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Dokumen - Tips Top Drive Manual

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0% found this document useful (0 votes)
166 views236 pages

Dokumen - Tips Top Drive Manual

Uploaded by

mohamed ramadan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 236

8/9/2019 Top Drive Manual

TDS-11SA

Top DriveManual
Service System

SM00856
Revision B
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Counterbalance
System

Motor Cooling
System

Hydraulic Disc Gooseneck


Brakes (2) (S-Pipe)

AC Drilling
Motors (2)
Transmission/
Motor Housing

Hydraulic
System

Rotating Link
Adapter

Guide Beam
and Carriage

Rear Right Side

Pipehandler

Left Side Front

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General Information

Specifications

Lubrication

Installation, Commissioning
and Decommissioning

Guide Beams and Carriage

Motor Housing,
Transmission

PH-75 Pipehandler

PH-50 Pipehandler

Hydraulic System

TDS-11SA Rev. B
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General Information

Specifications

Lubrication

Installation, Commissioning
and Decommissioning

Guide Beams and Carriage

Motor Housing,
Transmission

PH-75 Pipehandler

PH-50 Pipehandler

Hydraulic System

Varco Systems
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General Information

Preface ...................................................1-3

Manual conventions ........................................... 1-3

Note ............................................................................... 1-3


Caution .......................................................................... 1-3
Warning ......................................................................... 1-3

Overall equipment safety requirements ............ 1-3


Personnel training ......................................................... 1-3
Systems safety practices ............................................... 1-4
Electrical systems and components .................................. 1-4
Hydraulic systems and components .................................. 1-4
Pneumatic systems and components................................ 1-5
General safety ............................................................... 1-5
Equipment motion hazards................................................ 1-5
When replacing components ............................................. 1-6
During routine maintenance .............................................. 1-6
Visibility of equipment operation........................................ 1-6
Proper use of equipment ................................................... 1-6
Varco Service Centers .................................................. 1-6

Identification numbers ....................................... 1-7


Lifting points....................................................... 1-8
Safety wiring....................................................... 1-9
Torque values ..................................................... 1-10
Basic useage ...................................................... 1-11
Drilling ahead with singles ............................................. 1-11
Drilling ahead with triples............................................... 1-12
Backreaming ................................................................. 1-13

Consumables ...................................................... 1-14

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General Information

Counterbalance
System

Motor Cooling
System

Hydraulic Disc Gooseneck


Brakes (2) (S-Pipe)

AC Drilling
Motors (2)
Transmission/
Motor Housing

Hydraulic
System

Rotating Link
Adapter

Guide Beam
and Carriage

Rear Right Side

Pipehandler

Left Side Front

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General Information

Preface

Manual conventions

This Preface contains the conventions used throughout this manual.


Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or
servicing the equipment.

The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.

Note

i Provides additional information on procedures involving little or no


risk of injury to personnel or equipment damage.

Caution

! Alerts the reader to procedures involving a risk of equipment


damage.

Warning

Warns the reader of procedures involving a definite


risk of injury to rig personnel.

Overall equipment safety requirements


Varco drilling equipment is installed and operated in a controlled
drilling rig environment that involves hazardous operations and
situations.

i To avoid injury to personnel or equipment damage, carefully observe


the following safety requirements.

Personnel training
All personnel installing, operating, repairing, or maintaining
equipment, or those in the vicinity of this equipment, should be
trained in rig safety, tool operation, and maintenance as applicable.

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This measure helps ensure the safety of everyone exposed to the


equipment for whatever purpose.

i During installation, operation, maintenance, or repair of this


equipment, personnel should wear protective equipment.

Contact the Varco Service Department to arrange for training for


equipment operation and maintenance.

Systems safety practices


The equipment covered by this manual may require or contain one
or more utilities such as electrical, hydraulic, pneumatic, and
cooling water.

i Before installing, performing maintenance or repairs on the


equipment, read the following instructions to avoid endangering
exposed persons or damaging equipment.

Isolate all energy sources before beginning work.

Avoid performing maintenance and repairs while the equipment


is in operation.

Wear proper protective equipment during the installation,


maintenance, or repair of this equipment.

Electrical systems and components


All electrical wiring, junction boxes, sensors, glands, and related
equipment are designed for the specific application, environment
and particular zone where the equipment is intended to be used.

Before beginning work on this equipment, familiarize yourself


with the electrical schematics, as well as the equipment power
and voltage requirements.

When performing installation, maintenance, or repairs on the


equipment, isolate all power. Lock out switches and tag them to
prevent injur y.
Prior to disconnecting wires, verify that all wires and terminals
are properly labeled to ensure proper reconnection.

Hydraulic systems and components


Hydraulic systems and components are designed for specific use in
the drilling industry. The hydraulic pressure for this equipment can
be as high as 3,000 psi.

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Before beginning work on any portion of the hydraulic system,


familiarize yourself with the hydraulic and electrical schematics.

Isolate, lock out, and tag the hydraulic and electrical power and
controls.

Take precautions when bleeding down residual system


pressure, using bleed valves or equivalent techniques.

Hydraulic fluids can be extremely hot and under high


pressure.

Properly discharge all system accumulators.

Collect all residual hydraulic fluid in a container to prevent rig or


environmental contamination.

Take precautions to prevent hydraulic oil from leaking into other


open electrical or mechanical components, such as junction
boxes.

Pneumatic systems and components


Pneumatic systems and components are designed for specific use
in the drilling industry. The pneumatic pressure for this equipment
can be as high as 150 psi.

Prior to beginning work on any portion of the pneumatic system,


familiarize yourself with the pneumatic and electrical
schematics.

Isolate, lock out, and tag the pneumatic, electrical power and
controls.

Take precautions when bleeding down residual system pressure


using bleed valves or equivalent techniques.

Properly discharge all system accumulators.

General safety

Equipment motion hazards


Some Varco equipment can travel horizontally, vertically or both.

i Avoid placing objects in or near the path of motion for this


equipment. Such interference could cause personnel to be trapped
or crushed by equipment.

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General Information

i Keep the working envelope/zone of the equipment free from


personnel.

When replacing components


During disassembly and reassembly of any equipment, verify all
components such as cables, hoses, etc. are tagged and labeled
to ensure reinstalling the components correctly.

Replace failed or damaged components with Varco certified


parts. Failure to do so could result in a hazard, equipment
damage, or personal injury.

During routine maintenance


Equipment must be maintained on a regular basis. See the body of
the service manual for maintenance recommendations.

i Failure to conduct regular maintenance can result in a hazard,


equipment damage or injury to personnel.

Visibility of equipment operation


Clear, unobstructed visibility of all equipment functions is critical to
safe operation. Do not block or impair the equipment operator’s
field of view. In cases where this is not possible, the customer must
install video cameras to ensure adequate visibility.

Proper use of equipment


Varco equipment is designed for specific functions and
applications, and should be used only for the intended purpose.

i Do not hoist personnel using this equipment.

Contact the Varco service center for questions regarding equipment


operation, maintenance, hazards, and designed function.

Varco Service Centers


If you need technical assistance, see the back cover of this manual
for a complete list of Varco’s Worldwide Service Centers.

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General Information

Identification numbers

i Trace code identifies the


configuration of your equipment

Encoder
Instruction Label
Located on the righthand
brake cover
SALES ORDER NO.
ASSY NO. REV
TRACE CODE
DATE OF MANUFACTURE

AC Motor
Identification Label Top Drive
Located on the side Identification Plate
of each AC motor Located on the front
of the motor housing

Warning Labels
Located on the side
of each AC motor

Warning Label
Located on the
side of the bonnet

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General Information

Safety wiring

1 2

3 4 5

i
Refer to ASP00019
Procedure for Safety Wiring

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General Information

Torque values
(Unless otherwise specified)

Bolts Lubricated with Bolts Lubricated with


Light Machine Oil Anti-seize Compound

Grade 5 Grade 5

Min. Max. Clamp Min. Max. Clamp


Threads Torque Torque Force Torque Torque Force
Diameter per inch (ft lb) (ft lb) (lb) (ft lb) (ft lb) (lb)

Coarse Thread Series, UNC


1/4 20 7.6 8.4 2020 5.7 6.3 2020
5/16 18 16 18 3340 12.1 13.4 3340
3/8 16 29 32 4940 21.4 23.6 4490
7/16 14 48 53 6800 36 39 6800
1/2 13 71 79 9050 53 59 9050
9/16 12 105 116 11600 78 87 11600
5/8 11 143 158 14400 107 118 14400
3/4 10 247 273 21300 185 205 21300
7/8 9 409 452 29400 306 339 29400
1 8 608 672 38600 456 504 38600
1 1/8 7 760 840 42300 570 630 42300
1 1/4 7 1064 1176 53800 798 882 53800
1 3/8 6 1387 1533 64100 1040 1150 64100
1 1/2 6 1843 2037 78000 1382 1528 78000

Fine Thread Series, UNF


1/4 28 9.5 10.5 2320 7.1 7.9 2320
5/16 24 18 20 3700 13.5 15.0 3700
3/8 24 33 37 5600 25 28 5600
7/16 20 52 58 7550 39 43 7550
1/2 20 86 95 10700 64 71 10700
9/16 18 114 126 12950 86 95 12950
5/8 18 162 179 16300 121 134 16300
3/4 16 285 315 23800 214 236 23800
7/8 14 447 494 32400 335 370 32400
1 14 665 735 42200 499 551 42200
1 1/8 12 836 924 47500 627 693 47500
1 1/4 12 1178 1302 59600 884 977 59600
1 3/8 12 1596 1764 73000 1197 1323 73000
1 1/2 12 2090 2310 87700 1568 1733 87700

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi


T.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi

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General Information

Basic useage

Drilling ahead with singles

Step 1 Step 2 Step 3 Step 4 Step 5

Set slips on string Tilt links to Pickup single Lower block to Pull slips
mousehole with elevator stab motor into
Stop circulation top of single Open IBOP
Latch drill pipe Release link tilt
Close IBOP elevator around Spin in motor Start circulation
single Stab bottom of and single
Breakout connection single onto string Begin drilling
using pipehandler Makeup both
and drilling motor connections
(in reverse) with motor in
torque mode

Makeup

Open
IBOP

Link Tilt
Close IBOP
Stab Makeup

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General Information

Basic useage

Drilling ahead with triples


Step 1 Step 2 Step 3 Step 4 Step 5

Set slips on string Raise block Pickup stand


with elevator Lower block
stab motor to
into Pull slips
Stop circulation Tilt link tilt to top of stand Start circulation
derrickman Stab bottom of
Breakout connection stand onto string Spin in motor Begin drilling
using pipehandler and stand
and drilling motor
(in reverse) Makeup both
connections
with motor

Link Tilt Makeup

Start
Circulation

Stop
Circulation

Stab Makeup

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General Information

Basic useage

Backreaming
Step 1 Step 2 Step 3 Step 4 Step 5

Hoist whileand
circulating Set slips on string Hoist free stand
with elevator Setback stand
using link tilt Lower block,
motor into stab
string
rotating Breakout
connection using Spin in motor
When 3-rd pipehandler and and makeup
connection drilling motor connection with
surfaces, stop (reverse) motor
rotation and
circulation Breakout and Start circulation,
spinout stand pull slips, hoist
at floor and rotate

Breakout Hoist Setback

Hoist and
Rotate

Breakout

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General Information

Consumables
Consumable Part Quantity Part Number

Tong Dies 4 16401-2


Stabilizer, Front 1 118368
Stabilizer, Rear 1 118367
Guide Arm (Stabbing Guide Flippers) 2 76442
Wash Pipe (Standard) 1 30123289
Wash Pipe (Tungsten Coated, High Pressure) 1 30123289-TC
Wash Pipe Assembly (Standard) 1 30123290
Wash Pipe Assembly (High Pressure) 1 30123290-1000
Wash Pipe Packing Kit, 3" Standard 1 30123290-PK
(Use with Wash Pipe 123289)
Wash Pipe Packing Kit, 3" High Pressure 1 30123290-PK-1
(Use with Wash Pipe 123289-TC only)

Hydraulic Oil Filter 1 114416-1


Gear Oil Filter 1 30111013-1
Brake Pads 8 109528-1

Brake
Pads

Wash
Hydraulic Pipe
Oil Filter

Gear
Oil Filter

Stabilizers

Tong Dies

Stabbing
Guide

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Specifications
Specifications

Size specifications ............................................. 2-2


General specifications ....................................... 2-4

Typical mast interface ....................................... 2-5


Performance curve ............................................. 2-6

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Specifications

Size specifications
Bail
120 in.
31.0 in.

Bail
88 in.

260.0 in.

230.0 in.

To Center
of Gravity
160.0 in.

To Center
of Gravity To Center
25.0 in. of Gravity
50.0 in. 41.5 in.

67.0 in. = 35,000 lb 65.0 in.

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Specifications

Size specifications

Rear

35.9 in.

34.0 in.

C
L
Well

21.1 in.

26.0 in. 31.0 in.


C
L
Well

Front

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Specifications

General specifications
Components Items Description

Top Drive Weight 27,000 lb


Stack-up Height 17.8 ft
Power Requirements 700 KVA @ 575-600 VAC, 50/60 Hz
Horsepower 800 hp
Output torque (continuous) 37,500 ft lb (800 hp)
Tool torque (intermittent @ stall) 55,000 ft lb
Maximum Speed @ full power 228 rpm
Hoisting capacity 500 ton
Load Path Single
Gooseneck Entry 3" 1002 Female Union
S-Pipe Mude Hose Connection 4" API Line Pipe or 4" 1002 Female Union

Drill Pipe Sizes 3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)

Pipe Handler Type PH-75 (75,000 ft lb backup torque)

Drilling Motor Type Reliance AC-575 VAC (2 x 400 hp)

Variable Frequency Drive Type IDM Yaskowa Drive (800 hp, 575 VAC) or
Siemens (800 hp, 600 VAC)

Motor Braking Type Hydraulic caliper disc brakes

Motor Cooling System Type Local intake pressure blower


Power (2) 5 hp AC motors
Speed 3,600 rpm

Gearcase Type Single speed, double reduction helical gear system


Gear ratio 10.5:1 (4.38:1 optional)

Gearcase Lubrication Type Pressure feed


Reservoir capacity 15 gal
Full internal flow 10 gpm
Oil Type EP Grade (See chart)
Oil Pressure Minimum 10 psi, Maximum 30 psi
Hydraulic System Power 10 hp, AC motor
Flow 8.0 gpm/3.5 gpm (hi/lo)

Reservoir capacity 25 gal


Oil Type Mineral based hydraulic oil

Electrical House Size 125.4 in. x 84.0 in., 91.2 in. height (Siemens)
Type 140.0 in. x 90.0 in., 91.0 in. height (IDM)
Weight 9,500 lb
Input requirement 600 VAC(50/60 Hz), or 750 VDC, or 690 VDC(50/60 Hz)

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Specifications

Typical mast interface


Existing
* Dimensions are Subject Traveling Equipment
to Verification Crown
500-ton Hook/Block Combo-Typ.
**Standard TDS Configuration- Clearance
Two IBOP’s with 108 in. 13.5 ft. (4.1 m)**
Elevator Links Block Top
TDS
Varco Portable
Top Drive System Stroked-Typ.
13.5 ft. (4.1 m)*
Bail Rest

Sectional Guide Beam TDS Work Height


18.0 ft. (5.4 m)**

Tool Joint
Derrick Termination
at ~73 ft. (24.4 m) Level*

Mud Hose
75 ft. (22.9 m)* Drill Stand
Connected to Standpipe Made-up at
at 73 ft. (22.3 m) Level 4 ft. (1,2 m)
Level
93 ft. (28.3 m)
Service Loop

Portable Torque Reaction Beam


“U”- Bolted to Spanners - (by Customer) Clear
Working
* Height
2 Custom Spanners m
u m
u
142 ft.
im
(43.3 m)
On A-Frames or Mast Side Panels (by Customer) im
in in
M M
)- )-
m m
Varco Driller’s Control 3( 1.
tf. 2(
0. tf.
0 0.
Control Cable with Connectors 1
7
150 ft. (45.7 m)
LC
Beam
Unitized Variable Frequency Service Loop
Inverter & Varco Control Panel Tool Joint
4.0 ft. (1.2 m)
Local Power Supply Drill Floor
Diesel/Alternator Set/AC Buss

AC Power and
AC Cables Control Cables

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Specifications

Performance curve
55,000

50,000

45,000
800 HP
) 40,000
s
lb-
tf
( 35,000
e Dual AC Motor Top Drive TDS-11SA
u
q
2 x 400 = 800 HP, 500 Ton System
r 30,000
o 10.5:1 Transmission
T
e
ip 25,000
P
ll
i
r
D 20,000

15,000

10,000

5,000

0
0 25 50 75 100 125 150 175 200 225 250
Drill Pipe RPM

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Lubrication and
Maintenance

Transmission ...................................................... 3-2


Selecting the proper gearbox oil .................................... 3-2
Lubrication schedule ..................................................... 3-2
Recommended gear oils ............................................... 3-3

Gearbox lubrication ............................................ 3-4


Hydraulic system ................................................ 3-5
Precautions ................................................................... 3-5
Lubrication schedule ..................................................... 3-5
Recommended hydraulic fluid ....................................... 3-6
Hydraulic lubrication ...................................................... 3-7

Motors ................................................................. 3-8


Lubrication schedule ..................................................... 3-8
Recommended motor grease ........................................ 3-8
Motor lubrication ............................................................ 3-9
General purpose lubrication ............................... 3-10
Lubrication schedule ..................................................... 3-10
Recommended lubricants .............................................. 3-11
General lubrication ........................................................ 3-12

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Lubrication

Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of the
gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating (EP), and a
minimum viscosity of 100 SUS at internal operating temperature.

Varco Top Drives also operate under a wide variety of ambient


temperatures. Select lubrication for the TDS based on the minimum
ambient temperature (surrounding air) to be expected before the
next oil change. Under all but the most severe operating conditions,
Varco recommends changing the oil every six 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

Lubrication schedule
Description Frequency

Replace the Gearbox Oil Following Intial Break-in Following first month of operation
Replace the Gearbox Oil and Perform an Oil Analysis Every 6 Months
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 30111013-1) Every 3 Months
Remove, clean and replace the Magnetic Drain Plug Yearly

The first oil change should be performed after the first month of
operation since new units often contain metal contaminates and
contaminates caused by initial break-in.

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Lubrication

Transmission
Recommended gear oils
Ambient Temperature Range
-6˚ to 16 ˚ C 7˚ to 30˚ C Above 21˚ C
(20˚ to 60˚ F) (45˚ to 85˚ F) (Above 70˚ F)

Manufacturer
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 150 or Omala 150 Omala 320 or
Spirax 80W-90 GL5 Spirax 85W-140 GL5
Statoil Loadway EP68 Loadway EP150 Loadway EP320
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL4EP Extra Duty NL4EP Extra Duty NL6EP
76 MP Gear Lube 76 MP Gear Lube
80W-90 GL5 85W-140 GL5

Viscosity Index
AGMA 4EP 5EP 6EP
ISO Viscosity Grade 150 220 320

! Oils of insufficient viscosity can damage gears by allowing metal to


metal contact.

i For minimum temperatures below 20 ° F, 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 20 ° F. If drilling conditions dictate oil temperatures below 20 ° F,

consult Varco service center.

If the oil temperature rises above 200 ° F, Varco recommends shutting


down or reducing drilling loads to stabilize the oil temperature below
200 ° F If drilling conditions dictate oil temperatures above 200 ° F,

consult Varco service center.

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Lubrication

Gearbox lubrication

Cork Ball
(Level Sight
Indicator) Glass

Gearbox
Oil Drain

i
Gear Oil
Sight Gauge
Check with Top Drive
“OFF” Replace gear oil every
6 Months

Gearbox Oil Fill


Clean area before
i
removing plug, then
use a 1 3/8 inch, 12 point
socket to remove plug
“Pop-up”
Dirt
Alarm Procedure
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)

Gear Oil Filter Ensure that the unit is turned OFF


Replace every The area must be wiped clean
prior to adding gearbox oil
3 Months
Recheck oil level and replace the
plug after adding oil
Yearly Run the unit and recheck the oil
level (not foam level), after the unit
Magnetic Drain Plug has been running and the
Remove and clean contamination transmission oil is warm

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Lubrication

Hydraulic system
Precautions

Release all hydraulic oil pressure by bleeding


accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean


work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent injury
to personnel.

! Use care when handling components to prevent nicking close


tolerance finishes.

! Use care to prevent contamination from entering the hydraulic


system during maintenance activities.

Lubrication schedule
Description Frequency

Perform Hydraulic System Oil Analysis Every 6 Months


Replace the Hydraulic Fluid Yearly, or Earlier Based on Oil Analysis
Replace the Hydraulic System Filter (P/N 114416-1) Every 3 Months

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Lubrication

Hydraulic system
Recommended hydraulic fluid
Oil Temperature Range
-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)

Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46

Viscosity Index
ISO Viscosity Grade 32 46

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Lubrication

Motors

Varco recommends that lubrication of all AC motors


should be done by the rig electrician.

Lubrication schedule
Description No. of Points Frequency Type

Lubricate the AC Drilling Motor 4 Every 3 Months Motor Grease


Lubricate the AC Blower Motor 4 Every 3 Months Motor Grease
Lubricate the Hydraulic Pump AC Motor 2 Every 3 Months Motor Grease

Recommended motor grease


Motor Grease

Manufacturer

Chevron Black Pearl EP2 (Do Not Substitute)

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Lubrication

Motors
Motor lubrication

i Grease Fittings

Apply
to motor grease
designated Grease
grease fittings Fitting
with hand grease gun 1/8 inch
Varco P/N
53201

3 Months
!
Pipe Plug
AC Blower 1/8 inch
Motor (2) (remove and
3 pumps reinstall after
(2 grease fittings lubricating)
each motor)

As Viewed From Below

3 Months

AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months

Hydraulic Pump AC Motor


3 pumps
(2 grease fittings)

Procedure
Remove the lubrication point plug
Install a grease fitting
Grease with a hand pump only
Re-install the plug

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Lubrication

General purpose lubrication


Recommended lubricants
Ambient Temperature Range
Below -20 °C Above -20 °C
(Below -4 ° F) (Above -4 ° F)

Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2

Viscosity Index
NGLI 1 2

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Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose grease to
designated grease fittings with
grease gun. Use a brush when
greasing other parts.

Daily
IBOP Actuator Yoke
One pump each side

Daily
IBOP Actuator Cranks
One pump each side

Daily
Weekly Stabilizer Liner
One pump each side
Upper IBOP Valve
Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps Weekly
Replace Clamp Cylinder Gate
! plug before
operating
One pump each side

Daily Weekly
Stabilizer Liner Elevator Link Eyes
One pump each side (4)
Pipe Dope

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Lubrication

General purpose lubrication


General lubrication

i
Apply general purpose grease
to designated grease fittings
with grease gun

Weekly

Guide Rollers
4 Places
One pump each
(if equipped)

Weekly

Guide Rollers
16 Places
One pump each
(if equipped)

Weekly

Bogies
4 Places
One pump each
(if equipped)

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Illustrated index ................................................. 4-3


Preinstallation .................................................... 4-4
Preparation .................................................................... 4-4

Installing the crown padeye and hang-off link ............... 4-5


Installing the intermediate tieback ................................. 4-6
Installing the main tieback ............................................. 4-7
Locating the control house ............................................ 4-8
Installing power cables .................................................. 4-9
Earthing the control house (land rigs)............................ 4-10
Checklist ........................................................................ 4-11

Installation .......................................................... 4-12

Raising the top guide beam section to the drill floor ...... 4-12
Attaching the carriage sling to the hook ........................ 4-13
Moving guide beam sections ......................................... 4-14
Hooking the first guide beam section ............................ 4-15
Hoisting the first guide beam section............................. 4-16
Stabbing and pinning the first guide beam section ........ 4-17
Completing guide beam installation............................... 4-18
Hoisting and attaching the guide beam ......................... 4-19
Removing the hoist carriage.......................................... 4-20
Moving the top drive to the drill floor.............................. 4-21
Attaching the top drive to the hook ................................ 4-22
Lifting the top drive to the rig floor ................................. 4-23
Hoisting and connecting the top drive to the guide
beam ............................................................................. 4-24
Attaching the torque tieback .......................................... 4-25
Pinning the top drive to the guide beam ........................ 4-26
Releasing the top drive from the skid ............................ 4-27
Installing derrick termination .......................................... 4-28
Installing the service loop to the derrick ........................ 4-29
Installing the driller’s console ......................................... 4-30
Installing the driller’s console cabling ............................ 4-31
Motor rotation checkout procedure ................................ 4-32
Installing the pipe elevator and links .............................. 4-33

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Preinstallation
Installing the crown padeye and hang-off link

Crown Padeye
■ Weld at 30 inches
from well center
■ Padeye to be suitable
for 25 ton load
Crown

30 inches

25 Ton
Shackle

i
For land rig applications,
when possible, install crown
padeye, hang-off link and
tieback with mast layed down.
Hang-off Link
■ Adjust length per
General Arrangement
Drawing

Hang-off
Tieback

Drill Typical
Floor CrossCrown
Below Girt

C
L
Well

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Preinstallation
Installing the intermediate tieback

To rotate intermediate tieback


loosen locking bolt and rotate
out of the way. To secure after Intermediate
rotating tighten locking bolt. Tieback
(Shown in Locked
Position)
Rotate

Locking
Bolt

Pivot
Point

Drill i
Floor
Refer to General Arrangement
30.0 inches Drawing for installation heigth.

C
L
Well

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Preinstallation
Installing power cables

COM
POS
ITE
CONNEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL
Ground Lug CON
NEC
TOR
to Top Drive
Plug Panel
i
Typical installation
UIN
COM
ING
575
VAC
VIN
COM
ING
575
VAC
WI
NCO Incoming Power Cables
MIN
G575VA
C 575VAC to main circuit breaker
(3 Places)

UO
UTG
OIN
G5
75V
AC
VO
UTG
OIN
G5
75V Outgoing Power Cables
AC
WO to Top Drive
UTG
OIN
G5 (3 or 6 Places)
75V
AC

Varco
Rain Cover Control House
Typical
Plug Panel

Procedure
Clean all connector contacts
Connect the power cables with the isolation
circuit breaker turned OFF
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
Lockwire all connector nuts
Earth the control house with the Varco
Ground Rod Kit (See page 4-10)

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Preinstallation
Earthing the control house (land rigs)

Copper Plated
Steel Rod

Cable Clamp

Cable Lug

Copper Wire
10 ft

The control house must


be properly grounded to
prevent injury to personnel

Procedure
Insert the grounding rod into the soil (the rod
Ground Rod Kit
must be in contact with ground water) Grounding Points
Connect the rod to the control house P/N 116004 Located at opposite
(connection must be clean) corners of the house floor

For offshore installations the control house


i must be grounded to the ground point on the
rig structure

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Preinstallation
Checklist
The following assumes that all pre-installation planning and rig-up is
complete prior to installation of the guide beam assembly and TDS.
This includes:
Make sure the derrick/mast is vertical, with the block over the
center of the rotary table .

Derrick/mast modifications are completed (if required) and the


guide bean support bracket and torque reaction beam are
installed per recomendations on the general arangement
drawing.

The service loop bracket is installed in the derrick/mast.

The control panel and frequency drive are installed.

Rigging of tong lines, etc. is inspected to ensure that they will


not foul with the TDS.

The hook or adaptor becket is installed. The hook should open


toward the drawworks when possible.

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Installation
Raising the top guide beam section to the drill floor
Procedure
Locate the top guide beam section near the

V-Doorthe hoist carriage is free to slide the


Ensure
entire length of the guide beam
Ensure the latch moves freely
Attach lifting slings to the lifting eyes of the
hoist carriage
Eusure the transport shipping pins are in
place and secure
Hoist the guide beam section to the drill floor
using a tugger line with a backup line to tail
Remove tugger line after top guide beam is in Hoist
position on drill floor Carriage

Tugger Line
Attachment
Points
(Rig UP)

P
U
N
W
O
D
Tugger Line G
I
3,0000 Lbs Attachment R
Tugger Pull Points
(Rig DOWN)

Top Guide
Beam
Shipping
Latch Pins
2 places

Drill

Floor

Backup
Line

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Installation
Attaching the carriage sling to the hook

Hoist
Carriage

Cable Sling
Attachment
Points
(RIG UP)

P
U
N
W
O
Cable Sling D
G
I
Attachment R
Points
(RIG DOWN)

Top Guide
Beam

Disengage
Shipping Pins

Hoist

Procedure
Cable Sling Attach a short cable sling from the hook/block
to the hoist carriage at the RIG UP
attachment points
Disengage the shipping pins

Hoist the top guide beam using the


drawworks

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Installation
Moving guide beam sections
Procedure
Locate the remaining guide beam sections
near the V-Door
Attach tugger lines to the lifting eyes of the
first guide beam section to be hoisted
Hoist the guide beam section to the drill floor
using the rear tugger line or tailing line to
stabilize and balance the guide beam

Tugger
3,200 lb Line
(1450 kg )
24 ft. G ui de Beam Section

Tugger
Line

Guide Beam Section G uide Beam


Hoist to the drill floor Section
Tugger
Line

Tugger
Line

Lifting Eyes
Attach tugger lines
for hoisting
Drill
Floor

Guide Beam Sections


Prior to Installation

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Installation
Hooking the first guide beam section

Guide Beam
Top Section
1 2
Present Match
Grease
the bores on
both joint halves
Guide
Surface

Radius locks joint


from unhooking
at 8 rotation

Hook Pin Grease


the bores on
both joint halves

3 4

Engage Hook

Hook Pin
In fully engaged
position

Present
and Hook
the first guide
beam section Hook Pin
Saddle

Procedure
Tugger Line
Guide Beam
Leave attached Locate the guide beam to be hooked
Secti o n
to stabilize the under the top guide beam section
Hooke d
back end of Grease the bores on both joint halves
the guide beam
Align the guide surface with the hook pin as

shown
Lower the top guide beam to match and
engage the hook pin to the hook pin saddle
Hoist the top guide beam to fully engage the
hook pin
Manually stabilize the back end of
the guide beam

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Installation
Hoisting the first guide beam section

Guide Beam
Top Section

Hoist

Hook Pin

First Guide
Beam Section
Initially hoisted
by the hook pin

Bar and Radius


Locates pin bores for
easy insertion of pins
Hoist
Using the
drawwork

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Installation
Stabbing and pinning the first guide beam section

1
Guide Beam
Top Section Stab
the guide beam
joints together

Lynch Pin
2

Joint Pin
Install after stabbing

4 3
Secure Retainer Pin
with the Apply grease
lynch pin and insert

Stab
and Pin
the guide
beam joint

Block as Procedure
Required Lower the guide beam to drill floor and stab
the guide beam joints together
Secure the guide beam in a vertical position if
required
Install the cleaned and greased joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown

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Installation
Hoisting and attaching the guide beam

Latch is held in Latch locks beam


unlock position to hang-off link when
when carriage is carriage is lowered
at top position

Diverter To Protect
Against Accidental
Unlatching

Procedure
Hoist Carriage
Attach guide beam Extension
assembly to hangoff link

Procedure Tieback
Handle
Rotate intermediate
tieback handle UP 90
degrees
Insert the intermediate
tieback into the slot
located on the lower
guide beam
Rotate intermediate
tieback handle DOWN 90
degrees to lock the guide
beam in place
Adjust the tieback bracket
so the center of the guide Guide
beam is 30 inches from Beam
well center Slot
Intermediate
Tieback

Attach Intermediate
Tieback into Lower
Guide Beam Slot

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Installation
Removing the hoist carriage

Hoist
Carriage

Drill
Floor Procedure
Lower hoist carriage to drill floor
Remove hoist carriage from drill floor and
store (to be used again for rig down and
transport)

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Installation
Moving the top drive to the drill floor
Procedure
Ensure the safety of all personnel
■ Locate the Top Drive at the bottom of the
V-Door ramp
■ Attach a lifting sling to the bail
■ Attach backup lines to the skid
■ Hoist the Top Drive and skid to the drill floor

30,000 Lbs Crane Lift

30,000 lb
(13600 kg)
TDS-11SA
on the skid

Lifting
Block
Hoist using
the drawwork

Optional Crane Placement

Side Bracket
(2 Places)

TDS
2 hoisted up
V-Door Ramp

Drill Bail
Floor 60 ft Slings Lifting Detail
(2 Places
Typical)

1 TDS Backup
on skid Line

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Installation
Attaching the top drive to the hook

i There are two basic methods for installing the TDS-11SA top drive, depending on the travelling equipment

configuration. Follow the installation procedures for option 1 or option 2 as appropriate for the rig.

Bail Bail Lock TDS-11SA V-Door


Post
Attach Sling
or Tugger Lines
to Secure Skid

V-Door
Ramp

Procedure
Remove hoist cable slings
Attach bail to block or hook
Secure lower end of skid to prevent
movement toward or down V-door
ramp
Hoist using drawworks

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Installation
Lifting the top drive to the rig floor

Option 1 Procedure Option 2 Procedure

Set TDS on the rig floor Hoist the TDS from the v-door
Secure the bottom end of the to a vertical position using
skid to the floor or the v-door slings
posts to prevent the TDS Connect the TDS skid to the
from moving back down the guide beam
v-dor ramp
If the traveling equipment
and the TDS bail length
allows, the bail can be
connected directly to the
hook/block (refer to the
general arrangement
drawing)

Hook open
towards
drawworks

i
Hook open
towards Depending on the
v-door traveling equipment and
bail length, variations of
this procedure may be
required

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Installation
Hoisting and connecting the top drive to the guide beam

Guide 1 2
Beam
Lower Present
Insert hook pin LowerHook
TDS/Skid
Section into hook pin saddle until it makes
contact with Lower
Tieback
Hook Pin
Grease
the bores on Hook Pin
both joint In fully engaged
halves position

Grease
the bores on Hook Pin
both joint Saddle
halves

Guide Beam
/Skid Section
Skid not shown
3

Attach
Lower
Tieback
OPTION
2
Lower
Tieback
Present
and Hook
TDS to the guide
beam section Guide Beam
Hook /Skid Section
Joint Skid not shown

OPTION
1

Procedure
Lower
Tieback Backup Locate the TDS skid to be hooked
Line under the bottom guide beam section
Grease the bores on both joint halves
Align the guide surface with the hook pin as
shown
Lower the TDS skid to match and engage the
hook pin to the hook pin saddle
The lower guide beam section and skid will
contact the lower tieback

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Installation
Attaching the torque tieback

Tieback

Retainer
Pins

Tieback
Tieback Hook
Pivot Pin

OPTION
2

Tieback
Pivot Pin

OPTION Tieback
1 Hook

Procedure
Engage tieback hooks to secure the
lower guide beam/skid
Insert retainer pins

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Installation
Releasing the top drive from the skid

After hoisting the TDS


disengage the Lower
Carriage Latch and pin it
as shown.

Pin

1
View of
Carriage Upper
from Rear Latch
Engaged

Lower
Latch
Pin Disengaged

Pin

Latches
OPTION Both sides
engaged
2

Pin
2
Pin
Upper
Latch
Disengaged

Lower
Latch
Lower the TDS , disengage the
Disengaged
OPTION Upper Carriage Latch
1 and pin it as shown.

Pin

Drill
Floor Option 2 Procedure
Lower the blocks
Remove the slings
Connect the hook/block to the bail
Disengage the carriage latches

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Installation
Installing derrick termination
Hoist Line Derrick/
Attachment Point Mast Leg

Derrick
Leg Plate
Hoist Line Service Loop
Attachment Brackets
Points

Mount the
Derrick
Termination
Plate
as recommended

83 ft
from drill floor

Recommendations
Mount on the side of the derrick adjacent to the
service loop brackets on the Top Drive

Drill Mount as far as practical from well center, to


Floor maintain a 36 inch minimum bend radius

! Maintaining a larger radius increases loop life and


reduces damage due to “pinching”
Location must ensure that the loops do not
catch under the guide beam during operations
and provide clearance for tong lines, the
stabbing board, tugger lines, etc

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Installation
Installing the service loop to the derrick
Hoist
Derrick
Termination Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

!
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the
V-door

Lifting Eyes
Do not remove

Derrick
Service Loop

! Recommendations
Avoid damage to the
service loops by maintaining a Do not unpack the service loops until they are
40 inch minimum ready to hang
bend radius Use a sling attached to the lifting eyes to hoist
each service loop
Service Loop Use the swivel at the tugger line attachment to
and Storage Tub allow each service loop to uncoil without
3,600 lb twisting
(1600 kg)

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Installation, Commissioning
and Decommissioning

Installation
Installing the driller’s console

s V-Door
k
r TDS Ramp
o
w
w
a
r
D

Recommended Area
for Varco Driller’s
Console Location

UE
RQ
TO

Customers who choose to use control


! BR
AK
E
IBO
P

GE
ER P
EMSTO
NC
Y

systems that are not manufactured by Varco PIP


EH
AN
DL
ER

should be aware that Varco systems are


specifically designed with operational
interlocks and safety devices to prevent
possible injury to personnel and damage to
the system. Other control systems must
meet Varco requirements. Varco highly
recommends the use of its system, as it is
specifically made for use with the Top Drive.

Recommendations
Mount within easy reach and in plain view of the
driller while the drawworks brake and clutches
are being operated
Pigtail Cable Location must ensure that the gauges are easily
Connect to seen by the driller during drilling operations
control house Location must be visible and readable at night

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Installation, Commissioning
and Decommissioning

Installation
Installing the driller’s console cabling

COM
POS
ITE
CONNE
CTO
R
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL Profibus Serial Link
CON
NEC
TOR to Driller’s Console

UIN
COM
ING
575
VAC
VIN
COM
ING
575
VAC Plug Panel
WI
NCO
MIN
G575VA
C

UO
UTG
OIN
G5
75V
AC
VO
UTG
OIN
G5
75V
AC
WO
UTG
OIN
G5
75V
AC

Varco
Rain Cover Control House

Plug Panel

Recommendations
Ensure that the Varco Driller’s Console is
properly located

Connect the power


circuit breaker cablesOFF
turned with the isolation

Connect cables in accordance with the


electrical schematic provided in the Technical
Drawings book
Tighten connector nuts
Lockwire connector nuts to prevent loosening

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Installation, Commissioning
and Decommissioning

Installation
Motor rotation checkout procedure
Direction
of Rotation
Counterclockwise
Procedure
Assign the Top Drive and inverter by selecting Direction
FORWARD or REVERSE on the driller’s console of Rotation
Clockwise
Check the rotation direction of the cooling and oil
pump motors
Rotate the drill stem using the THROTTLE on the
driller’s console and observe proper operation

Cooling Motors
2 Places

UE
RQ
TO

RQ
TO
X
MA
P
IBO
PD
IBO Y
NC
E
OS
CL
GE
MERTOP RQ
UE
E S 0
ILL
TO
DR

E D
P LOS AR
IBO C F RW
OF FO X
EN MA
OP E
RS
IVE VE
DRULT RE 0
A
F
Throttle Direction
of Rotation
Counterclockwise
Forward/Reverse
Control
Varco
Driller’s
Oil Pump
Console
TO
RQ
UE Motor
P
IBO
CY
E GEN
ER P
BR
AK
EMSTO

LER
ND
HA
PIPE

Drill Stem

Direction Reverse
of Rotation

Forward

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Installation, Commissioning
and Decommissioning

Installation
Installing the pipe elevator and links

Catch
Link Bolt

Rear Motor
Guard

Catch Link 600-2,400 lb


Pin (270-1100 kg)

R LO
AT Elevator Link
LETILT F
AND
LINK
EH Catch
PIPE HT
T
TA RIG Link
RO
FT
LE ILT
KT T
LINOFF TIL
H L
NC
RELD DRIL
UEW
H O
RQ &
TOPUSH
Front

Pipehandler
Rotate Switch
Link Tilt

Varco
Driller’s
Console
Link
UE
RQ
TO

IBOP
Y
NC
GE
AKE ER
BR EMSTOP

ER
DL
AN
EH
PIP

Clevis
Pin

Procedure
Using the Varco Driller’s Console, rotate the
pipehandler 90˚ (positioning the catch link under

the front of the motor guard)


Lubricate the elevator link eyes with pipe dope
Hoist the elevator link onto the rotating link adapter
(the small link eye at the bottom)
Secure the catch link with the pin and bolt
Secure the elevator link to the link tilt
Rotate the pipehandler 180˚ and install the other
elevator link
Install the pipe elevator in accordance with the pipe
elevator manual

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Installation, Commissioning
and Decommissioning

Commissioning
Checkout procedure
Initial Rig-Up
Pre-charge all accumulators (See the
Hydraulics System section of this manual)
Adjust the hydraulic system
Bleed the air from the hydraulic system Cork Ball
(Level Indicator)
Constantly monitor the hydraulic fluid level, and
never allow the level to fall below the middle of
the sight glass (system power OFF)

Checkout Procedure
Lubricate all grease points (See Lubrication )
Check for loose or missing connectors Sight
Glass
Lockwire all connector nuts
Check for interference along entire mast Hydraulic
Remove exhaust covers from AC drilling motors Oil Sight
Gauge
Check blower inlets and outlets for blockage
Set the air conditioner to 75˚F (27˚C)
Turn on the main breaker

Air Inlet
Between motor
and brake housing,
2 Places

Exhaust Cover
4 Places
T
O
P INS
D T
R
IV WHALL
E UN EN
O
ST IT IS C
OR R
ED A
V

Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places

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Installation, Commissioning
and Decommissioning

Commissioning
Electrical system checkout procedure

Emergency Stop

Latch
9 Places

M
RP

UE
RQ
TO
UE
X
TORQ RPM Meter
MA
P
IBOO
P
IBSED Y
O NC
CL
GE
AK
E ER P UE
BRRAKE EMSTO 0
ILL
TO
RQ
BON DR

ER OA
DL TFL
T
P LOS
IBO C
E
F RW
AR
D Torque Meter
OF FO
AN TIL MA
X
EH LINK EN
PIP T E E
OP
VE
RS
E
E H AK AK IVE RE 0
TAT RIG BRUTO BRON DR LT
RO A FAU
T
EF OF
F
OILLOSS L TILT
S K T
ES LINOFF TIL
PR
H
-UP IT NC
KE LIM RELD RILL
MAENT UEW H O D
RR RQ &
CU TOPUSH
OR
OTP ER
LMEM OW
A XDRILERT ICP ON
M OV UL
RA
MPK HYD
O
0 LAEC UT
RM/ CH A
ALACE
EN
SIL
SS
O
RL
WE
BLO
E
QU
PIN TOR
S

ILL
DR

Procedure
All personnel must stand clear
All personnel operating the Top Drive should be
trained in rig safety and tool operation
Operate each control on the Varco driller’s console
(See Varco FIP00003)
Check for alarm conditions and resolve any alarms
at this time (See Varco FIP00003)
Check all connectors for tightness and lockwire
Check operation of meters
Check operation of emergency stop
Check the latches on the driller’s console for
tightness
Pigtail Cable
Connected to
control house

TDS-11SA Rev. B
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Installation, Commissioning
and Decommissioning

Commissioning
Mechanical checkout procedure
Checking gearbox oil level

Procedure
With the drive motors and hydraulic
system off, check to see that the oil level
(identified by a floating cork ball) is at the
middle of the glass located on the lube
pump adapter plate mounted on the side
of the gearbox
Always check the oil level, not foam level
(oil is dark brown, foam is tan) after the
unit has been running and the
transmission oil is warm
If the oil level is low, add gear oil (see the
Lubrication and Maintenance section of
this manual
Check the red “pop-up” alarm on the gear
oil filter for contamination
Replace the filter (P/N 111013-1) if the
indicator has popped up

Cork Ball
(Level Sight
Indicator) Glass

i i
Gear Oil Gearbox Oil Fill
Sight Gauge Clean area before removing plug,
Check with Top Drive then use a 1 3/8 inch, 12 point
“OFF”
socket to remove plug

“Pop-up”
Dirt Alarm

Gear Oil Filter

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Installation, Commissioning
and Decommissioning

Commissioning
Adjusting the link tilt

i
Jam Nut
Adjust the derrickman position
with the adjusting screw and
lock in position with the jam nut

Link Tilt
Crank
Assembly

Pin

26 inches
(660 mm)
Typical

Clamp

i
Mousehole
Position Cable 3-4 inches
Pull “up” or “down” (76-102 mm)
to set mousehole
position

i
Drill Down
Position
Bottom of elevator
should be above
Link the bottom of the
Mousehole stabbing guide
Position

Derrickman’s Position
Link clamps should be adjusted
so that the elevator does not Elevator
hit the diving board in this position Well Center
Float Position

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Installation, Commissioning
and Decommissioning

Commissioning
Breaking out the saver sub
During normal operation, the torque backup clamp cylinder is
sitting on the springs, which are supported by the bottom plate of
the torque arrestor.
1. Loosen the tool joint lock between the saver sub and the lower
IBOP valve by unscrewing the ten bolts. Refer to the tool joint
lock assembly and disassembly procedures in the
Maintenance section. Slide the tool joint lock down until it
rests on the clamp cylinder body.

2. Raise the clamp cylinder until the clamp cylinder positioning


slot lines up with the first hole on the torque arrestor. Insert
the safety pin through the clamp cylinder and torque arrestor.

3. Select TORQUE mode. Pressurize the clamp cylinder to clamp


on the saver sub by pressing and holding the TORQUE
WRENCH PRESS AND HOLD button.

4. Switch the drilling motor to REVERSE to break out the


connection.

5. Once the connection is broken out, switch to SPIN and allow


the motor to spin until the saver sub and lower IBOP valve
separate. Remove the safety pin. Lower the clamp cylinder
with the saver sub. The saver sub is ready for removal.

6. Unclamp the saver sub by releasing the TORQUE WRENCH


PRESS AND HOLD button.

Stand clear. The saver sub must be supported before


unclamping it. It will fall through the bottom of the
stabbing guide if not supported.

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Installation, Commissioning
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Commissioning

V1 V1
CB1 CB1

CB2 V2 CB2 V2

Upper IBOP
Valve

Clamp
Lower IBOP Body
Valve Positioning
1 Holes
Tool Joint Lock
Torque
Loosen Screws Arrestor Clamp
Cylinder
Safety
Pin
2
Tool Joint Lock
Rest on Clamp
Cylinder
Positioning
Slot

Saver Sub
3
Clamp Cylinder Raise to Next Hole
Using VDC: In Torque Arrestor

4 Support Saver Sub and release


Select TORQUE mode. 8
from Torque Back-up Clamp Cylinder.
5 TORQUE WRENCH PUSH & HOLD.

6 Drilling Motor REVERSE.

7 Drilling Motor SPIN.

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Installation, Commissioning
and Decommissioning

Commissioning
Breaking out the lower IBOP
Remove the saver sub first as described in the previous section.

1. Loosen the tool joint lock between the lower IBOP valve and the
upper IBOP valve by unscrewing the bolts. Slide it down and
rest it on the tool joint lock sitting on the clamp cylinder.

2. Raise the clamp cylinder with the two tool joint locks until the
clamp cylinder slot lines up with the second hole on the torque
arrestor. Insert the pin.

3. Select TORQUE mode. Pressurize the torque backup clamp


cylinder to clamp on the lower IBOP valve by pressing and
holding the TORQUE WRENCH PRESS AND HOLD button.

4. Once the connection is broken out, switch to SPIN and allow the
motor to spin until the upper IBOP valve and the lower IBOP
valve separate.

5. Remove the safety pin. Lower the clamp cylinder with the lower
IBOP. The lower IBOP is ready for removal.

6. Unclamp the lower IBOP valve by releasing the TORQUE


WRENCH PRESS AND HOLD button.

Stand clear. The lower IBOP valve and saver sub must

be supported before unclamping them. They will fall


through the bottom of the stabbing guide if not
supported.

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Installation, Commissioning
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Commissioning

V1 V1
CB1 CB1

CB2 V2 CB2 V2

Torque
Arrestor

Upper IBOP
Valve

Lower IBOP
Valve 7
Loosen Screws Clamp
Cylinder
8 Safety
1 Rest on Pin
Tool Joint Lock Clamp Cylinder
Loosen Screws
9
Raise
2 Clamp
Tool Joint Lock Cylinder
Rest on Clamp to Next Hole
Cylinder

3
Clamp
Cylinder Raise to Next Hole
In Torque Arrestor
Using VDC: (Saver Stub Breakout) Using VDC:
4 Select TORQUE mode. 10 Select TORQUE mode.

TORQUE WRENCH PUSH & HOLD. TORQUE WRENCH PUSH & HOLD.
5 11
6 Drilling Motor REVERSE. 12 Drilling Motor REVERSE.

13 Drilling Motor SPIN.

14 Support Sub and Valve and Release From


Torque Back-up Clamp Cylinder

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Installation, Commissioning
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Commissioning
Making up the lower IBOP
1. Screw in the replacement saver sub and the lower IBOP valve
together manually and stand them under the clamp cylinder (a
pup joint may be used to support it). Position the clamp cylinder
by stabbing over the lower IBOP valve. Make sure the lower
IBOP valve comes up through both tool joint locks sitting on the
clamp cylinder body. Tighten four alternate screws on the top
tool joint lock to secure it to the lower IBOP valve to provide a
temporary shoulder to support the weight of the lower IBOP
valve and the saver sub.

Make sure all four screws are tightened sufficiently so


that the tool joint will not slide through when the

clamp cylinder is raised.

2. Select SPIN and FORWARD modes.

3. Raise the clamp cylinder with the lower IBOP valve and saver
sub while rotating the upper IBOP to engage the threads. Once
the upper IBOP valve and the lower IBOP valve start to spin
together, stop the drilling motor.

4. Lower the clamp cylinder and line up the first slot and hole on
the clamp cylinder and the torque arrestor. The clamp cylinder
jaws line up with the saver sub.

5. Select TORQUE mode. Pressurize the torque backup clamp


cylinder to clamp on the saver sub by pressing and holding the
TORQUE WRENCH PRESS AND HOLD button.

6. Switch the drilling motor to FORWARD. Select SPIN mode and


rotate the drilling motor. Select TORQUE mode and apply
desired torque and makeup both connections.

7. Release the TORQUE WRENCH PRESS AND HOLD button to


unclamp. Lower the clamp cylinder all the way using the winch.

8. Loosen the temporarily made-up tool joint lock. Position both


tool joint locks correctly and follow the proper assembly
procedure described in the Tool joint locks section.

TDS-11SA Rev. B
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Installation, Commissioning
and Decommissioning

Commissioning
Breaking out the upper IBOP
Refer to the illustration on the next page. Remove the saver sub
and the lower IBOP first, as described in the previous section.

i The saver sub and the lower IBOP can be removed as one unit by
breaking the connection between the upper and lower IBOPs.
1. Lower the clamp cylinder with the broken out lower IBOP
valve and the saver sub.
2. Unclamp the lower IBOP valve/saver sub assembly by
releasing the TORQUE WRENCH PRESS AND HOLD button.
3. Remove the two tool joint locks sitting on the clamp cylinder.

Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.

4. Remove the IBOP actuator yoke by unpinning it at three


places.

5. Remove the two upper IBOP cranks by unscrewing the 2 sets


of screws.

6. The IBOP actuator shell stays on the upper IBOP valve


assembly.

7. Loosen the top tool joint lock and rest it on the actuator shell.
8. Raise the clamp cylinder with the actuator shell and the tool
joint lock until the third slot and hole line up. Insert the pin.

9. Select TORQUE mode. Pressurize the clamp cylinder to clamp


on the upper IBOP valve by pressing and holding the
TORQUE WRENCH PRESS AND HOLD button and switch to
REVERSE.

10. Switch the drilling motor to REVERSE to break the


connection.

11. Once the connection is broken out, switch to SPIN and allow
the motor to spin until the upper IBOP valve and drive stem
separate.

12. Remove the safety pin. Lower the clamp cylinder with the
upper IBOP. The upper IBOP is ready for removal from the
clamp cylinder.

13. Unclamp the upper IBOP valve by releasing the TORQUE


WRENCH PRESS AND HOLD button.

14. Remove the tool joint lock and the actuator shell.

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Installation, Commissioning
and Decommissioning

Commissioning

V1 V1
CB1 CB1

CB2 V2 CB2 V2

10
Tool Joint
Lock
Loosen
Upper IBOP 9 Screws
Valve Remove Clamp
Actuator Cylinder
1
Tool Joint Yoke Safety
Pin
Lock
Loosen
Screws

2
Tool Joint
Lock
Rest on
Clamp
Cylinder

11
Raise to Next Hole
Clamp
Cylinder
8 In Torque Arrestor
Support Saver Sub/
Lower IBOP Valve
and release from
Clamp Cylinder.
3 Remove Lower
Raise to Next Hole Tool Joint Locks.
In Torque Arrestor

Using VDC: Using VDC:

4 Select TORQUE mode. 11 Select TORQUE mode.

5 TORQUE WRENCH PUSH & HOLD. 12 TORQUE WRENCH PUSH & HOLD.

6 Drilling Motor REVERSE. 13 Drilling Motor REVERSE.

7 Drilling Motor SPIN. 14 Drilling Motor SPIN.

TDS-11SA Rev. B
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Installation, Commissioning
and Decommissioning

Commissioning
Making up the upper IBOP
1. Place the upper IBOP valve on the floor under the clamp
cylinder so that the clamp cylinder can be stabbed over it (a
pup joint may be used to support it). Lower the clamp cylinder
so that the upper IBOP comes up through the clamp cylinder.
Place the actuator shell and tool joint lock over the upper
IBOP and tighten four alternate locking screws to secure it to
the upper IBOP, providing a temporary shoulder to support its
weight.

2. Install the actuator shell and the cranks.

3. Raise the clamp cylinder with the upper IBOP valve while
rotating the drive stem clockwise to engage the threads. Once
the drive stem and upper IBOP valve start to spin together,
stop the motor, switch to FORWARD and SPIN and press and
hold the TORQUE WRENCH PRESS AND HOLD button to
spin in.

4. Spin the lower IBOP and saver sub into position (refer to the
appropriate procedures in the previous sections). Make sure
that the two tool joint locks are properly installed on the clamp
cylinder and in the correct sequence.

5. Release the TORQUE WRENCH PRESS AND HOLD button


to unclamp. Lower the clamp cylinder until it lines up with the

first hole. Now the clamp cylinder is lined up with the saver
sub.

6. Select TORQUE mode. Pressurize the clamp cylinder to clamp


on the saver sub by pressing and holding the TORQUE
WRENCH PRESS AND HOLD button and apply desired
torque to makeup all three connections.

7. Place the three tool joint locks at their respective joints. Install
the three tool joint locks by using the proper assembly
procedure described in the Tool joint locks section.

8. Install the IBOP actuator yoke and secure it.


9. Remove the winch and store it in its box.

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Installation, Commissioning
and Decommissioning

Decommissioning
Securing the TDS for rig-down
Procedure
Lower the Top Drive to the drill floor
Remove the mud hose, drill pipe elevator
and links
Power may be needed to turn rotating head
into position for removing the links
Locate the RIG-UP/RUN/SHUTDOWN valve
on the hydraulic manifold
With the hydraulic power ON select the
“RIG-UP” position and remove the extended
counterbalance cylinders from the hook ears
Select the “SHUTDOWN” position and turn
off the Top Drive
Isolate and lock out ALL power to the Varco
control house

Hydraulic
Manifold

N
W
DO R
UN
UT
SH

Lower CO
UN
T ER
BA
LA
NC P
-
U
I
G
R

the TDS to
E
MO
DE

the drill floor


Rig-up/Run/
Shutdown Valve
Rotate from RIG-UP to
SHUTDOWN for Top Drive rig-down

RUN
Drill N
Floor W R
O IG
D
T -U

H
U P
S
COUNTERBALANCE MODE

TDS-11SA Rev. B
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Installation, Commissioning
and Decommissioning

Decommissioning
Removing and storing the electrical cables
and service loops
Derrick
Termination Lower
Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

!
Avoid damage
to the service
loops by using
care when
dragging it near
sharp edges
and allow room
for passing under Derrick
the V-door Service
TDS Loop
Service
Loop

! Lifting Eyes
Avoid damage to Do not remove
the service loops by
maintaining a Procedure
36 inch minimum
bend radius Position the service loop tubs for convenient
loading of the service loops
Disconnect the derrick service loop from the
An electrical short can occur if quick
derrick termination plate and the control house
connectors are not kept clean and dry.
Whenever separating quick Disconnect jumper cables (if installed)
connector(s), immediately install Cap all connectors and lower the derrick service
the weather plugs to prevent loop into a service loop tub
connectors from becoming Use a sling attached to the lifting eyes to lower
contaminated with water or debris. each service loop and a swivel at the tugger line
When the connector is not in use attachment to allow each service loop to coil
secure/locate the connector so that is without twisting
Service
does not lie on the ground and make
Loop and Disconnect the Top Drive service loop and repeat
sure to minimize any exposure to water,
Storage Tub the above procedure
mud, etc. Prior to re-connecting, inspect
3,600 lb
the inside of the connectors to make Remove the service loop tubs from the area
(1600 kg)
sure they are clean and dry. Remove the derrick termination plate if necessary

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Installation, Commissioning
and Decommissioning

Decommissioning
Setting the latches and locking the bail
Counterbalance
View of Cylinders

Carriage
from Rear Disconnect
from the hook

Exhaust
Cover T
O
P
D
R
IV
IN
STA
WH LL
UN EN
E O
STOIT IS C
R

4 Places
RED A
V

Pin

Latches
Both sides
engaged
Lower
the TDS to
the drill floor

Pin

Procedure
Lower the Top Drive to the Drill Floor
Drill It is NOT necessary to drain gear oil or
Floor hydraulic fluid for rig down
Disconnect the counterbalance cylinders
from the hook
Install exhaust covers
Engage the upper and lower carriage
latches as shown
Remove TDS using the reverse of
installation procedure

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Installation, Commissioning
and Decommissioning

Decommissioning
Long term storage procedures
Top Drive Long Term Storage Procedures
For indoor storage, cover the Top Drive in its shipping and handling skid. A cargo

container is appropriate for outdoor storage.


Avoid wide variations in temperature and high humidity. The preferred environment is
clean and dry at 60˚ -80˚F ambient.
All exposed unpainted metal surfaces are coated with a rust preventive 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. Make sure that the gearbox
and hydraulic systems are properly filled. Use rust inhibitors where appropriate.
Cover all openings to prevent water or dust from entering. Leave enough space
around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent.
During storage, rotate the motors and gear train periodically to distribute lubricant.
Perform this at three month intervals if stored indoors, and at one month intervals if
stored outdoors.

For long term storage recommendations dealing with the AC drilling motors, see the
motor manufacturer’s manual.

Returning the Top Drive to Service After Storage


Remove all rust preventive and any corrosion that may have taken place, taking
special care with load carrying components.
Repaint the tool if necessary.
Follow the return to service procedures in the AC drilling motor manufacturer’s manual.
Check for water and remove if any is found.
Change the hydraulic fluid and gearbox oil.
Lubricate the cooling and oil pump motors.
Lubricate the tool with general purpose grease.
Megger all motors (> 2 meg ohm on cold motor).

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Guide Beams and Carriage

Inspecting the crown padeye and hang-off link 5-2


Inspecting the guide beam joints....................... 5-3

Inspecting the main tieback .............................. 5-4


Inspecting the intermediate restraints .............. 5-5
Inspecting the carriage ...................................... 5-6

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Guide Beams
and Carriage

Inspecting the crown padeye and hang-off link


Crown
Cotter Pin
2.1" Replace if missing
(52 mm) Yearly
Monthly
minimum
Crown Padeye

Monthly
Crown Padeye
Visually inspect
weld for cracks

Shackle

2.0"
(50 mm)
minimum

Monthly
Shackle
Inspect and
replace if worn

Monthly

1.5" Hang-off Link Bores


(37 mm) Inspect and
minimum repair if worn

Hang-off Link Bores

Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.

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and Carriage

Inspecting the guide beam joints

!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Replace
any missing or damaged pins.

Secure

Daily

Lynch Pin

Weekly

Joint Pin

Yearly

Typical Guide
Beam Joint
Daily
Retainer Pin

Monthly

Inspect welds
for cracks

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Inspecting the main tieback


Guide Beam
Bottom Section
Daily

Check that the tool is aligned


directly over well center

Main
Spreader Beam

Tieback Plate

Yearly
Tieback Link
Inspect retainer pins,
tieback hooks, and
pivot pins for wear.

Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.

Auxiliary Spreader Beam

Mast Leg

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and Carriage

Inspecting the intermediate tieback


Intermediate
Tieback
(Shown in Locked
Position)

Locking
Bolt

Pivot
Point

Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.

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Inspecting the carriage

Weekly

allTypical
rollers
Inspect for uneven
wear, damage and
looseness, replace
as required

Yearly

Bogey (16)
Disassemble,
inspect for wear,

and relubricate

Daily

Typical all
detent pins
Verify that pins
are in place
and secure

See General Information


for torque values

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Transmission

Illustrated index ................................................. 6-2


Inspection schedules ......................................... 6-3

Inspecting the internal lubrication flow ............ 6-4


Adjusting the encoder ........................................ 6-5
Gearbox lube pump assembly ............................ 6-7
Disassembling/assembling the gearbox lube pump ...... 6-7
Inspecting the gearbox lube pump assembly ................ 6-8

Inspecting gear backlash ................................... 6-9


Inspecting the bail and main body ..................... 6-10
Inspecting the S-pipe ......................................... 6-11
Inspecting the upper mainshaft liner ................. 6-12
Washpipe assembly ............................................ 6-13
Assembling the washpipe assembly .............................. 6-13
Inspecting the washpipe assembly ................................ 6-14

Inspecting the upper bonnet seals .................... 6-16


Mainshaft ............................................................ 6-17
Inspecting the mainshaft ............................................... 6-17

Inspecting mainshaft end play ....................................... 6-18


Inspecting the blower motor assemblies .......... 6-19
Inspecting the motor brakes .............................. 6-20
Inspecting the AC drilling motors ...................... 6-21
Disassembling/assembling the transmission..... 6-22
Performing nondestructive Examination (NDE) . 6-23
Making visual inspections .............................................. 6-23
Performing Magnetic Particle Inspections (MPI) ........... 6-24
Perfoming Ultrasonic Inspections .................................. 6-25
Inspecting the safety valves (IBOP) .............................. 6-25

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Illustrated index

AC Motor
Bail
Blower
Page 6-10
Assembly (2)
Page 6-19

S-Pipe
Page 6-11
AC Motor
Brakes (2)
Page 6-20

AC Drilling Washpipe
Motors (2) Assembly
Page 6-21 Page 6-13

Gearbox
Gearbox
Lubrication
Assembly
Pump Assembly
Page 6-4, 6-7
Page 6-7

Gear Oil Filter


Page 3-2, 3-4

For AC motor and


transmission lubrication
see Page 3-2 through 3-12

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Inspection schedules
Daily Page Number

Check for missing lockwire and cotter pins

Check for loose or broken parts and leaks

Check for damaged hoses and fittings

Check the wash pipe assembly for leaks See page 6-13

Check fluid levels and filter condition See page 3-4

Weekly

Check the AC motor louvers for damage See page 6-21

Check the AC motor screens for contamination See page 6-21

Monthly

Check the flow of oil throughout the main body while the lube pump is running See page 6-4
Check the blower motor assemblies for loose bolts See page 6-19

Check brake pads for wear See page 6-20

6 Months

Check the gear teeth for pitting and corrosive wear See page 6-9

Check for primary and secondary gear set backlash See page 6-9

Check the S-pipe for pitting, corrosion, or erosion See page 6-11

Check the upper mainshaft liner for erosion caused by leaking wash pipe packing See page 6-12

Yearly

Check the gearbox lubrication pump assembly for wear or damage See page 6-8

Check bail, bushings and bail pins for wear See page 6-10

Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear See page 6-16

Check the radial grooves on the stem and the load collar for wear See page 6-17

Check the mainshaft for axial movement See page 6-18

Megger motors

5 Years

Magnetic particle inspection (MPI) See page 6-24

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Inspecting the internal lubrication flow


Procedure
■ Remove the 3 in pipe plugs from the main
body and check the flow of oil coming from
the four spray nozzles (two in the body, two in
cover) while the lube pump is operating
■ Check that oil is running out of the upper gear
drain holes in each compound gear set
(indicates upper orifice is not blocked) and
that oil is running through the spillway running
from the thrust bearing (indicates orifice is not
blocked)

Pipe Plug

Pipe Plugs

Monthly

Upper
Compound
Gear Drain Hole
Check flow

Monthly

Body Spray
Nozzles
Cover spray Monthly
nozzles not shown
Spillway
Check flow

Pipe Plug
Remove using a
2 inch, 12 point socket

Main Body

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Adjusting the encoder


Use the following procedure to adjust the encoder belt tension:

1. Remove the access covers

2. Disconnect all of the electrical connectors from the encoder.


3. Remove the lockwire and loosen the four sled hold-down
screws.

4. Allow the sled to move freely, allowing the belt tension spring to
apply the proper tension to the belt.

! Do not tension the belt by hand.

5. Carefully tighten the sled hold-down screws and torque them to


7 ft lb.

6. Lockwire the sled hold-down screws.

7. Reconnect the encoder electrical connections.

8. Replace both access covers and tighten the access cover


screws to 15 ft lb and lockwire them.

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Adjusting the encoder

Sled
Hold-down
Belt Tension Screws
4 Places
Spring
View from Side

Encoder Belt Sled

View from Top


(Blower Motor
removed for clarity)

Electrical
Connector
Sled
Encoder Belt

Encoder

Belt Tension Sled Hold-down


Spring Screws
(Allow the sled to move
freely before tightening)
4 Places

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Gearbox lube pump assembly


Disassembling/assembling the gearbox lube pump
Disassemble the gearbox lubrication pump assembly and inspect
the pump assembly components yearly for wear and damage as
follows:
1. Drain the gearbox oil and disconnect the hydraulic lines from the
pump assembly

2. Remove the pump assembly by removing the eight lockwired


capscrews that attach the pump adapter plate to the main body

3. Disassemble the spline adapter, pump, and housing using the


pump vendor service instruction HS15 (located in the Vendor
Documentation Package)

4. Inspect the pump assembly components, replacing any parts


that are worn or damaged. Pay particular attention to the spline
between the pump and motor, the gears, and the motor and
pump sideplates.

5. Assemble the lubrication pump assembly in the reverse order of


disassembly

i Follow the pump vendor service instruction HS15 (located in the


Vendor Documentation Package) when assembling the lubrication
pump components, and torque all fasteners in accordance with
DS00008.

i When reinstalling the pump assembly into the main body, inspect
the O-ring for damage and replace the O-ring if any flat spots, nicks,
or other damage is found.

6. Install the pump assembly into the main body. Torque the
fasteners in accordance with DS00008, and reconnect the
hydraulic and electrical connections.

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Gearbox lube pump assembly


Inspecting the gearbox lube pump assembly
End Cover

Yearly Thrust Plate


2 Places
Ring Seal
Gearbox Lubrication
Body Seal
Pump Assembly
2 Places
Check parts for wear or damage
Gear
Housing

Gear Set
Roller Bearing
4 Places

Pump
Adapter Plate

Capscrew
10 Places

Hydraulic Motor
Low-Speed/High-Torque
O-ring Main Body

Procedure
Drain the gearbox oil and disconnect the
hydraulic lines from the pump assembly
Remove the pump assembly by removing the
ten lockwired capscrews that attach the pump
adapter plate to the main body
Disassemble using the drawings in the
Technical Drawing Package as well as the
pump vender service instruction
Inspect and relace any parts that are worn or
damaged

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and Transmission

Inspecting gear backlash

A 6 Months

Gear Teeth
Check for wear, pitting,
and gear set backlash

B Solid Wire Solder

A B

Dim. A + Dim. B = Backlash

Procedure

i Inspect the pump adapter plate at the same


time the gear backlash is checked

Drain the gearbox oil


Remove the access cover and the pump
adapter plate to check primary and secondary
gear set backlash
Run a piece of solid wire solder through the
primary and secondary gear meshes and
measure the thickness of the two flat spots
made by the gear teeth surfaces with a
micrometer
If the primary gear mesh backlash exceeds
.030 in. or the secondary gear mesh backlash
exceeds .040 in., excessive gear wear or
bearing failure may be indicated

i Check the gear teeth for pitting or corrosive


wear at the same time the gear set backlash
is checked

i Record backlash data for future reference

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and Transmission

Inspecting the S-pipe


Procedure
Unscrew the two nuts that hold the S-pipe in Wing Nut
place along with the six bolts that secure the
clamp to remove and inspect the S-pipe
Clean the bore of the S-pipe and inspect for Seal Ring
visible signs of pitting, corrosion, or erosion
Plug
Use a flashlight and mirror to visually inspect the
i bore of the S-pipe. A Bore-o-Scope is best for
6 Months

inspection, if available. Pressure test to


rated working pressure
Remove and perform an ultrasonic inspection
on the S-pipe if visual inspection indicates
erosion or corrosion
6 Months
Check condition of the seals
Apply pipe dope to the threads before S-Pipe
re-installing Check for
visible signs of pitting,
corrosion, or erosion
(pitting or corrosion
should be no deeper
than 0.125 inch)

Clamp

Bolts

Seal Ring

Right-hand (inside of guard)


configuration shown. Your S-pipe Wing Nut
configuration may vary.

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Inspecting the upper mainshaft liner


Procedure
Remove the wash pipe assembly
Check the upper mainshaft liner for erosion
caused by leaking wash pipe packing and
replace the liner if erosion is found. The
upper surface of the mainshaft liner must be
flat and smooth

The Polypack Seal must also be replaced


i whenever the upper stem liner is replaced

Grease the Polypack Seal and clean the


mainshaft bore before re-installing Wash Pipe
Make sure the O-ring of the seal is facing Assembly

6 Months
Upper
Mainshaft Liner
Replace ONLY if
erosion is found
during inspection

Polypack
Seal

Polypack Seal
Replace the Polypack
Seal when the upper
mainshaft liner is replaced
Main Shaft
Remove any
corrosion found on
bore of mainshaft

Upper
Mainshaft Liner

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Washpipe assembly
Inspecting the washpipe assembly

!
The wash pipe nut and
the packing box have
left-handed threads

Dowel Slide the


wash pipe nut
Pin and the packing box
together for installation

Hand pack all seals


with multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void

Ensure that the nose of the


socket head dog nose screw
is fully engaged in the groove of
the lower spacer

Special Tools

3" Bore
Wash Pipe Wrench
30150084

Recommended for proper


tightening of the wash pipe
nut and packing box

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and Transmission

Washpipe assembly
Inspecting the washpipe assembly

O-Ring

Snap Ring

Holding Ring

Upper Spacer
Packing Seal
Daily 5 per set

Wash Pipe
Assembly Wash Pipe
Inspect for leaks Nut

Middle Spacer

Wash Pipe

Middle Spacer

Packing
Assembly Box

Straight Ext. Lower Spacer


Grease Fitting

Socket Head
Dog Nose Screw
O-Ring

Procedure
Visually inspect the wash pipe assembly for leaks
Replace any worn or damaged parts
Apply pipe dope to the threads before installing in
the Top Drive

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Motor Housing
and Transmission

Inspecting the upper bonnet seals

Procedure

Remove the bearing shield, the bearing retainer Bearing


cap screws, and the bearing retainer Retainer
Inspect the bearing isolator, the oil seal, and the Cap Screw
retainer o-ring for wear 6 Places
Replace any worn or damaged parts

i Align the shims so that the bearing lube


tube bore is not blocked
Bearing
Shield

Bearing
Retainer

Lube Tube

Oil Bearing Bearing


Isolator
Seal Retainer Lube Tube O-Ring
Cap Screw 2 Places
Bearing 6 Places
Shield
Bearing
Retainer
Retainer Yearly
O-Ring Retainer O-Ring

Yearly
Bearing Isolator

Yearly

Lube Tube Oil Seal

Shims

Hand pack the


void with grease

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Mainshaft
Inspecting the mainshaft
Wear allowances
Component Replace when

Stem Grooves Groove width exceeds 0.650 in.


Load Collar Groove width is less than 0.620 in.
Grooves

Stem
5 Years
Split Load Collar
Yearly

Radial Grooves
Inspect for groove
wear and pitting Radial Grooves
0.650 Inspect for groove
Yearly
wear and pitting
max Yearly

0.620
min

Retainer Ring

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Mainshaft
Inspecting mainshaft end play

Dial
Indicator

Mainshaft Bearing Retainer


Check for Cap Screw
axial movement 6 Places
Yearly

Shims

Bearing
Retainer

Procedure
Check mainshaft endplay with every washpipe
changeout
Remove the washpipe assembly
Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator
If axial shaft movement is not .001 in. to .002 in.,
remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .002 in. of axial

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Inspecting the AC drilling motors


Procedure

Check for missing or damaged louvers


Check screens for contamination

Check motor leads for damage


Check for missing lockwire
Megger motors yearly

Weekly
Motor Leads
Check for damage

Weekly
Louvers
Check for damage

Weekly
Screen
Check for contamination

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Motor Housing
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Performing 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.

Making visual inspections


Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.

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Nondestructive Examination (NDE)


Performing Magnetic Particle Inspections (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 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:

Mainshaft (lower portion)

Bail

Landing collar (yearly)

Upper and lower IBOP

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. Drilling Manual, 9th Edition

ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings

ASTM E-709 Std. Recommended Practice for Magnetic Particle Inspection

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Nondestructive Examination (NDE)


Perfoming Ultrasonic Inspections
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 load-
carrying capability of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.

Inspecting the safety valves (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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PH-75 Pipehandler
PH-75 Pipehandler

Pipehandler illustrated index ............................. 7-2


Inspection schedule ........................................... 7-3
Precautions ......................................................... 7-4
Elevator links ...................................................... 7-6
Disassembling/Assembling the elevator links ................ 7-6
Inspecting the elevator links .......................................... 7-7
Link tilt ................................................................ 7-9
Disassembling/assembling the link tilt ........................... 7-9
Inspecting the link tilt ..................................................... 7-10
Torque wrench assembly ................................... 7-11
Disassembling/assembling the clamp cylinder body ..... 7-11
Removing the clamp cylinder body ................................ 7-13
Disassembling/assembling the clamp cylinder body ..... 7-14
Inspecting the clamp cylinder body ............................... 7-15
Inspecting the IBOP actuator cylinder and yoke ............ 7-17
Well control system ............................................ 7-19
Assembling/disassembling the tool joint locks ............... 7-19
Inspecting the tool joint locks ......................................... 7-20
Inspecting the IBOP valves and saver subs .................. 7-21
Shot pin assembly .............................................. 7-22
Disassembling/assembling the shot pin assembly ........ 7-22
Inspecting the shot pin assembly .................................. 7-23
Rotating link adapter/load stem ......................... 7-24
Removing the pipehandler and link tilt from the top drive
(while in mast) ............................................................... 7-24
Disassembling the link tilt assembly .............................. 7-24
Inspecting the rotating link adapter ................................ 7-25

Assembling the link adapter .......................................... 7-26


Assembling the link adapter to the top drive
(while in mast) ............................................................... 7-27
Performing nondestructive examination (NDE) . 7-28
Visual inspection ........................................................... 7-28
Performing magnetic particle inspections (MPI) ............ 7-29
Performing ultrasonic inspection ................................... 7-30
Inspecting the safety valves (IBOP) .............................. 7-30

TDS-11SA
TDS-11SA Rev.
Rev. BB
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PH-75 pipehandler illustrated index

Rotating Link
Adapter
Page 7-24

Link Tilt
Page 7-8

IBOP Actuator
Yoke and Cylinder
Page 7-17

Stabilizer
Page 7-15

Clamp Cylinder
Body
Well Control System Page 7-10
Page 7-19

Stabbing Guide
Page 7-13

Drill Pipe Elevator


and Elevator Links
Page 7-5

For pipehandler lubrication


see Page 3-13

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PH-75 Inspection schedule


Daily Page Reference

Check for missing lockwire and cotter pins


Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check tong dies for wear See page 7-14
Check clamp cylinder for leaks See page 7-14
Check hoses for wear or damage See page 7-17
Check tool joint locks for tightness See page 7-20
Check upper and lower IBOP valves for proper operation See page 7-21

Weekly

Check link tilt clamps for position and tightness See page 7-6
Check stabbing guide and flippers for damage and wear See page 7-14

Check clamp cylinder gate hinge pin for wear See page 7-14
Check IBOP actuator cylinder for leaks See page 7-17
Check IBOP actuator cam followers for wear or excessive play See page 7-19
Check upper and lower IBOPs and IBOP crank for damage (if equipped) See page 7-21
Check shot pin assembly for leaks See page 7-23

Monthly

Check elevator link eyes for wear See page 7-8


Check link tilt bushings for wear See page 7-9
Check link tilt actuator cylinders for leaks See page 7-9

Check link tilt actuator cylinder pins for wear See page 7-9
Check clamp cylinder body wear bushings for wear See page 7-14
Check stabilizer springs for damage See page 7-16
Check front and rear stabilizers for wear See page 7-16
Check pins and bushings on IBOP actuator cylinder and yoke for wear See page 7-17
Check shot pin assembly for wear or damage See page 7-23

Yearly

Check piston ring for pitting and chipping See page 7-25
Check stem for pitting, grooves and chipping See page 7-25

Replace GLYD rings, o-rings and bushings on rotating link adapter See page 7-25

5 Years

MPI Inspection See page 7-31

i After inspecting above components, repair or replace as necessary.

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PH-75 Pipehandler

Precautions

To avoid serious injury or death, read and understand the following


warnings before performing inspection and maintenance
procedures:

Properly lockout the main power source before


performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from


fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is


moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil


under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious
injury. Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.

Always discharge the three hydro pneumatic


accumulators before performing repairs on the
hydraulic system.

Do not attempt repairs you do not understand.

Read and understand all safety precautions and


warnings before performing maintenance procedures.

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Shutting Down the Top Drive Starting Up the Top Drive


Use the following procedure before Before turning the main power back on,
performing any work on the Top Drive. be sure that all rig personnel are well
clear of the TDS, pipehandler and all
Operate the Link Tilt control on the VDC to
link tilt system components.
the "FLOAT" position prior to shutting down
the TDS. Turn the hydraulic control switch on the TDS
Make sure that the elevator links are hanging from the "SHUTDOWN" to the "RUN" mode.
vertically. Turn the main power "ON" at the main power
Turn the UIBOP valve control to the "OPEN" breaker in the VFD house. Reset brake. You
position on the VDC. may then function test the TDS after repairs
have been made.
Turn the main power "OFF" at the main
power breaker in the VFD house.
Turn the hydraulic control switch on the TDS
hydraulic manifold (Figure 1) from "RUN" to
"SHUTDOWN" mode.
Attempt to function test the LINK TILT
(Derrickman and Drilldown), the UIBOP, and
pipehandler left and right rotation. If none of
these functions operate, all hydraulic
pressure is off.

Rig-up/Run/
Shutdown Valve
Shown in RIG-UP
position (switch to RUN
i
after the counterbalance Typical location for
is installed) Rig-up/Run/
Shutdown Valve.
RUN This valve may be in
a different location
N
W on your TDS.
R
O I
T
D -G
U
U P
H
S

COUNTERBALANCE MODE

N
OW R
TD U
N
HU
CO
S

Hydraulic
UN
TE R
RB I
G
AL -
P U
AN
CE
MO

Manifold
DE

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PH-75 Elevator links


Disassembling/Assembling the elevator links
1. Disconnect and remove the drill pipe elevator from the
elevator links.

2. Using the Varco Driller’s Console (VDC), rotate the


pipehandler 90 ° to position one of the elevator links directly
below the front of the motor guard.

3. Remove the catch link bolt from the catch link.

4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.

5. Using the sling, hoist the elevator link away from the
pipehandler.

6. Rotate the pipehandler 180 °, repeat the procedure to remove


the other elevator link.

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Elevator links
Inspecting the elevator links

Recess in
Motor Guard

950 lb
(431 kg)
Elevator Link
2

Lift and
Link Tilt
remove

Catch Link Pin


Upper
Catch
Link Monthly
Elevator
Link Eyes
Inspect for wear
26"
(see table)
(635mm)
Typical
Rear
LE RO IPE
P
FT TA H
TE AN
DL
RIG LI ER
HT NKT
ILT
FL
OA
Clevis Pin
T
TO
RQ
PU UE
SH WR
Link
&H EN
OL CH
D
DR LINK
ILL O TIL
FF T
TIL
T

Pipehandler
Rotate Switch Weekly
Front Link Tilt Clamps
Inspect for position
and tightness

1
PIP
EH
AN
DL
ER
Rotate
BR
AK
E

IBO
P

EM
ER TO
STGENC RQ
UE
OP Y

Monthly
Elevator
Varco TO
RQ
UE Link Eyes
Driller’s Console Inspect for wear
RP
M
(see table)

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Elevator links
Inspecting the links (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 2 7/8 in., 250-Ton

4 7/8 inches 2 3/16 inches 225

4 3/4 inches 2 1/16 inches 200

4 1/2 inches 2 inches 175

4 3/16 inches 1 7/8 inches 150

B = 3 1/2 in., 350-Ton B

5 inches 2 3/4 inches 350

4 13/16 inches 2 9/16 inches 300


4 5/8 inches 2 3/8 inches 225
B
7 7/16 inches 2 3/16 inches 175

B = 4 1/2 in., 500-Ton

6 inches 3 1/2 inches 500


A
5 3/4 inches 3 1/4 inches 420

5 1/2 inches 3 inches 325

5 1/4 inches 2 3/4 inches 250

B = 6 1/4 in., 750-Ton Lower


Eye
7 1/2 inches 7 1/2 inches 750 (Elevator)

7 1/4 inches 7 1/4 inches 725

7 inches 7 inches 700 A


6 3/4 inches 6 3/4 inches 650

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.

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PH-75 Pipehandler

PH-75 Link tilt


Disassembling/assembling the link tilt
1. Shutdown the power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines from the link tilt cylinders and cap
all connections.

3. Unpin and remove the link tilt cylinders.

4. Unpin and remove the link tilt crank.

i Use the recommended spanner wrench to remove the rod gland


seal.

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PH-75 Pipehandler

PH-75 Torque wrench assembly


Disassembling/assembling the clamp cylinder body
1. Shutdown power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines on the clamp cylinder body and


cap all connections.

3. Support the clamp cylinder body.

4. Remove the two hex-head capscrews and lockwashers that hold


the end cap in place.

5. Remove the end cap, spring spacer, spring sleeve, and spring.

6. Slowly lower the clamp cylinder body off the torque wrench
frame and move it to a suitable work area.

7. Remove the 16 hex-head screws and lockwashers that hold the


wear bushings on the clamp cylinder body.

8. Remove the four wear bushings, and replace the wear bushings
as necessar y.

9. Remove the two hinge pin retainer hex-head screws.

10. Swing out the two hinge pin retainers.

11. Remove the two hinge pins.

12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.

13. Remove the two socket-head capscrews and hi-collar washers


from the front jaw.

14. Remove the front jaw from the gate.

15. Repeat steps 11 and 12 for the rear jaw.

16. Push the cylinder head in enough to relieve the load on the
cylinder head ring. Remove the cylinder head ring. Use care in
this operation.

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Torque wrench assembly


17. Slowly pull out the cylinder head using the threaded holes.
Remove and discard the piston seal.

18. Carefully push the piston out of the body. Remove and discard
the piston seal.

19. Remove the wiper rod and rod seal from the body. Discard the
seals.

20. Clean the piston, cylinder head, and the body. Clean and
lightly lubricate the new seals and seal surfaces prior to
reassembly.

i Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

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Torque wrench assembly


Removing the clamp cylinder body

Clamp Cylinder
Safety Pin
Store Position

Torque
Arrestor

Clamp Cylinder
Safety Pin

Clamp Cylinder
Hanger

Clamp
Cylinder
Assembly

Spring

Spring
Post Support clamp
cylinder body
before removing
Bottom Bottom Plate.
Plate

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Torque wrench assembly


Inspecting the clamp cylinder body
Wear allowances

Component Replace when


Stabilizer Wear exceeds 1/8 in. (radius >3.625")
Flippers Wear exceeds 1/8 in. (radius >3.625")
Gate Hinge Pins Wear exceeds .06 in.

V1
CB1

CB2 V2

Clamp Cylinder
Front and Gate Hinge Pin
Rear Stabilizers Check for pin wear,
Inspect for wear replace as necessary
Weekly 6 Months

Tong Dies
Inspect for
Daily
excessive wear
Daily
Clamp Cylinder
Check for leaks,
replace seals
as necessary

Swing Clear

Weekly
Clamp Weekly Stabbing Guide
Cylinder Gate Inspect for damage
Flippers
Shown open
Inspect for damage
and excessive wear

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Torque wrench assembly


Inspecting the stabilizer
Procedure
Remove the two screws (with slotted
nuts and cotter pins) that hold the
front stabilizer
Check the springs for damage and
replace if needed
Pack spring cavities with grease and
reassemble
Be sure all safety wire, cotter pins,
and screws are tight, and tighten or
replace as necessary.

Screw

Washer

Nut
6 Month
Cotter
Stabilizer Springs Pin
Check for damage,
replace as necessary

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Torque wrench assembly


Inspecting the IBOP actuator cylinder and yoke
Disassembling the IBOP actuator cylinder and yoke

1. Shutdown the power and bleed the system (turn the valve on
the bottom of the gearcase to the SHUT DOWN position).

2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.

3. Disconnect the hydraulic lines from the IBOP actuator cylinder


and cap all connections.

4. Unpin and remove the IBOP actuator cylinder and yoke.

5. Replace the hydraulic lines as necessary.

6. Check for cylinder leaks.

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PH-75 Pipehandler

Well control system


Inspecting the IBOP valves and saver subs
Wear allowances
Component Replace when

Saver Sub Threads have been recut to a minimum


shoulder-to-shoulder length of 5 in.

i See the IBOP Service Manual for IBOP


disassembly/assembly and servicing
information.

Weekly Daily

Upper IBOP Valve


(Remote) Check for
Open Inspect for damage proper operation
and pressure test
for leaks

Weekly
Close IBOP Crank
(Remote)
Inspect for damage

Weekly Daily
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test

for leaks

5 Years
Upper and Lower IBOP

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Shot pin assembly


Inspecting the shot pin assembly
Wear allowances
Component Replace when
Gear
Shot Pin Outer diameter is Shaft
less than 1.375 in.
Shot Pin Sleeve Inner diameter is
greater than 1.510 in.
Flanged
Weekly Bearing
Hydraulic
Shot Pin Assembly Motor
Check for leaks,
Compound
tighten fittings
Gear
Hydraulic
Dowel Manifold
Pin Flanged
Bearing
Bearing

Drive
Gear

Bearing

Shot Pin
Housing
Assembly

Rod Seal
Assembly

Monthly Bearing
Shot Pin Retainer
Check for wear,
remove burrs

Rod Seal
Assembly

Monthly O-ring
Shot Pin Sleeve
Check for wear Retaining
Ring
Shot Pin
Flange Bushing

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PH-75 Rotating link adapter/load stem


Removing the pipehandler and link tilt from the top drive
(while in mast)
1. Drain the oil from the gearbox.

2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.

3. Build a support over well center to support the weight of the


link adapter.

4. Lower the top drive to the support built in Step 3.

5. Remove the bolts that attach the load stem to the main body.

6. Raise the top drive slowly to separate the link adapter from

the main body.


7. Move the link adapter assembly to a clean, safe work area.

8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.

Disassembling the link tilt assembly


1. Attach a 3-point sling to the stem and pull the stem out of the
link adapter.

2. Turn the stem over and place it on its flange.

! Protect the internal surfaces of the rotating link adapter and the
surfaces of the drive stem when separating the two components.
When removing the rotating link adapter from the stem, carefully
tap with a mallet. There can be misalignment between the two
bores when raising the drive stem and gear assembly.

i The piston ring is assembled with a light press fit. Provide a


support under the gear so that it does not drop when it breaks
loose.

3. Remove and discard all rotary seals, O-rings, thrust ring, and
the wear bushings from inside the rotating link adapter and
gear inside dimension.

4. Remove and discard the stem flange O-rings and stem bore
shaft seals.

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Rotating link adapter/load stem


Assembling the link adapter
1. Orient the stem so the drive stem flange is down on a suitably
protected surface.

2. Install the gear with its rotating seal and wiper in place.

3. Install the O-ring for the piston ring.

4. Install the piston ring by tapping on it lightly with a mallet to


press it into place (Heat to 220-250 °)

5. Install the retainer ring.

6. Install all of the rotary seals on the rotating link adapter, and
an O-ring on the top surface.

7. Install the two wear bushings and the thrust ring in the rotating
link adapter.

8. Rest the rotating link adapter on its bottom surface.

9. Clean and then lubricate (with hydraulic oil) the sealing


surface of the stem and the inside diameter of the rotating link
adapter.

10. Attach three lifting slings symmetrically through the holes on


the top of the stem flange and slowly lower the assembly into
the rotating link adapter body. Hammering with a large plastic
mallet is an aid when assembing the stem to the link adapter.
i
Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts.

12. Pressure test each port at 1,000 psi and inspect for leaks at
the adjacent ports.

13. Grease all lubrication points on the assembly.

14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.

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Performing 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.

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Nondestructive Examination (NDE)


Performing 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 load-
carrying capability of the part. Any subsurface irregularity can also
compromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the publication:


ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.

Inspecting the safety valves (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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PH-50 Pipehandler

PH-50 Pipehandler illustrated index .................. 8-2


Inspection schedule ........................................... 8-3
Precautions ......................................................... 8-4
Elevator links ...................................................... 8-5
Disassembly/assembly .................................................. 8-5
Inspection ...................................................................... 8-6
Link tilt ................................................................ 8-8
Disassembly/assembly .................................................. 8-8
Inspection ...................................................................... 8-9
Torque wrench assembly ................................... 8-10
Clamp cylinder body disassembly/assembly ................. 8-10
Inspecting the clamp cylinder body ............................... 8-14
Inspecting the stabilizer ................................................. 8-15
Inspecting the IBOP actuator cylinder and yoke ............ 8-17
Well control system ............................................ 8-19
Tool joint locks disassembly/assembly .......................... 8-19
Inspecting the tool joint locks ......................................... 8-20
Inspecting the IBOP valves and saver subs .................. 8-21
Shot pin assembly .............................................. 8-22
Disassembly/assembly .................................................. 8-22
Inspection ...................................................................... 8-23
Rotating link adapter/load stem ......................... 8-24
Removing the pipehandler and link tilt from the top
drive (while in mast) ...................................................... 8-24
Disassembling the link tilt assembly .............................. 8-24
Inspecting the rotating link adapter ................................ 8-25
Assembling the link adapter .......................................... 8-26

Assembling the ...............................................................


(while in mast) link adapter to the top drive 8-27
Wireline adapter ................................................. 8-28
Nondestructive Examination (NDE) ............................... 8-29
Visual inspection ........................................................... 8-29
Magnetic Particle Inspection (MPI) ................................ 8-30
Ultrasonic Inspection ..................................................... 8-31
Safety valve inspection procedures (IBOP) ................... 8-31

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PH-50 Pipehandler illustrated index

Rotating Link
Adapter
Page 8 -24

Link Tilt
Page 8 -8

IBOP Actuator
Yoke and Cylinder
Page 8 -17

Stabilizer
Page 8 -15

Well Control System


Page 8 -19
Clamp Cylinder
Body
Page 8 -10

Stabbing Guide
Page 8 -13

Drill Pipe Elevator


For pipehandler lubrication and Elevator Links
see Page 3-13 Page 8 -5

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Inspection schedule
Each Use Page Reference

Check wireline adapter sheaves for excessive wear or damage See page 8-28

Daily

Check for missing lockwire and cotter pins


Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check tong dies for wear See page 8-14
Check clamp cylinder for leaks See page 8-14
Check hoses for wear or damage See page 8-17
Check tool joint locks for tightness See page 8-20
Check upper and lower IBOP valves for proper operation See page 8-21

Weekly

Check link tilt clamps for position and tightness See page 8-6
Check stabbing guide and flippers for damage and wear See page 8-14
Check clamp cylinder gate hinge pin for wear See page 8-14
Check IBOP actuator cylinder for leaks See page 8-17
Check IBOP actuator cam followers for wear or excessive play See page 8-19
Check upper and lower IBOPs and IBOP crank for damage (if equipped) See page 8-21
Check shot pin assembly for leaks See page 8-23

Monthly

Check elevator link eyes for wear See page 8-8


Check link tilt bushings for wear See page 8-9
Check link tilt actuator cylinders for leaks See page 8-9
Check link tilt actuator cylinder pins for wear See page 8-9
Check clamp cylinder body wear bushings for wear See page 8-14
Check stabilizer springs for damage See page 8-16
Check front and rear stabilizers for wear See page 8-16
Check pins and bushings on IBOP actuator cylinder and yoke for wear See page 8-17
Check shot pin assembly for wear or damage See page 8-23

Yearly

Check piston ring for pitting and chipping See page 8-25
Check stem for pitting, grooves and chipping See page 8-25
Replace GLYD rings, o-rings and bushings on rotating link adapter See page 8-25

5 Years

MPI Inspection See page 8-31

i After inspecting above components, repair or replace as necessary.

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PH-50 Pipehandler

Elevator links
Disassembly/assembly
1. Disconnect and remove the drill pipe elevator from the
elevator links.

2. Using the Varco Driller’s Console (VDC), rotate the


pipehandler 90 ° to position one of the elevator links directly
below the front of the motor guard.

3. Remove the catch link bolt from the catch link.

4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.

5. Using the sling, hoist the elevator link away from the
pipehandler.

6. Rotate the pipehandler 180 °, repeat the procedure to remove


the other elevator link.

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PH-50 Pipehandler

Elevator links
Inspection (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 2 7/8 in., 250-Ton

4 7/8 inches 2 3/16 inches 225

4 3/4 inches 2 1/16 inches 200

4 1/2 inches 2 inches 175

4 3/16 inches 1 7/8 inches 150

B = 3 1/2 in., 350-Ton B

5 inches 2 3/4 inches 350

4 13/16 inches 2 9/16 inches 300


4 5/8 inches 2 3/8 inches 225
B
7 7/16 inches 2 3/16 inches 175

B = 4 1/2 in., 500-Ton

6 inches 3 1/2 inches 500


A
5 3/4 inches 3 1/4 inches 420

5 1/2 inches 3 inches 325

5 1/4 inches 2 3/4 inches 250

B = 6 1/4 in., 750-Ton Lower


Eye
7 1/2 inches 7 1/2 inches 750 (Elevator)

7 1/4 inches 7 1/4 inches 725

7 inches 7 inches 700 A


6 3/4 inches 6 3/4 inches 650

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.

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PH-50 Pipehandler

Link tilt
Inspection

Pins
Inspect for wear
replace as needed
Monthly

Monthly
Bushings
Inspect for wear
replace as needed

Monthly
Link Tilt
Actuator Cylinders
Inspect the hydraulic
connections for leaks
Link Tilt

Monthly
Bushings
Inspect for wear
replace as needed

Wear allowances
Component Replace when
Pins Wear exceeds .06 in. on diameter
Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear

Bushings should be pressed in using the mating pin


i as an installation mandrel.

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PH-50 Pipehandler

Torque wrench assembly


17. Slowly pull out the cylinder head using the threaded holes.
Remove and discard the piston seal.

18. Carefully push the piston out of the body. Remove and discard
the piston seal.

19. Remove the wiper rod and rod seal from the body. Discard the
seals.

20. Clean the piston, cylinder head, and the body. Clean and lightly
lubricate the new seals and seal surfaces prior to reassembly.

i Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

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PH-50 Pipehandler

Torque wrench assembly

RUN
N
W R
O IG
D
T -U
U P
H
S

Hydraulic
COUNTERBALANCE MODE
Manifold
Rig-up/Run/
Shutdown Valve
Shown in SHUTDOWN
position

(Shown with
link tilt removed)

Torque Arrestor

Spring

Spring Spacer

Spring Shims
Adjust to ensure
the torque wrench
clamps fully onto
the saver sub Support clamp
cylinder body
before removing
end cap.
End Cap

Clamp Cylinder
Body

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PH-50 Pipehandler

Torque wrench assembly


Inspecting the IBOP actuator cylinder and yoke

Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings

Daily Monthly
Hoses Pins and Bushings
Replace if worn Check for wear
or damaged or excessive play

Monthly

IBOP Weekly
Actuator Yoke IBOP
Check pins and Actuator Yoke
bushings for wear Check cam followers for wear
or excessive play or excessive play

Wear allowances
Component Replace when

Pins Wear exceeds .03 in. on diameter


Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear

Bushings should be pressed in using the mating pin


i as an installation mandrel

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PH-50 Pipehandler

Rotating link adapter/load stem


Removing the pipehandler and link tilt from the top drive
(while in mast)
1. Drain the oil from the gearbox.

2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.

3. Build a support over well center to support the weight of the


link adapter.

4. Lower the top drive to the support built in Step 3.

5. Remove the bolts that attach the load stem to the main body.

6. Raise the top drive slowly to separate the link adapter from

the main body.


7. Move the link adapter assembly to a clean, safe work area.

8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.
Disassembling the link tilt assembly
1. Attach a 3-point sling to the stem and pull the stem out of the
link adapter.

2. Turn the stem over and place it on its flange.

! Protect the internal surfaces of the rotating link adapter and the
surfaces of the drive stem when separating the two components.
When removing the rotating link adapter from the stem, carefully
tap with a mallet. There can be misalignment between the two
bores when raising the drive stem and gear assembly.

i The piston ring is assembled with a light press fit. Provide a


support under the gear so that it does not drop when it breaks
loose.

3. Remove and discard all rotary seals, O-rings, thrust ring, and
the wear bushings from inside the rotating link adapter and
gear inside dimension.

4. Remove and discard the stem flange O-rings and stem bore
shaft seals.

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PH-50 Pipehandler

Wireline adapter
Inspection

i
Inspect the condition of the
sheaves before and after each use

Each Use

Sheaves
Replace or repair damaged
parts as necessary

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PH-50 Pipehandler

Nondestructive Examination (NDE)


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 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:

Mainshaft (lower portion)

Bail

Landing collar (yearly)

Upper and lower IBOP

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. Drilling Manual, 9th Edition

ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings

ASTM E-709 Std. Recommended Practice for Magnetic Particle Inspection

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PH-50 Pipehandler

Nondestructive Examination (NDE)


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 load-
carrying capability of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.

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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Hydraulic System

Hydraulic system diagram


Drilling Upper IBOP Link Tilt Pipehandler
Motor Brake Actuator Cylinder Cylinders Clamp Cylinder

Link Tilt
Counterbalance Manifold
Accumulator

Rotating Head
(Elevator Positioner)

Counterbalance Shot Pin Rotating


Cylinders Cylinder Link Adapter
Lift

Rotating
Head Gearbox Lube
Motor Oil Distribution
Pre-Fill Valve
Manifold

Main Hydraulic Manifold

Low Speed Lube Oil


Hydraulic Pump
Motor

Upper IBOP System


Time-Delay Accumulator Gearbox Sump
Accumulator

M
10 HP A.C. Variable
Displacement Fixed
Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
Reservoir

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Hydraulic System

Inspection
Precautions

To avoid serious injury or death, read and understand the following


warnings before performing inspection and maintenance
procedures:

Properly lockout the main power source before


performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from


fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is


moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil


under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious injury.
Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.

Always discharge the three hydro pneumatic


accumulators before performing repairs on the
hydraulic system.

Do not attempt repairs you do not understand.

Read and understand all safety precautions and


warnings before performing maintenance procedures.

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Hydraulic System

Inspection
Inspecting the hydraulic fluid level and filter

Cork Ball
(Level Indicator)

Daily
Red
Pop-up Sight
Dirt Alarm Glass

Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter

Procedure
Check the red “pop-up” alarm on the hydraulic
filter daily
Replace the filter (Varco P/N 114416-1) if the
indicator has popped up or as recommended
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities

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Hydraulic System

Inspection
Adding the hydraulic fluid

Specifications

Reservoir Capacity 25 gal

Procedure
Cork Ball
Turn the Top Drive OFF (Level Indicator)
Ensure that the area is clean prior to adding
hydraulic fluid
Remove dust plug from the male quick
disconnect at the Top Drive hydraulic oil fill
Remove dust plug from the female quick
disconnect on the lubrication kit
Connect the two fittings and pump fluid until
the level reaches the middle of the sight Sight
glass as showm Glass
See Lube Schedule for specifications
Hydraulic
After adding fluid, replace the dust plugs Oil Sight
Gauge

Hydraulic Oil Fill


Male Quick Disconnect

Hydraulic
Oil Fill

Female
Quick
Disconnect

Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643

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Hydraulic System

Inspection
Inspecting the heat exchanger

Blower and
Brake Covers

Monthly

Oil Heat
Exchanger
Remove any dirt
and inspect for leaks,
corrosion, and cleanliness

Drill Motor
Assembly
Left side

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Hydraulic System

Inspection
Using the hydraulic system test ports

Stand Jump Brake Clamp/


SV9 SV1 P1 Shot Pin Float
Link
IBOP SV5 SV8 Tilt
L4 PV PF * B8
SV4 SV6
A4 G5
CB

* SA

* P

* T1
C4
SV2 A6
C5
Rotating B6
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.

As Viewed From Below

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Hydraulic System

Inspection
Inspecting the IBOP timing circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod Hydraulic
Cylinder
Open
Close

Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge

Gas Charged
Accumulator
(Small)

Rotating
Link Adapter -
6
-
6

A4 B4

A4 B4
6 6
- -
IBOP Close Solenoid
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close

Cable ID
A B
Number
b
C04
P T
6 6 6
- - -

A4 SV4 B4 C4 Manifold Assembly

D03

500 PSI CV4


D4 Flow Control
1 T-11A Valve
3 1 2
T-11A

2 3

PC4

System Tank
Pressure

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Hydraulic System

Inspection
Inspecting the IBOP and oil pressure switch

Hoses
Inspect for wear
or damage.
Replace yearly
or as required.
Yearly

IBOP Pressure Switch Oil Pressure Switch


Configuration Configuration

Pressure
Adjusting Screw

Yearly
Wires
Inspect for wear
Switch Pressure Settings or lose connections.

Component Setting

IBOP Pressure Switch Factory preset at 1500 psi (102.0 BAR) rising
+0
Oil Pressure Switch Factory preset at 10.0 psi decreasing
-1.0

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Hydraulic System

Setting up the circuits


Setting up the hydraulic pumps and unloading circuit
There are two pumps – a fixed displacement pump runs the
transmission lubrication system and a variable displacement pump
provides hydraulic flow to the hydraulic system.

Pump Pressure
Compensator
Adjustment Point

Guide Beam Pump/Motor

Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump

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Hydraulic System

Setting up the circuits


Setting up the fixed displacement (lube) and variable
displacement pumps

! Make sure the Top Drive is properly filled with hydraulic fluid and
lube oil before performing this procedure. Also make sure the Rig-
Up/Shutdown valve is in the SHUTDOWN position.

1. Locate the tube connecting manifold port PF to the lubrication


motor. Disconnect the tube at the manifold end, cap the tube
and plug the PF port using steel fittings.

2. Set the relief valve RV1 for the variable displacement pump to
a minimum setting, fully counterclockwise, which allows the
hydraulic system to operate without building up pressure, and
turn the motor off.

3. Set the relief valve RV2 to minimum pressure, fully


counterclockwise.

4. Jog-start the electric motor to make sure the direction of


rotation is correct (clockwise when looking into pump shaft/
electric motor fan). Correct as required.

5. Start the electric motor and allow both hydraulic pumps to


circulate oil. Listen for unusual noises that would indicate
cavitation; check for leaks.

6. Connect a gauge to test point PF. Increase the pressure by


adjusting relief valve RV2 clockwise until the pressure
increases to 400 psi at test point PF. Set the jam nut on RV2.
A steel cap is installed over the adjustment screw to
discourage unauthorized adjustment.

i While adjusting valves, verify a linear relationship between turning


the adjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between


manifold port PF and the lubrication motor.

8. Connect an ammeter to the electric motor. Note the full-load


amps on the motor nameplate.

9. Restart the hydraulic system electric motor.

10. Set the counterbalance mode valve to the RUN position.

11. Adjust UV1, fully clockwise, to maximum pressure.

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Setting up the circuits


Setting up the fixed displacement (lube) and variable
displacement pumps
12. Connect a gauge to test point PV. Note the ammeter reading
while RV1 is at minimum setting.

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

14. Adjust relief valve RV1 to its minimum setting. If maximum motor
current does not occur at 800 psi, adjust the pump pressure
compensator as required.

15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.

16. Connect a gauge to test point SA, and leave the gauge on PV.

17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.

18. Install steel cap over the adjustment screw to discourage


unauthorized adjustment.

19. Adjust unloading valve UV1 counterclockwise until the pressure


at PV drops off, then an additional two turns counterclockwise.
The pressure cycles like a sawtooth wave.

3000 Pressure at PV

Pressure at SA

2000

Pressure 1700
(psi)

1000
800

150

0 10 20 30 40 50 60
Approximate Time
(seconds)

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Hydraulic System

Setting up the circuits


Setting up the fixed displacement (lube) and variable
displacement pumps
20. Observe the unloaded pressure at PV (about 0 psi) while SA
reads about 2,000 psi. The pressure at SA decays until UV1
reloads. After reloading, the pressure rapidly rises to the
unload pressure.

21. Observe several unload-reload cycles to determine the unload


pressure.

22. Adjust the setting of UV1 as required to a 2,000 psi unload


pressure.

! Perform the adjustment with reasonable speed. The process takes


no longer than two minutes. Taking longer increases the
temperature of the hydraulic fluid.

23. Observe the cycle of loading and unloading of the relief valve.
To verify the setting of UV1, note the difference in pump noise
level between the loaded and unloaded condition.

RV2 RV1
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A B2

Manifold
Side View

Manifold
Manifold End View
Bottom View B6 A6 DR Z1

P
TF
B5 B5 C5 B4 B9
TR

SA
T1
C S
T A
R
SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5
C4
B8
PF C
B S
A
R U

G5 U
SV4 PF V
1
D
O
M
R
N P

1
PV MV U X
C C
DF
S

UV1

PF

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Hydraulic System

Setting up the circuits


Setting up the fixed displacement (lube) and variable
displacement pumps

Manifold Assembly

T-21A 4 UV1 2200 PSI


2 T-10A
2 RV2
3
T-11A 1
3
2000 PSI Z1
1 400 PSI
1 2

RV1
PV PF

800 PSIG

Variable Displacement
Pump-Motor Assembly
B

1.00 IN^ 3/REV.


L

Fixed
1.10 IN^ 3/REV. MAX. Displacement
.50 IN^ 3/REV. MIN. Pump

L1
S

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Hydraulic System

Setting up the circuits


Setting up the counterbalance circuit and stand-jump
circuit
1. For the counterbalance circuit there are three adjustments:

Relief valve (on counterbalance cylinder)


PCC – operator set
SJR – operator set

2. To set the relief valve, make sure the pumps are operating.

3. Adjust pressure reducing valve PCC to the maximum setting,


fully clockwise.

4. Connect a gauge to test port CB.

5. Adjust the cylinder-mounted relief valve to mid-scale to lower


the pressure setting.

6. Increase the pressure clockwise using a 5/32 in. Allen wrench


and 9/16 in. open-end wrench.

7. Observe the relationship of turning the relief valve adjustment


clockwise to pressure increase.

8. When the relief valve reaches system pressure, turn the


setting one full turn clockwise beyond the setting and set the
jam nut.

9. Install a steel cover over the valve.

10. Adjust PCC to 1,200 psi.

11. Measure pressure at test port CB.

12. Prepare the hardware to attach the cylinder pear links to the
hook.

13. Rotate the counterbalance mode valve from the RUN position
to RIG-UP position. This causes the counterbalance cylinders
to slowly extend.

! Cylinders stroke to the end of stroke with the mode valve in the
RUN position.

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Hydraulic System

Setting up the circuits


Setting up the counterbalance circuit and stand-jump
circuit
PCC
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A B2

Manifold
Side View

RIG-UP/SHUTDOWN
Manifold Valve
Bottom View B6 A6 DR Z1
Manifold
End View
P

TF
B5 B4
B5 C5 B9
TR C S
T A
T1 R

SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5
C
B S
C4 A
B8
PF
U
V
RIG UP 1
G5 SV4 PF
E
D
O
N
M
1
U
R E
C X
N P
C
B
R
T
PV MV
N
U
O
C

DF
S

CB

Manifold
Side View SJR
D4 A4 PC5 AR5

CV3 PC4 D1

SJR P1
PF

A8

PV
A4 A5
D5
C4

CB G5 DF
2

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Hydraulic System

Setting up the circuits


Setting up the counterbalance circuit and stand-jump
circuit
Pressure 1500 PSI
Relief Valve
T-3A 1

-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø

75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T

-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16

5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø

Counterbalance Mode Stand


Jump 2 Position
Rig-up Shut-down Valve
Run

A B A B
b
C09
P T 6 P T
-

3 Position D03 MV .055ø CB SV9 Manifold Assembly


Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
SJR
PCC 4
T-13A 2 200 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI

SA To Tank

TDS-11SA Rev. B
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Hydraulic System

Setting up the circuits


Setting up the AC motor brake circuit
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 1,500 psi. The pressure reducing valve
regulates the pressure to 1,500 psi. The solenoid valve operates to
apply pressure, setting the brakes, or stop pressure to release the
brakes.

To test the system, turn the auto brakes switch on the driller’s
console to the ON position. Attach a pressure gauge to B1 in the
manifold. The pressure reading should be 1,500 psi. If the reading
is not 1,500 psi, adjust the pressure control reducing valve PC 1 to
1,500. Turn the auto brakes switch to the OFF position. The
pressure reading should be very low.
PC1
CB6 CA6 CV5

CV4

A2
B2 CDR CV1

PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1

T1
B1
C5 A B2

Manifold
Side View

Manifold
Bottom View B6 A6 DR Z1

TF
B5 B4
B5 C5 B9
TR
T1

SV5
B1
B4 SV2 SV1 SV9 CV2

G6 E6 E5 PV
P5
C4
B8
PF

RIG UP

G5 SV4 PF

D
O
M
R
N P

PV MV U
C
DF S

B1

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Hydraulic System

Setting up the circuits

Rotating Link Adapter


Drive Motor and
Shot Pin Assembly

10 HP AC Motor
and Pump Assembly

(Simplified for Clarity) Hydraulic


Drive Motor

Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin
B5 Relief Valve
Adapter Relief Valve

C5

Link Adapter
A5
Rotation Gear

Shot Pin

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Hydraulic System

Setting up the circuits


Setting up the link tilt cylinder circuit
1. There is nothing to adjust on the manifold for the link tilt circuit.

2. Adjust the four load holding valves in pairs – the upper pair and
lower pair. Adjust all four counterbalance valves fully clockwise,
then one turn counterclockwise.

i If the valves are not adjusted correctly, link tilt operation is not
synchronized.

3. The correct pressure setting is 1,500 psi. The procedure is the


same for both valves. Adjust the valves one at a time.

4. There are two test points on the link tilt cylinder manifold.

5. From the driller’s console, move the link tilt to go to the


mousehole position.

6. The cylinders go to full extension and the pressure at the test


port C1 is 2,000 psi.

7. Command the link tilt to the OFF position and observe the
pressure decay at C1. This decayed pressure is the setpoint of
the counterbalance valve.

8. Raise the valve setpoint by turning the adjusting screw 1/4 turn
counterclockwise.

9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

i This is an iterative process. Continue to set the driller’s console


control to the mousehole position and OFF, taking present and
decayed pressure readings.

! Turning the counterbalance valve counterclockwise increases the


pressure.

10. Command the link tilt to the DRILL position and repeat the
procedure above, using test port C2 to set the counterbalance
valve on the DRILL side.

TDS-11SA Rev. B
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Hydraulic System

Setting up the circuits


Setting up the rotating link adapter hydraulic motor
relief circuit
1. Set the relief valves mounted on rotation motor.

2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.

3. Turn the manual override on the SV2-rotation circuit to drive


the head in the counterclockwise direction. Test the pressure
at A and adjust the relief valve to 1,700 psi.

4. Turn the manual override on the SV2-rotation circuit to drive


the rotating head in the clockwise direction and test the
pressure at B. Adjust the relief valve to 1,700 psi.

Hydraulic
Drive Motor

Test Points
(3)

Motor
Relief
Valve
(2)

Link Adapter
Rotation Gear

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Hydraulic System

Troubleshooting
Troubleshooting the HPU and reservoir bladder
Problem Probable cause Remedy

Hydraulic system Relief valves RV1 and RV2 out of adjustment. Test pressures and adjust relief valves.
overheating
Unloading valve is not working. Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down Check system pressure.


position too long and pressure bleeds down.

No precharge in system accumulator. Charge system accumulator.

Hydraulic components System pressure is down. First make sure RIG-UP/SHUTDOWN valve is in
do not operate. the correct position. Test pumps and motors.
Test relief valve pressures. Adjust as required.
Check for leaks, loose fittings, loose cylinders,
worn hoses, fluid levels and seals.

Piston pump is not working. Replace the piston pump.

Flexible coupling is damaged. Replace the flexible coupling.

Lubrication pump is not working. Replace the lubrication pump.

Pressure at UV1 is too low. Adjust pressure at UV1.

Pumps are rotating in the wrong direction. Inspect hydraulic connections and
correct rotation.

Suction valve closed. Open suction valve.

Low oil level in reservoir. Fill hydraulic reservoir.

TDS-11SA Rev. B
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Hydraulic System

Troubleshooting
Troubleshooting the counterbalance and stand jump
The accumulator, with precharge pressure of 900 psi, along with
check valve CV3, maintains a hydraulic pressure.

A three-position manually operated valve controls counterbalance


operation for rig-up, run, and shut down modes. In the rig-up mode,
system pressure is applied to XC and the prefill valve, causing both
cylinders to extend. When the cylinders extend, you make up the
mechanical connection to the bail. In the run mode, for
counterbalance operation, approximately 1,600 psi is needed at the
counterbalance cylinders to lift the TDS-11SA off the hook.

The optional stand jump feature is controlled by solenoid valve SV9.


With the counterbalance in the run mode and the stand jump switch
on, additional pressure of approximately 300 psi is applied to over
the normal counterbalance pressure to lift the TDS-11SA and drill
string off the hook.

In the shutdown mode, the hydraulic system bleeds down the


system accumulator and the counterbalance accumulator pressure.

Counterbalance testing
For the counterbalance operation, a lift of approximately 30,000 lb is
achieved with a pressure of 1600 psi at CB. Perform the following
steps to adjust the force:

1. Set the counterbalance mode valve on the bottom of the

manifold to the RUN mode. Set the pressure control valve PCC
to the minimum setting (fully counterclockwise).

2. Test the pressure at port B9. There should be a 0 psi reading.

3. Test the pressure at port CB. Observe the position of the top
drive on the hook.

4. Adjust the pressure at pressure control valve PCC clockwise,


observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on the
hook.

TDS-11SA Rev. B
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Hydraulic System

Troubleshooting
Stand jump testing
For the optional stand jump feature, a lift of about 33,000 lb is
achieved with a pressure of approximately 1800 psi at CB. The
additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve
SV9. Perform the following steps to adjust the pressure:

1. Set the counterbalance mode switch to RUN and engage the


stand jump switch. Test the pressure at por t CB and B9. Adjust
relief valve SJR fully counterclockwise to the minimum setting.

2. Slowly increase the pressure at CB by adjusting relief valve


SJR clockwise until the bail lifts off the hook with a stand of
pipe in the elevator.

i Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

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Hydraulic System

Troubleshooting
Problem Probable cause Remedy

Counterbalance does not Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.
function.
No hydraulic pressure. Test pressure and ajust pressure reducing valve.

Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on the accumulator is low. Charge the accumulator.

Stand jump does not


function. Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.

No hydraulic pressure. Test pressure and adjust pressure


reducing valve.

Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.

PCC is not operating. Replace the valve.

Relief valve is not operating. Replace the valve.

Precharge on the accumulator is low. Charge the accumulator.

TDS-11SA Rev. B
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Hydraulic System

Troubleshooting
Counterbalance and stand jump schematic diagram

Pressure 1500 PSI


Relief Valve
T-3A 1

-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø

75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T

-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16

5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø

Counterbalance Mode Stand


Jump 2 Position
Rig-up Shut-down Valve
Run

A B A B
b
C09
P T 6
P T
-

3 Position D03 MV .055ø CB SV9 Manifold Assembly


Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
SJR
PCC 4
T-13A 2 200 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI

SA To Tank

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Hydraulic System

Troubleshooting
Troubleshooting the brakes
Problem Probable cause Remedy

Brake does not release. Directional valve is stuck. Test the valve and replace if necessary.
Brake releases but still drags. Check valve is blocked or tube is pinched. Replace the check valve or tube as required.

Mechanical problems with brakes. Repair brake mechanism.

Brakes do not engage or slip. Hydraulic oil on brake pads. Check for hydraulic leaks and repair.

Pressure is not 1,500 psi or does not rise Reducing valve is plugged or needs to be
crisply to 1,500 psi. adjusted or replaced.

Directional valve is stuck Replace valve or check electrical signal.


(check pressure at B1).

Delay in brakes
after console actuating
switch is Hydraulic oil is contaminated. Replace hydraulic oil.
turned on. Pressured reducing valve is faulty. Replace valve.

TDS-11SA Rev. B
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Hydraulic System

Brake circuit schematic diagram


Brake Calipers

2 Position
Solenoid Valve
Brakes On

Cable ID
Number
A B

b
C01

P T
4
-

SV1 B1 Manifold Assembly


.071ø
D03
Non-Adjustable
Orifice

P1
Test Point

1500 PSI

PC1 1 T-11A

Reducing 2 3
Valve

System Tank Drain


Pressure

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Hydraulic System

Troubleshooting
Troubleshooting the shot pin cylinder and clamp
cylinder
Problem Probable cause Remedy

Shot pin does not engage. Solenoid valve is not operating or relief valve Check electrical actuation and test pressure.
is not adjusted. Adjust as required.

Abnormal pressure change at B5 and C5 Replace directional control valve.


indicates valve problem.

Normal pressure change indicates plumbing Repair plumbing or shot pin cylinder.
or shot pin cylinder are faulty.

Shot pin applies Relief valve is not operating or Test pressures and adjust as required.
excessive force to out of adjustment.
rotating head gear.

Clamp cylinder does No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.
not actuate.
Cylinder is damaged. Inspect cylinder and repair or replace.

To provide high pressure to the clamp circuit, Repair plumbing, rotating head, or clamp cylinder.
i pressure at C5 must be 2,000 psi and G5 must
be less than 100 psi. If this condition is met,
pressure at CP should increase from less than
100 psi to higher than 2,000 psi. If not, check
the plumbing, rotating link adapter, and
clamp cylinder.

While clamping, pressure at CR should be Clean or repair CNEC valve.


2.7 times the pressure at CP. When the dies
contact the pipe, pressure at CR should be
less than 100 psi. If the pressure does not
fade, check valve CNEC for contamination.

Shot pin engages Control valve not operating. Check pressure at C5. Replace valve CV5
but clamp cylinder if required or the regenerate manifold.
does not activate.

TDS-11SA Rev. B
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Hydraulic System

Troubleshooting
Shot pin cylinder and clamp cylinder schematic diagram
Clamp Cylinder
10.000" Dia. Bore X 2.0" Stroke
8.000" Dia. Rod

Hydraulic Cylinder

Cavity Plug CP CR

1 3
Pilot-to-Close CKEB
T-2A
Check Valve 2

30 PSID
2 1
CNEC
Shot-Pin Cylinder 3 T-2A
2.000" Dia. Bore X 2.31" Stroke 1 T-5A
Relief Valve 1.500" Dia. Rod COFA
.047ø

400 PSI 2 30 PSID


Shot Pin
Cylinder 2x .094ø 2
VP VR

1
2 Position
T-10A Non-Adjustable
Solenoid
B5 C5 Flow Control
Valve 5
Clamp/Shot Pin Clamp -
8
-
8

E5 G5

Cable ID Rotating Link


A B
Number b E5 G5 Adapter Assembly
C05 -
8
-
8

6
P T 6
- -

A5 SV5 B5 C5 E5 G5

D03 Pressure
.159ø 1
50 PSI .031ø T-11A Reducing
3 AR5 Valve
3
1 2
LC5 2
.031ø 1000 PSI
Logic T-11A
Cartridge
Externally-Drained
Pilot-to-Open
3 2 Valve
T-21A
4 75 PSI
CV5 1
P5
Drain 1
3
System Pressure T-11A
PC5 2

Tank Drain

System Pressure

Tank

T1 T1 D5 Manifold Assembly

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Hydraulic System

Troubleshooting
Troubleshooting the link tilt cylinders
Problem Probable cause Remedy

Drill pipe elevator does Link clamp incorrectly adjusted. Readjust


not reach mouse hole/
derrickman position.

Links drift when Pressure at B8 does not decay to Replace the pilot to open check valve.
valve is released. less than 100 psi.

Pilot to open check valve is stuck open Replace the pilot to open check valve.
or contaminated.

Faulty cylinder seal. Replace the seal.

Load holding relief valves are out of Adjust or replace the load holding relief valve.
adjustment, stuck open, or contaminated.

Drill pipe elevator Use manual override. If the link tilts, the Test the solenoid and connectors.
does not float back problem is electrical. If the links do not tilt, Test the hydraulic system.
to center position. the problem is hydraulic.

Link tilt does not tilt. Solenoid valve is not shifting. Check electrical continuity.

TDS-11SA Rev. B
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Hydraulic System

Troubleshooting
Link tilt cylinders schematic diagram

Link Tilt Cylinder


3.250" Dia. Bore X 10.3" Stroke
1.380" Dia. Rod

Mousehole
Drill Down

C1 C1 C1 X1 C2 C2 C2

1500 PSI T-11A 1500 PSI T-11A


CV1
T-11A 1 CB1 1 CB2
1 CV2 1 X2
3 3 T-11A 3 3
2 2 2 2
V1 V2

V1 V2
FL

6 6 8 8 8 8 8 8
- - - - - - - -
X X X X X
B8 B8 E6 E6 G6 G6 H J

B8 E6 G6 H J
X X
8 8 8 8
- -
Rotating Link 8
- - -

Adapter Assembly

Link Tilt Link Tilt Link Tilt


"Float" Solenoid "Drill Down" Solenoid "Tilt" Solenoid
(Solenoid Valve 8) (Solenoid Valve 6) (Solenoid Valve 6)

Link-Tilt Float Link Tilt


Cable ID
A B A B Logic
Number b b a
Cartridge
C08 C07 C06
P T 6
-
8
- Drill Down P T M'hole 8
-

SV8 D03 B8 E6 .031ø .031ø SV6 D03 .031ø G6


Logic
Cartridge LA6 T-11A .071ø
.031ø
75 PSI B6
1
50 PSI 2 4 2 3 T-11A
3
CA6 1
1 T-21A
3 .071ø
.031ø 50 PSI 2
A6
LB6 2
4 3
1
Pressure
CB6 75 PSI
Tank T-21A

A8 D1 Manifold Assembly
X X

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Hydraulic System

Troubleshooting
Gearbox lubrication hydraulic system schematic
diagram
Pressure Spray
Switch Nozzles (4) Orifices (6)

S04 10 PSI
Decreasing

-16
1.0 1.5 .062ø .205ø .059ø .059ø .047ø .047ø L4
GPM GPM
Ea. Ea.
Upper Lower Upper Lower Upper Lower
Compound Compound Mainshaft Radial/Main Compound Compound
Gear Gear Bearing Thrust Bearing Bearing
Bearings

Lube-Oil
Filter
Lube Pump 5.10 In.^ 3/Rev. 60 µ m

L1 -16
Lube-Oil Pump

-10
A B
Tank
-10
3.0 In.^ 3/Rev.

Lube Pump Motor

Hydraulic Hydraulic
Motor Heat Exchanger

Tank

2 T-10A
RV2

400 PSI

Manifold PF

1.00 IN^ 3/REV.

Part of
Pump Motor
Assembly Reservoir
Assembly

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Hydraulic System

Troubleshooting
Troubleshooting the IBOP actuator schematic diagram
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod Hydraulic
Cylinder
Open
Close

Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge

Gas Charged
Accumulator
(Small)

Rotating
Link Adapter 6
-
6
-

A4 B4

A4 B4
6 6
- -
IBOP Close Solenoid
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close

Cable ID
A B
Number
b
C04
P T
6 6 6
- - -

A4 SV4 B4 C4 Manifold Assembly

D03

500 PSI CV4


D4 Flow Control
1 T-11A Valve
3 1 2
T-11A

2 3

PC4

System Tank
Pressure

TDS-11SA Rev. B
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Hydraulic System

Hydraulic schematic symbols


The following hydraulic troubleshooting section provides a
schematic diagram and description for each TDS-11SA hydraulic
circuit. Following each schematic is a group of troubleshooting
charts to help you quickly locate and correct hydraulic system
problems.

When performing hydraulic troubleshooting, be aware that:

The electrical control system can be bypassed for


troubleshooting by manually overriding the solenoid valve for
each operational system.

Alert all personnel near the top drive before overriding


a solenoid valve. When you override a solenoid valve,
you bypass the safety interlock and top drive
components will move possibly causing serious injury
or death.

Test points shown in the hydraulic schematic with a box (e.g.,


A4) can be found on the manifold under the main body. There
are also test points on the rotating link adapter motor.

The system is preadjusted. Hydraulic problems are usually


related to faulty valves, contamination, or other damage to the
system rather than misadjustments. Changes to adjustments
should be made only after all other possible causes have been
eliminated.

9-48
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Hydraulic schematic symbols


Description Symbol Schematic Reference

2 Position 4 Way Valves


SV1, SV4, SV5, SV8, SV9
Solenoid (Single Solenoid)
Operated 33-1

Valves
3 Position 4 Way Valves
(Double Solenoid) SV2, SV6

33-2

Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3

Fixed Displacement

Pumps 33-4

Variable Displacement

33-5

Standard Valve RV2, A2R, B2R, SJR

33-6

Pressure
Relief
Valves Ventable Relief Valve RV1
33-7

Differential Unloading Valve UV1

33-8

Pressure Reducing Valve PC1, PC4

33-9

Pressure Reducing/Relieving Valve PCC

33-10

CDF, CTF, CV2, CTR,


CDR, CXCD
Chack Valve
Prefill valve assembly
33-11
CV1, CV2

TDS-11SA Rev. B
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Hydraulic schematic symbols


Description Symbol Schematic Reference

Pilot-To-Open CKCB (Link Tilt)


Check 33-12
Valves

CA6, CB6, CV3, CV4


Pilot-To-Close
(Clamp Body)
33-13

1
3
Cavity Plug PC5
2
33-14

Internal Plug

33-15

Non Adjustable Flow Control Valves CV1

33-16

Non Adjustable Orifice Diameter in inches

33-17

3 Port (Internal Drain) CBCA (Link Tilt Circuit)


Counter-
33-18
balance
Valves
4 Port (External Drain) CWCK (Link Tilt Circuit)

33-19

Standard Cartridge LA6, LB6, LC5, LODC

Logic 33-20

Cartridge

With Metering See Prefill Assembly

33-21

Quick Disconnect Coupling

33-22

9-50
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Hydraulic schematic symbols


Description
Description Symbol
Symbol Schematic
SchematicReference
Reference

Non Bypass Filter See Lube Oil Circuit

33-23

Filter with Bypass See Return Circuit

33-24

Manual Shutoff Valve

33-25

Thermostat Lube Oil Circuit


33-26

Pressure Switch Lube Oil Circuit

33-27

Hydraulic Circuit
Heat Exchanger
(Inside Brake Housing)
33-28

Pressure Compensator Control Part of the Pump

33-29

Hydro-Pneumatic Accumulator
33-30

Hydraulic Motor (Bi-Directional)

33-31

Hydraulic Cylinder
33-32

Tank (Reservoir)
33-33

Test Point
33-34

TDS-11SA Rev. B
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