AC Top Drive

‫المؤسســــــــة الوطنيـــــــــــة لألشغــــــــــال في اآلبـــــــــار‬

ENTREPRISE NATIONALE DES TRAVAUX AUX PUITS

General Information

Preparé Par : L’ Ingenieur Souici

 TDS-11S Top Drive
Counterbalance
Motor Cooling System
System
System
Bail

AC Drilling
Motors (2) Gooseneck
(S-Pipe)

Transmission/
Washpipe Motor Housing
Assembly

Rotating Link
Adapter

Sectional
Guide PH-50
Beam Pipehandler
 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)
 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
 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 - 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
 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 Power Train
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
 Transmission Housing
Pinion
Gears

Spur
Gears

Transmission Bull Gear

Motor Housing
Main Body

Main Shaft
Assembly
 Motor Cooling System
5 HP AC
Motors
Centifugal
Blowers

Air AC Drilling
Ducting Motors

Air Flow

Intake Air Flow

(Between Motor and
Brake Housing

Louvers

Exhaust
Air Flow
AC Drilling Motor Brakes
Caliper
Mounting Bolts (2)
Steel Plate

0.09” Calipers & Pads

Monthly
Adjust

Inspect

Brake Pads

Caliper
Mounting Bracket
Ac Drilling Motors

Motor Cables
Weekly
Inspect

Louvers
Weekly
Inspect

Screens
Weekly
Inspect
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
Motor Housing & Transmission
Inspecting Motor Brakes

Caliper
Mounting Bolts (2)
Steel Plate

0.09” Calipers & Pads

Monthly
Adjust

Inspect

Brake Pads

Caliper
Mounting Bracket
 PH-50 Pipe Handler
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

le
ho

an
se

i ckm
ou
M

Der r
Drill Stem Assembly

Main Shaft Upper IBOP

Actuator Cylinder
Assembly
Tool Joint
Clamps (3)
Upper IBOP
& Dual Crank
Actuator

Lower IBOP
(Manual)
Saver Sub
Counterbalance System

Counterbalance
Cylinders

System
Bail
 On-Board Hydraulics
Specifications
Reservoir Capacity 25 Gallons
Hydraulic Oil Counterbalance
Filter Manifold Pump Motor 10hp, 1,800rpm
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 Piphandler Clamp
Cylinders Cylinder
Counterbalance
Accumulator Link-Tilt
Manifold

Counterbalance Rotating Head

Cylinders

Shot-PinRotating Link
Rotating Cylinder Adaptor Lift
Head Motor

Lube Oil
Counterbalance Distribution
Manifold
Variable Fixed Lube
Main Hydraulic Manifold
Displacement Displacement Oil Pump
Pump Pump
Hydraulic
Accumulator

Accumulator

Motor
System

Sump
M
IBOP

10hp AC Reservoir
Motor
Hydraulic System Maintenance
Blower &
Brake Covers

Oil Heat
Oil Heat Exchanger Exchanger
Monthly
Inspect

Drill Motor Assy.

(LHS)
Lube Oil System
Hydraulic System Maintenance
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
 Brakes On

PC1
Adjust Point
B1 Test Point
 Hydraulic System Maintenance
Setting up the Circuits
PC1

Manifold
Side View

B1

Manifold
Bottom View
 Hydraulics Troubleshooting
Brakes
Problem Probable Causes Remedy
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
 Electrical Interface

DC Top Drive
Generator
Encoder

Drilling Motors
Mast
Saddle
or Generator Set

Varco Control House

AC Highline

Electrical
Panel
Service Solenoids

Sensors
Loop Junction
Box

Varco
Skid
Driller’s
Console
 Varco Drillers Console
Top Drive Speed/
Torque Controls
Make-Up Current Throttle R.P.M.
Limit Potentiometer Gauge

Torque
Gauge

Emergency
Stop Drill Current Limit
Pottentiometer
Forward/Off/Reverse
Drill/Spin/Torque
 Electrical Interface

DC Varco Top Drive

Generator Control
House Encoder

Drilling Motors
Mast
Saddle
or Generator Set

Varco Control House

AC Highline

Electrical
Panel
Service Solenoids

Sensors
Loop Junction
Box

Varco
Skid
Driller’s
Console
 Varco Control House

Variable Frequency Drive (VFD) Motor Starters

Siemens 70 Series Drive Auxiliary Motors

Plug
Panel

Door

Programmable Logic Controller (PLC) Air Conditioning Unit

Siemens Step 7 PLC 5 Ton Units
Single or Dual
 Drive Details

2700
Output Current
860A Continuous
1165A For 60 Seconds

2363
Output KW
630 KW
 AC Motor &
Variable Frequency
Drive
Alternating Current Motor

Rotor Assembly
(Laminated)

Stator Assembly
VAR3 Construction

Motor Shaft
 Rotor Construction
•Squirrel Cage Most Common
•Rotor consists of Stack of Steel Laminations with evenly
•spaced conductor bars
 Stator Principles
•Rotating Magnetic Field produced in Motor
Stator windings

•Number of Poles is depending by how many

times a phase winding appears

•TDS-9, 10 and 11,

4 Pole (2 pole pairs)

2- Pole Stator
Windings.
•TDS-8,
6 Pole (3 pole pairs)
 Rotating Magnet
•No direct electrical connection between Stator and Rotor
•To visualize how a Rotor works, substitute a
Magnet for the Squirrel cage Rotor
•Magnet Field interacts with rotating Stator Field
•North Pole of Stator attracts South Pole of Magnet
•Magnet follows rotating Magnetic fields

2- Pole Stator
Windings.
 Synchronous speed
Speed of Rotating Magnet Field Refereed to as Synchronous
Speed (Ns).
Equal to 120 Times the Frequency (F) Divided by the
Number of Poles.
 Rotating Magnet

C
 Variable Frequency Drive
600 VAC
3-phase, 42-62Hz Resultant DC Pulse 780 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

 Variable Frequency Drive
600 VAC
3-phase, 42-62Hz Resultant DC Pulse 780 VDC
AC Power

Capacitors
Rectifier
Source

DC Bus

Variable Frequency Drive

DC Bus Input to Inverter
and DC Bus Fuses
 Variable Frequency Drive

780 VDC

IGB Transistors
Source
Power
AC

Mounted Behind
Capacitor Banks
On Heat Sink

Inverter Controller
(CUVC Card)

Variable Frequency Drive

CUVC Card
 Variable Frequency Drive
IGD8 Board
Fibre Optic Drive HeatSink
Connections

Fibre
Optic
Cables

Power
Connections

IGBT’s On Heatsink
IVI Board 4 Off Each Phase
(12 Total)

CUVC Card
 Variable Frequency Drive
•Insulated Gate Bipolar Transistor
Collector Emitter

Mounting
Bolts
Holes (6)
for mounting Gate
IGBT to
Heat Sink
Variable Frequency Drive
•Insulated Gate Bipolar Transistor
•Provides High Switching Speed Required by PWM’s

•Capable of Switching On and Off Several Thousand Times a Second

•Turn ON in Less Than 400 Nanoseconds

•Turn OFF in 500 Nanoseconds

•When a Positive voltage

(typically +15 VDC) is applied to the Gate
, the IGBT will turn ON, Current Flow
this is similar to closing a switch

+15 VDC
Variable Frequency Drive
•Insulated Gate Bipolar Transistor
•Provides High Switching Speed Required by PWM’s

•Capable of Switching On and Off Several Thousand Times a Second

•Turn ON in Less Than 400 Nanoseconds

•Turn OFF in 500 Nanoseconds

-15 VDC

•When the positive voltage is removed,

the IGBT will turn OFF, during the OFF
state a Negative voltage is applied
(typically -15VDC) to prevent the device
from turning ON.
Variable Frequency Drive
•Developing a basic AC Output
•Switches replace the IGBT’s

•A voltage that alternates between positive and negative is developed by

opening and closing switches in a specific sequence
 Variable Frequency Drive
•During Step 1 and Step 2 A+ and B- are Closed, the A-B Output voltage is Positive
•During Step 3 A+ and B+ are Closed, the A-B Output voltage is Zero

•During Step 4 A- and B+ are Closed, the A-B Output voltage is Negative

Adding Sine Wave,

shows how AC Output
is Simulated

•The Voltage is dependant on the value of the DC Voltage

•The Frequency is dependant on the speed of the Switching

 Variable Frequency Drive
•The Voltage and Frequency is controlled electronically by circuitry within the AC Drive

•The fixed DC Bus Voltage of 780 VDC is modulated or clipped with this
method to provide a Variable Voltage and Variable Frequency Output

•At Low Output Frequencies a

Low Output Voltage is required,
780 VDC
the IGBT’s are turned on
for Shorter periods of time.

•At High Output Frequencies a

High Output Voltage is required, 780 VDC
the IGBT’s are turned on
for Longer periods of time.
 Inverter Cooling Fan

Air Blown Out

at Top of
Inverter
Inverter
Cooling
Fan

Air Drawn In
at Bottom of
Inverter
 OP1S
Fault LED
230.5A
0.0A 780V
478VDC
Inverter Faulted 00.00
20.56HzHz
DC Link Undervoltage
00.00
20.14HzHz
Operation
Ready On
F008
Consult Manual

Run LED
Flashing – Ready to Go
Constant – Inverter in Operation
3 x Hz = Main-shaft RPM
i.e. 20hz = 60 RPM
 OP1S

0.0A 780V DC
00.00 Hz
00.00 Hz
ReadyInhibit
Drive On

No LED
Emergency Stop Activated
Siemens Manual
Faults Information
Siemens Manual
Fault F008

DC Link Undervoltage
Siemens Step 7 PLC
 Understanding PLC’s

CPU
Input Output
Module Module
Central
Processor
Unit

Programming Device
 Understanding PLC’s

Switch TEST CIRCUIT

Lamp
Battery
Closes Turns On

9V
BLACK
BOX
 Understanding PLC’s

Switch Lamp
THIS COULD BE A PLC
Closes Turns On

BLACK BOX
BLACK BOX
9V 9V
INPUT OUTPUT

Battery
Battery
Relay Energizes
and closes contact
Understanding PLC’s

INPUT OUTPUT
CPU
RUN

STOP

RUN

STOP
GND GND
 Understanding PLC’s
OUTPUT LIGHT COMES ON
SWITCH
CLOSES
INPUT CPU POWER OUTPUT
SUPPLY
RUN

ON
STOP 24V
24V
+ 24 V
RELAY
RELAY
RUN OFF

STOP
GND GND

INPUT LIGHT COMES ON

FLOW
Understanding Ladder Logic

Start/Stop Motor Circuit

Understanding Ladder Logic

Start button pressed Motor starts

Understanding Ladder Logic

Hold on contact keeps motor on when start button released

Understanding ladder Logic

Stop button pressed Motor stops

Understanding Ladder Logic

Awaiting Input
Siemens Step 7 PLC
Back-Up Battery
Flash EEPROM Memory Card
Training
AC Top Drive Training

•Mechanical Courses 3 days

•Electrical Courses 3 days

•Combination Courses 5 days

•Varco UK in Aberdeen

•Onsite at customer location

•AC Top Drive Simulator can be shipped to customer location

 Course Content
•Varco Company overview including service and spare parts
•System overview and development
•Top Drive major components

•Operating procedures
•Hydraulic system set up procedures
•Disassembly and assembly of major components
•Program Logic Controller
(use the control system PLC to program and troubleshoot the Top Drive Simulator)

•Control System (theory of operation, VFD, interface)

•PLC to VFD interface use simulator

•Maintenance of system
•Course review & exam
 Maintenance
Preparé Par : L’ Ingenieur Souici
Maintenance Charts
Spare Parts
Recommended Spares
QTY VARCO P/N DESCRIPTION

VFD
2 116199-14 FUSE, 250V, 30A
4 116199-15 FUSE, 1000V, 630A
2 116199-25 FUSE, 2A
2 116199-26 FUSE, 800V, 800A
1 116199-27 FUSE, 250V, 7A
2 116199-46 FUSE, 600V, 30A
1 116199-48 FUSE, 250V 1/2A
1 116199-49 FUSE, 250V, 2A
1 116199-77 CPB BOARD, AC INVERTER
1 116199-75 CUVC AC INVERTER
1 116199-34 DIGITAL TACH INTERFACE CARD
Recommended Spares
PLC
1 122627-09 MODULE, 16PT, 24VDC, INPUT
1 122627-18 MODULE, 8PT, 24VDC, OUTPUT
1 122627-45 REMOTE I/O, 4PT ANALOG
1 122627-46 REMOTE I/O, DIGITAL, 24 IN, 8 OUT
1 122627-47 REMOTE I/O, ANALOG
1 122627-54 FUSE, 2.5A, 250V
1 122627-55 FUSE, 1.6A, 250V
1 122627-57 BASE, ANALOG
1 122627-58 BASE, DIGITAL
1 122627-64 MODULE, 16PT, OUTPUT
Recommended Spares

VDC
1 96920 PCB +5VDEC REGULATOR
1 116551 RHEOSTAT ASSY, IDM CONTROLS
2 117952 ENTRELEC SINGAL CONVERTER
2 81736-2 POTENTIOMETER, 10K
1 87708--02 SWITCH, PUSHBUTTON
1 87708-26 SWITCH, 2 POS MAINTAINED
2 87708-30 SWITCH, 3 POS RETURN TO CENTER
1 87708-33 SWITCH, SPRING RETURN FROM RIGHT
1 87708-36 SWITCH, 3 POS MAINTAINED
1 87708-46 TORQUE POT OPERATOR
1 87708-67 E-STOP OPERATOR
2 91548-2 INDICATING LIGHT, RED
Recommended Spares

ELECTRICAL, GENERAL
1 115299 ENCODER, DIGITAL, BEI
1 120357 ENCODER BELT DRIVE ASSY
1 122243 ENCODER PIGTAIL ASSY
1 124457-200-25-4-B SRVC LOOP, AUX POWER
1 122517-200-25-3-B SRVC LOOP, CONTROL
1 127908-D2 SOLENOID, SINGLE
1 127908-J2 SOLENOID, DOUBLE
1 79386 PRESSURE SWITCH, AIR
1 87542-1 PRESSURE SWITCH, OIL
1 83095-1 PRESSURE SWITCH, IBOP
Recommended Spares
HYDRAULIC
1 109542 PUMP, HYDRAULIC PISTON
1 110023 FLEX COUPLING
1 112640 PUMP ADAPTOR
1 114375 HYDRAULIC MOTOR (ROT HEAD)
1 117846 MANIFOLD ASSY (LT CYL)
1 117865 MANIFOLD ASSY (LT CYL)
1 124191 HOSE, MAIN SUPPLY
1 107028-1ANB DIFFERENTIAL UNLOADING (UV1)
1 107031-1AN CARTRIDGE VALVE (RV1)
1 107783-5C11R PUMP, HYDRAULIC VANE
1 109302-130NC CARTRIDGE, FLOW CONTROL (CLAMP)
1 109858-1AN CARTRIDGE VALVE (PC1)
1 110161-49S PUMP, GEAR OIL
1 110191-501 BLADDER, HYDRAULIC
3 111013-1 FILTER, GEAR OIL
1 111664-1EN CARTRIDGE VALVE (SJR)
3 114416-1 FILTER, HYDRAULIC
1 13547-1B30N PILOT TO OPEN CHECK (LT CYL)
1 93548-1S30N CARTRIDGE, CHECK VALVE (IBOP)
1 94518-13HN COUNTERBALANCE VALVE (LT CYL)
2 94520-1AN VALVE, RELIEF (ROTATING HEAD)
1 94520-1NN CARTRIDGE VALVE (RV2)
1 94522-1EN VALVE RELIEF, SHOT PIN
1 94534-1CXN LOGIC CARTRIDGE (LB6, LA6, LC5)
1 94536-14N CARTRIDGE CHECK VALVE (CDR)
1 94536-230N CARTRIDGE CHECK VALVE (CTF)
1 94537-130N CARTRIDGE, CHECK (CLAMP)
Recommended Spares

PIPE HANDLER
8 16781 TONG DYES
2 71847 IBOP ROLLERS
2 98898 EXTERNAL CRANK ASSY
4 121789 RING, WEAR
4 122367 U-BOLT, 500 TON
4 119139 U-BOLT, 350 TON
8 50412-C LOCK NUT
Recommended Spares
GENERAL
5 53201 GREASE FITTING, 90 DEGREE
5 53209 GREASE FITTING, SHORT
1 91249 WASH PIPE, 5000 PSI
1 109528 BRAKE, CALIPER DISC
3 123292 WASH PIPE PACKING
1 30123290 WASH PIPE ASSY, 3" BORE
1 301232289 WASH PIPE, 3" BORE
4 109528-1 PADS, BRAKE FRICTION
4 109582-3 SPRING, HEAVY DUTY
5 123292-3 PACKING SEAL KIT
2 51300-017B O-RING
1 51300-038-B O-RING
3 51300-153B O-RING
5 51300-220F O-RING
1 51300-223F O-RING
2 51300-246B O-RING
3 51300-278B O-RING
1 51300-386F O-RING
13 53219-1 GREASE FITTING, DRIVE IN
2 53219-2 GREASE FITTING, LONG
Gearbox lubriction