TDS-11S

Training
 Program Contents

TDS 11 Mechanical Systems

 Safety!
 Top Drive Development
 Lubrication
 Guide Beams & Carriage
 Motor Housing & Transmission
 PH-50 Pipehandler
 On-Board Hydraulics
Safety!
 Safety at Varco!

Varco drilling equipment is installed and operated in a controlled

drilling rig environment that involves hazardous operations and
situations
Safety is our FIRST Consideration!
General Safety

 Isolate all energy sources

before beginning work
 During installation, operation,
maintenance, or repair of this
equipment, personnel must
wear the appropriate
protective equipment
Equipment Use

 Varco equipment is designed

for specific functions and
applications and should be
used only for the intended
purpose
 NEVER hoist personnel using
this equipment
Personnel Training

 All personnel installing,

operating, repairing, or
maintaining equipment, or
those in the vicinity, must be
trained in rig safety, tool
operation, and maintenance
 This measure helps ensure
the safety of everyone
exposed to the equipment for
whatever purpose
 Contact Varco’s Training
Department for training on
equipment operation and
maintenance
Motion Hazards

 Some Varco equipment

travels either horizontally,
vertically on rails, or both
 Avoid placing objects in or
near the path of this
equipment as such
interference could cause
personnel to become trapped
or crushed by the equipment
 Keep the working
envelope/zone of the
equipment free from
personnel
Maintenance Hazards

 Failure to conduct regular

maintenance may result in
injury to personnel or
equipment damage
 During disassembly of any
equipment, verify that all
components are clearly
tagged and labeled to ensure
that components are re-
installed correctly
 Always replace failed or
damaged components with
Varco certified parts as
failure to do so may result in
personal injury or equipment
damage
Equipment Visibility

 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, video cameras must
be installed to ensure
adequate visibility
Electrical Systems

 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
 When performing installation,
maintenance, or repairs,
isolate all power - lock out
switches and tag them to
prevent injury
Electrical Systems

 Before beginning work on this

equipment, familiarize
yourself with the electrical
schematics, as well as power
requirements
 Prior to disconnecting wires,
verify that all wires and
terminals are properly
labeled to ensure proper
reconnection
Hydraulic Systems

 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
 Isolate, lock out, and tag the
hydraulic and electrical
power & controls
 Before beginning work on any
portion of the hydraulic
system, familiarize yourself
with the hydraulic and
electrical schematics
Hydraulic Systems

 Properly discharge all system

accumulators
 Take precautions when
bleeding down residual
system pressure, using bleed
valves or alternative
techniques
 Hydraulic fluids can be
extremely hot and under high
pressure
Hydraulic Systems

 Never check for hydraulic

leaks with your hands
 Oil under pressure and
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
Hydraulic Systems

 Collect all residual fluid in a

container to prevent spillage
– for both safety and
environmental reasons
 Take precautions to prevent
hydraulic oil from leaking into
other open electrical or
mechanical components,
such as junction boxes
Pneumatic Systems

 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
 Isolate, lock out, and tag the
pneumatic and electrical
power & controls
Pneumatic Systems

 Properly discharge all system

accumulators
 Take precautions when
bleeding down residual
system pressure using bleed
valves or alternative
techniques
 Safety Wiring

1 2
 Safety Wiring

3 4 5
History of Top Drive
Development
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
The Advantages of Top Drives

+
INCREASED SAFETY
 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
 Single Speed 5.33:1 TDS-1

DCThe
New
TDS-1
TDS-3
TDS-7
TDS-4
TDS-2

TDS-9
1981

AC
toIDS
High
Integrated
uses
TDS-3

becomes
becomes
Two Speed - 7.95 & 5.08:1 1983

becomes
TDS-4

–1Torque
Swivel
Upgrades
the
the
the
Single Speed - 6.67:1

abecomes
TDS-5

are
First
Motors
Locomotive
NEW
First
TDS-3H

Reduces AC
Industry
are
Varco’s
Dual
Offered
TDS-4H

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

Standard
ACDrive
1988
Single Speed - 5.33:1

Motor
Introduced
TDS-4S

Height
Portable
1989

Standard
Two Speed DC - 5.33:1 @ 2,200hp TDS-6S
1990

TopDrive
Drive
TDS-6SB
1991
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

General Information
TDS-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-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-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-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

Ov
e rd
ril
l
o le

n
eh

ckma
us
Mo

D e rri
PH-50 – Kick-Out Option

Spreader
Beam
Optional
Mousehole
Kick-Out
-O
ut Assembly
ck
Ki
or
Do
V-

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

Sensors
Loop 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 780 VDC 20Hz = 600rpm

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

Capacitors
Source

Rectifier

TDS-11S

40Hz = 1,200rpm

Inverter Controller

Variable Frequency Drive

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

88” Bail

214.0”
5.43m

5.82m
233”
2.85m
112”
28” 37”
0.71m 0.94m
56”
72”
1.42m
1.83m
62”
1.58m
 TDS-11S - Envelope
33.7” (856mm)
Rear
33.8” (859mm)

Standard Setback
32.0” (762mm)

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

31.0” (787mm)

32.6” (828mm)

26” (660mm) 36.9” (937mm) Front

 Typical Mast Interface
Existing Travelling Equipment Crown
500 ton Hook/Block Combo Type 13.5’
Block Top 4.1m
TDS-11S
Varco Portable Top Drive System 13.5’
4.1m
Bail Rest

Sectional Guide Beam 18.0’

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

Clear Working Height

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

93.0’ (28.3m)
Service Loop

Portable Torque Reaction Beam

U-Bolted to Spanners

To CL of Beam
10.0’ (3m) min.

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
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
Gearbox
Oil Drain

Cork Ball

Gear Oil Filter

Pop-Up
Dirt Alarm

Gearbox Oil Fill

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
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
Alignment
Gear Housing
Daily
Inspect 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 Screws
Bearing (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
Adjust

Inspect

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
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 Assembly
Piston

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
recut to minimum
Upper & Lower IBOPs Saver Sub
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 Ring Thrust 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
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 Motor

Switch and Shot-Pin
Assembly
Upper IBOP
Actuator
Cylinder

Motor and Pump

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

Counterbalance Rotating Head

Cylinders

Shot-PinRotating Link
Rotating Cylinder Adaptor Lift
Head Motor

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

Accumulator

Motor
System

Sump
M
IBOP

10hp AC Reservoir
Motor
 Hydraulic System Maintenance
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
Reservoir Bladder

Hydraulic Reservoir Bladder

Reservoir Reservoir
Breather Cover

Reservoir
Bladder

Gasket
Reservoir Bladder
Annually
Inspect

Hydraulic Oil
Reservoir
 Hydraulic System Maintenance
Reservoir Bladder

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

 Hydraulic System Maintenance
IBOP Timing Circuit
 Hydraulic System Maintenance
IBOP and Oil Pressure Switch
Hoses

Hoses
Annually
Inspect

Oil Pressure
IBOP Pressure Switch
Switch Configuration
Configuration

Wires
Pressure Adjusting
Annually
Screw
Inspect

Wires

Component Factory Setting

IBOP Pressure Switch 1500psi (102.0 bar) rising
Oil Pressure Switch 18.0psi (+0/-1) decreasing
 Hydraulic System Maintenance
Setting up the Circuits

Guide Beam

Pump/Motor

Pump Pressure
Compensator

Variable Displacement Fixed Displacement 10hp AC Pump

Pump Pump Motor
 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
Setting up the Circuits
RV2 RV1

Manifold
Side View

Manifold
Bottom View

PF
 Hydraulic System Maintenance
Setting up the Circuits
 Hydraulic System Maintenance
Setting up the Circuits
PCC

Manifold
Side View

CB

Manifold Manifold
Bottom View End View
 Hydraulic System Maintenance
Setting up the Circuits
 Hydraulic System Maintenance
Setting up the Circuits
RV2

Manifold
Side View

B1

Manifold
Bottom View
 Hydraulic System Maintenance
Setting up the Circuits

Hydraulic
Motor

SV5

C5

Link Adaptor
Rotation Gear

Shot Pin
 Hydraulic System Maintenance
Setting up the Circuits Motor Relief Hydraulic Test Points
Valve Motor A B
Shot Pin Motor Relief
Relief Valve Valve

B5

C5

A5

Link Adaptor
Rotation Gear

Shot Pin
 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

 Hydraulics Troubleshooting
HPU & Reservoir Bladder
 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 necessary
Directional Valve stuck
Release

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

Directional Valve stuck (check pressure at Replace valve or check electrical

B1) 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 & test
adjustment pressure
Shot-Pin Does
Abnormal pressure change at B5/C5 indicates Replace Directional Control Valve
Not Release
valve problem

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

plumbing or faulty cylinder cylinder

Shot-Pin Applies Relief Valve not operating or needs

Excessive Force adjustment Test pressures & adjust

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 should Repair plumbing, rotating head, or
increase from less than 100psi to higher clamp cylinder.
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 at
Does Not Actuate 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
 Hydraulics Troubleshooting
Shot-Pin & Clamp Cylinder
 Hydraulics Troubleshooting
Link Tilt Cylinders
Problem Probable Causes Remedy
Elevator Does Not
Reach Mousehole or Link clamp incorrectly adjusted Check & readjust
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 or Replace the pilot to open

Links Drift When 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 holding
contaminated or need adjustment relief valve

Elevator Does Not Use manual override

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

Link Tilt Does Solenoid Valve is not shifting Check electrical continuity
Not Tilt

Links Do Not
Move Together Load holding valves need adjustment Adjust all (4) valves to 1,500psi
 Hydraulics Troubleshooting
Link Tilt Cylinders
 Hydraulics Troubleshooting
Gearbox Lubrication System
Problem Probable Causes Remedy
Oil Leaking From
Lower Seal Worn oil seals Replace seals

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
 Hydraulics Troubleshooting
Gearbox Lubrication System (contd)

Check pressure at PF and replace

Faulty fixed displacement pump.
pump if pressure is low
Oil Pump Loss Alarm
is On Low hydraulic fluid in reservoir Add hydraulic fluid

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

Metal in Oil Worn gears or damaged bearings Replace gears or bearings

Damaged oil pump Replace oil pump

Restricted Oil Flow

Foreign particles blocking orifice/ nozzle Clean orifice/nozzle
 Hydraulics Troubleshooting
Gearbox Lubrication System
 Hydraulics Troubleshooting
Rotating Link Adaptor
Problem Probable Causes Remedy
Direct control valve or relief valve is Inspect, repair or replace the valve
sticking

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

Test pressure left and right

Directional valve does not shift
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
Return to Home Broken sensor Replace sensor

Faulty control system Check control system

Links Not
Syncronized Counterbalance valves need adjustment Adjust valves
 Hydraulics Troubleshooting
Rotating Link Adaptor
 Hydraulics Troubleshooting
Rotating Link Adaptor
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