TDS-11S

Training
 Program Contents

TDS 11 Mechanical Systems

 Top Drive Development
 Lubrication
 Guide Beams & Carriage
 Motor Housing & Transmission
 PH-50 Pipehandler
 On-Board Hydraulics
 Safety!
History of Top Drive
Development
A brief history of Top Drives
Since the advent rotary drilling in the early 1900s, drilling technology has made steady and, in some
cases, spectacular progress. In a little over 100 years, well depths have gone from the 70-foot
depth of Drake's Well to over 40,000 feet at the rig on Kola Peninsula east of Finland.

To accomplish this, advances were necessary in rig design, equipment, bits, materials and
drilling techniques.

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

technology of drilling. In 1982 they introduced the industry's first top drive drilling system. By
replacing the traditional rotary drive and kelly with an advanced system that rotates the drill
string and handles entire 93-ft. stands of pipe, Varco was able to reduce drilling time by up to
25% while increasing the overall capability and efficiency of the drilling operation.
As a result, Varco Top Drive Drilling Systems have now become the new performance standard
for the drilling industry.

Varco continues to extend the threshold of Top drive technology with the introduction of a
complete line of AC top drive systems.
A new threshold in AC technology
For years the backbone of oil industry power has been the 1000 hp DC traction motor adapted
from locomotives.

They are used extensively to power a variety drilling operations including

drawworks, rotary tables and mud pumps. DC traction motors area rugged, dependable, readily
available source of high torque electric power.
These characteristics made them the ideal choice for the conversion of drilling equipment from
direct drive diesel to electric power.
In developing its Top Drive systems, Varco first turned to these DC motors to power its new
technology. And while they were appropriate for some applications, it became evident that
smaller, more compact motors were needed for today's performance requirements.
There was a need for an efficient,high performance alternative to traditional DC systems
. As part of Varco’s ongoing development effort, various AC motors and drives were reviewed in an
effort to satisfy the specific requirements of drilling applications. Varco design engineers determined
that rapid developments in adjustable frequency technology made AC drives and motors a better
solution for certain applications traditionally served by DC systems. These modern AC motor/control
combinations are uniquely suited for the requirements of the drilling industry. By optimizing various
components, rugged, reliable AC drives and motors nowcanproduce superior power density for a
given frame size. The result - compact, efficient power plants that extend the performance envelope
of drilling operations.
 Single Speed 5.33:1

DC
TDS-1

New
TDS-1
TDS-3
TDS-7
TDS-9
TDS-4
TDS-2 1981

ThetoIDS
AC
High
Integrated
–1
uses
TDS-3

becomes
Two Speed - 7.95 & 5.08:1 TDS-4 1983

Torque
Swivel
Upgrades
the
becomes
Single Speed - 6.67:1 TDS-5

are
First
NEW
Motors
a Locomotive
TDS-3H

ReducesAC
Industry
Varco’s
are
Dual
TDS-4H

Offered
Motor
Top
First
Industry
Single Speed - 5.33:1 TDS-3S

System
1988

Standard
ACDrive
Single Speed - 5.33:1 TDS-4S

Motor
Introduced
1989

Height
Two Speed DC - 5.33:1 @ 2,200hp

Portable
TDS-6S

Standard
1990
TDS-6SB

TopDrive
1991

Drive
Single Speed Planetary - 6:1 @ 1,150hp IDS-1
Top Drive Development

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

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

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

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

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

The Advantages of Top Drives

• Reaming in or out in sloughing formations

• Minimized Stuck Pipe, Jarring & Lost Wells
• Higher Average ROPs (drilling with stands)
• Reduced Tool face re-orientation times
• Improved well control while tripping (IBOPs)
• More Precise Torque Control on Connections
 Deviated Wells
Typical Horizontal Comparisons ~ 14,000’ Wells

9,000

10,000

11,000
Depth Drilled (ft)

12,000

13,000

14,000
No Top Drive
Top Drive Installed
15,000
0 2 4 6 8 10 12 14 16 18 20
Drilling Days
 Deviated Wells
Typical Horizontal Comparisons ~ 16,500’ Wells

11,000

12,000

13,000
Depth Drilled (ft)

14,000

15,000

16,000
No Top Drive
Top Drive Installed
17,000
0 2 4 6 8 10 12 14 16 18 20 22 24
Drilling Days
General Information
TDS- 9/11S Top Drive

 Small, Compact Top Drive

 Land Rigs
 Small Platform Rigs
 Small Jack-Up Rigs

 Portable & Mobile

 Reduced Size & Weight
 Quick Rig-Up & Rig-Down

 Low Maintenance Cost

 Precise Torque Control
TDS- 9/11S Top Drive

Large Top Drive Features…….

 Full Torque Capability
 Remote Break-Out
 Reverse Link-Tilt
 Rotating Head
 Dual IBOP
…..Plus Many Other Features…..
Remote (Powered) Elevator Positioning
On-Board Hydraulic Power
Integrated Mousehole Kick-Out
Self-Locking Guide Beam
Precision AC Control
Higher Stall Without Overheating
No Brush Maintenance
TDS- 9/11S Top Drive

 500 Ton, 700 hp or 800 hp Versions

 Integrated Swivel and Counterbalance
 Dual AC Drilling Motors
10.5 : 1 Single Speed Transmission
32,500 or 37,500 ft.lbs Continuous Torque
46,000 or 55,000 ft.lbs Intermittent Torque
0-228 rpm Drilling Speed

 PH-50 Pipehandler
50,000 ft.lbs Torque
15,000 psi Rated Dual IBOPs
Compact Link Tilt

 Mousehole Kick-Out
 Self-Locking Guide Beam
 Ex and UL Electrical Models
 25,250 lbs Unit Weight
 Torque/Speed Curves

55,000
Torque (ft.lbs)

50,000

45,000 800hp
Version
40,000

35,000

30,000

25,000

20,000
700hp
15,000 Version
10,000

5,000

0
0 50 100 150 200 250
Rotating Speed (rpm)
 TDS- 9/11S Power Train
Cooling Fan System Bail
Motor (2)

Cooling System Gooseneck

Air Duct (2) ( S-Pipe)

Hydraulic
Brake (2) Bonnet

350 or 400 hp AC Washpipe

Drilling Motor (2) Packing Assembly

10.5 : 1
Transmission

Drive Stem
Alternating Current Motor

Motor Brake Thrust

Ball Bearing

Air Inlet
Rotor Assembly (550 CFM)
(Laminated)
End Coil

Stator Assembly
(Laminated)
Motor Frame
(Laminated)
End Coil

Motor Shaft
Air Exhaust

Guide
Pinion Gear Roller Bearing
 PH-50 Pipe Handler

Powered Elevator Rotating

Positioner (360º) Link Adapter

Upper IBOP &

Link-Tilt Assembly Accumulator
Assembly

Lower IBOP Valve Torque Arrester

Frame

Back-Up Clamp

350T - 108”
Elevator Links
Adjustable
Stabbing Guide
350 or 500T
Elevators
PH-50 - Link-Tilt Positions
 PH-50 – Kick-Out Option

This is an optional extra

Spreader
Beam
Optional
Mousehole
Kick-Out
Assembly

Center
Well

57.7” Max.
116” Ref.
Drill Stem Assembly

Main Shaft Upper IBOP

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

Lower IBOP
(Manual)
Saver Sub
 Electrical Interface

DC Top Drive
Generator
Encoder

Drilling Motors
Mast
Saddle
or Generator Set
AC Highline

Variable Frequency
Inverter and Varco
Control Panel
Electrical
Panel
Service Solenoids
Loop

Sensors
Junction
Box

Varco
Skid
Driller’s
Console
 Service Loop Configurations

Service
Cables J-Boxes
Connections
Land/ Quick 1 set (3) 444 MCM
Portable Disconnects + 1 x Composite N/A
UL
700hp

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

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

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

Fixed Connections + 1 x Composite + 1 x Composite

Land/ Quick 1 set (4) 646 MCM

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

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

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

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

Fixed Connections + 1 x Composite + 1 x Composite
 Variable Frequency Drive

600 VAC
3-phase, 42-62Hz Resultant DC Pulse 810 VDC 20Hz = 600rpm

IGB Transistors
600 VAC
3-Phase, 0-80Hz
AC Power

Capacitors
Source

Rectifier

TDS-11S

40Hz = 1,200rpm

Inverter Controller

Variable Frequency Drive

 Typical Floor Layout
86’ Service Loop Mast Saddle
@ 80ft

75’
Rotary Hose

Sectional Rathole
Guide
Beam

Mousehole
Universal
Spreader
Beam

Driller’s TDS-11S
Console
 Unit Identification
Encoder Instruction Label
Located on the side
of the brake housing

AC Motor Identification Label Top Drive

Located on the side of Identification Plate
each AC motor Located on the front of the
motor housing

Warning Labels
Located on the side
of each AC motor

Warning Label
Located on the
side of the bonnet
 TDS-11S - Envelope
33.7” (856mm)
Rear
33.8” (859mm)

Standard Setback
32.0” (762mm)

22.8” (579mm)
21.1” (536mm)
22.1” (660mm)

31.0” (787mm)

32.6” (828mm)

26” (660mm) 36.9” (937mm) Front

 TDS-11S - Dimensions
18.5” 120” Bail
0.47m

88” Bail

214.0”
5.43m

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

Sectional Guide Beam 18.0’

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

Clear Working Height

142.0’ (43.3m)
Drill Stand Made Up @ 4’ (1.2m)
Mud Hose
Connected to Standpipe @ 73’ (22.3m Level)

Service Loop

93.0’ (28.3m)
Portable Torque Reaction Beam
U-Bolted to Spanners

To CL of Beam
10.0’ (3m) min.

7.0’ (2.1m) min.

To Service Loop
2 x Custom Spanners
On A-Frames or Mast Side Panels

Varco Driller’s Console

Control Cable with Connectors

150’ (45.7m)

Unitized Variable Frequency Drive & Drill

Control Panel Floor

Power Supply
AC Power &
Cables Control Cables
 TDS-11S - Consumables
Hydraulic Wash Pipe
Oil Filter

Part Qty Part No.

Tong Dies 4 16781
Stabilizer - Front 1 118368

Stabilizer - Rear 1 118367

Flippers – Stabbing Guide 1 76442

Wash Pipe 1 123289

Wash Pipe Tungsten Coated 1 123289-TC

Wash Pipe Packing Kit (Standard) 1 123290-PK

Wash Pipe Packing Kit (HP) 1 123290-PK-1

Hydraulic Oil Filter 1 114416-1

Gear Gear Oil Filter 1 111013-1

Oil Filter

Stabilizers

Tong Dies

Stabbing Guide
Installation
Installation
 Installation

The control house must be

properly grounded to
prevent injury to personnel

Insert the grounding rod into the soil (the rod

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

Crown Pad eye

Weld according to table above

Shackle

Guide Beam Connecting/Hang off Link

Installation TDS Lifting Points
Lifting Point Net Weight = 27,000 lb (12,300 kg)
For lowering/hoisting the With Skid = 30,000 lb (13,600 kg)
Top Drive to/from the skid

Lifting Points
For Lifting the Skid with
the Top Drive Attached

Bail Lock
Must be installed before
lowering/hoisting the
Top Drive to/from the skid

Lifting Points
For Lifting the Skid with
the Top Drive Attached

!Locking Pins
Must be in place prior to
moving the skid with the
Locking Pins Top Drive attached
Must be in place prior to
moving the skid with the
Top Drive attached
Installation TDS
Pre-installation
Checklist
The following assumes that all pre-installation planning and
rig-up is complete prior to installation of the guide beam
assembly and TDS-11SA. This includes:
. Make sure the derrick/mast is vertical, with the block over
the center of the rotary table.
. Derrick/mast modifications are completed (if required) and
the guide bean support bracket and torque reaction beam
are installed and inspected to conform to Varco
specifications as detailed in FIP00003.
. The service loop bracket is installed in the derrick/mast.
. The control panel and frequency drive are installed.
. Rigging of tong lines, etc. is inspected to ensure that
they will not foul with the TDS-11SA.
. The hook or adaptor becket is installed. The hook should
open toward the drawworks.
Installation TDS

Ensure that both carriage latches

are engaged for hoisting from the
skid
Ensure that the bail lock
assembly is installed
Engage the hook with the bail
Remove the lock pin
Ensure the Top Drive does not
contact the rig
Hoist the Top Drive from the skid
 Installation TDS

After hoisting the TDS-11SA

from the skid, disengage the
Lower Carriage Latch
and pin it as shown.

Ensure that the lower carriage latch is disengaged

Ensure that the upper carriage latch is engaged
Hoist the Top Drive
Remove the skid from the drill floor
Ensure the Top Drive or the guide beam
does not contact the rig
Remove from drill floorafter hoisting the TDS
Installation Guide beam
Installation Guide beam
Installation Guide beam

Floor Clearance
Using the drawwork, hoist the top guide beam
to the hang-off link
Ensure that the shackle is pinned and it’s
cotter pin is in place
Pin the guide beam to the hang-off link in the
appropriate position
Check for 7 ft clearance from bottom of guide
beam to the drill floor
Secure the pin to the hang-off link with the nut
and safety pin
 Guide Beams & Tie back
Check for Top Drive mainshaft alignment over
well center
Install the main spreader beam at the
Guide Beam
appropriate distance from well center Bottom Section
Install the tieback plate and tieback link
Check for Top Drive mainshaft alignment over
well center
Torque and lock wire all bolts

Tie-Back Plate

Main
Spreader Beam

Bolted Connections
Tie-Back Link

Auxiliary
Spreader Beam

Mast Leg
 Guide Beams & Tie back

Intermediate tiebacks are installed on girts

closest to 55 feet and 105 feet above the drill
floor
Weld two padeyes to the guide beam if the
space between the girt and the guide beam is
greater than 3 inches
Weld a single centered padeye if the space
between the girt and the guide beam is less
than 3 inches
Install intermediate tieback plates as required
Torque and lock wire all bolts
Secure all pins with cotter pins
On-Board Hydraulics
 On-Board Hydraulics
Specifications
Reservoir Capacity 10hp, 1,800rpm
Hydraulic Oil Counterbalance
Filter Manifold Pump Motor 25 Gallons
Counterbalance
Accumulator
Counterbalance
Upper IBOP Cylinders
Time Delay
Accumulator Main Hydraulic
Manifold
Hydraulic
Oil Fill Hydraulic Oil
Link Tilt Reservoir
Oil Pressure Manifold
Switch
Link Tilt
System Cylinders
Accumulator

IBOP Pressure Rotating Head

Switch Motor and Shot-Pin
Assembly
Upper IBOP
Actuator
Cylinder

Motor and Pump

Assembly
 On Board Hydraulics
Drilling Upper IBOP Link-Tilt
Motor Brake Actuator Cylinder Cylinders Piphandler Clamp
Cylinder
Counterbalance Link-Tilt
Accumulator Manifold

Rotating Head
Counterbalance
Cylinders

Shot-Pin
Rotating Cylinder Rotating Link
Head Motor Adaptor Lift
Counterbalance
Manifold Lube Oil
Distribution

Variable Fixed Lube

Displacement Displacement Oil Pump
Pump Pump
Main Hydraulic Manifold Hydraulic
Accumulator

Accumulator

Motor
System

M Sump
IBOP

10hp AC Reservoir
Motor
 Hydraulic System Maintenance
Daily Inspections

Description
Check Condition of the Hydraulic Filter Indicator

Check Hydraulic Fluid Levels

Check for Hydraulic Fluid Leaks

Check Condition of All Hydraulic Hoses

 Hydraulic System Maintenance
Maintenance Schedule

Description Frequency
Replace Hydraulic System Filter Once Every 3 Months

Analyze Hydraulic System Oil Once Every 6 Months

Replace Hydraulic Fluid Annually (or Depending on Analysis)

Inspect Reservoir Bladder Annually

Replace Reservoir Bladder Bi-Annually

 Hydraulic System Maintenance
Recommended Hydraulic Oils

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

Castrol Hyspin AWS-32 Hyspin AWS-46

Chevron AW Hyd Oil 32 AW Hyd Oil 46

Exxon Nuto H32 Nuto H46

Gulf Harmony 32AW Harmony 46AW

Mobil DTE 24 DTE 245

Shell Tellus 32 Tellus 46

Statoil Hydraway HMA 32 Hydraway HMA 46

Texaco Rando Oil HD 32 Rando Oil HD 46

Total Azolla ZS 32 Azolla ZS 46

Union Unax AW32 Unax AW46

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

Cork Ball

Hydraulic Oil Fill

Male
Quick-Connect

Hydraulic Pump

Dust Plug

Female
Quick-Connect Pump Inlet
Drain Adaptor
Hydraulic
Lubrication Kit
 Hydraulic System Maintenance
Heat Exchanger

Blower &
Brake Covers

Oil Heat
Oil Heat Exchanger Exchanger
Monthly
Inspect

Drill Motor Assy.

(LHS)
 Hydraulic System Maintenance
System Test Ports
 Hydraulic System Maintenance
Pre-charging the Accumulators

Counterbalance
Accumulator

Upper BOP
Time Delay
Accumulator

System
Accumulator

Accumulator Setting Port

System Accumulator (125in³ Displacement) 800psi Discharge SA

Counterbalance Accumulator (728in³ Displacement) 900psi Discharge CB

Time Delay Accumulator (30in³ Displacement) 800psi Discharge C4

 Hydraulics Troubleshooting
HPU & Reservoir Bladder
Problem Probable Causes Remedy
Relief Valves RV1 & RV2 improperly set Test pressures & re-set valves

Unloading Valve not working Test & adjust UV1 (or replace)
Hydraulic System
Overheating
Pressure has bled down due to counter-
Check System Pressure
balance mode valve in shut-down too long

No pre-charge in System Accumulator Charge System Accumulator

Test Pumps & Motors

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

Hydraulic Flexible Coupling damaged Replace Flexible Coupling

Components Don’t
Operate Lubrication Pump not working Replace Lubrication Pump

Pressure at UV1 is too low Adjust UV1

Pumps rotating in wrong direction Check connections & rotation

Suction Valve closed Open Suction Valve

Low Reservoir oil Fill Reservoir

 Hydraulic System Maintenance
Reservoir Bladder

Hydraulic Reservoir Bladder

Reservoir Reservoir
Breather Cover

Reservoir
Bladder

Gasket
Reservoir Bladder
Annually
Inspect

Hydraulic Oil
Reservoir
 Hydraulics Troubleshooting
Gearbox Lubrication System (contd)

Check pressure at PF and

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

Missing inspection plugs Replace inspection plugs

Water/Mud in Oil
Upper gearbox seals worn Replace seals

Water in oil Replace oil

Excessive
Foaming Oil viscosity too high or oil too cold Lower oil viscosity

Worn gears or damaged bearings Replace gears or bearings

Metal in Oil

Damaged oil pump Replace oil pump

Restricted Oil
Foreign particles blocking orifice/ nozzle Clean orifice/nozzle
Flow
 Hydraulics Troubleshooting
Gearbox Lubrication System
Problem Probable Causes Remedy
Oil Leaking From
Worn oil seals Replace seals
Lower Seal

Oil Leaking From

Upper Bearing Worn oil seals Replace seals
Retainer

Oil level too low or too high Adjust oil level

Gearbox Oil
Temperature less Incorrect oil Replace with recommended oil
than 230ºF
Damaged gears or bearings Repair or replace

Oil level too low or oil overheating Add oil

Oil pressure switch needs adjustment Adjust

Gear spray nozzle missing Replace spray nozzle

Oil Pump Loss
Alarm is On Oil viscosity too high Lower oil viscosity

Faulty motor Replace motor

Oil pump hydraulic motor faulty Replace motor

Broken lube pump adaptor plate spline Replace adaptor plate spline
 Hydraulic System Maintenance
1. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when
looking into pump shaft/ electric motor fan). Correct as required.
2. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would
indicate cavitation; check for leaks.
3. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end,
cap the tube and plug the PF port using steel fittings. 8
4. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise,
which allows the hydraulic system to operate without building up pressure.
5. Set the relief valve RV2 to minimum pressure, fully counterclockwise.
i Make sure the variable displacement pump case is filled with clean hydraulic oil.
6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the
pressure increases to 400 psi at test point PF. Set the jam nut on RV2.
A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.
i While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the
pressure change.

7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor.

8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate.
9. Restart the hydraulic system electric motor.
Pressure Switch
Set @ 18 psi

Spay Nozzles
Lube Pump

Lube Filter

Heat Exchanger
Hydraulic Motor

RV2 Set @ 400 PSI

Test port PF

Fixed Displacement Pump

 Hydraulic System Maintenance
Setting up the Circuits
RV2

Manifold
Side View

B1

Manifold
Bottom View
 Hydraulic System Maintenance
Setting up the Circuits

Pump/Motor
Guide Beam

Pump Pressure
Compensator

Variable Displacement Fixed Displacement 10hp AC Pump

Pump Pump Motor
 Hydraulic System Maintenance
Setting up the Circuits RV2 RV1
Fixed Variable
Displacement Displacement

Manifold
Side View

Manifold
Bottom View

PF
 Hydraulics Troubleshooting
Pumps
 Hydraulic System Maintenance
Setting up the Variable Pump
 Hydraulic System Maintenance
Setting up the Circuits

3000 Reading @ PV
Reading @ SA

2000
Pressure (psi)

1700

1000
800

150

0 10 20 30 40 50 60

Approximate Time (s)

Hydraulic System Maintenance
Reading from test port PV

2000PSI 2000PSI
2000PSI

20 Seconds
20 Seconds

100 PSI
0 PSI 100 PSI
Hydraulic System Maintenance

3000 Pressure reading at

SA

2000
Pressure (psi)

1700

20 Seconds 20 Seconds

1000
800

150

0 10 20 30 40 50 60

Approximate Time (s)

 Hydraulic System Maintenance
Setting up the Circuits
PCC

Manifold
Side View

CB

Manifold Manifold
Bottom View End View
Counterbalance System

Counterbalance systems vary widely in configuration

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

Q. What does the counterbalance system consist of.

A. The counterbalance system consists primarily of two hydraulic cylinders, a
counterbalance manifold, cartridge valves, a hydraulic accumulator, and connecting links
Q. How does the counterbalance function.
A. The two hydraulic cylinders are connected to the hydraulic accumulator, the
accumulators are pre-charged to 900 psi, When properly adjusted the
counterbalance systems supports all but about 800lbs of the weight of the Top Drive.
 Hydraulic System Maintenance
Setting up the
Counterbalance

900 PSI Pre-Charge

CV3

.055 ORIFICE

TEST PORT

PCC
 COUNTERBALANCE
CYLINDERS

ACCUMULATOR
PRECHARGE 900 PSI

CV3
MODE VALVE

PCC
 Hydraulic System Maintenance
Setting up the
Counterbalance

900 PSI Pre-Charge

CV3

.055 ORIFICE

TEST PORT

PCC
 Hydraulics Troubleshooting
Counterbalance & Stand-Jump
Problem Probable Causes Remedy

Cylinder damaged or seals leaking Inspect & repair cylinder/seals

Test pressure & adjust reducing

No hydraulic pressure valve

Counterbalance Test electrical/hydraulic

Solenoid Valve SV9 is not operating
Does Not Function connection – repair as required
PCC not operating Replace valve

Relief valve not operating Replace valve

Pre-charge too low Charge the accumulator

Cylinder damaged or seals leaking Inspect & repair cylinder/seals

Test pressure & adjust reducing

No hydraulic pressure valve
Stand-Jump Test electrical/hydraulic
Solenoid Valve SV9 is not operating
Does Not Function connection – repair as required
PCC not operating Replace valve

Relief valve not operating Replace valve

Pre-charge too low Charge the accumulator

 Hydraulics Troubleshooting
Counterbalance & Stand-Jump
 Hydraulics Troubleshooting
Brakes
Problem Probable Causes Remedy

Brake Does Not Test valve and replace if

Directional Valve stuck
Release necessary

Check Valve is blocked or tube is pinched Check valve & tube

Brake Releases
But Drags Mechanic problem with brake Check brake mechanism

Hydraulic oil on brake Check for leaks

Brake Does Not Pressure < 1,400psi or does not rise

Adjust or replace reducing valve
Engage or Slips quickly to 1,400psi

Directional Valve stuck (check pressure Replace valve or check

at B1) electrical signal

Hydraulic oil contaminated Replace oil

Delay in Brakes
Actuating Pressure Reducing Valve faulty Replace valve
 Hydraulics Troubleshooting
Brakes
 Hydraulics Troubleshooting
Shot-Pin & Clamp Cylinder
Problem Probable Causes Remedy

Solenoid Valve not operating or needs Check electrical actuation &

adjustment test pressure
Shot-Pin Does
Abnormal pressure change at B5/C5 Replace Directional Control
Not Release
indicates valve problem Valve

Normal pressure change at B5/C5 Repair plumbing or shot-pin

indicates plumbing or faulty cylinder cylinder

Shot-Pin Applies Relief Valve not operating or needs

Test pressures & adjust
Excessive Force adjustment

No/low pressure at cylinder Test pressures & adjust/repair

Cylinder is damaged Inspect/repair/replace cylinder

Clamp Cylinder To provide high pressure to the clamp

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

While clamping, pressure at CR should be

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

Shot-Pin Engages Check pressure at C5. Replace

But Cylinder Control valve not operating valve CV5 if required or the
Does Not Activate regenerate manifold
 Hydraulic System Maintenance
Setting up the Circuits Motor Hydraulic Test Points
Relief Valve Motor A B
Shot Pin Motor Relief
Relief Valve Valve

B5

C5

A5

Link Adaptor
Rotation Gear

Shot Pin
 Hydraulics Troubleshooting
Shot-Pin & Clamp Cylinder
 Hydraulic System Maintenance
Setting up the Circuits

Hydraulic
Motor

SV5

C5

Link Adaptor
Rotation Gear

Shot Pin
 Hydraulics Troubleshooting
Link Tilt Cylinders
Problem Probable Causes Remedy
Elevator Does Not
Reach Mousehole Link clamp incorrectly adjusted Check & readjust
or Derrickman

Pressure at B1 does not decay Replace the pilot to open

to less than 100psi check valve

Pilot to open check valve is contaminated Replace the pilot to open

Links Drift When or stuck in open position check valve
Valve is Released
Faulty cylinder seal Replace cylinder seal

Load holding relief valves are stuck open, Replace or adjust the load
contaminated or need adjustment holding relief valve

Use manual override

Elevator Does Not
If the link tilts, the problem is electrical Test the solenoid & connectors
Float Back to
If the links do not tilt, the problem is Test the hydraulic system
Center Position
hydraulic

Link Tilt Does Solenoid Valve is not shifting Check electrical continuity
Not Tilt
Links Do Not
Load holding valves need adjustment Adjust all (4) valves to 1,500psi
Move Together
 Hydraulics Troubleshooting
Link Tilt Cylinders
 Hydraulics Troubleshooting
Rotating Link Adaptor
Problem Probable Causes Remedy
Direct control valve or relief valve is Inspect, repair or replace the
sticking valve

Solenoid valve not electrically operating Check electrical/valve functions

Motor worn or gear teeth broken Replace the motor

Tool Does Shot-pin engaged Adjust the relief valve

Not Rotate
Mechanical interference Inspect and repair

Directional valve does not shift Test pressure left and right
Replace valve if necessary

Fixed valve orifice plugged Clear orifice or replace valve

Hydraulic valves damaged Replace hydraulic lines

Valve sticking or relief valve needs Test pressures & inspect valves
adjustment Adjust relief valves as required
Tool Does Not
Broken sensor Replace sensor
Return to Home
Faulty control system Check control system

Links Not
Counterbalance valves need adjustment Adjust valves
Syncronized
 Hydraulics Troubleshooting
Rotating Link Adaptor
 Hydraulics Troubleshooting
IBOP Actuator
 Hydraulic System Maintenance
IBOP and Oil Pressure Switch
Hoses

Hoses
Annually
Inspect

Oil Pressure
IBOP Pressure Switch
Switch Configuration
Configuration

Wires
Pressure
Annually
Adjusting Screw
Inspect

Wires

Component Factory Setting

IBOP Pressure Switch 1500psi (102.0 bar) rising

Oil Pressure Switch 18.0psi (+0/-1) decreasing

 Rotating Head
Port A4

.055”

PC4
500psi
 Hydraulics Troubleshooting
IBOP Actuator

Rotating Head
Port B4

.055”
 Hydraulics Troubleshooting
IBOP Actuator

Rotating Head
Port A4

.055”

PC4
.010”
500psi
Motor Housing
& Transmission
 Motor Housing & Transmission
Internal Lubrication Flow

Pipe Plugs

Gear Drain
Monthly
Inspect
Pipe Plugs
Monthly
Inspect

Spillway
Monthly
Inspect
 Motor Housing & Transmission
Adjusting the Encoder(s)
Sled Hold-Down
Screws (4)
Belt Tension
Spring

Encoder Belt Sled

Electrical
Connector
Sled

Belt Tension Sled Hold-Down

Spring Screws (4)
 Motor Housing & Transmission
Inspecting the Gearbox Lube Pump End Cover
Ring Seal
Thrust Plate

Gear Housing

Body Seal

Gear Set

Roller
Bearings (4)
Pump
Adaptor Plate

CapScrew (10)

Main Body
Hydraulic Motor

O-Ring
 Motor Housing & Transmission
Inspecting Gear Backlash
Gear Backlash
6 Monthly
Inspect

Solid
Wire Solder

A B

Dim A + Dim B = Backlash

 Motor Housing & Transmission
Inspecting Bail & Main Body

Bail
Annually
Inspect

Bushings (2)
Annually
Component Minimum Dimension
Inspect
Bushing ID < 4.45”
Bail Pin ID < 4.125”
Main Body Cover
5 Yearly
MPI

Main Body
5 Yearly
MPI

Bail Pin
Annually
Inspect
 Motor Housing & Transmission
Inspecting S-Pipe Wing Nut

Seal Ring

Plug
S-Pipe
Monthly
Inspect

S-Pipe
Monthly
Pressure Test

Clamp

Bolts
Seal Ring

Wing Nut
 Motor Housing & Transmission
Inspecting Main Shaft Liner

Wash Pipe
Assembly

Main Shaft Liner

Monthly
PolyPack Seal
Inspect

Polypack Seal

Main Shaft
 Motor Housing & Transmission
Inspecting Wash Pipe Assembly LEFT HAND THREADS!

Wash Pipe Nut

Packing Box

Dowel Pin

Socket Head Screw

3” Bore
Wash Pipe Wrench
 Motor Housing & Transmission
Inspecting Wash Pipe Assembly
Wash Pipe
O-Ring Daily
Snap Ring Inspect

Holding Ring

Packing Seal Upper Spacer

Wash Pipe Nut

Middle Spacer

Wash Pipe Middle Spacer

Packing Assembly Box

Lower Spacer
Straight Grease Fitting

O-Ring
Socket Head Screw
 Motor Housing & Transmission
Inspecting Upper Bonnet Seals Cap Screw (6)

Bearing Shield

Bearing Bearing Retainer

Oil Seal Isolator
Cap
Bearing Screws (6)
Shield Lube Tube
Bearing
O-Ring Retainer Lube Tube O-Ring

Retainer O-Ring
Annually
Inspect

Bearing Isolator
Annually
Lube
Tube Inspect

Oil Seal
Annually
Inspect

Shims
 Motor Housing & Transmission
Inspecting Main Shaft
Radial Grooves

Stem
5 Yearly
MPI
<0.65”

Split Load Collar

5 Yearly
MPI

Radial Grooves
<0.62”

Annually
Inspect

Retainer Ring
 Motor Housing & Transmission
Inspecting Main Shaft End-Play

Main Shaft
Annually Dial Indicator

Inspect
Cap
Screws (6)

Bearing Retainer Shims

 Motor Housing & Transmission
Inspecting Blower Motor Assemblies Loose Bolts
Monthly
Bolts (4)
Drip Shield Inspect

Fan Motor Cover

Bolts (4)

Motor Fan

Bolts (6)

Top Bearing Housing

 Motor Housing & Transmission
Inspecting Motor Brakes

Caliper
Mounting Bolts (2)
Steel Plate

0.09” Calipers & Pads

Monthly
Inspect
Adjust

Brake Pads

Caliper
Mounting Bracket
 Motor Housing & Transmission
Inspecting Drilling Motors

Motor Cables
Weekly
Inspect

Louvers
Weekly
Inspect

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

Compound Gear Dowel Pin

Upper Stem Liner

Internal Retaining Ring Poly Pack Seal

Spacer Ring

Lower Compound Roller Bearing

Bearing Lock Washer

Main Shaft Stem
Internal Locknut Retainer

Main Body O-Ring

Main Body
Tapered Roller
Thrust Bearing

Main Shaft Sleeve

Lower Main Roller Bearing

Lube Oil Pump Assembly Main
Bearing
Wear Sleeve
Lock Washer
Bearing
Cap Screw Retainer
Lubrication
 Lubrication Schedule
Transmission

Action Frequency
Replace Gearbox Oil Following Initial Break-In Following 1st Month of Operation

Replace Gearbox Oil and Perform Oil Analysis Every 6 Months

Replace Gearbox Oil Filter Every 3 Months

Remove, Clean and Replace Magnetic Drain Plug Annually

 Lubrication Schedule
Transmission Gearbox Drain

Sight Glass Check oil level,

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

Cork Ball

Gear Oil Filter

Pop-Up
Dirt Alarm

Gearbox Oil Fill

YEARLY

Remove and clean contamination

Magnetic Drain Plug

 Lubrication Schedule
Hydraulics

Action Frequency
Perform Hydraulic System Analysis Every 6 Months

Replace the Hydraulic Fluid Annually (or depending on analysis)

Replace the Hydraulic System Filter Every 3 Months

 Lubrication Schedule
Hydraulics Hydraulic Oil Filter
Pop-Up Sight Glass
Dirt Alarm

Cork Ball
Hydraulic Oil Fill
Male
Quick-Connect

Dust Plug

Hydraulic
Female Oil Drain
Quick-Connect

Hydraulic
Lubrication Kit
 Lubrication Schedule
Motors

Action Points Frequency

Lubricate the AC Drilling Motors 4 Every 3 Months

Lubricate the Blower Motors 4 Every 3 Months

Lubricate the Hydraulic Pump Motor 4 Every 3 Months

 Lubrication Schedule
Motors
Grease Fittings

Grease
Fitting (1/8”)

AC Blower Motors (2)

Pipe Plug
(1/8”)

AC Drilling Motors (2) Hydraulic Pump AC Motor

Grease
Fittings
 Lubrication Schedule
General Lubrication

Action Points Frequency

Wash Pipe Assembly 1 Daily

Upper Bonnet Seal 1 Weekly

Bail Pins 2 Weekly

Rotating Link Adaptor Gear - Weekly

IBOP Actuator Yoke & Cylinder Pins 5 Daily

IBOP Actuator Cranks 2 Daily

Upper IBOP Valve 1 Weekly

Stabilizer Bushing 4 Daily

Clamp Cylinder Gate 2 Daily

Carriage Assembly 8 Weekly

Torque Arrester @ Clamp Cylinder 4 Weekly

Wireline Adaptor 2 Weekly

Elevator Link Eyes 4 Weekly

 Lubrication Schedule
General Lubrication

Wash Pipe Assembly

Bail Pins (2) Upper Bonnet Seal

Rotating Link Adaptor Gear

Rotating Link Adaptor

 Lubrication Schedule
General Lubrication
Upper IBOP Valve

IBOP Actuator Cylinder Pins ¼”

NPT Plug

IBOP Actuator Yoke

IBOP Actuator Yoke

IBOP Actuator Cranks Stabilizer Bushing

Torque Arrester Tubes

Stabilizer Bushing
Clamp Cylinder Gate

Clamp Cylinder Gate

 Lubrication Schedule
General Lubrication

Rollers
 Lubrication Schedule
General Lubrication

Wireline Adaptor
Guide Beams
& Carriage
 Guide Beams & Carriage
Inspecting the Crown Padeye & Hang-Off Link Shackle

2.1” (52mm) min

Crown Padeye
Annually
MPI

Crown Padeye
Monthly 2.0”
(50mm) min
Visual

Cotter Pin
Monthly Hang-Off Link Bores
Visual
1.5”
Shackle (15mm) min
Monthly
Inspect

Hang Off Links

Monthly
Inspect
 Guide Beams & Carriage
Inspecting the Crown Padeye & Hang-Off Link

Bolt Assembly Hang-Off Link

Monthly Monthly
Inspect Inspect

Bolt Assembly

Hang-Off Link Bores

2.1” (52mm) min

1.5”
(15mm) min

Safety Pin
Monthly
Inspect
 Guide Beams & Carriage
Inspecting the Guide Beam Joints

Lynch Pin
Lynch Pin
Daily
Inspect

Beam Joints
Weekly
Inspect
Beam Joints
Annually
MPI

Retainer Pin
Daily
Beam Joints
Inspect
Monthly
Inspect
 Guide Beams & Carriage
Inspecting the Main Tie-Back Guide Beam
All Welds All Welds Bottom Section
Annually Weekly
Alignment
MPI Inspect
Daily
Inspect

Tie-Back Plate

Main
Spreader Beam
All Bolts
Weekly
Inspect

Tie-Back Link

Bolted Connections

Auxiliary
Spreader Beam
Mast Leg
 Guide Beams & Carriage
Inspecting the Intermediate Restraints
Alignment
Daily
Inspect

Studs/Nuts
Weekly
Inspect

Pin/Cotter Pin
Weekly
Inspect

Main Girt All Welds

Annually
MPI

Guide Beam
 Guide Beams & Carriage
Inspecting the Carriage

Rollers
Weekly
Inspect

Detent Pins
Daily
Inspect
PH-50 Pipehandler
 PH-50 Pipe Handler
Inspecting Elevator Links Recess in
Motor Guard

Rear
LIFT &
2 REMOVE

Link Tilt

Upper
Catch Link

Front
Catch Link Pin Link

26” (635mm)
Typical
Clevis
Pin

1
ROTATE
Link Clamps
Weekly
Inspect
Link Eyes
Varco
Monthly
Driller’s Console Inspect
 PH-50 Pipe Handler
Inspecting Elevator Links
C
Upper Eye Lower Eye Capacity C Upper Eye
(Hook)
Dimension (C) Dimension (A) per Set (Tons)
B = 3½” (350 Ton)
5” 2 3 /4 ” 350

4 13/
16” 2 9/16” 300

4 5 /8 ” 2 3 /8 ” 225

4 7/16” 2 3/16” 175 B

B = 4½” (500 Ton)
6” 3 1 /2 ” 500
B
5 3/
4” 3 1/
4” 420

5 1 /2 ” 3” 325

5 1 /4 ” 2 3 /4 ” 250
A
B = 6¼” (750 Ton)
7 1 /2 ” ? ?
7 1 /4 ” ? ?

7” ? ? Lower Eye
(Elevator)
6 3 /4 ” ? ? A
 PH-50 Pipe Handler
Inspecting Link-Tilt

Cylinders
Monthly
Inspect

Pins
Bushings
Monthly
Monthly
Inspect
Inspect

Bushings
Monthly
Inspect
 PH-50 Pipe Handler
Inspecting Link-Tilt

Hydraulic
Manifold
Rig-Up/Run/
Shutdown Valve

Torque
Arrestor

Spring

Spring
Spacer

Spring
Shims

End Cap

Clamp
Cylinder Body
 PH-50 Pipe Handler
Torque Wrench Assembly
Manifold

Rear
Stabilizer Front
Stabilizer

Hinge Pin Spring

Retainer
Hex Head
Cylinder Screws
Head Ring
Clamp
Cylinder Body
Cylinder Head
Body Seals
Piston Seals
Jaw
Piston Assembly

Tong Dies

Wear Bushing

Hinge Pin Gate

Rear/Front
Stabbing Guides

Stabilizer

Spring Retaining Plate

 PH-50 Pipe Handler
Inspecting the Torque Wrench Assembly Part Replace When
Stabilizer Wear > 1/8”
Flipper Wear > 1/8”

Tugger Liner

Stabilizers (F/R)
Weekly
Inspect

Stabbing Guide
Weekly
Tong Dies Inspect
Daily
Inspect
Flippers
Clamp
Cylinder Gate Weekly
(shown open)
Swing Clear
Inspect
 PH-50 Pipe Handler
Inspecting the Torque Wrench Assembly

Stabilizer Springs
Monthly
Inspect

Stabilizer
Springs
Cotter Pin
 PH-50 Pipe Handler
Inspecting the IBOP Actuator

Actuator Cylinder
Weekly
Inspect

Hoses
Daily
Inspect

Pins & Bushings Actuator Yoke

Monthly Weekly
Inspect Inspect

Part Replace When

Pins Wear > 0.3”
Bushings Metal Backing Visible
 PH-50 Pipe Handler
Inspecting the Tool Lock Joints

1.4”
1.4”
1”
1”

Tool Lock Bolts

Daily
1.4”

Inspect
1.4”
 PH-50 Pipe Handler
Inspecting the IBOP Valves & Saver Sub Part Replace When
Threads have been
Saver Sub recut to minimum
Upper & Lower IBOPs shoulder-to-shoulder
5 Yearly length of 5”
MPI

Upper IBOP Upper IBOP Valve

Weekly Daily
Inspect Pressure Test

IBOP Crank
Weekly
Inspect

Lower IBOP Lower IBOP Valve

Weekly Daily
Inspect Pressure Test
 PH-50 Pipe Handler
Shot Pin
Shot-Pin Assembly Base

Dowel Pin
Dual Port
Rod Seal Manifold
Assembly
Shot Pin

Rod Seal
Assembly

Shot Pin
Sleeve

Hydraulic
O-Ring Motor

Shot Pin
Bushing

Shot Pin
Cap Pinion
Gear
Part Replace When
Shot Pin OD < 1.375” Shot Pin
Cover
Shot Pin Sleeve ID > 1.510”
Shot Pin Bushing ID > 1.475”
 PH-50 Pipe Handler
Rotating Link Adaptor
Rotary GLYD Ring
Annually
Rotary Link Replace
Adaptor
O-Ring
Annually
Replace
Retainer Thrust Ring
Ring
Annually
O-Ring Replace

Rotary Turcite Bushing

GLYD Ring Annually
Wiper Seal Replace

Rotating Link
Piston Ring
Adaptor Gear Annually
Inspect

Part Replace When

Thrust Ring Less than 0.105” Stem
Annually
Turcite Bushing Less than 0.112”
Inspect

Stem O-Ring
Annually
Index Mark
Replace
LEVEL WORKING SURFACE
 PH-50 Pipe Handler
Wireline Adaptor

Sheaves
Each Use
Inspect
Drawings
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Hydraulic Manifold
Counterbalance Rig-Up
Counterbalance Run
Counterbalance Shut-Down
Brakes On
Rotate Left
Rotate Right
Shot-Pin
IBOP Open
IBOP Closed
Torque Wrench On
Torque Wrench Off
Lube Oil System
Pump System
Pump Rig-Up
Stand-Jump Position
Float Position
Mousehole
Drill-Down
 The Bail Lock Assembly
must be installed
Tube (P/N 113498)
U-Bolt (P/N 113497)
2x 3/4" nuts

Locate the Top Drive at the bottom of the

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

Be sure that Top Drive is pinned to

skid before hoisting to drill floor
 Safety Wiring

1 2
 Safety Wiring

3 4 5
 Hydraulics Troubleshooting
IBOP Actuator

.055”
 Rotating Head
Port A4

.055”

PC4
500psi
 Hydraulics Troubleshooting
Gearbox Lubrication System