IDS1 ServiceMAn Deutag

IDS-1
Top Drive
Drilling
System
Deutag, Rig T-75
Service Manual
SM00420
December 9, 1997
ii IDS-1 Contents
Contents
Book 1 – Description
Preface/Manual conventions
Safety information ........................................................... 1-5
Directional references ...................................................... 1-6
Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
Chapter 2 Theory of operation.............. 1-9
Chapter 3 Major component descriptions

Integrated traveling blocks ............................................. 1-12
Drilling unit assembly .................................................... 1-14
Drilling motor assembly........................................... 1-14
Single-speed planetary transmission ......................... 1-14
Rotating head .......................................................... 1-15
Integrated swivel assembly ....................................... 1-16
Carriage assembly and torque tube ........................... 1-17
Counterbalance system ............................................ 1-17
Local blower cooling system with extended intake ......... 1-19
PH-60d Pipe handler ..................................................... 1-21
Solid body elevator .................................................. 1-23
Safety valves (IBOP) ................................................ 1-25
Saver and crossover subs..................................... 1-25
Safety valve actuator ................................................. 1-25
Torque wrench ........................................................ 1-27
Extended reach link tilt mechanism ......................... 1-29
IDS-1 Contents iii

December 9, 1997
Bottleneck Center latch (BNC) drill pipe elevator.......... 1-31

Elevator links ................................................................. 1-33
IDS control system ........................................................ 1-33
Driller’s control and instrumentation console (VDC)1-33
Transfer control panel .............................................. 1-34
Purge control system ................................................ 1-34
Service loops .................................................................. 1-35
Derrick electrical termination kit ................................... 1-35
Optional equipment ...................................................... 1-36
Auxiliary floor equipment ........................................ 1-36
PS-16 power plip ............................................... 1-36
Master bushing ID wear guide ........................... 1-38
Swiveling drill collar dolly .................................. 1-38
Wireline adapter ................................................ 1-40
Hydraulic power unit ............................................... 1-41
Video monitoring system ......................................... 1-42
Crown height indicator ............................................ 1-43
Transportation, storage and maintenance skid ......... 1-43
IDS specifications .......................................................... 1-44
iv IDS-1 Contents
Book 2 – Installation and commissioning
Manual layout.................................................................. 2-6
Chapter 1 Installation
Installing the IDS-1 ......................................................... 2-7
Rig floor .................................................................... 2-7
Derrick ...................................................................... 2-9
Torque tube assembly .............................................. 2-11
Preinstallation checklist.................................................. 2-12
IDS and torque tube rig-up procedure ........................... 2-14
Installing the pipehandler ........................................ 2-19
Installing the cooling system .................................... 2-22
Installing the rotary hose .......................................... 2-22
Traveling block dolly rig-up procedure .......................... 2-23
Plumbing ....................................................................... 2-24
Air ........................................................................... 2-24
Derrick electrical termination ........................................ 2-25
Driller’s controls and instrumentation ........................... 2-26
Driller’s console ....................................................... 2-26
Throttle and torque limit controls ........................... 2-26
Wiring ..................................................................... 2-26
Service loops .................................................................. 2-28
Installation ............................................................... 2-28
Electrical loop .................................................... 2-29
Chapter 2 Commissioning
Checkout procedure....................................................... 2-31
Long term IDS storage procedures ................................. 2-33
Returning the IDS to service after storage ...................... 2-34
IDS installation checklists (FIP 0001) ............................ 2-34
IDS Installation checklists (FIP 0001)
IDS-1 Contents v
December 9, 1997
Book 3 – Operation
Manual layout .................................................................. 3-6
Chapter 1 Operating procedures

Stalling the DC motor ..................................................... 3-7
Counterbalance system .................................................... 3-8
Pipehandler operation ...................................................... 3-9
Rotating head ............................................................ 3-9
IBOP safety valves ................................................... 3-10
Torque wrench ........................................................ 3-12
Torque values for load carrying components ............ 3-16
Changing drill string sizes ........................................ 3-17
Drilling ahead ................................................................ 3-18
Drilling ahead with triples ....................................... 3-18
Drilling ahead with singles ....................................... 3-21
Tripping ........................................................................ 3-23
Reaming out .................................................................. 3-24
Well control procedures ................................................. 3-26
Running casing .............................................................. 3-27
Handling bottom hole assemblies .................................. 3-27
Post jarring checklist ...................................................... 3-28
Post jarring checklist/design torque specification
(DS00008)............................................................... 3-28
Lubrication and Maintenance Schedule (laminated)
Post Jarring Checklist (PI 93-1)
Design Specification, Design Torque Standard (DS00008)

vi IDS-1 Contents
Book 4 – Maintenance and Troubleshooting
Manual layout.................................................................. 4-8
Chapter 1 Inspection
Inspecting the DC drilling motor .................................... 4-9
Inspecting the air exhaust muffler .................................. 4-10
Inspecting the derrick termination kit air
filter/regulator/lubricators .............................................. 4-11
Inspecting the pipehandler ............................................. 4-12
Nondestructive Examination (NDE) ............................. 4-13
Visual inspection...................................................... 4-13
Inspecting the elevator link eyes ......................... 4-13
Inspecting the torque tube ................................. 4-13
Inspecting the landing collar .............................. 4-15
Magnetic particle inspection .................................... 4-16
Ultrasonic inspection ............................................... 4-17
Inspecting safety valves....................................... 4-17
Inspecting the shaft liner assembly ................................. 4-18
Chapter 2 Lubrication
Lubricating the block ..................................................... 4-20
Lubricating the wash pipe assembly ............................... 4-21
Lubricating the cooling system ....................................... 4-22
Lubricating the drilling unit assembly ............................ 4-22
Lubricating the gearbox assembly ............................. 4-22
Initial oil change period ........................................... 4-22
Oil capacity.............................................................. 4-23
Lubricating the DC motor ....................................... 4-24
Lubricating the hydraulic system.................................... 4-27
Lubricating the alignment strut assembly ....................... 4-28
Lubricating the rotating head ......................................... 4-29
Lubricating the solid body elevator ................................ 4-30
Lubricating the safety valve actuator .............................. 4-31
Lubricating the upper IBOP safety valve ........................ 4-32
Lubricating the carriage assembly ................................... 4-32
IDS-1 Contents vii

December 9, 1997
Lubricating the lower attachment assembly (torque tube)4-34

Lubricating the drill pipe elevator .................................. 4-35
Lubricating the master bushing wear guide .................... 4-36
Lubrication schedule ...................................................... 4-37
Lubricant specifications ................................................. 4-38
Chapter 3 Maintenance
Adjusting the hydraulic assembly ................................... 4-41
Adjusting the counterbalance system .............................. 4-44
Adjusting the torque wrench .......................................... 4-46
Upper safety valve (IBOP) and safety valve
actuator system .............................................................. 4-48
Assembly and disassembly .............................................. 4-49
Pipehandler (PH-60d) ............................................. 4-49
Torque wrench disassembly ............................... 4-49
Replacing the torque wrench clamping
piston seal .................................................... 4-51
Replacing the front and rear piston seal........ 4-51
Replacing the rotating head glyd ring ................. 4-54
Replacing the extended reach link tilt
air actuator ......................................................... 4-57
Removing the tong die ............................................. 4-60
Front jaw ........................................................... 4-60
Rear jaw ............................................................. 4-60
Removing the jaws ................................................... 4-61
Front jaw ........................................................... 4-61
Rear jaw ............................................................. 4-61
IBOP assembly/disassembly ..................................... 4-61
Counterbalance system assembly/disassembly .......... 4-62
Carriage assembly/disassembly ................................. 4-64
Wash pipe assembly/disassembly .............................. 4-66
Shaft liner assembly/disassembly .............................. 4-67
Replacing/installing the seal ............................... 4-69
Alignment strut assembly/disassembly...................... 4-73
Local blower cooling system assembly/disassembly ... 4-75
Brake assembly/disassembly ..................................... 4-77
Hydraulic power unit assembly/disassembly ............. 4-78
Removing the drilling motor assembly ..................... 4-79
Replacing the safety wiring ............................................ 4-82
Safety wiring tips ..................................................... 4-84
viii IDS-1 Contents

Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-85
Troubleshooting the drilling unit assembly .................... 4-86
Troubleshooting the motor brake ............................ 4-86
Troubleshooting the gearbox ................................... 4-87
Troubleshooting the hydraulic pump/
motor assembly ........................................................ 4-88
Troubleshooting the cooling system ......................... 4-89
Troubleshooting the pipehandler ................................... 4-90
Troubleshooting the torque wrench ......................... 4-90
Troubleshooting the safety valve actuator................. 4-92
Troubleshooting the link tilt .................................... 4-92
Troubleshooting pipehandler at the
hydraulic/pneumatic manifold ................................. 4-93
Book 5 – IBOP Service Manual
Book 6 – GE Motor Service Manual
Book 7 – Service Bulletin Index
IDS-1 Contents ix
December 9, 1997
x IDS-1 Contents
IDS-1
Integrated
Drilling
System
Description
December 9, 1997
1-2 IDS-1 Description

Contents
Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
Chapter 2 Theory of operation.............. 1-9
Chapter 3 Major component descriptions

Integrated traveling blocks ............................................. 1-12
Drilling unit assembly .................................................... 1-14
Drilling motor assembly........................................... 1-14
Single-speed planetary transmission ......................... 1-14
Rotating head .......................................................... 1-15
Integrated swivel assembly ....................................... 1-16
Carriage assembly and torque tube ........................... 1-17
Counterbalance system ............................................ 1-17
Local blower cooling system with extended intake ......... 1-19
PH-60d Pipe handler ..................................................... 1-21
Solid body elevator .................................................. 1-23
Safety valves (IBOP) ................................................ 1-25
Saver and crossover subs..................................... 1-25
Safety valve actuator ................................................. 1-25
Torque wrench ........................................................ 1-27
Extended reach link tilt mechanism ......................... 1-29
Bottleneck Center latch (BNC) drill pipe elevator.......... 1-31
Elevator links ................................................................. 1-33
IDS control system ........................................................ 1-33
Driller’s control and instrumentation
console (VDC)......................................................... 1-33
Transfer control panel .............................................. 1-34
Purge control system ................................................ 1-34
IDS-1 Description 1-3

December 9, 1997
Service loops .................................................................. 1-35

Derrick electrical termination kit ................................... 1-35
Optional equipment ...................................................... 1-36
Auxiliary floor equipment ........................................ 1-36
PS-16 power plip ............................................... 1-36
Master bushing ID wear guide ........................... 1-38
Swiveling drill collar dolly .................................. 1-38
Wireline adapter ................................................ 1-40
Hydraulic power unit ............................................... 1-41
Video monitoring system ......................................... 1-42
Crown height indicator ............................................ 1-43
Transportation, storage and maintenance skid ......... 1-43
IDS specifications .......................................................... 1-44

Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z Indicates advisories for operational or servicing procedures

involving little or no risk of personnel injury and equipment
damage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rig

personnel.
Avoid personnel injury and equipment damage by reading this

manual and related documents before operating, inspecting, or
servicing the equipment.

December 9, 1997
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 (IDS-1), standing behind the IDS-1 as it faces well
center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.

Chapter 1
Introduction
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 the
driller extended the drill string using the “make-a-single-
connection” process with the rotary table, kelly, pipe tongs,
drawworks cathead, master bushing and bowls, and slips. Apart
from minor improvements, such as kelly spinners, this method of
handling pipe and joint makeup remained unchanged until the
advent of top drive drilling systems.
Varco produces an Integrated Drilling System (IDS) that rotates
the drill string and allows the addition of entire 93 ft. stands of
pipe. This eliminates two thirds of the conventional single-pipe
drilling connections.
The IDS integrates the drill pipe connection handling and drive
systems with the traveling block (Figure 1-1). It uses a torque
tube instead of traditional guide rails and bracing. The IDS
connects directly to the traveling block, thus eliminating the
drilling hook and shortening the IDS working height.

December 9, 1997
The IDS provides more rotating power than a conventional rotary

table drive while eliminating the need to pick up the cumbersome
swivel/kelly combination. The IDS does not interfere with
existing conventional equipment. It allows tripping, circulation,
rotation, and the running of casing, and it provides 90 ft. back
reaming capabilities to reduce the chance of stuck pipe.
Crown Out
500 Ton Torque
Integrated Tube
Block Extended Support
Air Intake Bracket
Block Top
Torque
8 in Flex Tube
Cooling Duct
114 in.
500 Ton
Bail Rest Integrated Swivel Connection
Gooseneck Links
(Special)
C'Balance Torque
System Tube
Dolly
G.E. 752
Hi-Torque Torque
D.C. Motor Reaction
Arm
Planetary Bottom
Drive Train Torque
Gearcase Reaction
Mud Line Beam
Flange
Rotating
Head
Solid Body
Link Elevator
Tilt
IBOP
Actuator
Electrical (Remote)
& Fluids
Service Loops
Tool Joint 108 in.
350 Ton
Links
350 Ton
D/P Elevator
Drill Floor
Figure 1-1. Typical IDS-1

Chapter 2
Theory of operation
A vertically mounted GE 752, high torque drilling motor powers

the IDS. The hollow motor shaft permits the installation of a
three-inch ID wash pipe through the motor for mud circulation.
The IDS main stem functions as the main output shaft driving
the drill string. The motor output couples to a 6:1 planetary in-
line transmission. The transmission output shaft connects to the
drill string through a single or dual kelly valve much in the same
manner as conventional top drives.
The pipe handler assembly can make or break drill pipe at any
height in the derrick. It also performs the pipe hoisting function
and permits connecting and disconnecting the stand from the
drilling motor.
The carriage/torque arm assembly is part of the drilling unit
assembly. The assembly moves vertically on the torque tube
installed in the derrick. The torque tube assembly reacts the
motor torque during drilling operations.
Torque reacts through two side links attached to a roller-guided
torque tube bushing. The torque tube is a composite structural
shape suspended from the crown and attached to a torque
reaction beam located 10 ft. (min.) above the rig floor. This in-
line design permits installation of the IDS in a back girt to well
center space of only 36 in. The IDS attaches to a traveling block
with a set of 114 in., 500-ton connecting links.

December 9, 1997
Two internal blow out preventor (IBOP) valves connect to the

end of the drive stem. The driller can remotely close the upper
IBOP at any position in the derrick. The lower IBOP, can be
manually closed and sent downhole while controlling a kick.
The fluid service loop provides the hydraulic and pneumatic
power services to the IDS. The electric service loop provides DC
power and AC power and control. The following section of this
book describes each of these assemblies. More information on
equipment specific to your configuration appears in the following
books of this manual.

Chapter 3
Major component
descriptions
The information provided in this section includes brief

descriptions of the main assembly, its operation, and optional
equipment. Other books of this manual describe installation,
operation, and maintenance instructions for the equipment
specific to your configuration.

December 9, 1997
Integrated traveling blocks

Varco offers sheaves for integrated traveling blocks (Figure 1-2) in
the following sizes and ratings:
❏ Six 60 in. OD sheaves (for 1 3/8 or 1 1/2 in. line) 500-ton

rated
❏ Six 50 in. OD sheaves (for 1 1/4 or 1 3/8 in. line) 500-ton
rated
❏ Five 42 in. OD sheaves (for 1 1/4 or 1 3/8 in. line) 350-ton rated
The blocks include lifting ears to accommodate the IDS drilling
unit assembly or standard links for handling tubulars during
conventional drilling.
The sheaves mount independently on externally lubricated
bearings that minimize friction. Flame hardened rope grooves are
machined in accordance with API recommendations.
Varco 350- and 500-ton IDS traveling blocks can be modified as
necessary for conventional drilling to accommodate hooks or
other traveling equipment using customized Varco adapters for
setting the IDS unit aside.

Integrated traveling blocks
Figure 1-2. Typical 500-ton IDS traveling block

December 9, 1997
Drilling unit assembly

The drilling unit assembly consists of the following:
❏ Drilling motor assembly

❏ One-speed planetary transmission
❏ Rotating head
❏ Integrated swivel assembly
❏ Carriage and torque tube
❏ Counterbalance system
Drilling motor assembly

The drilling motor assembly on the IDS is a shunt DC drilling
motor. Mechanically, the motor has hollow armature shafts and
vertical thrust bearings.
Hydraulic brakes hold torque in the drill string and assist in the
positioning of directional work. A solenoid valve operates the brakes.
Single-speed planetary transmission

The single-speed transmission of the IDS consists of the following
major components:
❏ Ring gear and gearcase

❏ Motor pinion gear
❏ Planetary gear housing and swivel stem assembly
❏ Main thrust bearing
The transmission on the IDS is a single-speed planetary gear
reduction system. The gear combination provides a 6:1 ratio. The
main swivel stem, or shaft, passes through a load bearing housing
and transmits drilling torque to the drill string.
The transmission assembly connects to the integrated traveling
block through links attached to the block gears. The gear housing
provides a lubrication reservoir for the gears, as well as support for
the pipe handler.

An optional electrically driven gear pump (mounted externally on

the gearcase) lubricates the bearings and gear meshes. It force
feeds lubricant from the gearcase through a fine mesh screen onto
the bearings and gear meshes.
Rotating head
The rotating head transfers pneumatic and hydraulic pressure
from stationary ports on the IDS drilling motor housing to
rotating ports on the rotating head (Figure 1-3). It features two
hydraulic passages, three pneumatic passages, and two spare
passages capable of transferring either pneumatic or hydraulic
fluid. All are rated at 2,000 psi.
The rotating head assembly consists of:
❏ A stationary flange
❏ Eight rotary glyd rings
❏ A swivel block
❏ A cam
❏ A return cylinder
❏ A cam follower
❏ Swivel block locking mechanism
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking Swivel Block

Lever
Figure 1-3. Rotating head assembly

December 9, 1997
The hydraulic and air lines for the various pipe handler functions
(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.
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 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. A
return cylinder is also mounted on the stationary flange. The
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.
Integrated swivel assembly

The IDS integrates the swivel functions on the drilling unit
assembly. The swivel main thrust bearing is in the transmission
below the planetary gears. The main swivel stem is a one-piece
forging with a flange located above the main thrust bearing to
support the drill string load. The swivel packing assembly mounts
on top of the drilling motor and incorporates a standard wash
pipe, unitized packing and union type nuts enabling the operator
to remove the entire assembly as a unit. The standard wash pipe
connects to a shaft liner that passes through the motor shaft and
transmission assembly to the output swivel stem.

Carriage assembly and torque tube

The IDS carriage assembly travels on the torque reaction tube. It also
acts as the support for the drilling motor. Two torque reaction
carriage arms and 12 independently lubricated drive rollers transmit
up to 38,000 ft lb of drilling torque to the torque tube.
The drilling motor assembly connects to carriage torque reaction
arms with two motor trunnion pins. These trunnions enable the
motor assembly to align with the drill string while moving up and
down the torque tube.
The torque tube reacts torque action from the IDS through the
torque arms and carriage assembly. The torque tube assembly weighs
~190 lb ft, comes in 20 ft. (maximum) sections, and requires brackets
for mounting to the crown. The torque tube also requires a torque
reaction spreader beam mounted across the mast/derrick cage at
approximately 15 ft. above the drill floor.
Counterbalance system
The counterbalance system prevents damage to tool joint threads
while making or breaking connections with the IDS. The IDS offsets
the weight of the drilling unit while stabbing into a connection. It
provides a cushioned stroke similar to that provided by the hook.
The counterbalance system (Figure 1-4) consists primarily of two
hydraulic cylinders and a counterbalance manifold. The hydraulic
cylinder assemblies connect the motor housing assembly with the
traveling block.
When properly adjusted, the counterbalance system supports all
but about 800 lb of the weight of the IDS over a full 8 to 10 in.
of travel.
When adding a stand to the string during drilling operations, the
driller takes a stand in the elevators and stabs it into the box in
the rotary. The driller continues to lower the IDS until the saver
sub touches the box of the new stand. At this point, only about
800 lb load is on the saver sub or drill pipe connection. The
counterbalance cylinders support the remainder of the IDS
weight. The driller then spins in and torques up the connection
and is ready to drill ahead. The system is preadjusted. Once
drilling resumes, the hydraulic power unit (HPU) can be turned
off and restarted for breaking out the connection at the floor after
drilling the stand down.

December 9, 1997
Becket
(Ref.)
Hydraulic Cylinder
Assemblies (2)
Motor Housing
(Ref.)
Figure 1-4. Typical IDS counterbalance system

(Refer to the engineering drawings for rig specific information)

Major component descriptions
Local blower cooling system with

extended intake
The local blower cooling system with an extended intake provides
local cooling air to the drilling motor. It receives air
approximately 27 ft. above the rig floor at the lowest point of the
motor’s travel.
This system consists of the standard local blower with ducting.
The ducting allows you to mount the extended intake on the
hook or traveling block, and run a flexible hose to the motor
(Figure 1-5).
A heavy-construction pressure blower mounts on the drilling
motor. An explosion proof 20 hp, 3,450 rpm AC electrical motor
directly drives the blower.

December 9, 1997
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,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,,,,, Extended Air Intake Assembly
Explosion-Proof,
20 hp, 3450 rpm
Flexible Duct Hose AC Motor
Impeller
Housing Blower
Mount
Blower
Impeller
Bonnet
Intake
Duct
Drilling
Motor
,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,
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,,,,,,,,,,,,,,,,,
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,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,
Transition
Duct
Figure 1-5. IDS-1 local blower cooling system with extended air intake

PH-60d Pipe handler
PH-60d Pipe handler

The main components of the pipe handler (Figure 1-6) include:
❏ Solid body elevator

❏ Safety valves (IBOPs)
Upper IBOP
Lower IBOP
Saver and crossover subs
❏ Safety valve actuator
❏ Torque wrench
❏ Link tilt mechanism
The pipe handler provides two functions for IDS drilling systems:
❏ Tripping 93 ft. drilling pipe stands

❏ Providing up to 60,000 ft lb torque for makeup and breakout
of connections at any height in the derrick.
The pipe handler can be configured for various tool joint
connections. It includes a solid body elevator and a special-
purpose Varco torque wrench. It also incorporates a remote safety
valve actuator and link tilt actuator.
When not in use, the pipe handler remains stationary and free
from the drill string passing through it. When tripping or
performing bottom hole operations, the pipe handler is free to
rotate 360°, emulating the action of a standard hook.

December 9, 1997
Torque Arrestors
Rotating Head
Solid Body Elevator
Link Tilt
Safety Valve
Actuator
Torque Tube
Lower IBOP (inside)
Upper Safety Valve
Torque Wrench
Standard
350-Ton Links
Standard 350-Ton
Center-Latch BNC
Drill Pipe Elevator
Figure 1-6. PH-60d pipe handler assembly

PH-60d Pipe handler
Solid body elevator

The solid body elevator and the elevator links work in
conjunction with the torque arrestors to transfer the hoisting
loads to the drive stem (Figure 1-7).
The drive stem is free to rotate inside the solid body elevator
while drilling. The solid body elevator does not rotate with the
drive stem because torque arrestors raise the solid body elevator
up off the load supporting landing collar located on the drive
stem.
When hoisting loads, the springs inside the torque arrestors
transfer the load to the drive stem by pulling the solid body
elevator down onto the landing collar. The solid body elevator
rotates with the rotating head, which is required for tripping
operations.
The torque arrestors contain compression springs capable of
supporting any stand of drill pipe in the full up position. The
torque arrestors replace the hook spring.

December 9, 1997
Rotating Head
Assembly
Torque Arrestor
Assembly
Torque Arrestor
Assembly
500-Ton
Solid Body
Elevator
Solid Body
Elevator
Split Plate
Assembly
Figure 1-7. 500-ton IDS-1 solid body elevator/torque arrestor assembly

PH-60d Pipe handler
Safety valves (IBOP)

The Varco pipe handler includes two safety valves (IBOPs) to
provide blowout prevention. For detailed descriptions, or
installation, operation, maintenance, and parts information, refer
to the Varco IBOP Service Manual included as a separate book in
this manual.
Saver and crossover subs

Each pipe handler ships with three saver subs and one crossover
sub. Saver subs are dual-pin subs used to preserve the threads on
the lower IBOP and provide a pin for the box end of the drill
string. Saver sub threads can be recut to a minimum shoulder-to-
shoulder length of seven inches before the sub must be discarded.
The crossover sub converts the lower IBOP pin to a 4 1/2 in. IF
box for well control procedures with standard pipe.
e Saver subs are load bearing components in IDS drilling systems and
must be inspected periodically along with other load bearing
components. See the Maintenance and Troubleshooting book for
more information.
Safety valve actuator

The upper IBOP valve actuator allows upper IBOP actuation at
any height in the derrick. The upper IBOP actuator system
consists of:
❏ Two pneumatic air cylinders

❏ Two actuator arms
❏ An actuator shell
❏ Two crank assemblies
❏ A pneumatic solenoid valve
Double-acting air cylinders move the actuator arm. The actuator
arm connects to the valve actuator shell and moves the actuator
shell up or down (Figure 1-8). The actuator arm engages a slot in
the actuator shell. When the shell moves the cranks, it opens or
closes the IBOP. The air cylinders are operated remotely by a
solenoid valve controlled by an electrical switch at the driller’s
console.

December 9, 1997
DriveStem
(Ref.)
Solid Body
Elevator
Landing Collar
Upper IBOP Valve

Upper IBOP Valve Actuator Shell
Actuator Air Cylinders (2)
Crank
Assembly
Actuator
Arm
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Figure 1-8. Safety valve actuator system

PH-60d Pipe handler
Torque wrench
The torque wrench provides a means for making and breaking
out connections with the IDS drive stem. The torque wrench
assembly consists of (Figure 1-9):
❏ A hanger
❏ A torque tube
❏ A torque tube guide ring
❏ Two torque cylinders
❏ A clamping jaw
❏ A clamping piston
❏ A control manifold
❏ A lifting cylinder
❏ Two tube stops
❏ A stabbing guide
A hanger attached to the rotating head supports the torque
wrench. The torque wrench has two torque cylinders connected
to the torque tube.
The gripping jaw contains a 10 in. diameter clamping piston for
gripping the box end of the drill pipe. The torque tube contains a
female spline that engages a male spline on the lower section of
the upper IBOP during operation of the torque wrench.
Actuating the torque wrench raises it, engaging the splines on the
upper IBOP. From the control manifold 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 60,000 ft lb.
An electrical push button on the driller’s console controls the
torque wrench operation. The driller presses the button until the
connection is made or broken. The driller then releases the
button and the unit automatically recycles to the READY
position. A two-position, directional control valve located on the
drilling unit adjusts the cycle.
The torque wrench can also make up or break out the saver sub
or lower IBOP. A manually operated valve on the rear of the pipe
handler selects either the makeup or breakout function.

December 9, 1997
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator
Air Cylinders
IBOP Actuator
Arms
Stop Tube
Torque Tube
Torque Wrench
Manifold (Hidden)
Clamping Jaws Torque Cylinders (2)

(Inside Clamp Body)
Stabbing Guide Clamping Piston

(Inside Clamp
Body Cylinder)
Figure 1-9. Typical PH-60d torque wrench assembly

PH-60d Pipe handler
Extended reach link tilt mechanism

The extended reach link tilt assembly (Figure 1-10) allows:
❏ The elevators to move off the well center to pick up a stand in

the mousehole.
❏ The derrick man to handle pipe more easily.
The link tilt assembly mounts on the front of the link adapter.
This assembly consists of a pivoting lifting frame connected to the
drilling links with chains and clamps. A switch on the driller’s
console controls a pneumatic solenoid valve that inflates an air
spring within the lifting frame. Inflating the air spring pivots the
frame upward, tilting the links outward.
An adjustable intermediate stop mechanism provides clearance
between the drill pipe elevator and the monkey board to assist the
derrick man in racking operations.

December 9, 1997
Double Air
Actuator
Intermediate
Stop D/P Elevator
Link Clamp
Intermediate
Stop Release
Figure 1-10. Extended reach link tilt mechanism

Bottleneck Center latch (BNC) drill pipe elevator
Bottleneck Center latch (BNC)

drill pipe elevator
The 300-ton bottleneck center latch BNC elevator differs
from conventional elevators because of its shaped catch links
(Figure 1-11). Other elevators have straight catch links. An IDS
drilling system elevator allows the links to spread, increasing the
distance between them. The increased center distance is required
to avoid interference with other assemblies while drilling down to
the rig floor.
A nonmetal wear guide shields the inner surfaces of the elevator,
allowing the operator to leave it on the pipe while drilling
without damaging the elevator body.
Varco elevators are API rated and pull tested to 1-1/2 times the
rated load. The elevator bore is induction hardened for maximum
wear resistance.

December 9, 1997
Figure 1-11. 350-ton BNC drill pipe elevator

Elevator links
Elevator links
Varco elevator links attach to the solid body elevator and support
the drill pipe elevator. Elevator link options include:
❏ 108 in., 350-ton elevator links

❏ 132 in., 350-ton elevator links (special for type E pipe handlers)
❏ 180 in., 500-ton elevator links (special long links for running
casing, providing 120 in. of clearance for cementing heads)
IDS control system

The IDS control system provides the driller with a control
console that operates all IDS functions. The components of the
control system include:
❏ Driller’s control and instrumentation console (VDC)

❏ Transfer control panel (TP)
Driller’s control and instrumentation

console (VDC)
The driller’s control and instrumentation console consists of a
torque meter, an RPM meter, and various switches and indicator
lights. The basic IDS control functions are:
❏ Link tilt
❏ Remotely controlled IBOP valve
❏ Motor brake
❏ Motor spin-torque control
❏ Makeup torque limit
❏ Transfer switch (RT/IDS)
❏ Link position
Optional controls and status indicator lights are available.

December 9, 1997
Transfer control panel

The IDS is operated from the same Silicon Controlled Rectifier
(SCR) as the rotary table. The transfer control panel switches
power between them. This electrical enclosure contains the DC
contacts, the programmable controller, the auxiliary AC
components and the rig instrumentation interfaces for recording
torque and speed of the IDS.
As is typical for all top drives, the DC power cables run from the SCR
to the transfer panel. From the transfer panel, new cables run to the
rotary table motor and to the racking board junction boxes for the
IDS.
The transfer panel has a purge control system for use in a
hazardous area (Zone 2, or Class 1, Div. 2). If the panel is located
in the SCR room, the purge system is not required.
The panel is compatible with all currently installed SCR systems and
is configured at installation for the SCR it controls. Logic and alarm
functions are connected to the IDS by programming the transfer
panel’s programmable logic controller (PLC) to operate the rig’s
existing systems. Similarly, IDS interlocks and limits, such as spin-
in speed, are programmed into the controller and are the same for all
installations.
Purge control system

The transfer panel and driller’s control console have separate
purge systems. All systems provide positive internal pressure to
prevent hazardous gases from entering areas of potential ignition
in Zone 2 or Class 1, Div. 2 hazardous areas.
Pressure switches in the protection units monitor the pressure and
provide an alarm signal in the event of purge pressure loss.
Prior to starting an unpurged system, the purge control unit
purges the system for a specific time interval sufficient to remove
any trapped hazardous gas. Status lights on the driller control
console indicate to the driller correct purge pressure, loss of
purge, and system purging. If purge pressure loss alarms and
indicators are ignored for a preselectable time interval, the
isolation unit can be set to shut down the IDS.

Service loops
Service loops
The service loops transfer the required electric and fluid services
between the derrick service stand pipes and junction boxes and
the corresponding junction boxes and fluid connections located
on the IDS. Of the two loops, one contains the electric cables,
and one contains air and hydraulic lines.
The electric loop contains four 646 MCM DC power cables, one
2/0 AWG drilling motor ground cable, and a composite cable
consisting of:
❏ 26 14 AWG conductors for auxiliary features

❏ 4 8 AWG conductors for blower motor
❏ 2 5 AWG conductors for shunt motor field supply
❏ 2 14 AWG shielded pairs for the RPM pickup signal
The power, ground, and composite cables are spirally wound and
potted inside a protective cover with 7 1/2 in. mounting flanges
at each end.
The fluids loop consists of:
❏ 3 3/4 in. SAE 100-R9 for hydraulic supplies

(one is a spare)
❏ 2 1/2 in. SAE 100-R2 for air supply (one is a spare)
Derrick electrical termination kit

J-box configurations depends up the type of electrical system is
ordered. Each configuration complies with specific electrical
codes and regulatory agency requirements throughout the world.

December 9, 1997
Optional equipment
Optional and auxiliary equipment is compatible with all IDS
models. All equipment is selected or adapted for your specific rig.
Some of the options include:
❏ Auxiliary floor equipment:

PS-16 power slip
Master bushing ID wear guide
Swiveling drill collar dolly
Wireline adapter
❏ Hydraulic power unit
❏ Video monitoring system
❏ Crown height indicator
Auxiliary floor equipment
PS-16 power plip

The power slip provides remote control of the drill pipe slips from
a foot pedal in the driller’s cabin for increased safety and ease of
operation during tripping cycles. The air-operated PS-16 power
slip (Figure 1-12) replaces standard hand slips.
The PS-16 incorporates an ID wear guide for centering the
rotating drill string while drilling ahead.

Optional equipment
Split Elevator Support
Q.D. Coupler
Air Cylinder
(2)
Relief Valve
Q.D. Coupler
Slip Assembly
(4)
Bowl Assembly
Guide Ring
Figure 1-12. PS-16 power slip

December 9, 1997
Master bushing ID wear guide

The master bushing ID wear guide centers the rotating drill string
and protects the master bushing while drilling ahead. It hinges
open for removal or when setting manual slips (Figure 1-13).
Figure 1-13. Master bushing wear guide
Swiveling drill collar dolly

The swiveling drill collar dolly (Figure 1-14) allows the drill collar
elevators to turn freely when handling bottom hole assemblies.
The drill collar dolly’s upset, which latches in the standard drill
pipe elevator, mounts on a bearing that allows it to swivel even
under load. A shoulder elevator is suspended from the
“perfection” links (or a second drill pipe elevator if lifting subs are
used). The collars can be walked in or out with the elevator
turning on the drill collar dolly.

Optional equipment
Drill Pipe
Elevator
Drill Collar
Dolly
A
100 TON
VARCO
Perfection
, ,,,
,,,
,,, ,
,,,
Links (36")
91"
Square
Shoulder
Elevator
Lifting
Sub
37"
Drill
Collar
8" View A-A
Figure 1-14. Swiveling drill collar dolly

December 9, 1997
Wireline adapter
The wireline adapter (Figure 1-15) attaches to the pipe handler
and prevents wireline interference from damaging pipe and IDS
components. It can be used with a lubricator held in the elevators
by using 180 in. long casing elevator links.
View A-A
9/16 in. Max.
Wire Rope Dia.
Top Drive
Torque Wrench
Torque Wrench Guard

(remove for installation)
20 in. Dia.
Sheave
Elevator Links
(180 in. long-
Customer furnished)
Wireline Adapter installs in

place of Torque Wrench
To Mud Manifold Guard using existing Pins
Elevator Links
(180 in. or longer-
Customer furnished)
View A-A
Figure 1-15. PH-60d wireline adapter

Optional equipment
Hydraulic power unit

The Varco hydraulic power units (HPU) are high capacity
hydraulic power supplies (Figure 1-16). All Varco HPUs use axial
piston, variable displacement pumps for use with Varco closed
center tools. The HPU can include a distribution manifold
featuring six individual flow and pressure adjustable outlets that
enable connecting multiple closed center or open center hydraulic
tools.
Varco HPU configurations operate with any number of pumps at
one time, depending on flow demand. Any pumps not operating
are available on a “hot” standby basis. The electrical system for
any configuration can be designed to meet either UL
(Underwriters Laboratory) or EEx (CENELEC) certification.
The driller’s control and instrumentation console, and the HPU
have start/stops controls. The console also contains a status
indicator light.
Figure 1-16. Typical hydraulic power unit with a distribution manifold

December 9, 1997
Video monitoring system

The video monitoring system (VMS) helps the driller monitor
certain operations in the derrick (Figure 1-17). Cameras
positioned in the derrick observe the upper connection when
stabbing the IDS into an add-on stand and observe traveling
equipment clearances below the crown.
Each camera has an explosion proof, vibration resistant housing
and features video pan, tilt, zoom, and iris controls operated from
the monitor. The monitor installs in the driller’s cabin and has a
purge system to prevent ingress of explosive gases.
In a multicamera system, a selection switch enables viewing
multiple camera images from a single monitor.
Figure 1-17. Video monitoring system

Optional equipment
Crown height indicator

The crown height position indicator is a self-contained electronic
instrument that determines the position of the traveling assembly
relative to the derrick crown. The system contains the following
four major subassemblies:
❏ A metal target located on the IDS carriage

❏ Two hinged sensor bracket assemblies
❏ A sensor junction box located in the derrick near the upper
bracket assemblies
❏ A crown height indicator control box or an integral control in
the driller’s control and instrumentation console
The crown height indicator control (CHIC) control box contains
three indicator lights and an electronic printed circuit board. Two
of the indicators display the position of the IDS relative to the
crown. The third indicator displays system power status.
The yellow indicator on the CHIC control box illuminates when
the traveling assembly is within 10 ft. of the crown. The red
indicator illuminates when the traveling assembly is within five
feet of the crown. When the traveling assembly is within two feet
of the crown, both indicators flash alternately. The green
indicator illuminates when correct DC system power is available.
This indicator also contains a push button for testing which
switch simulates the two-feet position.
The integral crown height indicator controls on the driller’s
control and instrumentation console are identical to the separate
control box, but are built into the driller’s control console.
Transportation, storage and

maintenance skid
Use the transportation, storage, and maintenance skid to
transport and rig up of a fully assembled IDS (less the traveling
block). When the IDS is in place for drilling, remove the skid.
Use it also for IDS relocation and as a maintenance platform.

December 9, 1997
IDS specifications
Drilling motor/gearcase
Output horsepower 1,000 hp
Continuous torque 34,000 ft lb
Speed 155 rpm
Intermittent torque 38,100 ft lb @
1,400 Amps (for makeup)
Connections NC50 unless otherwise
specified
Water course 3 in. (76.2 mm)
Motor brake 38,700 ft lb @ 1,000 psi
Local blower cooling system

Flow 2,800 cfm minimum
Blower Motor HP 20
Voltage 220/460 VAC,
60 Hz, 3-phase
Speed 3,450 rpm
Pipehandler
Breakout torque 60,000 ft lb
Hydraulic pressure 2,000 psi maximum
Hydraulic flow 30 to 35 gpm
Air pressure 90 psi minimum

IDS specifications
Service loops
Electrical power cables (non-regulated areas)
4 x 646
Voltage 2,000 max
Length 86 ft. (flange to flange)
Composite cable 26 conductor, 14 gauge
4 conductor, 8 gauge
2 pair, 14 gauge
twisted and shielded
2 conductor, 5 gauge
1 pair, 6 gauge
twisted and shielded
Voltage 600 maximum
Ground cable 2/0 conductor tinned
copper ground
Diameter 5 in. ID SAE 100-R2
hose outer jacket
Fluids
Hydraulic pressure or return hose (3 total)
Length 86 ft. (flange to flange)
Size 3/4 in. ID, SAE 100-R9
Working pressure 3,000 psi
Air supply hose (2 each)
Size 1/2 in. ID, SAE 100-R2
Working pressure 150 psi
Maximum working pressure 3,500 psi

December 9, 1997
Electrical equipment accessories

API Class I, Division II -NEC.
Derrick junction boxes (2 each) Cast aluminum,
explosion proof
Motor junction boxes (1 each) Steel, purged with
cooling air
Solenoid valves (7 each) 1/2 in., 4-way, 2 position
Pressure switches (2 each) Cooling air pressure
Motor space heaters (2 each) 2 - 200 watt, 220 volt
Driller’s console/instrument kit Various switches
Torque meter (0 - 1,500 Amps)
RPM meter (0 - 280 rpm)
Temperature switch (1 each) Motor exit air temperature
Temperature switch (1 each) Gearcase oil temperature
(optional)

IDS specifications
INTEGRATED DRILLING SYSTEM IDS-1

Drill Pipe Torque Vs. Speed GE 752 High Torque Shunt Motor
(6.0 :1 in-line Transmission)
40,000
38,700 INTERMITTENT
1,000 H.P.
35,000
34,000 CONTINUOUS
TORQUE, CONTINUOUS (FT-LBS)
30,000
25,000
20,000
16,300 CONTINUOUS
15,000 REDUCED FIELD
REQUIRED
10,000
5,000 175 RPM 230 RPM

155 RPM
0
0 50 100 150 200 250 300
RPM
INTERMITTENT TORQUE VALUES ARE BASED ON 1,450 ARMATURE AMPS
WITH A 7 SECOND MAXIMUM DURATION AT FULL FIELD OF 57 AMPS.
May 12, 1994. A.N.

December 9, 1997

IDS-1
Top Drive
Drilling
System
Installation
December 9, 1997
2-2 IDS-1 Installation

Contents
Safety information ............................................................ 2-5
Directional references ....................................................... 2-6
Manual layout................................................................... 2-6
Chapter 1 Installation
Installing the IDS-1 .......................................................... 2-7
Rig floor ..................................................................... 2-7
Derrick ....................................................................... 2-9
Torque tube assembly ............................................... 2-11
Preinstallation checklist................................................... 2-12
IDS and torque tube rig-up procedure ............................ 2-14
Installing the pipehandler ......................................... 2-19
Installing the cooling system ..................................... 2-22
Installing the rotary hose ........................................... 2-22
Traveling block dolly rig-up procedure ........................... 2-23
Plumbing ........................................................................ 2-24
Air ............................................................................ 2-24
Derrick electrical termination ......................................... 2-25
Driller’s controls and instrumentation ............................ 2-26
Driller’s console ........................................................ 2-26
Throttle and torque limit controls ............................ 2-26
Wiring ...................................................................... 2-26
Service loops ................................................................... 2-28
Installation ................................................................ 2-28
Electrical loop ..................................................... 2-29
Chapter 2 Commissioning
Checkout procedure........................................................ 2-31
Long term IDS storage procedures .................................. 2-33
Returning the IDS to service after storage ....................... 2-34
IDS installation checklists (FIP 0001) ............................. 2-34
IDS-1 Installation 2-3

December 9, 1997

Preface
Manual conventions
Safety information

damage.

personnel.


December 9, 1997
center.
Manual layout

Chapter 1
Installation
Installing the IDS-1
Rig floor
Although many rig floor layouts are possible, installing the torque
tube on the drawworks side of the derrick, or mast, and opposite
the V-door is an ideal arrangement for handling tubulars from the
V-door (Figure 2-1).
The location of the service loops and mud hose is an important
installation consideration for setback purposes, to ensure proper
clearance and to help prevent wear to the service loops and mud
hose. Other important installation considerations include the
location of:
❏ The rat hole

❏ The casing stabbing board
❏ Floor and derrick accessories
To extend the mud stand pipe, reroute the derrick connection
end for maximum efficiency.
December 9, 1997
SERVICE LOOP BRKT.

AT 83 FT LEVEL
86 FT FLUIDS 86 FT ELECTR.
SERVICE LOOP SERVICE LOOP MUD STANDPIPE
AT 73 FT LEVEL
C
L STANDPIPE
WELL MANIFOLD
75 FT MUD HOSE
WINCH
RATHOLE
DRAWWORKS
MOUSEHOLE
VEE DOOR
RAMP
CL CL
WELL WELL
IDS
SETBACK AREA
WINCH
DRILLER'S
CONSOLE
CL
WELL
Figure 2-1. Typical IDS installation on drawworks side

Derrick
The IDS interfaces with the rig’s hoisting system and electrical
power system. Derrick and electrical system modifications are
required when installing the IDS on existing rigs.
For derricks that handle triples, the required swivel travel is about
100 ft. compared to about 75 ft. when using a kelly. It is
necessary to replace the regular rotary hose (which is normally 60
ft. long) with a 75 ft. hose. Extend the standpipe height to 73 ft.
to correctly position the hose loop. Position the hose loop about 7
ft. above the drill floor when the connection height is 4 ft. above
the rig floor.
Derrick height is a critical interface requirement. The integrated
drilling system has a length of about 29 ft. from the base of the
drill pipe elevator to the top of the integrated traveling block (500
ton). Handling a 93 ft. stand typically requires 97 ft., resulting in
an overall height from the floor to the top of the integrated
traveling block of 126 ft.
Derrick Derrick
Clear working height Crown clearance
152 ft. 26 ft.
147 ft. 21 ft.
142 ft. 16 ft.
136 ft. 10 ft.
Each rig has different crown clearance for efficient tripping.
Figure 2-2 illustrates typical derrick height interface requirements.
Installing the IDS with existing traveling equipment may require
an adapter, further reducing crown clearance.

December 9, 1997
Crown Out
21.34' Crown
Crown
Clear
Block Top
29.3' Torque Tube

IDS Support Bracket
Working
2.13' Height
Torque Tube
Tool Joint
Block
147.64'
IDS Unit
Clear
83' Working
Service Height Bottom Torque
Loop Reaction Beam
Bracket
73'
Mud
Standpipe 93.0' 3'
Stand
12'
Off-Bottom
Drill Floor
Tool Joint
7.0' Min
Drill Floor 4 0'
Figure 2-2. Typical IDS derrick height interface requirements

(Refer to the engineering drawings for rig-specific information)

Torque tube assembly

The torque tube assembly reacts a maximum of 38,000 ft lb of
torque generated by the IDS into a lower attachment beam. The
torque tube consists of two channels welded to 1 1/2 in. thick flat
plate and comes in 20 ft. sections (Figure 2-3).
The torque tube assembly weighs over 25,000 lb. It has a 35-ton
capacity master link and two shackles connected to a support
bracket that mounts under the water table of the derrick. The
bottom section of the torque tube is a custom length and pins to
a lower attachment assembly that ties the torque tube into the
derrick. This lower attachment requires a torque reaction spreader
beam mounted across the derrick cage at a minimum height of
10 ft. (suggested mounting length is 15 ft.).
The torque loading decreases to reaction forces of approximately
2,500 lb maximum torque at the derrick legs. Additional loads are
generated through the handling of tubulars and must be analyzed
on a rig-by-rig basis. Varco recommends that the manufacturer of
the derrick ensure compliance with all specifications.

December 9, 1997
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up
is complete prior to installation of the torque tube assembly and
integrated drilling system (IDS). This includes:
❏ Derrick/mast modifications are completed (if required) and

the torque tube support bracket and spreader beam are
installed and inspected to conform to Varco specification and
installation tolerances.
❏ Hydraulic and pneumatic standpipes are installed in the
derrick/mast, flushed clean and pressure tested.
❏ All electrical/fluid service loop brackets are installed in the
derrick/mast.
❏ The transfer panel is installed.
❏ The HPU is installed.
❏ Rigging of tong lines, etc. is inspected to ensure that they will
not foul with the IDS and other rig equipment.
❏ The traveling block is strung.
❏ The lower attachment assembly, used in conjunction with
torque tube, is installed.

Preinstallation checklist
,

9-1/2"

,
1-1/2"
,

,

18"
12"
A A

SECTION A-A
Pivot Pin Taper Pin
Torque Tubes
Connected
Figure 2-3. IDS Torque tube installation detail

December 9, 1997
IDS and torque tube rig-up procedure

Initial rig-up requires installation of the torque tube assembly
(refer to the engineering drawings).
1. When using an existing traveling block, attach the block
adapter to the traveling block. Place the side of the block
adapter with the three attachment lugs facing the guard side
of the IDS (refer to the block adapter drawing for specific
installation procedures).
2. Attach the counterbalance cylinders to the lugs provided on
the block adapter.
3. Install the block links. Make sure the curved eyes are
downward and the curved ends are oriented toward well
center.
4. Secure the catch links on the block adapter.
5. Position the drilling unit at the bottom of the pipe ramp with
the drilling motor facing the drawworks.
6. Use a deck crane to attach two slings to the gearbox lifting
ears and re-secure the catch links.
7. Attach two slings to the counterbalance cylinder brackets on
top of the drilling motor.
8. Install a cast steel thread protector on the gearbox output
stem.
9. Hoist (or drag) the drilling unit onto the rig floor using the
drawworks and deck crane.
10. Continue hoisting the drilling unit vertically with the
drawworks while tailing the bottom of the unit with the deck
crane.
11. When the drilling unit is vertical, slowly lower the main stem
of the unit through the slips in the rotary table.
12. Set slips on the output shaft with a drill collar clamp on top
of the slips and remove the deck crane slings.
13. Manually spin the rotary to rotate the unit 180° (slack off just
enough with the blocks to allow manual rotation).

14. Tie snub-off lines to the drilling unit to keep the drilling unit
stable.
15. Slack off the blocks and remove the hoisting slings.
16. Attach the block links to the gearcase lifting ears on the
drilling unit. Secure the catch links.
17. Attach the counterbalance cylinder clevis to the lugs on the
IDS drilling motor.
18. Hoist slightly so the block links just contact the gearbox
lifting ears.
e Do not pick up weight of IDS before installing the counterbalance

cylinders.
19. Pick up the top torque tube section. With the hinge down
and the lifting pockets facing toward the V-door, stab the top
torque tube section through the torque tube carriage assembly
on the IDS. Lower the top torque tube section until it rests
on the rig floor.
20. Unpin the lock assembly at the top of the carriage, rotate it
toward the torque tube and resecure with quick release pin
provided.
21. Attach the two support cables with a 1 1/2 in. shackle at each
end between the two upper eye brackets on the block adapter
and the two pad eyes on the torque tube carriage.
22. Adjust turnbuckle on each sling to take up slack.
23. Slowly lift the IDS assembly and upper torque tube using the
drawworks.
24. Place the installation guide in the two forward kelly bushing
dowel holes. Rotate the rotary table to point the installation
guide toward the V-door.
25. Bring up the next torque tube section, insert the guide rod
through the lower back hinge pin hole and lay it into the
installation guide.
26. Grease the faces and pin bores on both hinge halves.

December 9, 1997
27. Lower the top torque tube approximately 1 in. above the true
alignment of the forward hinge bores. Use the 5 ft. pry bar in
the back of the installation guide to align the section and
insert a pivot pin.
e Align the flats on the head of the pivot pin and the forward hinge
bore throughout the insertion. Do not lift the torque tube until the
head of the pivot pin is fully seated in the counter bore. To prevent
damage to the pins and bores avoid using a sledge hammer to install
the pins.
28. Slightly raise the IDS assembly using the drawworks. Remove
the guide rod and grease the bore of the taper pin.
29. Continue to raise the IDS assembly until the torque tube
clears the drill floor.
30. Install a taper pin while pushing the torque tube back into
position.
e Varco recommends having rig floor personnel in a riding belt install the
taper pin. If the torque tube is slightly rocked, install the pin by hand. To
prevent damage to the pins and bores avoid using a sledge hammer to
install pins.
31. Repeat steps 24-30 for each subsequent torque tube section.
32. Attach the top torque tube section to the crown bracket using
the supplied hardware.
33. Lower the IDS assembly to relieve pressure on the chock
assembly. Unpin the lock assembly, rotate it back and pin it
back into the stored position.
34. Pin the bottom section of the torque tube to the reaction
beam.
35. Slide the solid body elevator onto the drive stem and support
it up against the rotating head with adequate rigging and an
air winch. Be certain the link tilt mounting bosses are
opposite the torque wrench mounting clevis on the rotating
head.

Torque Tube
Top Bracket
Hanger
Link
Chain
Shackle (4)
Link
Top
Section
Retaining
Pin (6)
Taper
Pin (6)
Intermediate
Section (5)
Bottom
Section
Pivot
Pin (6)
Figure 2-4. Typical torque tube with pinned connections derrick/mast interface

December 9, 1997
36. Install the landing collar as follows (Figure 2-5):

a. Install the O-ring in the uppermost groove on the stem.
b. Load the O-ring and remaining grooves with a waterproof
grease.
c. Place the split landing collar around the grooves of the
drive stem, and drive in the remaining roll pin.
d. Grease the OD liberally. Wipe off excess grease.
37. Using the rig tongs, make up the upper IBOP safety valve
onto the bottom of the drive stem using a thread compound
having 60% lead by weight (splines end down). Refer to the
Torque Chart in the pipehandler installation description
following this section.
38. If making up new threads, use the following procedure:
a. Torque up to the recommended torque.
b. Back off of the connection and inspect the threads.
c. Torque up to the recommended torque.
O-Ring
Roll Pin (4)
Split Landing
Collar (2)
Drive Stem
Safety Link (4)
Figure 2-5. Landing collar installation

Installing the pipehandler

1. Assemble the two torque arrestors to their support plate. Stab
the torque arrestors through the bottom end of the solid body
elevator and pin them into the bottom of the rotating head
(Figure 2-6). The torque arrestors are position dedicated and
are marked on each cylinder. Refer to the engineering
drawing.
Lift the solid body elevator 6 in. with the air winch to allow
pinning of the torque arrestors.
2. Refer to the IBOP Service Manual (included as a separate
book in this manual) for detailed IBOP installation
procedures.
3. Pull down on the release handle and unlock the rotating head.
4. Rotate the solid body elevator and the rotating head so that
the mounting point for the torque wrench is at the front of
the tool.
5. Raise the torque wrench with the air winch and pin it into
place.
6. Adjust the hanging position per the procedure outlined in the
Maintenance and Troubleshooting book.
7. Rotate the pipehandler assembly to the rear and connect the
two air hoses and two hydraulic hoses. Quick disconnects
(QDs) on the hoses allow connection in only one way so that
the hoses cannot be interchanged.
8. Use the pipehandler to tighten the connection between the
lower IBOP and saver sub assembly to the upper IBOP as
follows:
a. Verify that neither the upper nor lower stop tubes are not
installed below the lift cylinder.
b. Activate torque wrench from the driller’s console to retract
the lift cylinder. This raises the splines of the torque tube
to engage with the upper IBOP. A sequenced signal from
the control manifold operates the clamping piston,
activating the clamping jaws to clamp onto the lower
IBOP.
c. Another sequenced signal directs the torque cylinder to
torque the connection.

December 9, 1997
500-Ton
Rotating
Head
Link Tilt
Torque
Arrestors
500-Ton
Solid Body
Elevator
Splined
Upper Solid Body
Safety Elevator
Valve Split Plate
Safety Valve
Actuator
Torque
Wrench
Elevator
Links
Lower Safety Valve
Saver Sub
Drill Pipe
Elevator
Figure 2-6. PH-60d Pipehandler installation

d. Install upper stop tube below the lift cylinder on the

pipehandler.
e. Activate the torque wrench to make the connection
between the upper and lower IBOPs and the saver sub.
f. Remove upper stop tube and store on pipehandler.
g. Reinstall lower stop tube below lift cylinder for normal
operation of the pipehandler.
9. Connect the hose to the back of the link tilt actuator. Use the
four bolts, lockwashers and safety wire provided to install this
assembly to the solid body elevator. Connect the opposite end
of the hose to the quick disconnect on the rotating head
assembly.
10. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). Maintain
about 1/2 in. slack in the chains.
11. Install the counterbalance system as illustrated in the
engineering drawing.
12. Attach the service loops to the bracket on the IDS. Use the
cable clamps provided to route the electrical cables into the
junction boxes.
Follow the electrical schematic to make the connections (refer
to the engineering drawing). Be certain that the cables are
securely tied or clamped to the structure along their length.
Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type, and identify spares.
13. Connect the air line to link tilt per the assembly drawing.
14. Connect the counterbalance system hydraulic hoses per the
assembly drawing.

December 9, 1997
Installing the cooling system

Remove the exhaust duct shipping cover from the spark arrestors
on the air exhaust duct at each side of the DC motor. Save the
covers for use during future shipping or storage.
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.
Installing the rotary hose

1. Remove the 4 in. female API line thread coupling from the
end of the S-pipe and install it onto the IDS end of the rotary
hose.
2. Install the hammer union end of the coupling to the S-pipe
and tighten. Verify that the orientation of the rotary hose does
not cause interference in the rig.

Traveling block dolly rig-up procedure
Traveling block dolly rig-up procedure
z Verify that mounting holes have been predrilled and tapped prior
to installing the traveling block dolly.
1. Lower traveling block to rig floor.
2. Install both dolly mounting pads to the traveling block using
four 1.25 in. bolts and lockwashers per mounting pad.
3. Safety wire the bolts per the procedure described in the
Maintenance and Troubleshooting book.
4. Install the block dolly to the traveling block by attaching
dolly/arms and pins to the mounting pad.
5. Install pin retainers to the top of the dolly pins using 5/8 in.
bolts and safety wire.
6. Slowly hoist the traveling block while guiding the dolly into
the torque tube.

December 9, 1997
Plumbing
The plumbing connections should terminate near the service loop
bracket. The hoses at the end of the service loop may be as short
as 12 ft. The mating halves are pre-assembled on the service loop.
Specifications for specific lines is described in the following
section.
Air
Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of
the purge supply for the IDS. 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.

Derrick electrical termination
Derrick electrical termination

The electrical installation requires routing power to the transfer
panel and then to the IDS through the service loops. In addition,
control cables are required between the transfer panel, the SCR,
the IDS driller’s console, the SCR driller’s console, the hydraulic
pumps and the drilling recorder.
The cable requirements, depending on options selected are:
Cable Runs
646MCM (4 shunt) SCR Room to Transfer Panel
Transfer Panel to Rotary
#6AWG/2C SCR Room to Transfer Panel
Transfer Panel to Rotary
#6AWG/4C AC Power to Hydraulic Pumps
#10AWG/4C AC Power to Transfer Panel
#12AWG/20C Transfer Panel to Hydraulic Pumps
#12AWG/3C Transfer Panel to Driller’s Console
#14AWG/37C Transfer Panel to Driller’s Console
#14AWG/2PR SHLD Transfer Panel to Derrick J-Box
Transfer Panel to Driller’s Console
Transfer Panel to Drilling Recorder
#16AWG/10C Transfer Panel to SCR Console
Transfer Panel to SCR Room
Purge control system (not shown)
#12AWG/3C Purge Control Unit to Transfer Panel
Isolation Unit to Floor Air Control Unit
Transfer Panel Protection Unit to Isolation
Unit
#16AWG/10C Purge Control Unit to Transfer Panel
Driller’s Console Protection Unit to
Isolation Unit
Terminate the J-boxes per the electrical schematic. Follow
applicable electrical codes during installation. Cable glands are
provided for the service loop cables. Cable glands for the
incoming power, control and signal cables are not provided.

December 9, 1997
Driller’s controls and instrumentation

The following controls and instrumentation are, or must be,
supplied for operation of the IDS system:
Driller’s console
This unit contains all of the unique IDS controls, along with
gauges indicating output torque, and output rpm.
Mount the driller’s console within easy reach and in plain view of
the driller while the drawworks brake and clutches are being
operated. The gauges must be easily seen by the driller during
drilling operations. Provide appropriate cable glands for the
electric cables.
Throttle and torque limit controls

The throttle and torque limit controls are the standard controls
used for the independent rotary drive table. If an independent
rotary drive is not used, then these controls must be added by the
SCR manufacturer.
Wiring
Refer to the engineering drawings for the electrical schematics.
n Customers who choose to use control systems that are not

manufactured by Varco should be aware that Varco systems
are specifically designed with operational interlocks and safety
devices to prevent possible injury to personnel and damage to
the system. Other systems must meet Varco requirements
outlined in the QA 73 document. Varco highly recommends the
use of its system, as it is specifically made for use with the IDS
system.

Driller’s controls and instrumentation
IDS
Control
Console
Drill Floor Derrick

Connections Connections
Transfer Instrument
Panel J-Box
IDS
Blower
MCC
Service
Loop IDS
SCR Motor
RT
RT Blower
Motor
Electrical Rotary Table
IDS
Control
Console
Drill Floor Derrick
Connections Connections
Transfer Instrument
Panel J-Box
IDS
Blower
MCC
Service
Loop IDS
SCR Motor
DW-B
DW-B Blower
Motor
Mechanical Rotary Table
Figure 2-7. Typical IDS control schematic

December 9, 1997
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 engineering drawing. Locate
it on the side of the derrick adjacent to the brackets on the
IDS and as far as practical away from well center to allow an
adequate bend radius for the service loops. The bracket must
be located far enough from the corner of the mast or derrick
to ensure that the loops do not catch under the torque tube
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 pipe deck (still in the crates) and then
remove them from the crates with the lifting eyes provided.
e Use care in lifting gear rigging so as not to damage electrical

conductors. Use lifting eyes only. Do not bend the service loops tighter
than a three-foot bend radius. Tighter bends damage the loops.
4. Attach a sling to the top drive end of the service loop and use
the crane to lift it using the lifting eyes only. Allow enough
room for the 86 ft. long service loop to hang and untwist.
5. Using the lifting eyes, pull the derrick end of the loop
through the V-door and attach it to the air tugger. Hoist this
end of the loop into the derrick while slacking off at the crane
end. Do not drag the loop on any sharp areas on the derrick .
Disconnect the crane from the sling and continue hoisting the
loop into the derrick.
6. Attach the derrick end to the derrick service loop bracket and
hold in place with flange clamps (Figures 2-1 and 2-2).
7. Pick up the IDS end of the loops and attach them to the
service loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in the
following sections.

Service loops
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 Connect the pre-terminated wire ends of the IDS service loop
to the pre-terminated ends of the stationary service loops (if
used) with connectors provided, or intor the derrick J-box.
3. Terminate the opposite end of the stationary service loop or
derrick cables to the transfer panel. Refer to the electrical
engineering drawing for proper connections.

December 9, 1997

Chapter 2
Commissioning
Checkout procedure
1. Fill the gearbox with specified gear oil (Refer to the Lube
specification chart in the Mainenance and Troubleshooting
book).
2. Tighten the drilling unit shaft liner. Refer to the adjustment
procedure in the Mainenance and Troubleshooting book.
3. Momentarily turn on the IDS blower motor. Verify that the
direction of rotation is counterclockwise as viewed through
the motor louvers and verify the current.
4. Assign the SCR to the IDS and verify that the direction of
rotation is clockwise.
5. Turn on the HPU and adjust for 2,000 psi output pressure
and check for leaks.
6. Adjust the counterbalance system hydraulic as outlined in
Book 4. Verify that the counterbalance-mounted pressure
relief valve operates at 1,800 ± 100 psi.
7. Slowly raise the IDS with the drawworks and verify smooth
travel along the length of the torque tube. Also verify that
there is adequate clearance at the pipe racking level. Lower the
IDS to the rig floor level.
December 9, 1997
8. Verify VDC functions as follows:

a. Drill/Spin/Torque switch operates properly.
b. Torque ramp UP/DOWN abort functioning.
c. Verify maximum drilling and torque current.
d. Verify RPM, current and torque readouts are correct.
9. Verify the following IDS functions:
a. Actuate the link tilt. Verify that it operates smoothly and
that the elevator reaches the mousehole. If adjustment is
required, refer to the Mainenance and Troubleshooting
book.
b. Operate the IBOP from the VDC and verify that the
IBOP CLOSED indicator lights up when the IBOP is
closed. Switch several times to verify smooth actuation.
c. Assign the SCR to the top drive and actuate the hydraulic
brake. Verify that the brake holds the main stem at full
torque. If the brake does not hold, refer to the
Mainenance and Troubleshooting book for brake hydraulic
manifold adjustment.
10. Verify the IDS gearcase is filled to the middle of the sight
glass (maximum) when the unit is not turning.
11. Lubricate all of the IDS grease points. Familiarize the drill
crew with grease locations and lubrication schedule.
12. With drill pipe set in the rotary table slips, lower the IDS
until the sub pin is just above the box connection. The pin
and box should be in alignment. If not, perform the following
procedure:
a. Measure the distance and note the direction that the pin
and box are out of alignment.
b. Verify that the derrick/mast is level.
c. Verify that the drill pipe is straight.
d. If misalignment is in the direction of well center, install/
remove shims between the lower attachment assembly
mounting plate and the derrick/mast spreader beam, as
required.
e. If misalignment is to the left or right with respect to the
front of the IDS, verify that the lower attachment
assembly is properly located on the spreader beam.
f. If misalignment still exists, adjust the preload in the
spring stabilizer assembly by rotating the stop bolts
counterclockwise.

Long term IDS storage procedures
Long term IDS storage procedures

1. Drain the oil from the gearbox prior to rigging down.
2. Palletize the main unit for indoor storage. A cargo container is
appropriate for indoor/outdoor storage.
3. Avoid wide variations in temperature and high humidity.
The preferred environment is clean and dry at 60° F ambient.
If high humidity is unavoidable, 70° F is recommended.
4. 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.
5. Cover all openings to prevent water or dust from entering.
Leave enough space around the drilling motor to allow the
machine to breathe. Do not use silica gel or a dehydrating
agent.
6. During storage, lubricant drains from the top half of the roller
bearings in the motor, allowing corrosion to take place on the
exposed areas. In order to counteract this, rotate the motor
and gear train periodically to distribute lubricant over the top
of the bearings. Perform this at three month intervals if stored
indoors, and at one month intervals if stored outdoors.
7. The drilling motor is equipped with AC space heaters in
order to keep the internal motor temperature above ambient,
preventing condensation. Connect power to the space heaters
at terminals 1 and 2 in the AC motor J-box (refer to the
electrical schematic in the back of this section for proper
voltage). Be sure to reseal the protective covering after
connection.
8. Megger the drilling motor armature and field (static voltage of
1,000 VAC and 2 meg ohm minimum) when placing into
storage and at three month intervals thereafter (one month 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.

December 9, 1997
Returning the IDS to service after storage

Before placing the IDS back into service, the following items
should be verified:
1. Remove all rust preventive and any corrosion that may have
taken place, taking special care with all load carrying
components.
2. Follow the procedure in the drilling motor service manual
included as a separate book in this manual. To verify the
condition of the motor, take note of the following:
a. Blow out all dust and dirt that may have accumulated in
the windings with clean, dry air.
b. Visually inspect for spring corrosion, sticking brushes and
general defects.
c. Remove the brushes from holders, inspecting and
replacing as necessary prior to operation.
d. Check the winding insulation continuity to ground with a
1,000 Volt megger. If the reading is less than 2 MOhms,
bake the winding until the moisture content is sufficiently
reduced to produce an acceptable reading.
3. Fill the gearbox with oil.
4. Perform a complete system test and adjustmen as detailed
later in this section.
IDS installation checklists (FIP 0001)

Use the checklists on the following pages to rig up the IDS.

IDS-1
Top Drive
Drilling
System
Operation
December 9, 1997
3-2 IDS-1 Operation

Contents
Manual layout.................................................................. 3-6
Chapter 1 Operating procedures

Stalling the DC motor ..................................................... 3-7
Counterbalance system .................................................... 3-8
Pipehandler operation ...................................................... 3-9
Rotating head ............................................................ 3-9
IBOP safety valves ................................................... 3-10
Torque wrench ........................................................ 3-12
Torque values for load carrying components ............ 3-16
Changing drill string sizes ........................................ 3-17
Drilling ahead ................................................................ 3-18
Drilling ahead with triples ....................................... 3-18
Drilling ahead with singles ....................................... 3-21
Tripping ........................................................................ 3-23
Reaming out .................................................................. 3-24
Well control procedures ................................................. 3-26
Running casing .............................................................. 3-27
Handling bottom hole assemblies .................................. 3-27
Post jarring checklist ...................................................... 3-28
Post jarring checklist/design torque specification
(DS00008)............................................................... 3-28
IDS-1 Operation 3-3

December 9, 1997
3-4 IDS-1 Operation

Preface
Manual conventions
Safety information

damage.

personnel.

IDS-1 Operation 3-5

December 9, 1997
center.
Manual layout
3-6 IDS-1 Operation

Chapter 1
Operating procedures
Stalling the DC motor
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.
IDS-1 Operation 3-7

December 9, 1997
e Do not leave the top drive DC motor stalled in a high torque

condition generally for more than 10 seconds (refer to the following
table).
Amps Stall time (sec)
280 240
470 90
670 45
820 30
900 25
1,000 20
1,200 15
1,400 10
Counterbalance system
e The counterbalance system is active only when the HPU is on. To

avoid equipment damage, the HPU should be running while making
or breaking connections between the IDS and the drill string, and
when setting slips while the IDS is connected to the drill string.
Running the HPU while tripping in or out of the hole with elevators,
or while actively drilling down or backreaming helps prevent
counterbalance bracket and cylinder wear associated with a “slack”
system.
3-8 IDS-1 Operation

Pipehandler operation
Rotating head
To operate the swivel block locking mechanism, pull down the
locking lever, pulling the locking pin out of one of 24 locking
slots in the cam (Figure 3-1). With the locking lever in the
vertical position, manually rotate the swivel block to the desired
position and release the locking lever, setting the pin.
The perimeter of the cam is machined with an indented area
where the cam follower normally rests. The rod end of the cam
follower is under pressure. When the cam follower is located on
this indented area, the return cylinder rod is fully retracted. When
the swivel block and cam is rotated to another position by the
drill string, the ramp of the cam extends the return cylinder rod.
Releasing the elevator automatically returns the system to its pre-
selected (indented) position.
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking Swivel Block

Lever
Figure 3-1. Rotating head
IDS-1 Operation 3-9

December 9, 1997
IBOP safety valves

Operating the switch on the driller’s console to the IBOP CLOSE
position causes the two actuator air cylinder rods to extend,
moving the arms and the actuator shell body upward (Figure 3-2).
This upward movement causes the crank assemblies to rotate 90°,
closing the IBOP ball valve.
Operating the switch to the OPEN position retracts the cylinder
rods, which draws the IBOP actuator shell downward and opens
the IBOP.
3-10 IDS-1 Operation

DriveStem
(Ref.)
Solid Body
Elevator
Landing Collar
Upper IBOP Valve

Upper IBOP Valve Actuator Shell
Actuator Air Cylinders (2)
Crank
Assembly
Actuator
Arm
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Figure 3-2. Safety valve actuator system
IDS-1 Operation 3-11

December 9, 1997
Torque wrench
The primary function of the IDS torque wrench is to breakout
the drill string from the saver sub before making a connection.
The IDS torque wench can also make connections if necessary–
i.e., when replacing the lower IBOP or saver sub, or while
backreaming, or when adding a pup joint to the drill stem.
The torque wrench has a control manifold with the following
components (Figure 3-3):
❏ A hydraulic pressure gauge

❏ Control and sequencing valves
❏ Hydraulic hose inlet and outlet quick disconnects (QDs)
❏ A manual Make/Break directional valve
Make/Break
Recycle Clamp Torque Valve
Sequence Sequence Sequence Torque
Valve Valve Valve Wrench
Manifold
Hydraulic BREAK MAKE

Pressure
Return
1500
00
20
10
00
B
RECYCLE CLAMP TORQUE
2500
500
PRV
30
0
Hydraulic
00
Pressure LIFT
Inlet LOWER
Lift/Lower
Flow Control
Valve
Pressure
Gauge
0 - 3000 PSI
Figure 3-3. Typical torque wrench control manifold

The manual directional valve controls the torque wrench

operating direction (makeup/breakout) during operation.
A pressure reducing valve (PRV) on the control manifold allows
presetting the makeup torque (this valve is bypassed when the
torque wrench is in breakout mode).
When the driller actuates the torque wrench from the driller’s
console, the lifting cylinder rod retracts, raising the torque tube to
engage the splines on the upper IBOP. A sequenced signal from
the control manifold then operates the clamping piston, clamping
the jaws onto the drill string box connection. Then another
sequenced signal from the control manifold automatically directs
pressure to the torque cylinders, rotating the torque tube up to
25° while developing a maximum torque of 60,000 ft lb. The
position of the Make/Break valve on the control manifold
determines the direction that the torque tube rotates.
A two-position hydraulic valve located on the hydraulic manifold
located on top of the IDS saddle controls the entire sequenced
cycle described above. A push button switch on the driller’s
console operates the hydraulic valve. The driller holds the button
down to makeup or breakout a connection, and then releases the
button to allow the torque wrench to automatically recycle to the
ready position. If the torque developed on the first pass is
insufficient, the driller simply operates the button again.
Manually switch the Make/Break valve on the torque wrench to
the MAKE position to use the top drive torque wrench to make
connections. This allows the driller to initiate automatic torque
wrench sequences and repeat them until reaching the preset
makeup torque.

December 9, 1997
n Failing to apply the correct amount of torque when using the

IDS torque wrench to makeup connections can result in
equipment damage and injury to rig personnel.
Do not switch the Make/Break valve to BREAK until

completing the makeup sequence, which may require repeating
the makeup sequence several times.
Verify the torque pressure regulating valve setting after every

makeup sequence before releasing the makeup switch. Repeat
the makeup sequence until the torque cylinders do not stroke
more than one inch during the final sequence, repeat the
sequence if uncertain. Varco recommends that the driller
operating the pipehandler verify that the torque cylinders do
not stroke more than one inch on the last makeup cycle.
Varco also recommends checking the torque gauge on the

pipehandler while making connections to make sure the torque
wrench applies the correct amount of torque to the connection.
Stop and verify correct operation whenever the operator

observes unsteady or inconsistent hydraulic pressure readings,
or finds it difficult to adjust set points.
Varco recommends that a second individual assist the driller

when making connections with the top drive torque wrench.
The second person can verify that the torque wrench applies
the correct torque to connections.

Table 3-1 shows the relationship between torque wrench

hydraulic pressure as read from the gauge located on the torque
wrench control manifold and the torque applied.
Table 3-1. PH-60d Torque vs. Pressure
To calculate values not shown in the table, multiply the pressure

in psi from the gauge by 30 to get the torque in foot pounds:
Torque (ft lb) = Pressure (psi) x 30
Pressure Torque
(psi) (ft lb)
100 3,000
200 6,000
300 9,000
400 12,000
500 15,000
600 18,000
700 21,000
800 24,000
900 27,000
1,000 30,000
1,100 33,000
1,200 36,000
1,300 39,000
1,400 42,000
1,500 45,000
1,600 48,000
1,700 51,000
1,800 54,000
1,900 57,000
2,000 60,000

December 9, 1997
Torque values for load carrying

components
Proper makeup torque is critical to the function of drill stem
components. Table 3-2 covers only components within the IDS.
Refer to the API charts for other components.
Table 3-2. Torque values for load carrying components
Components I.D. Connection O.D. Min. Torque Max. Torque

(ft lb) (ft lb)
Upper safety valve to 3" 6 5/8: ARP Reg. 7 3/4" 50,000 63,000
main stem/main shaft
Lower safety valve to 3" 6 5/8: ARP Reg. 7 3/4" 50,000 60,000
upper safety valve
Saver sub to lower 3" 6 5/8: ARP Reg. 7 3/8" 46,000 60,000
safety valve
Crossover sub to 3" 6 5/8: ARP Reg. 7 3/8" 46,000 60,000
lower safety valve
Upper safety valve to 3" 7 5/8: ARP Reg. 9" 83,000 91,000
main stem/main shaft
Lower safety valve to 3" 7 5/8: ARP Reg. 9" 75,000 84,000
upper safety valve
Saver sub to lower 3" 7 5/8: ARP Reg. 7 5/8" 66,000 85,000
safety valve
Crossover sub to 3" 7 5/8: ARP Reg. 9" 75,000 91,000
lower safety valve

Changing drill string sizes

To operate the pipehandler 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:
❏ P/N 78652-1 - Includes stabbing guide assembly, jaw
assemblies, saver subs, installation drawing.
❏ P/N 78652-2 - Includes stabbing guide assembly, jaw
asemblies, installation drawing.
z P/N 78652-1 includes 3 1/2 in. IF saver subs, while P/N 78652-2
does not. By purchasing the latter, the user assumes responsibility
for obtaining appropriate 6 5/8 in. reg. x 3 1/2 in. IF saver subs
separately. Specifications for these are available from the factory or
any Varco service center.

December 9, 1997
Drilling ahead
Drilling ahead with triples

Drilling ahead with triples is the common drilling mode for the
IDS. There are various sources for triples. On skidding rigs
drilling multiple well platforms, drill pipe can be left racked and
used to drill the next well.
If triples do not currently exist, there are two recommend
methods of obtaining them. One is to leave some triples racked in
the derrick when tripping back in the hole and finish the trip
with singles. Enough triples should be left racked to handle
anticipated bit life.
The second method for obtaining triples is to make up triples in
the mousehole while drilling ahead or during rig idle time.
n For safety reasons it is best to have a pivoting mousehole so it

can be put in a vertical plane to simplify making connections.
Use the following procedure to drill ahead with triples (Figure 3-

4):
1. Drill down until the elevators touch the rotary table.
2. Circulate bottoms up as necessary.
3. Stop the string rotation.
4. Pick up the string and set slips for a connection four to five
feet off the rig floor.
5. Switch the IDS motor from forward to REVERSE.
6. Stop the mud pumps.
7. Close the IBOP.
8. Break out the drill pipe connection using the torque wrench
on the pipehandler.
9. Using the IDS motor, spin out of the box while hoisting the
IDS with the drawworks (follow with the drawworks, do not
lead).

Drilling ahead
10. Dope the saver sub pin and stop the spin out mode.
11. Open the drill pipe elevators.
12. Switch the IDS motor from reverse to FORWARD.
13. Hoist the IDS to the racking board level to get the next stand.
14. Thoroughly dope the box connection in the rotary table.
15. When the IDS is fully raised, extend the elevators to the
derrickman.
16. The derrickman latches the elevator on the next stand.
17. Hoist the pin off setback area and clear the box with the
stand.
18. Release the link tilt.
19. Stab the connection at the floor and set the backup tong.
20. Switch the IDS to SPIN IN mode.
21. Continue to slack off approximately two feet to stab the upper
connection of the stand with the IDS.
22. Slack off to allow connections to shoulder up (lead with the
drawworks, do not follow).
23. Switch to TORQUE and hold for approximately six seconds.
The makeup torque is pre-set.
24. Verify full makeup to the correct value on the torque meter,
and back up tong load cell.
25. Switch to DRILL mode.
26. Unlatch the back-up tong.
27. Open the IBOP.
28. Start the mud pumps.
29. Hoist and pull slips
30. Drill ahead.

3-20
December 9, 1997
Set slips on Unlatch elevator Pickup stand with Lower block to Pull slips
string Raise block elevator stab motor into Start circulation
Stop circulation Stab bottom of top of stand Begin drilling
IDS-1 Operation
Breakout connection stand onto string Spin in motor

using pipehandler and stand
and drilling motor Makeup both
(in reverse) connections with
motor
Figure 3-4. Drilling ahead with triples
1 2 3 4 5
Drilling ahead
Drilling ahead with singles

Typically there are two situations when it is required to drill
ahead with singles. One is beginning operations on a new well
and there are no triples made up and racked back. The other is
when surveys are required every 30 ft. as when kicking off using a
downhole mud motor. The link tilt feature makes drilling with
singles safe and efficient by moving the elevators to the
mousehole to pick up the singles.
Use the following procedure to drill ahead with singles
(Figure 3-5):
1. Drill down the existing single, pull up to the 4 ft. level
(approximately) and set the slips.
2. Close the IBOP and stop the mud pump.
3. Break the connection between the saver sub and the drill pipe
using the torque wrench in the IDS pipehandler.
4. Spin out the connection using the drilling motor and dope
the saver sub pin.
5. Lift the IDS, opening the drill pipe elevators to allow them to
pass over the box setting in the rotary table.
6. Actuate the link tilt to bring the elevator over to the single in
the mousehole and latch the elevator around the single.
7. Dope the box in the rotary.
8. Pull the single out of the mousehole and as the pin clears the
rotary stub, deactivate the link tilt to allow the single to come
to well center.
9. Stab the connection at the floor and lower the IDS, allowing
the added single to enter the stabbing guide until the saver
sub pin stabs into the box of the new joint.
10. Using a backup tong to react the torque, spin up and torque
the connection using the IDS motor in the Torque Mode.
11. Verify full make up to the correct value on the torque meter,
and backup tong load cell.
12. Open the IBOP, pull the slips, start the mud pumps and drill
ahead.

3-22
December 9, 1997
Set slips on Unlatch elevator Pickup single with Lower block to Pull slips
string Tilt links to elevator stab motor into Open IBOP
Stop circulation mousehole Stab bottom of top of single Start circulation
IDS-1 Operation
Close IBOP Latch drill pipe single onto string Spin in motor Begin drilling
Breakout connection elevator around and single
using pipehandler single Makeup both
and drilling motor connections with
(in reverse) motor in
torque mode
Figure 3-5. Drilling ahead with singles
1 2 3 4 5
Tripping
Tripping
Perform tripping in the conventional manner. Use the link tilt
feature to tilt the elevator to the derrickman so the derrickman
can latch it around the pipe quickly.
The link tilt has an intermediate stop which is adjustable to set
the elevator at a convenient working distance from the monkey
board. Tilt the intermediate stop out of the way to allow the
elevator to reach the mousehole.
Unlock the rotation lock and rotate the pipehandler to position
the elevator in any direction. The elevator returns to its original
position if rotated by the drillstring.
When a tight spot or key seat is encountered while tripping, the
driller can spin the drilling motor into the stand at any height in
the derrick. Circulation and rotation can be established
immediately to work the pipe through the tight spot.

December 9, 1997
Reaming out
The IDS permits reaming out of an open hole to prevent pipe
sticking and to reduce key seat formation, without affecting
racking functions associated with normal tripping (i.e., there are
no singles to contend with). The pipehandler torque wrench can
break out 90 ft. stands in the derrick.
Use the following procedure to ream out of the hole (Figure 3-6):
1. Hoist the block while circulating and rotating the drilling
motor until the third connection appears.
2. Stop circulation and rotation and set the slips.
3. Break out the drilling motor from the top of the stand using
the pipehandler torque wrench. Hold a backup at the floor
and spin out the drilling motor.
4. Break out the stand at floor level using rig tongs and pipe
spinner.
5. Pick up the stand with the drill pipe elevator.
6. Rack the stand back.
7. Lower the IDS to the floor.
8. Stab the drilling motor into the box, spin up and torque it
with the drilling motor and backup tongs.
9. Resume circulation and continue reaming out of the hole.

Hoist while Set slips on Hoist free stand Set back stand Lower block
circulating and string with elevator Stab motor into
rotating. Breakout and string
When 3rd spinout stand Spin in motor
connection from motor using and makeup
surfaces, stop pipehandler connection with
rotation and circulation Breakout and motor
spinout stand Start circulation,
at floor pull slips,
hoist and rotate
Figure 3-6. Backreaming
IDS-1 Operation
Reaming out
3-25
1 2 3 4 5
December 9, 1997
Well control procedures

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

Running casing
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. As long as the links, elevator, and
traveling block are rated for 500 tons, the IDS is rated at 500 tons
for casing operations.
By attaching a short piece of hose to the saver sub in the
pipehandler, the casing can be filled while lowering by using the
remotely controlled upper IBOP valve to start and stop the fluid
flow.
Handling bottom hole assemblies

The link tilt mechanism facilitates handling bottom hole
assemblies. Unlocking the hydraulic positioner located at the
rotating head permits rotating the stand. A swiveling drill collar
dolly can also be used.
e Rotating the elevators with the IDS motor damages the landing
collar.

December 9, 1997
Post jarring checklist
e Jarring occurs on all drilling rigs. It is not practical to recommend

removing the IDS from the drill string during all jarring operations,
but the possibility of damage to a IDS during a jarring operation is
considerable. Consider removing the IDS from the drill string before
performing prolonged jarring. It is imperative to exercise caution
when using a IDS after a jarring operation.
Safe operation of the IDS is the responsibility of the user and rig crew.
Use the Post Jarring Checklist and Design Specification DS00008
(Design Torque Standards) to help ensure safe IDS operation. Note
that the checklist includes recommended procedures. Do not limit
inspections to items on the checklist.
The checklist draws attention to specific parts on major sub-
assemblies. Inspection should be rigorous, looking for any wear that
could cause a safety or operational risk.
Post jarring checklist/design torque

specification (DS00008)
Use the checklist and Design Torque Standard (DS00008) on the
following pages after performing any jarring operation while the
IDS is in the drill string.

IDS-1
Top Drive
Drilling
System
Maintenance
and
Troubleshooting
December 9, 1997
4-2 IDS-1 Maintenance and Troubleshooting

Contents
Manual layout.................................................................. 4-8
Chapter 1 Inspection
Inspecting the DC drilling motor .................................... 4-9
Inspecting the air exhaust muffler .................................. 4-10
filter/regulator/lubricators .............................................. 4-11
Inspecting the pipehandler ............................................. 4-12
Nondestructive Examination (NDE) ............................. 4-13
Visual inspection...................................................... 4-13
Inspecting the elevator link eyes ......................... 4-13
Inspecting the torque tube ................................. 4-13
Inspecting the landing collar .............................. 4-15
Magnetic particle inspection .................................... 4-16
Ultrasonic inspection ............................................... 4-17
Inspecting safety valves....................................... 4-17
Inspecting the shaft liner assembly ................................. 4-18
Chapter 2 Lubrication
Lubricating the block ..................................................... 4-20
Lubricating the wash pipe assembly ............................... 4-21
Lubricating the cooling system ....................................... 4-22
Lubricating the drilling unit assembly ............................ 4-22
Lubricating the gearbox assembly ............................. 4-22
Initial oil change period ........................................... 4-22
Oil capacity.............................................................. 4-23
Lubricating the DC motor ....................................... 4-24
Lubricating the hydraulic system.................................... 4-27
Lubricating the alignment strut assembly ....................... 4-28
Lubricating the rotating head ......................................... 4-29
Lubricating the solid body elevator ................................ 4-30
Lubricating the safety valve actuator .............................. 4-31
IDS-1 Maintenance and Troubleshooting 4-3

December 9, 1997
Lubricating the upper IBOP safety valve ........................ 4-32

Lubricating the carriage assembly ................................... 4-32
Lubricating the lower attachment assembly (torque tube)4-34
Lubricating the drill pipe elevator .................................. 4-35
Lubricating the master bushing wear guide .................... 4-36
Lubrication schedule ...................................................... 4-37
Lubricant specifications ................................................. 4-38
Chapter 3 Maintenance
Adjusting the hydraulic assembly ................................... 4-41
Adjusting the counterbalance system .............................. 4-44
Adjusting the torque wrench .......................................... 4-46
actuator system .............................................................. 4-48
Assembly and disassembly .............................................. 4-49
Pipehandler (PH-60d) ............................................. 4-49
Torque wrench disassembly ............................... 4-49
Replacing the torque wrench clamping
piston seal .................................................... 4-51
Replacing the front and rear piston seal........ 4-51
Replacing the rotating head glyd ring ................. 4-54
air actuator ......................................................... 4-57
Removing the tong die ............................................. 4-60
Front jaw ........................................................... 4-60
Rear jaw ............................................................. 4-60
Removing the jaws ................................................... 4-61
Front jaw ........................................................... 4-61
Rear jaw ............................................................. 4-61
IBOP assembly/disassembly ..................................... 4-61
Counterbalance system assembly/disassembly .......... 4-62
Carriage assembly/disassembly ................................. 4-64
Wash pipe assembly/disassembly .............................. 4-66
Shaft liner assembly/disassembly .............................. 4-67
Replacing/installing the seal ............................... 4-69
Alignment strut assembly/disassembly...................... 4-73
Local blower cooling system assembly/disassembly ... 4-75
Brake assembly/disassembly ..................................... 4-77
Hydraulic power unit assembly/disassembly ............. 4-78
Removing the drilling motor assembly ..................... 4-79
Replacing the safety wiring ............................................ 4-82
Safety wiring tips ..................................................... 4-84

Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-85
Troubleshooting the drilling unit assembly .................... 4-86
Troubleshooting the motor brake ............................ 4-86
Troubleshooting the gearbox ................................... 4-87
Troubleshooting the hydraulic pump/
motor assembly ........................................................ 4-88
Troubleshooting the cooling system ......................... 4-89
Troubleshooting the pipehandler ................................... 4-90
Troubleshooting the torque wrench ......................... 4-90
Troubleshooting the safety valve actuator................. 4-92
Troubleshooting the link tilt .................................... 4-92
hydraulic/pneumatic manifold ................................. 4-93

December 9, 1997

Preface
Manual conventions
Safety information

damage.

personnel.


December 9, 1997
center.
Manual layout

Chapter 1
Inspection
Inspecting the DC drilling motor

Thoroughly inspect the IDS for loose bolts and fittings daily. If
any safety wire or cotter pins were removed to facilitate repairs,
replace them immediately. Refer to the Maintenance chapter of
this book for safety wiring procedures.
z The DC motor has a complete manufacturer’s instruction manual

for your reference provided as a separate book in this manual.

December 9, 1997
Inspecting the air exhaust muffler

Varco installs air exhaust mufflers on the exhaust ports of the
multi-gang solenoid valve manifold for noise abatement. All such
mufflers reduce noise and collect contaminants that can
eventually restrict the air passage. Air passage constriction results
in back pressure on all of the solenoid valves and erratic valve
operation.
Periodically remove the mufflers and clean or replace them. If
noise abatement is not an issue on the rig, replace the mufflers
with simple pipe elbows.

Inspecting the derrick termination kit air filter/regulator/lubricators

filter/regulator/lubricators
IDS models that rely on rig air to power link tilt, upper IBOP, brake
and torque wrench makeup/breakout sequence pilot signal functions
require regular inspection. The air valves, cylinders and actuators for
these functions require proper lubrication and moisture-free and
particle contaminant-free air. Moisture in the air can cause corrosion
on internal cylinder surfaces. Particle contamination can damage the
seals in moving parts and cause solenoid valves to stick. Oil, injected
by the lubricator and carried by the air, reduces friction between
moving parts and increases the life of seals in valves and actuators.
e Varco supplies a filter/regulator/lubricator in the derrick installation

kit and recommends installing it at the fingerboard level in the
derrick. Improperly adjusted regulators can cause poor device
performance at reduced pressures, or valve and cylinder seals and
O-ring extrusion at excessive pressures.
Inspect the entire filter/regulator/lubricator monthly for damage to
the filter bowl, overall body, or inlet and outlet fittings. Replace any
damaged, corroded, or improperly functioning components.
Adjust the pressure regulator outlet pressure to 100-120 psig
monthly. Clean and drain the filter weekly. Fill the lubricator
with petroleum-based hydraulic oil with a fluid viscosity of
100-200 SSU at 100°F (ISO 32/34).
e Do not use fluids such as “Marvel Mystery Oil,” motor oil, or

Dextron II in the lubricator. Swollen seals may result.

December 9, 1997
Inspecting the 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 that they are not
separating from the pipehandler. Make sure the hinge pins are not
loose because of 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 (refer to Figure 4-17 later in this book). 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.

Nondestructive Examination (NDE)

Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path
items.
z NDE inspection includes visual examination, dye penetrant

examination, magnetic particle inspection, ultrasonic inspection,
x-ray examination, and other methods of nondestructive testing
for metallurgical integrity.
Visual inspection
Inspecting the elevator link eyes

Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. 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.
Inspecting the torque tube

Inspect the torque tube connection bolts, master link, connecting
link, shackles, upper support bracket and lower attachment
assembly weekly. Re-torque any bolts as appropriate. Replace any
retaining pins or keys as appropriate.

December 9, 1997
Upper
Eye
(Hook)
C
C
Wear chart - Forged Links ,,,,

,,,,
,,,,
Upper Lower Capacity ,,,,
Eye Eye (Per Set)
Dimen- Dimen- In
sion C sion A Tons
B = 3-1/2 in., 350-Ton
5 2-3/4 350 B
4-13/16 2-9/16 300
4-5/8 2-3/8 225 ,,,
,,,
4-7/16 2-3/16 175 ,,,
,,,
B = 4-1/2 in., 500-Ton B

6 3-1/2 500
5-3/4 3-1/4 420
5-1/2 3 325
5-1/4 2-3/4 250 A
B = 4-1/2 in., 500-Ton (Block)
,,,,
6 6 500 ,,,,
,,,,
To Determine the strength of worn links,

measure (with calipers) the amount of eye
wear and compare the measurements A
with the above Wear Chart to find the Lower
current capacity. The capacity of the set of Eye
links is determined by the weakest link. (Elevator)
Figure 4-1. Visual inspection of elevator links

Inspecting the landing collar

Disassemble and inspect the landing collar every six months. Use
the following procedure to disassemble the landing collar for
inspection (Figure 4-5 in the Installation book):
1. Disconnect the IDS from the drill string.
2. Remove the IBOPs and pipehandler.
3. Raise the solid body elevator to expose the landing collar.
4. Drive out one roll pin.
5. Remove the landing collar.
After disassembly, inspect all landing collar parts for wear,
damage, or corrosion. Check for:
❏ Grooves or other radial wear marks indicating that the bore of the
solid body elevator is rubbing on the outside diameter of the
landing collar retainer shell
❏ Radial grooves on the inside diameter of the retainer shell
❏ Wear, corrosion, or fatigue cracks on the inside or outside
diameter of the landing collar halves
❏ Evidence of drive stem contact with the solid body elevator
❏ Evidence of inside bore wear on the solid body elevator
indicating contact with the drive stem. Wear on the inside
shoulder of the elevator should not exceed 1/8 in.
❏ Evidence of wear, corrosion or fatigue cracks on the safety
links
Replace the appropriate part(s) if any of the above conditions
exist. Use the following procedure to reassemble the landing
collar:
1. Replace the existing O-ring.
2. Install one new roll pin and safety links on the split landing
collar halves.
3. Coat the landing collar halves with a generous amount of
water resistant grease.
4. Place the landing collar halves on the drive stem with 15°
taper closest to the IDS.
5. Drive in the remaining roll pin.
6. Reinstall the IBOPs and pipehandler.

December 9, 1997
Magnetic particle inspection

Once a year, or every 3.000 operating hours, Varco recommends
performing a Magnetic Particle Inspection of the exposed surfaces
of all load bearing components and load collar grooves to reveal
any fatigue or crack indications. Any indications found are a
potential cause for replacing the suspect component. Round
bottom pits and erosion are acceptable as long as the defect is less
than 1/16 in. deep. Larger defects or any crack indications are
cause for replacing the suspect component.
After approximately five years or 15,000 operating hours, depending
on the severity of operating conditions, Varco recommends performing
a Magnetic Particle Inspection of all load bearing components over
their entire surface (including internal bores) to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep. Larger
defects or any crack indications are cause for replacing the suspect
component. The load bearing components are:
❏ Main stem ❏ Gearbox

❏ Solid body elevator ❏ Ring retainer
❏ Landing collar ❏ Ears
❏ Upper and lower IBOPs ❏ Drill pipe elevator
❏ Saver sub
Details on Magnetic Particle Inspection procedures are in the
following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection
of Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic
Particle Inspection

Ultrasonic inspection
In addition to the Magnetic Particle Inspection, Varco also
recommends performing an Ultrasonic Inspection of the above
components to detect any erosion of the inside diameter. Any erosion
reduces the load-carrying capability of the part. Any subsurface
irregularity can also compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication: ASTM A-388 Std. Practice for Ultrasonic Examination
of Heavy Steel Forgings.
Inspecting safety valves
z Upper and lower safety valves, because of their internal grooves

and shoulders, are particularly susceptible to corrosion fatigue
cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly
inspect the safety valves on a frequent basis. Be sure to read and
use the safety valve inspection procedures described in the IBOP
Service Manual included as a separate book.

December 9, 1997
Inspecting the shaft liner assembly
e Because the shaft liner conducts drilling mud from the wash pipe to
the output stem through the hollow DC motor armature shaft, it is
subject to internal erosion and corrosion from the mud. Inspect it at
regular service intervals (about six months). Failure to regularly
inspect the shaft liner leads to drilling unit internal washout. If there
is little or no wear after the first inspection, extend the inspection
interval a reasonable length of time. Shaft liner wear is a function of
solids and pH control of the mud used. Some rigs report marginal
wear on shaft liners after two years of service.
Use the following procedure to visually inspect the shaft liner
assembly:
1. Remove the washpipe assembly from between the gooseneck
and the shaft liner. Both nuts have left-hand threads.
2. Clean the bore of the shaft liner and inspect for visible signs
of pitting, corrosion or erosion.
z Use flashlight and mirror (if necessary) to visually inspect the bore
of the shaft liner. A Bore-o-Scope is best for inspection, if
available.
3. Remove the shaft liner and perform ultrasonic testing if
inspection indicates erosion or corrosion.

Chapter 2
Lubrication
Refer to the Lubrication schedule and the Recommended lubricants

chart at the end of this section for lubrication frequency and
recommended lubricants.

December 9, 1997
Lubricating the block

Lubricate the six fittings daily on the Varco traveling block
(Figure 4-2). If you do not have a Varco traveling block, check the
manufacturer’s manual for lubrication specifications.
Grease Fittings
6 Places
Figure 4-2. Lubricating the block

Lubricating the wash pipe assembly
Lubricating the wash pipe assembly

Lubricate the wash pipe assembly (one fitting) daily with the mud
pump off (Figure 4-3).
Grease Fitting
Figure 4-3. Lubricating the wash pipe

December 9, 1997
Lubricating the cooling system

Lubricate the AC blower motor every three months. Remove the
spark arrestor screens and clean with high pressure water.
Lubricating the drilling unit assembly
Lubricating the gearbox assembly

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
gearcase. Drain and refill the gearbox every 1,500 operating hours
or three months, whichever occurs first.
Lubricate the gearcase oil seals daily. The seals are located in the
upper gearcase bearing retainer. Inspect for seal leakage in the area
between the gearcase and the motor.
Initial oil change period

Drain and refill the gearbox after the first 500 operating hours or
four weeks, whichever occurs first. Remove and clean the oil
pump suction strainer (or oil filter–depending on the model and
configuration) when changing the oil.

Oil capacity
The IDS holds approximately 10-15 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 using the hand pump supplied by Varco. Use the following
procedure to fill the transmission for the first time on a new top
drive:
1. Use the hand pump to fill the gearbox to the top of the sight
glass (approximately 10-15 gallons). Connect a hand pump
and hose to the fittings on the bottom of the gearbox and
open ball valve when filling.
2. Operate the IDS 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 IDS, 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 10-12 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).

December 9, 1997
Lubricating the DC motor

The upper motor armature bearings have grease points located on
the centralizing housing attached to the top of the motor (Figures
4-4a and 4-4b). The lower armature bearing grease points on the
GE motor are located at the motor adapter. The centralizing
housing also contains grease fittings for two shaft liner assembly
alignment bearings.
The grease points all have plugs or relief fittings installed during
operation. Install grease fittings to lubricate and then remove the
fittings and replace the plugs for operation. Lubricate the lower
motor armature pinion end bearings every 750 hours, or three
months, with two ounce by weight Shell Cyprina RA™. Lubricate
the upper motor commutator end bearings every 1,500 hours, or
six months, with two ounce by weight Shell Cyprina RA™.
For detailed motor lubrication information and procedures, refer
to the GE Motor Service Manual included as a separate book in
this manual.
e Excessive lubrication of electric motors can cause motor failure due to

shorting or heat buildup from grease coming in contact with the field
windings.

Fro
nt
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
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,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
Remove Grease ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
Plugs and install ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
Grease Fitting to ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
Permit Lubrication. ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
2 Places Total. ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
Figure 4-4a. Lubricating the drilling motor

December 9, 1997
Centralizer
Bearing Vent
Grease Fittings
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
Figure 4-4b. Lubricating the drilling motor

Lubricating the hydraulic system
Lubricating the hydraulic system

Check the hydraulic reservoir oil level daily on the IDS onboard
hydraulic power unit (HPU). With the HPU pump motor OFF,
verify that the oil level is in the “normal” range as indicated on
the level indicator on the side of the reservoir.
Drain and refill the reservoir after the first 500 operating hours or
four weeks, whichever occurs first. Thereafter, drain and refill the
reservoir every 1,500 operating hours or three months, whichever
occurs first.
Remove and clean the suction strainer and oil filter when
changing the oil. The reservoir assembly holds approximately
20 gallons of hydraulic oil. The pump casing holds approximately
1 pint.

December 9, 1997
Lubricating the alignment strut assembly

Lubricate the two rod end bearings of the alignment strut assembly
located at the carriage (one fitting) and drilling motor (one fitting)
on a weekly basis (Figure 4-5).
Grease
Fitting
Grease
Fitting
Figure 4-5. Lubricating the alignment strut

Lubricating the rotating head
Lubricating the rotating head

Apply grease daily at the five fittings (Figure 4-6). Inspect for seal
leakage around the lower bearing retainer weekly.
Grease Fitings
Grease Fitting
Grease Fitting
Grease Fitting
Figure 4-6. Lubricating the rotating head

December 9, 1997
Lubricating the solid body elevator

Apply grease weekly at the two fittings on the solid body elevator
(Figure 4-7).
500 Ton
Solid Body Elevator
Grease Fittings
2 places
as shown.
Figure 4-7. Lubricating the solid body elevator

Lubricating the safety valve actuator
Lubricating the safety valve actuator

Apply grease to the six fittings on the actuator stabilizer arms
daily. Loosen two bolts on the actuator shell at each crank to
reveal grease fittings (Figure 4-8).
Check for worn components and operate the valve to verify
correct adjustment weekly.
Open
Position
Actuator Shell
Grease Fitting
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 4-8. Lubricating the IBOP actuator shell

December 9, 1997
Lubricating the upper IBOP safety valve

Lubricate the upper IBOP daily at the lubrication fittings located
directly below the actuator cranks in the recessed counter bores
(Figure 4-8). Refer to the IBOP Service Manual included as a
separate book in this manual for details on IBOP lubrication
procedures.
Lubricating the carriage assembly

Lubricate the 12 carriage rollers (one fitting each), two torque
arm pivot pins (two fittings each), and two torque arm hubs (one
fitting each) each trip (Figure 4-9). Use dye penetrant NDE
methods to check the carriage flange rollers and web weekly for
cracks or excessive axial or radial play. Replace as necessary.

Lubricating the carriage assembly
Torque Tube Assy
Carriage Frame
Torque Arm
Grease Fittings
2 Each Side
(4 Total)
Grease Fittings
,,,,
At Carriage Rollers
,,,,
,,,,
,,,,
,,,,
6 Each Side
,,,,
,,,,
,,,, (12 Total)
Grease Fitting
1 Each Side
(2 Total)
Figure 4-9. Lubricating the carriage assembly

December 9, 1997
Lubricating the lower attachment assembly

(torque tube)
Lubricate the gimble pivot pin bearing (two fittings each) and the
gimble (four fittings) on a weekly basis (Figure 4-10). Lubricate
the two trunnion assembly pivot pins (one fitting each) on a
weekly basis. Inspect the gimble/torque tube for excessive axial or
radial play on a weekly basis.
Grease fittings, 2 places as shown

and 2 places opposite on bottom
of Trunnion Assembly.
(4 places total)
Grease fitting at pivot

as shown and side opposite.
Grease fitting at pivot (2 places total)
as shown and side opposite.
(2 places total)
Figure 4-10. Lubricating the lower attachment assembly (torque tube)

Lubricating the drill pipe elevator
Lubricating the drill pipe elevator

Lubricate the seven grease fittings on the Varco BNC elevator
each trip, and inspect the tool for wear on the bore, the link ears
and to make sure that the latch mechanism operates correctly.
Grease Fittings as Shown
Figure 4-11. Lubricating the Varco BNC drill pipe elevator

December 9, 1997
Lubricating the master bushing wear guide

The master bushing wear guide has four fittings (Figure 4-12).
Lubricate weekly. Inspect the guide ring periodically for wear or
damage and replace it as necessary.
Grease Fittings
2 places as shown
and 2 places
opposite side.
(4 Total)
Figure 4-12. Lubricating the master bushing wear guide

Lubrication schedule
Lubrication schedule
Lubricant Number
Frequency Location Code* of Points
Daily Torque wrench 1 12
Daily Gearbox oil (check level) 2 1
Daily Hydraulic reservoir assembly 4 1
Daily Rotating head 1 5
Daily IBOP actuator arms 1 6
Daily Safety valve actuator cranks 1 2
Daily Drilling motor shaft
liner assembly bearing 3 2
Daily Wash pipe assembly 1 1
Daily Hydraulic pressure filter † – –
Daily Gearbox upper seals 1 1
Each trip Drill pipe elevator 1 7
Each trip Carriage assembly 1 18
Weekly Lower attachment assembly 1 8
Weekly Alignment strut assembly 1 2
Weekly Solid body elevator 1 2
Weekly Master bushing wear guide 1 4
Weekly Link tilt Check condition
750 hrs/3 mos. G.E. drilling motor
lower bearing 3 1
1,500 hrs/6 mos. G.E. drilling motor
commutator bearing 3 1
Monthly Spark arrestors † – –
Every 3 months AC blower motor 1 2
Every 3 months Change gearbox oil 2 1
Every 3 months Suction strainer/oil filter † – 1
Every 3 months Change hydraulic oil – –
* See Lubricant specifications table
† Check condition and replace as necessary
e Use only 10-wt. hydraulic oil or non-detergent motor oil as a lubricant

in the air control system. Using any other type of oil or synthetic additive
causes the seals in the air valves to swell and cease to function.

December 9, 1997
Lubricant specifications
IDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of
the gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating, and a
minimum viscosity of 100 SUS at operating temperature.
Varco drilling systems also operate under a wide variety of
temperatures. Select lubrication for the IDS based on the
minimum ambient temperature to be expected before the next oil
change. Under all but the most severe operating conditions, Varco
recommends changing the oil every three months. Introducing an
oil viscosity greater than required by the ambient temperature can
damage the gearbox due to reduced oil flow.
All oils change viscosity with temperature and EP oil is no
exception. The IDS transmission lubrication system is limited to
pumping oils of a maximum of 9,000 SUS viscosity.
Varco recommends measuring the oil temperature with a contact
thermometer.
The following tables will aid in your lubricant selection and keep
your IDS transmission operating properly:
Min. ambient temperature Oil type required Varco part number
°F °C
Below 20° -6° See following note See following note
20° to 60° -6° to 16° 2 EP, ISO 68 56004-1
45° to 85° 7° to 30° 4 EP, ISO 150 56004-BSC
Above 70° 21° 6 EP, ISO 320 56004-2
z For minimum temperatures below 20°F, the IDS must be warmed

up by rotating at a very light load (less than 200 A) and at very
slow speeds (less than 50 rpm) until the oil temperature climbs
above 20°F.
If the oil temperature falls below 20°F, Varco recommends
running the IDS at very light loads (less than 100 A) until the oil
is above 20°F. If drilling conditions dictate oil temperatures below
20°F, consult Varco engineering.
If the oil temperature rises above 200°F, Varco recommends
shutting down or reducing drilling loads to stabilize the oil
temperature below 100°F. If drilling conditions dictate oil
temperatures above 200°F, consult Varco engineering.
Lubricant specifications
Table 4-1. Recommended lubricants
Lube Code and Description
1 2
General Purpose Grease Gear Oil
Ambient
temperature Above -20˚ Below -20˚C Above 21˚C 7˚ to 30˚C -6˚ to 16˚C
range
Castrol MP grease - Alpha LS-320 Alpha -150 Alpha LS-68
Chevron Avi-Motive Avi-Motive W Alpha LS-320 NL Gear 150 NL Gear 68
Exxon Lidok EP2 Lidok EP1 Alpha LS-320 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
NGL1 2 1 - - -
AGMA - - 6EP 4EP 2EP
ISO Viscosity - - 320 150 68

Grade

December 9, 1997
Table 4-1. Recommended lubricants (continued)
Lube Code and Description
3 4
Motor Grease Hydraulic Oil
Ambient All
temperature temperatures -10˚ to 85˚C -15˚ to 75˚C
range
Castrol - Hyspin AWS-46 Hyspin AWS-32
Chevron - AW Hyd oil 46 AW Hyd oil 32
Exxon - Nuto H46 Nuto H32
Gulf - Harmony 46AW Harmony 32AW
Mobil - DTE 25 DTE 24
Shell Cyprina RA Tellus 46 Tellus 32
Statoil - Hydraway HMA 46 Hydraway HMA 32
Texaco - Rando oil HD46 Rando oil HD32
Total - Azolla ZS 46 Azolla ZS 32
Union - Unax AW46 Unax AW32
NGL1 - - -
AGMA - 1 -
ISO Viscosity - 46 32
Grade

Chapter 3
Maintenance
Adjusting the hydraulic assembly

Use the following procedure to properly adjust the hydraulic
assembly:
1. Make sure the hydraulic reservoir fluid level is in the middle
of the sight glass.
2. Make sure the suction line ball valve is open.
3. Make sure the brake accumulator (BA) and counterbalance
accumulator (CB) precharges are the pressures specified on
the Hydraulic Schematic drawing.
4. Install a 0-3,000 psi pressure gauge on the P, BAX and BA test
ports of the IDS manifold assembly.
5. Connect an ammeter to the 5 hp electric motor and verify full
load current at horsepower and rpm specified on the motor
nameplate.

December 9, 1997
6. Adjust the hydraulic valves to the following positions:

Ball valve (SV), open
Needle valve (CV2), open
Counterbalance relief valve, at minimum setting
Pump control, as set by vendor
Reducing valve (PCC), at minimum setting
Reducing valve (PCB), at minimum setting
Relief valve (RV), at minimum setting
Unloading valve (UV), at maximum setting
7. Verify correct electric motor rotation (clockwise rotation
when viewed from the end of the shaft).
8. Loosen the mximum-volume stop cover (the adjustable stop
nearest the pressure compensator control).
9. Turn the maximum-volume stop counterclockwise until the
flow reaches the maximum (there is no spring resistance while
turning the stop).
10. Tighten the adjustment jam nut and the adjustment cover.
z The adjustment cover has an O-ring to prevent leakage.

The adjustment leaks about 20 drops/min when the
adjustment cover is off.
11. Close the ball valve (SV) and the needle valve (CV2).
12. Raise the relief valve (RV) setting while monitoring the pump
output flow, pressure (P) and the electric motor current. The
pump pressure compensator setting is the pressure when the
pump output flow decreases, about 900 psi.
13. Adjust the pressure compensator to prevent exceeding the full
load current of the electric motor while adjusting the relief
valve between 0-1,200 psi. This sets the high flow, low
pressure operating point.
14. Adjust the relief valve to 2,200 psi while monitoring the
output flow and motor current.
15. Adjust the minimum pump output flow so the motor is a full
load amps at 2,200 psi.
16. Tighten the jam nut and adjustment cover, verifying the cover
seal prevents leakage from the adjustment screw. This sets the
high pressure, low flow operating point.
17. Raise the relief valve to 2,500 psi and tighten the jam nut.

Adjusting the hydraulic assembly
18. Lower the set point of the differential unloading valve (UV)
to 2,200 psi. The pump fills the brake accumulator (BA) to
2,200 psi. Then the pump unloads. The pump remains
unloaded until the brake accumulator pressure decays to
about 1,600 psi.
19. Make sure the (UV) set point remains 2,200 psi while
observing several cycles of loading and unloading.
20. Tighten the relief valve jam nut.
21. Install a 0-3,000 psi pressure gauge on test point BR and
adjust the brake pressure control (PCB) one turn clockwise
from the minimum setting.
22. Operate the brake directional valve (DV) and verify that BR is
at pressure in one DV position and at 0 psi in the other DV
position.
23. Place the DV valve in the position that pressurizes the BR and
adjust PCB to 1,400 psi.
24. Tighten the jam nut on PCB and cycle the DV to verify that
BR alternates between 0-1,400 psi.
25. Install 0-3,000 psi pressure gauge on test point CB and adjust
the counterbalance pressure control (PCC) to the maximum
setting (fully clockwise).
26. Adjust the cylinder mounted relief valve to 2,000 psi and
tighten the jam nut. If this valve is difficult to adjust when
pressure is applied, lower the PCC setting to minimum and
adjust the relief valve. This process takes time because there is
a delay while filling and draining the counterbalance
accumulator.
27. Adjust PCC to 1,200 psi as measured at CB.
28. Tighten the jam nut on PCC (refer to the counterbalance
adjustment procedure).
29. Turn the electric motor off and inspect the IDS for external
leaks. The counterbalance accumulator and brake
accumulator are still filled with pressurized hydraulic oil.
30. Inspect the hydraulic system for hissing sounds, indicating
high internal leakage.
31. Open the ball valve (SV) and listen for hissing, indicating
counterbalance accumulator bleed down and decreasing
pressure at CB.
32. Close the SV and verify that the hissing stops.

December 9, 1997
Adjusting the counterbalance system

Use the following procedure to properly adjust the
counterbalance system (Figure 4-13):
1. Set drill string in rotary slips and disconnect the IDS from the
drill string.
2. Make sure the HPU is on.
3. Loosen the lock nut on the flow control valve on the
hydraulic manifold assembly.
4. Use a 5/32 in. hex wrench to make sure the flow control valve
is fully open. Unscrew in a counterclockwise direction until
reaching the internal stop. Do not force it.
5. Tighten the locknut.
6. Loosen the lock nut on the pressure reducing/relieving valve
on the hydraulic manifold assembly.
7. Use a 5/32 in. hex wrench to unscrew the pressure reducing/
relieving valve until reaching the internal stop. Do not force
it. The counterbalance cylinders and the block links bearing
the drilling unit weight should be relaxed, bearing no weight.
8. Slowly screw in the pressure reducing/relieving valve
adjustment in a clockwise direction. The counterbalance
cylinders gradually begin to take the drilling system weight,
and the gearbox begins to lift off of the links.

Adjusting the counterbalance system
9. Adjust the pressure reducing/relieving valve until the IDS

gearbox touches the links. The balance point is where the
gearbox touches the links.
z Any slight adjustment causes the gearbox to lift off of the links.
10. Tighten locknut.
Flow Control Valve
Pressure Reducing
Valve
Torque Wrench Valve
Counterbalance Valves
Brake Valve
Figure 4-13. Hydraulic manifold

December 9, 1997
Adjusting the torque wrench

Use the following procedure to adjust the pipehandler torque
wrench:
e The pipehandler torque wrench is properly adjusted and tested in the

factory before it is shipped. Perform the adjustment procedure after
performing maintenance on the torque wrench or if the torque
wrench does not function correctly.
1. Connect a pup joint or joint of drill pipe to the saver sub and
makeup hand tight. Be sure to use the correct thread
compound when making up.
z When adjusting torque wrench manifold needle valves, loosen the

locknut around the valve stem and use a 5/32 in. hex wrench to
adjust the valve. After obtaining desired setting tighten locknut
around valve stem.
2. With the hydraulic power unit off, fully screw in the RECYCLE,
CLAMP, and TORQUE sequence valves on the torque wrench
manifold (Figure 4-14).
3. Fully back out the pressure reducing valve (PRV), then screw
in one turn.
4. Fully turn in the lift/lower flow control valve, and then back
it out three turns.
5. Turn on the hydraulic power unit.
6. If the torque cylinders are in their full clockwise position, set
the Make/Break valve to MAKE. If they are in their full
counterclockwise position, set the Make/Break valve to
BREAK. Note that torque cylinders should not move if the
recycle sequence valve is fully in.
7. Slowly back out the recycle sequence valve until torque cylinders
just start to move, then screw out an additional full turn.
8. Move the Make/Break valve to BREAK. Set the pressure
reducing valve to 750 psi.
9. Switch the lever between MAKE and BREAK to adjust
recycle sequence valve until full rotation in each direction
takes six to eight seconds. Tighten the locknut around the
recycle sequence valve adjustment screw.

Adjusting the torque wrench
Make/Break
Recycle Clamp Torque Valve
Sequence Sequence Sequence Torque
Valve Valve Valve Wrench
Manifold
Hydraulic BREAK MAKE

Pressure
Return
1500
00
20
10
00
B
RECYCLE CLAMP TORQUE
2500
500
PRV
30
0
Hydraulic
00
Pressure LIFT
Inlet LOWER
Lift/Lower
Flow Control
Valve
Pressure
Gauge
0 - 3000 PSI
Figure 4-14. Torque wrench control manifold
10. Set the Make/Break valve to MAKE.

11. Depress and hold the torque wrench operating button on the
driller’s console. The torque wrench should lift and the clamp
jaws should remain retracted.
12. Slowly back out the clamp sequence valve until the clamp
jaws just begin to clamp onto the tool joint. Screw out an
additional half turn. Lock the clamp sequence valve
adjustment screw in position by tightening the locknut.
13. Back out the torque sequence valve until the torque cylinders
just begin to stroke, then back out an additional half turn.
Tighten the locknut around the torque sequence valve
adjustment screw.
14. Release the torque wrench operating button on the driller’s
console. The torque wrench should start to unclamp and
drop, then the torque cylinders should recycle.

December 9, 1997
15. If the torque cylinders recycle before the clamp cylinders

retract, screw in the recycle sequence valve until the torque
cylinders do not move before clamp cylinders have fully
retracted. Tighten the recycle sequence valve adjustment screw
locknut.
16. Cycle the torque wrench as many times as required to makeup
the connection.
17. Set the Make/Break valve to BREAK.
18. Verify that the torque wrench correctly breaks out the drill
pipe from the saver sub, without breaking out the saver sub or
lower IBOP.
19. The torque wrench is ready for operation.

actuator system
Refer to the IBOP Service Manual included as a separate book in
this manual for upper IBOP and safety valve actuator system
adjustment procedures.

Assembly and disassembly

This section describes assembly and disassembly procedures for
user serviceable IDS components. The procedures are guides and
should be used in conjunction with the appropriate engineering
drawings.
e Before performing any disassembly of hydraulically operated

assemblies, verify that the HPU is off and that the system has been
bled.
Pipehandler (PH-60d)
Torque wrench disassembly

(See Figure 4-15)
1. Remove the guard.
2. Disconnect the hard plumbing from the quick disconnects
near the left torque cylinder.
3. Remove the bolts holding the frame onto the cast body and
lift off.
4. Remove the pins holding the torque tube in place and
remove.
5. Disconnect and label the hoses from the torque cylinders and
remove the cylinders.
6 Disconnect and label the remaining plumbing, and remove
the Make/Break manifold assembly.
7. Remove the jaws.
8. Remove the stabbing guide.
9. Remove the retaining bolts, hinge pins and outer body.
10. Remove the cylinder ring from the clamping piston bore.
11. Pressurize the blind end of the clamping cylinder to remove
the gland and piston.
e Use care in this operation. High pressure air can be explosive.

December 9, 1997
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator
Air Cylinders
IBOP Actuator
Arms
Stop Tube
Torque Tube
Torque Wrench
Manifold (Hidden)
Clamping Jaws Torque Cylinders (2)

(Inside Clamp Body)
Stabbing Guide Clamping Piston

(Inside Clamp
Body Cylinder)
Figure 4-15. Torque wrench assembly/disassembly

Reassembly is accomplished in the reverse order of the above

procedure. Pay close attention to the following points:
1. Replace all seals.
2. Take great care when installing the clamping piston and
gland. If they are not closely aligned with the bore, they may
become jammed and could be extremely difficult to remove.
3. Use the following torque values:
Cylinder rod end to cylinder rod * 944 ft lb
Frame to clamp cylinder body 250 ft lb
Stabbing guide to body 250 ft lb
Die retainer screws 380 ft lb
Body hinge pin retainer screws 150 ft lb
Stabbing guide spring retainer screws 75 ft lb
Jaw retaining screws 110 ft lb
* The torque cylinder rod ends are threaded into the rods
with locktite and cross pinned.
Replacing the torque wrench clamping piston seal

The following procedures require that the torque wrench be
removed from the pipehandler.
Replacing the front and rear piston seal

Parts required for front and rear piston seal replacement:
Qty. P/N Description
3 72219 Piston seal
2 72220 Rod seal
2 72221 Rod wiper
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.
3. Remove the jaw pins from the rear clamping jaw and remove
the jaw.

December 9, 1997
4. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
5. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
6. Remove the pins holding the clamp body to the clamp clevis
and remove the clamp clevis. Be sure to remove the spacer
from the piston rod slot.
7. Push in the cylinder gland from the rear cylinder head
retainer ring and remove the ring with a screwdriver.
8. Attach the sliding hammer to the rear piston rod and carefully
pull the piston until the cylinder gland can be removed.
9. Continue to pull until the piston comes out.
10. Using a piece of wood or brass bar, tap the front clamp piston
from the front and remove it from the rear.
11. Remove and discard the piston seals, rod seals and rod wipers.
12. Remove the front piston rod seal and rod wiper from the
clamp cylinder body and discard.
13. Inspect the clamp cylinder bore thoroughly for dirt, burrs,
nicks, gouges and pitting. Repair and clean as necessary.
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 screws holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod
appears beyond the front cylinder bore.
5. Install new piston seal in rear piston groove and lubricate with
hydraulic fluid.
6. Insert rear piston into the clamp cylinder body with the two
screws holes on the rod oriented to the horizontal position.
7. Gently tap piston into place until there is enough space
between the piston face and retaining ring groove to insert
cylinder gland and retainer ring.

8. Install rod seal and rod wiper in inside grooves of the cylinder
gland.
9. Install piston seal in outside groove.
10. Lubricate all seals with hydraulic fluid.
11. Insert cylinder gland into bore rod and piston seals first. Push
gland past retainer groove and install retainer ring.
12. Insert the spacer and attach the clamp clevis to the rear
cylinder rod with the two hex head cap screws and flat
washers. Tighten firmly and lockwire.
13. Adjust orientation of the clamp clevis and attach to the clamp
body using the two clevis pins and cotter pins.
14. Attach the rear clamping jaw spacer to the front piston rod
using the spacer and two hex head cap screws and flat
washers. Tighten firmly and lockwire.
15. Attach the clamping jaw with the two jaw pins.
16 Swing the stabbing guide back into position and attach with
the slotted nut and cotter pin.
17. Reconnect the hydraulic lines from the clamp body cylinder
clamp port and front unclamp port at the torque wrench
manifold clamp and unclamp ports.
18. Reinstall and adjust the torque wrench (refer to Adjusting the
torque wrench earlier in this chapter).

December 9, 1997
Replacing the rotating head glyd ring
z Rotary glyd ring replacement is indicated when hydraulic oil is

detected in the pipehandler air supply. An indication of oil
contaminating the air supply would be an accumulation of oil in
the link tilt air actuator (bag).
Refer to Figure 4-16 when performing the following procedures:
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, a
flange gasket, and an 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 it is
removed from the IDS 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 solid body elevator while removing
the pins attaching the torque arrestors to the rotating block.
7. Remove the torque arrestors, link tilt and solid body elevator.
8. Place the rotating head stand, built prior to disassembly,
under the IDS and lower the IDS 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 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 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 10 hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures
described in this book.
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.

December 9, 1997
Gearcase
Seals Stationary Flange
Cam Follower
Return Cylinder
Clevis (2)
Hex Nut (2)
Cotter
Pin (2)
Cam Follower
Return
Cylinder
Return Cylinder
Clevis Pin (2)
Glyd Rings (8)
Retainer Ring
Figure 4-16. Rotating head assembly/disassembly


air actuator
The following procedure details the replacement of the extended
reach link tilt air actuator (Figure 4-17):
Parts required: 1 Air actuator (P/N 82353)
18 Button head cap screws (P/N 50186-10-01)
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 solid body elevator.
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 18 nuts and washers holding 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 attaching 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.

December 9, 1997
Lever Weldment
Sealing Plate (2) Pivot Pin
Nuts,
Lock Washers (18)
Pressure
Regulator
Sealing Air Actuator (2)
Plate Base
Bolt (4) Hanger Plate
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Stop Pivot Arm
Elevator Link (Ref) Stop Release

Loop
Figure 4-17. Extended reach link tilt assembly/disassembly

Assembly
1. Place a new actuator on the hanger plate.
2. Attach the air actuator to the hanger plate with the 18 button
head 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 eighteen 1 7/8 in. 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 book.

December 9, 1997
Removing the tong die
Front jaw
(Figure 4-15)
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 rear the 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.

Removing the jaws

(Figure 4-15)
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.
IBOP assembly/disassembly
Refer to the IBOP Service Manual (included as a separate book in
this manual) for assembly/disassembly procedures for the upper
and lower IBOPs.

December 9, 1997
Counterbalance system assembly/

disassembly
Refer to the engineering drawing and Figure 4-18 while
performing the following procedure:
1. Turn off the HPU.
2. Disconnect the hydraulic hoses from the counterbalance
system, as required.
3. Remove the cotter pin and clevis pins from both ends of the
counterbalance cylinders.
4. Remove cylinders from IDS drilling unit assembly.
5. To repair the cylinder use Varco Seal Kit Nos. 84208-1 and
99509-3.
6. To reassemble the counterbalance system, reverse the
disassembly procedure.

Bracket
Cotter Pin
Shackle
Rod End
Clevis
Clevis Pin
Bracket
Figure 4-18. Counterbalance assembly/disassembly

December 9, 1997
Carriage assembly/disassembly
Replacement parts for the IDS carriage assembly are included in the
Expendable Spare Parts Kit. Refer to the engineering drawing and
Figure 4-19 when performing the following procedure:
1. Attach a tugger line to support the weight of the carriage
assembly prior to disassembly from the drilling motor.
2. Loosen six 5/8 in. bolts and lockwashers and remove the
grease cap from the drilling motor end of the carriage
assembly.
3. Loosen three 3/4 in. bolts and remove the bearing retainer
from the torque arm.
4. Detach the torque arm from the brake/torque hub assembly.
5. Repeat steps 1-4 for opposite torque arm.
6. Lower the carriage assembly off of the torque tube and
relocate in suitable work area.
7. Remove either torque arm from the carriage, by loosening
and removing two
5/8 in. bolts, lockwashers and retainer plate.
8. Drive the pivot pin from the carriage from the opposite side
of the pin, taking care not to damage the pin.
z Clean all disassembled carriage assembly parts and inspect for

wear or damage prior to reassembly.
The IDS uses twelve 4 in. and four 3 in. roller cams. To replace
worn or damaged roller cams, loosen the nut and lock washer
and remove the roller cam from the carriage frame. Apply grease
to the roller threads and reinstall a new roller.
9. Inspect the DU bearing located in the torque arm pivot pin
bore and thrust washers. Replace if worn or damaged.
10. Align the torque arm pivot pin bore with the carriage pivot pin
bore, grease and insert the four thrust washers and pivot pin.
11. Install the retainer plate, lock washer and 5/8 in. bolts to the
retainer arms. Tighten the bolts and safety wire according to
the procedure described later in this book.
12. Clean and grease the brake/torque hub assembly.
13. Attach the torque arm to the hub, then lubricate and install
the spherical rod bearing.
14. Install the bearing retainer, three 3/4 in. bolts and tighten.
Safety wire the bolts per the procedure described later in this
book.
Figure 4-19. Carriage assembly/disassembly

December 9, 1997
Wash pipe assembly/disassembly

The integrated drilling system utilizes a standard type wash pipe
packing. Refer to the engineering drawing while performing the
following procedure:
1. Remove the wash pipe assembly from the IDS by loosening
the hammer union (P/N 91249-7) from the gooseneck
(P/N 105528).
2. Loosen the packing box assembly (P/N 91249-3) from the
shaft liner assembly (P/N 105801).
3. Lubricate and install the wash pipe packing set
(P/N 91249-4) (5 seals), as required.
4. Lubricate and install two O-rings (P/N 91249-12).
5. Thread the packing box end of the wash pipe assembly onto
the shaft liner and tighten the hammer connection.
6. Thread the holding nut end of the wash pipe assembly onto
the gooseneck and tighten the hammer connection.

Shaft liner assembly/disassembly

If any indications of corrosion or erosion of the shaft liner
assembly are noted during inspection, remove and inspect the
assembly further and replace if necessary.
Replacing the shaft liner requires the following tools and parts:
IDS tool kit P/N 105611
Torque wrench assembly P/N 105888
Lifting cap P/N 106160
Shear pin P/N 56406-6-S
Shaft liner P/N 105801
Seals (2) P/N 105866
Seal P/N 940285-1327
Excluder P/N 105481
Retaining ring P/N 944525-600
Disassembly
1. Turn on the HPU.
2. Set slips on the pup joint or the sub screwed onto the saver
sub of the drilling unit.
3. Turn off the HPU.
4. Slack off the blocks.
5. Disassemble the catch links from the gearcase lifting ears.
6. Withdraw the lower end of the block links from the gearbox
lifting ears.
7. Remove the lower counterbalance cylinder clevis rod end pins
and remove the hose between the extended intake and the
blower inlet housing.
8. Hoist the blocks to the racking level.
9. Remove the wash pipe assembly from between gooseneck and
shaft liner. Both nuts are left hand threads.
10. Remove the S-pipe saddle cap located on the gearbox-
mounted electrical service loop support bracket.
11. Unscrew the nut holding the S-pipe to the gooseneck. The
nut has right hand threads.
12. Remove the bolts holding the gooseneck to the bonnet and
remove the bonnet.

December 9, 1997
13. Drain the oil from the gearbox.

14. Loosen and remove the two 3/4 in. bolts, nuts, and lock
washers from the torque wrench assembly.
15. Separate the latch from the rest of the torque wrench
assembly.
16. Install and engage the torque wrench around the wrench flats
machined around the top of the shaft liner. Make sure that
the side of the torque wrench stamped “This side up” faces
towards the blocks, and that the handle faces towards the
torque tube.
17. Reinstall the 3/4 in. bolts, leaving aside the 3/4 in. nuts and
lock washers.
18. Assign the SCR to the IDS in reverse and slowly rotate the
IDS drilling motor. The torque wrench also rotates until the
wrench latch bears against the bonnet. Increase torque just
enough to breakout the threads between the shaft liner and
the gearbox output stem. Once the threads are loosened, stop
rotation and back out the shaft liner by hand. The threads are
left handed. If no electrical power is available, remove the
shaft liner by manually turning the main stem
counterclockwise using tongs.
19. Screw the lift cap onto the end of the shaft liner, and attach a
lifting line to the bail of the lift cap.
20. Slowly hoist the shaft liner out of the drilling unit. It should
come out easily when fully unscrewed from the gearbox
output stem. Take care not to damage the bottom end sealing
surfaces of the shaft liner.
21. Clean the bore of the shaft liner and inspect for visible signs
of pitting corrosion or erosion.
22. Use an ultrasonic depth gauge to measure the remaining wall
thickness directly over visibly corroded areas. The original
bore of the shaft liner is 3.000 in. with a nominal wall
thickness of 0.343 in.
23. Replace the shaft liner if any wall region shows
0.125 in. (1/8 in.) or more of general or localized wear.

Replacing/installing the seal

The primary seal between the shaft liner and gearbox output stem
is a metal to metal seal between the end of the shaft liner and the
output stem. Secondary seals reside in grooves below the shaft
liner mating threads in the top of the gearbox output shaft. These
seals are static seals and are not subject to rotating wear. Normally
these seals do not need replacement unless a drill stem test
subsequent to shaft liner replacement shows leakage.
Removal and replacement of these seals requires disassembly of
the drilling motor from the gearcase. If seal replacement is
necessary disassemble the IDS as outlined below. Refer to the
engineering drawings while performing the following procedure:
1. Disconnect the following assemblies as previously outlined:
❏ IBOP
❏ Pipehandler assembly
❏ Actuator assembly
❏ Counterbalance assembly
❏ Carriage assembly
❏ Alignment/strut assembly
❏ Washpipe assembly
❏ Shaft liner assembly
❏ Hydraulic installation kit
2. Set the drilling motor/gearcase assembly on a level surface.
3. Remove the spark arrestors.
4. Attach lifting slings to the counterbalance mounting lugs on
top of the drilling motor assembly. (Total weight of the
drilling motor hydraulic-pneumatic/electrical assembly is
approximately 8,100 lb.)
5. Loosen ten 12-point bolts on the drilling motor adapter
flange.
6. Take up slack on the lifting slings and remove the mounting
bolts.
7. Slowly lift the drilling motor assembly off of the gearcase
assembly.

December 9, 1997
8. Lower the drilling motor assembly and block it up to allow

access to the sungear, motor and deflector.
9. Remove both seals from the planetary gear housing. Discard
the used seals.
10. Inspect the seal groves of the new seals, clean them with a
cloth and lubricate with clean oil prior to installation.
11. Reinstall the seals making sure that the seal lip points
downward toward the gearcase. (Refer to Varco drawing
105802, Mud Conduit Assembly).
12. Perform steps 10 and 11 on the second seal.
13. Reassemble the assemblies listed in step 1.
Reassembly
1. Observe the condition of the uppermost seal in the centralizer
housing at the top of the drilling motor.
2. If replacement is warranted, pack a clean rag just below this
seal to keep dirt out of the centralizer bearings.
3. Remove the retaining ring just above the seal with a
screwdriver; and pry the seal upwards and out of the
centralizer housing. Do not damage the bearing below the seal
during this process.
4. Tap the new seal back into place taking care not to dent the
metal case. Make sure that the garter spring in the seal is
towards the bearing (or downwards). Push the top of the seal
case just past the retaining ring groove, but no further.
5. Replace the retaining ring, making sure it fully installs into
the groove.
6. Withdraw the packing rag and any debris which might be on
the seal or bearings.
7. Completely clean the replacement shaft liner with solvent.
8. Remove any burrs on the lower threads. Make sure that there
is no corrosion or impact damage to the lower end face or
sealing surface below the lower threads.
9. Replace the excluder on the shaft liner and install the lifting
cap.

10. Carefully hoist the shaft liner to a vertical position, taking

care not to damage the lower end.
11. Using clean pipe dope, coat the lower threads on the shaft
liner.
12. Using a clean rag, carefully remove all excess dope so the
crests of the threads are clean.
13. Wipe all pipe dope from the lower sealing diameter of the
shaft liner (below the threads). Coat this diameter with clean
grease.
14. Apply a thin coat of pipe dope directly to the end sealing face
of the shaft liner. Do not mix the dope with the previously
applied grease. Do not get any pipe dope on the seal entry
bevel next to the end face.
15. Coat the bearing surface at the top of the shaft liner with
clean grease (just below the excluder).
16 Slowly lower the shaft liner back into the drilling unit. Take
care to keep it centered while stabbing to keep the pipe dope
from contaminating the centralizer bearings.
17. Slack off and remove the lifting cap.
18. Rotate the shaft liner counterclockwise by hand until it is
fully screwed downwards into the gearbox output stem (left
hand threads).
19. Reinstall the shaft liner torque wrench as before.
20. Rotate the handle inwards into the body of the tool. Grasp
the torque wrench and continue rotating the shaft liner
counterclockwise until it is firmly bottomed.
21. Rotate the rotary table in the drilling direction until the
torque wrench handle faces the torque tube. Fold the handle
fully outwards until it contacts the internal stop of the tool.
Make sure that the markings “This side up” face the blocks
(upward).
22. Insert the shear pin body of the tool.
23. Shift the rotary table into neutral and make sure it is
unlocked.
24. Switch the SCR to FORWARD AND DRILL mode.

December 9, 1997 Assembly and disassembly
25. Slowly rotate the throttle until the handle of the torque tool
contacts the bonnet surface.
z If no electrical power is available, remove the shaft liner by

manually turning the main stem counterclockwise using tongs.
26. Increase the throttle slowly until the shear pin breaks.
This should occur between 3,500-5,500 ft lb.
Stop rotation immediately.
27. Remove the torque wrench.
28. Reinstall the gooseneck, swivel, wash pipe and S-pipe.
29. Fill the gearbox with oil.
30. Slack off the blocks and reinstall the block links, link locking
bars and counterbalance cylinders.
31. Perform a drill stem test to verify the pressure holding capacity
of the shaft liner.

Alignment strut assembly/
disassembly
Refer to the engineering drawing and Figure 4-20 while
1. Remove the flexloc nut and thrust washer from the alignment
strut at the carriage assembly connection. Detach the
alignment strut.
2. Remove the flexloc nut and thrust washer from the alignment
strut at the drilling motor connection. Detach the alignment
strut.
3. If it is necessary to replace either spherical rod end bearing,
the alignment strut assembly uses the same bearing as the link
tilt assembly (Expendable Spare Parts Kit No. 96363).
4. To install a replacement bearing, remove twelve 3/8 in.
capscrews and remove the bearing retainer from each side of
the rod end.
5. Grease and install replacement bearing. Reinstall retainers and
capscrews.
6. Reinstall thrust washer and flexloc nuts.

December 9, 1997 Assembly and disassembly
Bearing
Retainer Cap Screws
Spherical
Rod End
Bearing
Bearing
Retainer
Flexloc
Nut
Thrust
Washer
Cap Screws
Strut
Figure 4-20. Alignment strut assembly/disassembly

Local blower cooling system

assembly/disassembly
Use the following procedure to remove the blower motor in the
local blower cooling system (Figure 4-21):
z Parts required for repair of IDS drilling motor, gearbox, brake and
wash pipe assemblies are included in Expendable Spare Parts Kit
No. 96361.
1. Open the IDS motor guard.
2. Remove the electrical wires from the blower motor.
3. Remove the flexible duct hose.
4. Remove the four bolts connecting the blower mounting
bracket to the bonnet.
5. Remove the bolts connecting the blower impeller housing to
the transition duct.
6. Hoist the blower assembly off of the IDS and place on a clean
work space on the derrick floor.
7. Remove the blower intake duct on the side of the blower
motor.
8. Remove the taper lock bushing from the blower impeller.
9. Remove the blower impeller.
10. Remove the bolts connecting the blower housing to the
blower mount.
11. Remove the impeller housing.
12. Unbolt the four bolts connecting the blower motor feet to the
blower mount.
13. Lift out the motor.
Reverse the above procedure to install a new motor in the local
cooling system (Figure 4-21).

December 9, 1997
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,,,,,,,,,,,,, Extended Air Intake Assembly
Explosion-Proof,
20 hp, 3450 rpm
Flexible Duct Hose AC Motor
Impeller
Housing Blower
Mount
Blower
Impeller
Bonnet
Intake
Duct
Drilling
Motor
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Transition
Duct
Figure 4-21. Local blower cooling system assembly/disassembly

Brake assembly/disassembly
Refer to the engineering drawings while performing the following
procedure:
1. Disconnect the hydraulic hoses at the lower motor adapter
plate.
2. Remove the brake assembly from the drilling motor by
removing the carriage assembly. (See the procedure in the
previous section on carriage assembly.)
3. Remove eight 1 in. bolts and lockwashers from the brake/
torque hub assembly.
4. Lift the brake/torque hub assembly from the drilling motor
and place on a suitable working surface.
5. Loosen the adjustment nut on the spring return bolt to
reduce spring tension.
6. Remove the spring return bolt and the return spring.
7. Remove the retaining plate.
8. Remove the brake pads.
9. Remove the retaining ring and slide the piston from the
caliper housing.
Inspect the disassembled parts for wear or damage. Replace worn
or damaged parts. Reassemble the brake assembly in reverse order
of disassembly.

December 9, 1997
Hydraulic power unit assembly/

disassembly
Perform the following procedure to remove the onboard HPU
from the drilling unit:
1. Disconnect and cap hoses from the pump/motor assembly.
2. Loosen the four 3/8 in. bolts and lockwashers, and remove
the pump/motor assembly and bracket from the gearcase
adapter plate.
3. Disconnect and cap the hydraulic hoses between the
accumulators and the reservoir.
4. Loosen four 1 in. bolts, nine 1/2 in. bolts, and lockwashers,
and remove the reservoir/accumulator subassembly from the
IDS.
5. Disconnect and cap the hydraulic hoses from the filter
assembly.
6. Loosen the two 5/16 in. bolts and lockwahsers and remove
the hydraulic filter assembly from the IDS.
7. Reverse the above procedure to reassemble and reinstall the
HPU.

Removing the drilling motor

assembly
Refer to the engineering drawings and Figure 4-22 while
1. Disconnect the following assemblies as previously outlined:
❏ IBOP
❏ Pipehandler assembly
❏ Actuator assembly
❏ Counterbalance system
❏ Carriage assembly
❏ Cooling system
❏ Wash pipe
❏ Shaft liner assembly
❏ Alignment strut assembly
If the drilling motor assembly requires replacement, use the
following procedure to remove the hydraulic-pneumatic/electrical
assembly:
a. Attach a lifting sling to the assembly.
b. Remove the transition duct cover and disconnect power
cables per the interconnect drawing (see engineering
drawing).
c. Remove the fourteen 1/2 in. bolts holding the transition
duct to the drilling motor.
d. Take up the slack on the lifting sling prior to removing
any additional fasteners.
e. Remove the four 3/4 in. set screws. Two set screws are
located on the other sides of the mounting plate assembly.
f. Remove the two 1 in. bolts adjacent to the spark arrestor
assembly and lift the hydraulic-pneumatic/electrical
assembly from the drilling motor.

December 9, 1997
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Figure 4-22. Removing the drilling motor assembly

2. Set the drilling motor/gearcase assembly on a level surface.

3. Remove the spark arrestors.
4. Attach lifting slings to the counterbalance mounting lugs on
top of the drilling motor assembly. (Total weight of the
drilling motor is approximately 7,600 lb.)
5. Loosen ten 12-point bolts on the drilling motor adapter
flange.
6. Take up slack on the lifting slings and remove the mounting
bolts.
7. Slowly lift the drilling motor assembly off of the gearcase
assembly.
8. Lower the drilling motor assembly and block it up to allow access
to the sungear, motor and deflector.
9. The sungear is shrink-fitted onto the pinion shaft of the
drilling motor. Remove the sungear, motor and wear sleeve by
heating the sungear while applying vertical force on the
sungear through the hollow armature of the drilling motor.
10. Maintenance on the drilling motor is outlined in the
GE Motor Service Manual.

December 9, 1997
Replacing the safety wiring

Use the following procedures to safety wire screws, nuts, bolts, or
other fasteners where applicable.
n Torque fasteners before safety wiring any screw, nut, plug, or

other fastener. Never overtorque or loosen a torqued fastener
to align safety wire holes.
Use the size and type of safety wire required in the applicable
specifications and drawings. Whenever possible, use double-twist
safety wiring.
n Limit single-twist wiring to the following: small screws located

in closely spaced, closed geometrical patterns (e.g., triangle,
square, rectangle, circle), parts in electrical systems, or parts
that are difficult to reach.
n Do not reuse safety wire.
To install safety wire:

1. Open the jaws of the safety twist pliers:
2. Squeeze the handles of the pliers together and unlock the
round, perforated slider in the center of the pliers from the
hook lock.
3. Grip both safety wires in the jaw. Squeeze the handles
together with one hand and pull the slider toward the rear of
the pliers with the other hand to lock the pliers.
4. Twist the safety wire by pulling the aluminum knob and twist
the rod out from the pliers. Let the pliers spin free.
5. Return the knob and twist the rod by holding the pliers
steady with one hand and pushing against the end of the
knob the with other hand (step 4 in Figure 4-23).
6. Repeat the previous twisting cycle.

Replacing the safety wiring
7. After threading the safety wire through the hole in the

fastener, pull the wire straight through without nicking the
wire. Twist four to five complete revolutions per inch of wire.
8. Make a pigtail of approximately 1 in. (25 mm) length (four
twists minimum) at the end of the wiring and bend back or
under to prevent it from becoming a snag.
1
2
3 4
Figure 4-23. Safety wiring procedures

December 9, 1997
Safety wiring tips

❏ Pull the safety wire firmly, but do not stretch it or let kinks
develop. Make twists tight, even, and as taut as possible
without weakening the wire by overtwisting (Figure 4-24).
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.
❏ The number of nuts, bolts or screws that can be safety-wired

together depends on the application. As a guide, when safety-
wiring widely spaced bolts by the double-twist method, a
group of three, or a 24 in. (610 mm) length of safety wire is
usually the maximum.
Figure 4-24. Safety wiring examples

Chapter 4
Troubleshooting
Troubleshooting the counterbalance
Symptom Probable cause Remedy

System does not HPU is off. Turn HPU on.
function or hold
pressure.
Flow control valve is closed. See adjustment procedure and check
flow control valve.
Cylinder rod seals leak. Replace seals.
Fittings or hoses leak. Tighten or replace as required.
Dirty or defective pressure See adjustment procedure.
reducing valve. Clean or replace.
Cylinder rods Pressure setting too high. Adjust per adjustment procedure.
remain retracted
(closed).

December 9, 1997
Troubleshooting the drilling unit assembly
Troubleshooting the motor brake

Brake does not hold. Insufficient hydraulic Check hydraulic supply pressure with
supply. HPU on. 1,000 psi minimum required.
Solenoid valve not shifting. Check electrical continuity.
Check mechanical operation.
Lubricate if necessary.
Brake pads contaminated Inspect and replace if necessary.
with grease, worn or burnt.
Brake does not Insufficient hydraulic Check hydraulic supply pressure with
function. supply. HPU on. 1,000 psi minimum required.
Check mechanical operation of
solenoid valve manually.
Brake does not Solenoid valve sticking. Lubricate, repair with repair kit or
release. replace valve.
Hydraulic return line Open standpipe shutoff valve.
plugged or restricted.

Troubleshooting the gearbox
Problem Probable cause Remedy

Oil leaking from Lower gear case seals are dry Run IDS at moderate speed and
lower seal. or damaged. monitor if leakage disappears.
Gearcase seals displaced by If problem persists, replace gearcase
horizontal storage of IDS. seals. Verify and set end play on
gearcase.
Main stem sideplay due to When making/breaking IBOPs or
excessive side loading. EZY-Break, always provide backup
(i.e., pipe in rotary table slips).
Oil leaking from Oil level too high. Adjust oil level per recommended
upper bearing specification.
retainer (verify that
oil is not leaking
from the gearcase
breather tube
located on the upper
bearing retainer).
Incorrect lubricant used.
Oil is foaming. Replace oil.
Worn oil seals. Replace seals.
Gearbox Oil level too low or too Adjust oil level to middle of sight glass.
temperature is high.
excessive.
Incorrect lubricant used. Check recommended lubricants chart
and replace as needed.
Faulty overtemperature Repair or replace as needed.
switch or probe.
NOTE: Do not raise the heat range
setting.
Exceeding maximum rated Reduce rpm of drilling unit.
rpm.

December 9, 1997
Troubleshooting the hydraulic

pump/motor assembly

Pump not Motor is not running. Check electrical components to ensure
functioning power is available to motor. Repair or
replace as needed.
Incorrect motor rotation. Verify proper rotation and correct if
necessary.
Dirty or clogged oil pump Remove and clean suction screen,
suction screen. making sure to properly seal screen
cover when installing.
Oil pump cavitating– Check all connections and suction
evidence of air bubbles in screen cover plate to ensure there are no
discharge lines. air leaks on suction side of oil pump.
Repair as needed.
Oil leakage from pump. Replace seals.
Failure of oil pump drive Inspect, repair or replace as necessary.
coupling.
Faulty or worn oil pump. Check relief valve on back of pump.
Install test gauge in discharge line and
verify minimum suction pressure of 12
psi.
If unable to make oil pump work after
checking all of the above, repair or
replace as needed.
Incorrect lubricant used. Check the Recommended lubricants
chart to make sure proper viscosity of
oil is used.

Troubleshooting the cooling system

Mechanical noise in blower. Loose impeller. Reinstall impeller and hub and locktite
screws.
Faulty motor bearings. Repair or replace as needed.
Blower runs intermittently. Faulty or loose wiring. Locate and repair as needed.
Fault motor starter. Check for dirt or trash between starter
coil. Repair or replace as needed.
DC motor overheating, Incorrect blower rotation. Verify that blower rotation is correct.
OVERTEMP alarm stays
on with blower running.
Dirty or clogged spark Remove spark arrestors from motor
arrestors (local or remote and clean screens if screens are
cooling systems). damaged with holes. Replace as
needed.
Continuous drilling amps Check service manual for continuous
over recommended levels. amp motor rating and adjust drilling
program accordingly.
Motor being stalled for over DC motor should never be stalled for
recommended periods of more than 5 seconds with over 300
time. Amps applied.
NOTE: Serious damage could occur to
the motor if this is done.
Faulty temperature switch Repair or replace as needed.
or probe.
NOTE: Do not readjust or raise heat
range setting.
Restricted air flow (local or Check and clean spark arrestors as
remote cooling systems). needed.
Check air intake on blower to ensure
there are no restrictions.
Verify proper blower rotation.

December 9, 1997
Troubleshooting the pipehandler
Troubleshooting the torque wrench

Tool does not cycle Valves in manifold out of Readjust.
properly. adjustment.
Supply and return hoses are Reconnect hoses correctly.
crossed.
Improperly connected quick Check quick disconnects to make sure
disconnects. they are properly plugged together and
flowing in both directions.
Needle valve in Close needle valve (always with power
counterbalance manifold is unit running).
open.
Defective cartridge valve or Inspect valves for damaged seals or
PRV valve. stuck spools. Replace if necessary.
Improper component or Valve cartridge replaced with wrong
component installation. type.
NOTE: When changing make/break
valve, make sure valve is properly
oriented when installed.
Tool does not cycle Power unit not functioning. Make sure hydraulic system is on.
at all. Check pressure.
Check spool mechanical operation.
Lubricate if necessary.
Lift cylinder bypassing Repair cylinder.
fluid.
Tool goes up, clamps, Air pilot valve on Remove air supply line to verify air
and cycles but remains counterbalance manifold supply when solenoid valve is activated.
clamped on pipe when stuck or inoperative.
switch is released.
(Continued on next page) Pilot valve dirty. If air supply is available, remove end
camp on pilot valve, clean and lubricate.

Troubleshooting the torque wrench (cont.)

Tool goes up, clamps, Improperly connected quick If air pilot valve is operable, hook both
and cycles but remains disconnects. pipehandler hoses together and verify
clamped on pipe when flow in both directions by activating
switch is released. switch with hydraulics on. If there is
flow in only one direction, check QD’s.
If QD’s are properly connected, check
hydraulic pilot valve for stuck spool.
Hydraulic valve not shifting. Repair or replace.
Saver sub breaks out Saver sub not made up Make up saver sub per procedure
instead of tool joint. properly. described in IBOP Service Manual,
increase previous torque makeup by
10% to maximum torque
recommended in IBOP Service Manual
(for original Varco OEM subs).
Tong dies break or score Valves in manifold out of Readjust per procedure.
drill pipe. adjustment.
Tong dies worn. Replace tong dies.
Connection overtorqued. If saver sub is made up to 60,000 ft lb
and continues to break out instead of
drill pipe connection, break out using
rig tongs. If saver sub or drill pipe will
not break out using pipehandler,
remove pipehandler and break out with
rig tongs at floor.
Die retainer and die Improper saver sub length or Saver sub length too long. Sub should
retainer bolts damaged machining. not be longer that 5 1/2" shoulder to
while breaking out shoulder and have proper chamfer on
connections. both shoulders.
Torque wrench does Oil bypass in pipehandler Listen for oil bypassing in pipehandler
not lift. hydraulic components. cylinders or manifold. Locate and
repair bypass as necessary.

December 9, 1997
Troubleshooting the safety valve

actuator

Safety valves leak. Internal parts worn out. Check for washouts or defective parts.
Repair as needed.
Actuator out of adjustment. Check electrical continuity.
Check spool mechanical operation.
Lubricate if needed.
Check actuator cylinder adjustment
(see procedure).
Excessive vibration or Actuator support roller Check actuator shell adjustment and
wobble while rotating. brackets bent or out of crank assembly operation.
adjustment.
Worn cam rollers. Repair or replace rollers and roller
brackets, shimming as needed to
maintain smooth operation.
Troubleshooting the link tilt

Does not tilt. Solenoid valve not shifting. Check electrical continuity
Check spool mechanical operation and
lubricate as needed.
Does not reach Improperly adjusted. Readjust chains, shorten if necessary.
mousehole.
Retracts slowly. Quick exhaust valve not Clean or replace.
functioning.
Solenoid valve stuck in Repair or replace mechanical valve.
neutral position,
maintaining pressure on
quick exhaust.
Check quick exhaust valve.
Replace as needed.


hydraulic/pneumatic manifold

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

December 9, 1997

Safety Valve
(IBOP)
Service Manual
® ™
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
i
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the driller’s console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
1
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Splined Adapter
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
2
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
V
Link a
r
Splined Adapter c
o
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
N
OPE
Back-up
CL SD
Rings
O-Ring
O-Ring
Ball
Sleeve
Seal Ring Stabilizer

Ring
Crank
Grease/
Mud Seal
Seat
Wave Thread
Spring Protector
Back-up Ring
O-Ring
Figure 3. Typical Upper Safety Valve (IBOP)
4
Feb. 2, 1994
PH-60 IBOP/Actuator Upgrade Kit
Introduction
Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing
PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both
as a primary safety valve and as a mud saver while drilling ahead.
Maintenance and operating costs will be greatly reduced, allowing a minimum planned
maintenance interval of six months for the upper IBOP.
PRINCIPLE FEATURES
❏ The upper IBOP valves (2 ea.) are equipped with:

• PH-85 style dual-path operating systems
• New low-stress inside body contours
• Completely redesigned long-life internals
❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides.
❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
❏ The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, grease-
packed, and completely isolated from mud caking and corrosion to ensure full bore opening.
5
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Aug. 9, 1993. A.N.
Figure 4. PH-60 Upgrade Kit
6
Feb. 2, 1994
Remote IBOP Actuator Improvements
(Refer to Drawing 99261 in the Appendix)
1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%
larger piston area ensures positive, complete ball rotation under the most arduous conditions.
A 60% increase in available cylinder stroke eliminates the need for sensitive position
adjustments, both at initial rig-up as well as over the life of the system.
2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current
multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable)
guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides
directly on the IBOP outer diameter. The new design is very robust, requires no adjustments,
and is able to withstand punishing environments without damage.
3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This
change reduces the operating and environmental forces on the internal and external components
by 50%. It also provides a balanced reaction force to the actuating levers. This force balance
allows elimination of the bolt-on guide roller assemblies.
Each of the two external crank housings is anchored to the IBOP body with 1/2" screws
instead of the 3/8" screws used in the previous design. The crank housings are also secured
to react the ball stop torque using a close-tolerance fit between the base of the housing and
the machined recess in the IBOP valve body. When required, jacking screws make removing
the housings easier.
7
Feb. 2, 1994
Internal Valve Mechanism Improvements
1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They are
replaced with a smooth bore through the ball and seat region. This significantly lowers the
maximum stress in the valve body and effectively eliminates the possibility of leaks caused
by cracking at the crank bores under corrosive mud conditions.
2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball
rotation stop in the previous design. The crank was easily replaced, but the body was not
repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over
extended use could eventually allow the ball to over-travel, leading to washouts.
In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal
cranks (2) and external crank housings (2) need replacement should they ever become worn.
The external crank housings in the new design serve as the ball rotation stops. Each external
crank housing has two struts which contact the internal crank to stop the ball precisely at the
open or closed position. The torque required to stop the ball is then shared by four surfaces
rather than the previous design’s single surface.
The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated
regions beneath the external cranks. This eliminates the presence of caked drilling fluid
around the stop mechanism and is more reliable.
3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,
the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and
locating components, decreasing wear and eliminating mechanical failure.
8
Feb. 2, 1994
INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
5. Screw the stem/main shaft and upper IBOP together.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
a. Torque up to the recommended torque value (Table 1).

b. Back off the connection and inspect the threads and face.
c. Torque up to the recommended torque value (Table 1).
9
Feb. 2, 1994
Table 1. Make-Up Torque Values
Torque (ft-lb)
Components I.D. Connection O.D. (min.) (max.)
Mainshaft to Upper 3" 6-5/8 API Reg. 7-3/4 60,000 70,000

IBOP Safety Valve*
Upper IBOP Safety 3" 6-5/8 API Reg. 7-3/4 50,000 70,000
Valve to Lower
IBOP Valve
Lower IBOP Valve 3" 6-5/8 API Reg. 7-3/8 46,000 64,000
to Saver Sub
Crossover Sub to 3" 6-5/8 API Reg. 7-3/8 46,000 60,000

Lower IBOP Safety
Valve
Mainshaft to Upper 3" 7-5/8 API Reg. 9 83,000 91,000

IBOP Safety
Valve**
Upper IBOP Safety 3" 7-5/8 API Reg. 9 75,000 91,000

Valve to Lower
IBOP
Lower IBOP Valve 3" 7-5/8 API Reg. 8-5/8 66,000 85,000
to Saver Sub
Crossover Sub to 3" 7-5/8 API Reg. 9 75,000 91,000

Lower IBOP Valve
* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a. Carefully grind off any raised tong marks on the O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of the actuator).
c. Orient the levers on the crank assemblies horizontally as shown.
d. Slide the shell up onto the valve with the actuator arm groove on the bottom.
e. Hold the shell in position relative to the valve operating sockets.
f. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90° of crank travel.
10
Feb. 2, 1994
Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90° of crank travel.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Lock Tabs Groove
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
7/8" Allen Crank
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Crank
Crank Assembly Assembly
Roller Retaining Screw
Assembly (3)
Slot
Roller
Assembly
Actuator (3)
Shell
Crank*
Roller
Assembly (3) Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the driller’s console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
16
Feb. 2, 1994
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
1. Breakout and remove the lower IBOP.
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
4. Re-assemble the valves.
5. Reinstall and torque the lower valve.
Figure 9. Lower IBOP Seal Removal
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
1. To verify the integrity of the grease seal.
2. To lubricate the floating seat.
3. To flush mud and debris from the spring cavity.
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly —
the valve should be serviced.
2. Install a suitable grease fitting.
3. Open the valve.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT BALL

C C
Figure 10. Lubricating a Typical Upper IBOP
L L
FLOATING
SEAT
19
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
WAVE SPRING
FIXED SEAT BALL
Figure 11. Lubricating a Typical Lower IBOP

C C
L L
FLOATING
SEAT
20
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
Feb. 2, 1994
INSPECTION
Magnetic Particle Inspection

After approximately three to six months (depending on the severity of operating conditions)
Varco recommends performing a Magnetic Particle Inspection of all load bearing components
– including IBOPs – over their entire surface and internal bores to reveal any fatigue or crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic Particle
Safety Valve Inspection Procedures

Upper and lower safety valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack
may begin at the root of the pit.
Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH
levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse
cracks every three to six months, depending on the severity of the exposure.
Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be
hidden under corrosion products. Use the magnetic particle inspection procedure.
Concentrate attention on (Figure 12):

❏ The area inside the operating crank window
❏ The fillet radii of internal grooves and shoulders
❏ The last engaged threads of box connections
❏ The IBOP actuator shell
21
Feb. 2, 1994
Recommended
Inspection Areas
Figure 12. IBOP Inspection Points
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.
VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of the
mechanism and to minimize mechanical component wear. The actuator shell installs over the
upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the
safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13)
adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator
shell as follows:
1. After removing the crank assemblies, make sure the actuator shell easily moves up and down
over the upper IBOP.
NOTE
There is only one crank on upper IBOPs for the PH-60 pipehandler.
There are also three roller assemblies.
2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.

3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab.
4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check
for signs of binding. Make sure the shell travels freely throughout its full range of travel. If
binding exists, troubleshoot to eliminate any problems before returning to service.
5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders
should retract and the actuator ring should be down.
6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the
cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance
is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch.
7. Actuate the valve to make sure it opens and closes fully.
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Cylinder Adapter
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2) Upper IBOP Valve
Actuator Shell
Upper IBOP Valve
Actuator Air Cylinders (2) Crank Assy(Shown with
Valve OPEN. Note Crank
Assy Position
CLOSE
OPEN
*1 Inch Actuator
Arm
Cylinder
Gland Upper IBOP
Cylinder Rod
in OPEN End
Position Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &
Single Crank PH-60
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13 19
2 17 6 1 10 18 5 14 15
20 7 16
8
2X 4
9
12
11
12 7/8" Hex
Note: Dual Crank Remote IBOP Shown
Single Crank Remote and Lower IBOP
have similar construction.
Figure 14. IBOP Safety Valve Illustrated Parts List
25
Feb. 2, 1994
Parts List
ITEM DESCRIPTION PART NUMBERS QYT. / KIT
1 BALL, DUAL CRANK (SET) 90939-5 1 1 - 1
2 RETAINING RING 89141-1 1 1 -
3 O'RING 90441-9 1 1 1
4 BACK-UP RING 90441-10 1 1 1
5 LOWER SEAT (SET) 90939-5 1 1 - 1
6 UPPER SEAT (SET) 90939-5 1 1 - 1
7 POLYSEAL 96439 1 1 1
8 BACK-UP RING 89141-13 2 2 2
9 CROWN SEAL 89141-8 1 2 2
10 SLEEVE 90441-7 (93806-12 for Dual Crank) 1 2 -
11 O'RING 89141-11 1 2 2
12 BACKING RING 89141-12 2 4 4
13 CRANK, RIGHT HAND 89141-7 (93806-10 for Dual Crank) 1 1 -
14 WAVE SPRING 89141-9 1 1 -
15 BODY - - -
16 O'RING 89141-3 1 1 1
17 NYLON PLUG 2 2 2 2
18 CRANK, LEFT HAND 93806-11 - 1 -
19 PLUG 1 1 -
20 SEAL RING STABILIZER 96438 1 1 1
REPAIR KIT - SINGLE CRANK

Refer to the Appendix for Part Numbers
REPAIR KIT - DUAL CRANK

REPAIR KIT - SOFT SEAL ONLY

(For either Single or Dual Crank)
BALL/SEAT SET
Figure 14. IBOP Illustrated Parts List (Cont.)
26
Feb. 2, 1994
Shop Assembly and Disassembly
The following tools are required (Figure 15):

Crank wrench Varco Part No. 77408
Seat puller Varco Part No. 79489-14
Nut wrench (for internal nut) Varco Part No. 89141-18
Bushing installation tool
Open end or adjustable wrenches
Two large flat screwdrivers or light pry bars
1/4" and 3/4" allen wrenches
Pipe vise or suitable holding device to hold valve secure
Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or
mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,
but also serves to loosen internal components. Follow these general rules while working on the
valve:
1. Take proper precautions while working with the components of the valve to make sure
precision matched surfaces and seal contact surfaces are not damaged.
2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts
as they are removed.
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Seat Puller For All Models Nut Wrench for DSV Models
Varco Part No. 79489-14 Varco Part No. 89141-18
7/8" Hex Wrench For All Models

Varco Part No. 89141-18
Figure 15. IBOP Tools
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or

clamp to hold the valve
securely (Figure 16).
Figure 16
2. Engage the seat puller in

the inside groove of the
lower seat (Figure 17).
3. Using the load bar across

the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).
Figure 17
28
Feb. 2, 1994
4. At the other end of the

valve, insert the upper seat
wrench, P/N 89141-18, into
the upper seat engaging the
wrench lugs into the mating
slots (Figure 18).
5. Using the crank wrench,

P/N 77408, as a lever in the
hole provided in the upper
seat wrench, rotate the
upper seat clockwise until Figure 18
it stops (Figure 18).
6. Remove the wrench.
7. Remove the retainer ring

from the groove in the valve
body by using a screwdriver
to pry one end of the retainer
ring out of the groove. The
ring can then be removed
by hand (Figure 19).
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat

counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the

upper seat (Figure 20).
Figure 20
29
Feb. 2, 1994
11. Remove the ball valve

(Figure 21).
Figure 21
12. From the outside of the

valve, push the crank into
the valve body and remove
them (Figure 22).
Figure 22
13. Remove the pulling tool

from the lower seat.
14. Insert the pulling tool from

the opposite end of the
valve and engage the
groove on the I.D. of the
Figure 23
30
Feb. 2, 1994
15. Using the load bar across

tighten the nut against it to
remove the lower seat and
the wave spring (Figures
24 and 25).
16. Remove and discard the

seals from all IBOP
components.
17. Thoroughly clean and

inspect each item.
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
1. Inspect the lower seat.

Look carefully for signs of
corrosion, pitting and
gaulling – especially in the
sealing areas (Figure 26).
2. Make sure the wave spring

is not broken or damaged
(Figure 26).
3. Inspect the steel stabilizer

ring, making sure it is not
worn, pitted or damaged
(Figure 26).
Figure 26
4. Replace all O-rings, backup
rings and seals (Figure 26).
5. Install the steel stabilizer

and seal on the lower seat
(floating seat), by placing
the steel stabilizer in the
groove of the U-cup seal
and, starting on one side of
the seat, work the stabilizer
and seal around the seat
using a screw driver (Figure
27).
NOTE
The steel stabilizer ring
should be inside the seal
when properly installed.
Figure 27
32
Feb. 2, 1994
6. Install the wave spring on

the lower seat (Figure 28).
Figure 28
7. Inspect the ball valve for

corrosion, pitting and
gaulling (Figure 29).
Figure 29
33
Feb. 2, 1994
8. Install new nylon plugs on

the upper stationary seat
(Figure 30).
Figure 30
9. Make sure the snap ring is

not broken or damaged
(Figure 31).
Figure 31
34
Feb. 2, 1994
10. Make sure the crank

assembly notches are not
worn and there is no pitting
on the outside (Figure 32).
Check for a sliding fit with
the slots in the ball.
11. Install the seals on the crank

assembly.
12. Inspect the crank sleeve for

wear and washouts.
Replace as necessary.
Figure 32
13. Thoroughly lubricate the

valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the Figure 33
pulling tool until it seats on
the spring surface of the
17. Insert the threaded rod of
the pulling tool first into
the box opposite the splined
end of the upper valve,
pulling the lower seat into
place in the valve body
(Figure 33).
35
Feb. 2, 1994
18. Using the load bar against

tighten the nut to firmly
seat the lower seat in the
valve body (Figure 34).
Figure 34

grease to the outside of the
sleeve and crank.
20. From the inside of the valve

body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).
Figure 35
21. Make sure the crank moves

90° to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the

Closed position.

grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).
Figure 36
36
Feb. 2, 1994
24. Slide the ball onto the crank

inside the valve body. The
keyway must be in the
Closed position, or parallel
to the key of the crank.

grease to the outside threads
and seal of the upper seat.
26. Insert the upper seat into

the valve body, engaging
the threads (Figure 37). Figure 37
27. Insert the upper seat wrench

into the mating slots of the
upper seat.
28. Rotate the wrench

clockwise until the upper
seat sets firmly against the
ball.
29. Remove the upper seat

wrench and install the
retainer ring firmly into the
groove of the body (Figure
Figure 38
38).
30. Insert the upper seat wrench
into the mating slots of the
upper seat.
31. Rotate the upper seat

counterclockwise until the
seat is firmly against the
retainer ring.
32. Remove the puller and use

an allen wrench to make
sure the valve functions
properly.
33. Leave the valve in the Open

position.
34. Remove the wrench.
37
Feb. 2, 1994
35. Grease the valve through

the pressure plug until
grease extrudes from inside
the valve (Figure 39).
NOTE
The grease pressure should not exceed
300 psi. Excess pressure can cause the
mud/grease seal to extrude.
Figure 39
36. Install the 1/4" N.P.T. plug

into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.
38
Feb. 2, 1994
IBOP VALVE TESTING IN THE SHOP
Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test
pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the
following procedure to test IBOPs:
1. Rotate the valve crank to the Open position.
2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug
in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve
to the plug in the opposite end.
3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for
lower IBOP) with the ball and the bleed valve in the Open position.
4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,
but using water increases the liklihood of corrosion in the valve body—especially when the
valve is not in use for a prolonged period of time.
NOTE
Open and close the valve five times to release trapped air and
overflow through the bleed valve for approximately 30 seconds to
assure complete filling of the valve cavity.
5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed
position.
6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus
1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.
7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic
test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper
IBOP, box end up for lower IBOP).
8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP
(pin end of the lower IBOP).
9. Fill the valve cavity with water while rotating the ball full open to closed five times to release
trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working
pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the
duration of the test.
10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to
insure smooth operation.
11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is
acceptable.
12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to
release trapped fluid. When testing with water, coat the valve internals with a preservative
to prevent oxidation and install thread protectors.
39
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP TYPE OF REPAIR KIT SOFT SEALS BALL/SEAT

PART NO. SERVICE DESCRIPTION PART NO. PART NO. PART NO.
94769-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5

94769-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94769-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94770-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5

94770-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94099-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5

94099-501 NAM Landing Collar Design 90939-2 90939-1 90939-5
94100-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5

94100-501 NAM Landing Collar Design 90939-2 90939-1 90939-5
90815 STD Upper Valve - PH85 93806 93806-1 90939-5
- H2S 6 5/8 Box X 6 5/8 Box (Spl End) - - -
- NAM Land Collar Design - - -

- NAM Load Collar Design - - -

94206-500 STD Upper Valve - PH85 93806 93806-1 90939-5

94206-502 NAM Landing Collar Design 93806 93806-1 90939-5

40
Feb. 2, 1994
IBOP Part Numbers (Cont.)

IBOP TYPE OF REPAIR KIT SOFT SEALS BALL/SEAT
PART NO. SERVICE DESCRIPTION PART NO. PART NO. PART NO.
91138 STD Upper Valve - PH85 - Big Bore 95384 91137-SP 91137-1
89451-501 STD Lower Valve 90939-2 90939-1 90939-5

89491-503 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15
86434 NAM
89452-501 STD Lower Valve-Stepped 90939-2 90939-1 90939-5
89492-502 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15
- NAM 90939-2 90939-1 90939-5
90811 STD Lower Valve 93807 93807-1 90939-5
- H2S 7 5/8 Pin X 7 5/8 Box - - -
- NAM - - -
91138 STD Lower Valve - Big Bore 94385 91137-SP 91137-1

- H2S 7 5/8 Pin X 7 5/8 Box - - -
- NAM - - -
105629 STD Upper Valve - Type "E" - - 90939-5
- H2S 6 5/8 Pin X 6 5/8 Box - - - -
- NAM For Ids Only - - -
103220 STD Upper Valve - Type "E" 90939-2 90939-1 90939-5
- H2S 6 5/8 Pin X 6 5/8 Box - - -
- NAM For TDS and SDS - - -
98977-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
98977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
98977-501 NAM Landing Collar Design 99468-2 99468-1 65170014
99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
NAM Landing Collar Design 99468-2 99468-1 65170014
41
Feb. 2, 1994
Identifying Varco Safety Valves
42
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46

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IDS-1

Deutag, Rig T-75

Chapter 2 Theory of operation.............. 1-9

Chapter 3 Major component descriptions

IDS-1 Contents iii

Bottleneck Center latch (BNC) drill pipe elevator.......... 1-31

IDS Installation checklists (FIP 0001)

Chapter 1 Operating procedures

Lubrication and Maintenance Schedule (laminated)

Post Jarring Checklist (PI 93-1)

Design Specification, Design Torque Standard (DS00008)

IDS-1 Contents vii

Lubricating the lower attachment assembly (torque tube)4-34

viii IDS-1 Contents

Book 5 – IBOP Service Manual

Book 6 – GE Motor Service Manual

Book 7 – Service Bulletin Index

1-2 IDS-1 Description

Chapter 2 Theory of operation.............. 1-9

Chapter 3 Major component descriptions

IDS-1 Description 1-3

Service loops .................................................................. 1-35

1-4 IDS-1 Description

z Indicates advisories for operational or servicing procedures

e Indicates advisories involving a risk of equipment damage.

n Indicates advisories involving a definite risk of injury to rig

Avoid personnel injury and equipment damage by reading this

IDS-1 Description 1-5

1-6 IDS-1 Description

IDS-1 Description 1-7

The IDS provides more rotating power than a conventional rotary

Figure 1-1. Typical IDS-1

1-8 IDS-1 Description

A vertically mounted GE 752, high torque drilling motor powers

IDS-1 Description 1-9

Two internal blow out preventor (IBOP) valves connect to the

1-10 IDS-1 Description

The information provided in this section includes brief

IDS-1 Description 1-11

Integrated traveling blocks

❏ Six 60 in. OD sheaves (for 1 3/8 or 1 1/2 in. line) 500-ton

1-12 IDS-1 Description

Figure 1-2. Typical 500-ton IDS traveling block

IDS-1 Description 1-13

Drilling unit assembly

❏ Drilling motor assembly

Drilling motor assembly

Single-speed planetary transmission

❏ Ring gear and gearcase

1-14 IDS-1 Description

An optional electrically driven gear pump (mounted externally on

Locking Swivel Block

Figure 1-3. Rotating head assembly

IDS-1 Description 1-15

Integrated swivel assembly

1-16 IDS-1 Description

Carriage assembly and torque tube

IDS-1 Description 1-17

Figure 1-4. Typical IDS counterbalance system