Training Manual

Top Drive Training Manual
Company Owner
Varco Technical Education Centre Montrose Scotland
TOP DRIVE Training Manual
Description
Training Manual
Installation
Chapter 1 Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up has been accomplished prior to installation of the TDS. This includes: 1. Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances (Figures 1, 2, and 3). 2. Stops are ready for installation at the bottom of the rails. 3. Hydraulic and air standpipes are installed in the derrick, flushed clean and pressure tested. Water piping is installed, flushed and pressure tested as well for configurations with closed loop cooling systems. 4. All electronics are installed up to the derrick junction box: DC power leads, AC leads for blower motor, and control/ alarm signals. 5. The transfer panel is installed. 6. Rigging of the tong lines, etc. are inspected to ensure that they will not foul with the TDS and other rig equipment.
Training Manual June 99
Chapter 2 Installation
Derrick electrical termination kit

Installation
Refer to Figures 1, 2 and 3 for typical mounting dimensions of the plate assembly. Mount it at racking board height within 15' of the service loop support bracket. Remember to provide convenient access for wiring and maintenance. Usually, mounting the plate so that the J-box is four to five feet above the walk-around and near the service loop support bracket is adequate. If a walk-around does not exist, then construct a work platform to allow access to the J-boxes. Manufacture appropriate brackets and clamps to attach the plate to the derrick structure.
C L RAIL
1/4" OVER FULL LENGTH 3/8 1/8"
C L RAIL OVER FULL LENGTH WITHIN 25' OF FLOOR
C L RAIL C L WELL
C L RAIL
3/8" OVER FULL LENGTH 1/8" WITHIN 25' OF FLOOR C L WELL
TDS BACK OPERATIONAL CLEARANCE BETWEEN TOP DRIVE & NEAREST GIRT OR FASTLINE SHOULD BE 3 MINIMUM
GUIDE RAILS
NEAREST GIRT
SPLICE CLEARANCE SPLICE PLATES OR BOLTS ARE NOT PERMISSABLE ON INSIDE SURFACES OF BEAM DOLLY OVERHANG
MAXIMUM RAIL SUPPORT SPACING 16 FT FOR W12x53 RAILS 25 FT FOR W14x74 RAILS
6" RAIL STOP

GUIDE DOLLY CONFIG SPLICE DOLLY CLEAR OVERHANG INCHES
RAIL SIZE
10' 6" +0"/-4"
39 X 66 48 X 62 30 X 72 30 X 72
W14X74 W14X74 W12X53 W14X74
3.3 3.3 3.3 2.3
0 0 1.6 0.5
DRILL FLOOR C L WELL
Figure 1. General rail installation data
16.0 DERRICK J-BOX PLATE CLEARANCE HOLE FOR .75 DIA BOLT 4 PLACES
INSTRUMENT J-BOX ** MOTOR J-BOX ** BRACES *
16.0
CONVENIENT WORKING HEIGHT ABOVE WALKAROUND 16.0
B
16.00 MUST SUPPORT 4000 LBS
ELECTRICAL SERVICE LOOP ** HYDRAULIC STANDPIPES TO BE 1-1/2 SCHED 80 PIPE* AIR STANDPIPES TO BE 1-1/2 SCHED 40 PIPE* WATER STANDPIPES TO BE 2 SCHED 40 PIPE*
A
86 FT. SERVICE LOOPS
VIEW A-A TYPICAL SERVICE LOOP TERMINATION
A
GUSSETS *
75 FT. MUD HOSE REF
73 FT. MUD HOSE CONNECTION
EXISTING GIRT *
SERVICE LOOP BRACKET**
VIEW B-B
83 FT. HYD, AIR & WATER STANDPIPE HEIGHT & SERVICE LOOP BRACKET LOCATION * CUSTUMER SUPPLIED ** VARCO SUPPLIED
10' 6"+0"/-4"
7 FT REF
TYPICAL EQUIPMENT STACK-UP
Figure 2. Derrick services/general installation data
Motor Frame Setback L P 9'3" TDS-3S 10'3" TDS-4S P Rail Stops 42,600 LBS for a typical TDS-3S 48,000 LBS for a typical TDS-4S 52,000 LBS for a typical TDS-7S 7'0" TDS-3S 8'0"TDS-4S, TDS-6S L
Rails
Rail Loading with TDS in Setback position Load P - LBS Rail Spacing 39 x 66 48 x 62 30 x 72 TDS-3S 18,600 18,600 17,500 TDS-4S 18,900 18,900 17,800
Rail Loading while Drilling - 38,000 FT LBS for TDS-3S, 60,000 FT LBS for TDS-4S, 68,000 FT LBS for TDS-6S, and 34,000 FT LBS for TDS-7S. Load L - LBS Rail Spacing 39 x 66 48 x 62 30 x 72 91/101 x 108 TDS-3S 3450 3680 3170 -TDS-4S 5450 5800 5000 3330 TDS-6S ---3780 TDS-7S 3090 3290 2840 --
Figure 3. General installation data

Motor Frame Setback L
Rails
L 10'3" TDS-4H 7'0"TDS-4H, L L 48,000 LBS for a typical TDS-4H
Rail Stops
Rail Loading with TDS in Setback position Load P - LBS Rail Spacing 39 x 66 48 x 62 30 x 72 TDS-4H 18,900 18,900 17,800
Rail Loading while Drilling - 60,000 FT LBS
Load L - LBS Rail Spacing 39 x 66 48 x 62 30 x 72 91/101 x 108 TDS-4H 5450 5800 5000 3330
Figure 1c. General installation data (cont.)
Wiring
The electrical installation requires routing power to the transfer panel and then to the TDS through the service loops (Figure 4). In addition, control cables are required between the service loop, the transfer panel, the SCR, the TDS drillers console, the SCRs drillers console, the hydraulic and water pumps and the drilling recorder.
Derrick Power J Box #6AWG/2C* Shunt Field #16AWG/10C #12AWG/20C #10AWG/4C #14AWG/2 Pr Shld #6AWG/2C* Shunt Field Derrick A.C. J Box
Service Loop
Transfer Panel
(4)646MCM* SCR Room

#14AWG/2 Pr Shld #12AWG/3C #14AWG/2 Pr Shld #12AWG/3C #14AWG/37C #12AWG/20C #12AWG/20C #16AWG/10C #12AWG/20C
Top Drive System
#10AWG/4C E/P Torq AC Power E/P RPM

#10AWG/4C #10AWG/4C #6AWG/4C #6AWG/4C
Existing Power Cables
Rotary Table
RBS Controls
#12AWG/3C
#16AWG/10C
TDS Driller's Console HYD Pump #1 HYD Pump #2 #16AWG/10C #16AWG/10C
Existing Driller's Console
Water Pump #1
Water Pump #2
Figure 4. Typical cabling diagram

#16AWG/10C
The cable requirements, depending on options selected are: Cable 646MCM (4 Shunt) (8 Series) #6AWG/2C (Shunt only) Runs SCR room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary SCR Room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary AC Power to hydraulic pumps AC Power to water pumps AC Power to transfer panel Transfer panel to derrick J-box Transfer panel to derrick J-box Transfer panel to hydraulic pumps Transfer panel to water pumps Transfer panel to RBS unit Transfer panel to drillers console RBS unit to drillers console Transfer panel to drillers console Transfer panel to derrick J-box Transfer panel to drillers console Transfer panel to drilling recorder Transfer panel to SCR console Transfer panel to SCR room
#6AWG/4C #10AWG/4C
#12AWG/20C
#12AWG/3C
#14AWG/37C #14AWG/2PR SHLD
#16AWG/10C
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 Purge control unit to transfer panel Drillers console protection unit to isolation unit Transfer panel to derrick J-box
#16AWG/10C #14AWG/2PR SHLD
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.
Plumbing
The plumbing connections should terminate near the service loop bracket. The mating halves are preassembled on the service loop. Specifications for specific lines are described in the following sections.
Hydraulic
Hydraulic lines should be cleaned and pickled, black pipe lines (one pressure and one return) 1 1/2" or 2" schedule 80 pipe. Install shut-off valves at the drill floor or racking board level. The derrick connections are reduced to 1" NPT female pressure and fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1" or 1 1/2" pipe in the case of the purge supply for the TDS. Install a shut-off valve at drill floor or racking board level. The air lines connect to the filtered and lubricated supply. The derrick connections are reduced to 1" NPT female for the purge line (if required) and 1/2" for the air line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean, dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2" pipe. Install shut-off valves at the drill floor or racking board level. See the cooling system specifications for water supply requirements. The derrick connections are reduced to 1 1/4" NPT female pressure and return for connection to the fluids service loop.
September 16, 1996
Rig-up procedure
z
Refer to the engineering drawings to install the TDS. 1. Change out the swivel bail pins with the longer ones supplied (Figure 3). A welder may be required to weld in the pin retainers, depending on the manufacturer of the swivel.
Unless a new or recently-overhauled swivel is used, the old bail pins may need to be machined out. 2. Install the nipple and female union sub for the S-tube onto the swivel gooseneck. 3. Hang the swivel from the hook or block and makeup the main shaft to the swivel stem using a thread compound of 60% lead by weight (Refer to the IBOP Service Manual included as a separate book in this manual for torque specifications).
Generally, a swivel saver sub is not used unless a crossover sub is required. The connection on the main shaft is 7-5/8 API regular left hand. The bail bumper on the swivel faces the guide rails. On some swivel/rail setback combinations, the bumper side ears may require trimming to clear the motor guide dolly. 4. Loosely install the bearing shield around the flange on the main shaft with the T-bolt clamp supplied. After the main shaft is stabbed into the quill shaft, adjust the shield and tighten the clamp.
16
TDS-4H Installation and commissiioning
September 16, 1996
5. Use the four lift slings from the crane, one attached at each corner of the guide dolly, to lift the top drive motor and dolly assembly onto the rig floor. If possible, set it on the rig floor with the crane - do not drag it up the V-door. Position it on the rotary table with the swivel end under the guide rails. The slings must be a minimum of 15' long (equal length) and capable of lifting 40,000 lb combined. (BOP lift slings are usually adequate.)
Figure 3. Swivel assembly
TDS-4H Installation and commissioning
17
September 16, 1996
6. Attach lifting slings to the pad eyes located at the swivel end of the motor frame and lift the TDS into the guide rails.
On some configurations it may be necessary to remove the upper roller brackets from the dolly to allow the unit to engage the guide rails. 7. Once the TDS is fully engaged on the guide rails, install the stops at the bottom of the guide rails and lower the TDS onto the stops. 8. Apply a liberal amount of grease to the main shaft from 6" below the splines up to the top flange. Also grease the top and bottom 18"of the quill shaft I.D. Pack both the main shaft and bull gear splines flush with grease. Check the O-ring in the groove located 12" inside the quill shaft to be sure it is greased and located properly. 9. Spread apart the swivel links and stab the swivel/main shaft through the quill shaft with care, until the drive splines are fully engaged. Slide the swivel links onto the extended bail pins and install the retainers with the bolts, lockwashers and safety wire supplied. 10. Slide the link adapter onto the main shaft and support it up against the rotating head with adequate rigging and an air winch. Be certain that the link tilt mounting bosses are opposite from the torque wrench mounting clevis on the rotating head. 11. Slide the landing collar retainer onto the drive stem as shown in Figure 4. Install the O-ring in the uppermost groove on the stem. Load the O-ring and remaining grooves with a waterproof grease. Place the split landing collar around the grooves of the drive stem, and drive in the remaining roll pin. Grease the O.D. liberally, and slide the retainer down, covering the split landing collar. Use a hammer and drift to bend all 32 tabs on the retainer to secure the split landing collar. Wipe off excess grease. 12. Use the pipehandler to tighten the connection between the lower IBOP/saver sub assembly to the upper IBOP.
18
September 16, 1996
Landing Collar Retainer
Landing Collar Retainer Tabs O-Ring Drive Stem Roll Pin (4)
Split Landing Collar (2)
Safety Link (4)
Figure 4. Landing collar installation
19
September 16, 1996
13. Pull up on the release handle and unlock the rotating head. Rotate the link adapter and the rotating head so that the mounting point for the torque wrench is at the front of the tool. Raise the torque wrench with the air winch and pin into place. Adjust hanging position per the procedure described in Book 4. Rotate the pipehandler assembly to the rear and connect the two air hoses and two hydraulic hoses. Quick disconnects on the hoses allow connection in only one way so that the hoses cannot be interchanged. 14. Connect the hose to the back of the link tilt actuator. Use the four bolts, lockwashers and safety wire provided to install the link tilt acutator to the link adapter. Connect the opposite end of the hose to the quick disconnect on the rotating head assembly. 15. Install the elevator links and drill pipe elevator. Attach the link tilt clamps to the bails (U-bolts on the inside). Allow for 1/2" slack in the chains. 16. Install the counterbalance system as follows (Figure 5): a. Install pear links to ears on hook-block. b. With the hook supporting the top drive, measure distance from bottom of pear link to top of mounting lug on swivel link (Dimension A). c. Subtract 37 1/4" from dimension A. d. Cut chain to the length obtained in step c (measure inside chain links per illustration). The tolerance is: +3 1/4"/-0". e. Assemble remaining components and install per the illustration.
20
September 16, 1996
Figure 5. Counterbalance system
21
September 16, 1996
17. Attach the service loops to the bracket on the top drive frame. Use the cable clamps provided on the motor frame to route the electrical cables over the gear box and into the junction boxes. The front guard swings aside for access to the junction boxes by removing the attachment bolts on one side. Use the electrical schematic (refer to the engineering drawings) to make the connections. 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. 18. Attach the S-tube to the swivel gooseneck and the side of the motor frame as follows (Figure 6): a. Makeup the upper union just before clamping S-tube to side of motor frame. b. Install the drill pipe rubber onto the S-tube aligned with mounting saddle on the frame. c. Attach the mud hose to the bottom connection of S-tube. d. Position 15 S-tube elbow on bottom of S-tube to adjust the hanging direction of mud hose.
22
September 16, 1996
Figure 6. S-Tube installation
23
August 22, 1997
Rig-up procedure z
Refer to the engineering drawings to install the TDS. 1. Using four lift slings from the crane, one attached at each corner of the guide dolly, lift the TDS motor and dolly assembly to the V-door. 2. Attach the lifting slings from the hook or block to the pad eyes located at the swivel end of the motor support bonnet and lift the TDS into the guide rails. The slings must be a minimum of 15' long (equal length) and capable of lifting 40,000 lb combined. (BOP stack lift slings are usually adequate.)
On some configurations it may be necessary to remove the upper roller brackets from the dolly to allow the unit to engage the guide rails. 3. Once the TDS is fully engaged on the guide rails, install the stops at the bottom of the guide rails and lower the TDS onto the stops. 4. Slide the link adapter onto the drive stem and support it up against the rotating head with adequate rigging and an air winch. Be certain that the link tilt mounting bosses are opposite from the torque wrench mounting clevis on the rotating head. 5. Slide the landing collar retainer onto the drive stem as shown in Figure 5. Install the O-ring in the uppermost groove on the stem. Load the O-ring and remaining grooves with a waterproof grease. Place the split landing collar around the grooves of the drive stem. Grease the O.D. liberally, and slide the retainer down, covering the split landing collar. Use a hammer and drift to bend all 32 tabs on the retainer to secure the split landing collar. Wipe off excess grease. 6. Use the installation procedure in the IBOP Service Manual (included as a separate book in this manual) to install the pipehandler assembly. 7. Use the pipehandler to tighten the connection between the lower IBOP/saver sub assembly to the upper IBOP.
16
TDS-4S Installation
Landing Collar Retainer
O-Ring Landing Collar Retainer Tabs
Drive Stem Split Landing Collar (2)
Figure 5. Landing collar installation
TDS-4S Installation
17
August 22, 1997
8. Connect the hose to the back of the link tilt actuator. Use the four bolts, lock washers and safety wire provided to install this assembly to the link adapter. Connect the opposite end of the hose to the quick disconnect on the rotating head assembly. 9. Install the elevator links and drill pipe elevator. Attach the link tilt clamps to the bails (U-bolts on the inside). There should be about 1/2 inch slack in the chains. 10. Install the counterbalance system as illustrated in Figure 6. When using chain, use the following procedure to determine the chain length required: a. Install pear links to ears on hook-block. b. With the hook supporting the TDS, measure the distance from the point of contact inside the pear link to the top of the mounting lug on the integrated swivel bail. c. Subtract 37 1/4" from the measurement in step b. d. Cut the chain to the length obtained in step c. The tolerance is: +3-1/4" or -0". e. Assemble remaining components and install per Figure 6.
Connecting Link Counterbalance Manifold (On Guide Dolly)
Pear Link Hydraulic Accumulator (Inside Motor Frame)
Motor Frame & Guide Dolly Assy. Counterbalance Cylinder Assy. (2) Counterbalance Lug (Bolted to Bail) Integrated Swivel Bail
Figure 6. Counterbalance system

18 TDS-4S Installation
11. Attach the service loops to the bracket on the TDS dolly frame. Using the cable clamps provided on the motor support bonnet, route the electrical cables over the gear box and into the junction boxes. The front guard folds down for access to the junction boxes. Use the electrical schematic (refer to the engineering drawings) to make the connections. 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. 12. Attach the S-tube to the swivel gooseneck and the side of the motor frame as follows: a. Make up the upper union just before clamping the S-tube to the side of the motor frame. b. Install the drill pipe rubber onto the S-tube aligned with the mounting saddle on the frame. c. Attach the mud hose to the bottom connection of the S-tube. d. Position the 20 S-tube elbow on the bottom of the S-tube to adjust the hanging direction of mud hose. 13. 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.
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.
TDS-4S Installation
19
August 22, 1997
Counterbalance system
Figure 6 illustrates the installation arrangement for this system. Please see the Maintenance and troubleshooting book for the adjustment procedures. This assembly is pre-charged when it is shipped by land or water transport. When this assembly is shipped by air freight, it must be pre-charged according to the instructions inthe Maintenance and troubleshooting book.
20
TDS-4S Installation
Motor alignment cylinder system

Figure 7 shows the motor alignment cylinder installed on a typical motor frame. The split shipping brace, shown exploded from the cylinder rod, is only removed after unit is fully installed. If the brace is removed before the hydraulic system is powered, the motor will tend to rotate on its trunnions. If the cylinder is removed for service, use the three bleed holes (located along the top of the cylinder barrel) to remove trapped air from the cylinder before operating the unit. Refer to the Maintenance and troubleshooting book for the adjustment procedure, as this dimension can vary.
Split Shipping Brace
Motor Alignment Cylinder
Motor Frame Dolly (Ref)
Figure 7. Motor alignment cylinder
TDS-4S Installation
21
August 22, 1997
Drillers controls and instrumentation

The controls and instrumentation described in the following sections are, or must be, supplied for operation of the TDS system.
Drillers console
Mount the drillers console within easy reach and in plain view of the driller while he is operating the drawworks brake and clutches. 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 not using an independent rotary drive, then these controls must be added by the SCR manufacturer.
Wiring
Refer to the electrical schematics in the engineering drawings.
Customers who choose to use control systems 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 or damage to the system. Other systems must meet Varco requirements. Varco highly recommends the use of its system as it is specifically made for use with the TDS system.
Service loops
Installation
Install the service loops as follows: 1. Fabricate the appropriate brackets and clamps to attach the service loop mounting bracket to the derrick structure. 2. Place the service loop derrick mounting bracket at the height specified on the derrick interface drawing provided in the engineering drawings. Locate the bracket on the side of the derrick adjacent to the hinges on the TDS and as far as practical toward the corner where the guide rail bracing is attached. The bracket must be located far enough from the corner to insure the loops do not catch under the guide rails during operations, but far enough back to provide clearance for tong lines, the stabbing board, tugger lines, etc. 3. Do not unpack the service loops from the shipping protective crate until they are ready to hang in the derrick. Lift the service loops onto the rig floor (still in the crates) and then remove them from the crates with the lifting eyes provided.
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 lift using the lifting eyes only. Allow enough room for the 86-foot long service loop to hang and untwist. 5. Use the lifting eyes to 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. Check that the derrick end of the loop is hanging toward the crown. Attach the derrick end to the derrick service loop bracket and hold in place with flange clamps (Figures 1 and 2).
August 22, 1997
7. Pick up the TDS 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.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes using the appropriate glands. Refer to the electrical schematic provided to ensure proper terminal block assignments. 2 Cut wires and cables to length and terminate them at the derrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assembly equipment (crimping pliers, wire strippers, and hydraulic crimper for the DC power lugs with the correct dies for the cable) must be provided by the installer. Installation practices should comply with applicable electrical codes (i.e., NEC, etc.).
Fluids loop
1. Before connecting the hoses from the service loop, be certain that the service stand pipes have been flushed free of any contamination.
Use only 10 wt. hydraulic oil or non-detergent motor oil as a lubricant in the air system. Use of any other type of oil (i.e., Marvel Mystery Oil, etc.) or synthetic additive will cause the seals in the air valves to swell and cease to function. 2. Plug the quick disconnects into the appropriate mating end on the TDS. The quick disconnects are arranged to connect only one way so that the hoses cannot be mixed up. The hydraulic and air lines are identification stamped at both ends so they can be verified and connected properly. An assortment of pipe fittings are supplied with the termination kit to attach the fluid service loop hoses to the top of the standpipes in the derrick (Figure 2).
Training Manual June 99n
3. Connect the service loop to the standpipes, noting the codes (i.e., A for air, H for hydraulic, etc.) to separate the hoses.
The hoses in the fluid loop only extend 11' from the mounting bracket. It may be necessary to make jumper hoses to reach the standpipes.
Air loop
To reduce the possibility of accidental opening of the air operated elevator attach the airlines from the air operated elevators to the spare port S1 on the rotating head whenever possible. Port S1 is located next to the hydraulic return port in the rotating head. Port S2 is next to the hydraulic press port. Install a pressure relief valve on the elevator and set at 200 psi.
Chapter 3 Commissioning
Checkout procedure
1. Turn on the hydraulic and air power and check for leaks. Repair as required. 2. Turn on the electric power (drillers controls only). 3. Check the function of switches and solenoids. There is an audible click when each solenoid is actuated. 4. Actuate the link tilt. Be sure that it operates smoothly and the elevator reaches a joint in the mousehole. 5. Adjust the intermediate stop so that the elevator clears the monkey-board when actuated. Refer to the Maintenance and troubleshooting book if a problem occurs. 6. Actuate the motor brake. There is a loud sound as the air escapes when the brake releases. 7. Move the make/break valve located on the manifold at the back of the pipehandler torque wrench to the BREAK position. 8. Turn on the hydraulic power supply and adjust the pressure reducing valve (also located on the torque wrench manifold) to the appropriate pressure for the lower IBOP connection.
August 22, 1997
9. Return the Make/Break valve to the MAKE position. 10. Torque the connection between the upper and lower safety valves. The torque wrench automatic sequence is adjusted at the factory, but be sure that it follows the proper sequence. If necessary, refer to the Maintenance and troubleshooting book for the adjustment procedure. 11. Push and hold the control button on the drillers console a sufficient number of times to make up the connection. 12. Make up the lower IBOP to the saver sub. 13. Reset pressure to the appropriate setting for drill pipe connections (you can preset the pressure with the Make/Break valve in the MAKE position). 14. Use the procedure outlined in the Maintenance and Troubleshooting book to adjust the safety valve actuator mechanism. 15. Actuate the safety valve. Verify that the stroke adjustment is correct and that no binding occurs.
It is extremely important to verify that the stroke adjustment is correct and that no binding occurs as the valve will fail prematurely (wash out) if it does not open and close fully. 16. Verify that the indicator light on the drillers console lights up when the safety valve is closed. 17. Assign the TDS at the drillers console and check that the blower operates. 18. Advance the throttle and be sure that the motor is operating properly in both directions. 19. Calibrate the Amp meter and RPM meter. 20. With the hydraulic power unit off, bleed down the TDS accumulators (HYD SIDE, not gas side). 21. Remove the split shipping brace (Figure 12 book 1) from the motor alignment cylinder. 22. Open the two flow control valves 1-1/2 turns off their seats. 24. Set a joint of drill pipe in the slips.
25. Bring the TDS down as if stabbing the saver sub into box. The pin and box should be in alignment. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with the drill pipe box. b. Turn off the hydraulic power unit and bleed down the cylinder accumulator (open the needle valve on the back of the manifold). This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions until the integrated swivel bail contacts the motor support bonnet. c. Loosen the lock tab and jam nut on the cylinder clevis. d. With a wrench located on the cylinder rod flats, screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. e. Secure the jam nut and lock tab. f. The nominal position of the two cylinder flow control valves is 1-1/2 turn off their seats. If you experience heavy drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface. If motor movement becomes excessive due to continued vibration, (more than 1/2" of total cylinder stroke) close the flow controls to 3/4 turn off their seats.
August 22, 1997
Long term TDS storage procedures

1. Palletize the main unit for indoor storage. A cargo container is appropriate for indoor/outdoor storage. 2. 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. 3. 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. 4. 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. 5. 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. 6. 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 (see electrical schematic in the back of this section for proper voltage). Be sure to reseal the protective covering after connection. 7. Megger the drilling motor armature and field (static voltage of 1,000 VAC and 2 meg ohm minimum) when placed 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. 8. Varco recommends adding one gallon of Mobilarma 524 Rust Preventive prior to shutdown. Or drain the oil and mix with a rust preventive, then replace the oil, run the oil pump and rotate motor to insure 100% coverage.
Returning the TDS to service after storage

Before placing the TDS back into service, verify the following items: 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 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, inspect and replace them as necessary prior to operation. d. Check the winding insulation continuity to ground with a 1000 volt megger. If the reading is less than two meg ohms, bake the winding until the moisture content is sufficiently reduced to produce an acceptable reading. 3. Perform a complete system test and adjustment as detailed in the next section.
TDS Installation checklists (QA00026)

Use the checklists on the following pages to rig up the TDS.
Counterbalance
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, two hydraulic accumulators, and connecting links
Q. How does the counterbalance function. A. The two hydraulic cylinders are connected to the
two hydraulic accumulators, the accumulators are precharged to 900 psi, When properly adjusted the counterbalance systems supports all but about 800lbs of the weight of the Top Drive over full 8 to 10 in stroke of travel.
Q. What is the function of the accumulators and where

are they situated.
A. The counterbalance accumulators are situated in

each leg of the dolly frame. The two accumulators constantly maintained at system pressure, are always able to provide pressure to the counterbalance cylinders if the main hydraulic power unit is switched off. The accumulator is charged with nitrogen and a predetermined hydraulic pressure setting by the counterbalance circuit in the hydraulic control manifold.
Q. What type of accumulators do Varco use A. They are piston type with a shreader valve Q. How many different counterbalance configuration
does Varco have, and what are the differences in each of the systems.
A. The are four different configurations, TDS-AC

System, IDS (Integrated Drilling System) with on board hydraulics and IDS without onboard hydraulics and the TDS DC system. There is also the PRS (Pipe Racking System) that uses a counterbalance system. Each system uses different types of cartridge valves
Q. What system uses what cartridge valves A. The TDS AC System uses a pressure
reducing/pressure relieving valve to set the system along with a pilot to open check valve. The IDS with onboard hydraulics uses a pressure reducing pressure relieving valve with a pilot to open check valve and a needle valve. The IDS without onboard hydraulics uses a pressure reducing valve and a flow control valve. The TDS DC System uses a pressure reducing valve along with a needle valve and pilot open check valve. All systems have a pressure relief valve for safety
TOP DRIVE
Installation
Installation of Counterbalance System

Install counterbalance system as illustrated. When using chains use the following procedure to determine the chain length required. a) Install Pear links onto hook-block b) With the hook supporting the TDS, measure the distance from point of contact inside the pear link to top of the mounting lug on the integrated swivel bail. c) Subtract 37/-14 from the measurement in step b. d) Cut the chain to length obtained in step c. The tolerance is + 3-1/4 or 0 e) Assemble remaining components and install.
Precharging the counterbalance system

Please read these instructions completely before precharging, making note of the special cautions at the end of the section. 1. Use an inert gas such as Nitrogen for precharging accumulators. If oil-pumped is not available, use dry, waterpumped Nitrogen gas. 2. Before precharging, make certain: t The accumulator end caps are screwed flush into the accumulator body. t The gas valve is screwed in tight. t No oil remains trapped in the top end of the accumulator. 3. Remove the gas valve protector and the gas valve cap. 4. Attach the charging hose to the nitrogen bottle and to the gas valve using the following procedure: a. Use thread sealing and lubricating compound on the pipe threads of the gauge. b. Back the gas chuck stem completely out of the way before attaching the assembly to the accumulator gas valve. c. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the bleeder valve. d. Turn the gas chuck stem all of the way down, depressing the core in the accumulator gas valve. e. Only crack open the nitrogen bottle valve to slowly fill the accumulator. Shut it off when the gauge indicates 900 psi. f. If the 900 psi pre-charge pressure is exceeded, make sure the nitrogen bottle valve is closed, then open the bleeder valve (opposite gas valve below gauge) slightly, but only momentarily, to reduce pressure. g. Before loosening the swivel nut, turn the gas chuck stem out all of the way, then open the bleeder valve. h. Prevent the gas valve from turning, loosen swivel nut, and remove the assembly.
Hydraulic Components
Accumulators
The main task of an accumulator is to take a specific amount of fluid under pressure from the hydraulic system and store it until it is required within the system. As the fluid is under pressure, accumulators are treated as pressure vessels and must be designed taking into account the max operating pressure. How ever they must also pass the acceptance standards in the country in which they are being used. In order to store energy in accumulators, the fluid in an accumulator is weight or spring loaded or pressurised by gas. Therefore a balance is maintained between the pressure in a fluid and opposing pressure produced by the weight, spring or pressure created by gas. In most hydraulic systems hydro-pneumatic (gas pressurised) accumulators with a separating element are used. Depending on the type of separating element used, accumulators are categorised into Bladder, Piston and membrane accumulators. Function Accumulators have to carry out various functions in a hydraulic system:Energy storage Fluid reserve Emergency operation Balance in forces Damping of mechanical shocks Damping of pressure shocks Compensation of oil leakage Damping of shocks and vibrations Damping suspension Reclaiming of deceleration energy Maintaining constant pressure Compensation of flow (expansion tank)
Pressure Relief Valve

Pressure relief valves are used in hydraulic systems to limit the system pressure to a specific set level. If this set level is reached the pressure relief valve is activated and feeds the excess flow from system to tank
Theory of Operation
The basic principle of all pressure relief valves is that the inlet pressure is fed to a measuring surface which is acted on by force. The inlet pressure loads the poppet or lower side of the control spool with hydraulic force. The force of the pre-tensioned spring acts in the direction of the closure. The spring chamber is unloaded to tank. As long as the spring force is larger than the pressure force, the seating element stays on its seat. If the pressure force exceeds the spring force the element pushes against the spring and opens the connection. The excess fluid returns to tank. As the fluid flows away via the pressure control valve, hydraulic energy is converted into heat
Pilot Operated Check Valves

The pilot operated check valve positively locks a pressure load, but releases the load upon application of a pressure signal at the pilot port. This valve is normally used to lock an actuator in position when the directional control valve is centered. It it used in applications where overrunning load control and or a relief function is not needed or is provided by other means.
Theory of Operation
A pilot operated check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring. Directly opposite the check valve poppet are a plunger and a plunger piston that are biased by a light spring. Pilot pressure is sensed at the plunger piston through the pilot port. The valve allows free flow from its inlet port to its outlet port. Fluid flow attempting to pass through the valve from the outlet port to the inlet forces the poppet to its seat, blocking flow through the valve. When enough pilot pressure is sensed at the plunger piston, the plunger moves and unseats the check valve allowing fluid to pass. The ratio of the load pressure to the pilot presure required to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate and precise flow of the fluid within a hydraulic system. It can also be used to as a positive shut off for the hydraulic system.
Reducing /Relieving Valve

These valves are dual purpose valves the Reducing part of the valve maintains pressure at steady flow rate while ensuring that the hydraulic system does not become over pressurised Pressure relief valves are used in hydraulic systems to limit the system pressure to a specific set level. If this set level is reached the pressure relief valve is activated and feeds the excess flow from system to tank. The pressure reducing valves are used to influence the output pressure. The reduction of input pressure or the maintenance of output pressure is achieved at set value, which is below the charging pressure available in the main circuit. It is thus possible to reduce the pressure in one part of the system to a level lower than system pressure.
Theory of Operation
The basic principle of all pressure Reducing /Relieving valve is not to let the output pressure rise above a certain level, the relief valve monitors the pressure on the system, when the system pressure rises above a set pressure it returns the fluid back to tank. This pressure can be influenced by the relief port . (See hyd schematic)
TOP DRIVE
Set Up Procedure
Set up Procedures
TDS DC System
The way to set up the TDS DC System is as follows:e Check you have the following tools:9/16 Spanner and a 5/32 Allen Key e Check you have the following drawings available:-
Drawing VM 2126 SHEETS 1 T0 5 Drawing 92114 Drawing 75420 Drawing 107530 Drawing 110407 Check the following valves are correctly installed:Pilot to open check valve Needle Valve Pressure Reducing Valve Pressure Relief Valve P/N P/N P/N P/N 77616 76419 77615 94522-21N
e e e e e
Check all connecting liks are secure and all bolts are safety wired. Check TDS is not sitting on the guide stops . Check the Hydraulic reservoir is full and all quick disconnects are installed properly. Check all hose connections are tight. Check the 2 accumulators are pre-charged with 900 psi of Nitrogen. Check hydraulic power supply is set to 2000 psi.
Adjustment Procedure
Screw needle valve counterclockwise until fully open. Screw pressure reducing valve counterclockwise until fully open. Start hydraulic power unit and let hydraulic oil flow for 2 minutes. Bleed system cylinders. Screw needle vale clockwise until fully closed. Screw pressure reducing valve clockwise until cylinders start to retract raising the TDS. Slowly screw the pressure reducing valve counterclockwise reducing the pressure to the cylinders. When the swivel bail just contacts the hook note the pressure and decrease it by 25psi tighten lock nut.
Troubleshooting the counterbalance

Symptom System does not hold pressure. Probable cause Needle valve is not closed. Cylinder rod seals leak. Fittings or hoses leak. Dirty or defective PRV valve Dirty or stuck check valve. Remedy See adjustment procedure and check needle valve. Replace seals. Tighten or replace as required. . See adjustment procedure. Clean or replace. Clean or replace.
Counterbalance control valve Return valve to drilling position. in rig down position. Cylinder rods remain retracted (closed). Pressure setting too high. Adjust per adjustment procedure.
activating or reactivating the counterbalance system, never z When start an empty system with the needle valve closed. Always start hydraulic unit first, run for 3-5 minutes, then slowly close needle valve with hydraulic unit running. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals.
1) Where is the counterbalance manifold situated?
____________________________________ ____________________________________ ____________________________________ ____________________________________
2) Name the three valves in the counterbalance manifold?
_______________________________________ _______________________________________ _______________________________________

3) What stops the counterbalance system from being over pressurized?
____________________________________ ____________________________________
4) Where are the Counterbalance Accumulators situated ?
____________________________________ ____________________________________ ____________________________________ ____________________________________

5) What type of valve is on the Counterbalance Accumulators ?
____________________________________ ____________________________________ ____________________________________

6) What type of Accumulators are the Counterbalance Accumulators?
____________________________________ ____________________________________
7) What is the reason for having a counterbalance system ?
____________________________________ ____________________________________
8) What indicates that the Counterbalance is faulty or not set up properly?
9) Check the following drawings and mark up any defects missing parts. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________
10) What tools are required to set up the counterbalance system? ___________________________________________________________ ____________________________________________________________ ____________________________________________________________
Alignment
Training Manual
Motor Alignment System

All Varco DC Top Drives have an Alignment System, One Top Drive System Model that differs from the other DC Models is the TDS 6S, and this is due the size and weight of that particular model.
What does the Alignment System do The alignment cylinder is not intended to be used to align the pin with the box at the well bore. It is a device to counterbalance the offset weight of the DC motor and allow the system to accommodate external forces. It is adjustable to ensure that the mainshaft is straight at well centerto compensate for design tolerances in the guide rails and dolly. To work properly, the guide rails must be properly located, and the dolly must fit within design tolerances.. What does the system consist of The earlier Top Drive systems (TDS 3)Models did not have a separate accumulator system, but all other models do have a separate accumulator for the system. The system with the separate accumulator consist of a duplex counterbalance cylinder with 2 flow control valves attached, hydraulic accumulator, hydraulic manifold with a pressure reducing cartridge valve a needle valve, and a pilot to open check valve. Where is the system fitted The duplex cylinder is attached to a pad eye on the lower gear case and another pad eye attached to the motor guide frame.
Q A
Q A
Alignment
Training Manual
Adjusting the motor alignment cylinder

For units without a separate alignment cylinder accumulator The counterbalance system must be properly adjusted before attempting to adjust the alignment cylinder. Turn off the hydraulic power unit and bleed down the TDS accumulators by opening the needle valve located on the counterbalance valve manifold. Remove the split shipping brace from the motor alignment cylinder, then open the two flow control valves by 1 turns each these valve are located on the motor alignment cylinder supply and return lines. Close the needle valve and turn the hydraulic unit back on, then verify the pressure is 1100-psi +/- 100 psi. Set a joint or stand in the rotary slips, (do not use a pup joint as this could give a false position). Bring the TDS down until it is stabbed into the box. The pin and box should be in alignment within +/ - . The OD of the pin should clear the shoulder of the box so that the connection can be made up without damaging the threads. If adjustments are necessary, use the following procedure. a) Measure how far and in what direction the pin has to move to line up the pin and box. b) Turn off the hydraulic power unit and bleed down the system then loosen the lock tab and jam nut on the cylinder clevis. c) Using an open ended spanner (wrench),(do not use a pipe wrench) on the cylinder rod flats screw the rod in the direction required. turn on the rod results in the pin movement of . Note Alignment cylinder rod extension should be 2 3/8 +/ -1/8 Gland to rod threads when aligned properly. d) Secure the jam nut and lock the tab when alignment is set.
Alignment
Training Manual
For units with a separate alignment cylinder accumulator

Check you have a pre-charge of 900 psi in the accumulator The counterbalance system must be properly adjusted before attempting to adjust the alignment cylinder. The pressure setting is adjusted by screwing the pressure reducing valve in or out with a hex wrench (Figure 13). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the pressure reducing valve reduces pressure and moves the saver sub away from the rails (see additional notes at the end of this procedure). 1. Verify the correct pressure setting using the following procedure: a. With the power unit on, back down the pressure using the pressure reducing valve (PRV) until the saver sub begins to pivot away from the rails. Record this pressure. b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a dead band area. c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs. d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by two. The resulting pressure dead band provides equal preload in each direction both toward and away from the rails. e. Record the pressure setting for future reference. 2. Set a joint of drill pipe in the slips. 3. Bring the top drive down as if stabbing the saver sub into the box. The pin and the box should be in alignment so that the O.D. of the pin clears the shoulder of the box. If adjustment is necessary, use the following procedure:
Alignment
Training Manual
a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box. b. Turn off the hydraulic power unit and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame. c. Loosen the lock tab and jam nut on the cylinder clevis. d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4" of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2-3/8" 1/8" gland to rod threads when the system is properly aligned. e. Secure the jam nut and lock tab. f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2" of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats. g. Tighten the lock nuts and replace the caps on all valve stems. If the alignment cylinder is removed for service, install the alignment cylinder replacement brace to support the motor housing assembly while continuing to operate the TDS. After reinstalling the alignment cylinder, use the three bleed holes(located along top of cylinder barrel) to remove air trapped in the cylinder. Rail spacing and setback from the centerline of the well must be held within recommended tolerances in order to maintain vertical alignment of the TDS.
Alignment
Alignment Cylinder Lug (ref) Pressure Reducing Valve
Needle Valve
Motor Frame (ref)
Alignment Cylinder Manifold Accumulator
Bracket Gas Valve
Motor alignment cylinder manifold
Split Shipping Brace
Motor Frame Dolly (Ref)
Alignment cylinder
Troubleshooting the Motor Alignment Cylinder

Symptom Alignment cylinder fails to move transmission at trunnion pivot points with recommended pressure setting. Probable cause Transmission trunnion pins will not pivot in dolly support brackets, from lack of lubrication. Remedy Free trunnion pins as needed and lubricate area regularly.
Possible problem with Counterbalance system hydraulic system works erratically or does not components. work at all.
Chec kTroubleshooting the Counterbalance section of this book.
Loss of nitrogen precharge in Recharge accumulators as per the procedure in th Counterbalance e accumulators located in section of this book. motor dolly upright frame. System does not hold pressure. Needle valve is not closed. Cylinder rod seals leak. Fittings or hoses leak. Dirty or defective PRV valve Saver sub on TDS does not align with drill pipe. Alignment cylinder pressure too high or too low. Adjustment Se e procedure. Replace seals. Tighten or replace as required. . Clean or replace. Se eAdjustment procedure.
Alignment cylinder rod Adjust according to procedure. adjustment too long or short. Rails not properly aligned with centerline of well. Check to make sure that rotary is in center of floor and then check alignment of rails in relation to rotary. Se eAdjustment procedure. Normal adjustment is 1 1/2 turns from full closed position on flow control valves. If there is excessive movement close to 3/4 turn from full closed position.
Excessive motor movement.
Alignment cylinder fluid flow not adequately throttled.
Pilot Operated Check Valves

The pilot operated check valve positively locks a pressure load, but releases the load upon application of a pressure signal at the pilot port. This valve is normally used to lock an actuator in position when the directional control valve is centered. It it used in applications where overrunning load control and or a relief function is not needed or is provided by other means.
Theory of Operation
A pilot operated check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring. Directly opposite the check valve poppet are a plunger and a plunger piston that are biased by a light spring. Pilot pressure is sensed at the plunger piston through the pilot port. The valve allows free flow from its inlet port to its outlet port. Fluid flow attempting to pass through the valve from the outlet port to the inlet forces the poppet to its seat, blocking flow through the valve. When enough pilot pressure is sensed at the plunger piston, the plunger moves and unseats the check valve allowing fluid to pass. The ratio of the load pressure to the pilot presure required to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate and precise flow of the fluid within a hydraulic system. It can also be used to as a positive shut off for the hydraulic system.
Reducing /Relieving Valve

These valves are dual purpose valves the Reducing part of the valve maintains pressure at steady flow rate while ensuring that the hydraulic system does not become over pressurised Pressure relief valves are used in hydraulic systems to limit the system pressure to a specific set level. If this set level is reached the pressure relief valve is activated and feeds the excess flow from system to tank. The pressure reducing valves are used to influence the output pressure. The reduction of input pressure or the maintenance of output pressure is achieved at set value, which is below the charging pressure available in the main circuit. It is thus possible to reduce the pressure in one part of the system to a level lower than system pressure.
Theory of Operation
The basic principle of all pressure Reducing /Relieving valve is not to let the output pressure rise above a certain level, the relief valve monitors the pressure on the system, when the system pressure rises above a set pressure it returns the fluid back to tank. This pressure can be influenced by the relief port . (See hyd schematic)
Cooling Motor
Cooling Systems
Varco has four types of cooling systems the customer can choose from to cool the Varco Top Drive Drilling Motor. 1. 2. 3. 4. Closed Loop Cooling Local Blower Local blower with extended air intake Remote blower
Q Why have so many different systems. A The main reason is that countries around the world have their own underlying certifying authorities how govern their policies on certification. Many of these authorities have different rules governing specifications on electrical motors. Depending on where the drilling rig is going to operate will depend on what cooling system will be used. A Rig working in the North Sea may only have 2 systems to choose from, a Remote Blower system or a Closed Loop cooling System. A rig working in the Gulf of Mexico can have all 4 systems to choose from. Before a Top drive is sold a survey should be carried out on the installation to check the Top Drive System components conforms to the particular area where it is going to work. Q What is the best system A Each system has its own unique advantages and disadvantages, the following pages describe all four systems.
Varco Technical Education Centre
Closed Loop
Closed Loop System

The Close Loop Cooling System can use EXD OR UL components to meet all world underlying Authorities, by using EXD or UL components the Top Drive with closed loop cooling can have classification to work any where in the world. The system should be capable of producing a CFM of 3200. The closed Loop system consists of the following main parts :20 HP Blower motor Heat exchangers Air Flow Ducts Water detectors Differential pressure switch Pressure switch Temperature switch Expo purge system Water pumps Flow indicator Service loop containing water hoses
Blower Motors
The blower motor is a dual shaft 20 HP AC, that is attached to the blower mount brake cover. The motors are EXD or Ul rated it is always best to check the name plate before installing.
The impellers are attached to each shaft end and are fixed by a taper lock mechanism.
The Blower impellers are then incased in the ducting assembly. A 8 flex connects to the ducts on the GE 752 or EMD Drilling Motor. The Blower inlets are connected to the heat exchangers
. .
Heat Exchangers
The closed loop cooling system consists of two tube fin type heat exchangers cooled by twin blowers driven by a double ended AC Motor. Ducting passes air out the motor exhausts port to the heat exchangers and back to the blower inlets. The heat exchangers are built from Cupro Nickel tubes and the headers are pressure tested to 250 psi. The system requires a supply of liquid coolant (Sea Water, Chilled fresh water or Glycol) at 50 gpm ( in the case of a TSD 6S each motor requires 50gpm) at a maximum inlet temperature OF 90F.
As the drilling motor rotates carbon dust is being produced by the wear of the brushes inside the drilling motor. As the air flows round the system the carbon dust can then build up on the commutator and can cause a flash over inside the drilling motor resulting in a motor change There are Carbon dust filters that can be installed. These filters are an aid in stopping build up of the carbon but they must be replaced at regular intervals
Water Detectors
System operation The sensor is mounted in the scroll of the blower housing of drilling motor at such a position that the air circulation pattern from the blower,s impeller will cause leaking coolant water particles to strike the sensitive sensor element. If water is present the sensors resistance lowers causing the water detector amplifier to conduct a 24 Vdc to the Programmable Logic Controller (PLC). The PLC then sounds the warning horn and illuminates the Drillers console water detection indicator lamp.
Pressure/ Temperature Switches

Differential pressure switch The reason for having a differential pressure switch is to monitor the flow of pressure in the system. A line is connected to a fitting on the duct at the commutator end of the main drilling motor and attached to the high port fitting of the switch, and another line is connected to a fitting in the opposite air duct at the pinion end of the drilling Motor and connected to the fitting on the low pressure of the switch. Dureing normal operation the blower differential pressure switch on the TDS is in the open position. Upon Blower failure the pressure switch senses low or zero output pressure and the switch closes to supply a 24Vdc signal to the Programmable Logic Controller (PLC) Module. In addition another 24Vdc signal is sent to the auxiliary contacts of the Blower Starter Relay to the PLC. When the PLC receives the pressure switch signal and the auxiliary signal from the blower motor starter it sends no signal to the Drillers Console. If either signal is lost the PLC sends a pulse 24Vdc signal to the Blower Fail Indicator on the Drillers Console for a a flashing ON indication and sounds the warning alarm. If The operator depresses the alarm silence button to silence the alarm , the flashing indicator changes to a steady indication . After 5 minutes if the malfunction still exists then the indicator will revert back to flashing indicator and the warning horn will sound A clogged carbon filter can restrict the airflow and can cause the differential alarm.
Cooling Air Temperature switch The cooling Air Over-temperature switch monitors the Drilling Motor outlet air temperature to alert the operator of dangerously high temperature. It is a normally open pressure switch with a liquid filled temperature bulb connected to the pressure inlet of the switch with a capillary tube. The temperature bulb is mounted in the exhaust air outlet in the TDS Main Drilling Motor duct When air temperature exceeds 170 the switch closes sending a 24VDC signal to the PLC. The PLC activates the warning horn and illuminates the TDS OVERTEMP Indicator Lamp. If the water pumps are not producing 50 GPM or the flow is restricted this would cause an alarm situation.
A flow switch is installed on the return pipe work which is usually placed near the water reservoir, (except in the case of the TDS6S its switch is usually placed up at the diving board level ) When the blower is running the system is in a negative state and requires a purge air rate of 70 scfm per motor at 1.0 psig to provide a positive system. A purge control system is required to monitor system pressure for safe operations.
Local Blower
Local Blower System

The Local Blower System can be use UL or EX components to meet all world underlying authorities, by using EX or UL components the Top Drive with the Local blower can have classification to work in most areas where drilling operations are required. There are different classifications within the European Nations, (British Sector, Norwegian Sector, Danish Sector, Dutch Sector to name but a few. The Hazardous area zones differ in shape and sizes for most sectors, There is a hazardous area course that covers all these zones along with other important issues. (It would be beneficial to all Engineers if they attend one of these courses) The Local Blower Components consists of the following main Parts:20HP Blower Motor Spark Arrestors Air flow ducts Differential Pressure Switch Temperature Switch Pressure Switch Flex cooling Duct ( For extended intake system)
Local Blower
The basic local blower system is designed to provide local cooling air to the drilling motor. It receives air from approx 20 feet above the rig floor at the lowest point of the motors travel. A heavy constructed pressure blower is mounted to the motor. The motor is directly driven by an explosion proof 20 HP, 3450 rpm AC electrical motor.( older versions may have an 15 HP Motor) The motor is connected to the blower with a rigid duct. The design provides highly reliable service with positive ventilation through its normal inlet and spark arrestor protected outlets. It provides a safe, visibly verifiable system that will prevent explosion of flammable gasses or vapors coming from the well bore. The system should be capable of producing a CFM of 3200. The system is monitored in the same way as the closed loop system, and gives the operator the same alarms.
Local Blower with Extended Intake

To comply with certain Authorities requirements, the minimum intake height must be raised. In order to accomplish this is to fit an extended intake. This system consist of the standard type local blower with ducting to allow the intake to be mounted on the hook or traveling block with a flexible hose running down to the motor. This raises the air intake height to approximately 30 feet above the rig floor.
Axial Fan 20 hp Blower Motor Locking Key Blower Housing Gasket
Transmission Cooler
Oil Fittings (2)
Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket FLL-X Duct Connection Point Mounting Plate
Blower Duct to AC Drilling Motor
Spark Arrestor
Typical local blower cooling system
Typical local blower cooling system (Shown with optional extended intake)
Lubricating the cooling system

Lubricate AC blower motors every three months .
Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower
Transmission Cooler
. Lubricating the local cooling system
Use the following procedure to install a new motor in the local cooling system: 1. Install wear sleeves on the blower motor shaft. 2. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 3. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Use two 3/8 in. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. b. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. 4. Install shaft seal assemblies inside both blower housing assemblies. Make sure the seals are centered. 5. Tighten and safetywire the retainer plates in place on both sides. 6. Install the impellers and taper lock bushings on both sides and safetywire the bolts. 7. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. 8. Hoist the entire cooling system assembly onto the TDS. If the alignment holes were properly used, the cooling system assembly should line up perfectly on the TDS. 9. Install and safetywire the four bolts connecting the blower mount to the brake cover. 10. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. 11. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 12. Connect the electrical wires to the blower motor.
Remote Blower
Remote Blower System

The Local Blower System can be use UL or EX components to meet all world underlying authorities, by using EX or UL components the Top Drive with the Local blower can have classification to work in anywhere drilling operations are required. The remote Blower cooling system consists of the following components:40 HP Blower Motor Skid for Blower to mount on Spark Arrestors 8 flexible hose Differential Pressure switch Temperature switch Water detector (optional extra) The remote blower system is normally used when the rig cannot be assured of good safe cooling air. The system works the same as the Local system except that a 40HP motor is placed in the Derrick at diving board level and receives air from out side the derrick walls. The extra horse power is required to force the air down through the hose and through the motor, keeping it in a positive state. The system is monitored the same as the closed loop cooling system, and the Local Blower system, giving the operator the same alarms. The system should be capable of producing a CFM of 3200. The impeller is fitted the same way as the Closed Loop System and there is a mist filter to stop moisture getting into the system.
Air Inlet
40 hp Explosion Proof Electric Motor (AC) and Centrifugal Pressure Blower
Wind Wall
Racking Platform at Racking Board Level
Rigid Cooling Duct
Spark Arrestor
Motor Dolly Assembly
86' Flex Air Duct
Typical remote blower cooling system
Trouble-Shooting
Troubleshooting the cooling system

Symptom Mechanical noise in blower. Blower runs intermittently. Probable cause Loose impeller. Faulty motor bearings. Faulty or loose wiring. Faulty motor starter. Remedy Reinstall impeller and hub and locktite screws. Repair or replace as needed. Locate and repair as needed. Check for dirt or trash between starter coil. Repair or replace as needed. Replace as needed.
Excessive air loss in blower motor shaft area.
Worn or defective seal or wear sleeve. Loose or vibrating blower motor, wearing seals excessively.
Correct blower mounting problem or faulty motor bearing and replace blower shaft seals. Verify blower rotation. Correct as needed.
DC MOTOR OVERHEATING, OVERTEMP alarm stays on with blower running.
Incorrect blower rotation.
Dirty or clogged spark arrestors (local or remote cooling systems).
Remove spark arrestors from motor and clean screens if screens are damaged with holes. Replace as needed.
Clogged water or air passages Remove and clean passages as needed. in water cooled exchangers (closed loop cooling).
Troubleshooting the cooling system (cont.)
Symptom DC MOTOR OVERHEATING, OVERTEMP alarm stays on with blower running.
Probable cause Continuous drilling Amps over recommended levels.
Remedy Check service manual for continuous Amp motor rating and adjust drilling program accordingly.
Motor being stalled for over recommended periods of time.
e z
DC motor should never be stalled for more than 5 seconds with over 300 Amps applied. Serious damage could occur to the motor if this is done.
Faulty temperature switch or Repair or replace as needed. probe. Do not readjust or raise heat range setting.
Improper cooling water flow See the Installation and or incoming water temp too Commissioning book for recommended or required flow rates high (closed loop cooling). and water temp. Restricted air flow (local or remote cooling). Check and clean spark arrestors as needed. Check air intake on blower to ensure there are no restrictions. Verify proper blower rotation. WATER DETECTOR alarm is on (closed loop system). Moisture in air inside DC motor. Check for leaks in heat exchanger. Check air purge line filters. Ensure dry air is going into motor. Clean or replace as needed.
Dirty or faulty water detector.
COOLING SYSTEMS TEST
Varco Technical Education Centre Name Position
1) Name the different cooling systems Varco uses _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ 2) Explain why Varco uses different systems?
____________________________________ ____________________________________ ____________________________________ ____________________________________

3) What size of Blower Motor is used on the Closed Loop System?
_______________________________________ _______________________________________
4) What GPM is required for the cooling of the TDS 6S Model?
____________________________________
5) Why does the Local Cooling System require a Differential Pressure Switch ?
____________________________________ ____________________________________
6) What is the Air Temperature switch set at ?
____________________________________ ____________________________________
7) What Cooling System requires a CFM OF 3200?
____________________________________
8) What keeps the impeller in place on the Remote Cooling System?
____________________________________ ____________________________________
9) What causes excessive air loss in the Remote Blower Cooling system?
____________________________________ ____________________________________
10) What Direction Should the Local blower motor run ?
______________________________________________________________________________________ ______________________________________________________________________________________
Motor Brake
Training Manual
Top Drive Brake
5 6
10
3A
Note: Optional QuickRelease Valve. Notavailabl e for 11.5VC500.
2 12 13
1
Ventilated Construction
Friction shoe backing plates have large air passages through the entire length. This constuction coupled with scallop side plates allow cooling air to flow through the element In addition the large exposed inside diameter assures the coolest possible operation. None of the heat is generated deep in the element's internal parts where it can be trapped. The open construction assures rapid heat dissipation.
11
Item
1 2 3 3A 4 5 6 7 8 9 10 11 12 13 7, 12, & 13
ComponentDescription
Rim Tube(withvalvestemsnapringswhererequired) ElbowAssembly Optiona l - QuickReleaseValveAssembly CompressionRing(includedwithitem s 3 & 3A) Air Connection Tube Air Connection Gasket FrictionShoeAssembly Air TubeGroup(DualMounted) SpacerGroup(DualMounted) Replacement FrictionLinin g & FastenerKit Side Plate(2 required) TorqueBar ReleaseSpring FrictionShoe, TorqueBar & SpringKit
Motor Housing
Washpipe Assay
Washpipe assembly
1. With the packing box upside down, assemble the packing seals and spacers into the packing box using care to line up the upper spacer slot with the dowel pin. 2. Hand pack all seals with multipurpose lithium-based outside diameter of the spacers. 3. Install the socket head dog nose screw, ensuring that the screw nose is fully engaged in the groove of the lower spacer. 4. Install the grease fitting and turn the packing box upright. 5. Install the wash pipe into the packing box assembly (slotted end up). 6. Install the wash pipe nut onto the wash pipe. 7. Grease the packing seal and install into the holding ring using care not to grease the outside diameter of the holding ring. 8. Install the packing seal and holding ring over the slotted endof the wash pipe. 9. Install the snap ring. 10. Install the upper and lower o-rings using grease to hold them in place. 11. Compress the assembly to the length of the wash pipe. Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the Washpipe Assembly Guide, P/N 128844.
Drilling Motor
D.C. Motor Identification
Section 1 - Introduction
Varco has used two different types of Electrical DC motors on their DC Top Drive range they are from EMD (Electro Motive Diesel) and from GE (General Electric). The fist ever Top Drive built, TDS-1 utilized an EMD M89VTS series motor, and this motor had been previously used on a Locomotive. This Top Drive went to work on board the Sedco 201 rig in the Arabian Gulf on 1st April 1982. Initially the EMD motor was preferred, but as to production demands etc. Varco decided to utilize a second company (GE) in 1983, this then gave the option of utilizing either a Shunt or Series type motor as opposed to EMD who only supplied a Series type motor. The main operating difference between the Series and the Shunt type motors is the output Torque and Speed control. Where the Series motor has a slightly greater Output Torque, the Shunt motor gives greater speed control with the ability to also alter the Field current with an Active Field Supply and thus get greater speed control. This is one of the main reasons why a Shunt motor is more commonly specified as opposed to a Series motor on Top Drive applications. In 1989 GE introduced their new High Torque motors, this motor was able to increase the Top Drive torque output, this is now used as standard when a new motor is obtained from GE. The charts below show examples of the differences between Shunt and Series motors, and between Standard Torque and High Torque motors for continuous drilling maximum Top Drive output Torques. Shunt @ 57A TDS-3 TDS-4(Low gear) TDS-4(High gear) TDS-5 Series TDS-3 TDS-4(Low gear) TDS-4(High gear) TDS-5 Standard Torque motor 26,400 Ft/Lbs. @195 RPM 38,700 Ft/Lbs. @130 RPM 24,800 Ft/Lbs. @200 RPM 33,000 Ft/Lbs. @155 RPM Standard Torque motor 27,800 Ft/Lbs. @185 RPM 40,900 Ft/Lbs. @125 RPM 26,100 Ft/Lbs. @195 RPM 34,800 Ft/Lbs. @150 RPM High Torque motor 31,000 Ft/Lbs. @165 RPM 45,000 Ft/Lbs. @130 RPM 29,100 Ft/Lbs. @200 RPM 38,700 Ft/Lbs. @130 RPM High Torque motor 34,700 Ft/Lbs. @150 RPM 50,900 Ft/Lbs. @100 RPM 32,500 Ft/Lbs. @160 RPM 43,300 Ft/Lbs. @125 RPM
The above picture shows the EMD Series motor that was used in the construction of the First Top Drive. The commutator and shaft were removed and machined to fit the requirements of the Top Drive gearbox.
Section 3 DC Motor Types

General Electric
TDS 3,4,5+6 GE 752 AUP 1,2,3. Series wound standard torque motor Cable size 535 MCM GE 752 UP 1,2,3. Shunt wound standard torque motor P/N Cable size 646 MCM GE 752 AUT 1,2,3. Series wound high torque motor Cable size 535 MCM GE 752 US 1,2, Shunt wound high torque motor Cable size 646 MCM IDS GE752IDS Shunt wound high torque motor Cable size 646 MCM P/N P/N 75989-1
75989-2
P/N
86542-1
87966
PN
103609
EMD
TDS - 3 M89VTS Series wound standard torque motor Cable size 444 MCM P/N 77029
DC Motor Connectors
GE Motor connectors (TDS 3,4,5 +6) GE Motor Connectors (IDS Integrated J/B) EMD Motor connectors (TDS 3) P/N 79826 P/N 79826 * 1 P/N 99580 * 2 P/N 79835
Section 4 - Cooling Ducts Identification

To identify the motor type visually by the cooling ducts in the pinion end cover, 4 cooling holes is a standard Torque and 10 cooling holes high Torque, this is illustrated in the pictures below.
Above is a standard torque motor, with 4 cooling ports on the lower face with bolt on cooling ducting as used on TDS 3 and TDS 5 applications.
Above is a high torque motor with 4 cooling ports on lower face plus 6 circumferential slots in the main end cover.
Section 5 - Gearcase Identification

The gearcase application for a standard torque and high torque motor is also different, details of these is shown below.
Above is a standard torque motor gearcase application where the gearcase is separate from the cooling system and the ducting bolts directly to the motor.
Above is a high torque gearcase application where the gearcase is an interregnal part of the cooling system and the motor seals against the gearcase.
Section 6 - Testing the GE752 Motor

1. Remove commutator covers on motor to inspect and ensure all brushes are fully seated and their retaining springs are in place. 2. Check armature and field cables for signs of wear or damage and ensure all tails are sitting clear of both the motor and the shop floor. 3. Select the 1000V range on the Megger and check that the battery is O.K 4. Connect one lead from the Megger to the motor frame ensuring a good connection. Connect the other lead to one of the armature cables. Press the test pushbutton on the Megger and note down value below. 5. Repeat step 4 but this time move lead from the armature cable to the armature cable screen and note down value below. 6. Repeat steps 4 & 5 but this time use one of the field cables and note values below. 7. Connect one lead from the armature cable and the other from the field cable. Press test button on Megger and note down value below. Armature to Ground / Screen Megger Reading
This should give a reading somewhere in the region from 500M Ohms to 50M Ohms. When new this should be expected to be reasonably high. The lowest reading that the motor should be operated at is 0.5M Ohms, once the motor is electrically energized, this should rise. If the megger reading is lower than 0.5M Ohms, the motor should be heated up before use, as most SCR systems will fault below this level and there is also a possibility of damage to the motor.
Field to Ground / Screen Megger Reading

This reading should be about 500M Ohms, if this reading is lower, the motor should also be heated to bring the value a higher.
10
Training Manual
PINION GEAR INSTALLATION
Training Manual
PINION GEAR INSTALLATION SUBJECT: Pinion Gear and Drive Train Life. PURPOSE: To notify users of proper assembly procedures for Pinion Gears and Hubs to Top Drive drilling motors. EFFECTIVITY: All Varco BJ Top Drive Drilling Systems. Assembly of the Pinion Gear or Pinion Gear Hub to the Top Drive drilling motor shaft is extremely critical to the life expectancy to the drive train. The Pinion Gear and Hub used on the Varco Top Drive is unique to this application and the fit to the motor shaft is not necessarily the same as other gears, hubs, sprockets, etc, which may be used on other types of machinery. Improper assembly may lead to premature failure through material fractures and/or separation of the gear or hub from the shaft.
Training Manual
PINION GEAR INSTALLATION
Proper fit requires hand fitting and polishing of the mating surfaces while maintaining precise tolerances in relation to other dimensions of the pinion. Successful assembly depends a great deal on skill, knowledge, and training of the personnel performing the work. Final verification of correct installation dimensions is essential.
Here is an example of the Pinion Gear being heated using the Induction Heater.
Current date
Installing the top drive motor pinion
Installing a pinion gear can be dangerous to personnel installing it as well as anyone witnessing the procedure. Exercise caution at all times. Use the following procedure to install a TDS motor pinion: 1. Clean the motor shaft by hand and cover with a thin layer of Engineers Blue. 2. Firmly install the pinion on the motor shaft by hand. Mark reference lines on the pinion and the shaft to ensure identical angular orientation each time. 3. There must be a minimum of 75% surface contact between the pinion and motor shaft. Dress the motor shaft/pinion very lightly with a fine emery cloth and repeat the blueing procedure if necessary until there is at least 75% surface contact between the pinion and motor shaft. 4. After thoroughly cleaning all blueing, oil, and/or grease from the pinion bore and shaft, trial mount the cold pinion gear on the motor shaft, lining up the reference marks. 5. Make sure the fixture is clean and the horse shoe face and bar are parallel. 6. Place the fixture on the motor shaft with the horse shoe end against the inner face of the gear and the bar against the outer face of the gear, sandwiching the pinion gear in the fixture. 7. Adjust the adjusting screw to butt against the end of the motor shaft. 8. Attach a calibrated dial indicator gauge to the fixture and set to zero. 9. Back off the adjusting screw until the gauge reads 0.072 to 0.074 in. Then lock the screw in place with a locknut. 10. Remove the fixture from the pinion gear assembly.
e
4-70
Do not put the fixture in the oven.
TDS-3H Maintenance and Troubleshooting
11. Heat the pinion gear to 360 - 385F (182 - 196C) for three hours in an oven. After heating for three hours, remove the pinion gear assembly and immediately attach the fixture. 12. Place the pinion gear assembly and fixture on the motor shaft, lining up the reference marks. 13. Gently tap the pinion gear assembly and fixture into place until the adjusting screw butts against the motor shaft. 14. Wait 2-3 minutes and back off the nuts holding the fixture in place. There may be some noise as the pinion gear cools. 15. The pinion creeps up the shaft as it cools to the required position of 0.085 0.005 in. advancement. 16. When the pinion is fully cooled, fit the fixture and check final advancement. 17. Complete the required documentation recording pinion advancement.
4-71
Gearbox
Motor Removal
Removing the motor assembly from the guide dolly

You can perform some service procedures on top drives (i.e. upper quill shaft bearing and seal, air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. If service is required on the lower end (i.e. gear set, lower bearings or seals), you must remove the drilling motor from the dolly. 1 Set the TDS down horizontally on a good flat surface. Make sure that none of the components protrude past the guide dolly roller brackets before setting down. If so, block dolly up accordingly.
2. Disconnect all wiring and hoses between the transmission and guide dolly frame. 3. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with removing the transmission from the guide dolly frame. 4. Run a suitable sling through the quill shaft to support the weight of the motor and housing assembly (approximately 10,000 lb). 5. Attach the sling to the crane, take up slack and remove the trunnion blocks that hold the transmission to the guide dolly frame. 6. Hoist the transmission out of the guide dolly frame. 7. Set the motor and housing assembly down on wooden chocks, being careful not to damage the components. 8. Disconnect the wiring between the motor and the housing. Make sure the transmission is in neutral. 9. Remove the dowel pins in the motor feet. 10. Remove the four large motor bolts. 11. Lift the transmission off of the motor, angling the upper end slightly to clear the motor frame, and sliding the housing off of the motor towards the gearcase end. 12. Remove the blower and brake assemblies. 13. Reverse this procedure for reassembly.
TDS-3H Maintenance
Training Manual
Removing the drilling motor from the housing assembly

1. Remove the upper bearing cover and grease seal. 2. Pressurize the air brake to hold the drive mechanism in place and remove the quill shaft locknut. 3. Remove the cotter pins, slotted nuts and rotating head. 4. Remove the lower gear case. The lower gear case is located with dowel pins. 5. Carefully remove the quill shaft with bull gear so as to avoid damaging the bearing surfaces or wear sleeves. Do not remove the gear from the shaft unless replacing it. 6. Remove the large quill shaft bearings. 7. Remove the pinion seal and retaining ring. 8. Remove the upper gear case. 9. On the opposite end of the motor, remove the magnetic pickup and brake cover. 10. The brake may now be removed for service. Refer to the electric motor sections to remove the pinion or hub on the armature shaft or to service the motor itself.
Once the unit has been disassembled, inspect the assemblies for any wear or damage that may be critical, as follows: 1. Gear set: Check the teeth and splines for chips or heavy spalling. The wear pattern should be even and symmetrical. If not, replace it. Some small surface pitting is to be expected and is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090 in. 4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads. 5. Seals: Always replace seals and gaskets when removed.
TDS-3H Maintenance
6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gear case are critical. Any nicks or gouges must be cleaned up prior to re-assembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface. 9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems have been malfunctioning, remove the appropriate valve and repair or replace. Reassemble the drilling motor and housing assembly by reversing the steps in the above disassembly procedure. Replace all grease seals and O-rings. Refer to the following torque chart for bolt tightening guidelines. Torque chart Motor housing to motor Upper gear case to housing assembly Bull gear to hub Lower gear case to main body Rotating head to lower gear case Brake adapter ring to motor Brake to brake adapter plate Brake drum to hub Brake cover to brake Upper seal retainer to motor housing 1750 ft lb. 1100 ft lb 580 ft lb 250 ft lb 250 ft lb 250 ft lb 50 ft lb 250 ft lb 50 ft lb 75 ft lb (2373 N.m) (1492 N.m) (786 N.m) (339 N.m) (339 N.m) (339 N.m) (68 N.m) (339 N.m) (68 N.m) (102 N.m)
TDS-3H Maintenance
Training Manual
Gooseneck
Main Body Air Brake
Motor Support Bonnet
Bull Gear
D.C. Drilling Motor
Pinion Gear Drive Stem Motor Alignment Cylinder (Ref.) Lower Gear Case
Figure 19. Drilling motor and motor support bonnet assembly/disassembly
TDS-3S Maintenance
Training Manual

You can perform some service procedures on top drives (i.e. upper drive stem bearing and seal, air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. If service is required on the lower end (i.e. gear set, lower bearings or seals), you must remove the drilling motor from the dolly. 1. Set TDS down horizontally on a good flat surface. 2. Make sure that none of the components protrude past the guide dolly roller brackets before setting the TDS down. If so, block the guide dolly up accordingly. 3. Disconnect all wiring and hoses between transmission and guide dolly frame. 4. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with removing the transmission from guide dolly frame. 5. Use a suitable sling to support the weight of the TDS and motor support bonnet (approximately 10,000 lb). 6. Take up the slack and remove the trunnion blocks that hold the transmission to the guide dolly frame. 7. Hoist the transmission out of the guide dolly frame. 8. Set the TDS and motor support bonnet down on wooden chocks, being careful not to damage components. 9. Disconnect the wiring between the motor and motor support bonnet. 10. Make sure the transmission is in neutral. 11. Remove the dowel pins in the motor feet. 12. Remove the four large motor bolts. 13. Lift the transmission off of the motor, angling the upper end slightly to clear the motor support bonnet, and sliding the housing off of the motor toward the gearcase end. 14. Remove the blower and brake assemblies. 15. Reverse this procedure for reassembly.
TDS3 Maintenance
Training Manual
Disassembly/assembly of drilling motor and motor support bonnet

1. Remove the upper bearing cover and grease seal (Figure 19). 2. Pressurize the air brake to hold the drive mechanism in place. 3. Remove cotter pins, slotted nuts and the rotating head. 4. Remove the lower gearcase, carefully avoiding damage to the lower gearcase locator dowel pins. 5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear sleeves. Do not remove the gear from the shaft unless you are replacing it. 6. Remove the pinion seal and retaining ring. 7. Remove the main body. 8. On the opposite end of the motor, remove the magnetic pickup and brake cover. 9. Remove the brake for service. Refer to the GE Electric Motor Manual included as a separate book in this manual for procedures to remove the pinion or hub on the armature shaft, or to service the motor itself. Once the unit has been disassembled, inspect the following assemblies for any wear or damage that may be critical: 1. Gear set: Check the teeth and splines for chips or heavy spalling. The wear pattern should be even and symmetrical. If not, replace it. Expect some small surface pitting. It is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090". 4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads. 5. Seals: Always replace seals and gaskets when removed. 6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gearcase are critical. Clean up any nicks or gouges prior to reassembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface.
TDS3 Maintenance
Training Manual
9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems are malfunctioning, remove the appropriate valve and repair or replace. Reassemble the drilling motor and motor support bonnet by reversing steps in the disassembly procedure. Replace all grease seals and O-rings, and refer to the following torque chart for bolt tightening guidelines. Torque Chart Motor support /bonnet to main body 7850 ft lb Main body to motor bonnet 1100 ft lb Bull gear to hub 580 ft lb Lower gear case to main body 250 ft lb Rotating head to lower gearcase 250 ft lb Brake adapter ring to motor 250 ft lb Brake to brake adapter plate 50 ft lb Brake drum to hub 250 ft lb Brake cover to brake 50 ft lb
TDS3 Maintenance
Training Manual
Gooseneck
Main Body Air Brake
Motor Support Bonnet
Bull Gear
D.C. Drilling Motor
Pinion Gear Drive Stem Motor Alignment Cylinder (Ref.) Lower Gear Case
TDS-3S Maintenance
Training Manual

You can perform some service procedures on top drives (i.e. upper quill shaft bearing and seal, air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. If service is required on the lower end (i.e. gear set, lower bearings or seals), you must remove the drilling motor from the dolly. 1 Set TDS down horizontally on a flat surface. Make sure that none of the components protrude past guide dolly roller brackets before setting down. If so, block dolly up accordingly.
2. Disconnect all wiring and hoses between transmission and guide dolly frame. 3. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with removing the transmission from guide dolly frame. 4. Run a suitable sling through quill shaft to support weight of motor and housing assembly (approximately 10,000 lb). 5. Attach sling to crane, take up slack and remove trunnion blocks that hold the transmission to the guide dolly frame. 6. Hoist the transmission out of the guide dolly frame. 7. Set motor and housing assembly down on wooden chocks, being careful not to damage components. 8. Disconnect the wiring between the motor and the housing. Make sure the transmission is in neutral. 9. Remove the dowel pins in motor feet. 10. Remove the four large motor bolts. 11. Lift transmission off of motor by slightly angling upper end to clear the motor frame, and slide the housing off of the motor towards the gear case end. 12. Remove the blower and brake assemblies. 13. Reverse this procedure for reassembly.
TDS-4H Maintenance
Training Manual
Removing the drilling motor from the housing assembly

1. Remove upper bearing cover and grease seal. 2. Pressurize air brake to hold drive mechanism in place and remove quill shaft locknut. 3. Remove cotter pins, slotted nuts and rotating head. 4. Remove the lower gear case. Lower gear case is located with dowel pins (Figure 20). 5. Carefully remove quill shaft with bull gear so as to avoid damaging bearing surfaces or wear sleeves. Do not remove the gear from the shaft except to replace it. 6. Remove large quill shaft bearings. 7. Remove pinion seal and retaining ring. 8. Remove upper gear case. 9. On opposite end of motor, remove magnetic pickup and brake cover. 10. Brake may now be removed for service. Refer to electric motor sections to remove the pinion or hub on armature shaft or to service the motor.
TDS-4H Maintenance
Training Manual
Figure 20. Gear case assembly/disassembly
TDS-4H Maintenance
Training Manual
Once the unit has been disassembled, inspect the assemblies for any wear or damage that may be critical, as follows: 1. Gear set: Check the teeth and splines for chips or heavy spalling. The wear pattern should be even and symmetrical. If not, replace it. Some small surface pitting is to be expected and is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090". 4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads. 5. Seals: Always replace seals and gaskets when removed. 6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gear case are critical. Any nicks or gouges must be cleaned up prior to reassembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface. 9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems have been malfunctioning, remove the appropriate valve and repair or replace.
TDS-4H Maintenance
September 16, 1996 76 TDS-4H Maintenance and troubleshooting
Re-assemble the drilling motor and housing assembly by reversing the steps in the preceding disassembly procedure. Replace all grease seals and O-rings, and refer to the following torque chart for bolt tightening guidelines. Torque chart Motor housing to motor 1750 ft lb Upper gear case to housing assembly 1100 ft lb Bull gear to hub 580 ft lb Lower gear case to main body 250 ft lb Rotating head to lower gear case 250 ft lb Brake adapter ring to motor 250 ft lb Brake to brake adapter plate 50 ft lb Brake drum to hub 250 ft lb Brake cover to brake 50 ft lb Upper seal retainer to motor housing 75 ft lb
Training Manual

You can perform some service procedures on top drives (i.e. upper drive stem bearing and seal, air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. If service is required on the lower end (i.e. gear set, lower bearings or seals), the drilling motor must be removed from the dolly. 1. Set TDS down horizontally on a good flat surface. 2. Make sure that none of the components protrude past the guide dolly roller brackets before setting the TDS down. If so, block up the guide dolly accordingly. 3. Disconnect all wiring and hoses between transmission and guide dolly frame. 4. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with removing the transmission from guide dolly frame. 5. Use a suitable sling to support the weight of the TDS and motor support bonnet (approximately 10,000 lb). 6. Take up the slack and remove the trunnion blocks that hold the transmission to the guide dolly frame. 7. Hoist the transmission out of the guide dolly frame. 8. Set the TDS and motor support bonnet down on wooden chocks, being careful not to damage components. 9. Disconnect the wiring between the motor and motor support bonnet. 10. Make sure the transmission is in neutral. 11. Remove the dowel pins in the motor feet. 12. Remove the four large motor bolts. 13. Lift the transmission off of the motor, angling the upper end slightly to clear the motor support bonnet, and sliding housing off of the motor toward the gearcase 14. Remove the blower and brake assemblies. 15. Reverse this procedure for reassembly.
TDS-4S Maintenance
Training Manual
Disassembly/assembly of drilling motor and motor support bonnet

1. Remove the upper bearing cover and grease seal (Figure 20). 2. Pressurize the air brake to hold the drive mechanism in place. 3. Remove cotter pins, slotted nuts and the rotating head. 4. Remove the lower gearcase, carefully avoiding damage to the lower gearcase locator dowel pins. 5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear sleeves. Do not remove the gear from the shaft unless you are replacing it. 6. Remove the pinion seal and retaining ring. 7. Remove the main body. 8. On the opposite end of the motor, remove the magnetic pickup and brake cover. 9. Remove the brake for service.
TDS-4S Maintenance
Training Manual
Main Body
Air Brake
Low Gear Assembly D.C. Drilling Motor
Bull Gear
High Gear Assembly Manual Shifter Input
Pinion Gear Geneva Mechanism
Shaft
LO
HI
Oil Level Sight Glass Lower Gear Case
Motor Pinion Seal
Gear Selection Indicator
TDS-4S Maintenance
Training Manual
Refer to the GE Electric Motor Manual for procedures to remove the pinion or hub on the armature shaft, or to service the motor itself. Once the unit has been disassembled, inspect the following assemblies for any wear or damage that may be critical: 1. Gear set: Check the teeth and splines for chips or heavy wear. The wear pattern should be even and symmetrical. If not, replace it. Expect some small surface pitting. It is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090". 4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads. 5. Seals: Always replace seals and gaskets when removed. 6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gearcase are critical. Clean up any nicks or gouges prior to reassembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface. 9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems are malfunctioning, remove the appropriate valve and repair or replace.
TDS-4S Maintenance
Training Manual
Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. Replace all grease seals and O-rings, and refer to the following torque chart for bolt tightening guidelines. Torque Chart Motor support/bonnet to main body Main body to motor bonnet Bull gear to hub Lower gearcase to main body Rotating head to lower gearcase Brake adapter ring to motor Brake to brake adapter plate Brake drum to hub Brake cover to brake 1100 ft lb 1100 ft lb 580 ft lb 250 ft lb 250 ft lb 250 ft lb 50 ft lb 250 ft lb 50 ft lb
TDS-4S Maintenance
Gearbox Lubrication
Rotating Head
Training Manual
Rotating head
The rotating head allows transferring pneumatic and hydraulic pressure from stationary ports on the TDS drilling motor housing to rotating ports on the rotating head (Figure 9). It features two hydraulic passages, three pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2000 psi). The rotating head assembly consists of: t A stationary flange t Eight rotary glyd rings t A swivel block t A cam t A return cylinder t A cam follower t Swivel block locking mechanism The hydraulic and air lines for the various pipehandler 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 also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. There is also a return cylinder 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.
TDS-Rotating Head
Training Manual
Stationary Flange
Cam
Cam Follower
Auto-Return Cylinder
Locking Lever
Swivel Block
Figure 9. Rotating head assembly
Integrated swivel and swivel washpipe

The integrated swivel is a bearing assembly that allows transfer of the rotating load to the lifting components (Figure 2). The swivel washpipe is a rotating seal that allows mud to flow to the rotating drill string.
TDS-Rotating Head
Training Manuale
Replacing the rotating head glyd ring
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). The following disassembly and assembly procedures assume that the TDS is swung out for maintenance in accordance with the TDS Swing Out procedures. Refer to Figures 4-16 and 4-17, when performing the following procedures:
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin.
TDS-500 Ton Rotating Head
13. Push the cam follower away from the rotating block cam. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. 15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
Stationary Flange Cam Follower
Cam
Locking Lever
Swivel Block
Figure 4-16. Rotating head assembly
Training Manual
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the quick disconnect hydraulic fittings on the rotating block. 7. Attach the return cylinder rod to the clevis with the clevis pin and install the slotted hex-head nut and cotter pin. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book of this manual.
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 4-17. Rotating head assembly/disassembly
TDS-500 ton Rotating Head1
Training Manual
Replacing the rotating head glyd ring
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). The following disassembly and assembly procedures assume that the TDS is swung out for maintenance in accordance with the TDS Swing Out procedures. Refer to Figures 17 and 18, when performing the following procedures.
Stationary Flange
Cam
Cam Follower
Locking Lever
Swivel Block
Figure 17. Rotating head assembly
Training Manual
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench.
Training Manual
Cam Assembly Locking Handle Return Cylinder
Return Cylinder Clevis Pin
Return Cylinder Rod End Detail Hex Nut
CAM
Cotter Pin
,,
Excluder Cap
Cylinder Clevis
Detail C
Retainer Ring Glyd Ring (8)
Ball Bearing Cam
,,,,, , , , , ,,,,, , , , , ,,,,, , , , , ,,,,, , , , , ,,,,,
Excluder Cap Gasket
Ball Bearing
C
Stationary Flange Bull Gear Lip Seal
Figure 18. Rotating head glyd ring replacement
Training Manual
6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Push the cam follower away from the rotating block cam. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. 15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the quick disconnect hydraulic fittings on the rotating block.
Link Tilt
Current date
Replacing the link tilt air actuator

There is an air actuator on the link tilt mechanism (Figure 4-18). The following procedure details the replacement of the actuators: 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 link adapter. 3. Lower the link tilt to the floor with the air actuator to be replaced facing up. 4. Remove the cotter key and pin from one end of chain connecting the two sealing plates. 5. Remove the safety wire from the four hex-head cap screws holding the air actuator sealing plate to the link tilt base or lever and remove the screws. 6. Lift the lever or base off the air actuator sealing plate, and rotate it 180 on the link tilt pivot pin and lay down. 7. Remove the 18 nuts and washers holding the sealing plate to the air actuator and remove the plate. 8. Using a pry bar or screwdriver, pry the air actuator away from the screws 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.
4-62
Lever Weldment Pivot Pin Sealing Plate (2)
Nuts, Lock Washers (18)
Air Actuator Base Hanger Plate
Pressure Regulator
Sealing Plate Bolt (4) Quick Exhaust Valve Lever Intermediate Stop (2)
Connecting Chain Buttonhead Capscrew (18)
Stop Pivot Arm Elevator Link (Ref) Stop Release Loop
Figure 4-18. Link tilt assembly/disassembly
4-63
Current date
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.
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. Over-torquing may cause hex sockets to strip. 3. Torque the cap screws to the hanger plate at 80 ft lb. 4. Insert the 18 bolts into the neck ring of the air actuator. 5. Reinstall the air actuator sealing plate, coat the bolt threads with locktite and fasten with the lockwashers and nuts provided. 6. Torque the nuts to the sealing plate at 80 ft lb (see caution above). 7. 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. 8. Safety wire the four screws. 9. Reconnect the chain between the two sealing plates. 10. Reinstall and adjust the link tilt per the procedure outlined in the Installation and Commissioning book.
4-64
Torque Arrestors
Torque Arrestors
The Link Adapter (Solid body Elevator), link tilt, Link Bails and Pipe elevators are supported on components called Torque Arrestors. They are pinned to the rotating Head mounted on the bottom of the gear case. The torque arrestors contain compression springs that keeps the Solid body Elevator, link adapter, Link Bails and Pipe elevators above the load collar on the main shaft. The springs do provide a pre-load sufficient to support a stand of drill pipe in the full full up position. When hoisting these torque arrestor springs will be compressed by the hoisting load allowing the link adapter ( solid body elevator) to be pulled down onto the load collar transferring the load to the main shaft. Two torque arrestors are used in the 500 ton version TDS and four torque arrestors are used in the 650/750 ton version TDS
Caution: Under No circumstances should Torque Arrestors be disassembled in the field as the contain powerful springs under compression and could cause serious injury and damage if released inadvertently.
IBOP
IBOP Control Circuit

Q A, Why is there 30 psi on the actuator shell at all times. During rough drilling conditions especially surface hole, Vertical vibration of the drill string can cause the upper ibop actuator shell to hammer on the the ibop crank assembly damaging the crank arms and the bearings The IBOP Control circuit prevents excessive damage to the actuator and bearings by holding the shell down with a force of 500 lbs in the open position. There is an reducing valve on the circuit which is set to 30 psi. The control circuit has a 30 second timer,( controlled by the PLC) when the open solenoid is operated it stays fully open for 30 seconds then shuts of and the pressure is reduced to 30psi from a prv on the close circuit.
Rig air 90 psi
Schematic showing circuit after timer operation
Close solenoid
To manifold vent
Open solenoid
Shuttle Valve
PRV set at 30psi 30 PSI on cylinders
Actuator Cylinders

Rig air 90 psi
Schematic showing circuit in close operation
Close solenoid
To manifold vent
Open solenoid
Shuttle Valve
Actuator Cylinders
Rig air 90 psi
Schematic showing circuit before end of timer operation
Close solenoid
To manifold vent
Open solenoid
Shuttle Valve
Actuator Cylinders
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
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 drillers 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.
Feb. 2, 1994
Link Tilt
Rotating Head (Ref.)
Link Adapter
Torque Arrestor
Splined Upper Safety Valve
Link Adapter Support Plate
350 Ton 108" Links (Ref.)
Safety Valve Actuator
Torque Wrench
Plain Lower Safety Valve
350 Ton Center-Latch Drill Pipe Elevator (Ref.)
Saver Sub
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
Feb. 2, 1994
Link Tilt
Rotating Head (Ref.)
Link Adapter
Torque Arrestor
Splined Upper Safety Valve
Link Adapter Support Plate
V a r c o
350 Ton 108" Links (Ref.)
Safety Valve Actuator
Torque Wrench
Plain Lower Safety Valve
350 Ton Center-Latch Drill Pipe Elevator (Ref.)
Saver Sub
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

OPE
Back-up Rings O-Ring
CL SD
O-Ring Ball Sleeve Seal Ring Crank Grease/ Mud Seal Seat Stabilizer Ring
Wave Spring Back-up Ring
Thread Protector
O-Ring
Figure 3. Typical Upper Safety Valve (IBOP)
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
t 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 t The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides. t The new cylinders operating the upper IBOP are 45% larger for positive closure and they eliminate the need for periodic adjustment. t The dual external crank assemblies share the operating loads. Each is reinforced, with improved sealing and retention. t The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.
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
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.
Feb. 2, 1994
Internal Valve Mechanism Improvements

1. Internal stress concentrations at the valves 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 designs 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.
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).
Feb. 2, 1994
Table 1. Make-Up Torque Values

Components I.D. Connection O.D. Torque (ft-lb) (min.) (max.)
Mainshaft to Upper IBOP Safety Valve* Upper IBOP Safety Valve to Lower IBOP Valve Lower IBOP Valve to Saver Sub Crossover Sub to Lower IBOP Safety Valve Mainshaft to Upper IBOP Safety Valve** Upper IBOP Safety Valve to Lower IBOP Lower IBOP Valve to Saver Sub Crossover Sub to Lower IBOP Valve * 500 Ton ** 650 Ton
3" 3"
6-5/8 API Reg. 6-5/8 API Reg.
7-3/4 7-3/4
60,000 50,000
70,000 70,000
3" 3"
7-3/8 7-3/8
46,000 46,000
64,000 60,000
3"
7-5/8 API Reg.
83,000
91,000
3"
7-5/8 API Reg.
75,000
91,000
3" 3"
8-5/8 9
66,000 75,000
85,000 91,000
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows (Figures 5 & 6): a. b. c. d. e. f. Carefully grind off any raised tong marks on the O.D. of the safety valves. Open the valve exactly halfway (45 degree rotation of the actuator). Orient the levers on the crank assemblies horizontally as shown. Slide the shell up onto the valve with the actuator arm groove on the bottom. Hold the shell in position relative to the valve operating sockets. 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 Groove Crank Assembly Safety Wire Groove Upper IBOP Valve
Lock Tabs
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 Position
Closed 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
Roller Assembly (3)
Crank Assembly Retaining Screw Slot
Crank Assembly
Actuator Shell Crank* Roller Assembly (3) Actuator Arm Groove
Roller Assembly (3)
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 Position
Closed Position
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 drillers 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
C L
BALL
C L
Figure 10. Lubricating a Typical Upper IBOP
FLOATING SEAT
19
PRESSURE SEALS SPRING CAVITY
VALVE BODY PRESSURE PLUG GREASE PORT

Feb. 2, 1994
WAVE SPRING
FIXED SEAT
C L
BALL
C L
FLOATING SEAT
Figure 11. Lubricating a Typical Lower IBOP
PRESSURE SEALS SPRING CAVITY
VALVE BODY
Feb. 2, 1994
PRESSURE PLUG GREASE PORT
20
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. ASTM A-275 ASTM E-709 Drilling Manual, 9th Edition Std. Method for Magnetic Particle Inspection of Steel Forgings 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): t t t t 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
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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.
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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.
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Feb. 2, 1994
DriveStem (Ref.) Link Adapter Landing Collar Eye Bolts (2) Upper IBOP Valve Actuator Air Cylinders (2) Upper IBOP Valve Actuator Shell Crank Assy(Shown with Valve OPEN. Note Crank Assy Position C L OS E OP E N *1 Inch Cylinder Gland Actuator Arm 5/8 max 3/8 min Upper IBOP Torque Tube
Cylinder Adjustment Bolts (4)
Cylinder in OPEN Position *IMPORTANT
Rod End
Lower IBOP
Saver Sub
F igure 13. A djus ting the S afety V alve A c tuator S ys tem for the P H-85, P H-60d & S ingle C rank P H-60
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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
17
10
18
14
15 20 7 16 8
2X 4 3 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
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Feb. 2, 1994
Parts List
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DESCRIPTION BALL, DUAL CRANK (SET) RETAINING RING O'RING BACK-UP RING LOWER SEAT (SET) UPPER SEAT (SET) POLYSEAL BACK-UP RING CROWN SEAL SLEEVE O'RING BACKING RING CRANK, RIGHT HAND WAVE SPRING BODY O'RING NYLON PLUG CRANK, LEFT HAND PLUG SEAL RING STABILIZER 96438 93806-11 89141-3 PART NUMBERS 90939-5 89141-1 90441-9 90441-10 90939-5 90939-5 96439 89141-13 89141-8 90441-7 (93806-12 for Dual Crank) 89141-11 89141-12 89141-7 (93806-10 for Dual Crank) 89141-9 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 1 QYT. / KIT 1 1 1 1 1 1 1 2 2 2 2 4 1 1 1 2 1 1 1 1 1 1 2 2 2 4 1 2 1 2 1 1 1
REPAIR KIT - SINGLE CRANK Refer to the Appendix for Part Numbers REPAIR KIT - DUAL CRANK Refer to the Appendix for Part Numbers REPAIR KIT - SOFT SEAL ONLY (For either Single or Dual Crank) Refer to the Appendix for Part Numbers BALL/SEAT SET Refer to the Appendix for Part Numbers
Figure 14. IBOP Illustrated Parts List (Cont.)

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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 Varco Part No. 79489-14 Nut Wrench for DSV Models Varco Part No. 89141-18
7/8" Hex Wrench For All Models Varco Part No. 89141-18
Figure 15. IBOP Tools
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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
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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 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 18
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
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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 lower seat (Figure 23).
Figure 23
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Feb. 2, 1994
15. Using the load bar across the face of the connection, 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
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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). 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 26
Figure 27
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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
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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
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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 pulling tool until it seats on the spring surface of the lower seat (Figure 33). 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
Figure 33
Feb. 2, 1994
18. Using the load bar against the face of the connection, tighten the nut to firmly seat the lower seat in the valve body (Figure 34).
Figure 34
19. Apply a generous coat of 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. 23. Apply a generous coat of grease to the entire outside of the ball, but make sure the holes are clear (Figure 36).
Figure 36
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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. 25. Apply a generous coat of 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). 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 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.
Figure 37
Figure 38
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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.
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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 bodyespecially 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 PART NO. TYPE OF SERVICE DESCRIPTION REPAIR KIT PART NO. SOFT SEALS BALL/SEAT PART NO. PART NO.
94769-500 94769-502 94769-501 94770-500 94770-502 94770-501 94099-500 94099-502 94099-501 94100-500 94100-502 94100-501 90815 90814 90813 90812 94206-500 94206-501 94206-502 94205-500 94205-501 94205-502 94204-500 94204-501 94204-502
STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM
Upper Valve-PH60 6 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design Upper Valve-PH60 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design Upper Valve - PH60 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design Upper Valve - PH60 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Land Collar Design Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design
90939-2 89453-SP 90939-2 90939-2 89453-SP 90939-2 90939-2 89453-SP 90939-2 90939-2 89453-SP 90939-2 93806 93806 93806 93806 93806 89453-SP 93806 93806 89453-SP 93806 93806 89453-SP 93806
90939-1 90939-1 90939-1 90939-1 90939-1 90939-1 90939-1 90939-1 93806-1 93806-1 93806-1 93806-1 93806-1 93806-1 93806-1 93806-1 93806-1 93806-1
90939-5 89453-15 90939-5 90939-5 89453-15 90939-5 90939-5 89453-15 90939-5 90939-5 89453-15 90939-5 90939-5 90939-5 90939-5 90939-5 90939-5 89453-15 90939-5 90939-5 89453-15 90939-5 90939-5 89453-15 90939-5
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Feb. 2, 1994
IBOP Part Numbers (Cont.)

IBOP PART NO. TYPE OF SERVICE DESCRIPTION REPAIR KIT PART NO. SOFT SEALS BALL/SEAT PART NO. PART NO.
94203-500 94203-501 94203-502 91138 89451-501 89491-503 86434 89452-501 89492-502 90811 91138 105629 103220 98977-500 98977-502 98977-501 99461-500
STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM STD H2S NAM
Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design Upper Valve - PH85 - Big Bore 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design Lower Valve 6 5/8 Pin X 6 5/8 Box Lower Valve-Stepped 6 5/8 Pin X 6 5/8 Box Lower Valve 7 5/8 Pin X 7 5/8 Box Lower Valve - Big Bore 7 5/8 Pin X 7 5/8 Box Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For Ids Only Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For TDS and SDS Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design
93806 89453-SP 93806 95384 90939-2 89453-SP 90939-2 89453-SP 90939-2 93807 94385 90939-2 99468-2 99469-SP 99468-2 99468-2 99469-SP 99468-2
93806-1 93806-1 91137-SP 90939-1 90939-1 90939-1 93807-1 91137-SP 90939-1 99468-1 99468-1 99468-1 99468-1
90939-5 89453-15 90939-5 91137-1 90939-5 89453-15 90939-5 89453-15 90939-5 90939-5 91137-1 90939-5 90939-5 65170014 98966 65170014 65170014 98966 65170014
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Identifying Varco Safety Valves

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46
Pipe Handler
Adjusting the Torque Wrench

Use the following procedure to adjust the pipe handler torque wrench.
The pipe handler torque wrench is properly adjusted 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. Connect a pup joint or a joint of drill pipe to the saver sub and make up hand tight. Be sure to use the correct thread compound when making up.
1.
K When adjusting torque wrench manifold valves loosen the lock nut with a 9/16 wrench and use a 5/32 allen key to adjust the valve. After obtaining the correct setting tighten locknut around valve stem. K For PH85 ONLY Close one of the rotation speed valves 3 turns and adjust the second valve approximately 4 turns until the tube stays centered when operated. K The above operation should only be carried out if the torque tube is out of center when operating 2 With the hydraulic unit switched off, fully screw in all sequence valves including lift lower valve. The PRV valve should be set at a minimum pressure of 750 psi, Turn the hydraulic power unit on.
3 4
If the torque cylinders are in there full clockwise position, set the make/break valve to MAKE. If the torque cylinders are in the full counterclockwise position the set the make/break valve to BREAK. NOTE The torque cylinders should not move if the recycle valve is fully in. 5 Set make/break valve to MAKE/BRAKE
Back out the recycle valve until you have the cylinders recycling at 7-9 second speed then tighten the lock nut. Set Make Brake Valve to MAKE Depress and hold the torque wrench operating button on the drillers console. Back out the lift/lower sequence valve until it starts to lift then adjust an additional half turn. Back out the clamp sequence valve until the clamp cylinder starts to move then an additional of a turn.
7 8
10 Back out the torque valve until the torque cylinders start to move the an additional of a turn. 11 Release the torque wrench operating button on the drillers console and observe the toque wrench function it should start to unclamp then drop and recycle. If the torque wrench drops before unclamping adjust the lift/lower valve in a of a turn and back out the clamp sequence valve an additional turn.
Air - Piloted Hydraulic Valve
Supply Flow Return Flow
1 Lift 2 1200 PSI Sequence
1 Lift 2 1200 PSI Sequence
1500 PSI Sequence
Clamp
1500 PSI Sequence
Clamp
Torque 3
Torque
Pressure Adjust
Pressure Adjust
Torque wrench hydraulic operation schematic
TDS-TW Operation
Trouble Shooting Pipe Handler

The Driller presses the TW Button but nothing functions :Check Check Check Check Check Check Quick Disconnects Hydraulic Supply Air Supply Drill/Spin /Torque switch is in Drill position Throttle is in the off position Electrical Supply, (Solenoids, Wiring, VDC Switches)
Assembly and disassembly

Pipehandler (PH-60d)
Torque wrench disassembly
(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. 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.
Use care in this operation. High pressure air can be explosive.
Training Maual June 99
Frame
Mounting Shaft Safety Valve Actuating Cylinders (2) Vertical Positing Cylinder
Safety Valve Actuating Arm (2)
Torque Tube Stabilizer
Stop Tube
Hanging Height Adjustment Shim Body
Torque Tube Torque Cylinder (2)
Guard
Stabbing Guide
Clamp Cylinder Body
Clamping Jaws (2)
Clamping Cylinder Piston Control Manifold
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 * Frame to clamp cylinder body Stabbing guide to body Die retainer screws Body hinge pin retainer screws Stabbing guide spring retainer screws Jaw retaining screws * 944 ft lb (1275 N.m) 250 ft lb (339 N.m) 250 ft lb (339 N.m) 380 ft lb (515 N.m) 150 ft lb (203 N.m) 75 ft lb (102 N.m) 110 ft lb (149 N.m)
The torque cylinder rod ends are threaded into the rods with lock-tite and cross pinned.
Replacing the torque wrench clamping piston seal
The following procedures require removing the torque wrench from the pipehandler.
Parts required for replacing the front and rear piston seal
Qty. 3 2 2
Disassembly
P/N 72219 72220 72221
Description Piston seal Rod seal Rod wiper
1. Remove the pins from the torque wrench guard and remove the guard. 2. 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. 3. 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.
4. Remove the jaw pins from the rear clamping jaw and remove the jaw. 5. Remove the two screws holding the jaw spacer to the front clamp cylinder piston and remove the spacer and jaw spacer. 6. Remove the two screws holding the clamp clevis to the rear clamp cylinder piston. 7. 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. 8. Push in the cylinder gland from the rear cylinder head retainer ring and remove the ring with a screwdriver. 9. Attach the sliding hammer to the rear piston rod and carefully pull the piston until the cylinder gland can be removed. 10. Continue to pull until the piston comes out. 11. Using a piece of wood or brass bar, tap the front clamp piston from the front and remove it from the rear. 12. Remove and discard the piston seals, rod seals and rod wipers. 13. Remove the front piston rod seal and rod wiper from the clamp cylinder body and discard. 14. 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 perform the Torque wrench adjustment procedure.
May 22, 1996
Assembly and disassembly

Pipehandler (PH-85)
Torque wrench disassembly
(Figures 16a, 16b, 16c and 16d) 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. Use care in this operation. High pressure air can be explosive!
TDS-4S Maintenance and troubleshooting
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May 22, 1996
TORQUE TUBE
V a r c o
TORQUE CYLINDERS (2)
Figure 16a. Torque wrench assembly/disassembly
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May 22, 1996
BODY
CLAMPING JAWS (2)
CLAMP CYLINDER BODY
STABBING GUIDE
CLAMP CYLINDER PISTON
Figure 16b. Torque wrench assembly/disassembly
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May 22, 1996
MOUNTING SHAFT
FRAME
SAFETY VALVE ACTUATING CYLINDERS (2)
VERTICAL POSITIONG CYLINDER
HANGING HEIGHT ADJUSTMENT
GUARD
Figure 16c. Torque wrench assembly/disassembly
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May 22, 1996
Figure 16d. Torque wrench assembly/disassembly (optional link retractor)
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May 22, 1996
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 front and rear piston seal replacement: Qty. 3 2 2

Disassembly
P/N 72219 72220 72221
Description Piston seal Rod seal Rod wiper
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.
62
May 22, 1996
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.
TDS-4S Maintenance and troubleshooting 63
May 22, 1996
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 perform Torque Wrench Adjustment Procedure.
64
Lubrication
September 16, 1996
Chapter 2 Lubrication
Lubricating the motor and motor housing assembly

Lubricating the main shaft spline
There is a lube point on the quill shaft located behind the large plug on the side of the motor housing just below the trunnion. Lubricate it weekly.
Gearbox
Check the oil daily. With the motor off, check to see that the oil level is at the middle of the sight glass located on the side of the main body. Drain and refill the gearbox every 1,500 operating hours or three months, whichever occurs first (Refer to Oil capacities below).
TDS-4H Maintenance and troubleshooting
23
September 16, 1996
Properly maintaining the TDS gear shifting mechanism increases the operational life of the top drive. Use the following procedure to maintain proper gear lubrication: 1. Shift all top drive two speed gearboxes from one gear to the other and back again at least once a week. This helps to distribute lubricant and prevents contaminant buildup. 2. Remove the gear indicator lever assembly and the indicator gear case cover. 3. Repack the inside area with grease every six months. 4. Inspect the gears for corrosion or damage. Clean, lubricate or replace components as required. There is a timing mark on the gears to ensure correct orientation. If these marks are not visible when removing the gears, mark the gears before removal to ensure correct orientation when reinstalling them. If there are problems shifting from one gear to the other, use the following procedure to shift the gears: 1. Turn the drive stem with chain tongs to make sure the gear mesh aligns properly. Do not turn the DC motor while shifting gears. 2. Insert two 3/8" bolts in the threaded holes on the bottom of the shafts while shifting the gears and use a bar to turn the shaft in the proper direction. Do not shear the bolts. Eccentric shaft rotation direction is the same as the shifter input shaft when shifting into gear. 3. If the shift input mechanism slips when attempting to shift gears, use a torque wrench to check the torque of the shifter when the clutch begins to slip. If the torque is less than 65 ft lb, use the torque setting procedure on the following page to adjust the clutch. Gearbox oil must be drained before removing clutch. The factory setting of the clutch is 45 ft lb. Increase the torque if problems persist. 4. Remove the 3" inspection plugs on the rear of the gear case and make sure the compound gears are free to turn with the unit in neutral. If the gears cannot turn, it is an indication of a larger problem (i.e., contaminants in gears, damaged bearings, etc.).
24 TDS-4H Maintenance and troubleshooting
September 16, 1996
Torque setting procedure

Use the following procedure to set the torque limit clutch to 4550 ft lb: 1. Attach any torque indicator to the output stub (Figure 4). 2. Hold the body and determine the current torque setting. 3. Remove the snap ring and locking plate. 4. Use a 5/8" open end wrench to turn the nut clockwise to increase torque, or to turn the nut counterclockwise to decrease the torque. 5. Check the resulting torque and repeat the above steps if more adjustment is necessary. 6. Replace the locking plate and snap ring.
Other gearbox lubrication and maintenance considerations

t Keep the bottom of the eccentric gear shafts clean and free of corrosion, paint or other contaminants. Keep this area lightly lubricated with oil. t Contaminant build up or corrosion around the upper end of the eccentric shafts can cause persistent shifting problems. Install sealed caps on the top of the shaft to correct the problem. There are two ways to install sealed caps. One way requires shop installation during top drive overhaul. There is a kit for field installation (P/N 97926). It consists of a rubber gasket, a sealing cap and a stud which threads into an existing tapped hole in the top of the eccentric shaft. The stud holds the cap on top of the gear case and keeps contaminants away from the shaft. It also adds a secondary seal between the oil in the gearbox and the DC motor cooling air path.
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.
TDS-4H Maintenance and troubleshooting 25
September 16, 1996
Figure 4. Torque setting procedure

September 16, 1996
Oil capacity
The TDS holds approximately 10-20 gallons of oil, but oil capacities vary according to the type of cooling systems, etc. installed. Always fill the transmission to the middle of the sight glass. Use the following procedure to fill the transmission for the first time on a new top drive: 1. Fill the gearbox to the top of the sight glass (approximately 1020 gallons). 2. Operate the top drive 10-15 minutes and check the sight glass. 3. The oil level should be near the middle of the sight glass. If the oil level is below the middle of the sight glass, add more oil until the level reaches the middle of the sight glass. If the oil level is at, or above the middle of the sight glass, do not add any additional oil to the gear case. After installation and initial operation of the top drive, always fill the transmission to the middle of the sight glass. When draining oil from the drain plug at the bottom of the gear case, only 5-6 gallons of oil at the bottom of the gear case actually drains. Oil remains in the rotating head cavity (approximately 1-2 gallons), the oil lube/pump/cooler system (approximately 1-2 gallons), and the wetted surfaces inside the motor housing assembly (approximately 2-3 gallons). Removing the suction hose from the cover plate below the pinion shaft allows more oil to drain and also removes sediment that collects there.
27
September 16, 1996
Lubricating the DC motor

The upper motor armature bearings have grease points located on the brake adapter plate attached to the top of the motor. The lower armature bearing grease point on the GE motor is at the end of a small diameter tube projecting toward the back of the tool. 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 pinion (transmission) end bearing every 750 hours, or 90 days, with two ounce by weight Shell Cyprina RA. Lubricate the commutator (brake) end bearing every 1,500 hours, or six months, with two ounce by weight Shell Cyprina RA. Excessive lubrication of electric motors can cause motor failure due to shorting or heat buildup from grease coming in contact with the field windings.
28
September 16, 1996
Lubricating the rotating head

Apply grease daily at the five fittings. Inspect for seal leakage around the lower bearing retainer weekly.
Grease Fittings
Grease Fitting
Grease Fittings
Figure 5. Lubricating the rotating head
29
September 16, 1996
Lubricating the link adapter

Apply grease to the four fittings weekly.
650 Ton Solid Body Elevator 2 Grease Fittings on front, 2 Grease Fittings opposite. (4 places total)
Figure 6. Lubricating the Link Adapter
30
September 16, 1996
Lubricating the torque wrench

Apply grease to the six fittings daily. Inspect the stabbing for excessive wear or cracks. Replace as necessary.
Lubricating the elevator support and master bushing wear guide

Apply grease to the seven fittings on the elevator support weekly. The master bushing wear guide has four fittings (Figure 5). Lubricate weekly. Inspect the guide ring periodically for wear or damage and replace as necessary.
Grease Fittings 2 places as shown and 2 places opposite side. (4 Total)
Figure 5. Lubricating the master bushing wear guide
31
September 16, 1996
Lubricating the Varco BNC drill pipe elevator

Apply grease to the seven grease fittings on the 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 8. Lubricating the BNC drill pipe elevator
32
September 16, 1996
Lubricating the RBS

Grease the 17 fittings each trip. Also check for worn tong dies in the clap jaws and replace as necessary. RBS units with stabbing heads have an additional 10 fittingslubricate all 10 each trip.
Lubricating the safety valve actuator

Apply grease to the six fittings on the actuator arms daily. Check for worn components and operate the valve to verify correct adjustment weekly.
33
September 16, 1996
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. Refer to the IBOP Service Manual included in this manual for complete IBOP lubrication instructions.
Open Position
Closed Position
Upper IBOP Valve
Figure 9. Lubricating the IBOP actuator
34
September 16, 1996
Lubricating the guide dolly assembly

Lubricate the 20 guide rollers weekly at the four manifolds (5 fittings each) located on each corner of the guide dolly (Figure 10). Check guide rollers weekly for cracks or excessive axial or radial play and replace as necessary. Lubricate the hinges (one place on each hinge) once each trip. It is possible to over-grease (too much pressure, not volume) the guide rollers. This can push the plugs out. Visually inspect all of the guide rollers for evidence of grease extruding from the end(s) of the shaft. If you discover over-greasing, perform the following procedure: 1. Remove and disassemble the roller assembly. 2. Thoroughly clean and inspect all parts. 3. If the component parts are still serviceable, drill and tap the shaft end(s) for 1/8" NPT threads and install internal wrenching pipe plugs after thoroughly cleaning metal chips from the grease ports in the roller shaft. 4. Pre-grease roller bearings before reassembling and installing the rollers and shaft. 5. Re-grease roller bearings through grease lines to make sure lubricant is pumping through the roller bearings. Some grease should extrude between the rollers and roller shaft. 6. Replace unserviceable assemblies. 7. Improve plug retention on roller assemblies with intact sheet metal plugs by staking the edges of the port(s). To do this: a. Remove the roller or roller bracket assembly to improve accessibility. b. Use a hammer and chisel to stake the port edges. A preferred method is to rework the roller assembly for drill and tap operation, but the staking method is also effective. There are two grease points for the motor trunnions, one at each bottom corner of the motor frame (Figure 11). Lubricate these weekly.
35
September 16, 1996
Lubricate the wash pipe packing daily with the mud pump off. Check the filter gauge on the pressure filter daily with the hydraulic power on to determine the condition of the filter element. Replace the element when a bypass condition is indicated.
Do not weld or torch cut on or near the motor frame without removing hydraulic accumulators.
5 2 1
Lubrication Manifold (4)
4 3
Figure 10. Guide dolly assembly (with hinges rear half)

September 16, 1996
Figure 11. Motor frame/guide dolly assembly (with hinges front)

TDS-4H Maintenance and troubleshooting 37
September 16, 1996
Lubricating the bail pins

Lubricate the bail pins weekly, at the same time the dolly rollers are lubricated, at the two fittings, one on each bail pin.
Lubricating the cooling system

Lubricate AC blower motors every three months. On rigs with closed loop cooling systems also check the heat exchangers for water leakage weekly, and remove the access covers and operate the blower to remove dust buildup every 500 operating hours.
38
September 16, 1996
Lubrication schedule
Frequency Daily Daily Daily Daily Daily Daily Each trip Each trip Each trip Each trip Each trip Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly 750 hrs/90 days 1500 hrs/6 mos. Monthly Monthly 3 months 3 months 3 months Lubricant Number Location code* of points Torque wrench 1 6 Gearbox oil (check level) 2 1 Rotating head 1 5 Safety valve actuator cranks 1 2 Hydraulic pressure filter 4 Upper quill shaft bearings 1 1 BNC drill pipe elevator 1 7 PS-16 power slip 1 8 RBS 1 17 RBS stabbing head 1 10 Guide dolly rollers 1 20 Gearbox (shift gears) Dolly motor trunnions 1 2 Air filter/regulator/lubricator IBOP actuator arms 1 6 Link adapter 1 4 Elevator support 1 7 Master bushing wear guide 1 4 Link tilt (check condition) Main shaft spline 1 1 GE motor pinion bearing 3 GE motor commutator bearing 3 Motor frame/dolly hinges 1 4 Cooling system cleaning AC blower motor 1 2 Change gearbox oil 2 1 Gear oil filter/suction strainer 1
*See lubricant specification table Check condition and replace as necessary
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.
39
September 16, 1996
Lubricant specifications
TDS 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 top drives also operate under a wide variety of temperatures. Select lubrication for the TDS 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: t Damage the gearbox due to reduced oil flow t Damage the oil pump because of excessive load All oils change viscosity with temperature and EP oil is no exception. The TDS 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. Measure on the pump discharge fitting on the TDS. The following tables will aid in your lubricant selection and keep your TDS-S transmission operating properly:
40
September 16, 1996
Minimum Ambient Temperature F (C) Below 20 (-6) 20-60 (-616) 45-85 (730) Above 70 (21)
Oil Type Required See Note Below* 2EP, ISO 68 4EP, ISO 150 6EP, ISO 320
Varco Part Number See Note Below* 56004-1 56004-BSC 56004-2
For minimum temperatures below 20F, the TDS must be warmed up by rotating at a very light load (less than 200 amps) and at very slow speeds (less than 50 RPM) until the oil temperature climbs above 20F. If the oil temperature falls below 20F, Varco recommends running the TDS at very light loads (less than 100 amps) until the oil is above 20F. If drilling conditions dictate oil temperatures below 20F, consult Varco engineering. If the oil temperature rises above 200F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200F. If drilling conditions dictate oil temperatures above 200F, consult Varco engineering.
41
42
Lube Code and Description
1 2 3 4
September 16, 1996
General Purpose Grease Gear Oil Above 21C 7 to 30C -6 to 16C All temperatures Cyprina RA Carter EP 68 4EP 150 2EP I66 -10 to 85C Motor Grease Above -20 Below -20C
Hydraulic Oil -15 to 75C Hyspin AWS-32 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 46 Hydraway HMA 32 Rando oil HD46 Azolla ZS 46 Unax AW46 1 45 Rando oil HD32 Azolla ZS 32 Unax AW32 32
Ambient temperature range MP grease Alpha LS-320 Alpha -150 Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Statoil Meropa 68 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 Alpha LS-320 Alpha LS-320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320 Avi-Motive W Lidok EP1 Avi-Motive Lidok EP2
Castrol
Hyspin AWS-46

Mobilux EP2 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 1 6EP 320 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP
Chevron
Exxon
Gulf
Gulf Crown EP32 Gulf Crown EP31
Mobil
Shell
Statoil
Texaco
Total
Union
NGL1
AGMA
ISO Viscosity Grade
PH-60 Lubrication and Maintenance Guide 500 Ton Capacity

See the Service Manual for more detail
Weekly
Hydraulic Link Tilt Apply two pumps per grease fitting (8 places) Rotating Head Positioning Roller Apply two pumps
Weekly
500 Ton Rotating Head Apply two pumps per grease fitting (4 places)
Weekly
Weekly
Support Shaft Apply general purpose grease at the contact point between the shaft and frame
Weekly Weekly
Pneumatic Link Tilt Check condition of the air bladder, the pivot pin and the stops 500 Ton Link Adapter Apply two pumps per grease fitting (2 places)
Grease Lubrication Schedule

Description Rotating Head Positioning Roller 500 Ton Rotating Head 500 Ton Link Adapter Hydraulic Link Tilt Link Adapter Wear Shoe IBOP Actuator Cranks Upper IBOP Valve IBOP Actuator Arms IBOP Actuator Cam Followers Link Spreader (if equipped) Torque Tube Clevis Pins Clamp Body Cylinder Trunnion Clamp Body Support Shaft Elevator Link Eyes Points Frequency 1 4 2 8 4 2 1 4 2 6 2 4 6 1 4
Weekly Weekly Weekly Weekly Daily Daily Weekly Weekly Weekly Weekly Daily Weekly Weekly Weekly Weekly
Daily
IBOP Actuator Cranks Apply one pump per grease fitting (2 places, 1 each side)
Daily
Link Adapter Wear Shoe Apply two pumps per grease fitting (4 places)
Weekly
Upper IBOP Valve Remove 1/4" NPT plug, install grease fitting Apply ten pumps
Weekly
IBOP Actuator Cam Followers Apply two pumps per grease fitting (2 places, one each side)
Replace plug before operating
Weekly
IBOP Actuator Arms Apply two pumps per grease fitting (4 places, 2 each side)
Recommended Lubricants
Manufacturer General Purpose Grease
Ambient Temperature Range Below -20 C
(Below -4F)
N/R
Above -20 C
Weekly Weekly
Link Spreader (if equipped) Apply two pumps per grease fitting (6 places, 3 each side) Clamp Body Cylinder Trunnion Apply two pumps per grease fitting (4 places, 2 each side)
(Above -4F)
Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union Viscosity Index NGLI AGMA
MP Grease Avi-Motive Lidok EP2 Gulf Crown EP32 Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2
Avi-Motive W Lidok EP1 Gulf Crown EP31 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1
Daily
Torque Tube Clevis Pins Apply two pumps per grease fitting (2 places, 1 each side)
Weekly
Clamp Body Apply two pumps per grease fitting (6 places, 3 each side)
1 N/R
2 N/R
General Condition Checks

Description Check for missing lockwire Check for loose or broken parts Check for missing cotter pins Check for hydraulic and air leaks Check for wear on tong dies and guide flippers Test IBOPs for leakage (in place) Check for proper rotation of the IBOP actuator cam followers Check condition of the air bladder, stops, and pivot pin on the pneumatic link tilt Frequency
Daily Daily Daily Daily Daily Weekly Daily
Weekly
Elevator Link Eyes
Pipe Dope
See the other side for the PH-60 650/750 Ton Capacity
Weekly
Varco P/N
126732
PH-60 Lubrication and Maintenance Guide 650/750 Ton Capacity

650/750 Ton Powered Rotating Head Rotating Head Bull Gear Brush with grease
Hydraulic Link Tilt
Weekly
Apply two pumps per grease fitting (8 places)
Weekly
650/750 Ton Rotating Head Apply two pumps per grease fitting (5 places)
Weekly
Weekly
PH-60 Support Shaft Apply general purpose grease at the contact point between the shaft and frame
Weekly
650/750 Ton Powered Rotating Head Apply two pumps per grease fitting (5 places)
Weekly
650/750 Ton Link Adapter Apply two pumps per grease fitting (4 places)

Description 650/750 Ton Rotating Head 650/750 Ton Powered Rotating Head Powered Rotating Head Bull Gear 650/750 Ton Link Adapter Hydraulic Link Tilt Link Adapter Wear Shoe IBOP Actuator Cranks Upper IBOP Valve IBOP Actuator Arms IBOP Actuator Cam Followers Link Spreader (if equipped) Torque Tube Clevis Pins Clamp Body Cylinder Trunnion Clamp Body Support Shaft Elevator Link Eyes Points Frequency 5 5 1 4 8 4 2 1 4 2 6 2 4 6 1 4
Weekly Weekly Weekly Weekly Weekly Daily Daily Weekly Weekly Weekly Weekly Daily Weekly
Weekly
Pneumatic Link Tilt Check condition of the air bladder, the pivot pin and the stops
Weekly
Upper IBOP Actuator Cam Followers Apply two pumps per grease fitting (2 places, 1 each side)
Daily
Weekly Daily
IBOP Actuator Cranks Apply one pump per grease fitting (2 places, 1 each side) Link Spreader (if equipped) Apply two pumps per grease fitting (6 places, 3 each side)
Weekly
Weekly Weekly Weekly
Weekly
Clamp Body Cylinder Trunnion Apply two pumps per grease fitting (4 places, 2 each side)
(Below -4F)
N/R
Above -20 C
Weekly
(Above -4F)
Avi-Motive W Lidok EP1 Gulf Crown EP31 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1
Daily
1 N/R
2 N/R
Weekly

Weekly
Weekly
See the other side for the PH-60 500 Ton Capacity
Varco P/N
Elevator Link Eyes

Pipe Dope
126732
PH-85 Lubrication and Maintenance Guide 500 Ton Capacity

Weekly
Hydraulic Link Tilt Apply two pumps per grease fitting (8 places) Rotating Head Positioning Roller Apply two pumps
Weekly
500 Ton Rotating Head Apply two pumps per grease fitting (4 places)
Weekly
Weekly
Weekly
500 Ton Link Adapter Apply two pumps per grease fitting (2 places)
Weekly

Description Rotating Head Positioning Roller 500 Ton Rotating Head 500 Ton Link Adapter Hydraulic Link Tilt Link Adapter Wear Shoe IBOP Actuator Cranks Upper IBOP Valve IBOP Actuator Arms IBOP Actuator Cam Followers Link Spreader (if equipped) Torque Tube Clevis Pins Clamp Body Cylinder Trunnion Clamp Body Support Shaft Elevator Link Eyes Points Frequency 1 4 2 8 4 2 1 4 2 6 2 4 8 1 4
Weekly Weekly Weekly Weekly Daily Daily Weekly Weekly Weekly Weekly Daily Weekly Weekly Weekly Weekly
Daily Daily
IBOP Actuator Cranks Apply one pump per grease fitting (2 places, 1 each side) Link Adapter Wear Shoe Apply two pumps per grease fitting (4 places)
Weekly
Weekly
IBOP Actuator Cam Followers Apply two pumps per grease fitting (2 places, one each side)
Weekly Weekly
Link Spreader (if equipped) Apply two pumps per grease fitting (4 places, 2 each side)
(Below -4F)
Above -20 C
(Above -4F)
N/R Avi-Motive W Lidok EP1 Gulf Crown EP31 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1
Daily
Weekly
1 N/R
2 N/R
Weekly

Weekly
Elevator Link Eyes
Pipe Dope
See the other side for the PH-85 650/750 Ton Capacity
Weekly
Varco P/N
126731
PH-85 Lubrication and Maintenance Guide 650/750 Ton Capacity

650/750 Ton Powered Rotating Head Rotating Head Bull Gear Brush with grease
Hydraulic Link Tilt
Weekly
Apply two pumps per grease fitting (8 places)
Weekly
650/750 Ton Rotating Head Apply two pumps per grease fitting (5 places)
Weekly
Weekly
Weekly
650/750 Ton Powered Rotating Head Apply two pumps per grease fitting (5 places)
Weekly
650/750 Ton Link Adapter Apply two pumps per grease fitting (4 places)

Description 650/750 Ton Rotating Head 650/750 Ton Powered Rotating Head Powered Rotating Head Bull Gear 650/750 Ton Link Adapter Hydraulic Link Tilt Link Adapter Wear Shoe IBOP Actuator Cranks Upper IBOP Valve IBOP Actuator Arms IBOP Actuator Cam Followers Link Spreader (if equipped) Torque Tube Clevis Pins Clamp Body Cylinder Trunnion Clamp Body Support Shaft Elevator Link Eyes Points Frequency 5 5 1 4 8 4 2 1 4 2 6 2 4 8 1 4
Weekly Weekly Weekly Weekly Weekly Daily Daily Weekly Weekly Weekly Weekly Daily Weekly Weekly
Weekly
Weekly
Upper IBOP Actuator Cam Followers Apply two pumps (2 places, 1 each side)
Daily
Weekly
Link Spreader (if equipped) Apply two pumps per grease fitting (6 places, 3 each side)
Daily
IBOP Actuator Cranks Apply one pump per grease fitting (2 places, 1 each side)
Weekly
Weekly Weekly
Weekly
(Below -4F)
Above -20 C
(Above -4F)
Weekly
Daily
1 N/R
2 N/R
Weekly

Weekly
Weekly
See the other side for the PH-85 500 Ton Capacity
Varco P/N
Elevator Link Eyes

Pipe Dope
126731
TDS-4H Lubrication and Maintenance Guide

For more detail see the TDS-4H Service Manual See the other side of this chart for the TDS-4S Lubrication and Maintenance Guide

Swing Guide Dolly Description Check for missing lockwire Frequency
Daily Daily Daily Daily Daily Daily Daily
Monthly
Swing Guide Dolly Hinges Apply two pumps per grease fitting (4 places, 2 each hinge)
Check for loose or broken parts Check for missing cotter pins Check for hydraulic and air leaks Check condition of the oil and hydraulic filter gauges Check the gear oil levels Check for cracks and excessive axial or radial play on the guide dolly rollers and replace as necessary
Retract Guide Dolly Apply two pumps per grease fitting (28 places, 7 each manifold)
Weekly
Bail Pins Apply two pumps per grease fitting (2 places, 1 each side)
Weekly
Monthly
Motor Trunnions Apply two pumps per grease fitting (2 places, 1 each side)
Weekly
Swing Guide Dolly Apply two pumps per grease fitting (20 places, 5 each manifold, if equipped) Hydraulic Filter (Actual location may vary)
See the manufacturers documentation for Swivel lubrication information

Description Bail Pins Upper Bearing Motor Trunnions Swing Guide Dolly Hinges Swing Guide Dolly (Grease Fittings on Manifolds) Non-Swing Guide Dolly (Grease Fittings on Manifolds) Retract Guide Dolly (Grease Fittings on Manifolds) Points Frequency 2 1 2 4 20 20 28
Weekly Weekly Monthly Monthly Weekly Weekly Weekly
Gear Oil Filter (Actual location may vary)
See lubrication section of the TDS-4H service manual for lubrication of electric motors
Gear Oil Lubrication Schedule

Description Replace the Gearbox Oil and Perform an Oil Analysis Replace the Gearbox Oil Filter Frequency
3 Months 3 Months
Oil viscosity should be adjusted based on expected ambient conditions for next three months
LO
Mfr. Grease
Below -20C
(Below -4F)
Gear Oil
(20 to 60F)
Gear Oil Fill
Ambient Temperature Range

Above -20C
(Above -4F)
Monthly
7 to 30C
(Above 70F)
-6 to 16C
(45 to 85F)
Above 21C
Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union
Alpha LS-68 Alpha LS-150 Alpha LS-320 NL Gear 68 NL Gear 150 NL Gear 320 Spartan EP68 Spartan EP150 Spartan EP320 EP Lube HD68 EP Lube HD150 EP Lube HD320 MobilGear 626 MobilGear 629 MobilGear 632 Omala 68 Omala 150 Omala 320 Loadway EP68 Loadway EP150 Loadway EP320 Meropa 68 Meropa 150 Meropa 320 Carter EP 68 Carter EP 150 Carter EP 320 Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Weekly
Upper Bearing Apply two pumps per grease fitting Refer to the TDS-4H Service Manual or the Pipehandler Lubrication and Maintenance Guide for maintenance and lubrication of the Rotating Head Gear Oil Sight Gage Check with Top Drive OFF Gear Oil Drain and Sample Valve
Viscosity Index
NGLI AGMA ISO Viscosity Grade 1 N/R N/R 2 N/R N/R N/R 2EP 68 N/R 4EP 150 N/R 6EP 320
Varco P/N
127052
TDS-4S Lubrication and Maintenance Guide

For more detail see the TDS-4S Service Manual See the other side of this chart for the TDS-4H Lubrication and Maintenance Guide

Swing Guide Dolly Description Frequency
Daily Daily Daily Daily Daily Daily Daily Daily
Monthly
Swing Guide Dolly Hinges Apply two pumps per grease fitting (4 places, 2 each hinge)
Check for missing lockwire Check for loose or broken parts Check for missing cotter pins Check for hydraulic and air leaks Check the washpipe assembly for leaks Check condition of the oil and hydraulic filter gauges Check the gear oil levels Check for cracks and excessive axial or radial play on the guide dolly rollers and replace as necessary
Retract Guide Dolly Apply two pumps per grease fitting (28 places, 7 each manifold)
Weekly
Upper Bonnet Seals Apply one pump of general purpose grease Using hand pump only Washpipe Assembly Apply three pumps of general purpose grease at beginning of tour Mud pumps OFF
Weekly
Daily Monthly
Weekly
Swing Guide Dolly Apply two pumps per grease fitting (20 places, 5 each manifold, if equipped) Hydraulic Filter (Actual location may vary)

Description Washpipe Assembly Upper Bonnet Seal Bail Pins Motor Trunnions Swing Guide Dolly Hinges Swing Guide Dolly (Grease Fittings on Manifolds) Non-Swing Guide Dolly (Grease Fittings on Manifolds) Retract Guide Dolly (Grease Fittings on Manifolds) Points Frequency 1 1 2 2 4 20 20 28
Daily Weekly Weekly Monthly Monthly Weekly Weekly Weekly
Gear Oil Filter (Actual location may vary)
See lubrication section of the TDS-4S service manual for lubrication of electric motors
Gear Oil Lubrication Schedule

Description Replace the Gearbox Oil and Perform an Oil Analysis Replace the Gearbox Oil Filter Frequency
3 Months 3 Months
Oil viscosity should be adjusted based on expected ambient conditions for next three months
LO
Mfr. Grease
Below -20C
(Below -4F)
Gear Oil Gear Oil Fill

7 to 30C
(Above 70F) (20 to 60F)
Ambient Temperature Range

Above -20C
(Above -4F)
-6 to 16C
(45 to 85F)
Above 21C
Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union
Alpha LS-68 Alpha LS-150 Alpha LS-320 NL Gear 68 NL Gear 150 NL Gear 320 Spartan EP68 Spartan EP150 Spartan EP320 EP Lube HD68 EP Lube HD150 EP Lube HD320 MobilGear 626 MobilGear 629 MobilGear 632 Omala 68 Omala 150 Omala 320 Loadway EP68 Loadway EP150 Loadway EP320 Meropa 68 Meropa 150 Meropa 320 Carter EP 68 Carter EP 150 Carter EP 320 Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Weekly
Bail Pins Apply two pumps per grease fitting (2 places, 1 each side)
Monthly
Refer to the TDS-4S Service Manual or the Pipehandler Lubrication and Maintenance Guide for maintenance and lubrication of the Rotating Head Gear Oil Sight Gage Check with Top Drive OFF Gear Oil Drain and Sample Valve Motor Trunnions Apply two pumps per grease fitting (2 places, 1 each side)
Viscosity Index
NGLI AGMA ISO Viscosity Grade 1 N/R N/R 2 N/R N/R N/R 2EP 68 N/R 4EP 150 N/R 6EP 320
Varco P/N
127052
Varco Wash Pipe Assembly Guide

See the Top Drive Service Manual for more detail
3" Bore
Lubrication Schedule
Description
Packing Box
4" Bore
123440 & 123440-750
O-Ring 51300-359-F Snap Ring 123634 Holding Ring 123437 Packing Seal (5 per Set) 123584-2 or 123584-3
Recommended for proper tightening of the wash pipe nut and packing box
123290 & 123290-1000

Frequency
Each Tour
Special Tools
Wash Pipe Wrench
Lubricant
Apply 3 pumps of multipurpose lithium-based or high temperature moly-based grease (do not mix lubricants)
or
Twice Daily
O-Ring 51300-348-F Snap Ring 123562 Holding Ring 123288 Packing Seal (5 per Set) 123292-2 or 123292-3
3" Bore Wash Pipe Wrench 30150084 4" Bore Wash Pipe Wrench 141481
Rotate the mainshaft at approximately 50 rpm for 1 to 2 minutes before turning on the mud pumps Regular greasing will increase packing seal and wash pipe life
3" Bore Packing Kits

Part #'s
123290-PK (Standard)
4" Bore Packing Kits

Part #'s
123440-PK (Standard)
Contents
(1) Packing Set 123292-2 (2) O-Rings 51300-348-F (1) Grease Fitting 53219-1 (1) Packing Set 123292-3 (2) O-Rings 51300-348-F (1) Grease Fitting 53219-1
Comments
Nitrile/Cotton, Pressure rated at 5,000 psi (Use with Wash Pipe 123289 or 123289-TC) Nitrile/Armide, Pressure rated at 10,000 psi (Use with Wash Pipe 123289-TC only)
Contents
(1) Packing Set 123584-2 (2) O-Rings 51300-359-F (1) Grease Fitting 53219-1 (1) Packing Set 123584-3 (2) O-Rings 51300-359-F (1) Grease Fitting 53219-1
Comments
Nitrile/Cotton, Pressure rated at 5,000 psi (Use with Wash Pipe 123438 or 123438-TC) Nitrile/Armide, Pressure rated at 7,500 psi (Use with Wash Pipe 123438-TC only)
123290-PK-1 (High Pressure)
Wash Pipe Nut 123284
Wash Pipe Nut 123431
123440-PK-1 (High Pressure)
Reassembly Procedure
Checklist
With the packing box upside down, assemble the packing seals and spacers into the packing box using care to line-up the upper spacer slot with the dowel pin Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease using care not to grease the outside diameter of the spacers Install the socket head dog nose screw, ensuring that the screw nose is fully engaged in the groove of the lower spacer Install the grease fitting and turn the packing box upright Install the wash pipe into the packing box assembly (slotted end up) Install the wash pipe nut onto the wash pipe Grease the packing seal and install into the holding ring using care not to grease the outside diameter of the holding ring Install the packing seal and holding ring over the slotted end of the wash pipe Install the snap ring Install the upper and lower o-rings using grease to hold them in place Compress the assembly to the length of the wash pipe
Wash Pipe 123289 *123289-TC * Tungsten Coated
Wash Pipe 123438 *123438-TC * Tungsten Coated
The wash pipe should be replaced when any measurable wear or grooving is present
Packing Box 123563 Grease Fitting 53219-1 Socket Head Dog Nose Screw 123564
Packing Box 123626 Grease Fitting 53219-1 Socket Head Dog Nose Screw 123564
If the packing box is properly tightened, and a leak is still present, do not attempt to eliminate the leak with additional hammering (See Installation Procedure)
Typical Assembly View
!
Long-Arm Allen Wrench 53303-14 Upper Spacer 123285 Long-Arm Allen Wrench 53303-14 Upper Spacer 123434
The wash pipe nut and the packing box have left-handed threads
Installation Procedure
Checklist
Install the wash pipe assembly on the Top Drive and hand tighten the wash pipe nut and packing box (apply pipe dope to the threads) Manually rotate the mainshaft 1 or 2 revolutions to seat and align the pipe in the packing box Set the Top Drive brake Tighten the packing box first with the wash pipe wrench or by hammering a few blows on every other lug, releasing the brake, turning the mainshaft and reseting the brake with each blow (the packing box should tighten at approximately 3/4 turn or advance 1/4 inch from the hand tightened position) Tighten the wash pipe nut next with the wash pipe wrench or by hammering gently on a lug (the wash pipe nut should tighten at approximately 1/4 turn or advance 1/10 inch from the hand tightened position) Apply 6 to 8 pumps of multipurpose lithium-based or high temperature moly-based grease to the grease fitting Rotate the Top Drive at approximately 50 rpm for 1 minute without mud pumps Turn on the mud pumps and check for leaks (if leaks occur, disassemble and repeat all previous steps) If leaks continue, see the Top Drive service manual for inspection of alignment and runout of mating parts.
Varco P/N
Middle Spacer 123286
Dowel Pin
Slide the wash pipe nut and the packing box together for installation
Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease completely filling the void
Lower Spacer 123287
Lower Spacer 123436
O-Ring 51300-348-F
O-Ring 51300-359-F
Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer
128844
Upper IBOP Break-out Procedure

For more detail see the PH-85 Pipehandler Service Manual
Step 1
A. Breakout saver sub and lower IBOP the normal way using PH-85 pipe handler. B. Tilt links with elevator to mouse hole or remove. C. Tie up links with cable to Top Drive (safety). D. Hang the RTBS intensifier assembly on guard of PH-85. Connect (2) 1/4" hoses to line body on PH-85 manifold, connect the 1/2" hose to the TDS brake by disconnecting the existing brake hose at the brake drum, and hook up rig air to (A1) location on the intensifier assembly.
Step 2
A. Hoist RTBS with the shackle on the end of the stem and place and secure RTBS on rotary table, remove shackle. B. Lock rotary table. C. Lock main shaft with TDS brake, switch valve handle to horizontal position and adjust air pressure to 175 psi.
Step 3
A. Stab PH-85 over RTBS & lower it to line up with top of yellow area. B. Select "MAKE-UP" mode (reverse from normal). C. Screw the PRV valve on PH-85 manifold all the way in D. Push "TORQUE WRENCH" button on VDC. PH-85 will rise, clamp on RTBS, and break out upper IBOP. It will stroke back down when the button is released. Repeat until IBOP is loose. (Note: IBOP valve should breakout @ approximately 2500 psi)
Step 4
A. Raise TDS/PH-85 until stabbing guide clears the top of RTBS. B. Place drive ring over RTBS shoulder with square boss engaged with drive ring.
RTBS Intensifier Assembly Tie-up Cable Upper IBOP Valve PH-85 Lower IBOP Adjust Air Pressure To 175 Psi Intensifier Adjustment Torque Tube
Saver Sub Yellow Area Drive Ring
Engaged On Square Boss
RTBS Intensifier Assembly Top of Rotary Table and Deck
RTBS (Rotary Table Back-up Structure)
Handle Shown in Horizontal Lock Position
Lock Rotary Table
Step 5
A. Swing PH-85 back with tugger line. B. Install thread protector in IBOP valve and lower TDS/PH-85 so splines are engaged. C. Tie up PH-85 with cable and leave tugger line slack (safety). D. Unlock TDS main shaft and spin out upper IBOP until it is separated from main shaft E. Raise TDS/PH-85. F. Screw in lifting plug to upper IBOP. G. Remove upper IBOP with shell.
RTBS Intensifier Assembly Secure To Pad Eye On GE Motor
Step 6
A. Install thread protector in replacement upper IBOP. B. Position replacement upper IBOP with shell over RTBS and drive ring. C. Lower TDS/main shaft slowly into new upper IBOP, (PH-85 swung out) while spinning main shaft until upper IBOP connection is shouldered. D. Lock main shaft again.
Step 7
A. Raise TDS/PH-85 above RTBS, remove thread protector. Remove drive ring. B. Release tie-up cable (Ref 5B), stab PH-85 over RTBS and lower it to yellow area as shown C. Switch PH-85 valve to "BREAK OUT" mode (reverse from normal). D. Push "TORQUE WRENCH" button on VDC, PH-85 will rise, clamp on RTBS and make-upupper IBOP to desired torque indicated by pressure gauge on RTBS intensifier assy panel and stroke back down. Note: make up torque 91,000 lb-ft = 2,150 psi)
Step 8
A. Remove RTBS from rotary table. B. Unlock main shaft and rotary table. C. Disconnect rig air to intensifier assy, disconnect (2) 1/4" hoses and the 1/2" hose from the TDS brake drum. Reconnect the brake hose from TDS manifold. D. Readjust the PRV valve to its original setting. E. Remove the RTBS intensifier assembly and store away. F. Reinstall lower IBOP and saver sub in the normal way using the PH-85. G. Release the links (Ref 1C).
150
125
175
200
100
225
75
250
25
275
10
1500
1250
1000
1750
2000
750
500
250
To Release Brake Move Handle To Vertical Position
Lifting Plug
Varco P/N
30150095
3000
300
2250
2500
2750
Tie-up Cable New Upper IBOP Lifting Plug
Old Upper IBOP Yellow Area Step 7D
Top of Rotary Table and Deck
Inspection
Maintenance
Inspection
Swinging out the TDS for maintenance
Varco top drives with swing-out guide dollies can be quickly swung aside on its own dolly frame for inspection, maintenance, running casing, or to allow drilling operations requiring a kelly and rotary table. Electrical, hydraulic and air supplies do not have to be disconnected. Use the following procedure to swing out the TDS only if your rig has a guide dolly with hinge pins (refer to the engineering drawings for information specific to your rig configuration): 1. If you have a retract system, operate the switch on the drillers console to retract the TDS. 2. Slowly lower the TDS until the elevator nears the rig floor. 3. Remove the elevator and elevator links. 4. Lower the TDS guide dolly to the stop.
4-9
Current date
On some rigs, it may be necessary to secure the traveling block frame to the guide dolly frame using chain and/or rope. 5. Turn off the hydraulic power unit and bleed down hydraulic pressure by opening the needle valve (NV) on the counterbalance manifold. (The counterbalance manifold is located on the upper motor frame.) 6. Detach the counterbalance system cylinders from the hook or block by unhooking the pear links from the ears on the hook or block. 7. Disconnect the air intake hose. 8. Disconnect the mud hose from the TDS S-tube.
Unlatching the hook from the swivel bail may cause the TDS motor assembly and/or the hook to lurch suddenly. Always keep adequate tension on the tailing lines to prevent sudden movement of these assemblies. 9. Unlatch the hook. 10. Attach tugger lines to the TDS motor frame, opposite the frame hinges, to assist in swinging out the TDS motor assembly. Use tailing lines on the motor frame to control swing out. 11. Unfasten the two swing-out bolts, opposite the hinges, holding the motor frame to the guide dolly. 12. Operate the air tuggers to slowly pull on the motor frame while unhooking the traveling block from the swivel bail. 13. When the traveling block is disconnected, continue swinging out the TDS 180 and secure the motor assembly to the derrick with chain and/or rope.
4-10
To swing the TDS back in for operation after inspection or maintenance, perform the following procedure: 1. Lower the traveling block guide dolly far enough to allow swinging the TDS back into place.
While latching the hook to the swivel bail, the swivel and/or the TDS motor assembly may suddenly lurch. Always keep adequate tension on tailing lines to prevent sudden movement of these assemblies. 2. Attach tugger lines to the TDS motor assembly, opposite the hinges, to aid in swinging back the TDS assembly. Use tailing lines on the motor frame to control swing back. 3. Release the chain and/or rope securing the TDS motor assembly to the derrick and slowly swing back the TDS motor assembly to the guide dolly. While swinging it back, latch the hook onto the swivel. 4. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the hinges. 5. Connect the mud hose to the S-tube. 6. Connect the air intake hose. 7. Hook the counterbalance system pear links onto the ears of the hook or block. 8. Turn on the hydraulic power unit and bleed air out of the system. 9. Adjust the hydraulics as outlined later in this section.
4-11
Current date
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide dolly assembly for loose bolts and fittings daily. If any safety wire or cotter pins were removed to facilitate repairs, replace them immediately.
The DC motor has a complete manufacturers instruction manual for your reference provided as a separate book in this manual.
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. It also holds pressure on the air brake. 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.
4-12
Derrick termination kit air filter/ regulator/lubricators

Top drives 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.
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 Oring 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 100200 SSU at 100F (ISO 32/34).
Do not use fluids such as Marvel Mystery Oil, motor oil, or Dextron II in the lubricator. Swollen seals may result.
4-13
Current date
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire or cotter pins were removed during repairs, replace them immediately. Inspect the hinge bolts daily to make sure they are not separating from the pipehandler. Make sure the hinge pins are not loose either because of excessive wear in the bore of the clamp clevis or a broken retaining bolt.
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 the figure in the Air Actuator Replacement procedure 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.
Drill stem load-carrying components

Because the drill stem load carrying components are critical, Varco recommends performing the following procedures and inspections on a regular basis.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on the elevator link eyes (Figure 4-1). Compare the measurements with the Wear Chart (Figure 4-1) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.
4-14
Upper Eye (Hook)
Wear Chart - Forged Links

Lower Upper Eye Eye Dimension Dimension A C B = 3 1/2 in., 350-Ton 5 in. 4 13/16 in. 4 5/8 in. 4 7/16 in. 2 3/4 in. 2 9/16 in. 2 3/8 in. 2 3/16 in. 350 300 225 175 Capacity (per set) in Tons
,,,, ,,,, ,,,, ,,,,
B = 4 1/2 in., 500-Ton 6 in. 5 3/4 in. 5 1/2 in. 5 1/4 in. 3 1/2 in. 3 1/4 in. 3 in. 2 3/4 in. 500 420 325 250 A
,,, ,,, ,,, ,,,

B
B = 6 1/4 in., 750-Ton 7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in. 7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in. 350 300 225 175
,,,, ,,,, ,,,,
To determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link.
A
Lower Eye (Elevator)
Figure 4-1. Visual inspection of elevator links
4-15
Current date
Landing collar
Disassemble and inspect the landing collar every six months. Use the following procedure to disassemble the landing collar (Figure 2-4 in the Installation and Commissioning book) for inspection: 1. Disconnect the top drive from the drill string. 2. Remove the IBOPs and pipehandler. 3. Raise the solid body elevator to expose the landing collar retainer. 4. Straighten the retainer tabs. 5. Slide the retainer ring above the split landing collar halves. 6. Drive out one roll pin. 7. Remove the landing collar halves. 8. Slide the retainer off the drive stem. After disassembly, inspect all landing collar parts for wear, damage, or corrosion. Check for: t 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 t Radial grooves on the inside diameter of the retainer shell t Missing tabs from the retainer shell t Wear or corrosion induced pitting on the retainer shell shoulder t Wear, corrosion, or fatigue cracks on the inside or outside diameter of the landing collar halves t Evidence of drive stem contact with the solid body elevator t Evidence of inside bore wear on the solid body elevator indicating contact with the drive stem or landing collar retainer. Wear on the inside shoulder of the elevator should not exceed 1/8 in. t Evidence of wear, corrosion or fatigue cracks on the safety links
4-16
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 in the retainer shell. 2. Grease the inside diameter of the retainer shell. 3. Slide the retainer onto the drive stem above the landing collar grooves. 4. Install one new roll pin and safety links on the split landing collar halves. 5. Coat the landing collar halves with a generous amount of water resistant grease. 6. Place the landing collar halves on the drive stem with 15 taper closest to the top drive. 7. Drive in the remaining roll pin. 8. Slide the retainer shell over the landing collar halves. 9. Use a hammer and drift to bend all 32 retainer tabs to secure the retainer shell. 10. Coat the retainer shell and drive stem with a generous amount of water resistant grease to prevent corrosion. 11. Reinstall the IBOPs and pipehandler.
4-17
Current date
Drive stem
Regularly inspect and measure the drive stem/mainshaft for wear. Remove the drive stem/mainshaft from service if bore wear is greater than the dimensions shown in Figure 4-2. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections.
Figure 4-2. 500-ton drive stem minimum bore wear dimensions
4-18
Use the following API recommended guidelines (Figure 4-3) to determine the tensile load bearing capacities of the drive stem landing collar.
Figure 4-3. 500-ton drive stem landing collar tensile dimensions
4-19
September 16, 1996
Main shaft
Regularly inspect and measure the drive stem/main shaft for wear. Remove the main shaft from service if bore wear is greater than the dimensions shown in Figure 2. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections.
* See Figure 3
Figure 2. TDS-4H 650-ton minimum bore wear dimensions
18
September 16, 1996
Use the following API recommended guidelines (Figure 3) to determine the tensile load bearing capacities of the drive stem/ main shaft landing collar.
Figure 3. 650-Ton drive stem /main shaft landing collar, tensile dimensions
19
Current date
Magnetic particle inspection

After approximately three to six months, depending on the severity of operating conditions, or 1,500 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 the replacement of the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/8 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 the replacement of the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/8 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. These components are: t Drive stem/main shaft (lower portion) t Landing collar t Upper and lower IBOP t 350-ton BNC drill pipe elevator t Link adapter t Saver and spacer subs t Power subs t Power swivels t Elevator links
4-20
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 components integrity. Details on magnetic particle and ultrasonic 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 ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings
Safety valves inspection procedures (IBOP)
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 in this manual.
4-21

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Top Drive Training Manual

Varco Technical Education Centre Montrose Scotland

TOP DRIVE Training Manual

Varco Technical Education Centre Montrose Scotland

TOP DRIVE Training Manual

Training Manual June 99

Derrick electrical termination kit

Training Manual June 99

1/4" OVER FULL LENGTH 3/8 1/8"

C L RAIL OVER FULL LENGTH WITHIN 25' OF FLOOR

3/8" OVER FULL LENGTH 1/8" WITHIN 25' OF FLOOR C L WELL

6" RAIL STOP

10' 6" +0"/-4"

W14X74 W14X74 W12X53 W14X74

3.3 3.3 3.3 2.3

DRILL FLOOR C L WELL

Figure 1. General rail installation data

Training Manual June 99

INSTRUMENT J-BOX ** MOTOR J-BOX ** BRACES *

CONVENIENT WORKING HEIGHT ABOVE WALKAROUND 16.0

VIEW A-A TYPICAL SERVICE LOOP TERMINATION

75 FT. MUD HOSE REF

73 FT. MUD HOSE CONNECTION

SERVICE LOOP BRACKET**

TYPICAL EQUIPMENT STACK-UP

Figure 2. Derrick services/general installation data

Training Manual June 99

Figure 3. General installation data

Motor Frame Setback L

L 10'3" TDS-4H 7'0"TDS-4H, L L 48,000 LBS for a typical TDS-4H

Rail Loading while Drilling - 60,000 FT LBS

Figure 1c. General installation data (cont.)

Training Manual June 99

(4)646MCM* SCR Room

Top Drive System

#10AWG/4C E/P Torq AC Power E/P RPM

Existing Power Cables

TDS Driller's Console HYD Pump #1 HYD Pump #2 #16AWG/10C #16AWG/10C

Existing Driller's Console

Figure 4. Typical cabling diagram

#14AWG/37C #14AWG/2PR SHLD

#16AWG/10C #14AWG/2PR SHLD

Training Manual June 99

Training Manual June 99

September 16, 1996

TDS-4H Installation and commissiioning

September 16, 1996

Figure 3. Swivel assembly

TDS-4H Installation and commissioning

September 16, 1996

TDS-4H Installation and commissiioning

September 16, 1996

Landing Collar Retainer

Split Landing Collar (2)

Safety Link (4)

Figure 4. Landing collar installation

TDS-4H Installation and commissioning

September 16, 1996

TDS-4H Installation and commissiioning

September 16, 1996

Figure 5. Counterbalance system

TDS-4H Installation and commissioning

September 16, 1996

INSTRUMENT J-BOX MOTOR J-BOX BRACES *

___________________ _ _____________________