttle and be sure that the motor is operating
properly in both directions.
19. Calibrate the Torque meter and RPM meter.
20. With the Hydraulic Power Unit (HPU) off, bleed down the
TDS accumulators (HYD SIDE, not gas side).
21. Remove the split shipping brace (Figure 2-7) from the motor
alignment cylinder.
22. Open the two flow control valves 1-1/2 turns off their seats.
23. Set a joint of drill pipe in the slips.
Operation
SM00620-3
October 20, 1998
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, or a caution note. See the examples
below and pay close attention to these important advisories.
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), 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.
Start-up procedure
Use the following procedure to start up the TDS:
1. Place the blower/oil pump switch in the AUTO position.
2. Place the hydraulic power unit (HPU) switch in the PLC
position.
3. Place the water pumps switch in the PLC position.
4. Place the motor space heater switch in the ON position.
5. Place the top drive/rotary table (TDS/ROT) lockout switch
in the TDS position.
6. Assign a SCR.
e The brake on the top end of the TDS drilling motor armature shaft is
a static, or parking brake. It is not a running or dynamic brake. It is
not intended to, nor is it capable of, slip-releasing the wind-up torque
in the drill string. 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, Varco
recommends using the following procedure to safely release the
torque in the string:
1. Use the hand throttle to develop motor torque equal to the
wind-up torque held by the parking brake.
2. Release the parking brake.
3. Reduce the drill current, reducing motor torque, as the drill
string slowly releases the wind-up torque.
4. Turn the hand throttle off and reset the drill current to the
normal operating position after the pipe unwinds completely.
Rotating Head
Assembly
Shifter
Input Shaft
HI LO
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
Top View
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8) Swivel Block
Controls
The powered rotating head is controlled by two switches.
Rotary Glyd
Ring (11)
Torque Arrestor
Hanger
Bull Gear
Swivel Block
Hydraulic Motor
Assembly
H1
S1
A1
RE
A3
PRESSU
H1
H3
A2
S2
A5
A4
H2
S2
A4
A1
A5
A2
H3
A3
H2 S1
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Torque wrench
The primary function of the TDS torque wrench is to breakout
the drill string from the saver sub before making a connection.
The torque wench can also make connections if necessary (i.e.,
when replacing the lower IBOP or saver sub, or while back-
reaming, or when adding a pup joint to the drill stem).
The torque wrench has a control manifold with the following
components (Figure 3-5):
Make/Break
Valve
BREAK MAKE
Hydraulic
Pressure
Return
70
1000 1500
30
Hydraulic
80
Pressure
LIFT LOWER
20
500 2000
Inlet
90
Lift/Lower
10
®
0 2500
10
Flow Control PSI
0
0
Valve
Ft.Lbs. x1000
Torque Gauge
0 - 2500 PSI
PH-60d
To operate the torque wrench with a 3 1/2 in. drill string, install a
separate drill string handling kit. The following lists available kits
for a PH-60d:
z Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No.
78652-2 does not. By purchasing the latter, the user assumes
responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver
subs separately. Specifications for these are available from the
factory or any Varco service center.
Upper IBOP to
main stem/main shaft 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 63,000 ft lb
Lower IBOP valve
to upper safety valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 60,000 ft lb
Saver sub to
lower IBOP valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft lb 60,000 ft lb
Crossover sub to
lower IBOP valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft lb 60,000 ft lb
Upper IBOP valve to
main stem/main shaft 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 83,000 ft lb 91,000 ft lb
Lower IBOP valve
to upper IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 84,000 ft lb
Saver sub to
lower IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 7 5/8 in. 66,000 ft lb 85,000 ft lb
Crossover sub to
lower IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 91,000 ft lb
Set slips on Raise block Pickup stand with Lower block to Pull slips
string elevator stab motor into
Tilt link tilt top of stand Start circulation
Stop circulation to derrickman Stab bottom of
stand onto string Spin in motor Begin drilling
Breakout and stand
connection
using pipehandler Makeup both
and drilling motor connections with
(in reverse) motor
1 2 3 4 5
Link
Makeup
Tilt
Start
Circulation
Stop
Circulation
Stab Makeup
1 2 3 4 5
Makeup
Open
IBOP
Close Link
IBOP Tilt
Stab Makeup
1 2 3 4 5
Makeup
Start
Circulation
Stop
Circulation
Makeup
Tripping
Perform tripping operations in the conventional manner. Use the
link tilt feature to tilt the elevator to the derrickman so the
derrickman can quickly latch it around the pipe.
The hydraulic link tilt allows the elevator to also reach the
mousehole.
The air actuated link tilt has an intermediate stop which is
adjustable to set the elevator at a convenient working distance
from the monkeyboard. The intermediate stop tilts out of the way
to allow the elevator to reach the mousehole.
If a tight spot or key seat is encountered while tripping out of the
hole, spin the drilling motor into the stand at any height in the
derrick. Establish circulation and rotation immediately to work
the pipe through the tight spot.
Hoist while Set slips on Hoist free stand Setback stand Lower block,
circulating and string with elevator using link tilt stab motor into
rotating string
Breakout connec-
When 3rd tion using pipehandler Spin in motor
connection and drilling motor and makeup
surfaces, stop (reverse) connection with
rotation and motor
circulation Breakout and
spinout stand Start circulation,
at floor pull slips,
hoist and rotate
1 2 3 4 5
Hoist and
Rotate
Breakout
Running casing
For casing operations, longer elevator links (180 in.) must be used
to allow clearance for the cementing head under the torque
wrench in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.
If desired, run casing conventionally using the block and hook
and swinging the TDS aside. Use longer bails (180 in.) to prevent
the block dolly (if used) from contacting the TDS dolly.
Drill Pipe
Elevator
Drill Collar
Dolly
A
100 TON
VARCO
Perfection
Links (36")
;;
;;; ;;
;;; ;;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
Drill
8 in. Collar
View A-A
Maintenance
and
Troubleshooting
SM00620-4
Rev. B
March 8, 2001
Chapter 1 Maintenance
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
Replacing the standard rotating head
glyd rings ........................................................... 4-71
Replacing the powered rotating head
glyd rings ........................................................... 4-75
Replacing the standard or extended reach
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
Removing the motor assembly
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97
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, or a caution note. See the examples
below and pay close attention to these important advisories.
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), 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.
Inspection
n Unlatching the hook from the integrated swivel bail may cause the
TDS motor assembly and/or the hook to lurch suddenly. Always
keep adequate tension on the tailing lines to prevent sudden
movement of these assemblies.
n While latching the hook to the integrated swivel bail, the swivel
and/or the TDS motor assembly may suddenly lurch. Always keep
adequate tension on tailing lines to prevent sudden movement of
these assemblies.
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide
dolly assembly for loose bolts and fittings daily. If any safety wire
or cotter pins were removed to facilitate repairs, replace them
immediately.
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings
daily. If any safety wire or cotter pins were removed during
repairs, replace them immediately.
Inspect the hinge bolts daily to make sure they are not separating
from the pipehandler. Make sure the hinge pins are not loose due
to excessive wear in the bore of the clamp clevis or a broken
retaining bolt.
n Inspect the link tilt intermediate stop and adjustment device for
overall integrity weekly. Replace the components if there is
excessive looseness of the threaded rod in the threaded hole of the
pivot arm (Figures 4-24 and 4-25). An indication of a possible
problem is if the two intermediate stops are not adjusted equally
(i.e., if the thread engagement differs between the two stops).
Failure to perform this inspection and/or component replacement
can result in injury to rig personnel.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes (Figure 4-1). Compare the measurements
with the Wear Chart (Figure 4-1) to determine the current
strength of the elevator links. The capacity of the links equals the
capacity of the weakest link.
Upper Lower
Capacity ;;;;
Eye Eye ;;;;
(per set) ;;;;
Dimension Dimension in Tons
;;;;
C A
Landing collar
Disassemble and inspect the landing collar every six months.
Use the following procedure to disassemble the landing collar
(Figure 2-5) for inspection:
1. Disconnect the top drive from the drill string.
2. Remove the IBOPs and pipehandler.
3. Raise the solid body elevator to expose the landing collar
retainer.
4. Straighten the retainer tabs.
5. Slide the retainer ring above the split landing collar halves.
6. Drive out one roll pin.
7. Remove the landing collar halves.
8. Slide the retainer off the drive stem.
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear.
Remove the drive stem/mainshaft from service if bore wear is
greater than the dimensions shown in Figure 4-2.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B as
guidelines for interpreting and performing inspections.
Measurement techniques are specified in API RP 7G, Section 10.
Use API Bulletin 5T1 to identify and define imperfections found
during inspections.
Large Bore
9.000
Diameter
7.500-3 ACME-3G
Left-hand Thread
Small Bore
1.30 Minimum @ Landing
Collar Grooves (2.45 New)
3.00
(1.70 New)
Diameter (New)
9.000
Diameter
3800000
3700000
New Condition (3.00 Bore)
3600000
3500000
3400000
3300000
3200000
Load (Lbs)
3100000
New Condition
3000000
(3.82 Bore)
2900000
2800000
2700000
2600000
2500000
2400000
2300000
2200000
1.75
1.70
1.65
1.60
1.55
1.50
1.45
1.40
1.35
1.30
1.25
1.20
1.15
1.10
1.05
1.00
Gearbox
Check oil daily. With the motor off, check to see that the oil level
is at the middle of the sight glass located on the side of the main
body. Drain and refill the gearbox every 1,500 operating hours or
three months, whichever occurs first. (Refer to Oil capacity later
in this chapter.)
Properly maintaining the TDS gear shifting mechanism increases
the operational life of the top drive. 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. This helps to
distribute lubricant and prevents contaminant buildup.
2. Remove the gear indicator lever assembly and the indicator
gearcase cover.
3. Repack the inside area with grease every six months (refer to
Figures 1-9 and 1-10 in the Description book).
4. Inspect the gears for corrosion or damage. Clean, lubricate or
replace components as required. There is a “timing mark” on
the gears to ensure correct orientation. If these marks are not
visible when removing the gears, mark the gears before
removal to ensure correct orientation when reinstalling them.
If there are problems shifting from one gear to the other, use the
following procedure to shift the gears:
1. Turn the drive stem with chain tongs to make sure the gear
mesh aligns properly. Do not turn the DC motor while
shifting gears.
2. Insert two 3/8 in. 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. Do not shear the bolts.
Eccentric shaft rotation direction is the same as the shifter
input shaft when shifting into gear.
3. If the shift input mechanism slips when attempting to shift
gears, use a torque wrench to check the torque of the shifter
when the clutch begins to slip. If the torque is less than
65 ft lb, then use the Torque setting procedure to adjust the
clutch
Gear Subplate
A
Lower Gearcase
Detail A
Oil capacity
The TDS-4S holds approximately 10-20 gallons of oil, but oil
capacities vary according to the type of cooling systems, etc.
installed. Always fill the transmission to the middle of the sight
glass. Use the following procedure to fill the transmission for the
first time on a new top drive:
1. Fill the gearbox to the top of the sight glass
(approximately 10-20 gallons).
2. Operate the top drive 10-15 minutes and check the
sight glass.
3. The oil level should be near the middle of the sight glass.
If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass. If the
oil level is at, or above the middle of the sight glass, do not add
any additional oil to the gearcase.
After installation and initial operation of the top drive, always fill
the transmission to the middle of the sight glass.
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. Oil still remains in the rotating head cavity
(approximately 1-2 gallons), the oil lube/pump/cooler system
(approximately 1-2 gallons), and the wetted surfaces inside the
motor housing assembly (approximately 2-3 gallons). 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.
Grease
Fittings
Wash Pipe
Assembly
Bonnet
Grease
Fittings
Grease
Fitting
Grease
Fittings
Grease Fitting
Grease Fittings
Grease Fitting
(6 on IBOP Actuator
Rollers, 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)
Master Bushing
Wear Guide
Open
Position
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Grease
Fitting
(20) Grease Fittings
Grease Fittings
Grease
Fitting
(20)
Swing
Guide Dolly
Grease
Fitting
Grease
Fitting
Grease Fittings
Grease
Fitting Grease Fittings
(28)
Grease Fittings
Bail
Grease Fitting
Grease Fitting
Transmission Cooler
Lubrication schedule
Frequency Location Lubricant code* Number of points
Daily Bonnet seal 1 2
Daily Torque wrench (PH-85) 1 6
Daily Gearbox oil (check level) 2 1
Daily Rotating head 1 5
Daily Safety valve actuator cranks 1 2
Daily Hydraulic pressure filter † – –
Daily Wash pipe assembly 1 1
Each trip BNC drill pipe elevator 1 7
Each trip Guide dolly rollers (Retract ‡) 1 20
Weekly Gearbox (shift gears) - -
Weekly Dolly motor trunnions 1 2
Weekly Air filter/regulator/lubricator † – –
Weekly IBOP actuator arms 1 6
Weekly Link adapter (650-Ton) 1 4
Weekly Elevator support 1 7
Weekly Master bushing wear guide 1 4
Weekly Link tilt (check condition)
Weekly Bail pins 1 2
750 hrs/90 days GE drilling motor pinion bearing 3
1,500 hrs/6 mos. GE drilling motor commutator bearing 3
Monthly Motor frame/dolly hinges (Retract ‡) 1 4
Monthly Cooling system cleaning – –
3 months AC blower motor 1 2
3 months Change gearbox oil 2 1
3 months Gear oil filter/suction strainer † – 1
* See Table 4-1, Recommended lubricants
† Check condition and replace as necessary
‡ Refer to Retract Guide Dolly supplement
1 2
General Purpose Grease Gear Oil
Exxon Lidok EP2 Lidok EP1 Spartan EP320 Spartan EP150 Spartan EP68
Gulf Gulf Crown EP32 Gulf Crown EP31 EP Lube HD320 EP Lube HD150 EP Lube HD68
Mobil Mobilux EP2 Mobilux EP1 MobilGear 632 MobilGear 629 MobilGear 626
Shell Alvania EP2 Alvania EP1 Omala 320 Omala 150 Omala 68
Statoil Uniway EP2N Uniway EP1N Loadway EP320 Loadway EP150 Statoil
Texaco Multifak EP2 Multifak EP1 Meropa 320 Meropa 150 Meropa 68
Total Multis EP2 Multis EP1 Carter EP 320 Carter EP 150 Carter EP 68
Union Unoba EP2 Unoba EP1 Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP
NGLI 2 1 - - -
3 4 5
Motor Grease Hydraulic Oil Bio-degradable
NGLI 2 - -
AGMA - - -
ISO Viscosity - 46 32
Grade
Adjustment procedures
Make/Break
Valve
BREAK MAKE
Hydraulic
Pressure
Return
1000 1500
30
Hydraulic
80
Pressure
LIFT LOWER
20
500 2000
Inlet
90
Lift/Lower
10
0 2500
10
Valve
Ft.Lbs. x1000
Torque Gauge
0 - 2500 PSI
Pressure Reducing
Valve
Needle Valve
Alignment
Cylinder
Manifold
Accumulator
Bracket
Gas Valve
Needle Valve
Alignment Cylinder
Valve Manifold
Bracket
Gas Valve
Accumulator
Shipping
Brace
Motor
Frame Dolly (Ref)
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, water-
pumped 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.
Pipehandler
V
a
r
c
o
Torque Cylinders
Clamping Jaws
Body
Stabbing Guide
Frame
Hanging
Height
Adjustment
Guard
Mounting
Shaft
Safety Valve
Actuating Vertical
Cylinders (2) Positing
Cylinder
Safety Valve
Actuating
Arm (2) Torque
Tube
Stabilizer
Stop Tube
Clamping Clamping
Jaws (2) Cylinder
Piston
Control
Manifold
Disassembly
1. 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.
2. 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.
Assembly
1. Insert a new front rod seal and rod wiper in the clamp
cylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and
lubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with the
two jaw spacer screw holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod
appears beyond the front cylinder bore.
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8) Swivel Block
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one
flange gasket, and one excluder cap gasket from Varco.
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.
2. Disconnect the hydraulic and air hoses from the rotating head
rotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly while
removing the pins attaching the torque arrestors to the
rotating block.
7. Remove the torque arrestors, link tilt and link adapter.
8. Place the rotating head stand, built prior to disassembly,
under the TDS and lower the TDS until the rotating head
rests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotating
head on the stand.
10. Remove the quick disconnect fittings from the rotating block
hydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Push the cam follower away from the rotating block cam.
14. Remove the safety wire from the ten hex-head screws
attaching the rotating block to the stationary flange.
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.
Hex Nut
;;;;
Cotter Pin
Cam
;;;;;;
;;;;;;
Cylinder Clevis
;;;;;;
Excluder
Cap
;;;;;;
C;;;;;;
Retainer Ring
Detail
;;;;;;
;;;;;;
Glyd Ring (8)
Ball Bearing
;;;;;; Excluder Cap
Gasket
Cam
Ball Bearing
C
Stationary Flange
Bull Gear
Lip Seal
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the quick disconnect hydraulic fittings on the
rotating block.
7. Attach the return cylinder rod to the clevis with the clevis pin
and install the slotted hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.
Disassembly
1. Order eleven replacement glyd rings, two gearcase seals, one
flange gasket, and one excluder cap gasket from Varco.
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.
2. Disconnect the hydraulic and air hoses from the rotating head
rotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly while
removing the pins attaching the torque arrestors to the
rotating block.
7. Remove the torque arrestors, link tilt, and link adapter.
8. Place the rotating head stand, built prior to disassembly,
under the TDS and lower the TDS until the rotating head
rests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotating
head on the stand.
10. Remove the quick disconnect fittings from the rotating block
hydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Remove the hydraulic motor assembly.
14. Remove the safety wire from the ten hex-head screws
attaching the rotating block to the stationary flange.
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eleven new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the QD hydraulic fittings on the rotating block.
7. Reinstall the hydraulic motor assembly.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.
Disassembly
1. Disconnect the air hose from the rotating head rotating block
to the link tilt assembly.
2. Support the link tilt and remove the two upper and two lower
screws attaching the link tilt to the link adapter.
3. Lower the link tilt to the floor with the air actuator to be
replaced facing up.
4. Remove the cotter key and pin from one end of chain
connecting the two sealing plates.
5. 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.
6. Lift the lever or base off the air actuator sealing plate, and
rotate it 180° on the link tilt pivot pin and lay down.
7. Remove the nuts and washers holding the sealing plate to the
air actuator and remove the plate.
8. Using a pry bar or screwdriver, pry the air actuator away from
the screws, attach the actuator to the hanger plate and remove
the screws using a hex wrench.
9. Remove and discard the air actuator.
10. Remove any burrs or gouges on sealing surfaces of the hanger
and sealing plates.
Lever Weldment
Pivot Pin
Pressure
Air Actuator Regulator
Nuts, Lock
Washers (18) Base
Sealing Plate
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Buttonhead
Capscrew (18)
Stop Release
Loop
Hanger Plate
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Assembly
1. Place a new actuator on the hanger plate.
2. Attach the air actuator to the hanger plate with the 18
buttonhead cap screws. Coat the screw threads with locktite
before installation.
e The air actuator has aluminum neck bead rings on both sealing
surfaces. These beads must be compressed equally to ensure a good air
seal. This requires more than one tightening pass to accomplish.
Over-torquing may cause hex sockets to strip.
4. Torque the cap screws to the hanger plate at 80 ft lb.
5. Insert the 18 bolts into the neck ring of the air actuator.
6. Reinstall the air actuator sealing plate, coat the bolt threads
with locktite and fasten with the lockwashers and nuts
provided.
7. Torque the nuts to the sealing plate at 80 ft lb.
(See Caution above.)
8. Lift and rotate the link tilt lever or base to line up with the air
actuator sealing plate. Attach with the four hex-head cap
screws and torque to 250 ft lb.
9. Safety wire the four screws.
10. Reconnect the chain between the two sealing plates.
11. Reinstall and adjust the link tilt per the Installation and
Commissioning book.
Front jaw
1. Remove the cotter pin from the retaining bolts
and slotted nut.
2. Remove the nuts securing the die retainer to the jaw.
3. Remove the die retainer from the jaw.
4. Remove the tong dies from the jaw.
Rear jaw
1. On the rear jaw, remove the cotter pins from the retaining
bolts and slotted nuts.
2. Support the retaining bolt while removing the slotted nut.
3. Remove the retaining bolt from the piston jaw.
4. Support the remaining retaining bolt while removing the
slotted nut and upper die retainer.
5. Remove the retaining bolt and lower die retainer.
6. Remove the tong dies from the jaw.
Front jaw
1. Loosen the socket head cap screws securing the jaw assembly
to the torque wrench body.
2. Support the jaw and remove the socket-head cap screws and
washers from the jaw assembly and the torque wrench body.
3. Remove the front jaw assembly from the torque wrench body.
Rear jaw
1. Loosen the socket head cap screws securing the jaw assembly
to the piston.
2. Support the jaw assembly and remove the socket-head cap
screws and washers from the jaw assembly and piston.
3. Remove the rear jaw assembly from the piston.
Disassembly/assembly of the
drilling motor and motor support
bonnet
1. Remove the upper bearing cover and grease seal
(Figure 4-32).
2. Pressurize the air brake to hold the drive mechanism in place.
3. Remove cotter pins, slotted nuts and the rotating head.
4. Remove the lower gearcase, carefully avoiding damage to the
lower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to the
bearing surfaces or wear sleeves. Do not remove the gear from
the shaft unless you are replacing it.
6. Remove the pinion seal and retaining ring.
7. Remove the main body.
8. On the opposite end of the motor, remove the magnetic
pickup and brake cover.
9. Remove the brake for service.
Low DC
Gear Drilling
Assembly Motor
Bull Gear
High
Gear
Assembly
Pinion Gear
Manual
Shifter
Input Geneva
Mechanism
HI Motor
Shaft
Oil Level Pinion Seal
LO Sight Glass
Lower Gear
Case
Motor Gear
Alignment Selection
Cylinder Indicator
5. Make sure the fixture is clean and the “horse shoe” face and
bar are parallel.
6. 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, sandwiching the pinion gear in the fixture.
7. Adjust the adjusting screw to butt against the end of the
motor shaft.
8. Attach a calibrated dial indicator gauge to the fixture and set
to zero.
9. Back off the adjusting screw until the gauge reads 0.072-
0.074 in. Then lock the screw in place with a locknut.
10. Remove the fixture from the pinion gear assembly.
Axial Fan
20 hp Transmission
Blower Motor Cooler
Locking Key
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
Use the size and type of safety wire required in the applicable
specifications and drawings. Whenever possible, use double-twist
safety wiring.
1
2
3 4
n Do not nick the wire with the edge of the hole in the fastener.
Position the safety wire so the pull exerted by the wire tightens the
nut. For best results, let the wire leave the fastener in a clockwise
direction
❏ 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, with resulting slack in the safety wiring.
n When securing castellated nuts with safety wire, tighten the nut to
the low side of the selected torque range, unless otherwise specified.
If necessary, continue tightening within specified torque limits
until a slot aligns with the hole.
Troubleshooting the
retract guide dolly
Troubleshooting the
safety valve actuator
Troubleshooting the
crown height indicator
Torque Wrench
Brake
IBOP Open
Link Tilt
IBOP Close
Control System
SM00620-5
March 8, 2001
General description
The Top Drive Drilling System (TDS) typically operates from the
same SCR as the rotary table. A panel, located in a Central
Electronics Enclosure (CEE), switches power from one to the
other. The CEE typically contains the following components:
❏ DC contactors
❏ A programmable logic controller (PLC)
❏ Auxiliary AC components
❏ Rig instrumentation interfaces for recording
TDS torque and speed
In dedicated top drive SCR configurations, the SCR runs the top
drive only.
The panel can feature a purge control system so it can be located
in hazardous areas. If the panel is located in the SCR room, a
purge system is not required.
The 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. Logic and alarm functions are connected to the
TDS via PLC programming so the TDS can operate existing rig
systems. Also, TDS interlocks and limits, such as spin-up and
makeup speeds, are programmed into the PLC and are the same
for all installations.