TDS 11S Training

TDS-11S
Training
Program Contents
TDS 11 Mechanical Systems
 Top Drive Development
 Lubrication
 Guide Beams & Carriage
 Motor Housing & Transmission
 PH-50 Pipehandler
 On-Board Hydraulics
 Safety!
History of Top Drive
Development
A brief history of Top Drives
Since the advent rotary drilling in the early 1900s, drilling technology has made steady and, in some
cases, spectacular progress. In a little over 100 years, well depths have gone from the 70-foot
depth of Drake's Well to over 40,000 feet at the rig on Kola Peninsula east of Finland.
To accomplish this, advances were necessary in rig design, equipment, bits, materials and
drilling techniques.
Varco International, Inc., is proud of its part in advancing the

technology of drilling. In 1982 they introduced the industry's first top drive drilling system. By
replacing the traditional rotary drive and kelly with an advanced system that rotates the drill
string and handles entire 93-ft. stands of pipe, Varco was able to reduce drilling time by up to
25% while increasing the overall capability and efficiency of the drilling operation.
As a result, Varco Top Drive Drilling Systems have now become the new performance standard
for the drilling industry.
Varco continues to extend the threshold of Top drive technology with the introduction of a
complete line of AC top drive systems.
A new threshold in AC technology
For years the backbone of oil industry power has been the 1000 hp DC traction motor adapted
from locomotives.
They are used extensively to power a variety drilling operations including

drawworks, rotary tables and mud pumps. DC traction motors area rugged, dependable, readily
available source of high torque electric power.
These characteristics made them the ideal choice for the conversion of drilling equipment from
direct drive diesel to electric power.
In developing its Top Drive systems, Varco first turned to these DC motors to power its new
technology. And while they were appropriate for some applications, it became evident that
smaller, more compact motors were needed for today's performance requirements.
There was a need for an efficient,high performance alternative to traditional DC systems
. As part of Varco’s ongoing development effort, various AC motors and drives were reviewed in an
effort to satisfy the specific requirements of drilling applications. Varco design engineers determined
that rapid developments in adjustable frequency technology made AC drives and motors a better
solution for certain applications traditionally served by DC systems. These modern AC motor/control
combinations are uniquely suited for the requirements of the drilling industry. By optimizing various
components, rugged, reliable AC drives and motors nowcanproduce superior power density for a
given frame size. The result - compact, efficient power plants that extend the performance envelope
of drilling operations.
Single Speed 5.33:1
DC
TDS-1
New
TDS-3
TDS-1
TDS-4
TDS-7
TDS-9
TDS-2
ThetoIDS
1981
AC
High
Integrated
–1
uses
TDS-3
becomes
becomes
Two Speed - 7.95 & 5.08:1 TDS-4 1983
Torque
Swivel
Upgrades
the
the
becomes
Single Speed - 6.67:1 TDS-5
are
First
NEW
Motors
a Locomotive
TDS-3H
ReducesAC
Industry
Varco’s
are
Dual
TDS-4H
Offered
Motor
Top
Industry
First
Single Speed - 5.33:1
System
TDS-3S
1988
Standard
ACDrive
Single Speed - 5.33:1 TDS-4S
Motor
Introduced
1989
Height
Two Speed DC - 5.33:1 @ 2,200hp
Portable
Standard
TDS-6S
1990
TDS-6SB
TopDrive
1991
Drive
Single Speed Planetary - 6:1 @ 1,150hp
Top Drive Development
IDS-1
Single Speed AC - 5.3:1 @ 990hp TDS-7S 1993
Dual Motor AC - 10.5:1 @ 700hp TDS-9S 1994
Single AC - 13.1 or 4.8:1 Ratio @ 350hp TDS-10S

1996
Single Motor AC – 9.0:1 @ 1,150hp
TDS-8S
1997
1,150hp AC Upgrades TDS-3/4SAC
Dual Motor AC - 10.5:1 @ 820hp TDS-11S

TDS 1 1983 TDS 3
1981
Proto type Drilled 1st well in Arabian Gulf
TDS 5 1988 TDS 4
1988
Interim solution Became industry Standard
TDS 3/ 4H MODEL
1989 TDS 3,4,6S MODELS
1990
Higher Torque Integrated Swivel
1991 IDS TDS 7S
1993
Planetary gear system 1st Varco AC Top Drive
With Integrated Swivel
1996 TDS 10S
TDS 9S
1994
1 x 350HP Motor
2 x 350HP Motors same oil for all functions
TDS 11S TDS 8S
1997 2000
2 x 400HP Motors 1000 TON
2004
IDS AC TDS 8S
2002
Hollow shafted GE 752 AC Motor
The Advantages of Top Drives
• Reaming in or out in sloughing formations

• Minimized Stuck Pipe, Jarring & Lost Wells
• Higher Average ROPs (drilling with stands)
• Reduced Tool face re-orientation times
• Improved well control while tripping (IBOPs)
• More Precise Torque Control on Connections
Deviated Wells
Typical Horizontal Comparisons ~ 14,000’ Wells
9,000
10,000
11,000
Depth Drilled (ft)
12,000
13,000
14,000
No Top Drive
Top Drive Installed
15,000
0 2 4 6 8 10 12 14 16 18 20
Drilling Days
Deviated Wells
Typical Horizontal Comparisons ~ 16,500’ Wells
11,000
12,000
13,000
Depth Drilled (ft)
14,000
15,000
16,000
No Top Drive
Top Drive Installed
17,000
0 2 4 6 8 10 12 14 16 18 20 22 24
Drilling Days
General Information
TDS- 9/11S Top Drive
 Small, Compact Top Drive
 Land Rigs
 Small Platform Rigs
 Small Jack-Up Rigs
 Portable & Mobile

 Reduced Size & Weight
 Quick Rig-Up & Rig-Down
 Low Maintenance Cost

 Precise Torque Control
Large Top Drive Features…….
 Full Torque Capability
 Remote Break-Out
 Reverse Link-Tilt
 Rotating Head
 Dual IBOP
…..Plus Many Other Features…..
Remote (Powered) Elevator Positioning
On-Board Hydraulic Power
Integrated Mousehole Kick-Out
Self-Locking Guide Beam
Precision AC Control
Higher Stall Without Overheating
No Brush Maintenance
 500 Ton, 700 hp or 800 hp Versions
 Integrated Swivel and Counterbalance
 Dual AC Drilling Motors
10.5 : 1 Single Speed Transmission
32,500 or 37,500 ft.lbs Continuous Torque
46,000 or 55,000 ft.lbs Intermittent Torque
0-228 rpm Drilling Speed
 PH-50 Pipehandler
50,000 ft.lbs Torque
15,000 psi Rated Dual IBOPs
Compact Link Tilt
 Mousehole Kick-Out
 Self-Locking Guide Beam
 Ex and UL Electrical Models
 25,250 lbs Unit Weight
Torque/Speed Curves
55,000
Torque (ft.lbs)
50,000
45,000 800hp
Version
40,000
35,000
30,000
25,000
20,000
700hp
15,000 Version
10,000
5,000
0
0 50 100 150 200 250
Rotating Speed (rpm)
Cooling Fan System Bail
Motor (2)
Cooling System Gooseneck

Air Duct (2) ( S-Pipe)
Hydraulic
Brake (2) Bonnet
350 or 400 hp AC Washpipe

Drilling Motor (2) Packing Assembly
10.5 : 1
Transmission
Drive Stem
TDS- 9/11S Power Train

34 Tooth motor Pinion
102 Tooth Bull Gear
63 x 18 Tooth Compound Gear
500 Ton Swivel Overall Reduction

Thrust Bearing 10.5 : 1
Alternating Current Motor
Motor Brake Thrust
Ball Bearing
Air Inlet
Rotor Assembly (550 CFM)
(Laminated)
End Coil
Stator Assembly
(Laminated)
Motor Frame
(Laminated)
End Coil
Motor Shaft
Air Exhaust
Guide
Pinion Gear Roller Bearing
5 HP BLOWER MOTORS
Motor Cooling
Air Intake Flow

between Motor $
Brake Housing
Exhaust Flow
Powered Elevator Rotating
Positioner (360º) Link Adapter
Upper IBOP &

Link-Tilt Assembly Accumulator
Assembly
Lower IBOP Valve Torque Arrester

Frame
Back-Up Clamp
350T - 108”
Elevator Links
Adjustable
Stabbing Guide
350 or 500T
Elevators
PH-50 - Link-Tilt Positions
Ov
er
dr
ill
e
ol
an
h
se
i ckm
ou
M
Derr
PH-50 – Kick-Out Option
This is an optional extra
Spreader
Beam
Optional
Mousehole
Kick-Out
Assembly
t
Ou
k-
ic
rK
oo
D
Center
V-
Well
57.7” Max.
116” Ref.
Drill Stem Assembly
Main Shaft Upper IBOP

Actuator Cylinder
Assembly
Tool Joint
Clamps (3)
Upper IBOP
& Dual Crank
Actuator
Lower IBOP
(Manual)
Saver Sub
Electrical Interface
DC Top Drive
Generator
Encoder
Drilling Motors
Mast
Saddle
or Generator Set
AC Highline
Variable Frequency
Inverter and Varco
Control Panel
Electrical
Panel
Service Solenoids
Sensors
Loop Junction
Box
Varco
Skid
Driller’s
Console
Service Loop Configurations
Service
Cables J-Boxes
Connections
Land/ Quick 1 set (3) 444 MCM
Portable Disconnects + 1 x Composite N/A
UL
700hp
Offshore/ Hardwire 1 set (3) 646 MCM 1 x Power

Fixed Connections + 1 x Composite + 1 x Composite
Land/ Hardwire 1 set (3) 646 MCM 1 x Power
Portable Connections + 1 x Composite + 1 x Composite
Ex
Offshore/ Hardwire 2 sets (3) 444 MCM 2 x Power

Land/ Quick 1 set (4) 646 MCM

Portable Disconnects + 1 x Composite N/A
UL
800hp

Land/ Hardwire 1 set (4) 646 MCM 1 x Power
Portable Connections + 1 x Composite + 1 x Composite
Ex

Variable Frequency Drive
600 VAC
3-phase, 42-62Hz Resultant DC Pulse 810 VDC 20Hz = 600rpm
IGB Transistors
600 VAC
3-Phase, 0-80Hz
AC Power
Capacitors
Source
Rectifier
TDS-11S
40Hz = 1,200rpm
Inverter Controller
Variable Frequency Drive

Typical Floor Layout
86’ Service Loop Mast Saddle
@ 80ft
75’
Rotary Hose
Sectional Rathole
Guide
Beam
Mousehole
Universal
Spreader
Beam
Driller’s TDS-11S
Console
Unit Identification
Encoder Instruction Label
Located on the side
of the brake housing
AC Motor Identification Label Top Drive

Located on the side of Identification Plate
each AC motor Located on the front of the
motor housing
Warning Labels
Located on the side
of each AC motor
Warning Label
Located on the
side of the bonnet
TDS-11S - Envelope
33.7” (856mm)
Rear
33.8” (859mm)
Standard Setback
32.0” (762mm)
22.8” (579mm)
21.1” (536mm)
22.1” (660mm)
31.0” (787mm)
32.6” (828mm)
26” (660mm) 36.9” (937mm) Front

TDS-11S - Dimensions
18.5” 120” Bail
0.47m
88” Bail
214.0”
5.43m
5.82m
233”
2.85m
112”
28” 37”
0.71m 0.94m
56”
72”
1.42m
1.83m
62”
1.58m
Typical Mast Interface
Existing Travelling Equipment Crown
500 ton Hook/Block Combo Type 13.5’
Block Top 4.1m
TDS-11S
Varco Portable Top Drive System 13.5’
4.1m
Bail Rest
Sectional Guide Beam 18.0’

Assembled On Site 5.4m
Tool Joint
Derrick Termination
@ ~80’ (24.4m)
Clear Working Height

142.0’ (43.3m)
Drill Stand Made Up @ 4’ (1.2m)
Mud Hose
Connected to Standpipe @ 73’ (22.3m Level)
93.0’ (28.3m)
Service Loop
Portable Torque Reaction Beam

U-Bolted to Spanners
To CL of Beam
10.0’ (3m) min.
To Service Loop
7.0’ (2.1m) min.
2 x Custom Spanners
On A-Frames or Mast Side Panels
Varco Driller’s Console
Control Cable with Connectors

150’ (45.7m)
Unitized Variable Frequency Drive & Drill

Control Panel Floor
Power Supply
AC Power &
Cables Control Cables
Installation
Installation
The control house must be
properly grounded to
prevent injury to personnel
Insert the grounding rod into the soil (the rod

must be in contact with ground water)
Connect the rod to the control house
(connection must be clean)
Grounding Points
Located at opposite corners of the house floor
Ground Rod Kit
P/N 116004
For offshore installations the control house
must be grounded to the ground point on the
rig structure
Pre-installation
Installing the crown pad-eye and hang-off link Crown
36.8 inches :-Standard height configuration (adjustable )
30.0 inches :-Original setback for TDS-9S/11S
Crown Pad eye

Weld according to table above
Shackle
Guide Beam Connecting/Hang off Link

The Bail Lock Assembly
must be installed
Tube (P/N 113498)
U-Bolt (P/N 113497)
2x 3/4" nuts
Locate the Top Drive at the bottom of the

V-Door ramp
Ensure that the bail lock assembly is installed
Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor
Ensure the safety of all personnel
Be sure that Top Drive is pinned to

skid before hoisting to drill floor
Installation TDS Lifting Points
Lifting Point Net Weight = 27,000 lb (12,300 kg)

For lowering/hoisting the With Skid = 30,000 lb (13,600 kg)
Top Drive to/from the
skid
Lifting Points
For Lifting the Skid with
the Top Drive
Attached
Bail Lock
Must be installed before
lowering/hoisting the
Top Drive to/from the
skid
Lifting Points
For Lifting the Skid with
the Top Drive
Attached
!Locking Pins
Must be in place prior to
moving the skid with the
Locking Pins Top Drive attached
Must be in place prior to
moving the skid with the
Top Drive attached
Pre-installation
Checklist
The following assumes that all pre-installation planning and
rig-up is complete prior to installation of the guide beam
assembly and TDS-11SA. This includes:
Make sure the derrick/mast is vertical, with the block
over the center of the rotary table.
Derrick/mast modifications are completed (if required)
and the guide bean support bracket and torque reaction
beam are installed and inspected to conform to Varco
specifications as detailed in FIP00003.
The service loop bracket is installed in the derrick/mast.
The control panel and frequency drive are installed.
Rigging of tong lines, etc. is inspected to ensure that
they will not foul with the TDS-11SA.
The hook or adaptor becket is installed. The hook
should open toward the drawworks.
Ensure that both carriage latches
are engaged for hoisting from the
skid
Ensure that the bail lock
assembly is installed
Engage the hook with the bail
Remove the lock pin
Ensure the Top Drive does not
contact the rig
Hoist the Top Drive from the skid
After hoisting the TDS-11SA
from the skid, disengage the
Lower Carriage Latch
and pin it as shown.
Ensure that the lower carriage latch is disengaged

Ensure that the upper carriage latch is engaged
Hoist the Top Drive
Remove the skid from the drill floor
Ensure the Top Drive or the guide beam
does not contact the rig
Remove from drill floorafter hoisting the TDS
Installation Guide beam
Floor Clearance
Using the drawwork, hoist the top guide beam
to the hang-off link
Ensure that the shackle is pinned and it’s
cotter pin is in place
Pin the guide beam to the hang-off link in the
appropriate position
Check for 7 ft clearance from bottom of guide
beam to the drill floor
Secure the pin to the hang-off link with the
nut
and safety pin
Guide Beams & Tie back
Check for Top Drive mainshaft alignment over
well center
Install the main spreader beam at the
Guide Beam
appropriate distance from well center Bottom Section
Install the tieback plate and tieback link
Check for Top Drive mainshaft alignment over
well center
Torque and lock wire all bolts
Tie-Back Plate
Main
Spreader Beam
Bolted Connections
Tie-Back Link
Auxiliary
Spreader Beam
Mast Leg
Guide Beams & Tie back
Intermediate tiebacks are installed on girts

closest to 55 feet and 105 feet above the drill
floor
Weld two padeyes to the guide beam if the
space between the girt and the guide beam is
greater than 3 inches
Weld a single centered padeye if the space
between the girt and the guide beam is less
than 3 inches
Install intermediate tieback plates as required
Torque and lock wire all bolts
Secure all pins with cotter pins
On-Board Hydraulics
On-Board Hydraulics
Hydraulic system
The hydraulic control system is a completely self-contained,
onboard system. A 10-horse power, 1800 rpm, AC motor, drives
two hydraulic pumps and powers the hydraulic system. A fixed
displacement pump drives the lube oil system motor. A variable
displacement pump provides hydraulic power for the AC motor
brakes, powered rotating head, remote actuated IBOP, pipe backup
clamp cylinder, link tilt, and counterbalance system. Three hydropneumatic
accumulators are located on the main body.
The hydraulic manifold attaches to the main body and contains
solenoid, pressure and flow control valves.
A sealed stainless steel reservoir supplies hydraulic oil, eliminating
the need for draining and refilling during normal rig moves. The
reservoir is mounted between the AC drilling motors and is
equipped with strainers and an oil level sight gauge.
Specifications
Reservoir Capacity 10hp, 1,800rpm
Hydraulic Oil Counterbalance
Filter Manifold Pump Motor 25 Gallons
Counterbalance
Accumulator
Counterbalance
Upper IBOP Cylinders
Time Delay
Accumulator Main Hydraulic
Manifold
Hydraulic
Oil Fill Hydraulic Oil
Link Tilt Reservoir
Oil Pressure Manifold
Switch
Link Tilt
System Cylinders
Accumulator
IBOP Pressure Rotating Head

Switch Motor and Shot-Pin
Assembly
Upper IBOP
Actuator
Cylinder
Motor and Pump

Assembly
On Board Hydraulics
Drilling Upper IBOP Link-Tilt
Motor Brake Actuator Cylinder Cylinders Piphandler Clamp
Cylinder
Counterbalance
Link-Tilt
Accumulator Manifold
Rotating Head
Counterbalance
Cylinders
Shot-Pin
Rotating Cylinder Rotating Link
Head Motor Adaptor Lift
Counterbalance
Manifold Lube Oil
Distribution
Variable Fixed Lube

Displacement Displacement Oil Pump
Pump Pump
Main Hydraulic Manifold Hydraulic
Accumulator
Accumulator
Motor
System
Sump
M
IBOP
10hp AC Reservoir
Motor
Recommended Hydraulic Oils
Manufacturer -15ºC to 75ºC -10ºC to 85ºC

Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd Oil 32 AW Hyd Oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 245
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando Oil HD 32 Rando Oil HD 46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46

Viscosity Index 32 46
Hydraulic System Maintenance
Adding & Draining
Hydraulic Oil Filter Sight Glass
Pop-Up
Dirt Alarm
Cork Ball
Hydraulic Oil Fill

Male
Quick-Connect
Hydraulic Pump
Dust Plug
Female
Quick-Connect Pump Inlet
Drain Adaptor
Hydraulic
Lubrication Kit
Heat Exchanger
Blower &
Brake Covers
Oil Heat
Oil Heat Exchanger Exchanger
Monthly
Inspect
Drill Motor Assy.

(LHS)
System Test Ports
Pre-charging the Accumulators
Counterbalance
Accumulator
Upper BOP
Time Delay
Accumulator
System
Accumulator
Accumulator Setting Port

System Accumulator (125in³ Displacement) 800psi Discharge SA
Counterbalance Accumulator (728in³ Displacement) 900psi Discharge CB
Time Delay Accumulator (30in³ Displacement) 800psi Discharge C4

Counterbalance
accumulator
900 psi Pre-Charge
System
Accumulator
800 psi Pre-charge
IBOP Timer
Accumulator
800 psi pre-charge
Reservoir Bladder
Hydraulic Reservoir Bladder
Reservoir Reservoir
Breather Cover
Reservoir
Bladder
Gasket
Reservoir Bladder
Annually
Inspect
Hydraulic Oil
Reservoir
Reservoir Bladder
Setting Fixed displacement pump
1. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when
looking into pump shaft/ electric motor fan). Correct as required.
2. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would
indicate cavitation; check for leaks.
3. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end,
cap the tube and plug the PF port using steel fittings. 8
4. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise,
which allows the hydraulic system to operate without building up pressure .
5. Set the relief valve RV2 to minimum pressure, fully counterclockwise .
i Make sure the variable displacement pump case is filled with clean hydraulic oil.
6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the
pressure increases to 400 psi at test point PF. Set the jam nut on RV2.
A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.
i While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the
pressure change.
7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor.
8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate.
9. Restart the hydraulic system electric motor.
Setting up the Fixed Displacement Pump
RV2
Manifold
Side View
PF
Manifold
Bottom View
Pressure Switch
Set @ 18 psi
Spay Nozzles
Lube Pump
Lube Filter
Heat Exchanger
Hydraulic Motor
RV2 Set @ 400 PSI
Test port PF
Fixed Displacement Pump

Lube Oil System
Pumps
Hydralic
Motor
Lub Pump
Inspecting the Gearbox Lube Pump End Cover
Ring Seal
Thrust Plate
Gear Housing
Body Seal
Gear Set
Roller
Bearings (4)
Pump
Adaptor Plate
CapScrew (10)
Main Body
Hydraulic Motor
O-Ring
Hydraulics Troubleshooting
Gearbox Lubrication System (contd)
Check pressure at PF and

Faulty fixed displacement pump.
replace pump if pressure is low
Oil Pump Loss
Alarm is On Low hydraulic fluid in reservoir Add hydraulic fluid
Suction valve closed on fixed

displacement pump Open suction valve
Missing inspection plugs Replace inspection plugs

Water/Mud in Oil
Upper gearbox seals worn Replace seals
Water in oil Replace oil

Excessive
Foaming
Oil viscosity too high or oil too cold Lower oil viscosity
Metal in Oil Worn gears or damaged bearings Replace gears or bearings
Damaged oil pump Replace oil pump
Restricted Oil
Foreign particles blocking orifice/ nozzle Clean orifice/nozzle
Flow
Gearbox Lubrication System
Problem Probable Causes Remedy
Oil Leaking From
Lower Seal Worn oil seals Replace seals
Oil Leaking From

Upper Bearing Worn oil seals Replace seals
Retainer
Oil level too low or too high Adjust oil level

Gearbox Oil
Temperature less Incorrect oil Replace with recommended oil
than 230ºF
Damaged gears or bearings Repair or replace
Oil level too low or oil overheating Add oil
Oil pressure switch needs adjustment Adjust
Gear spray nozzle missing Replace spray nozzle

Oil Pump Loss
Alarm is On Oil viscosity too high Lower oil viscosity
Faulty motor Replace motor
Oil pump hydraulic motor faulty Replace motor
Broken lube pump adaptor plate spline Replace adaptor plate spline
Setting the Variable Displacement Pump
1. Connect an ammeter to the electric motor. Note the full-load

amps on the motor nameplate.
2. Restart the hydraulic system electric motor.
3. Set the counterbalance mode valve to the RUN position.
4. Adjust UV1, fully clockwise, to maximum pressure.
5. Connect a gauge to test point PV. Note the ammeter reading

while RV1 is at minimum setting.
6. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a
steady rate. During the pressure rise, observe the ammeter. The motor current
should rise to a maximum value at 800 psi, then drop off and begin to rise again. The
point where the current drops is the pump pressure compensator setpoint.
7. Adjust relief valve RV1 to its minimum setting. If maximum motor

current does not occur at 800 psi, adjust the pump pressure
compensator as required.
8. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.
9. Connect a gauge to test point SA, and leave the gauge on PV .
10. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.
11. Install steel cap over the adjustment screw to discourage
unauthorized adjustment.
12. Adjust unloading valve UV1 counterclockwise until the pressure
at PV drops off, then an additional two turns counterclockwise.
The pressure cycles like a sawtooth wave.
3000 Reading @ PV
Reading @ SA
2000
Pressure (psi)
1700
1000
800
150
0 10 20 30 40 50 60
Approximate Time (s)

13. Observe the unloaded pressure at PV (about 0 psi) while SA
reads about 2,000 psi. The pressure at SA decays until UV1
reloads. After reloading, the pressure rapidly rises to the unload
pressure.
14. Observe several unload-reload cycles to determine the unload pressure.
15. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.
Perform the adjustment with reasonable speed. The process takes no longer than two
minutes. Taking longer increases the temperature of the hydraulic fluid.
16. Observe the cycle of loading and unloading of the relief valve.
To verify the setting of UV1, note the difference in pump noise level between the
loaded and unloaded condition.
Setting up the Variable Pump
Pump/Motor
Guide Beam
Pump Pressure
Compensator
Fixed Displacement Variable 10hp AC Pump

Pump Displacement Pump Motor
Fixed displacement
Pump
Variable Pump Compensator Valve

RV1
Variable
Displacement
Manifold
Side View
PV
UV1
30 PSI
UV1
.078 ”
Accumulator
Charged to
900 PSI 2500 PSI
RV1
Hydraulic manifold
2700 PSI
Pump
compensator Oil Reservoir
650 PSI Air Bag

M Shut off Valve
Strainer
30 PSI
UV1
.078 ”
2500 PSI
RV1
2700 PSI
Pump
compensator
Oil Reservoir
Air Bag
M Shut off Valve
Strainer
Variable Pump System
Variable Pump System
Reading from test port PV
2000PSI 2000PSI
2000PSI
20 Seconds
20 Seconds
100 PSI
0 PSI 100 PSI
3000 Pressure reading at SA
2000
Pressure (psi)
1700
20 Seconds 20 Seconds
1000
800
150
0 10 20 30 40 50 60
Approximate Time (s)

HPU & Reservoir Bladder
Relief Valves RV1 & RV2 improperly set Test pressures & re-set valves
Unloading Valve not working Test & adjust UV1 (or replace)
Hydraulic System
Overheating
Pressure has bled down due to counter-
Check System Pressure
balance mode valve in shut-down too long
No pre-charge in System Accumulator Charge System Accumulator
Test Pumps & Motors

Test Relief Valves
System pressure is too low
Check for leaks, loose valves,
loose cylinders or worn hoses
Piston Pump not working Replace Piston Pump
Hydraulic Flexible Coupling damaged Replace Flexible Coupling

Components Don’t
Operate Lubrication Pump not working Replace Lubrication Pump
Pressure at UV1 is too low Adjust UV1
Pumps rotating in wrong direction Check connections & rotation
Suction Valve closed Open Suction Valve
Low Reservoir oil Fill Reservoir

Daily Inspections
Description
Check Condition of the Hydraulic Filter Indicator
Check Hydraulic Fluid Levels
Check for Hydraulic Fluid Leaks

Check Condition of All Hydraulic Hoses
Maintenance Schedule
Description Frequency
Replace Hydraulic System Filter Once Every 3 Months
Analyze Hydraulic System Oil Once Every 6 Months
Replace Hydraulic Fluid Annually (or Depending on Analysis)

Inspect Reservoir Bladder Annually
Replace Reservoir Bladder Bi-Annually
Counterbalance System
Counterbalance systems vary widely in configuration

The principles are the same regardless of which counterbalance configuration the drilling rig
uses. For description purposes this section of the module describes all Varco
counterbalance arrangements used in the Varco Top Drive Systems.
Q. What does the counterbalance do
A. The counterbalance system prevents damage to the threads of the saver sub and drill
pipe by offsetting the weight of the Top Drive while stabbing into a connection.
Q. What does the counterbalance system consist of.

A. The counterbalance system consists primarily of two hydraulic cylinders, a
counterbalance manifold, cartridge valves, a hydraulic accumulator, and connecting links
Q. How does the counterbalance function.
A. The two hydraulic cylinders are connected to the hydraulic accumulator, the
accumulators are pre-charged to 900 psi, When properly adjusted the
counterbalance systems supports all but about 800lbs of the weight of the Top Drive.
Setting up the Counterbalance System
1. For the counterbalance circuit there are three adjustments:
. Relief valve (on counterbalance cylinder)
. PCC – operator set
. SJR – operator set
2. To set the relief valve, make sure the pumps are operating.
3. Adjust pressure reducing valve PCC to the maximum setting,
fully clockwise.
4. Connect a gauge to test port CB.
5. Adjust the cylinder-mounted relief valve to mid-scale to lower
the pressure setting.
6. Increase the pressure clockwise using a 5/32 in. Allen wrench
and 9/16 in. open-end wrench.
7. Observe the relationship of turning the relief valve adjustment
clockwise to pressure increase.
8. When the relief valve reaches system pressure, turn the
setting one full turn clockwise beyond the setting and set the
jam nut.
9. Install a steel cover over the valve.
10. Adjust PCC to 1,200 psi.
11. Measure pressure at test port CB.
12. Prepare the hardware to attach the cylinder pear links to the
hook.
13. Rotate the counterbalance mode valve from the RUN position
to RIG-UP position. This causes the counterbalance cylinders
to slowly extend.
14. Once cylinders reach end of stroke, attach hardware to the pear
links on the hook.
15. Rotate the counterbalance mode valve back to the RUN
position.
16. Adjust PCC counterclockwise to raise the pressure at test port
CB until the rail just begins to lift off of the hook.
17. Reduce the pressure slowly (25 psi) to allow the pressure to
stabilize.
18. Rotate the counterbalance mode valve to the SHUTDOWN
position to bleed down counterbalance cylinders and system
accumulator before shipping or performing maintenance.
19. Adjust pressure reducing valve PCC counterclockwise until the
bail rests on the hook. Note the pressure at CB.
20. Reduce PCC an additional 25 psi. The pressure at CB is about
1,600 psi.
CB
Setting up the
Counterbalance
900 PSI Pre-Charge
CV3
.055 ORIFICE
TEST PORT
PCC
Counterbalance Run
COUNTERBALANCE
CYLINDERS
ACCUMULATOR
PRECHARGE 900 PSI
CV3
MODE VALVE
PCC
Mode Valve
Counterbalance Rig-Up
Setting up the Stand jump
1. Connect a gauge to test point B9. Activate the STAND JUMP

mode on the drilling console. Adjust relief valve SJR until the
bail lifts off the hook. The gauge at B9 should read about 190
psi.
2. Switch back to DRILL counterbalance mode and observe the
pressure at test point CB.
3. Switch back to STAND JUMP mode and observe the pressure
CB increase by 190 psi.
SJR
CB
B9
Setting up the
Stand jump function
900 PSI Pre-Charge
CV3
.055 ORIFICE
TEST PORT SJR
PCC
Stand-Jump Position
Counterbalance Shut-Down
Counterbalance & Stand-Jump
Cylinder damaged or seals leaking Inspect & repair cylinder/seals
Test pressure & adjust reducing

No hydraulic pressure valve
Counterbalance Test electrical/hydraulic

Solenoid Valve SV9 is not operating
Does Not Function connection – repair as required
PCC not operating Replace valve
Relief valve not operating Replace valve
Pre-charge too low Charge the accumulator
Cylinder damaged or seals leaking Inspect & repair cylinder/seals
Test pressure & adjust reducing

No hydraulic pressure valve
Stand-Jump Test electrical/hydraulic
Solenoid Valve SV9 is not operating
Does Not Function connection – repair as required
PCC not operating Replace valve
Relief valve not operating Replace valve
Pre-charge too low Charge the accumulator

Setting the Brake system
The AC drilling motor brakes are spring released and

hydraulic
pressure applied at 1,400 psi.
The pressure reducing valve
regulates the pressure to 1,400 psi. The solenoid valve
operates to
apply pressure, setting the brakes, or stop pressure to
release the
brakes.
To test the system, turn the auto brakes switch on the

driller’s
console to the ON position. Attach a pressure gauge to B1
in the
manifold. The pressure reading should be 1,400 psi. If the
reading
is not 1,400 psi, adjust the pressure control reducing valve
PC 1 to
1,400. Turn the auto brakes switch to the OFF position. The
pressure reading should be very low. If the pressure is high,
the
solenoid valve might be sticking.
Inspecting Motor Brakes
Caliper
Mounting Bolts (2)
Steel Plate
0.09” Calipers & Pads

Monthly
Inspect
Adjust
Brake Pads
Caliper
Mounting Bracket
Setting the Brake system
PC1
B1
Setting the Brake System
Brakes On
Brakes
Brake Does Not Test valve and replace if
Directional Valve stuck
Release necessary
Check Valve is blocked or tube is pinched Check valve & tube

Brake Releases
But Drags
Mechanic problem with brake Check brake mechanism
Hydraulic oil on brake Check for leaks
Brake Does Not Pressure < 1,400psi or does not rise

Engage or Slips quickly to 1,400psi Adjust or replace reducing valve
Directional Valve stuck (check pressure Replace valve or check

at B1) electrical signal
Hydraulic oil contaminated Replace oil

Delay in Brakes
Actuating Pressure Reducing Valve faulty Replace valve
Setting up the Rotating Link Adapter
1. Set the relief valves mounted on rotation motor.

2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.
3. Turn the manual override on the SV2-rotation circuit to drive the
head in the counterclockwise direction. Test the pressure at A
and adjust the relief valve to 1,600 psi.
4. Turn the manual override on the SV2-rotation circuit to drive the
rotating head in the clockwise direction and test the pressure at
B. Adjust the relief valve to 1,600 psi.
SV2
Setting up the Circuits Motor Hydraulic Test Points
Relief Valve Motor A B
Shot Pin Motor Relief
Relief Valve Valve
B5
C5
A5
Link Adaptor
Rotation Gear
Shot Pin
New Rotating gear arrangement
Rotating Link Adaptor
Rotate Left
Rotate Right
Rotating link adapter
Rotating Link Adapter The powered rotating link adapter, located
at the top of the
Pipe-handler, is a slip ring assembly. It
allows the hydraulic lines to remain
connected as the pipe-handler rotates with
the drill stem components while tripping
out or positioning the link tilt.
The rotating link adapter also provides an
attachment for the link tilt, pipe backup
Lifting Port
clamp cylinder, and remote IBOP actuator
assembly.
Grooves in the rotating link adapter align
with radial holes in the load stem, allowing
Grease Port hydraulic fluid to flow between the rotating
Glyd Ring link adapter and the load stem as they
Rotary Seals rotate.
Hyd Function The radial passages at the upper end of the
Ports
load stem intersect with each hose
attachment that runs to the hydraulic
manifold. The radial
passages in the lower end of the load stem
intersect sealed grooves in the rotating link
adapter that, in turn, connect with hose
attachments that run to all the actuators
on the pipe-handler.
The rotating link adapter is powered in
either direction by a hydraulic drive motor
An electric solenoid valve operates the
rotating link adapter hydraulic motor.
Rotating Link Adapter
Rotating Link Adapter
PH-50 Pipe Handler
Rotary GLYD Ring
Annually
Rotary Link Replace
Adaptor
O-Ring
Annually
Replace
Retainer Thrust Ring
Ring
Annually
O-Ring Replace
Rotary Turcite Bushing

GLYD Ring Annually
Wiper Seal Replace
Rotating Link
Piston Ring
Adaptor Gear Annually
Inspect
Part Replace When

Thrust Ring Less than 0.105” Stem
Annually
Turcite Bushing Less than 0.112”
Inspect
Stem O-Ring
Annually
Index Mark
Replace
LEVEL WORKING SURFACE
Direct control valve or relief valve is Inspect, repair or replace the
sticking valve
Solenoid valve not electrically operating Check electrical/valve functions
Motor worn or gear teeth broken Replace the motor
Tool Does Shot-pin engaged Adjust the relief valve

Not Rotate
Mechanical interference Inspect and repair
Test pressure left and right

Directional valve does not shift
Replace valve if necessary
Fixed valve orifice plugged Clear orifice or replace valve
Hydraulic valves damaged Replace hydraulic lines
Valve sticking or relief valve needs Test pressures & inspect valves
adjustment Adjust relief valves as required
Tool Does Not
Broken sensor Replace sensor
Return to Home
Faulty control system Check control system
Links Not
Syncronized Counterbalance valves need adjustment Adjust valves
Safety Valve Leaks Worn parts worn out Check for washouts or defective
parts and reair –replace as
needed
Actuator not functioning properly Check mechanical operation of

actuator. Check Reducing Valve
Excessive wobble Yoke bushing or actuator bushing worn Replace Bushing

or Vibration while out
rotating Worn Cam Followers Replace or renew rollers and
roller brackets
Pressure Reducing Valve plugged orifice Clear orifice or replace valve
Cylinder does not
actuate
Hydraulic valves damaged Replace hydraulic lines
Valve sticking or relief valve needs Test pressures & inspect valves
adjustment Adjust relief valves as required
Broken sensor Replace sensor
Faulty control system Check control system
Links Not
Syncronized Counterbalance valves need adjustment Adjust valves
Setting up the Circuits
Hydraulic
Motor
SV5
C5
Link Adaptor
Rotation Gear
Shot Pin
Shot pin circuit
1. Set the adjustable relief valve near the body of the cylinder.
The shot pin often misses the hole in the rotating gear.
The force the shot pin exerts is limited until the pin engages a hole.
The electrical system jogs the rotating head until the pin engages a hole.
2. To limit the amount of force, you set the valve by operating
solenoid valve SV5 manually, forcing the pin to stop on the face of the gear.
3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to
400 psi.
4. Tighten the jam nut on the relief valve.
5. At rest, the SV5 valve is de-energized.
6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi.
Shot-Pin
Torque Wrench On
Torque Wrench Off
Shot Pin
Shot-Pin Assembly Base
Dowel Pin
Dual Port
Rod Seal Manifold
Assembly
Shot Pin
Rod Seal
Assembly
Shot Pin
Sleeve
Hydraulic
O-Ring Motor
Shot Pin
Bushing
Shot Pin
Cap Pinion
Gear
Part Replace When
Shot Pin OD < 1.375” Shot Pin
Cover
Shot Pin Sleeve ID > 1.510”
Shot Pin Bushing ID > 1.475”
Torque Wrench Assembly
Manifold
Rear
Stabilizer Front
Stabilizer
Hinge Pin Spring

Retainer
Hex Head
Cylinder Screws
Head Ring
Clamp
Cylinder Body
Cylinder Head
Body Seals
Piston Seals
Jaw
Piston Assembly
Tong Dies
Wear Bushing
Hinge Pin Gate
Rear/Front
Stabbing Guides
Stabilizer
Spring Retaining Plate

Inspecting the Torque Wrench Assembly Part Replace When
Stabilizer Wear > 1/8”
Flipper Wear > 1/8”
Tugger Liner
Stabilizers (F/R)
Weekly
Inspect
Stabbing Guide
Weekly
Tong Dies Inspect
Daily
Inspect
Flippers
Clamp
Cylinder Gate Weekly
(shown open)
Swing Clear
Inspect
Inspecting Link-Tilt
Hydraulic
Manifold
Rig-Up/Run/
Shutdown Valve
Torque
Arrestor
Spring
Spring
Spacer
Spring
Shims
End Cap
Clamp
Cylinder Body
Inspecting the Torque Wrench Assembly
Stabilizer Springs
Monthly
Inspect
Stabilizer
Springs
Cotter Pin
Inspecting the Tool Lock Joints
1.4”
1.4”
1”
1”
Tool Lock Bolts

Daily
1.4”
Inspect
1.4”
Shot-Pin & Clamp Cylinder
Solenoid Valve not operating or needs Check electrical actuation &
adjustment test pressure
Shot-Pin Does
Not Release Abnormal pressure change at B5/C5 Replace Directional Control
indicates valve problem Valve
Normal pressure change at B5/C5 Repair plumbing or shot-pin

indicates plumbing or faulty cylinder cylinder
Shot-Pin Applies Relief Valve not operating or needs

Test pressures & adjust
Excessive Force adjustment
No/low pressure at cylinder Test pressures & adjust/repair
Cylinder is damaged Inspect/repair/replace cylinder
Clamp Cylinder To provide high pressure to the clamp

Does Not Actuate circuit, pressure at C5 must be 2,000psi
and G5 must be less than 100psi.
If this condition is met, pressure at CP Repair plumbing, rotating head,
should increase from less than 100psi to or clamp cylinder.
higher than 2,000psi.
If not, check the plumbing, rotating link
adapter, and clamp cylinder.i
Shot-Pin & Clamp Cylinder (contd)
While clamping, pressure at CR should be

2.7 times the pressure at CP
Clamp Cylinder When the dies contact the pipe, pressure
Does Not Actuate at CR should be less than 100psi Clean or repair CNEC valve
If the pressure does not fade, check
valve CNEC for contamination
Shot-Pin Engages Check pressure at C5. Replace

But Cylinder Control valve not operating valve CV5 if required or the
Does Not Activate regenerate manifold
Setting the Link Tilt System
Link tilt cylinder circuit

1. There is nothing to adjust on the manifold for the link tilt circuit.
2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all four
counterbalance valves fully clockwise, then one turn counter-clockwise.
i If the valves are not adjusted correctly, link tilt operation is not
synchronized.
3. The correct pressure setting is 1,500 psi. The procedure is the same for all four valves. Adjust the
valves one at a time.
4. There is a test point on each loading manifold.
5. From the driller’s console, move the link tilt to go to the mouse-hole position.
6. The cylinder goes to full extension and the pressure at the test port TP is 2,000 psi.
7. Command the link tilt to the OFF position and observe the
pressure delay at TP. This delayed pressure is the set point of the counterbalance valve.
8. Raise the valve set point by turning the adjusting screw ¼ turn counter-clockwise.
9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.
i This is an iterative process. Continue to set the driller’s console control to the mouse-hole position and
OFF, taking present and decayed pressure readings.
! Turning the counterbalance valve counteclockwise increases
the pressure.
10. Repeat the procedure above for the other cylinder at the mouse-hole position.
11. Command the link tilt to the DRILL position and repeat the
procedure above to set both counterbalance valves on the DRILL side.
Link Tilt Cylinders
Drill-Down
Mousehole
Float Position
Inspecting Link-Tilt
Cylinders
Monthly
Inspect
Pins
Bushings
Monthly
Monthly
Inspect
Inspect
Bushings
Monthly
Inspect
Link Tilt Cylinders
Elevator Does Not
Reach Mousehole Link clamp incorrectly adjusted Check & readjust
or Derrickman
Pressure at B1 does not decay Replace the pilot to open

to less than 100psi check valve
Pilot to open check valve is contaminated Replace the pilot to open

Links Drift When or stuck in open position check valve
Valve is Released
Faulty cylinder seal Replace cylinder seal
Load holding relief valves are stuck open, Replace or adjust the load
contaminated or need adjustment holding relief valve
Elevator Does Not Use manual override

If the link tilts, the problem is electrical Test the solenoid & connectors
Float Back to Test the hydraulic system
If the links do not tilt, the problem is
Center Position
hydraulic
Link Tilt Does Solenoid Valve is not shifting Check electrical continuity
Not Tilt
Links Do Not
Load holding valves need adjustment Adjust all (4) valves to 1,500psi
Move Together
Setting the IBOP SYSTEM
The IBOP is in the open position under low hydraulic pressure,

A4 = 500 psi, B4 and C4 = less than 100 psi. When you close the
IBOP, high pressure is applied to the cylinder. A4 is less than 100
psi; B4 and C4 are 2000 psi. When the solenoid is de-energized,
for opening the IBOP, A4 goes to 500 psi after a small time delay.
B4 is less than 100 psi and C4 reaches 2000 psi after a small time
delay. The time delay is operated by the time delay accumulator.
A4
PC4
C4
IBOP Actuator
IBOP Open
IBOP Closed
Rotating Head
Port A4
.055”
PC4
500psi
IBOP Actuator
Rotating Head
Port B4
.055”
Ball Valve
Seals Assembly
Inspecting the IBOP Actuator
Actuator Cylinder
Weekly
Inspect
Hoses
Daily
Inspect
Pins & Bushings Actuator Yoke

Monthly Weekly
Inspect Inspect
Part Replace When

Pins Wear > 0.3”
Bushings Metal Backing Visible
Inspecting the IBOP Valves & Saver Sub Part Replace When
Threads have been
Saver Sub recut to minimum
Upper & Lower IBOPs shoulder-to-shoulder
5 Yearly length of 5”
MPI
Upper IBOP Upper IBOP Valve

Weekly Daily
Inspect Pressure Test
IBOP Crank
Weekly
Inspect
Lower IBOP Lower IBOP Valve

Weekly Daily
Inspect Pressure Test
IBOP and Oil Pressure Switch
Hoses
Hoses
Annually
Inspect
Oil Pressure
IBOP Pressure Switch
Switch Configuration
Configuration
Wires
Pressure
Annually
Adjusting Screw
Inspect
Wires
Component Factory Setting

IBOP Pressure Switch 1500psi (102.0 bar) rising
Oil Pressure Switch 18.0psi (+0/-1) decreasing
Motor Housing
& Transmission
Adjusting the Encoder(s)
Sled Hold-Down
Screws (4)
Belt Tension
Spring
Encoder Belt Sled
Electrical
Connector
Sled
Belt Tension Sled Hold-Down

Spring Screws (4)
Internal Lubrication Flow
Pipe Plugs
Gear Drain
Monthly
Inspect
Pipe Plugs
Monthly
Inspect
Spillway
Monthly
Inspect
Inspecting Gear Backlash
Gear Backlash
6 Monthly
Inspect
Solid
Wire Solder
A B
Dim A + Dim B = Backlash

Inspecting Bail & Main Body
Bail
Annually
Inspect
Bushings (2)
Annually
Component Minimum Dimension
Inspect
Bushing ID < 4.45”
Bail Pin ID < 4.125”
Main Body Cover
5 Yearly
MPI
Main Body
5 Yearly
MPI
Bail Pin
Annually
Inspect
Inspecting S-Pipe Wing Nut
Seal Ring
Plug
S-Pipe
Monthly
Inspect
S-Pipe
Monthly
Pressure Test
Clamp
Bolts
Seal Ring
Wing Nut
Inspecting Main Shaft Liner
Wash Pipe
Assembly
Main Shaft Liner

Monthly
PolyPack Seal
Inspect
Polypack Seal
Main Shaft
Inspecting Wash Pipe Assembly LEFT HAND THREADS!
Wash Pipe Nut
Packing Box
Dowel Pin
Socket Head Screw
3” Bore Wash
Pipe Wrench
Inspecting Wash Pipe Assembly
Wash Pipe
O-Ring Daily
Snap Ring Inspect
Holding Ring
Packing Seal Upper Spacer
Wash Pipe Nut
Middle Spacer
Wash Pipe Middle Spacer
Packing Assembly Box

Lower Spacer
Straight Grease Fitting
O-Ring
Socket Head Screw
Inspecting Upper Bonnet Seals Cap Screw (6)
Bearing Shield
Bearing Bearing Retainer

Oil Seal Isolator
Cap
Bearing Screws (6)
Shield Lube Tube
Bearing
O-Ring Retainer Lube Tube O-Ring
Retainer O-Ring
Annually
Inspect
Bearing Isolator
Annually
Lube
Tube Inspect
Oil Seal
Annually
Inspect
Shims
Inspecting Main Shaft
Radial Grooves
Stem
5 Yearly
MPI
<0.65”
Split Load Collar

5 Yearly
MPI
Radial Grooves
<0.62”
Annually
Inspect
Retainer Ring
Motor Housing & Transmission
Inspecting Main Shaft End-Play
Main Shaft
Annually Dial Indicator
Inspect
Cap
Screws (6)
Bearing Retainer Shims

Inspecting Blower Motor Assemblies Loose Bolts
Monthly
Bolts (4)
Drip Shield Inspect
Fan Motor Cover
Bolts (4)
Motor Fan
Bolts (6)
Top Bearing Housing

Inspecting Drilling Motors
Motor Cables
Weekly
Inspect
Louvers
Weekly
Inspect
Screens
Weekly
Inspect
Transmission Assembly/Disassembly
Stem Sleeve
Main Body Cover
Cap Screw Taper Roller Bearing
Upper Spray Nozzles
Dowel Pin
Upper Compound Roller Bearing Lock Washer
Internal Retaining Ring Bull Gear
Compound Gear Dowel Pin

Upper Stem Liner
Internal Retaining Ring Poly Pack Seal

Spacer Ring
Lower Compound Roller Bearing
Bearing Lock Washer

Main Shaft Stem
Internal Locknut Retainer
Main Body O-Ring
Main Body
Tapered Roller
Thrust Bearing
Main Shaft Sleeve
Lower Main Roller Bearing

Lube Oil Pump Assembly Main
Bearing
Wear Sleeve
Lock Washer
Bearing
Cap Screw Retainer
Lubrication
Lubrication Schedule
Transmission
Action Frequency
Replace Gearbox Oil Following Initial Break-In Following 1st Month of Operation
Replace Gearbox Oil and Perform Oil Analysis Every 6 Months
Replace Gearbox Oil Filter Every 3 Months

Remove, Clean and Replace Magnetic Drain Plug Annually
Transmission Gearbox Drain
Sight Glass Check oil level,

Gearbox
prior to adding oil Oil Drain
(do not mistake
the tan colored
foam for the dark
brown oil)
Cork Ball
Gear Oil Filter

Pop-Up
Dirt Alarm
Gearbox Oil Fill
YEARLY
Remove and clean contamination
Magnetic Drain Plug

Hydraulics
Action Frequency
Perform Hydraulic System Analysis Every 6 Months
Replace the Hydraulic Fluid Annually (or depending on analysis)
Replace the Hydraulic System Filter Every 3 Months

Hydraulics Hydraulic Oil Filter
Pop-Up Sight Glass
Dirt Alarm
Cork Ball
Hydraulic Oil Fill
Male
Quick-Connect
Dust Plug
Hydraulic
Female Oil Drain
Quick-Connect
Hydraulic
Lubrication Kit
Motors
Action Points Frequency

Lubricate the AC Drilling Motors 4 Every 3 Months
Lubricate the Blower Motors 4 Every 3 Months
Lubricate the Hydraulic Pump Motor 4 Every 3 Months

Motors
Grease Fittings
Grease
Fitting (1/8”)
AC Blower Motors (2)
Pipe Plug
(1/8”)
AC Drilling Motors (2) Hydraulic Pump AC Motor
Grease
Fittings
General Lubrication
Action Points Frequency

Wash Pipe Assembly 1 Daily
Upper Bonnet Seal 1 Weekly
Bail Pins 2 Weekly

Rotating Link Adaptor Gear - Weekly
IBOP Actuator Yoke & Cylinder Pins 5 Daily
IBOP Actuator Cranks 2 Daily

Upper IBOP Valve 1 Weekly
Stabilizer Bushing 4 Daily
Clamp Cylinder Gate 2 Daily

Carriage Assembly 8 Weekly
Torque Arrester @ Clamp Cylinder 4 Weekly
Wireline Adaptor 2 Weekly

Elevator Link Eyes 4 Weekly
General Lubrication
Wash Pipe Assembly
Bail Pins (2) Upper Bonnet Seal
Rotating Link Adaptor Gear

General Lubrication
Upper IBOP Valve
IBOP Actuator Cylinder Pins ¼”

NPT Plug
IBOP Actuator Yoke
IBOP Actuator Yoke
IBOP Actuator Cranks Stabilizer Bushing
Torque Arrester Tubes
Stabilizer Bushing
Clamp Cylinder Gate
Clamp Cylinder Gate

General Lubrication
Rollers
General Lubrication
Wireline Adaptor
Guide Beams
& Carriage
Guide Beams & Carriage
Inspecting the Crown Padeye & Hang-Off Link Shackle
2.1” (52mm) min
Crown Padeye
Annually
MPI
Crown Padeye
Monthly 2.0”
(50mm) min
Visual
Cotter Pin
Monthly Hang-Off Link Bores
Visual
1.5”
Shackle (15mm) min
Monthly
Inspect
Hang Off Links

Monthly
Inspect
Inspecting the Crown Padeye & Hang-Off Link
Bolt Assembly Hang-Off Link

Monthly Monthly
Inspect Inspect
Bolt Assembly
Hang-Off Link Bores

2.1” (52mm) min
1.5”
(15mm) min
Safety Pin
Monthly
Inspect
Inspecting the Guide Beam Joints
Lynch Pin
Lynch Pin
Daily
Inspect
Beam Joints
Weekly
Inspect
Beam Joints
Annually
MPI
Retainer Pin
Daily
Beam Joints
Inspect
Monthly
Inspect
Inspecting the Main Tie-Back Guide Beam
All Welds All Welds Bottom Section
Annually Weekly
Alignment
MPI Inspect
Daily
Inspect
Tie-Back Plate
Main
Spreader Beam
All Bolts
Weekly
Inspect
Tie-Back Link
Bolted Connections
Auxiliary
Spreader Beam
Mast Leg
Inspecting the Intermediate Restraints
Alignment
Daily
Inspect
Studs/Nuts
Weekly
Inspect
Pin/Cotter Pin
Weekly
Inspect
Main Girt All Welds

Annually
MPI
Guide Beam
Inspecting the Carriage
Rollers
Weekly
Inspect
Detent Pins
Daily
Inspect
PH-50 Pipehandler
PH-50 Pipe Handler
Inspecting Elevator Links Recess in
Motor Guard
Rear
LIFT &
2 REMOVE
Link Tilt
Upper
Catch Link
Front
Catch Link Pin Link
26” (635mm)
Typical
Clevis
Pin
1
ROTATE
Link Clamps
Weekly
Inspect
Link Eyes
Varco
Monthly
Driller’s Console Inspect
PH-50 Pipe Handler
Inspecting Elevator Links
C
Upper Eye Lower Eye Capacity C Upper Eye
(Hook)
Dimension (C) Dimension (A) per Set (Tons)
B = 3½” (350 Ton)
5” 2 3 / 4” 350
4 13
/16” 2 9/16” 300
4 5 / 8” 2 3 / 8” 225
4 7/16” 2 3/16” 175 B
B = 4½” (500 Ton)
6” 3 1 / 2” 500
B
5 / 4”
3
3 / 4”
1
420
5 1 / 2” 3” 325
5 1 / 4” 2 3 / 4” 250
A
B = 6¼” (750 Ton)
7 1 / 2” ? ?
7 1 / 4” ? ?
7” ? ? Lower Eye
(Elevator)
6 3 / 4” ? ? A
PH-50 Pipe Handler
Wireline Adaptor
Sheaves
Each Use
Inspect
Drawings
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Safety Wiring
1 2
Safety Wiring
3 4 5
IBOP Actuator
.055”
Rotating Head
Port A4
.055”
PC4
500psi
Gearbox Lubrication System
IBOP Actuator
Rotating Head
Port A4
.055”
PC4
.010”
500psi
TDS-11S - Consumables
Hydraulic Wash Pipe
Oil Filter
Part Qty Part No.

Tong Dies 4 16781
Stabilizer - Front 1 118368
Stabilizer - Rear 1 118367
Flippers – Stabbing Guide 1 76442

Wash Pipe 1 123289
Wash Pipe Tungsten Coated 1 123289-TC
Wash Pipe Packing Kit (Standard) 1 123290-PK

Wash Pipe Packing Kit (HP) 1 123290-PK-1
Hydraulic Oil Filter 1 114416-1
Gear Gear Oil Filter 1 111013-1

Oil Filter
Stabilizers
Tong Dies
Stabbing Guide

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TDS-11S

Varco International, Inc., is proud of its part in advancing the

They are used extensively to power a variety drilling operations including

Single Speed AC - 5.3:1 @ 990hp TDS-7S 1993

Dual Motor AC - 10.5:1 @ 700hp TDS-9S 1994

Single AC - 13.1 or 4.8:1 Ratio @ 350hp TDS-10S

Dual Motor AC - 10.5:1 @ 820hp TDS-11S

• Reaming in or out in sloughing formations

 Portable & Mobile

 Low Maintenance Cost

Cooling System Gooseneck

350 or 400 hp AC Washpipe

TDS- 9/11S Power Train

102 Tooth Bull Gear

63 x 18 Tooth Compound Gear

500 Ton Swivel Overall Reduction

Air Intake Flow

Upper IBOP &

Lower IBOP Valve Torque Arrester

Main Shaft Upper IBOP

Offshore/ Hardwire 1 set (3) 646 MCM 1 x Power

Offshore/ Hardwire 2 sets (3) 444 MCM 2 x Power

Land/ Quick 1 set (4) 646 MCM

Offshore/ Hardwire 2 sets (3) 444 MCM 2 x Power

Offshore/ Hardwire 2 sets (3) 444 MCM 2 x Power

Variable Frequency Drive

AC Motor Identification Label Top Drive

26” (660mm) 36.9” (937mm) Front

Sectional Guide Beam 18.0’

Clear Working Height

Portable Torque Reaction Beam

Varco Driller’s Console

Control Cable with Connectors

Unitized Variable Frequency Drive & Drill

Insert the grounding rod into the soil (the rod

Crown Pad eye

Guide Beam Connecting/Hang off Link

Locate the Top Drive at the bottom of the

Be sure that Top Drive is pinned to

Lifting Point Net Weight = 27,000 lb (12,300 kg)

Ensure that the lower carriage latch is disengaged

Intermediate tiebacks are installed on girts

IBOP Pressure Rotating Head

Motor and Pump

Variable Fixed Lube

Manufacturer -15ºC to 75ºC -10ºC to 85ºC

Chevron AW Hyd Oil 32 AW Hyd Oil 46

Exxon Nuto H32 Nuto H46

Gulf Harmony 32AW Harmony 46AW

Mobil DTE 24 DTE 245

Shell Tellus 32 Tellus 46

Statoil Hydraway HMA 32 Hydraway HMA 46

Texaco Rando Oil HD 32 Rando Oil HD 46

Total Azolla ZS 32 Azolla ZS 46

Union Unax AW32 Unax AW46

Hydraulic Oil Fill

Drill Motor Assy.

Accumulator Setting Port