D811000252 Man 001

Bill of Material Item 1 2 3 4 5 Quantity 1 1 1 1 1 Part Number SM00620 SM01053 D811000252-DOS-001 30184939 30184734 Description Service Manual, TDS-4S
Service Manual, Washpipe Assembly Technical Drawing Package, TDS-4S Mechanical Spares Control Spares
NEXT ASSY M614000012-GEN-001
PRODUCT TDS-4S
This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. National Oilwell Varco
Owners Manual
CURRENT
DRAWN CHECKED APPVD DATE
INITIAL J. Kellstrom K. Schmidt R. Shumski 10/23/2007

SCALE: WT LBS:
Petrobras, P14 TDS-4S

SIZE: SHT:
AV
1 OF 1
REV:
D811000252-MAN-001
01
D811000457-GEN-001/01
Top Drive System Service Manual
TDS-4S
SM00620 Revision B
March 8, 2001
ii
TDS-4S Contents
Contents
Book 1 Description
Preface/Manual conventions
Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
Chapter 2 Major component description

Motor housing assembly ................................................ 1-19 Drilling motor ......................................................... 1-20 Two speed transmission ........................................... 1-20 Integrated swivel bail and swivel washpipe ............... 1-22 Standard rotating head ............................................. 1-24 Powered rotating head ............................................. 1-26 Rotating head controls ....................................... 1-26 Cooling systems ............................................................. 1-28 Local blower ............................................................ 1-28 Closed loop .............................................................. 1-30 Remote blower ......................................................... 1-32 Guide dolly assemblies ................................................... 1-34 Motor alignment system ................................................ 1-37 Pipehandler .................................................................... 1-38 Link adapter ............................................................ 1-39 Safety valves (IBOP) ................................................ 1-40 Saver and crossover subs..................................... 1-40 Safety valve actuator ................................................. 1-40 Torque wrench ........................................................ 1-42
TDS-4S Contents
iii
March 8, 2001
Link tilt mechanisms ................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51 TDS Control System (TDCS) ....................................... 1-53 Varco Drillers control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62
Chapter 3 Specifications
Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower ...................................................... 1-66 Derrick mounted remote blower ........................ 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70
iv
TDS-4S Contents
Book 2 Installation and Commissioning

Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Drillers controls and instrumentation ........................... 2-23 Varco Drillers Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33
TDS-4S Contents
March 8, 2001
Book 3 Operation
Safety information ........................................................... 3-5 Directional references ...................................................... 3-6 Manual layout .................................................................. 3-6
Chapter 1 Operating procedures

Start-up procedure ........................................................... 3-7 Stalling the DC motor ..................................................... 3-8 Changing transmission speeds .......................................... 3-9 Pipehandler operation .................................................... 3-11 Standard rotating head ............................................. 3-11 Powered rotating head ............................................. 3-12 Controls............................................................. 3-12 ROTATING HEAD LEFT/RIGHT switch ..... 3-12 AUTO STOP/FREE ROTATE switch ............ 3-12 Safety valves (IBOP) ................................................ 3-14 Torque wrench ........................................................ 3-16 Changing drill string sizes ........................................ 3-19 PH-85 ............................................................... 3-19 PH-60d ............................................................. 3-19 Torque values for load carrying components ............ 3-20 Drilling ahead ................................................................ 3-21 Drilling ahead with triples ....................................... 3-21 Drilling ahead with singles ....................................... 3-24 Drilling ahead on a semi .......................................... 3-26 Tripping ........................................................................ 3-28 Reaming out .................................................................. 3-29 Well control procedures ................................................. 3-31 Running casing .............................................................. 3-32 Handling bottom hole assemblies .................................. 3-32 Post jarring operations ................................................... 3-34
vi
TDS-4S Contents
Book 4 Maintenance and Troubleshooting

Chapter 1 Maintenance
Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Contents vii
March 8, 2001
Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45
Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97
viii TDS-4S Contents
Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111
Book 4 TDS-4S Control System

General description .......................................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................................................ 5-7
TDS-4S Contents
ix
March 8, 2001
TDS-4S Contents
TDS-4S Top Drive Drilling System
Description
SM00620-1
Rev. B
March 8, 2001
1-2
TDS-4S Description
Contents
General description .......................................................... 1-7

Motor housing assembly ................................................ 1-19 Drilling motor ......................................................... 1-20 Two speed transmission ........................................... 1-20 Integrated swivel bail and swivel washpipe ............... 1-22 Standard rotating head ............................................. 1-24 Powered rotating head ............................................. 1-26 Rotating head controls ....................................... 1-26 Cooling systems ............................................................. 1-28 Local blower ............................................................ 1-28 Closed loop .............................................................. 1-30 Remote blower ......................................................... 1-32 Guide dolly assemblies ................................................... 1-34 Motor alignment system ................................................ 1-37 Pipehandler .................................................................... 1-38 Link adapter ............................................................ 1-39 Safety valves (IBOP) ................................................ 1-40 Saver and crossover subs..................................... 1-40 Safety valve actuator ................................................. 1-40 Torque wrench ........................................................ 1-42 Link tilt mechanisms................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51
TDS-4S Description
1-3
March 8, 2001
TDS Control System (TDCS) ....................................... 1-53 Varco Drillers control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62
Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower ...................................................... 1-66 Derrick mounted remote blower ........................ 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70
1-4
TDS-4S Description
Preface Manual conventions
Safety information
Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the readers attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.
z e
Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.
Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
TDS-4S Description
1-5
March 8, 2001
Directional references
References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.
Manual layout
This binder contains several separate books that you can remove individually for convenience.
1-6
TDS-4S Description
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45 ft. kelly was the industry standard for years. For decades, drillers extended the drill string with the making-a-single-connection process using the rotary table, kelly, pipe tongs, drawworks cathead, master bushing, bowls, and slips. This method of handling pipe and joint makeup remained unchanged, apart from minor improvements such as kelly spinners, until the advent of top drive drilling systems. Varco produces several Top Drive Drilling Systems (TDS) to rotate the drill string and allow adding entire 93 ft. stands of pipe, eliminating two thirds of the conventional single-pipe drilling connections. This manual describes the function and maintenance of the TDS-4S, which integrates the drill pipe connection handling and drive systems with the drilling swivel. The TDS (Figures 1-1 and 1-2) provides the rotating power of a conventional rotary table drive while eliminating the need to pick up the cumbersome swivel/kelly combination. The TDS does not interfere with the existing conventional equipment. It allows tripping, circulation, rotation, and the running of casing as well as providing 90 ft. back reaming capabilities to reduce the chance of stuck pipe.
TDS-4S Description 1-7
March 8, 2001
Guide Dolly Assembly
Motor Housing Assembly
LO
Pipehandler Assembly
Figure 1-1. Typical TDS-4S overall view
1-8
TDS-4S Description
The TDS integrated swivel bail connects directly to a drilling hook. Connecting the TDS integrated swivel bail directly to the traveling block or motion compensator frame can eliminate the drilling hook and shorten the TDS working height further.
Integrated Swivel Bail Counterbalance Cylinder (2)
Gooseneck Air Brake
Standard Washpipe Packing
Motor Support Bonnet
Swivel Bearing
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Bull Gear
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; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;; ;
; ; ; ; ; ; ; ; ; ; ; ;; ;
DC Drilling Motor
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Motor Pinion Gear
; ; ; ; ; ; ;;;; ;;;;;;;;;;;; ;; ;; ;;;; ;;;;;;;;;;;; ; ; ; ; ;; ; ; ;; ; ; ;; ; ;; ;;; ;; ; ;;;;;; ;;;;; ;; ;;;;;; ;; ;;;;;;; ;; ;;;; ;; ;;;;;;;;; ;; ;; ;; ;; ;;;;;;;;;;; ;; ;;;;;;;;;;;;;
Upper Gearcase
Low Gear (Engaged)
; ;;;;; ;; ;; ; ; ; ; ; ;; ;; ;; ; ; ; ; ; ; ; ; ; ;;;;;;; ;; ; ; ;; ;; ;;; ; ; ; ;; ;; ;; ;; ;; ; ; ; ;;;;;;;;
High Gear (Disengaged) Rotating Head Main Shaft/Drive Stem Lower Gearcase
Figure 1-2. TDS-4S motor and swivel housing assembly
TDS-4S Description
1-9
March 8, 2001
The integrated drive stem functions as the main output shaft driving the drill string. The electric drilling motor and transmission, located next to the stem, rotates the stem. The DC motor bolts to an upper assembly of the gearcase, called the motor support bonnet. The motor frame/guide dolly attaches to the motor housing assembly. The entire assembly moves vertically on two rails installed in the derrick. The vertical rails react the motor torque during drilling operations and keeps the TDS positioned over wellcenter. The pipehandler assembly (Figures 1-3 and 1-4) can make or break drill pipe at any height in the derrick.
1-10
TDS-4S Description
Rotating Head (Part of the Motor Housing Assembly)
Torque Arrestor (4)
Link Adapter (Also know as: Solid Body Elevator) (Landing Collar Inside on Main Shaft/Drive Stem)
Hydraulic/Pneumatic Link Tilt
Upper IBOP Valve Actuator
Splined Upper IBOP Valve Lower IBOP Valve (Inside Torque Tube)
Torque Wrench
350-Ton 108 in. Link (2) (Optional Varco Equipment)
Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment)
Figure 1-3. Typical 650-Ton, PH-85 pipehandler assembly
TDS-4S Description
1-11
March 8, 2001
650-Ton Rotating Head (Part of Motor Housing Assembly)
Torque Arrestor (4)
Link Adapter (Also known as Solid Body Elevator) (Landing Collar Inside On Main Shaft/Drive Stem)
Pneumatic Link Tilt
Safety Valve Actuator
Lower IBOP Valve (Inside Torque Tube) Splined Upper IBOP Valve
Torque Wrench
108 in. 350-Ton Links (Optional Varco Equipment)
Figure 1-4. 650-Ton, PH-60d pipehandler assembly
1-12
TDS-4S Description
Internal Blow Out Preventor (IBOP) valves connect to the end of the drive stem (Figure 1-5). The driller can close the upper IBOP at any position in the derrick from the drillers control console. A second, lower IBOP can be manually closed and sent downhole while controlling a kick.
Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar
Upper IBOP Valve Actuator Air Cylinder (2)
Crank Assembly (2)
Actuator Arm (2)
Safety Valve Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 1-5. Safety valves (IBOPs) and actuator assembly

March 8, 2001
The drive stem passes through the link adapter. The torque arrestors keep the link adapter above the landing collar on the drive stem when drilling (Figures 1-6, 1-7 and 1-8). When hoisting, the link adapter is pulled down onto the landing collar due to the added weight of the drill string. This directs the hoisting load through the drive stem, motor housing assembly, and swivel bail. The fluid service loop provides the hydraulic, pneumatic power, and optional cooling water services to the TDS. The electric service loops provide DC power and AC power/control. A drill pipe elevator hangs from a pair of conventional links that attach to the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up pipe. The Major component description chapter of this book describes each of these assemblies. Subsequent books provide more information on the equipment specific to your rig configuration.
1-14
TDS-4S Description
Rotating Head (Part of Motor Housing Assembly)
Link Adapter (Also known as Solid Body Elevator)
Torque Arrestors (4)
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors
TDS-4S Description
1-15
March 8, 2001
Hydraulic/Pneumatic Link Tilt
650/500-Ton Rotating Head (Part of Motor Housing Assembly)
650/500-Ton Link Adapter (Also known as Solid Body Elevator)
Torque Arrestor 650-Ton: (4) 500-Ton: (2)
Link Adapter Support Plate
Upper IBOP Valve
Safety Valve Actuator Torque Wrench
Lower IBOP Valve
Saver Sub
Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies
1-16
TDS-4S Description
Pneumatic Link Tilt
650-Ton Rotating Head (Part of Motor Housing Assembly)
650-Ton Link Adapter (Also known as Solid Body Elevator)
Torque Arrestor (4)
Link Adapter Support Plate
Upper IBOP Valve
Safety Valve Actuator Torque Wrench
Lower IBOP Valve
Saver Sub
Figure 1-8. 650-Ton, PH-60d pipehandler in relation to other TDS assemblies
TDS-4S Description
1-17
March 8, 2001
1-18
TDS-4S Description
Motor housing assembly

The motor housing assembly is composed of the following: Drilling motor and brake Two speed transmission Rotating head Integrated swivel and washpipe
TDS-4S Description
1-19
March 8, 2001
Drilling motor
The drilling motor on the TDS is a 1,100 hp DC drilling motor. Mechanically, the motor features a double-ended armature shaft and thrust bearings for vertical operation. There is an air brake on the motor to hold torque in the drill string to assist in directional work. It is remotely operated by a solenoid valve. Please refer to the specifications included later in this book for additional details.
Two speed transmission

The two speed transmission consists of the following major components: Bull gears 96 tooth, 2.0 diametral pitch High range compound gears 27 tooth and 30 tooth Low range compound gears 23 tooth and 40 tooth Motor pinion gears 21 tooth Geneva transmission shifter mechanism (Figure 1-9) Main body and lower gearcase Main shaft/drive stem Bonnet Swivel bearing The compound gears mount to their eccentric shafts with a tworow, full complement roller bearing on one end and a spherical roller bearing on the other end.
1-20
TDS-4S Description
Rotating Head Assembly
Shifter Input Shaft
External HI / LO Indicator
Compound Gear Shafts
Bottom View
High Gear Eccentric Shaft (Engaged)
Geneva Mechanism
Top View
Figure 1-9. Transmission/geneva mechanism
LO
Low Gear Eccentric Shaft (Disengaged) Shifter Input
HI
TDS-4S Description
1-21
March 8, 2001
Lubrication to the bearings and gear meshes is force fed by an electrically driven gear pump externally mounted on the gearcase (Figure 1-10). The lower gearcase is a heavy duty steel casting, fully ribbed for added heat dissipation. The transmission shifts gears by rotating two vertical compound gear eccentric shafts. The two compound shafts (high and low) are supported on heavy trunnions between the main body and lower gearcase halves. As the shafts rotate (less than one-half turn), the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. Each compound shaft carries a large, internally splined geneva slave. A common geneva master sequentially unlocks, rotates, and locks both gears. The master rotates using a reduction gear set with a vertical manual input shaft. It carries its own latching mechanism and provides the security of a double lock on the compound shafts. A 1 in. male hex at the bottom of the transmission case (Figure 1-9), rotates the input shaft. After pushing inward on the male hex, it takes five turns of the input shaft to unlock both gear sets, rotate the engaged gear set to full disengagement, rotate the disengaged gear set into full engagement, and lock both gear sets in their proper positions with positive stops in the locked position. An external indicator shows the gear range selection.
Integrated swivel bail and swivel washpipe

The integrated swivel bail is a bearing assembly that allows transfer of the rotating load to the lifting components (Figure 1-2). The swivel washpipe is a rotating seal that allows mud to flow to the rotating drill string.
1-22
TDS-4S Description
Lower Radial Shaft Bearing
Motor Pinion Gears
Side View
Bull Gears
Inlet
Compound Shafts (Not Visible)
Bull Gears
Motor Pinion Gears
LEGEND
Pressure Tap
Bottom View
Fabricated Drilled
Figure 1-10. Transmission lubrication system

March 8, 2001
Standard rotating head

The standard rotating head allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head (Figure 1-11). It features two hydraulic passages, three pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2,500 psi). The rotating head assembly consists of: Stationary flange Eight rotary glyd rings Swivel block Cam Auto-return cylinder Cam follower Swivel block locking mechanism The hydraulic and air lines for the various pipehandler functions (air link tilt, torque wrench, etc.) run from their respective solenoid valves to the stationary flange. The fluids travel from the flange to the swivel block via sealed rotating passages. The glyd rings maintain the seal between the passages. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates relative to the flange without twisting or damaging any hoses. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. There is also an auto-return cylinder mounted on the stationary flange. The auto-return cylinder is hydraulically connected to the counterbalance manifold. The rod end of the cylinder connects to a cam follower assembly that tracks the cam mounted to the swivel block.
1-24
TDS-4S Description
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return Cylinder
Torque Arrestor Location Glyd Ring (8) Swivel Block Torque Wrench Hanger (Lug not shown)
Figure 1-11. Standard 650-Ton rotating head assembly
TDS-4S Description
1-25
March 8, 2001
Powered rotating head

The 10-port powered rotating head (Figure 1-12) allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head. It features three hydraulic passages, five pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2,000 psi). The rotating head assembly consists of the following components: Stationary flange Eleven rotary glyd rings Swivel block Bull gear Hydraulic motor assembly Proximity sensor and adjustable targets The hydraulic and air lines for the various pipehandler functions (hydraulic link tilt, torque wrench, etc.) run from their respective solenoid valves to the stationary flange. The fluids travel from the flange to the swivel block via sealed rotating passages. The glyd rings maintain the seal between the passages. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates relative to the flange without twisting or damaging any hoses. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. The hydraulic motor assembly mounts to the swivel flange which engages a compound gear, driven by a pinion gear on the hydraulic motor shaft. Two switches on the drillers control panel control the hydraulic motor.
Rotating head controls

The powered rotating head has two switches. The ROTATING HEAD LEFT/RIGHT switch rotates the rotating head, pipe handler, and link tilt to the right or left (same direction as the drill string). The AUTO STOP/FREE ROTATE switch controls the powered rotating head operating mode.
1-26 TDS-4S Description
Stationary Flange
Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly
Bull Gear
S1
H1
A1
PRESSU
A1
RE
H2
S2
A2
A5
A2
H3
H2
A3
S1
Figure 1-12. Powered rotating head assembly
TDS-4S Description
S2
A4
H1
A3 H3 A5 A4
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March 8, 2001
Cooling systems
Local blower
The local blower cooling system with an optional extended intake provides local cooling air to the drilling motor (Figure 1-13). It receives air approximately 27 ft. above the rig floor at the lowest point of the motors travel. An explosion-proof 20 hp, 3,450 rpm AC electrical motor directly drives the impeller in the blower housing. An optional flexible duct connects the blower housing to the extended intake mounted on the traveling equipment. Two spark arrestor assemblies are mounted on the exhaust ports of the upper gearcase. These components hinder the egress of any air born sparks from the DC motor.
1-28
TDS-4S Description
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 Flex Duct Connection Point Mounting Plate
Blower Duct to AC Drilling Motor
Spark Arrestor
Figure 1-13. Typical local blower cooling system
TDS-4S Description
1-29
March 8, 2001
Closed loop
The closed loop cooling system (Figure 1-14) consists of two air/ water heat exchangers cooled by twin blowers driven by a double ended AC motor. Ducting directs air out the motor exhaust port to the heat exchangers and back to the blower inlets. The heat exchangers are built from Cupro-Nickel tubes and the headers are pressure tested to 250 psi. The system requires a supply of liquid coolant (sea water, chilled fresh water or glycol) at 100 gpm at a maximum inlet temperature of 90F. Purge air at a rate of 70 scfm per motor at 1.0 psig is also required to provide positive system pressure, and a purge control system (refer to TDS Control System information provided later in this chapter) monitors system pressure to insure safe operation.
1-30
TDS-4S Description
Dual Shaft 20 hp AC Blower Motor
Blower Mount/ Brake Cover Blower Housing (2)
Impeller (2)
8 in. Flex Connection (2)
Blower Inlet (2)
Water Connections
DC to Motor Exhaust Port on Upper Gear Case Inspection Cover
GE Drilling Motor Heat Exchanger (2)
Figure 1-14. Typical closed loop cooling system
TDS-4S Description
1-31
March 8, 2001
Remote blower
The remote blower motor cooling system consists of a motor and pressure blower mounted in the derrick at racking board level (Figure 1-15). Air is drawn in from outside the wind wall, through a flexible duct into the top of the drilling motor, and exits through spark arrestors attached to the air outlets of the motor. A pressure switch monitors the motor air inlet pressure to verify blower operation. The contacts of the pressure switch are usually wired into the SCR assignment logic for the drilling motor. A moisture separator is attached to the blower inlet duct to prevent water from entering the motor.
1-32
TDS-4S Description
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
Figure 1-15. Typical remote blower cooling system
TDS-4S Description
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March 8, 2001
Guide dolly assemblies

The guide dolly assembly transmits the drilling torque reaction to the guide rails keep the TDS positioned over wellcenter and can provide a method for setting the entire unit aside for maintenance or to allow rig operation without the TDS if necessary. The standard guide dolly assembly consists of two frames connected by hinges on the pivot side and hold-down bolts on the other (Figure 1-16). Non-swing retract guide dollies use hold-down bolts (swing bolts) on both sides (Figure 1-17). One frame attaches to the motor housing assembly and includes attachment points for the service loops and rotary hose. The other frame includes the guide rollers and remains in the guide rails during all normal operations. Centralized lubrication manifolds provide roller lubrication.
1-34
TDS-4S Description
Motor Frame
Guide Dolly Frame
Hinge Pin (2)
Hold-down Bolt (Swing Bolt) (2)
Figure 1-16. Typical swing guide dolly assembly
TDS-4S Description
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March 8, 2001
Upper Stabilizer Arm Motor Frame
Guide Dolly Frame
Retract Cylinder
Lower Extend/Retract Arm
LEGEND
Intermediate Frame
Extended Mode Retracted Mode
45.0"
Figure 1-17. Typical retract guide dolly assembly
1-36
TDS-4S Description
Motor alignment system

The motor alignment system consists of a duplex cylinder, hydraulic accumulator, pressure reducing valve manifold, and related hardware. The duplex cylinder attaches between the bottom of the lower gearcase and the motor frame. It connects to an accumulator circuit located on the guide dolly. The accumulator is charged with nitrogen and maintained at a predetermined pressure setting by the alignment cylinder manifold. Figure 1-18 shows the motor alignment cylinder installed in a typical motor frame. The duplex cylinder maintains a wellcenter orientation for the swivel stem when disconnected from the drill sting, while allowing the motor housing assembly to float slightly about its trunnions.
Motor Alignment Cylinder
Shipping Brace
Motor Frame Dolly (Ref)
Figure 1-18. Motor alignment cylinder
TDS-4S Description
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March 8, 2001
Pipehandler
The main components of the pipehandler include the following (Figures 1-3 and 1-4): Link adapter Safety valves (Upper and Lower IBOPs) IBOP valve actuator Torque wrench Link tilt mechanism The pipehandler provides two basic functions for the TDS: Tripping 93 ft. drilling pipe stands Providing up to 85,000 ft lb torque for makeup and break-out of connections at any height in the derrick (the PH-60d provides up to 60,000 ft lb torque) The pipehandler can be configured for various tool joint connections. It includes a link adapter and a special-purpose Varco torque wrench assembly. It also incorporates a remote IBOP valve actuator and link tilt mechanism. When not in use, the pipehandler remains stationary and free from the drill string passing through it. When tripping or performing bottom hole operations, the pipehandler is free to rotate 360, emulating the action of a standard hook.
1-38
TDS-4S Description
Link adapter
The link adapter (solid body elevator) and the elevator links (Figures 1-7 and 1-8), working in conjunction with the torque arrestors, transfer the hoisting loads to the drive stem. The drive stem is free to rotate inside the link adapter while drilling. The link adapter does not rotate with the drive stem because torque arrestors raise the link adapter up off the load supporting landing collar located on the drive stem. When hoisting loads, springs inside the torque arrestors compess to transfer the load to the drive stem by pulling the link adapter down onto the landing collar. The link adapter rotates with the rotating headwhich is required for tripping operations. The torque arrestors contain compression springs capable of supporting any stand of drill pipe in the full up position.
TDS-4S Description
1-39
March 8, 2001
Safety valves (IBOP)

The Varco pipehandler includes two Internal Blowout Preventor safety valves (IBOPs) to provide blowout prevention. For detailed descriptions, installation, operation, maintenance, and parts information, refer to the IBOP Service Manual.
Saver and crossover subs

Each pipehandler ships with two saver subs and one crossover sub. Saver subs (Figures 1-7 and 1-8) are dual pin subs used to preserve the threads on the lower IBOP and provide a pin for the box end of the drill string. Saver sub threads can be recut to a minimum shoulder-to-shoulder length of 5 in. before the sub must be discarded. The crossover sub converts the lower IBOP pin to a box connection for well control procedures with standard pipe.
Saver subs are load bearing components in the TDS and must be inspected periodically along with other load bearing components. Refer to the Maintenance and Troubleshooting book for more information.
Safety valve actuator

The remotely operated upper IBOP valve actuator allows upper IBOP actuation at any height in the derrick. The upper IBOP actuator system consists of the following: Two pneumatic air cylinders Two actuator arms Actuator shell Two crank assemblies Two pneumatic solenoid valves Double-acting air cylinders move the actuator arm. The actuator arm connects to the valve actuator shell and moves the actuator shell up or down (Figure 1-19). A slot in the actuator shell engages the crank assemblies, which opens or closes the IBOP. The air cylinders are operated remotely by a solenoid valve controlled by an electrical switch at the VDC.
Crank Assembly (2)
Actuator Arm (2)
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 1-19. Safety valve actuator system
TDS-4S Description
1-41
March 8, 2001
Torque wrench
The torque wrench provides a means for making and breaking out connections with the drive stem. The torque wrench assembly consists of the following components (Figures 1-20 and 1-21): Hanger Torque tube Torque tube guide ring Two torque cylinders Two clamping jaws Two clamping pistons Control manifold Lift cylinder Two stop tubes Stabbing guide IBOP actuator cylinders and arms
A hanger attached to the rotating head supports the torque wrench. The torque wrench has two torque cylinders connected to the torque tube. The clamping jaw contains a 10 in. diameter clamping piston for gripping the box end of the drill pipe. On the lower section of the upper IBOP, a female spline engages the mating male spline on the lower IBOP contained inside the torque tube. When actuated, the torque wrench rises and engages the splines on the upper IBOP. It then receives sequenced pressure to clamp the clamping piston on the box connection. After the clamping pressure develops, another sequence valve automatically opens and directs pressure to the torque cylinders. The torque cylinders can rotate up to 25 while developing a maximum torque of 85,000 ft lb (60,000 ft lb for PH-60d). One electrical push button on the VDC controls the entire torque wrench operation. The driller simply holds the button down until the connection is made or broken. The driller then releases the button to allow the unit to automatically recycle to the ready position. A two-position, air piloted hydraulic valve located on the counterbalance manifold controls the cycle. The torque wrench can also make up or break out the saver sub or the lower IBOP. A manually operated valve on the rear of the pipehandler selects either the make up or break out function.
IBOP Actuator Hoses (Air)
Hanger Torque Wrench Hoses (Hydraulic)
IBOP Actuator Air Cylinders Lift Cylinder IBOP Actuator Arms
Torque Tube
Clamping Jaw (Inside Clamp Body)
V a r c o
Stop Tube (2)
Control Manifold (Hidden) Stabbing Guide Torque Cylinder (2)
Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)
Figure 1-20. PH-85 torque wrench assembly
TDS-4S Description
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March 8, 2001
IBOP Actuator Hoses (Air)
Hanger
Torque Wrench Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator Air Cylinders IBOP Actuator Arms
Torque Tube Stop Tube (2) Clamping Jaws (Inside Clamp Body)
Control Manifold (Hidden) Torque Cylinder (2)
Stabbing Guide
Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)
Figure 1-21. PH-60d torque wrench assembly
1-44
TDS-4S Description
Link tilt mechanisms

Standard and extended reach pneumatic link tilt mechanisms
The standard (Figure 1-22) and extended reach (Figure 1-23) link tilt assembly allows: The elevators to move off of well center to pick up a stand in the mousehole. The derrickman to handle pipe more easily. The link tilt assembly mounts on the front of the solid body elevator (link adapter). This assembly consists of a pivoting lifting frame connected to the drilling elevator links with chains and clamps. A switch on the VDC controls a pneumatic solenoid valve that inflates an air spring within the lifting frame. Inflating the air spring pivots the frame upward, tilting the links outward. Extended reach link tilt mechanisms have two air springs and extend 76 in. A standard reach link tilt will extend links 52 in. Both reaches are based on 108 in. elevator links. An adjustable intermediate stop mechanism provides clearance between the drill pipe elevator and the monkey board to assist the derrickman in racking operations.
TDS-4S Description
1-45
March 8, 2001
Lifting Frame
Intermediate Stop
Air Actuator D/P Elevator Link Clamp
Intermediate Stop Release
Figure 1-22. Standard pneumatic link tilt mechanism
1-46
TDS-4S Description
Lifting Frame
Double Air Actuator
Intermediate Stop Intermediate Stop Release
D/P Elevator Link Clamp
Figure 1-23. Extended reach pneumatic link tilt mechanism
TDS-4S Description
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March 8, 2001
Hydraulic link tilt mechanism

The hydraulic link tilt assembly (Figure 1-24) provides lateral movement of the drill pipe elevator to a position above the mousehole or toward the monkeyboard. The link tilt assembly mounts on the front of the link adapter (solid body elevator). The link tilt uses dual hydraulic cylinders. Full link tilt extension moves drill pipe approximately 78 in. from well center, based on 108 in. links. During operation, the operator can stop link tilt movement at any position and hold the supported load in place. The link tilt also enables retracting the open drill pipe elevator from the drill pipe while drilling, tripping, and adding stands (available only on PH-85 models).
Link tilt controls
The link tilt is controlled by a four-position switch. The positions are RETRACT, FLOAT, HOLD, and EXTEND.
RETRACT
In the RETRACT position, the elevator backs away from well center.
FLOAT
FLOAT returns the elevators to well center from the retracted or extended position. A 1/2-second delay is programmed into the FLOAT function to allow the control switch to travel from the RETRACT position to the HOLD position without activating the FLOAT.
HOLD
This setting holds the position of the elevators extended or retracted.

EXTEND
This setting extends the elevator forward to the mousehole through wellcenter.
1-48
TDS-4S Description
Hydraulic Link Tilt with Passive Stop Passive Stop Assembly (2) Cylinder Assembly (2) Link Tilt Arm
Hydraulic Link Tilt with Intermediate Stop
Intermediate Stop
Stop Adjuster
Figure 1-24. Hydraulic link tilt
TDS-4S Description
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March 8, 2001
Elevator links
Varco elevator links attach to the link adapter and support the drill pipe elevator. Elevator link options include: 108 in., 350-Ton elevator links 132 in., 350-Ton elevator links 180 in., 500-Ton elevator links (special long links for running casing, providing 120 in. of clearance for cementing heads)
1-50
TDS-4S Description
Counterbalance system
The counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS. It provides cushioned stroke similar to that provided by the hook. 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. The system (Figure 1-27) consists primarily of two hydraulic cylinders, a counterbalance manifold, and two hydraulic accumulators. The hydraulic cylinder assemblies connect the integrated swivel bail and the traveling equipment (hook, block, becket, hook adapter, etc.). When properly adjusted, the counterbalance system supports all but about 800 lb of the weight of the top drive over a full 8 to 10 in. of travel. The system also incorporates a complete backup. The two accumulators, constantly maintained at system pressure, are always able to provide pressure to the counterbalance cylinders if the HPU is off or non-operational for any reason. For normal operation, however, the HPU is on when using the torque wrench for breaking out the top drive at the floor and is left on while making up the next stand. When adding a stand to the string during drilling operations, the driller takes a stand in the elevators and stabs it into the box in the rotary table. The driller continues to lower the TDS until the saver sub touches the box of the new stand. At this point, only about 800 lb load is on the saver sub/drill pipe connection. The counterbalance cylinders support the remainder of the TDS weight. The driller then spins in and torques up the connection with the pipehandler assembly and is ready to drill ahead. Note that the driller does not have to do anything extra to get the counterbalance system to function properly. It is a pre-adjusted system. Once drilling resumes, the HPU can be turned off and restarted again for breaking out the connection at the floor after drilling the stand down.
TDS-4S Description
1-51
March 8, 2001
Stabbing Mode: Top Drive Lowered Past Thread Contact

Guide Dolly Assembly 18,970 lb 18,970 lb
Hydraulic Cylinders (2)
Hydraulic Accumulators (2)
38,750 lb Typical System Weight
Counterbalance Manifold 810 lb Weight on Threads
Hydraulic Power Supply Rig Floor
Fluids Service Loop
Figure 1-27. Counterbalance system
1-52
TDS-4S Description
TDS Control System (TDCS)

The TDS Control System (TDCS) provides the driller with a control console that operates all of the TDS functions. The components of the TDCS include: Varco Drillers control and instrumentation Console (VDC) Transfer control panel (TP) Purge control system for closed loop cooling systems
Varco Drillers control and instrumentation Console (VDC)

The Varco drillers control and instrumentation Console (VDC) consists of a torque meter, an RPM meter and various switches and indicator lights. The basic TDS control functions are: Link tilt Remotely controlled upper IBOP valve Motor brake Motor spin-torque control Makeup torque limit Transfer switch (TDS/ROT) The existing rotary table controls adjust motor speed, torque and direction while drilling. A typical VDC also contains indicator lights for determining the status of: The brake The remotely controlled upper IBOP valve The oil pump Blower pressure loss Cooling air temperature The purge system(s) Optional controls and status indicator lights are available. Refer to Engineering Drawing 98952 for VDC configurations.
TDS-4S Description
1-53
March 8, 2001
Transfer control panel

The TDS operates from the same SCR as the rotary table. The Transfer control panel switches power between them. This electrical enclosure contains the DC contacts, the programmable controller, the auxiliary AC components and the rig instrumentation interfaces for recording torque and speed of the TDS. The DC power cables running from the SCR to the rotary table motor are disconnected from the rotary table and connect to the transfer panel. New cables run from the TP to the rotary table motor and to the racking board junction boxes for the TDS. The transfer panel has a purge control system for use in a hazardous area (Zone 2 or Class 1, Div. 2). If the panel is in the SCR room, a purge system is not required. The panel is compatible with all currently installed SCR systems and is configured at installation for the SCR it will control. Logic and alarm functions are connected to the TDS by programming the transfer panels Programmable Logic Controller (PLC) to operate the rigs existing systems. Similarly, TDS interlocks and limits, such as spin-up and makeup speeds, are programmed into the PLC and are the same for all installations.
Purge control system

The transfer panel, VDC, and TDS closed loop cooling system have separate purge systems. All systems provide positive internal pressure to prevent hazardous gases from entering areas of potential ignition in Zone 2 or Class 1, Div. 2 hazardous areas. Pressure switches in the protection units monitor the pressure and provide an alarm signal in the event of purge pressure loss. Prior to starting an unpurged system, the purge control unit purges the system for a specific time interval sufficient to remove any trapped hazardous gas. Status lights on the VDC indicate to the driller correct purge pressure, loss of purge and system purging. If purge pressure loss alarms and indicators are ignored for a preset time interval, the isolation unit can be set to shut down the TDS.
1-54
TDS-4S Description
Service loops
The service loops transfer the required electric and fluid services between the derrick service standpipes and junction boxes, and the corresponding junction boxes and fluid connections located on the TDS. There are two kinds of loops: one containing the electric cables, and one containing air, hydraulic and water lines (water lines included only on units with a closed loop cooling system). The power electrical loop contains four 646 MCM DC power cables, one 2/0 AWG drilling motor ground cable. The other electrical service loop contains a composite cable consisting of: 26 14 AWG conductors for auxiliary features 4 2 2 8 AWG conductors for blower motor 5 AWG conductors for series motor field supply 14 AWG shielded pairs for the RPM pickup signal
The power and ground cables are spiral wound and potted inside a protective cover with 7 1/2 in. mounting flanges at each end. The composit cable is pathed in its own smaller service loop. This allows for easy changeout of either the power loop or the composit loop in the event of a failure. The TDS can use optional dual electrical service loops in order to meet certain regulatory agency requirements for power cable current carrying capacity. The fluids loop can consists of any combination of the following: 3 2 1 2 2 3/4 in. diameter hoses for hydraulic supplies (one is a spare) 1/2 in. diameter hoses for air supply (one is a spare) 1 in. diameter hoses for purge supply 1 1/4 in. diameter hoses for cooling water (closed loop cooling systems only) 1 in. diameter hoses for retract cylinder supply and return Additional 7-conductor, 20 AWG cables as required
TDS-4S Description
1-55
March 8, 2001
Derrick electrical termination kit

This kit consists of all the necessary electrical junction boxes attached to a bulkhead mounting plate, which is then mounted in the derrick to connect the rig electric supplies to the service loop. There are several J-box configurations, depending upon which electrical system is ordered. Each configuration complies with specific electrical codes and regulatory agency requirements throughout the world.
1-56
TDS-4S Description
Auxiliary equipment
Auxiliary equipment is compatible with all TDS models. All of the equipment is selected or adapted for your specific rig. Below is a list of auxiliary equipment available: Master bushing ID wear guide Swiveling drill collar dolly Wireline adapter Crown height indicator Drillers recorder tranducer kit
TDS-4S Description
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March 8, 2001
Master bushing ID wear guide

The master bushing ID wear guide centers the rotating drill string and protects the master bushing while drilling ahead (Figure 1-26). It hinges open for removal or when setting manual slips. The bushings can be changed out to accomodate different size drill pipe.
Figure 1-26. Master bushing ID wear guide
1-58
TDS-4S Description
Swiveling drill collar dolly

The swiveling drill collar dolly (Figure 1-27) allows the drill collar elevators to turn freely when handling bottom hole assemblies. The drill collar dollys upset, which latches in the standard drill pipe elevator, mounts on a bearing which allows it to swivel even under load. A shoulder elevator is suspended from the perfection links (or a second drill pipe elevator if lifting subs are used). The collars can be walked in or out with the elevator turning on the drill collar dolly.
A
Drill Pipe Elevator
A
100 TON VARCO
Drill Collar Dolly
Perfection Links (36")
;;; ;;; ;; ;;; ;; ;;;
91 in. Square Shoulder Elevator
Lifting Sub 37 in.
8 in.
Drill Collar View
A-A
Figure 1-27. Swiveling drill collar dolly
TDS-4S Description
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March 8, 2001
Wireline adapter
The wireline adapter (Figures 1-28 and 1-29) attaches to the pipehandler and prevents wireline from interfering and damaging pipe and TDS components. It can be used with a lubricator held in the elevators by using 180 in. casing elevator links.
42.52 in.
26.0 in.
23.1 in.
Typical Section through Sheave
Figure 1-28. Typical PH-85 wireline adapter
1-60
TDS-4S Description
View A-A
Top Drive Torque Wrench
9/16 in. Max. Wire Rope Dia.
Torque Wrench Guard (remove for installation)
20 in. Dia. Sheave
Elevator Links (180 in. longCustomer furnished)
Lubricator Wireline Adapter installs in place of Torque Wrench Guard using existing Pins
To Mud Manifold
Elevator Links (180 in. or longerCustomer furnished)
View A-A
Figure 1-29. Typical PH-60d wireline adapter
TDS-4S Description
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March 8, 2001
Crown height indicator

The crown height position indicator is a self-contained electronic instrument which determines the position of the traveling equipment with respect to the derrick crown. The system contains four major subassemblies: A metal target typically located on the Varco block dolly assembly Two hinged sensor bracket assemblies located on the rear of the guide track A sensor junction box located in the derrick near the above bracket assemblies A crown height indicator control box, or an integral control in the drillers control and instrumentation console The Crown Height Indicator Control (CHIC) control box (Figure 1-30) contains three indicator lights and an electronic printed circuit board. Two of the indicators display the position of the top of the traveling equipment relative to the crown. The third indicator displays system power status. The yellow indicator on the CHIC control box illuminates when the top of the traveling equipment is within ten feet of the crown. The red indicator illuminates when the traveling equipment is within five feet of the crown. When the traveling equipment is within two feet of the crown both indicators flash alternately. The green indicator illuminates when correct DC system power is available. This indicator also contains a push-to-test button which simulates the 2 ft. position. The integral crown height indicator controls on the VDC are identical to the separate control box.
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TDS-4S Description
CROWN CLEARANCE 2 FEET WHEN FLASHING
IBOP CLOSE
BRAKE ON
R
5 FEET IBOP CLOSE OPEN BRAKE OFF ON
Y
10 FEET
ACTIVE/TEST
TORQ. WRENCH PUSH & PULL
LINK TILT OFF ON
Integrated Controls
IBOP CLOSE
BRAKE ON
CROWN CLEARANCE 2 FEET WHEN FLASHING
Purge Air in
IBOP CLOSE OPEN BRAKE OFF ON
R
5 FEET
Y
10 FEET
TORQ. WRENCH PUSH & PULL
LINK TILT OFF ON
G
ACTIVE/TEST
Purge Air out to Protection Unit
VDC
Independent Controls
Figure 1-30. Typical CHIC control box
TDS-4S Description
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March 8, 2001
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TDS-4S Description
Drilling motor
Horsepower: 1,100 Maximum stall time at full power is generally about 10 seconds. Refer to the Operation book for details.
Main gearbox lube system

Provides lubrication to both the primary gear set and swivel bearing. It includes explosion proof 5 hp AC motor/pump combination, filter/strainer, pressure loss sensor, and oil level sight glass. The TDS-4S main gearbox lube system holds approximately 20 gallons (refer to the Maintenance and Troubleshooting book for details on oil capacity and adding oil to the gearbox).
TDS-4S Description
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March 8, 2001
Cooling systems
Local blower *
Flow Blower motor Typical voltage Speed Spark arrestors 3,200 cfm 20 hp 220/460 VAC, 3-phase, 60 Hz 3,450 rpm Standard style, BASEEFA approved type available
Derrick mounted remote blower *

Flow Blower motor Typical voltage Speed Spark arrestors 3,200 cfm 40 hp 220/460 VAC, 3-phase, 60 Hz 3,450 rpm Standard style, BASEEFA approved type available
* These systems include an additional oil cooler/heat exchanger mounted on top of the gearcase on the TDS.
Closed loop
Flow Blower motor Typical voltage Speed Heat exchanger Cooling water supply Oil cooler Max. inlet temp 3,200 cfm 20 hp 220/460 VAC, 3-phase, 60 Hz 3,450 rpm 220,000 BTU/Hr. for GE motor 50 gpm at 250 foot head, measured at rig floor 6 gpm 90F
1-66
TDS-4S Description
Guide dollies
Standard rail setback 30, 39 or 48 in. (Wellcenter to centerline of rails) Standard rail spacing (Centerline of rails) Recommended rail sizes Roller size Frame material 62, 66 or 72 in. W12x53 (land masts), or W14x74, W14x90 6 in. flange and 6 in. side ASTM A-500/A-36 steel or equivalent
Pipehandler
Break-out torque Hydraulic pressure Hydraulic flow Air pressure PH-85 and PH-85H = 85,000 ft lb PH-60d = 60,000 ft lb 2,000 psi maximum 30 to 35 gpm 90 psi minimum
TDS-4S Description
1-67
March 8, 2001
Service loop kits

Power loop (non-regulated areas)
646 mcm Standard length Diameter Power cable voltage Ground cable 4 (each) 86 ft. (flange to flange) 5 in. ID SAE 100-R2 hose outer jacket 2,000 maximum (each) 2/0 conductor tinned copper ground
Control composite loop

26 conductor, 14 guage 4 conductor, 8 guage 2 pair, 14 guage twisted and shielded 2 conductor, 5 guage 1 pair, 6 gauge twisted and shielded
1-68
TDS-4S Description
Fluid loop
Not all hoses are required for all configurations. Overall length of assembly Size Maximum working pressure
Air supply hose (2 each)
86 ft. (flange to flange) 3/4 in. ID, SAE 100-R9 3,000 psi 1/2 in. ID, SAE 100-R2 150 psi 3,500 psi 1 in. ID, SAE 100-R2 150 psi 2,000 psi 1 1/4 in. ID, SAE 100-R2 150 psi 1,625 psi 1 in. ID, SAE 100-R2 3,000 psi
Hydraulic pressure or return hose (3 total)
Size Working pressure Maximum working pressure

Purge air supply hose (2 each)

Water hose (2)

Retract hoses (2)
Size Maximum working pressure
TDS-4S Description
1-69
March 8, 2001
Electrical equipment accessories

API Class I, Division II -N.E.C.
Derrick J-boxes (2 each) Motor J-boxes (2 each) Solenoid valves (6 each) Pressure switches (2 each) Cast aluminum, explosion proof Cast aluminum, explosion proof 1/2 in., 4-way, 2 position 6 in. of H2O sensor
Motor space heaters (2 each) 2 - 200 watt, 110 volt VDC/instrument kit Torque meter RPM meter Various switches (0 - 1,500 Amps) (0 - 350 rpm)
European standard zone 2 area-EExd

Derrick J-boxes (2 each) Motor J-boxes (2 each) Solenoid valves (6 each) Pressure switches (2 each) Stainless steel Stainless steel 1/2 in., 4-way, 2 position 6 in. of H2O sensor
Motor space heaters (2 each) 2 - 200 watt, 220 volt
1-70
TDS-4S Description
TDS-4S TOP DRIVE DRILLING SYSTEM

Drill Pipe Torque Vs. Speed GE 752 High Torque Series Motor 60,000 58,200 INTERMITTENT 55,000 1,130 HP LIMIT 50,000 50,900 CONTINUOUS
LOW GEAR
45,000
40,000
160 RPM 37,200 INTERMITTENT 1,130 HP LIMIT
TORQUE, CONTINUOUS (ft lb)
35,000 32,500 CONTINUOUS 30,000
25,000
HIGH GEAR
20,000
15,000 12,000 ft lb 10,000 5,000 ft lb 5,000 120 0 0 50 100 150 200 250 300 190
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC. MAX. DURATION JUNE 3, 1991 A.N.
TDS-4S Description
1-71
March 8, 2001
TDS-4S TOP DRIVE DRILLING SYSTEM

Drill Pipe Torque Vs. Speed GE 752 High Torque Shunt Motor
55,000
50,000 45,000
50,100 INTERMITTENT 45,500 CONTINUOUS
LOW GEAR
TORQUE, CONTINUOUS (ft lb)
40,000
35,000
32,000 INTERMITTENT
30,000
29,100 CONTINUOUS
25,000
HIGH GEAR
20,000
Reduced Field Required in this Area
15,000
10,000 5,000
130 RPM 205 RPM
0 0 50 100 150 200 250 300
RPM
Continuous Torque Values are based on 1250 Armature Amps. Intermittent Torque Values are based on stall at 1400 Amps with a 7 second maximum duration. Reduced Field area is based on a 30 Amps Field.
1-72
TDS-4S Description
Installation and Commissioning

SM00620-2
October 20, 1998
2-2
TDS-4S Installation and Commissioning
Contents
Preinstallation checklist.................................................... 2-7
Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Drillers controls and instrumentation ........................... 2-23 Varco Drillers Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27
Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33
2-3
October 20, 1998
2-4
Safety information
z e
2-5
October 20, 1998
Manual layout
2-6
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up has been accomplished prior to installation of the TDS. This includes: 1. Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances (Figures 2-1, 2-2, and 2-3). 2. Stops are ready for installation at the bottom of the rails. 3. Hydraulic and air standpipes are installed in the derrick, flushed clean, and pressure tested. Water piping is installed, flushed, and pressure tested as well for configurations with closed loop cooling systems. 4. All electronics are installed up to the derrick junction box: DC power leads, AC leads for blower motor, and control/ alarm signals. 5. The transfer panel is installed. 6. Rigging of the tong lines, etc. are inspected to ensure that they will not foul with the TDS and other rig equipment.
2-7
October 20, 1998
2-8
Derrick electrical termination kit

Installation
Refer to Figures 2-1, 2-2, and 2-3 for typical mounting dimensions of the plate assembly. Mount it at racking board height within 15 ft. of the service loop support bracket. Remember to provide convenient access for wiring and maintenance. Usually, mounting the plate so that the J-box is four to five feet above the walk-around and near the service loop support bracket is adequate. If a walk-around does not exist, then construct a work platform to allow access to the J-boxes. Manufacture appropriate brackets and clamps to attach the plate to the derrick structure.
2-9
October 20, 1998
1/4 in.
C L Rail
Over Full Length
C L Rail 3/8 in. Over Full Length 1/8 in. Within 25 ft. of Floor C L Rail
C L Rail C L Well Center
3/8 in. Over Full Length 1/8 in. Within 25 ft. of Floor
C L Well Center
TDS Back Guide Rails Operational Clearance Between Top Drive And Nearest Girt or Fastline Should Be 3 in. Minimum Nearest Girt
Splice Clearance
Splice Plates or Bolts Are Not Permissible 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.
Rail Size
Splice Dolly Clear Overhang Inches
10 ft. 6 in. +0/-4 in.
39 x 66 48 x 62 30 x 72 30 x 72
W14 x 90 W14 x 90 W12 x 90 W14 x 90
3.3 3.3 3.3 2.3
0 0 1.6 0.5
Drill Floor C L Well Center
Figure 2-1. General rail installation data
2-10
Clearance Hole For .75 in. Dia. Bolt (4 Places) 36.0 in. Motor J-Box **
Instrument J-Box **
Electrical Supply*
Filter/Regulator Lubrication Assembly**
48.0 in.
800 lb Load
B
18.0 in. Must Support 4,000 lb
Control Service Loop**
Electrical Service Loop** Fluids Service Loop**
Hydraulic Air Standpipes Standpipes To Be 1 1/2 in. To Be 1 1/2 in. Sch 40 Pipe* Sch 80 Pipe* Water Standpipes A To Be 2 in. Sch 40 Pipe* 86 ft. Service Loops 75 ft. Mud Hose Ref
36.0 in.
View A-A Typical Service Loop Termination
Gussets *
73 ft. Mud Hose Connection
Service Loop Bracket** Existing Girt * 5500 lb Load
View B-B
83 ft. Hydraulic, Air and Water Standpipe Height and Service Loop Bracket Location
10 ft. 6 in. +0/-4 in.
7 ft. Ref
* Customer Supplied ** Varco Supplied
Typical Equipment Stack-Up
Figure 2-2. Derrick services/general installation data
2-11
October 20, 1998
Motor Frame Setback Rails
L P
9 ft. 3 in. TDS-3S 10 ft. 3 in. TDS-4S, TDS-8S 7 ft. TDS-3S 8 ft. TDS-4S, TDS-6S, TDS-8S
P L
Rail Stops
L
42,600 lb for a typical TDS-3S 48,000 lb for a typical TDS-4S 52,000 lb for a typical TDS-7S 48,000 lb for a typical TDS-8S
Rail Loading with TDS in Setback position Load P - lb Rail Spacing 39 in. x 66 in. 48 in. x 62 in. 30 in. x 72 in. TDS-3S 18,600 18,600 17,500 TDS-4S, TDS-8S 18,900 18,900 17,800
Rail Loading while Drilling - 38,000 ft lb for TDS-3S, 60,000 ft lb for TDS-4S, 68,000 ft lb for TDS-6S, 34,000 ft lb for TDS-7S and 62,250 ft lb for TDS-8S. Load L - lb Rail Spacing 39 in. x 66 in. 48 in. x 62 in. 30 in. x 72 in. 91/101 in. x 108 in. TDS-3S 3450 3680 3170 -TDS-4S, TDS-8S 5450 5800 5000 3330 TDS-6S ---3780 TDS-7S 3090 3290 2840 --
Figure 2-3. General installation data
2-12
Wiring
The electrical installation requires routing power to the transfer panel and then to the TDS through the service loops (Figure 2-4). In addition, control cables are required between the service loop, the transfer panel, the SCR, the TDS Varco Drillers Console (VDC), 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 AC 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
#6AWG/2C* Existing Power Cables
Rotary Table
RBS Controls
#12AWG/3C
#16AWG/10C
TDS Drillers Console HYD Pump #1 HYD Pump #2 #16AWG/10C #16AWG/10C
Existing Drillers Console
Water Pump #1
Water Pump #2
Figure 2-4. Typical cabling diagram

TDS-4S Installation and Commissioning 2-13
#16AWG/10C
October 20, 1998
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 existing drillers console Transfer panel to derrick J-box Transfer panel to hydraulic pumps Transfer panel to water pumps Transfer panel to RBS unit Transfer panel to VDC RBS unit to VDC Transfer panel to VDC Transfer panel to derrick J-box Transfer panel to VDC Transfer panel to drilling recorder Transfer panel to SCR console Transfer panel to SCR room Hydraulic pumps to transfer panel Water pumps to transfer panel
#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 VDC 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.
2-14 TDS-4S Installation and Commissioning
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 in. schedule 80 pipe. Install shut-off valves at the drill floor or racking board level. The derrick connections are reduced to 1 in. NPT female pressure and fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of the purge supply for the TDS. Install a shut-off valve at drill floor or racking board level. The air lines connect to the filtered and lubricated supply. The derrick connections are reduced to 1 in. NPT female for the purge line (if required) and 1/2 in. for the air line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean, dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2 in. pipe. Install shut-off valves at the drill floor or racking board level. See the cooling system specifications for water supply requirements. The derrick connections are reduced to 1 1/4 in. NPT female pressure and return for connection to the fluids service loop.
2-15
October 20, 1998
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 ft. 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 2-5. 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, and drive in the remaining roll pin. Grease the OD liberally. Wipe off excess grease. 6. Use the installation procedure in the IBOP Service 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.
2-16
O-Ring
Roll Pin (4)
Split Landing Collar (2)
Drive Stem
Safety Link (4)
Figure 2-5. Installing the landing collar 8. Use the four bolts, lock washers and safety wire provided to install this assembly to the link adapter. Connect the opposite end of the hose to the quick disconnect on the rotating head assembly. 9. Install the elevator links and drill pipe elevator. Attach the link tilt clamps to the bails (U-bolts on the inside). There should be about 1/2 in. slack in the chains.
2-17
October 20, 1998
10. Install the counterbalance system as illustrated in Figure 2-6. 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 in. from the measurement in step b. d. Cut the chain to the length obtained in step c. The tolerance is: +3 1/4 in. or -0 in. e. Assemble remaining components and install per Figures 2-6 and 2-7. 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 J-boxes. The front guard folds down for access to the Jboxes. 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 covers 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.
2-18
Pear Link Connecting Link Hydraulic Accumulator (Inside Motor Frame)
Counterbalance Cylinder Assembly (2)
Motor Frame and Guide Dolly Assembly
Counterbalance Lug (Bolted to Bail) Integrated Swivel Bail
Counterbalance Manifold (On Guide Dolly)
Figure 2-6. Typical counterbalance assembly
2-19
October 20, 1998
Loop Assembly
Guide Assembly
Cylinder Assembly
Hose Assemblies
Hydraulic Accumulator (Inside Dolly Tube) Swivel Bail
Counterbalance Operation Switch
Figure 2-7. Optional counterbalance assembly with parking system
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.
2-20
Counterbalance system
Figures 2-6 and 2-7 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 in the Maintenance and Troubleshooting book.
2-21
October 20, 1998
Motor alignment cylinder system

Figure 2-8 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.
Shipping Brace
2-22
Drillers controls and instrumentation

The controls and instrumentation described in the following sections are, or must be, supplied for operation of the TDS system.
Varco Drillers Console (VDC)

Mount the VDC 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.
2-23
October 20, 1998
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 TDS end of the service loop and lift using the lifting eyes only. Allow enough room for the 86 ft. 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 2-2).
2-24
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 2-2).
2-25
October 20, 1998
3. Connect the service loop to the standpipes, noting the codes (i.e., A for air, H for hydraulic, etc.) to separate the hoses.
z e
The hoses in the fluids loop only extend 11 ft. from the mounting bracket. It may be necessary to make jumper hoses to reach the standpipes.
Air loop
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.
2-26
Retract loop
If your rig is equipped with a retract guide dolly, attach the retract loop to the derrick mounting brackets as follows:
There are four separate service loops needed for a TDS with retractable dollies: two electrical loops, a fluids loop, and a retract system loop. The electrical and fluids service loops attach to the derrick service loop mounting bracket, the retract loop attaches to the retract system service loop bracket. 1. Lift the crate containing the retract system service loop onto the rig floor. 2. Uncrate the service loop. 3. Attach an air winch to the lifting eyes on the derrick end (derrick end has 8 ft. of hose extending beyond the flange) and hoist to the retract system mounting bracket. 4. Attach the service loop flange to the mounting bracket with the hardware provided. Ensure that the service loop hangs straight in the derrick without any twists or kinks.
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. 5. Connect the retract service loop hydraulic and pneumatic hoses to the derrick standpipes.
Before connecting the hoses from the service loop, be certain that the standpipes have been flushed free of any contamination.
2-27
October 20, 1998
2-28
Checkout procedures
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 monkeyboard when actuated. Refer to the Maintenance and Troubleshooting book if a problem occurs. 6. Actuate the motor brake. There is a loud sound as the air escapes when the brake releases. 7. Move the Make/Break valve located on the manifold at the back of the pipehandler torque wrench to the BREAK position. 8. Turn on the hydraulic power supply and adjust the pressure reducing valve (also located on the torque wrench manifold) to the appropriate pressure for the lower IBOP connection.
2-29
October 20, 1998
9. Return the Make/Break valve to the MAKE position. 10. Torque the connection between the upper and lower IBOP 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 makeup button on the VDC 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 IBOP 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 VDC lights up when the IBOP 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 Torque meter and RPM meter. 20. With the Hydraulic Power Unit (HPU) off, bleed down the TDS accumulators (HYD SIDE, not gas side). 21. Remove the split shipping brace (Figure 2-7) from the motor alignment cylinder. 22. Open the two flow control valves 1-1/2 turns off their seats. 23. Set a joint of drill pipe in the slips.
2-30
24. Bring the TDS down as if stabbing the saver sub into the 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 HPU 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 tightened 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 in. of total cylinder stroke) close the flow controls to 3/4 turn off their seats.
2-31
October 20, 1998
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 60F ambient. If high humidity is unavoidable, 70F 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 MOhm 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.
2-32 TDS-4S Installation and Commissioning
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. 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 1,000 volt megger. If the reading is less than two MOhms, 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.
2-33
October 20, 1998
2-34
Operation
SM00620-3
October 20, 1998
3-2
TDS-4S Operation
Contents

Start-up procedure ........................................................... 3-7 Stalling the DC motor ..................................................... 3-8 Changing transmission speeds .......................................... 3-9 Pipehandler operation .................................................... 3-11 Standard rotating head ............................................. 3-11 Powered rotating head ............................................. 3-12 Controls............................................................. 3-12 ROTATING HEAD LEFT/RIGHT switch ..... 3-12 AUTO STOP/FREE ROTATE switch ............ 3-12 Safety valves (IBOP) ................................................ 3-14 Torque wrench ........................................................ 3-16 Changing drill string sizes ........................................ 3-19 PH-85 ............................................................... 3-19 PH-60d ............................................................. 3-19 Torque values for load carrying components ............ 3-20 Drilling ahead ................................................................ 3-21 Drilling ahead with triples ....................................... 3-21 Drilling ahead with singles ....................................... 3-24 Drilling ahead on a semi .......................................... 3-26 Tripping ........................................................................ 3-28 Reaming out .................................................................. 3-29 Well control procedures ................................................. 3-31 Running casing .............................................................. 3-32 Handling bottom hole assemblies .................................. 3-32 Post jarring operations ................................................... 3-34
TDS-4S Operation
3-3
October 20, 1998
3-4
TDS-4S Operation
Safety information
z e
TDS-4S Operation
3-5
October 20, 1998
Manual layout
3-6
TDS-4S Operation
Start-up procedure
Use the following procedure to start up the TDS: 1. Place the blower/oil pump switch in the AUTO position. 2. Place the hydraulic power unit (HPU) switch in the PLC position. 3. Place the water pumps switch in the PLC position. 4. Place the motor space heater switch in the ON position. 5. Place the top drive/rotary table (TDS/ROT) lockout switch in the TDS position. 6. Assign a SCR.
TDS-4S Operation
3-7
October 20, 1998
Stalling the DC motor e

The brake on the top end of the TDS drilling motor armature shaft is a static, or parking brake. It is not a running or dynamic brake. It is not intended to, nor is it capable of, slip-releasing the wind-up torque in the drill string. Using the brake to slip-release the drill string wind-up torque causes the brake to heat up and can destroy the brake lining. When the TDS motor brake holds the down-hole torque, Varco recommends using the following procedure to safely release the torque in the string: 1. Use the hand throttle to develop motor torque equal to the wind-up torque held by the parking brake. 2. Release the parking brake. 3. Reduce the drill current, reducing motor torque, as the drill string slowly releases the wind-up torque. 4. Turn the hand throttle off and reset the drill current to the normal operating position after the pipe unwinds completely.
Do not leave the top drive DC motor stalled in a high torque condition generally for more than 10 seconds (refer to the following table): Amps 280 470 670 820 Stall time (sec) 240 90 45 30 Amps 900 1000 1200 1400 Stall time (sec) 25 20 15 10
3-8
TDS-4S Operation
Changing transmission speeds

The transmission shifts gears by rotating two vertical compound gear eccentric shafts (Figure 3-1). The two compound shafts (high and low) are supported between the main body and lower gear case halves on heavy trunnions. As the shafts rotate (less than onehalf turn), the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. To change transmission speeds, use a 1 in. wrench to turn the 1 in. male hex, located on the well side of the guide dolly lower cross members at the bottom of the transmission case, to rotate the input shaft. It takes five turns of the input shaft to unlock both gear sets, rotate the engaged gear set to full disengagement, rotate the disengaged gear set into full engagement and lock both gear sets in their proper positions with positive stops in the locked position. An external indicator shows the gear range selection. An optional remote gear shifter is available. It allows the operator to change gears simply by turning a switch to select the desired gear. Refer to the Remote Gear Shifter Supplement for more information.
TDS-4S Operation
3-9
October 20, 1998
Rotating Head Assembly
Shifter Input Shaft
External HI / LO Indicator
Compound Gear Shafts
Bottom View
High Gear Eccentric Shaft (Engaged)
Geneva Mechanism
Top View
Figure 3-1. Transmission/geneva mechanism
3-10
TDS-4S Operation
LO
Low Gear Eccentric Shaft (Disengaged) Shifter Input
HI
Pipehandler operation
Standard rotating head
The perimeter of the rotating head cam (Figure 3-2) has an indented area where the cam follower normally rests. When the cam follower is in this indented area, the return cylinder rod is fully retracted and hydraulic pressure inside the cylinder is at equilibrium. When the swivel block and cam rotates to another position along with the drill string, the ramp of the cam extends the return cylinder rod, unbalancing hydraulic pressure in the cylinder. When the elevator is released, the system automatically returns to its pre-selected (indented) position (equilibrium). To operate the swivel block locking mechanism, pull down the locking lever, pulling the locking pin out of one of 24 locking slots in the cam. With the locking lever in the vertical position, manually rotate the swivel block to the desired position and release the locking lever, setting the pin.
Cam
Stationary Flange
Cam Follower
Locking Lever
Figure 3-2. Standard 650-Ton rotating head assembly
TDS-4S Operation
3-11
October 20, 1998
Powered rotating head

The 10-port powered rotating head (Figure 3-3) functions as a hydraulic slip ring. It provides ten hydraulic and pneumatic passages between the stationary swivel flange and the rotating swivel block and attached pipe handling equipment. The powered rotating head is operated by controls on the drillers console. The driller can rotate the swivel block and attached pipe handling equipment freely, or to a predesignated AUTO STOP position. The position can be set by locating a target in the bull gear on the rotating head, to align with the proximity sensor mounted on the flange of the rotating head.
Controls
The powered rotating head is controlled by two switches.
ROTATING HEAD LEFT/RIGHT switch
This switch rotates the powered rotating head, pipe handler, and link tilt to the right or left (same direction as the drill string). Rotation only occurs when the switch is held in the RIGHT or LEFT position. Rotation stops when the switch returns to the center position.
The ROTATING HEAD function is only active when the LINK TILT switch is in the FLOAT position.
AUTO STOP/FREE ROTATE switch
This switch is in the AUTO STOP mode when the light is illuminated (on). In the AUTO STOP mode, a proximity sensor automatically stops rotating head rotation. The AUTO STOP function is independent of the direction of rotation. Rotation continues when the ROTATE switch returns to the center position, then activated again. When the AUTO STOP/FREE ROTATE light is off, the FREE ROTATE mode is active. In this mode, the rotating head rotates as described in the ROTATING LEFT/RIGHT section above.
3-12
TDS-4S Operation
Stationary Flange
Rotary Glyd Ring (11) Torque Arrestor Hanger Swivel Block Hydraulic Motor Assembly
Bull Gear
S1
H1
A1
PRESSU
A1
RE
H2
S2
A2
A5
A2
H3
H2
A3
S1
Figure 3-3. Powered rotating head assembly
TDS-4S Operation
S2
A4
H1
A3 H3 A5 A4
3-13
October 20, 1998
Safety valves (IBOP)

Operating the switch on the VDC to the IBOP CLOSED position causes the two actuator air cylinder rods to extend, moving the arms and the actuator shell body upward (Figure 3-4). This upward movement causes the crank assemblies to rotate 90, closing the upper IBOP. Operating the switch to the OPEN position retracts the cylinder rods, drawing the IBOP actuator shell downward-opening the upper IBOP.
Closing the manually operated lower IBOP requires an Allen wrench.
3-14
TDS-4S Operation
Crank Assembly (2)
Actuator Arm (2)
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 3-4. Safety valve actuator system
TDS-4S Operation
3-15
October 20, 1998
Torque wrench
The primary function of the TDS torque wrench is to breakout the drill string from the saver sub before making a connection. The torque wench can also make connections if necessary (i.e., when replacing the lower IBOP or saver sub, or while backreaming, or when adding a pup joint to the drill stem). The torque wrench has a control manifold with the following components (Figure 3-5): Hydraulic pressure gauge Control and sequencing valves Hydraulic hose inlet and outlet Quick Disconnects (QDs) Manual Make/Break directional valve The Make/Break valve controls the torque wrench operating direction (makeup/breakout) during operation. A pressure reducing valve (PRV) on the control manifold allows presetting the makeup torque (this valve is bypassed when the torque wrench is in breakout mode). When the driller actuates the torque wrench from the VDC, the lifting cylinder rod retracts, raising the torque tube to engage the splines on the upper IBOP. A sequenced signal from the control manifold then operates the clamping piston, clamping the jaws onto the drill string box connection. Then another sequenced signal from the control manifold automatically directs pressure to the torque cylinders, rotating the torque tube up to 25 while developing a maximum torque of 85,000 ft lb (65,000 ft lb on the PH-60d Pipehandler). The position of the Make/Break valve on the control manifold determines the direction that the torque tube rotates. A two-position, air-piloted, hydraulic valve located on the counterbalance manifold located on top of the TDS guide dolly controls the entire sequenced cycle described above. A push button switch on the VDC operates the hydraulic valve. The driller holds the button down to makeup or breakout a connection, and then releases the button to allow the torque wrench to automatically recycle to the ready position. If the torque developed on the first pass is insufficient, the driller simply operates the button again.
3-16
TDS-4S Operation
Manually switch the Make/Break valve on the torque wrench to the MAKE position to use the top drive torque wrench to make connections. This allows the driller to initiate automatic torque wrench sequences and repeat them until reaching the preset makeup torque.
Make/Break Valve
Recycle Sequence Valve
Clamp Sequence Valve
Torque Sequence Valve
Torque Wrench Manifold
BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE
MAKE
PRV
40
50
60
70
30
1000
1500
80
LIFT LOWER
20
500
2000
90
10
2500
10 0
PSI Ft.Lbs.
x1000
Torque Gauge 0 - 2500 PSI
Figure 3-5. Typical torque wrench control manifold
TDS-4S Operation
3-17
October 20, 1998
Failing to apply the correct amount of torque when using the torque wrench to makeup connections can result in equipment damage and injury to rig personnel. Do not switch the Make/Break valve to BREAK until completing the makeup sequence, which may require repeating the makeup sequence several times. Verify the torque pressure regulating valve setting after every makeup sequence before releasing the makeup valve. Repeat the makeup sequence until the torque cylinders do not stroke more than one inch during the final sequence, repeat the sequence if uncertain. Varco recommends that the driller operating the pipehandler verify that the torque cylinders do not stroke more than one inch on the last makeup cycle. Varco also recommends checking the torque gauge on the pipehandler while making connections to make sure the torque wrench applies the correct amount of torque to the connection. Stop and verify correct operation whenever the operator observes unsteady or inconsistent hydraulic pressure readings, or finds it difficult to adjust set points. Varco recommends that a second individual assist the driller when making connections with the torque wrench. The second person can verify that the torque wrench applies the correct torque to connections.
3-18
TDS-4S Operation
Changing drill string sizes

PH-85
To operate the torque wrench using drill string sizes that are different from the size specified on your rigs original configuration, install a separate drill string handling kit. Refer to the following tables when ordering a drill string handling kit for a PH-85:
Drill String Change-Over Kits

750/650 Ton PH-85 Pipehandling Original Part Number 95497-A-H-N-*-* 95497-A-J-N-*-* 95497-A-K-N-*-* 95497-B-K-N-*-* 95497-A-L-N-*-* Desired Tool Joint Connection NC 38 91873-650 91873-650 91873-651 91873-651 n/a NC 50 94731-650 94731-650 n/a 5 1/2 F.H. 94730-650 94730-651 94730-652 TBD 6 5/8 F.H. 94729-650 94729-651 94729-652 97219-651 n/a 2 7/8 F.H.
*These designators do not affect kit choice.
PH-60d
To operate the torque wrench with a 3 1/2 in. drill string, install a separate drill string handling kit. The following lists available kits for a PH-60d: Part No. 78652-1 Includes stabbing guide assembly, jaw assemblies, saver subs, installation drawing. Part No. 78652-2 Includes stabbing guide assembly, jaw assemblies, installation drawing.
Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No. 78652-2 does not. By purchasing the latter, the user assumes responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver subs separately. Specifications for these are available from the factory or any Varco service center.
TDS-4S Operation
3-19
October 20, 1998
Torque values for load carrying components

Proper makeup torque is critical to the function of drill stem components. Table 3-3 only includes components within the TDS. Refer to the API charts for other components. Table 3-3. Torque values for load carrying components Components Upper IBOP to main stem/main shaft Lower IBOP valve to upper safety valve Saver sub to lower IBOP valve Crossover sub to lower IBOP valve Upper IBOP valve to main stem/main shaft Lower IBOP valve to upper IBOP valve Saver sub to lower IBOP valve Crossover sub to lower IBOP valve ID 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. 3 or 3 3/4 in. Connection OD Min. torque Max. torque 50,000 ft lb 50,000 ft lb 46,000 ft lb 46,000 ft lb 83,000 ft lb 75,000 ft lb 66,000 ft lb 75,000 ft lb 63,000 ft lb 60,000 ft lb 60,000 ft lb 60,000 ft lb 91,000 ft lb 84,000 ft lb 85,000 ft lb 91,000 ft lb
6 5/8 in. API Reg. 7 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 6 5/8 in. API Reg. 7 3/8 in. 7 5/8 in. API Reg. 7 5/8 in. API Reg. 9 in. 9 in.
7 5/8 in. API Reg. 7 5/8 in. 7 5/8 in. API Reg. 9 in.
3-20
TDS-4S Operation
Drilling ahead
Drilling ahead with triples
Drilling ahead with triples is the common drilling mode for the TDS. There are various sources for triples. On skidding rigs drilling multiple well platforms, drill pipe can be left racked and used to drill the next well. If triples do not currently exist, there are two recommended methods of obtaining them. One is to leave some triples racked in the derrick when tripping back in the hole and finish the trip with singles. Leave enough triples racked to handle anticipated bit life. The second method for obtaining triples is to make up triples in the mousehole while drilling ahead or during idle rig time. For safety reasons a pivoting mousehole is best because it can pivot to a vertical plane to simplify making connections. Use the following procedure to drill ahead with triples (Figure 3-6): 1. Drill down until the saver sub is within three feet of the rotary table. 2. Circulate bottoms up as necessary. 3. Stop the string rotation. 4. Pick up the string and set slips for a connection four feet off the rig floor. 5. Switch the TDS motor from FORWARD to REVERSE. 6. Stop the mud pumps. 7. Close the IBOP. 8. Break out the drill pipe connection using the torque wrench on the pipehandler. 9. Using the TDS motor, spin out of the box while hoisting the TDS with the drawworks (follow with the drawworks, do not lead).
TDS-4S Operation
3-21
October 20, 1998
Set slips on string Stop circulation Breakout connection using pipehandler and drilling motor (in reverse)
Raise block Tilt link tilt to derrickman
Pickup stand with elevator Stab bottom of stand onto string
Lower block to stab motor into top of stand Spin in motor and stand Makeup both connections with motor
Pull slips Start circulation Begin drilling
1
Link Tilt
Makeup
Start Circulation
Stop Circulation Stab Makeup
Figure 3-6. Drilling ahead with triples
3-22
TDS-4S Operation
10. Stop the spin out mode. 11. Open the drill pipe elevators. 12. Retract the TDS away from the hole. 13. Hoist the TDS to the racking board level to get the next stand. 14. Latch the backup tong on the box connection. 15. Thoroughly dope the box connection in the rotary table. 16. When the TDS is fully raised, extend the TDS. 17. Tilt the links. 18. Switch the TDS motor from REVERSE to FORWARD. 19. Derrickman latches the elevator on the next stand. 20. Hoist the pin off setback area and clear the box with the stand. 21. Release the link tilt. 22. Stab the connection at the floor. 23. Switch the TDS to SPIN IN mode. 24. Continue to slack off approximately two feet to stab the upper connection of the stand with the TDS. 25. Slack off to allow connection to shoulder up (lead with the drawworks, do not follow). 26. Switch to TORQUE and hold for approximately six seconds. The makeup torque is preset. 27. Verify full makeup to the correct value on the torque meter. 28. Switch to DRILL mode. 29. Unlatch the backup tong. 30. Open the IBOP. 31. Start the mud pumps. 32. Pick up to pull the slips. 33. Drill ahead.
TDS-4S Operation
3-23
October 20, 1998
Drilling ahead with singles

Typically there are two situations requiring drilling ahead with singles. One is beginning operations on a new well where there are no triples made up and racked. The other is when making surveys every 30 ft. (i.e., when kicking off using a downhole mud motor). The link tilt feature makes drilling with singles safe and efficient by moving the elevators to the mousehole to pick up the singles. Use the following procedure to drill ahead with singles (Figure 3-7): 1. Drill down the existing single, pull up to the 4 ft. level (approximately), close the IBOP, stop mud circulation, and set the slips. 2. Break the connection between the saver sub and the drill pipe using the torque wrench in the pipehandler. 3. Spin out the connection using the drilling motor. 4. Lift the TDS, opening the drill pipe elevators to allow them to pass over the box setting in the rotary table. 5. Actuate the link tilt to bring the elevator over to the single in the mousehole and latch the elevator around the single. 6. Pull the single out of the mousehole and as the pin clears the floor, deactivate the link tilt to allow the single to come to well center. 7. Stab the connection at the floor and lower the TDS, allowing the added single to enter the stabbing guide until the saver sub pin stabs into the box of the new joint. 8. Using a backup tong to react the torque, spin up and torque the connection using the TDS motors in the TORQUE mode. 9. Pull the slips, start the mud pumps and drill ahead.
3-24
TDS-4S Operation
Set slips on string Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse)
Tilt links to mousehole Latch drill pipe elevator around single
Pickup single with elevator Release link tilt Stab bottom of single onto string
Lower block to stab motor into top of single Spin in motor and single Makeup both connections with motor in torque mode
Pull slips Open IBOP Start circulation Begin drilling
Makeup
Open IBOP Close IBOP Link Tilt Stab Makeup
Figure 3-7. Drilling ahead with singles
TDS-4S Operation
3-25
October 20, 1998
Drilling ahead on a semi

Derrick clearances are critical for drilling operations with the TDS on a floater. When making a connection, kelly drilling pulls the bit off bottom far enough to account for vessel heave. The 54 ft. kelly must be pulled all the way up to add the next joint. With the TDS, there is no kelly to pull up. Therefore, you must be able to pull the bit off bottom enough to allow for vessel heave when making a connection. The practical method for doing this is to pull up the pipe string until the bit is sufficiently off bottom, and then set the slips. The distance should equal the maximum expected heave. The TDS pipehandler can break out the drive shaft, and the TDS motor can spin out the connection. Then hoist the TDS into the derrick and add a new 90 ft. stand from the pipe rack in the same manner as on a fixed rig. Because the pin connection of the new stand is about 15 ft. above the floor, a torque backup device is required, as well as a means to assist stabbing. Varco provides a simple, remotely-operated Raised Backup System (RBS) which retracts out of the way when not in use. Use the following procedure to drill ahead with triples on a semi (Figure 3-8): 1. Drill the stand down until the elevator is to the floor. 2. Pull the string up sufficiently off bottom. 3. Set the slips. 4. Breakout the TDS and spinout shaft using the drilling motor. 5. Raise the TDS to the racking platform and latch the elevator on a new stand. 6. Extend the RBS and adjust the height. Clamp the RBS tong on the elevated box of the drill string. 7. Stab the pin of the new stand into the string using the RBS stabbing head if so equipped, or use the lower racking arm. 8. Stab the TDS into the upper end of the stand, spin in, and make up both connections. 9. Retract the RBS. 10. Pull the slips and drill ahead.
3-26 TDS-4S Operation
Drill down stand Stop circulation
Pickup string 10 to 20 ft. Set slips
Raise block Extend RBS and adjust height Pickup stand Stab stand using RBS to assist
Spin in stand Makeup both connections with motor
Pull slips Retract RBS Start circulation Begin drilling 90 ft.
Unlatch elevator Breakout/spinout with pipehandler and motor
Makeup
Start Circulation
Stop Circulation Makeup
Figure 3-8. Drilling ahead with triples (floaters)
TDS-4S Operation
3-27
October 20, 1998
Tripping
Perform tripping operations in the conventional manner. Use the link tilt feature to tilt the elevator to the derrickman so the derrickman can quickly latch it around the pipe. The hydraulic link tilt allows the elevator to also reach the mousehole. The air actuated link tilt has an intermediate stop which is adjustable to set the elevator at a convenient working distance from the monkeyboard. The intermediate stop tilts out of the way to allow the elevator to reach the mousehole. If a tight spot or key seat is encountered while tripping out of the hole, spin the drilling motor into the stand at any height in the derrick. Establish circulation and rotation immediately to work the pipe through the tight spot.
3-28
TDS-4S Operation
Reaming out
The TDS permits reaming out of an open hole to prevent pipe sticking and to reduce key seat formation, without affecting racking functions associated with normal tripping (i.e., there are no singles to contend with). The pipehandler torque wrench can break out 90 ft. stands in the derrick. Use the following procedure to ream out of the hole (Figure 3-9): 1. Hoist the block while circulating and rotating the drilling motor until the third connection appears. 2. Stop circulation and rotation and set the slips. 3. Break out the drilling motor from the top of the stand using the pipehandler torque wrench. Hold a backup at the floor and spin out the drilling motor. 4. Break out the stand at floor level, and spin out using pipe spinners. 5. Pick up the stand with the drill pipe elevator. 6. Rack the stand back. 7. Lower the block and TDS to the floor. 8. Stab the drilling motor into the box, spin up and torque it with the drilling motor. With light slip loads, the pipehandler torque wrench can be used to torque the connection. 9. Resume circulation and continue reaming out of the hole.
TDS-4S Operation
3-29
October 20, 1998
Hoist while circulating and rotating When 3rd connection surfaces, stop rotation and circulation
Set slips on string Breakout connection using pipehandler and drilling motor (reverse) Breakout and spinout stand at floor
Hoist free stand with elevator
Setback stand using link tilt
Lower block, stab motor into string Spin in motor and makeup connection with motor Start circulation, pull slips, hoist and rotate
1
Breakout
2
Hoist
4
Setback
Hoist and Rotate
Breakout
Figure 3-9. Reaming out
3-30
TDS-4S Operation
Well control procedures

The TDS can stab into the string in any position in the derrick. While drilling, the remotely controlled IBOP valve is always in the string for immediate use as needed. Use the following TDS well control procedure in conjunction with standard IBOP well control procedures: 1. On indication of a kick, set the slips at the nearest connection and stab the TDS into the string. 2. Spin up and torque the connection using the Spin/Torque control, after setting the backup tong. 3. Remotely close the upper IBOP valve.* 4. Lower the string to the floor and reset the slips. 5. Manually close the lower IBOP valve. 6. Remove the torque wrench vertical travel stops. 7. Breakout the lower IBOP from the upper IBOP. 8. Engage the top drive motor in reverse to spin out the connection. 9. Install the appropriate crossover sub, check valve or circulation sub on top of the lower IBOP valve. 10. Proceed with normal well control procedures. * Operation of the IBOP valves is the same as any standard valve. A 7/8 in. hex wrench is included with the system to operate the upper valves if the remote actuator should fail, or for checking that the valve is functioning correctly.
TDS-4S Operation
3-31
October 20, 1998
Running casing
For casing operations, longer elevator links (180 in.) must be used to allow clearance for the cementing head under the torque wrench in the pipehandler. Attach a short piece of hose to the saver sub in the pipehandler to fill the casing while lowering. Use the remotely controlled upper IBOP valve to start and stop the fluid flow. If desired, run casing conventionally using the block and hook and swinging the TDS aside. Use longer bails (180 in.) to prevent the block dolly (if used) from contacting the TDS dolly.
Handling bottom hole assemblies

For handling bottom hole assemblies, use the swiveling drill collar dolly (Figure 3-10) to allow the elevators to turn freely. The drill collar dollys upset, which latches in the standard drill pipe elevator, is mounted on a bearing allowing it to swivel even while it is under load. A shoulder elevator is suspended from the perfection links (or a second drill pipe elevator if lifting subs are used.) The collars can be walked in or out with the elevator turning on the drill collar dolly.
3-32
TDS-4S Operation
A
Drill Pipe Elevator
A
100 TON VARCO
Drill Collar Dolly
Perfection Links (36")
;;; ;;; ;; ;;; ;; ;;;
91 in. Square Shoulder Elevator
Lifting Sub 37 in.
8 in.
Drill Collar View
A-A
Figure 3-10. Swiveling drill collar dolly
TDS-4S Operation
3-33
October 20, 1998
Post jarring operations e

Jarring occurs on all drilling rigs. It is not practical to recommend removing the top drive from the drill string during all jarring operations. But the possibility of damage to a top drive during a jarring operation is considerable. Consider removing the top drive from the drill string before performing prolonged jarring. It is imperative to exercise caution when using a top drive after a jarring operation. Safe operation of the TDS is the responsibility of the user and rig crew. Use the Post Jarring Checklist (PI 93-1) and Design Specification, Design Torque Standard (DS00008) to help ensure safe top drive operation. Note that the checklist includes recommended procedures. Do not limit inspections to items on the checklist. The checklist draws attention to specific parts on major subassemblies. Inspection should be rigorous, looking for any wear that could cause a safety or operational risk. Use the Post Jarring Checklist (PI 93-1) and Design Specification, Design Torque Standard (DS00008) after performing any jarring operation while the top drive is in the drill string.
3-34
TDS-4S Operation
Maintenance and Troubleshooting

SM00620-4
Rev. B
March 8, 2001
4-2
TDS-4S Maintenance and Troubleshooting
Contents
Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21
Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Maintenance and Troubleshooting 4-3
March 8, 2001
Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45
Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97
4-4 TDS-4S Maintenance and Troubleshooting
Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111
This section contains some information regarding the GE motor. Refer to the GE Motor Service Manual, VDR00023 (included in VDP0001) for specific details such as: Inspection and maintenance schedule Recommended storage instructions drilling motors and generators Removing motors or generators from storage
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March 8, 2001
4-6
Safety information
z e
4-7
March 8, 2001
Manual layout
4-8
Inspection
TDS swing out procedure
Varco top drives with swing-out guide dollies can be quickly swung aside on their own dolly frames 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 VDC 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.
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March 8, 2001
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 (HPU) and bleed down hydraulic pressure by opening the needle valve 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 integrated swivel bail may cause the TDS motor assembly and/or the hook to lurch suddenly. Always keep adequate tension on the tailing lines to prevent sudden movement of these assemblies. 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 guide dolly far enough to allow swinging the TDS back into place. 2. Retract the TDS and secure it.
While latching the hook to the integrated swivel bail, the swivel and/or the TDS motor assembly may suddenly lurch. Always keep adequate tension on tailing lines to prevent sudden movement of these assemblies. 3. 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. 4. 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. 5. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the hinges. 6. Connect the mud hose to the S-tube. 7. Connect the air intake hose. 8. Hook the counterbalance system pear links onto the ears of the hook or block. 9. Turn the HPU on and bleed air out of the system.
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March 8, 2001
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 service manual for your reference provided in the Vendor Documentation Package.
Motor alignment cylinder
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. Check alignment cylinder operation weekly. Also, inspect all moving parts and check accumulator pressures on a weekly basis.
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 O-ring extrusion at excessive pressures. Inspect the entire filter/regulator/lubricator monthly for damage to the filter bowl, overall body, or inlet and outlet fittings. Replace any damaged, corroded, or improperly functioning components. Adjust the pressure regulator outlet pressure to 100-120 psig monthly. Clean and drain the filter weekly. Fill the lubricator with petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU at 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.
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March 8, 2001
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire or cotter pins were removed during repairs, replace them immediately. Inspect the hinge bolts daily to make sure they are not separating from the pipehandler. Make sure the hinge pins are not loose due to excessive wear in the bore of the clamp clevis or a broken retaining bolt.
Inspect the link tilt intermediate stop and adjustment device for overall integrity weekly. Replace the components if there is excessive looseness of the threaded rod in the threaded hole of the pivot arm (Figures 4-24 and 4-25). An indication of a possible problem is if the two intermediate stops are not adjusted equally (i.e., if the thread engagement differs between the two stops). Failure to perform this inspection and/or component replacement can result in injury to rig personnel.
Nondestructive Examination (NDE)

Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.
NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity.
Visual inspection
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
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March 8, 2001
Landing collar
Disassemble and inspect the landing collar every six months. Use the following procedure to disassemble the landing collar (Figure 2-5) for inspection: 1. Disconnect the top drive from the drill string. 2. Remove the IBOPs and pipehandler. 3. Raise the solid body elevator to expose the landing collar retainer. 4. Straighten the retainer tabs. 5. Slide the retainer ring above the split landing collar halves. 6. Drive out one roll pin. 7. Remove the landing collar halves. 8. Slide the retainer off the drive stem. After disassembly, inspect all landing collar parts for wear, damage, or corrosion. Check for: Grooves or other radial wear marks indicating that the bore of the solid body elevator is rubbing on the outside diameter of the landing collar retainer shell Radial grooves on the inside diameter of the retainer shell Missing tabs from the retainer shell Wear or corrosion induced pitting on the retainer shell shoulder Wear, corrosion, or fatigue cracks on the inside or outside diameter of the landing collar halves Evidence of drive stem contact with the solid body elevator Evidence of inside bore wear on the solid body elevator indicating contact with the drive stem or landing collar retainer. Wear on the inside shoulder of the elevator should not exceed 1/8 in. Evidence of wear, corrosion, or fatigue cracks on the safety links
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.
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March 8, 2001
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear. Remove the drive stem/mainshaft from service if bore wear is greater than the dimensions shown in Figure 4-2. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections.
Large Bore
1.30 Minimum @ Landing Collar Grooves (2.45 New) (1.70 New) 3.75 Diameter (New)
9.000 Diameter
7 5/8 API REG R.N. Pin 7.500-3 ACME-3G Left-hand Thread
Small Bore
1.30 Minimum @ Landing Collar Grooves (2.45 New) (1.70 New) 3.00 Diameter (New)
9.000 Diameter
7 5/8 API REG R.N. Pin 6.250-3 ACME-2G Left-hand Thread
Figure 4-2. Typical minimum bore wear dimensions (Refer to engineering drawings for exact dimensions)
4-18
Use the following API recommended guidelines (Figures 4-3) to determine the tensile load bearing capacities of the drive stem/ main shaft landing collar.
3800000 3700000 3600000 3500000 3400000 3300000 3200000
New Condition (3.00 Bore)
Load (Lbs)
3100000 3000000 2900000 2800000 2700000 2600000 2500000 2400000 2300000 2200000
New Condition (3.82 Bore)
1.75
1.70
1.65
1.60
1.55
1.50
1.45
1.40
1.35
1.30
1.25
1.20
1.15
1.10
1.05
Remaining Wall Thickness Under Pin Thread Relief Groove (Inches)
Figure 4-3. 750-Ton and 650-Ton drive stem/main shaft landing collar tensile dimensions
1.00
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March 8, 2001
Magnetic Particle Inspection (MPI)

Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components and load collar grooves to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. After approximately five years, or 15,000 operating hours, depending on the severity of operating conditions, Varco recommends performing a MPI of all load carrying components over their entire surface (including internal bores) to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. The load carrying components are: Drive stem/main shaft (lower portion) Landing collar Upper and lower IBOP 350-Ton BNC drill pipe elevator Link adapter Saver, crossover, and spacer subs Power subs Power swivels Elevator links Details on MPI 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 Inspection
4-20
Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a components integrity. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.
Safety valve inspection procedures (IBOP)
Upper and lower IBOP 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 IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).
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March 8, 2001
4-22
Lubricating the motor and motor support bonnet assembly

Gearbox
Check oil daily. With the motor off, check to see that the oil level is at the middle of the sight glass located on the side of the main body. Drain and refill the gearbox every 1,500 operating hours or three months, whichever occurs first. (Refer to Oil capacity later in this chapter.) Properly maintaining the TDS gear shifting mechanism increases the operational life of the top drive. Use the following procedure to maintain proper gear lubrication: 1. Shift all top drive two speed gearboxes from one gear to the other and back again at least once a week. This helps to distribute lubricant and prevents contaminant buildup. 2. Remove the gear indicator lever assembly and the indicator gearcase cover.
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March 8, 2001
3. Repack the inside area with grease every six months (refer to Figures 1-9 and 1-10 in the Description book). 4. Inspect the gears for corrosion or damage. Clean, lubricate or replace components as required. There is a timing mark on the gears to ensure correct orientation. If these marks are not visible when removing the gears, mark the gears before removal to ensure correct orientation when reinstalling them. If there are problems shifting from one gear to the other, use the following procedure to shift the gears: 1. Turn the drive stem with chain tongs to make sure the gear mesh aligns properly. Do not turn the DC motor while shifting gears. 2. Insert two 3/8 in. bolts in the threaded holes on the bottom of the shafts while shifting the gears and use a bar to turn the shaft in the proper direction. Do not shear the bolts. Eccentric shaft rotation direction is the same as the shifter input shaft when shifting into gear. 3. If the shift input mechanism slips when attempting to shift gears, use a torque wrench to check the torque of the shifter when the clutch begins to slip. If the torque is less than 65 ft lb, then use the Torque setting procedure to adjust the clutch
Gearbox oil must be drained before removing clutch. The factory setting of the clutch is 45 ft lb. However, increase the torque if there are persistent problems. 4. Remove the 3 in. inspection plugs on the rear of the gearcase and make sure the compound gears are free to turn with the unit in neutral. If the gears cannot turn, it indicates a larger problem (i.e., contaminants in gears, damaged bearings, etc.).
4-24
Torque setting procedure

Use the following procedure to set the torque limit clutch to 45-50 ft lb: 1. Attach any torque indicator to the output stub (Figure 4-4). 2. Hold the body and determine the current torque setting. 3. Remove the snap ring and locking plate. 4. Use a 5/8 in. 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.
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March 8, 2001
Gear Subplate
Lower Gearcase
Housing Gear Changer
Gear Shaft Changer
Torque Limiter (Clutch)
Detail A
Torque Limit Clutch
Figure 4-4. Torque setting procedure
4-26
Other gearbox lubrication and maintenance considerations

Keep the bottom of the eccentric gear shafts clean and free of corrosion, paint or other contaminants. Keep this area lightly lubricated with oil. 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 to install sealed caps 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 gearcase 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.
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March 8, 2001
Oil capacity
The TDS-4S holds approximately 10-20 gallons of oil, but oil capacities vary according to the type of cooling systems, etc. installed. Always fill the transmission to the middle of the sight glass. Use the following procedure to fill the transmission for the first time on a new top drive: 1. Fill the gearbox to the top of the sight glass (approximately 10-20 gallons). 2. Operate the top drive 10-15 minutes and check the sight glass. 3. The oil level should be near the middle of the sight glass. If the oil level is below the middle of the sight glass, add more oil until the level reaches the middle of the sight glass. If the oil level is at, or above the middle of the sight glass, do not add any additional oil to the gearcase. After installation and initial operation of the top drive, always fill the transmission to the middle of the sight glass. When draining oil from the drain plug at the bottom of the gearcase, only the 5-6 gallons of oil at the bottom of the gearcase actually drains. Oil still remains in the rotating head cavity (approximately 1-2 gallons), the oil lube/pump/cooler system (approximately 1-2 gallons), and the wetted surfaces inside the motor housing assembly (approximately 2-3 gallons). Removing the suction hose from the cover plate below the pinion shaft allows more oil to drain and also removes sediment that collects there. Removing the oil drain plug from the rotating head allows more oil to drain.
4-28
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 G.E. 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 operating hours, or three months, with two ounce by weight Shell Cyprina RA. Lubricate the commutator (brake) end bearing every 1,500 operating 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.
4-29
March 8, 2001
Lubricating the washpipe and bonnet seal

Apply grease daily to the washpipe grease fitting and the two bonnet seal fittings (located below the washpipe grease fitting) (Figure 4-5).
Grease Fittings Wash Pipe Assembly
Bonnet
Figure 4-5. Lubricating the washpipe and bonnet seal
4-30
Lubricating the rotating head

Apply grease daily at the fittings (Figures 4-6 and 4-7). Inspect for seal leakage weekly around the lower bearing retainer.
Grease Fittings Grease Fitting
Grease Fittings
Figure 4-6. Lubricating the standard rotating head
Grease Fitting
Grease Fittings
Figure 4-7. Lubricating the powered rotating head

March 8, 2001
Lubricating the link adapter

Apply grease to the link adapter fittings weekly as shown in Figure 4-8.
2 Grease Fittings on front, 2 Grease Fittings opposite. (4 places total)
Figure 4-8. Lubricating the link adapter
4-32
Lubricating the torque wrench

Apply grease daily to the torque wrench fittings (Figure 4-9). Inspect the stabbing guide for excessive wear or cracks. Replace as necessary.
Grease Fitting (6 on IBOP Actuator Rollers, Cylinder Pins and Arm Pins)
Grease Fitting (6 on Optional Link Stop and Cylinder Assembly)
Grease Fitting (1 each side of Torque Tube on Clevis Pin)
Grease Fitting (8 on Bottom of Clamp)
Figure 4-9. Lubricating the PH-85 torque wrench

March 8, 2001
Lubricating the master bushing ID wear guide

The master bushing ID wear guide has four fittings (Figure 4-10). Lubricate weekly. Inspect the guide ring periodically for wear or damage and replace it as necessary.
Master Bushing Wear Guide
Grease Fittings (4)
Figure 4-10. Lubricating the master ID bushing wear guide
Lubricating the safety valve actuator

Apply grease daily to the fitting in the crank assemblies (Figure 411). Check for worn components and operate the valve to verify correct adjustment weekly.
4-34
Lubricating the upper safety valve (IBOP)

Lubricate the upper IBOP valve weekly at the lubrication fittings located directly below the actuator cranks in the recessed counter bores (Figure 4-11). Refer to the IBOP Service Manual for complete IBOP lubrication instructions.
Open Position
Actuator Shell Crank Arm Grease Port
Grease Fitting
Actuator Arm Groove
Upper IBOP Valve
Figure 4-11. Lubricating the IBOP
4-35
March 8, 2001
Lubricating the guide dolly assembly

Lubricate the 20 guide rollers every trip at the four manifolds (5 fittings each) located on each corner of the guide dolly (Figure 4-12). If your rig has a retract system, refer to the Retract Guide Dolly supplement. Check guide rollers weekly for cracks or excessive axial or radial play and replace as necessary. Lubricate the hinges (one place on each hinge) monthly. 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 in. 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.
4-36
A preferred method is to rework the roller assembly for drill and tap operation, but the staking method is also effective. At each bottom corner of the motor frame are the two grease points for the motor trunnions (Figure 4-13). Lubricate these weekly. Lubricate the washpipe packing daily with the mud pump off. Daily, with the hydraulic power on, check the filter gauge on the pressure filter 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.
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March 8, 2001
Grease Fitting (20)
Grease Fittings
(TDS Removed for clarity) Non-Swing Guide Dolly
Grease Fittings
Figure 4-12. Lubricating the non-swing guide dolly assembly
4-38
Grease Fittings Grease Fitting (20)
Swing Guide Dolly
Grease Fitting
Grease Fitting
Grease Fittings
Figure 4-13. Lubricating the swing guide dolly assembly
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March 8, 2001
Grease Fitting (28)
Grease Fittings
Retract Guide Dolly
(TDS Removed for clarity)
Grease Fittings
Figure 4-14. Lubricating the retract guide dolly assembly
4-40
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 (Figure 4-15).
Bail
Bail Pin
Bail Pin
Grease Fitting
Grease Fitting
Figure 4-15. Lubricating the bail pins

March 8, 2001
Lubricating the cooling system

Lubricate AC blower motors every three months (Figure 4-16). On rigs with closed loop cooling systems (Figure 4-17) 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.
Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower
Transmission Cooler
Figure 4-16. Lubricating the local cooling system
4-42
Explosion Proof AC Blower Motor
Grease Fitting
Grease Fitting
Motor Cooling Blower
Motor Cooling Blower
Heat Exchanger
Heat Exchanger
Figure 4-17. Lubricating the closed loop cooling system
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March 8, 2001
Lubrication schedule
Frequency Daily Daily Daily Daily Daily Daily Daily Each trip Each trip Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly 750 hrs/90 days 1,500 hrs/6 mos. Monthly Monthly 3 months 3 months 3 months Location Bonnet seal Torque wrench (PH-85) Gearbox oil (check level) Rotating head Safety valve actuator cranks Hydraulic pressure filter Wash pipe assembly BNC drill pipe elevator Guide dolly rollers (Retract ) Gearbox (shift gears) Dolly motor trunnions Air filter/regulator/lubricator IBOP actuator arms Link adapter (650-Ton) Elevator support Master bushing wear guide Link tilt (check condition) Bail pins GE drilling motor pinion bearing GE drilling motor commutator bearing Motor frame/dolly hinges (Retract ) Cooling system cleaning AC blower motor Change gearbox oil Gear oil filter/suction strainer Lubricant code* 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 2 4 2 1 1 Number of points 2 6 1 5 2 1 7 20 2 6 4 7 4 2
* See Table 4-1, Recommended lubricants Check condition and replace as necessary Refer to Retract Guide Dolly supplement
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.
4-44
Lubricant specifications
TDS-4S 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: Damage the gearbox due to reduced oil flow 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-4S transmission operating properly: Minimum ambient temperature F C Below 20 20 to 60 45 to 85 Above 70 -6 -6 to 16 7 to 30 21 Oil type required See note below 2EP, ISO 68 4EP, ISO 150 6EP, ISO 320 Varco P/N 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.
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March 8, 2001
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. Table 4-1. Recommended lubricants
Lube Code and Description
1 2
General Purpose Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade Above -4F (-20C) MP grease Avi-Motive Lidok EP2 Below -4F (-20C) Avi-Motive W Lidok EP1 Above 70F (21C) Alpha LS-320 NL Gear 320 Spartan EP320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320
Gear Oil 45 to 85F (7 to 30C) Alpha -150 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 20 to 60F (-6 to 16C) Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Statoil Meropa 68 Carter EP 68
Gulf Crown EP32 Gulf Crown EP31 Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 1 -
Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP 6EP 320 4EP 150 2EP 68
4-46
Table 4-1. Recommended lubricants (continued)

Lube Code and Description
3 4 5
Motor Grease Ambient temperature range Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade All temperatures N/R Black Pearl N/R N/R N/R N/R N/R N/R N/R N/R 2 -
Hydraulic Oil 14 to 185F (-10 to 85C) Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 46 5 to 167F (-15 to 75C) Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 32
Bio-degradable
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March 8, 2001
4-48
Adjustment procedures
Adjusting the torque wrench
Use the following procedure to adjust the pipehandler torque wrench:
The pipehandler torque wrench is properly adjusted and tested in the factory before it is shipped. Perform the adjustment procedure after performing maintenance on the torque wrench or if the torque wrench does not function correctly. 1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight. Be sure to use the correct thread compound when making up.
When adjusting torque wrench manifold needle valves, loosen the locknut around the valve stem and use a 5/32 in. hex wrench to adjust the valve. After obtaining desired setting tighten locknut around valve stem.
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March 8, 2001
2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUE sequence valves on the torque wrench manifold fully in (Figure 4-18). 3. Fully back out the Pressure Reducing Valve (PRV), then screw in one turn. 4. Turn the LIFT/LOWER flow control valve fully in, and then back it out three turns. 5. Turn on the HPU. 6. If the torque cylinders are in their full clockwise position, set the Make/Break valve to MAKE. If they are in their full counterclockwise position, set Make/Break valve to BREAK. Note that torque cylinders should not move if the recycle sequence valve is fully in. 7. Slowly back out the RECYCLE sequence valve until torque cylinders just start to move, then screw out an additional full turn.
Make/Break Valve
Recycle Sequence Valve
Clamp Sequence Valve
Torque Sequence Valve
Torque Wrench Manifold
BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE
MAKE
PRV
40
50
60
70
30
1000
1500
80
LIFT LOWER
20
500
2000
90
10
2500
10 0
PSI Ft.Lbs.
x1000
Torque Gauge 0 - 2500 PSI
Figure 4-18. Torque wrench control manifold

8. Move the Make/Break valve to BREAK. Set the PRV to 750 psi. 9. Switch the lever between MAKE and BREAK to adjust the RECYCLE sequence valve until full rotation in each direction takes six to eight seconds. Tighten the locknut around the RECYCLE sequence valve adjustment screw. 10. Set the Make/Break valve to MAKE. 11. Depress and hold the torque wrench operating button on the VDC. The torque wrench should lift and the clamp jaws should remain retracted. 12. Slowly back out the CLAMP sequence valve until the clamp jaws just begin to clamp onto the tool joint. Screw out an additional half turn. Lock the CLAMP sequence valve adjustment screw in position by tightening the locknut. 13. Back out the TORQUE sequence valve until the torque cylinders just begin to stroke, then back out an additional half turn. Tighten the locknut around the TORQUE sequence valve adjustment screw. 14. Release the torque wrench operating button on the VDC. The torque wrench should start to unclamp and drop, then the torque cylinders should recycle. 15. If the torque cylinders recycle before the clamp cylinders retract, screw in the RECYCLE sequence valve until the torque cylinders do not move before clamp cylinders have fully retracted. Tighten the RECYCLE sequence valve adjustment screw locknut. 16. Cycle the torque wrench as many times as required to makeup the connection. 17. Set the Make/Break valve to BREAK. 18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub, without breaking out the saver sub or lower IBOP. 19. The torque wrench is ready for operation.
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March 8, 2001
Adjusting the upper safety valve (IBOP) and safety valve actuator system
Refer to the IBOP Service Manual for upper IBOP and safety valve actuator system adjustment procedures.
Adjusting the counterbalance system

Leave the HPU on during the entire adjustment procedure, and disconnect the TDS from the drill string near the bottom of the rails, but well off the stops. 1. Remove the caps and loosen the lock nuts on the needle valve and PRV located on the counterbalance manifold (Figure 419). It is not necessary to remove the front guard for access to the manifold. A small amount of oil will leak around the adjusting stems after removing the caps. 2. Open the needle valve and let the stem circulate for two minutes. Crack both upper cylinder fittings and bleed air from system. Tighten the fittings. Close the needle valve. 3. Using a hex wrench, screw in the PRV until the cylinder retracts, raising the TDS. 4. Slowly back out the PRV. The pressure decreases and the cylinder rods begin extending. When the integrated swivel bail contacts the hook, note the pressure on the gauge. Allow the pressure to decrease an additional 25 psi and tighten the locknut. Replace the caps on the valve adjustment stem.
4-52
Needle Valve (on opposite side)
Upper Motor Frame Crossmember
Pressure Reducing Valve
Pressure Gauge
Figure 4-19. Counterbalance manifold
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March 8, 2001
Adjusting the motor alignment cylinder system

Once the alignment cylinder is installed, use the following procedure to properly adjust the motor alignment before operating TDS systems that have a separate alignment cylinder accumulator and valve manifold. 1. With the HPU turned off, bleed down the alignment cylinder accumulator by opening the needle valve located at the alignment cylinder valve manifold (Figures 4-20 and 4-21). 2. Remove the split shipping brace from the motor alignment cylinder (Figure 4-22). 3. Turn on the HPU and allow the system to circulate for approximately two minutes. 4. Close the needle valve. 5. Open the two flow control valves located at the alignment cylinder supply return lines 1-1/2 turns off their seats.
4-54
Alignment Cylinder Lug (ref) Pressure Reducing Valve
Needle Valve
Motor Frame (ref)
Alignment Cylinder Manifold Accumulator
Bracket Gas Valve
Figure 4-20. Typical motor alignment cylinder valve manifold
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March 8, 2001
Prefill Valve Assembly
Directional Control Valve (Operation Switch) Pressure Reducing Valve (PRV)
Needle Valve
Motor Frame (ref)
Alignment Cylinder Valve Manifold
Bracket Gas Valve Accumulator
Figure 4-21. Motor alignment cylinder valve manifold
4-56
Shipping Brace
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March 8, 2001
The pressure setting is adjusted by screwing the PRV in or out with a hex wrench (Figure 4-19). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the PRV reduces pressure and moves the saver sub away from the rails (see additional notes at the end of this procedure). 6. Verify the correct pressure setting using the following procedure: a. With the HPU on, back down the pressure using the 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 pre-load in each direction both toward and away from the rails. e. Record the pressure setting for future reference. 7. Set a joint of drill pipe in the slips. 8. 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 OD of the pin clears the shoulder of the box. 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 drill pipe box. b. Turn off the HPU 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.
4-58
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 in. of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2 3/8 1/8 in. 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 in. 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.
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March 8, 2001
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: a. The accumulator end caps are screwed flush into the accumulator body. b. The gas valve is screwed in tight. c. No oil remains trapped in the top end of the accumulator. 3. Remove the gas valve protector and the gas valve cap. 4. Attach the charging hose to the nitrogen bottle and to the gas valve using the following procedure: a. Use thread sealing and lubricating compound on the pipe threads of the gauge. b. Back the gas chuck stem completely out of the way before attaching the assembly to the accumulator gas valve. c. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the bleeder valve. d. Turn the gas chuck stem all of the way down, depressing the core in the accumulator gas valve. e. Only crack open the nitrogen bottle valve to slowly fill the accumulator. Shut it off when the gauge indicates 900 psi. f. If the 900 psi precharge pressure is exceeded, make sure the nitrogen bottle valve is closed, then open the bleeder valve (opposite the gas valve below the gauge) slightly, but only momentarily, to reduce pressure. g. Before loosening the swivel nut, turn the gas chuck stem out all of the way, then open the bleeder valve. h. Prevent the gas valve from turning, loosen swivel nut, and remove the assembly. 5. When precharging is complete, replace the cap on the gas valve and install the gas valve protector.
4-60
Do not loop or twist hose as it stiffens when gas pressure is released from nitrogen bottles. Never loosen the swivel nut attached to the gas valve in the accumulator without first backing the gas chuck stem all of the way out. Do not reduce accumulator precharge by depressing valve core (high pressure may rupture rubber valve seat). Instead, slowly turn gas valve out until gas begins to escape through bleed hole drilled through threads of valve. This hole is a safety feature, it warns of stored pressure whenever gas valve is being removed. Install new gas valve O-ring each time gas valve is removed.
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March 8, 2001
Assembly and disassembly

Pipehandler
Torque wrench disassembly
For PH-85, see Figures 4-23, 4-24, 4-25, and 4-26. For PH-60d, see Figure 4-27. 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.
4-62
Torque Tube
V a r c o
Torque Cylinders
Figure 4-23. PH-85 torque wrench assembly/disassembly
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March 8, 2001
Clamping Jaws
Body
Clamp Cylinder Body
Clamp Cylinder Pistons
Stabbing Guide
4-64
Mounting Shaft
Frame
Safety Valve Actuating Cylinder (2)
Vertical Positioning Cylinder
Hanging Height Adjustment
Guard
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March 8, 2001
Figure 4-26. PH-85 torque wrench assembly/disassembly (optional link retractor)
4-66
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 27. PH-60d torque wrench assembly/disassembly
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March 8, 2001
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 seals
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.
4-68
3. Remove the jaw pins from the rear clamping jaw and remove the jaw. 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 screw holes orientated vertically. 4. Gently and evenly tap the piston into place until the rod appears beyond the front cylinder bore.
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March 8, 2001
5. Install a new piston seal in the rear piston groove and lubricate with hydraulic fluid. 6. Insert the 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 the rod seal and rod wiper in the inside grooves of the cylinder gland. 9. Install the piston seal in the outside groove. 10. Lubricate all seals with hydraulic fluid. 11. Insert cylinder gland into the bore rod and piston seals first. Push the gland past retainer groove and install the retainer ring. 12. Insert the spacer and attach the clamp clevis to the rear cylinder rod with the two hex head cap screws and flat washers. Tighten firmly and lockwire. 13. Adjust orientation of the clamp clevis and attach to the clamp body using the two clevis pins and cotter pins. 14. Attach the rear clamping jaw spacer to the front piston rod using the spacer and two hex head cap screws and flat washers. Tighten firmly and lockwire. 15. Attach the clamping jaw with the two jaw pins. 16 Swing the stabbing guide back into position and attach with the slotted nut and cotter pin. 17. Reconnect the hydraulic lines from the clamp body cylinder clamp port and front unclamp port at the torque wrench manifold clamp and unclamp ports. 18. Reinstall and adjust the torque wrench (refer to Adjusting the torque wrench earlier in this chapter).
4-70
Replacing the standard rotating head glyd rings
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 TDS swing out procedure in Chapter 1 of this book). Refer to Figures 4-28 and 4-29, when performing the following procedures.
Cam
Stationary Flange
Cam Follower
Locking Lever
Figure 4-28. 650-Ton rotating head assembly
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March 8, 2001
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Push the cam follower away from the rotating block cam. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. 15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
Cam Assembly Locking Handle
Return Cylinder
Return Cylinder Clevis Pin
Return Cylinder Rod End Detail Hex Nut
Cam
Cotter Pin
; ; ;;
Cylinder Clevis Excluder Cap
Detail
Retainer Ring
Ball Bearing Glyd Ring (8) Cam
; ; ; ;;;;;; ; ; ; ;;;;;; ; ; ; ;;;;;; C ;;; ;;;;;; ;;;;;; ;;;;;;

Excluder Cap Gasket
Ball Bearing
C
Stationary Flange
Bull Gear Lip Seal
Figure 4-29. Replacing the 650-Ton rotating head glyd rings
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March 8, 2001
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.
4-74
Replacing the powered rotating head glyd rings

Refer to the assembly drawings when performing the following procedures.
Disassembly
1. Order eleven replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt, and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Remove the hydraulic motor assembly. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange.
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March 8, 2001
15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eleven new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the QD hydraulic fittings on the rotating block. 7. Reinstall the hydraulic motor assembly. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book.
4-76
Replacing the standard or extended reach link tilt air actuator

The link tilt mechanism has two air actuators. Use the following procedure to replace one air actuator (Figures 4-30 and 4-31). Parts required: One 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 nuts and washers holding the sealing plate to the air actuator and remove the plate. 8. Using a pry bar or screwdriver, pry the air actuator away from the screws, attach the actuator to the hanger plate and remove the screws using a hex wrench. 9. Remove and discard the air actuator. 10. Remove any burrs or gouges on sealing surfaces of the hanger and sealing plates.
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March 8, 2001
Lever Weldment Pivot Pin Sealing Plate (2)
Nuts, Lock Washers (18)
Air Actuator Base
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 4-30. Standard reach link tilt assembly/disassembly
4-78
Lever Weldment Pivot Pin Sealing Plate (2)
Nuts, Lock Washers (18) Hanger Plate Sealing Plate Bolt (4) Air Actuator (2)
Pressure Regulator
Base
Quick Exhaust Valve Lever Intermediate Stop (2)
Connecting Chain Stop Pivot Arm Elevator Link (Ref) Stop Release Loop
Figure 4-31. Extended reach link tilt assembly/disassembly
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March 8, 2001
Assembly
1. Place a new actuator on the hanger plate. 2. Attach the air actuator to the hanger plate with the 18 buttonhead cap screws. Coat the screw threads with locktite before installation.
The air actuator has aluminum neck bead rings on both sealing surfaces. These beads must be compressed equally to ensure a good air seal. This requires more than one tightening pass to accomplish. Over-torquing may cause hex sockets to strip. 4. Torque the cap screws to the hanger plate at 80 ft lb. 5. Insert the 18 bolts into the neck ring of the air actuator. 6. Reinstall the air actuator sealing plate, coat the bolt threads with locktite and fasten with the lockwashers and nuts provided. 7. Torque the nuts to the sealing plate at 80 ft lb. (See Caution above.) 8. Lift and rotate the link tilt lever or base to line up with the air actuator sealing plate. Attach with the four hex-head cap screws and torque to 250 ft lb. 9. Safety wire the four screws. 10. Reconnect the chain between the two sealing plates. 11. Reinstall and adjust the link tilt per the Installation and Commissioning book.
4-80
Removing the tong dies

Front jaw
1. Remove the cotter pin from the retaining bolts and slotted nut. 2. Remove the nuts securing the die retainer to the jaw. 3. Remove the die retainer from the jaw. 4. Remove the tong dies from the jaw.
Rear jaw
1. On the rear jaw, remove the cotter pins from the retaining bolts and slotted nuts. 2. Support the retaining bolt while removing the slotted nut. 3. Remove the retaining bolt from the piston jaw. 4. Support the remaining retaining bolt while removing the slotted nut and upper die retainer. 5. Remove the retaining bolt and lower die retainer. 6. Remove the tong dies from the jaw.
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March 8, 2001
Removing the jaws

Front jaw
1. Loosen the socket head cap screws securing the jaw assembly to the torque wrench body. 2. Support the jaw and remove the socket-head cap screws and washers from the jaw assembly and the torque wrench body. 3. Remove the front jaw assembly from the torque wrench body.
Rear jaw
1. Loosen the socket head cap screws securing the jaw assembly to the piston. 2. Support the jaw assembly and remove the socket-head cap screws and washers from the jaw assembly and piston. 3. Remove the rear jaw assembly from the piston.
Upper safety valve (IBOP)

Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures.
Lower safety valve (IBOP)

Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures.
4-82
Removing the motor assembly from the guide dolly

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 the TDS down horizontally on a good flat surface. 2. Make sure 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 the housing off of the motor toward the gearcase 14. Remove the blower and brake assemblies. 15. Reverse this procedure for reassembly.
March 8, 2001
Disassembly/assembly of the drilling motor and motor support bonnet

1. Remove the upper bearing cover and grease seal (Figure 4-32). 2. Pressurize the air brake to hold the drive mechanism in place. 3. Remove cotter pins, slotted nuts and the rotating head. 4. Remove the lower gearcase, carefully avoiding damage to the lower gearcase locator dowel pins. 5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear sleeves. Do not remove the gear from the shaft unless you are replacing it. 6. Remove the pinion seal and retaining ring. 7. Remove the main body. 8. On the opposite end of the motor, remove the magnetic pickup and brake cover. 9. Remove the brake for service.
4-84
Main Body Air Brake
Low Gear Assembly
DC Drilling Motor
Bull Gear
High Gear Assembly Pinion Gear Manual Shifter Input
Geneva Mechanism
Shaft
LO
HI
Oil Level Sight Glass
Motor Pinion Seal
Lower Gear Case Motor Alignment Cylinder Gear Selection Indicator
Figure 4-32. Drilling motor and motor support bonnet assembly/disassembly
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March 8, 2001
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 in. 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. 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.
4-86
Torque Chart Motor support/bonnet to main body Main body to motor support/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
Installing the TDS 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.
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March 8, 2001
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 0.0720.074 in. Then lock the screw in place with a locknut. 10. Remove the fixture from the pinion gear assembly.
Do not put the fixture in the oven. 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.
4-88
Local blower cooling system assembly/disassembly

Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-33): 1. Remove the electrical wires from the blower motor. 2. Remove the eight bolts on each side connecting the ducts to the blower housing ducts. 3. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. 4. Remove the four bolts connecting the blower mount to the brake cover. 5. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. 6. Remove the blower inlet ducts on both sides of the blower motor. 7. Remove the taper lock bushings from both blower impellers. 8. Remove both blower impellers. 9. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. 10. Remove the shaft seal assemblies from both sides. 11. Remove the blower housing and inner plate assemblies as units from both sides. Do not separate the blower housing assemblies from the inner plates. 12. Unbolt the four bolts connecting the blower motor feet to the blower mount. 13. Lift the motor out.
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March 8, 2001
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 Flex Duct Connection Point Mounting Plate
Blower Duct to AC Drilling Motor
Spark Arrestor
Figure 4-33. Typical local blower cooling system assembly/disassembly
4-90
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.
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March 8, 2001
Closed loop cooling system assembly/disassembly

Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-34): 1. Remove the electrical wires from the blower motor. 2. Remove the eight bolts on each side connecting the ducts to the blower housing ducts. 3. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. 4. Remove the four bolts connecting the blower mount to the brake cover. 5. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. 6. Remove the blower inlet ducts on both sides of the blower motor. 7. Remove the taper lock bushings from both blower impellers. 8. Remove both blower impellers. 9. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. 10. Remove the shaft seal assemblies from both sides. 11. Remove the blower housing and inner plate assemblies as units from both sides. Do not separate the blower housing assemblies from the inner plates. 12. Unbolt the four bolts connecting the blower motor feet to the blower mount. 13. Lift the motor out.
4-92
Dual Shaft 20 hp AC Blower Motor
Blower Mount/ Brake Cover Blower Housing (2)
Impeller (2)
8 in. Flex Connection (2)
Blower Inlet (2)
Water Connections
DC to Motor Exhaust Port on Upper Gear Case Inspection Cover
GE Drilling Motor Heat Exchanger (2)
Figure 4-34. Typical closed loop cooling system assembly/disassembly
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March 8, 2001
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.
4-94
Replacing the safety wiring

Use the following procedures to safety wire screws, nuts, bolts, or other fasteners where applicable.
Torque fasteners before safety wiring any screw, nut, plug, or other fastener. Never overtorque or loosen a torqued fastener to align safety wire holes. Use the size and type of safety wire required in the applicable specifications and drawings. Whenever possible, use double-twist safety wiring.
n n
Limit single-twist wiring to the following: small screws located in closely spaced, closed geometrical patterns (e.g., triangles, squares, rectangles, or circles), parts in electrical systems, or parts that are difficult to reach.
Do not reuse safety wire. To install safety wire: 1. Open the jaws of the safety twist pliers. 2. Squeeze the handles of the pliers together and unlock the round, perforated slider in the center of the pliers from the hook lock. 3. Grip both safety wires in the jaw. Squeeze the handles together with one hand and pull the slider toward the rear of the pliers with the other hand to lock the pliers. 4. Twist the safety wire by pulling the aluminum knob and twist the rod out from the pliers. Let the pliers spin free. 5. Return the knob and twist the rod by holding the pliers steady with one hand and pushing against the end of the knob the with other hand (step 4 in Figure 4-35). 6. Repeat the previous twisting cycle.
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March 8, 2001
7. After threading the safety wire through the hole in the fastener, pull the wire straight through without nicking the wire. Twist four to five complete revolutions per inch of wire. 8. Make a pigtail of approximately 1 in. (25 mm) length (four twists minimum) at the end of the wiring and bend back or under to prevent it from becoming a snag.
1 2
Figure 4-35. Safety wiring procedures
4-96
Safety wiring tips

Pull the safety wire firmly, but do not stretch it or let kinks develop. Make twists tight, even, and as taut as possible without weakening the wire by overtwisting (Figure 4-36).
Do not nick the wire with the edge of the hole in the fastener. Position the safety wire so the pull exerted by the wire tightens the nut. For best results, let the wire leave the fastener in a clockwise direction Twist the safety wire so the loop around the bolt or head has sufficient tension to keep it from slipping up and over the bolt head, with resulting slack in the safety wiring.
When securing castellated nuts with safety wire, tighten the nut to the low side of the selected torque range, unless otherwise specified. If necessary, continue tightening within specified torque limits until a slot aligns with the hole. The number of nuts, bolts or screws that can be safety-wired together depends on the application. As a guide, when safetywiring widely spaced bolts by the double-twist method, a group of three, or a 24 in. (610 mm) length of safety wire is usually the maximum.
Figure 4-36. Safety wiring examples

March 8, 2001
4-98
Troubleshooting the counterbalance

Symptom System does not hold pressure. Probable cause Needle valve is not closed. Cylinder rod seals leak. Fittings or hoses leak. Remedy See adjustment procedure and check needle valve. Replace seals. Tighten or replace as required.
Dirty or defective PRV valve. See adjustment procedure. Clean or replace. Dirty or stuck check valve. 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.
When activating or reactivating the counterbalance system, never start an empty system with the needle valve closed. Always start the Hydraulic Power Unit (HPU) first, run for 3-5 minutes, then slowly close needle valve with HPU running. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals.
March 8, 2001
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.
Check Troubleshooting the counterbalance section of this book.
Loss of nitrogen precharge in Recharge accumulators as per the procedure in the Troubleshooting the accumulators located in counterbalance 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. Saver sub on TDS does not align with drill pipe. Alignment cylinder pressure too high or too low. See the adjustment procedure. Replace seals. Tighten or replace as required. See the adjustment procedure.
Dirty or defective PRV valve. Clean or replace.
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. See the adjustment 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.
4-100
Troubleshooting the drilling motor and guide dolly

Troubleshooting the motor air brake
Symptom Brake does not hold. Probable cause Insufficient air supply. Solenoid valve not shifting. Remedy Check air supply pressure, 90 psi minimum required. Check electrical continuity. Check lubricator on air supply. Check mechanical operation of solenoid valve. Brake drum contaminated with grease or pads worn or burnt. Brake does not release. Solenoid valve sticking. Inspect and replace if necessary.
Lubricate, repair with repair kit or replace valve. Check air supply lubricator. Clean or replace.
Quick exhaust valve not functioning properly.
Troubleshooting the retract guide dolly

Symptom Guide dolly retracts too slow or too fast. Probable cause Flow control valves on the guide dolly are not properly set. Remedy Set the flow controls to attain desired retract speed.
4-101
March 8, 2001
Troubleshooting the transmission

Symptom Oil leaking from lower seal. Probable cause Lower gear case seals are dry or damaged. Remedy Apply grease to seal. Grease fitting daily. If problem persists replace gearcase seals and bearing. Oil leaking from shaft Oil level too high. housing breather. Incorrect lubricant used. Oil is foaming. Gearbox temperature is excessive. Adjust oil level per recommended specification. Check recommended lubricants chart and replace as needed. Replace oil.
Oil level too low or too high. Adjust oil level to recommended level in sight glass. Incorrect lubricant used. Clogged oil suction screen. Check recommended lubricants chart and replace as needed. Remove suction screen from oil pump. Check discharge or pressure hoses at outlets to confirm circulation.
Check heat exchangers for air flow Clogged or dirty heat exchangers on unit equipped or water flow to ensure adequate heat transfer and dissipation. with such.
4-102
Troubleshooting the oil pump

Symptom OIL PUMP LOSS alarm is on. Probable cause Motor is not running. Remedy Check electrical components to ensure power is available to motor. Repair or replace as needed. Verify proper rotation and correct if necessary. Remove and clean suction screen making sure to properly seal screen cover when installing. Check all connections and suction screen cover plate to ensure there are no air leaks on suction side of oil pump. Repair as needed. Check switch operation. Repair or replace as needed. Inspect, repair or replace as needed. Check relief valve on back of pump. Install test gauge in discharge line and adjust to 10 psi. If unable to make oil pump work after checking all of the above, repair or replace as needed. Incorrect lubricant used. Check recommended lubricants chart to make sure proper viscosity of oil is used. Replace as needed.
Incorrect motor rotation. Dirty or clogged oil pump suction screen. Oil pump cavitatingevidence of air bubbles in discharge lines. Defective or improperly adjusted pressure switch. Failure of oil pump drive coupling. Faulty or worn oil pump.
4-103
March 8, 2001
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).
4-104
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.
4-105
March 8, 2001
Troubleshooting the pipehandler

Troubleshooting the torque wrench
Symptom Tool does not cycle properly. Probable cause Valves in manifold out of adjustment. Supply and return hoses are crossed. Remedy Readjust. Reconnect hoses correctly.
Improperly connected Quick Check QDs to make sure they are Disconnects (QDs). properly plugged together and flowing in both directions. Needle valve in counterbalance manifold is open. Defective cartridge valve or PRV valve. Improper component or component installation. Close needle valve (always with HPU running). Inspect valves for damaged seals or stuck spools. Replace if necessary. Valve cartridge replaced with wrong type. When changing the Make/Break valve, make sure the valve is properly oriented when installed.
Die retainer and die retainer bolts damaged while breaking. Torque wrench does not lift.
Improper saver sub length or Saver sub length too long. Sub machining. should also have proper chamfer on both shoulders. Oil bypass in pipehandler hydraulic components. Listen for oil bypassing in pipehandler cylinders or manifold. Locate and repair bypass as necessary.
4-106
Troubleshooting the torque wrench (cont.)
Symptom
Probable cause
Remedy Remove air supply line to verify air supply when solenoid valve is activated.
Tool goes up, clamps, Air pilot valve on counterbalance manifold stuck or and cycles, but inoperative. remains clamped on pipe when switch is released. Pilot valve dirty.
If air supply is available remove end cap on pilot valve, clean and lubricate. If air pilot valve is operable, hook both pipehandler hoses together and verify flow in both directions by activating switch with hydraulics on. If there is flow in only one direction, check QDs. If QDs are properly connected, check hydraulic pilot valve for stuck spool.
Improperly connected quick disconnects.
Hydraulic valve not shifting. Repair or replace. Saver sub breaks out instead of tool joint. Saver sub not made up properly. Make up saver sub per procedure described in the IBOP Service Manual, increase previous torque makeup by 10% to maximum torque recommended in the IBOP Service Manual (for original Varco OEM subs). Readjust per procedure. Replace tong dies. If saver sub is made up to recommended torque and continues to break out instead of drill pipe connection, break out using rig tongs. If saver sub or drill pipe will not break out using pipehandler, remove pipehandler and break out with rig tongs at floor.
Tong dies break or score drill pipe.
Valves in manifold out of adjustment. Tong dies worn. Connection overtorqued.
4-107
March 8, 2001
Troubleshooting the safety valve actuator

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

Symptom Does not tilt. Probable cause Solenoid valve not shifting. Remedy Check electrical continuity. Check spool mechanical operation and lubricate as needed. Does not reach mousehole. Retracts slowly, does not make it back to well center. Improperly adjusted. Pressure setting on float valve too low. Passive stop not in right spot. Retracts past well center in float mode. Pressure setting on float valve too high. Passive stop not in right spot. Readjust drag link, shorten if necessary. Adjust pressure setting.
Adjust jam not on passive stop to position elevators over well center. Adjust pressure setting. Adjust jam not on passive stop to position elevators over well center.
4-108
Troubleshooting the pipehandler at the counterbalance manifold

Symptom Pipehandler goes up and clamps when the HPU is turned on without pressing switch. Probable cause Improperly connected QDs. Remedy Check all QDs to make sure that they are properly connected, also making sure that each half is intact and not coming apart and restricting fluid. Disconnect air line from solenoid to air pilot valve. If there is a constant air flow, the solenoid valve is stuck in the open position. Remove the solenoid and valve. Clean as needed. Repair or replace valve as needed. Check oil lubricator to make sure valves are being lubricated. Air pilot valve sticking. If there is no constant air flow from air line, remove end cover on air pilot valve and check spool to see if it is operating freely. Clean as needed and lubricate. Repair or replace valve as needed. Check electrical continuity to switches and solenoids. Check air supply. There must be 90 psi minimum pressure.
Solenoid valve stuck or inoperative.
Faulty or loose wiring. IBOP valve actuator remains either in closed or open position. No air supply or air supply incorrect.
Crank assembly, actuator Check crank assembly, actuator arms and cylinders. Repair as needed. arms or cylinders sticking. Solenoid valves stuck in the open position or in center position. IBOP valve does not fully Actuator cylinder out of open or close. adjustment. Cam follower rollers sticking. Crank assembly retainer bolts loose. Check solenoid valves to see if they are not stuck in the open position or in center position. Repair or replace valve as needed. Check actuator cylinder adjustment and adjust as needed. Check cam follower rollers on crank assembly and arms. Check crank assembly retainer bolts to assure tightness. Crank assembly retainer bolts should be checked weekly to make sure they remain tight.
4-109
March 8, 2001
Troubleshooting the crown height indicator

Symptom Green power indicator does not illuminate. Probable cause Remedy No AC power being applied. Check Expo purge system and input AC power. Internal AC breaker tripped. Check internal circuit breaker on control electronic module for tripped condition. Failure of DC power supply. Check AC power LED on control electronic module. Replace electronic control module necessary. Replace electronic control module. Depressing the PUSH TO Malfunction of control electronics. TEST indicator does not cause position indicators to flash or illuminate. Misadjusted lower sensor Check proximity switch alignment. Yellow indicator is proximity switch. constantly illuminated while traveling assembly is below ten feet. Defective lower sensor Check mechanical operation of sensor bracket assembly. bracket assembly. Perform cable continuity tests. Defective sensor cable between sensor junction box and control electronics. Defective proximity switch. Replace proximity switch. Malfunction of electronics control module. Misadjusted lower sensor proximity switch. Replace electronic control module. Check proximity switch alignment.
Yellow and red indicator constantly flash while traveling assembly is below ten feet.
Defective sensor cable between the sensor junction box and control electronics. Defective upper sensor bracket assemblies. Defective upper proximity switches.
Perform cable continuity tests.
Malfunction of electronics control module.
Check the mechanical operation of the upper sensor bracket assembly. Check voltages from upper proximity switch by measuring voltage between TB3 and TB2 for upper sensor at the sensor junction box. A measurement of less than 2.0 VDC indicates a working sensor when metal is detected. Replace proximity switches as required. Replace electronic control module.
4-110
Six-gang air valve assembly illustration

Air Elevator Torque Wrench Brake IBOP Open Link Tilt IBOP Close
4-111
March 8, 2001
4-112
Control System
SM00620-5
March 8, 2001
5-2
TDS-4S Control System
Contents
General description .......................................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................................................ 5-7
5-3
March 8, 2001
5-4
General description
The Top Drive Drilling System (TDS) typically operates from the same SCR as the rotary table. A panel, located in a Central Electronics Enclosure (CEE), switches power from one to the other. The CEE typically contains the following components: DC contactors A programmable logic controller (PLC) Auxiliary AC components Rig instrumentation interfaces for recording TDS torque and speed
5-5
March 8, 2001
In dedicated top drive SCR configurations, the SCR runs the top drive only. The panel can feature a purge control system so it can be located in hazardous areas. If the panel is located in the SCR room, a purge system is not required. The panel is designed to be compatible with all presently installed SCR systems and is configured at installation for the specific SCR used on a rig. Logic and alarm functions are connected to the TDS via PLC programming so the TDS can operate existing rig systems. Also, TDS interlocks and limits, such as spin-up and makeup speeds, are programmed into the PLC and are the same for all installations.
5-6
Maintenance and troubleshooting/ checkout procedures

The Varco Top Drive Drilling Control System (TDCS) is straightforward in its operation and relatively easy to service. Refer to the following documentation for maintenance, troubleshooting and checkout information: Periodic control system maintenance schedule (See Table 1 below.) Rig checklist PLC manual Card rack terminal specifications Table 1. Periodic control system maintenance schedule Location Indicator lamps Heater High voltage connections Procedure Test using the lamp test switch on the drillers console. Check operation with an Ohm meter. Check for discolored or brittle insulation. Check retaining bolt torque (needs to be 25 ft lb). Component mounting Blower mounting current Check fastener tightness, especially in vibration-prone areas. Check and record current. (A drop in the current may indicate restriction or blockage of the air intake.) Verify and record. Check for integrity. Apply a light film of silicone lubricant to the transfer panel door. Frequency Each time the TDS is assigned. Monthly Monthly Monthly Monthly Monthly
Drilling motor field current Seals and gaskets
Weekly Monthly Every 3 months
5-7
March 8, 2001
5-8
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WASHPIPE ASSEMBLY
Service Manual
SM01053 Revision A
Copyright 2004 Varco LP. All rights reserved. Varco is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This publication is the property of, and contains information proprietary to, Varco International, Inc. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Varco International, Inc. All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. Information in this manual is subject to change without notice.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intended Audience and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Washpipe Assembly Pressure Ratings . . . . . . . . . . . . . . . . . . . . . 10 General Maintenance Practices . . . . . . . . . . . . . . . . . . . . 11 Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Standard Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . 12 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hammerless Washpipe Assembly . . . . . . . . . . . . . . . . . . 36 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removing the Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Washpipe
Varco
General Information
Intended Audience and Use
This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Varco International, Inc., will not be held liable for errors in this material, or for consequences arising from misuse of this material. This manual is intended as a supplement to the service manuals supplied with the Varco Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note:
i
The note symbol indicates that additional information is provided about the current topics.
Caution:
!
The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.
Warning:
The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.
Illustrations
Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see the technical drawings included with your Varco documentation.
Washpipe
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by Varco manuals are the recommended methods of performing those operations.
!
To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.
!
During installation, maintenance, or repair of equipment, personnel should wear protective gear. Protective gear must be worn during certain operation. Contact the Varco training department for more information about equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose being described. Varco recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when using service procedures or tools not specifically recommended by Varco.
Varco
Safety Requirements
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water.
!
Before installing or performing maintenance or repairs on equipment, read the following instructions to avoid endangering exposed persons or damaging equipment. Isolate all energy sources before beginning work. Avoid performing maintenance or repairs while the equipment is in operation. Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
Verify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment to ensure correct installment. Replace failed or damaged components with Varco certified parts. Failure to do so could result in equipment damage, or personal injury.
Routine Maintenance
Equipment must be maintained on a regular and routine basis. See the service manual for maintenance recommendations.
!
Failure to conduct routine maintenance could result in equipment damage or injury to personnel.
Proper Use of Equipment

Varco equipment is designed for specific functions and applications, and should be used only for their intended purpose.
Washpipe
General Description
Washpipe Assembly
The washpipe assembly is located between the main shaft and the gooseneck (S-pipe) on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard and hammerless.
Varco
General Description
Special Tools
The standard washpipe assembly has hammer nuts on its washpipe nut and packing box. The hammer nuts are provided so that a special wrench and a hammer can be used to tighten to washpipe nut and packing box during installation. The hammerless washpipe assembly uses gear nuts which are tightened more precisely without a hammer but with a special torque wrench kit. This feature makes the unit easier to install by allowing the unit to swing in and out of its support bonnet before being torqued and does not require the use of a hammer.
Standard Washpipe
Standard Washpipe Wrench
Strike here
Hammerless Washpipe Torque Wrench 30-250 ft lb Hammerless Washpipe Torque Multiplier 3200 ft lb Removable extension not shown
Socket Adapter
Washpipe
Specifications
Washpipe Assembly Pressure Ratings
i
Assembly descriptions are repeated for similar units. Use the assembly part number when referencing pressure ratings.
Standard Washpipe Assembly

Description Part No. Pressure Rating (psi)
7,500 7,500 7,500
Small Bore (3-inch) Large Bore (4-inch) Large-to-Small Bore
30123290 30123440 30153491-50
Hammerless Washpipe Assembly

Description Part No. Pressure Rating (psi)
7,500 7,500
Large Bore (4-inch) Large-to-Small Bore
30156883 30173058-50
10
Varco
General Maintenance Practices

Equipment Maintenance Records
Keep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.
i
Procedures in this chapter relate to Varco only components. See the vendor manuals for maintenance procedures and schedules for the vendor equipment.
Maintenance Schedules
Maintenance schedules list preventive maintenance tasks. Inspection schedules assume normal operating conditions. Some conditions (excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent inspection intervals. Perform the procedures indicated, as warranted by the inspection.
Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual. To avoid serious injury or death, read and understand the following Warnings before performing maintenance or troubleshooting procedures:
Unless instructed otherwise, properly lock out the main power source before performing any maintenance procedure. Wear protective glasses to prevent eye injuries. Do not attempt any adjustments while the machine is moving. Read and understand all safety precautions and warnings before performing maintenance procedures.
Washpipe
11

Initial Installation
Procedure
1. Install the washpipe assembly on the TDS/IDS and hand-tighten the washpipe nut and packing box, then back off the packing box and washpipe nut by 1/4 turn.
the packing box.
securely tighten.)
Nut
12
Varco

Washpipe
13

Procedure
11. Check washpipe alignment. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 12. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.
Washpipe
Dial Indicator Packing Box
14
Varco

Inspection Schedule
Item
Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck
Inspect for
Interval
When washpipe assembly is to be removed from TDS/ IDS Once every six months and immediately after jarring
Surface should be
smooth and free of flaws or burrs ID of stem liners Endplay is within specification (refer to TDS/IDS Service Manual) Proper operation
TDS/IDS main shaft bearing endplay
Washpipe Assembly grease fitting
Replace every six months After TDS/IDS main shaft bearing endplay has been checked and is within specification Upon disassembly of washpipe assembly
Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft
Proper alignment between pilots
All parts
Refer to Disassembly Procedure
Cleaning Schedule
Item
TDS/IDS bonnet (inside)
Procedure
Remove residual mud
Interval
Weekly
Lubrication Schedule
Item
Procedure
Apply 3 to 4 pumps of grease (refer to Lubrication Procedure)
Interval
Twice daily or every 10 rotating hours
Washpipe
15

Inspection Procedures
When Washpipe is to be Removed from TDS/IDS
Service Limit (inches) 3.090 3.840 3.120
16
Varco

Every Six Months
Procedure
1. Remove the washpipe assembly and replace the grease fitting. 2. Check the main shaft axial movement by applying an upward force to the main shaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).
Washpipe Grease Fitting Replace
Dial Indicator
Washpipe
17

Every Six Months
Gooseneck Pilot
Dial Indicator
0.002 TIR between these two surfaces
Bonnet removed for clarity.
Main Shaft Pilot
18
Varco

Lubrication Procedures
Daily Lubrication
Description Cyprina 2. grease fitting.
Washpipe
19

Troubleshooting
i
The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.
Symptom
Leakage at threads between packing box and TDS/IDS main shaft
Probable cause
Poly Pak seal failure in main shaft stem liner
Remedy
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner. 1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS. Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS. Follow inspection procedures as outlined in step 8 of the Disassembly Procedure. Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner. 1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.
Lower O-ring failure
Stem liner not smooth and does not allow O-ring to seal properly Stem liner not flat and does not allow O-ring to seal properly Spacers not flat and prevents packing seals from sealing between spacers proper Leakage at grease fitting access hole Poly Pak seal failure in main shaft stem liner
20
Varco

Troubleshooting
Symptom
Leakage through grease fitting access hole (cont) Leakage at grease fitting Leakage between the washpipe and the packing box Leakage between the washpipe and the washpipe nut
Probable cause
Spacers not flat and prevents packing seals from sealing between spacers proper Grease fitting failure Packing failure
Remedy
Follow inspection procedures as outlined the Inspection Procedure. Follow inspection procedures as outlined in step 12 of the Disassembly Procedure. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.
Packing failure or packing is improperly seated Upper O-ring failure
Upper O-ring failure Leakage at threads between washpipe nut and gooseneck
Packing failure or packing is improperly seated Premature failure after greasing Improper greasing procedure
Washpipe
21

Troubleshooting
Symptom
Premature failure accompanied by occasional spurts of mud from packing box
Probable cause
Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay
Remedy
If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment. Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure. The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure). Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure. Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation. During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).
Misalignment of gooseneckto-washpipe pilot
Installation problems
Premature failure due to flanged packing
Nut not torqued
Too mush grease during assembly of the unit
22
Varco

Troubleshooting
Washpipe
Washpipe
23

Troubleshooting
Symptom
Packing is worn out
Probable cause
Poor greasing schedule or improper grease. RPM, pressure and mud temperature too high
Remedy
Follow proper lubrication procedures. Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe. If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures. Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure. Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue. 1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.
Packing extruding between spacers
Spacers too flat
Nut not torqued
Blue spacers
Improper torque or grease on the OD of the spacers
Unable to maintain torque on packing box
Improper assembly or installation
24
Varco

Troubleshooting
Symptom
Unable to maintain torque on packing box (cont)
Probable cause
Remedy
4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.
Washpipe
25

Disassembly
Procedure
1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced. Snap Ring
Holding Ring
Washpipe Nut
O-Ring
Packing Box
i
Washpipe Discard and replace these non-serviceable parts from the washpipe assembly. Upper Spacer
Grease Fitting
Socket Head Dog Nose Screw
Packing Set (5 per Set)
Middle Spacer
Middle Spacer
O-Ring
26
Varco

Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat
ID This surface to be smooth and flat
This edge to be sharp
Washpipe Assembly Small Bore
Spacer Upper Middle Lower Upper Middle Lower Upper Middle Lower
Varco Part No. 123585 30123286 123287 30123434 30123435 30123436 123585 30123286 123287
Proper ID (inches) 3.635 to 3.640 3.635 to 3.640 3.635 to 3.640 4.895 to 4.900 4.895 to 4.900 4.895 to 4.900 3.635 to 3.640 3.635 to 3.640 3.635 to 3.640
Service Limit ID (inches) 3.645 3.645 3.645 4.905 4.905 4.905 3.645 3.645 3.645 Upper Spacer
Large Bore
Middle Spacer
Large to Small Bore
Middle Spacer
Washpipe
27

Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through.
Washpipe Nut
ID Packing Box
Washpipe Assembly Small Bore Large Bore Large to Small Bore Washpipe Assembly Small Bore Large Bore Large to Small Bore
Washpipe Nut Part No. 123284 30123431 30153493
Proper ID (inches) 3.655 to 3.660 4.905 to 4.910 3.655 to 3.660
Service Limit ID (inches) 3.665 4.915 3.665
Packing Box Part No. 30123563 30123626 30153494
Proper ID (inches) 3.637 to 3.644 4.900 to 4.905 3.637 to 3.644
Service Limit ID (inches)
28
Varco

Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.
Holding Ring
This surface to be smooth and flat Undercut rease i
This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.
Washpipe
29

Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer
2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer
Sharp edge of spacer Sharp edge of spacer Sharp edge of spacer
Wipe grease from area shown, all the way around on each spacer.
Middle Spacer
Middle Spacer
30
Varco

Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Grease Fitting Dowel Pin
Socket Head Dog Nose Screw Packing Box
Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min
i
In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.
Washpipe
31

Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe.
Washpipe Nut
Washpipe
Packing Box
32
Varco

Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.
Holding Ring Wipe grease from area shown, all the way around the holding ring. Fill with grease to level shown. 10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings. Snap Ring O-ring
Packing Seal Holding Ring
Packing Seal
13. approximately the length of the washpip pe. 14. Initial Installation Procedure.
Washpipe
33

Illustrated Parts List
O-Ring Snap Ring
Holding Ring Upper Spacer Packing Set 5 per set
Washpipe Nut Middle Spacer
Middle Spacer Washpipe
Lower Spacer
Packing Box O-Ring
Grease Fitting Socket Head Dog Nose Screw
Long-Arm Allen Wrench
34
Varco

Description Small Bore (3-inch)
30123290
Large Bore (4-inch)

30123440
Large-to-Small Bore
30153491
Washpipe Assembly
O-Ring Snap Ring Holding Ring Washpipe Nut Washpipe
51300-348-F 30123562 30123288 123284 30123289 (7,500 psi) 30123563 53219-1 30123564 123585 30123286 123287
51300-359-F 123634 30123437 30123431 30123438 (7,500 psi) 30123626 53219-1 30123564 30123434 30123435 30123436
51300-348-F 30123562 30123288 30153493 30123289 (7,500 psi) 30153494 53219-1 30123564 123585 30123286 123287
Packing Box Grease Fitting Socket Head Screw Upper Spacer Middle Spacer Lower Spacer
Pressure Seal Kit (Packing Set) Stem Liners Poly Pak Seal
30123290-PK
30123440-PK
30123290-PK
98290 98291
112871 112895
30153492 112895
Grease
56005-1
56005-1
56005-1
Washpipe
35

Procedure
i
During installation the washpipe assembly is brought into place as one unit and handled by a tugger line. Ensure that the washpipe assembly is strapped together securely before lifting.
1. Unlock the TDS/IDS handling yoke from its stored position and swing it out to accept the washpipe assembly.
Makes the washpipe assembly easier to install by allowing it to swing in and out of the motorsupport bonnet.
Nut 2 places
Yoke
36
Varco

Procedure
the TDS/IDS main shaft. 4. it until it makes contact with the top of the main shaft. 5. packing box and the washpipe nuts. 6. Apply pipe dope to the threads and hand-tighten the washpipe nut and packing box. 7. align the pipe in the packing box. 8. Set the TDS/IDS brake.
Torque Multiplier Ratio 18.5 to 1 Removable extension
Torque Wrench
9. Loosen the thumb screw on the pinion gear and raise the pinion gear from its stored position and lock the thumb screw in place when it aligns with the gear on the packing box. It may be necessary to rotate the square drive shaft to engage the gears. 10. Install the torque kit assembly over the square shaft. Set the torque wrench to 100 ft-lb and begin applying torque to the packing box gradually until the torque wrench clicks. Torque Wrench Setting-ft.-lbf. 75 100 125 150 Applied Torque to Nut-ft.-lbf. 4,500 6,000 7,500 9,000
11. Disengage the pinion gear from the packing box gear and engage it with the washpipe nut gear and secure it in place. Similarly, apply torque to the washpipe nut, completing the installation of the washpipe assembly. 12. Apply 6 to 8 pumps of grease to the grease fittings. 13. Return the pinion gear to its stored position and secure it with the thumb screw. Secure the handling yoke to its stored position by pinning it with the two pins. 14. Release the TDS/IDS brake and rotate the TDS/IDS at approximately 50 rpm for one minute.
Washpipe
37

Inspection Schedule
Item
Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck
Inspect for
Interval
When washpipe assembly is to be removed from TDS/ IDS Once every six months and immediately after jarring
Surface should be
smooth and free of flaws or burrs ID of stem liners Endplay is within specification (refer to TDS/IDS Service Manual) Proper operation
TDS/IDS main shaft bearing endplay
Replace every six months After TDS/IDS main shaft bearing endplay has been checked and is within specification Upon disassembly of washpipe assembly
Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft
Proper alignment between pilots
All parts
Refer to Disassembly Procedure
Cleaning Schedule
Item
TDS bonnet (inside)
Procedure
Remove residual mud
Interval
Weekly
Lubrication Schedule
Item
Procedure
Apply 3 to 4 pumps of grease
Interval
Twice daily or every 10 rotating hours
!
To prevent rust from damaging parts, properly clean and grease the following parts before storage: 1. Jacking nut and shaft threads 2. Square shaft from top to bottom 3. Gear teeth on all three gears
38
Varco

Every Six Months
Washpipe Assembly Alignment Satisfactory packing life depends on good washpipe alignment. Use the following procedure to check sleeve-to-gooseneck support alignment: 1. Attach an indicator base to the gooseneck support and place the indicator at the top of the sleeve. 2. Raise and lower the sleeve and record the total indicator reading. 3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or packing box. 4. Rotate the sleeve 360 and record the TIR. Washpipe Assembly Tolerances Use the following procedure to check washpipe assembly tolerances: 1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to 0.003 inch. 2. Check the clearance by raising and lowering the sleeve. The maximum allowable misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum allowable misalignment after complete assembly of the washpipe assembly is 0.010 inch TIR.
i
Inspection may indicate misalignment exceeding recommended limits. The packing box assemblies are designed to accommodate misalignment of the sleeve to the gooseneck and can operate with some excessive misalignment. However, to achieve maximum packing life, maintain the misalignment at the washpipe within the recommended limits.
Washpipe
39

Every Six Months
Procedure
1. Remove the washpipe assembly and replace the grease fitting. 2. Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).
Washpipe Grease Fitting Replace
Dial Indicator
40
Varco

Every Six Months
Gooseneck Pilot
Dial Indicator
0.002 TIR between these two surfaces
Bonnet removed for clarity.
Main Shaft Pilot
Washpipe
41

Lubrication Procedures
Daily Lubrication
Recommended Grease
Manufacturer Shell Description Cyprina
Procedure
1. Twice daily or once every 10 hours of rotation, apply 3 to 4 pumps of grease to the washpipe grease fitting. 2. Rotate the TDS/IDS at 50 rpm for one minute with 0 psi standpipe pressure. 3. Turn on the mud pumps and check for leaks.
42
Varco

Troubleshooting
i
The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.
Symptom
Leakage at threads between packing box and TDS/IDS main shaft
Probable cause
Poly Pak seal failure in main shaft stem liner
Remedy
Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner. 1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS. Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS. Follow inspection procedures as outlined in step 8 of the Disassembly Procedure. Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner. 1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.
Stem liner not smooth and does not allow O-ring to seal properly Stem liner not flat and does not allow O-ring to seal properly Spacers not flat and prevents packing seals from sealing between spacers proper Leakage at grease fitting access hole Poly Pak seal failure in main shaft stem liner
Washpipe
43

Troubleshooting
Symptom
Leakage through grease fitting access hole (cont) Leakage at grease fitting Leakage between the washpipe and the packing box Leakage between the washpipe and the washpipe nut
Probable cause
Spacers not flat and prevents packing seals from sealing between spacers proper Grease fitting failure Packing failure
Remedy
Follow inspection procedures as outlined the Inspection Procedure. Follow inspection procedures as outlined in step 12 of the Disassembly Procedure. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. 1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly. Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe. Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.
Packing failure or packing is improperly seated Upper O-ring failure
Upper O-ring failure Leakage at threads between washpipe nut and gooseneck
Packing failure or packing is improperly seated Premature failure after greasing Improper greasing procedure
44
Varco

Troubleshooting
Symptom
Probable cause
Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay
Remedy
If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment. Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure. The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure). Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure. Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation. During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).
Misalignment of gooseneckto-washpipe pilot
Installation problems
Premature failure due to flanged packing
Nut not torqued
Too mush grease during assembly of the unit
Washpipe
45

Troubleshooting
Washpipe
46
Varco

Troubleshooting
Symptom
Packing is worn out
Probable cause
Poor greasing schedule or improper grease. RPM, pressure and mud temperature too high
Remedy
Follow proper lubrication procedures. Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe. If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures. Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure. Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue. 1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.
Packing extruding between spacers
Spacers too flat
Nut not torqued
Blue spacers
Improper torque or grease on the OD of the spacers
Unable to maintain torque on packing box
Improper assembly or installation
Washpipe
47

Troubleshooting
Symptom
Unable to maintain torque on packing box (cont)
Probable cause
Remedy
4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.
48
Varco

Removing the Washpipe Assembly
Remove the washpipe assembly by reversing the Installation Procedure.
!
Once the packing box and washpipe nuts are unscrewed, the assembly must be strapped together as one unit before it is picked up by the handling yoke.
i
The hammerless washpipe assembly must always be handled as one unit. Avoid disassembly unless you suspect faulty parts (refer to Troubleshooting).
Washpipe
49

Disassembly
Procedure
1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced. Snap Ring
Holding Ring
Washpipe Nut
O-Ring
Packing Box
i
Washpipe Discard and replace these non-serviceable parts from the washpipe assembly. Grease Fitting Socket Head Dog Nose Screw Upper Spacer
Packing Set (5 per Set)
Middle Spacer
Middle Spacer
O-Ring
50
Varco

Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat
ID This surface to be smooth and flat
This edge to be sharp
Washpipe Assembly Large Bore
Spacer Upper Middle Lower Upper Middle Lower
Varco Part No. 30123434 30123435 30123436 123585 30123286 123287
Proper ID (inches) 4.895 to 4.900 4.895 to 4.900 4.895 to 4.900 3.635 to 3.640 3.635 to 3.640 3.635 to 3.640
Service Limit ID (inches) 4.905 4.905 4.905 3.645 3.645 3.645
Upper Spacer
Large to Small Bore
Middle Spacer
Washpipe
51

Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through. hpipe ut
ID Packing Box
Washpipe Assembly Large Bore Large to Small Bore Washpipe Assembly Large Bore Large to Small Bore
Washpipe Nut Part No. 30123431 30153493
Proper ID (inches) 4.905 to 4.910 3.655 to 3.660
Service Limit ID (inches) 4.915 3.665
Packing Box Part No. 30123626 30153494
Proper ID (inches) 4.900 to 4.905 3.637 to 3.644
Service Limit ID (inches)
3 650
52
Varco

Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring. Holding Ring
This surface to be smooth and flat Undercut Grea Fitti
This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.
Washpipe
53

Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer
2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer
Sharp edge of spacer Sharp edge of spacer Sharp edge of spacer
Wipe grease from area shown, all the way around on each spacer.
Middle Spacer
54
Varco

Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Grease Fitting Dowel Pin
Socket Head Dog Nose Screw
Packing Box
Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min
i
In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.
Washpipe
55

Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe. Washpipe Nut
Washpipe
Packing Box
56
Varco

Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.
Holding Ring Wipe grease from area shown, all the way around the holding ring. Fill with grease to level shown. 10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings. Snap Ring O-ring
Packing Seal Holding Ring
Packing Seal
13. approximately the length of the washpip pe. 14. Initial Installation Procedure.
Washpipe
57

O-Ring Snap Ring
Holding Ring Upper Spacer Packing Set 5 per set
Washpipe Nut Middle Spacer
Middle Spacer
Washpipe
Lower Spacer
Packing Box O-Ring
Grease Fitting
Socket Head Dog Nose Screw Long-Arm Allen Wrench
58
Varco

Description Large Bore (4-inch)
30156883 & 30156883-750
Large-to-Small Bore
Washpipe Assembly
30173058-50 & 30173058-100
O-Ring Snap Ring Holding Ring Washpipe Nut Washpipe - Low Pressure Washpipe - High Pressure Packing Box Grease Fitting Socket Head Screw Upper Spacer Middle Spacer Lower Spacer
51300-359-F 123634 30123437 30152547 30123438 (7,500 psi) 30123438-TC (7,500 psi) 30156884 53219-1 30123564 30123434 30123435 30123436
51300-348-F 30123562 30123288 30173057 30123289 (7,500 psi) 30123289-TC (10,000 psi) 30173056 53219-1 30123564 123585 30123286 30123287
Pressure Seal Kit (Packing Set) Stem Liner Poly Pak Seal
30123584-2 (7,500 psi)
123292-2 (7,500 psi)
112871 112895
30153492 112895
Grease
56005-1
56005-1
Washpipe
59
Glossary
ID - Inner Diameter IDS - Integrated Drilling System OD - Outer Diamaeter TDS - Top Drive System TIR - Total Indicator Reading
60
Varco
Technical Drawing Package

TDS-4S Petrobras P14
RIG/PLANT REFERENCE ADDITIONAL CODE REMARKS MAIN TAG NUMBER CLIENT PO NUMBER CLIENT DOCUMENT NUMBER DISCIPLINE SDRL CODE TOTAL PGS REFERENCE DESCRIPTION
M614000012-GEN-001
Customer Configuration
This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. National Oilwell Varco DOCUMENT NUMBER
National Oilwell Varco RIG SOLUTIONS 12950 West Little York Houston, TX 77041
Client Document Number
REV
D811000252-DOS-001
01
www.nov.com
D811000461-GEN-001/01
Document number Revision Page REVISION HISTORY
D811000252-DOS-001 01 2
01
Rev
17.04.2008
Date (dd.mm.yyyy)
First Issue
Reason for issue
J. Kellstrom
Prepared
K. Schmidt
Checked
R. Shumski
Approved
CHANGE DESCRIPTION
Revision
01
Change Description
New Release
www.nov.com
D811000461-GEN-001/01
Document number Revision Page
D811000252-DOS-001 01 3
TECHNICAL DRAWING PACKAGE

This document provides a list of drawings for the TDS-4S. The actual drawings are arranged in the binder in numerical order.
Drawings by Assembly
General Customer Configuration................................................................... M614000012-GEN-001 General Arrangement, Overall.. .D721000114-GAD-001 General Arrangement .......................................................................D721000256-GAD-001 Hydraulic Schematic.. ..D614000084-SCH-001 Single Line Diagram... 30184728 Interconnect Diagram .. .................................................... 30184729 Cable Schedule ............................... 30184730 Network Diagram. 30184731 I/O Map ............................................ 30184732 Hazardous Equipment Index 30184733 Hose Kit, CRT to PH-85. ........................................ M614000509-ASM-001 Top Drive Assembly Motor Housing Assembly.. ........................................ .121344-SE-088-10-50SB Drilling Motor Assembly............................................................... 88585-SH-Q Rotating Head Assembly ........................................ 116417-500 Hydraulic Motor Assembly .........116418 Washpipe Assembly .. ........................................ 30123290 Compound Gear Assembly (Helical). ............................ 116804-500/-501 Guide Dolly Assembly......................................... ................................................. 30184932 Cylinder Assembly. ............................................................... 30151882 Alignment Cylinder Assembly ...................................................... 30172237 Motor Electrical Installation Kit ..............................M614000217-SE-U24 Motor Power J-Box Assembly....................................... 79073-3 Valve Manifold Assembly............................................116021-C16 J-Box Assembly I.S... .............................................. 108616-6 Kit, Weather Seal, Electrical Gland. .......................... 30156499-500 Motor Cooling System.......................................................109412-1A1 Oil Circulating Kit.. ............................................................... 30181397 Oil Circulating Assembly .............................. 30181991 Pump/Motor Assembly. .................................................... 30182305
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D811000461-GEN-001/01
D811000252-DOS-001 01 4
S Pipe Installation Kit........................................................... 94075-1 S-Pipe Assembly. .................................................................... 91677-502 Retrofit Kit, Rotating Head Motor Assembly.. M614000418-500 Gearbox Lubrication Kit.................................................................. 92643-1 Counterbalance Kit................................. 95031-1 Dolly Assembly, Block...........................................................................................30184930 Dolly Assembly, Auxiliary. . 30184928
Pipe Handler and Adapter Kits Pipe Handler Installation Kit, PH-85. ....................................................... 30179600-J35A Torque Wrench Assembly...95461-AJBX Cylinder, Clevis Assembly..91265 Lift Cylinder Assembly. .........90864 Stabbing Guide Assembly...30115170 Manifold Assembly, Elevator Rotate.....116023 Manifold Assembly, Rectifier. ....... 30171689-501 Torque Arrestor Assembly ....................................................................... .90471-1, -2 Stabbing Guide Assembly...108362 Jaw Assembly, PH-85.90851 Hydraulic Link Tilt Assembly........128996 Crank Assembly. ................................................................................. 30173893 Upper IBOP.30173885-500 Lower IBOP90811-500 PH-85 Adapter Kit.....109961-2 Stabbing Guide Assembly, NC50..99302 Actuator Shell/Crank Assembly...141324-1 Kit, Link Tilt Clamp....M614000290-50
Control System Control Panel.. ......................................................................... 30184445
Service Loops, Derrick Terminations, and Miscellaneous Kits Service Loop Kit, Electrical. ........................................................................ 117933-86-10 Service Loop, Fluids....................................................................109179-86-19-10 Derrick Termination Kit. ..................................................................................123371
www.nov.com
D811000461-GEN-001/01
D811000252-DOS-001 01 5
Drillers Recorder Transducer Kit.80149
www.nov.com
D811000252-DOS-001 01 6
Drawings In Numerical Order

Motor Power J-Box Assembly................................................. 79073-3 Drillers Recorder Transducer Kit.80149 Drilling Motor Assembly.. ....................................................................... 88585-SH-Q Torque Arrestor Assembly................................................................................. .90471-1, -2 Lower IBOP..90811-500 Jaw Assembly, PH-8590851 Lift Cylinder Assembly..............90864 Cylinder, Clevis Assembly....91265 S-Pipe Assembly. .............................................................................. 91677-502 Gearbox Lubrication Kit.................................................................. 92643-1 S Pipe Installation Kit........................................................... 94075-1 Counterbalance Kit................................. 95031-1 Torque Wrench Assembly.....95461-AJBX Stabbing Guide Assembly, NC50 ........ ..99302 Stabbing Guide Assembly..108362 J-Box Assembly I.S... ........................................................ 108616-6 Service Loop, Fluids....................................................................109179-86-19-10 Motor Cooling System.......................................................109412-1A1 PH-85 Adapter Kit.....109961-2 Valve Manifold Assembly.. ...................................................116021-C16 Manifold Assembly, Elevator Rotate.......... ..116023 Rotating Head Assembly .................................................. 116417-500 Hydraulic Motor Assembly ...........................116418 Compound Gear Assembly (Helical). ...................................... 116804-500/-501 Service Loop Kit, Electrical. ........................................................................ 117933-86-10 Motor Housing Assembly.. ........................................ .121344-SE-088-10-50SB Derrick Termination Kit. ..................................................................................123371 Hydraulic Link Tilt Assembly..128996 Actuator Shell/Crank Assembly...141324-1 Stabbing Guide Assembly......30115170 Washpipe Assembly .. .................................................. 30123290 Cylinder Assembly. ......................................................................... 30151882 Kit, Weather Seal, Electrical Gland. .......................... 30156499-500 Manifold Assembly, Rectifier ........ 30171689-501
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D811000461-GEN-001/01
D811000252-DOS-001 01 7
Alignment Cylinder Assembly ................................................................ 30172237 Upper IBOP...30173885-500 Crank Assembly. ........................................................................................... 30173893 Pipe Handler Installation Kit, PH-85. ....................................................... 30179600-J35A Oil Circulating Kit.. ............................................................... 30181397 Oil Circulating Assembly ....................................... 30181991 Pump/Motor Assembly. ...................................................................... 30182305 Control Panel.. ......................................................................... 30184445 Single Line Diagram... 30184728 Interconnect Diagram .. .................................................... 30184729 Cable Schedule ............................... 30184730 Network Diagram. 30184731 I/O Map ............................................ 30184732 Hazardous Equipment Index 30184733 Dolly Assembly, Auxiliary. . 30184928 Dolly Assembly, Block...........................................................................................30184930 Guide Dolly Assembly......................................... ................................................. 30184932 Hydraulic Schematic.. ..D614000084-SCH-001 General Arrangement, Overall.. .D721000114-GAD-001 General Arrangement .......................................................................D721000256-GAD-001 Customer Configuration................................................................... M614000012-GEN-001 Motor Electrical Installation Kit ..............................M614000217-SE-U24 Kit, Link Tilt Clamp....M614000290-50 Retrofit Kit, Rotating Head Motor Assembly.. M614000418-500 Hose Kit, CRT to PH-85. ........................................ M614000509-ASM-001
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MECHANICAL SPARES KIT PETROBRAS P14 TDS-4S
NOTES: 1. 2. 3. 4.
30184939-1 Recommended Commissioning Spares 30184939-2 Recommended Operational Spares 30184939-3 Recommended Insurance Spares See Customer Configuration M614000012-GEN-001.
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT
DRAWN CHECKED APPD DATE
INITIAL R SHUMSKI D. STEPHENS R SHUMSKI 7 JUL 08

SIZE DWG NO
MECHANICAL SPARES LIST PETROBRAS P14 TDS-4S

REV
A
SCALE
30184939
NONE
WT LBS
1 OF 9
DCF0045 (REV B)
NONE
SHEET
-1 Part Number Description Commission Spare
-2 Operational Spare
-3 Insurance Spare Where Used Description Where Used
Auxiliary Dolly Assembly, Non-Retract, C-Face Rollers (30184930)

30184930-DWG 76771 Drawing, Aux Dolly Assembly Cam Follower 1 1 1 8 30184930 30184930 Aux Dolly Assembly Aux Dolly Assembly
Block Dolly Assembly, Non-Retract, C-Face Rollers (30184928)

30184928-DWG 76771 Drawing, Block Dolly Assembly Cam Follower 1 1 1 8 30184928 30184928 Block Dolly Assembly Block Dolly Assembly
Counterbalance Kit (95031)

95030-DWG 94780-DWG 94764 94764-SK Drawing, Counterbalance Kit Drawing, Cylinder Assembly Cylinder Seal Kit, Counterbalance Cylinder 1 1 1 1 1 1 1 2 96289 96289 94780 94764 Counterbalance Kit Cylinder Assy, CBal Cylinder Assy, CBal Cylinder Assy, CBal
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
6 OF 9
DCF0045 (REV B)
Motor Housing Assembly (121344-SE-***-10-50SB) 50SB

121344-DWG 30123440-DWG 107138 75981 91255 91046 91923 73302 90133 51300-392-B 51300-349-B 51300-276-B 51300-458-B 89053-V 51300-142-B 88956 88953 74004 88585-SE-Q 30123290 30123290-PK 30173521 30154362 98290 94990 112895 Drawing, Motor Housing Assy Drawing, Washpipe Assembly Sleeve, Wear Gasket Seal Retainer Seal, Housing Bushing, Bail Pin Lip Seal Ring, 3, Fig 1002 Brake, Air Seal Main Body O-Ring, Bonnet O-Ring, Bail Pin O-Ring, Housing Seal O-Ring, Housing Seal Seal Lip O-Ring, Gear Changer Gasket, Gear Changer Seal, Piston, Gear Changer Sight Gage, Oil Motor, A/C Hi-Torque Washpipe Assembly, SB Packing / Seal Kit Bearing Isolator Shield, Bearing, Washpipe Liner, Upper Stem, Tapered, Washp Seal, Oil, Washpipe Seal, Poly Pak, Washpipe 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 121344-X 30123440 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 30123290 121344-X 121344-X 121344-X 121344-X 121344-X Motor Housing Assembly Washpipe Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Washpipe Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly
Rotating Head Assembly (116417-500, Sub Assembly of 121344-**-***-10-****)

116417-DWG 88302 88098 88096 Drawing, Rotating Head Assembly Gasket Glyd Ring Seal, Lip, Bull Gear 1 1 1 4 2 1 1 12 2 116417-500 116417-500 116417-500 116417-500 Rotating Head Assembly Rotating Head Assembly Rotating Head Assembly Rotating Head Assembly
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
2 OF 9
DCF0045 (REV B)
Guide Dolly Assembly, Non-Retract, Swing, C-Face Rollers (30184932)

30184932-DWG 30172237-DWG 30172237 14783 15208 85195 85678 79862-2 73719 76420-DWG (-3) 77616 76419 76790 76417 77615 76771 82747 82747-N92151 82747-932633Q 88904-DWG 84601-3 82674-SK 82674 82674-SK Drawing, Guide Dolly Assy Drawing, Motor Align Cyl Assy Motor Align Cylinder Assembly Gauge Valve, Flow Control Motor Alignment Cylinder Seal Kit, Motor Align Cyl Bushing Thrust Bearing Drawing, Counterbalance Manifold Valve, Cartridge, Check Valve, Cartridge, Needle Valve, Directional Control Valve, Directional, Pilot Valve, Pressure Reducing Cam Follower Pressure Filter Seal, Filter Pressure Filter Element Drawing, Accumulator Kit, Align Cyl Accumulator Seal Kit, Accumulator Accumulator, Counterbalance Seal Kit, Accumulator 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 20 1 1 2 2 30184932 30184932 30184932 30172237 30172237 30172237 85195 30184932 30184932 30184932 76420-3 76420-3 76420-3 76420-3 76420-3 30184932 30184932 82747 82747 30184932 88904 94601-3 30184932 82674 Guide Dolly Assembly Guide Dolly Assembly Guide Dolly Assembly Motor Align Cylinder Assy Motor Align Cylinder Assy Motor Align Cylinder Assy Motor Alignment Cylinder Guide Dolly Assembly Guide Dolly Assembly Guide Dolly Assembly Manifold Assy, CBalance Manifold Assy, CBalance Manifold Assy, CBalance Manifold Assy, CBalance Manifold Assy, CBalance Guide Dolly Assembly Guide Dolly Assembly Pressure Filter Pressure Filter Guide Dolly Assembly Accumulator Kit Accumulator Guide Dolly Assembly Accumulator
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
3 OF 9
DCF0045 (REV B)
Motor Electric Kit, UL (M614000217-SE/SH-U24)

M614000217-DWG 129991-01A 93939 76842 79388 87541 76841 83095 84882 84665 10743 88083 110572-DWG 92814-DWG 85986-U24 82172 82173 116021-DWG 82695-1 82695-1 82695-1 94518-23IN 82697-10-B16 82695-12-B16 82695-10-B16 93547-2B75N 111664-1EN 94518-13HN 94536-130N 116641-2BN 116585-1N010 Drawing, Motor Electric Kit Gland, Barrier Proximity Sensor Switch, Differential Pressure Switch, Pressure, IBOP Switch, Pressure, Oil Switch, Pressure, Purge Switch, Pressure, BX Elev Switch, Proximity Switch, Temp Muffler, Short Exhaust Valve, Quick Exhaust Drawing, Air Manifold Assembly Drawing, 6-Gang Valve Assembly Valve, Versa Seal Kit, Valve Body Seal Kit, 4-Way Valve Drawing, Hydraulic Manifold Assy Kit, Seal Kit, Seal Kit, Seal Valve, Cartridge, Counterbalance Valve, Solenoid, EEx Valve, Solenoid, EEx Valve, Solenoid, EEx Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Relief Valve, Cartridge, Counterbalance Valve, Cartridge, Check Valve, Cartridge, Relief Valve, Cartridge, Flow Fuse 1 3 2 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 110572-U24 110572-U24 M614000217 110572-U24 92814-U24 85986-U24 85986-U24 30181871 82697-10-B16 82695-12-B16 82695-10-B16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Manf Assy, 6-Gang w/JBox Manf Assy, 6-Gang w/JBox Motor Electric Kit Manf Assy, 6-Gang w/JBox Manifold Assy, 6-Gang
Auxiliary Hydraulic Manifold for Hydraulic Link Tilt and BX Elevators

Motor Electric Kit Solenoid, Hyd Manf Assy Solenoid, Hyd Manf Assy Solenoid, Hyd Manf Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy
Local Cooling System (109412-2A1)

109412-DWG 109411 88229 Drawing, Motor Cooling System Heat Exchanger Motor Blower, 20HP, UL 1 1 1 1 1 109412-2A1 109412-2A1 109412-2A1 Local Cooling Assembly Local Cooling Assembly Local Cooling Assembly
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
4 OF 9
DCF0045 (REV B)
Oil Circulation Kit, UL, 460VAC (30181397)

30181397-DWG 30177032 115217-1D0 30111013 30111013-1 30111013-5 97575 115217-1F2 30156468-P1D 30176001 30175768-MECH 30175768-15 30175768-1 30173422-14 30156633-10 108216-16 30176000 30176000-3 Drawing, Oil Circulation Kit Thermometer, 3 inch diameter Gage, Pressure Filter Assembly, 60 Microns Dual Element, Filter, 60 Microns Magnetic Separator Valve, Thermostatic Gage, Pressure Switch, Differential Pressure Gage, Differential Pressure Filter, 25 , w/Dirt Alarm Connector Filter Filter Element Magnet Assembly O-Ring Ball Valve, 1 NPTF Strainer, Y-Style Element, Y-Style Strainer 1 4 1 2 4 4 4 2 1 6 2 1 3 6 6 6 3 1 1 1 1 1 1 1 1 1 1 30181397 30181397 30181397 30181233 30111013 30111013 30181233 30181397 30181397 30181397 30181397 30175768-MECH 30175768-MECH 30175768-MECH 30175768-MECH 30181233 30181397 30176000 Oil Circulating Kit Oil circulating Kit Oil circulating Kit Oil Circulating Kit Filter Assembly Filter Assembly Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Filter, 25 Filter, 25 Filter, 25 Filter, 25 Oil Circulating Kit Oil Circulating Kit Strainer, Y-Style
Oil Circulating Assembly (30181991) 30181991-DWG 30181832-DWG 30176029 30155689-2 30155689-3 30182305 97578-2 30156301-3 30177975 Drawing, Oil Circulating Assembly Drawing, Electrical Interconnect Flowmeter Flow Switch, .25 GPM Flow Switch, 1.2 GPM Motor/Pump Assembly Motor, 5HP, 460VAC, UL Pump, Screw Coupling 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 30176118 30176118 30176118 30176118 30176118 30181991 30176118 30176118 30176118 Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Motor/Pump Assembly Motor/Pump Assembly Motor/Pump Assembly
S-Pipe Installation Kit (94075-17)

94075-DWG 51300-425-B 91677-DWG 91677-515 84617-501 114833 Drawing, S-Pipe Installation Kit O-Ring Drawing, S-Pipe Assembly S-Pipe Assembly Elbow, 4, Fig 1002 Seal 1 2 1 2 1 2 1 2 1 2 1 1 2 94075 94075 94075 94075 91677-515 84617-501 S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Assembly Elbow
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
5 OF 9
DCF0045 (REV B)
PH-85 Installation Kit (30179600-J35A)

30179600-DWG 30173885-DWG 30173885-500 30177237-DWG 30177237-2 30177237-1 77408 79489-14 89141-18 90811-DWG 90811-500 95385-2 95385-1 Drawing, PH-85 Installation Kit Drawing, UIBOP Upper IBOP Valve Assembly Drawing, Repair Kit Repair Kit, - Complete Repair Kit Soft Seals Wrench, IBOP Seat Puller Nut Wrench Drawing, LIBOP Lower IBOP Valve Assembly Repair Kit, - Complete Repair Kit Soft Seals 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 30179600-*** 30179600 3017960-W35A 30172885-500 30172885-500 30172885-500 30172885-500 30172885-500 30172885-500 90811 3017960-W35A 90811-500 90811-500 PH-85 Installation Kit Upper IBOP PH-85 Installation Kit Upper IBOP Upper IBOP Upper IBOP Upper IBOP & Lower IBOP Upper IBOP & Lower IBOP Upper IBOP & Lower IBOP Lower IBOP PH-85 Installation Kit Lower IBOP Lower IBOP
PH-85 Torque Wrench Assembly (95461-ATBX, Sub Assembly of 30179600-J**) 72221 72219 72220 81788 30116378-DWG 94537-175N 94518-13HN 94521-1DN 91223 91224 90849 91854 71847 91265 95461-DWG 98006-13N 98006-13N 30116378-DWG 94536-130N Rod, Wiper Seal, Piston Seal, Rod Die Drawing, Manifold Assy, Elev Tilt Valve, Cartridge, Check Valve, Cartridge, Counterbalance Valve, Cartridge, Shuttle Bushing, Actuator Bushing, Sleeve Bushing, Torque Cylinder Bushing, Torque Cylinder Cam Follower Cylinder, Hydraulic, Clevis Assy Drawing, Torque Wrench Assy Seal Kit, Counterbalance Valve Seal Kit, Check Valve Drawing, Manifold Valve, Cartridge, Check 4 1 1 1 50 1 2 2 2 2 2 1 1 1 1 1 2 1 1 2 2 2 1 1 1 1 1 2 95461-*** 95461-*** 95461-*** 95461-*** 95461-***B & -***BX 95461-***B & -***BX 95461-***B & -***BX 95461-***B & -***BX 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 94518-13HN 94537-175N 30116378 30116378 Clamp Cylinder Clamp Cylinder Clamp Cylinder Jaw Assembly Manifold, Elevator Tilt Manifold, Elevator Tilt Manifold, Elevator Tilt Manifold, Elevator Tilt Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Valve, Cartridge, Cbalance Valve, Cartridge, Check Manifold, Rectifier Manifold, Rectifier
Rectifier Manifold Assembly (30116378, Sub Assembly of 95461-***B & -***BX)
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
7 OF 9
DCF0045 (REV B)
RBS-4 Installation Kit (30183592 & -1)

30183592-DWG 126558-DWG 126992-DWG 127321-DWG 127354 83444-05 86959-5 86959-4 107030-16 94536-330N 30126664-DWG 94518-13HN 126663-DWG 108894-B25 108894-P23 108894-R13 108894-G13 108894-Z703 108894-Y2 140717-DWG 83444-01 126811-220 126584-DWG 126584 109302-375NB 94537-375N 126581-DWG 112554-SK 94536-330N 107029-375N 107029-130N 93547-1B75N 94534-3CXN 94534-1CLN 93542-05D 107610-1HN 116641-3AN 94522-1BN 117068-1REN 107236-1AN 94521-1DN Drawing, RBS-4 Installation Kit Drawing, Hyd Schematic, RBS-4 Drawing, Elec Interconnect Drawing, Bulkhead Plate Assy Assembly, Inlet Manifold Gland Inlet Filter Assembly Element Inlet Filter Assembly Ball Valve Valve, Cartridge, Check Drawing, Lift Cylinder Assembly Valve, Cartridge, Counterbalance Drawing, Lift Cylinder SCD Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland Drawing, Tong Arm Elec/Stab Head (140717-2) Gland Flow Divider Drawing, Regen Clamp Manifold Manifold, Clamp Regen Valve, Cartridge, Fixed Flow Valve, Cartridge, Pilot-Close Drawing, Control Manifold Seal Kit, Solenoid Valve Valve, Cartridge, Check Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Logic Valve, Cartridge, Logic Valve, Cartridge, Pilot Operated Valve, Cartridge, Pressure Comp Valve, Cartridge, Reducing Valve, Cartridge, Relief Valve, Cartridge, Remote Pilot Valve, Cartridge, Sequence Valve, Cartridge, Shuttle 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 30183592 30183592 30183592 30183592 127321 127321 86959-4 127354 127354 127354 30183592 30126664 30126664 126663 126663 126663 126663 126663 126663 30183592 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 140717 140717 140717 126584 126584 140717 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S RBS-4 Installation Kit RBS-4 Installation Kit RBS-4 Installation Kit Bulkhead Assembly Bulkhead Assy Bulkhead Assy Bulkhead Assy/Inlet Filter Bulkhead Assy/Inlet Filter Bulkhead Assy/Inlet Manf Bulkhead Assy/Inlet Manf Lift Cylinder Assembly Lift Cylinder Assy Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Tong Arm Electrical Tong Arm Elec/Gland Tong Arm Elec/Flow Divider Tong Arm Elec/Reg Manifold Tong Arm Elec/Reg Manifold Tong Arm Elec/Reg Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
8 OF 9
DCF0045 (REV B)
112554-D2 112554-J2 126540-DWG 30158598 30158597-DWG 108894-B50 108894-P50 108894-R20 108894-G20 108894-Z677 108894-Y4 30113000 30158763 30158597 124223-3 94518-13HN 108894-B20 30158763-PK 108894-10 108894-G10 108894-Z676 108894-Y1 123305-DWG 118844-24-16 126648-DWG 118844-32-32 118844-28-38 118844-48-48 118844-32-40 118844-48-40 118844-32-28 118844-32-40 30158606-1-DWG 126404-DWG 30126114 126650-DWG
Valve, Directional Valve, Directional Drawing, Tong Arm & Stab Head Hyd (126540-1) Retract Cylinder Assy Drawing, Cylinder Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland Bushing Cylinder, Latch, 1-1/2 Stroke Cylinder, Latch, 1-1/2 Stroke Switch, Limit Valve, Cartridge, Counterbalance Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland Drawing, Stabbing Head Assembly (123305-500) Bushing, Fiberglide Frame Assembly Bushing Bushing Bushing Bushing Bushing Bushing Bushing Drawing, Clamp Cylinder Assembly Drawing, Carriage Assembly Cam Follower, 6 inches Drawing, Retract/Latch Cyl Assy
1 1 1 1 1 2 1
1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 1 1 2 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1
126581-SGE-3-S 126581-SGE-3-S 140717 126540 30158598 30158597 30158597 30158597 30158597 30158597 30158597 30158598 30158598 30158598 30158598 30158598 30158763 30158763 30158763 30158763 30158763 30158763 123305 30158717 30158592 30178431 30178431 30178431 30178431 30178431 30178431 30158606-1 30178431 126404 126404 30182592
Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cy Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Stab Head Tong Arm Elec/Stab Head Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Carriage Tong Arm Elec/Carriage RBS Installation Kit
SIZE
DWG NO
REV
A
SCALE
30184939
NONE
WT LBS SHEET
9 OF 9
DCF0045 (REV B)
TDS-4S CONTROL SPARES LIST PETROBRAS P-14
NOTES: 1. 30184734-1 Recommended Commissioning Spares 2. 30184734-2 Recommended Operational Spares 3. 30184734-3 Recommended Insurance Spares
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT
DRAWN CHECKED APPVD DATE
INITIAL T. GONZALEZ T. JORDAN T. JORDAN 11/07/07

SIZE
CONTROL SPARES LIST, TDS-4S, PETROBRAS P-14

DWG NO REV
A
SCALE
30184734
NONE
WT LBS SHEET
1 OF 3
DCF0045 (REV B)
Part No.
Description
-1 Recom. Commission Spare 1 1 1
-2 Recom. Operational Spare -
-3 Recom. Insurance Spare 1 1 1
Where Used 30184445 30184445 30184445 & P804000014ASM-001 30184445 30184445 30184445& P804000014ASM-001 30184445 30184445 30184445 & P804000014ASM-001 30184445 & P804000014ASM-001 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 30184445 & P804000014ASM-001 30184445 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001
Description Where Used Control System Assy. Control System Assy. Control System Assy.
92119-6 Barrier, Potentiometer Converter 141611 Power Supply 15VDC, 1A 122627-02 Power Supply 24VDC, 10A
122627-36 Digital Input Module, 16x24VDC 112627-101 Digital Relay Output Module, SM322 122627-142 Analog Input, SM331, 8Ch
1 1 2
1 1 2
Control System Assy. Control System Assy. Control System Assy.
122627-19 Analog Output 122627-76 Frequency Counter 112627-101 Digital Relay Output Module, SM322 122627-14 Digital Output
1 1 2
1 1 2
Control System Assy. Control System Assy. Control System Assy.
Control System Assy.
122627-27 Front Connector, Screw Terminal, 20 Pins 122627-75 Front Connector, Screw Terminal, 40 Pins 122627-34 Profibus Connector w/PG Socket . 122627-143 CPU 315-2DP 30123233-10E Isolator, Analog Signal 3071075 Isolator, Analog Signal 30087708-59 Light, Indicator, Clear 24V DC 30087708-39 Light, Indicator, Green 24V DC 30087708-44 Lamp, Bayonet 24V DC 30087708-37 Switch, 3 Position 30087708-27 Switch, 2 Position 81736-2 Potentiometer, 2W, 10K 118910-7 Relay,DPDT, 2NO, 24V
1 1 1 1
1 1 10 -
1 1 1 1 1 1 1 1 1 1 1 1 2
Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy.
118910-17 Relay,DPDT, 2NO, 120V 30171978 Barrier, .I.S. 92119-8 Barrier, I.S.
1 1 1
2 1 1
Control System Assy. Remote I/O J-Box Remote I/O J-Box
98263 Barrier, I.S. 111070 Barrier, I.S. 122627-01 Power Supply 24VDC, 5A 122627-127 ET200S POWER MODULE
1 1 1 1
1 1 1 1
Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box
SIZE
DWG NO
REV
A
SCALE
30184734
NONE
WT LBS SHEET
2 OF 3
DCF0045 (REV B)
122627-128 ET2OOS Power Module Base 122627-125 ET200S Counter Module 122627-126 ET200S Counter Module Base 114054-3110 Thermostat 114054-3107 Heater 30156246 Atos Profibus Solenoid Driver
1 1 1 -
1 1 1 1 1 1
P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001
Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box
SIZE
DWG NO
REV
A
SCALE
30184734
NONE
WT LBS SHEET
3 OF 3
DCF0045 (REV B)

D811000252 Man 001

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Bill of Material Item 1 2 3 4 5 Quantity 1 1 1 1 1 Part Number SM00620 SM01053 D811000252-DOS-001 30184939 30184734 Description Service Manual, TDS-4S

NEXT ASSY M614000012-GEN-001

INITIAL J. Kellstrom K. Schmidt R. Shumski 10/23/2007

Petrobras, P14 TDS-4S

Top Drive System Service Manual

Chapter 2 Major component description

Book 2 Installation and Commissioning

Chapter 1 Operating procedures

Book 4 Maintenance and Troubleshooting

Book 4 TDS-4S Control System

TDS-4S Top Drive Drilling System

Chapter 2 Major component description

Preface Manual conventions

Guide Dolly Assembly

Motor Housing Assembly

Figure 1-1. Typical TDS-4S overall view

Integrated Swivel Bail Counterbalance Cylinder (2)

Gooseneck Air Brake

Standard Washpipe Packing

Motor Support Bonnet

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Motor Pinion Gear

Low Gear (Engaged)

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Figure 1-2. TDS-4S motor and swivel housing assembly

Rotating Head (Part of the Motor Housing Assembly)

Torque Arrestor (4)

Hydraulic/Pneumatic Link Tilt

Upper IBOP Valve Actuator

350-Ton 108 in. Link (2) (Optional Varco Equipment)

Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment)

Figure 1-3. Typical 650-Ton, PH-85 pipehandler assembly

650-Ton Rotating Head (Part of Motor Housing Assembly)

Torque Arrestor (4)

Pneumatic Link Tilt

Safety Valve Actuator

108 in. 350-Ton Links (Optional Varco Equipment)

Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment)

Figure 1-4. 650-Ton, PH-60d pipehandler assembly

Upper IBOP Valve Actuator Air Cylinder (2)

Crank Assembly (2)

Actuator Arm (2)

Safety Valve Actuator Shell

Figure 1-5. Safety valves (IBOPs) and actuator assembly

Rotating Head (Part of Motor Housing Assembly)

Link Adapter (Also known as Solid Body Elevator)

Torque Arrestors (4)

Hydraulic/Pneumatic Link Tilt

650/500-Ton Rotating Head (Part of Motor Housing Assembly)

650/500-Ton Link Adapter (Also known as Solid Body Elevator)

Torque Arrestor 650-Ton: (4) 500-Ton: (2)

Link Adapter Support Plate

Upper IBOP Valve

108 in. 350-Ton Links (Optional Varco Equipment)

Safety Valve Actuator Torque Wrench

Lower IBOP Valve

Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment)

Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies

Pneumatic Link Tilt

650-Ton Rotating Head (Part of Motor Housing Assembly)

650-Ton Link Adapter (Also known as Solid Body Elevator)