Beruflich Dokumente
Kultur Dokumente
Top Drive
Drilling
System
Service Manual
SM00400
March 2, 1998
Manual conventions
This manual uses conventions that make it easy for the reader to
locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and its components.
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention. Note the examples below
and pay close attention to these important advisories.
ii TDS-10S
About thisContents
manual
Contents
Preface
Manual conventions............................................................ 5
Safety information .............................................................. 5
Directional references ......................................................... 6
Illustrations ......................................................................... 6
Manual layout..................................................................... 6
Varco service centers ........................................................... 6
Chapter 1 Introduction
Introduction to the TDS-10S ............................................. 7
Chapter 2 Description
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
Chapter 4 Operation
Driller’s interface and driller’s console ............................... 33
Throttle control .......................................................... 33
Torque control............................................................ 34
Switches ...................................................................... 34
Indicators .................................................................... 36
Varco control system ................................................... 37
Variable frequency inverter ............................................... 38
Rectifier and DC link filter ......................................... 38
Power modules ........................................................... 38
Control section ........................................................... 38
Service loop ...................................................................... 39
Drilling ahead ................................................................... 40
Drilling ahead with triples .......................................... 40
Drilling ahead with singles .......................................... 42
Tripping in and tripping out ....................................... 44
Back reaming .............................................................. 44
Well control procedures .............................................. 46
Running casing ........................................................... 48
Chapter 5 Specifications
General ............................................................................. 49
Drilling parameters ..................................................... 50
Rated capacities..................................................... 50
Drilling motor ...................................................... 50
Pipehandler (PH-55) ............................................ 50
Chapter 6 Appendix............................... 51
iv TDS-10S Contents
Book 2 – Maintenance and Troubleshooting
Preface
Manual conventions............................................................ 7
Safety information .............................................................. 7
Directional references ......................................................... 8
Illustrations ......................................................................... 8
Manual layout..................................................................... 8
Varco service centers ........................................................... 8
Chapter 1 Introduction
Precautions ......................................................................... 9
Chapter 3 Inspection
Inspecting hardware and fittings ....................................... 17
Inspecting the AC drilling motor brakes ........................... 18
Inspecting the AC drilling motor louvers .......................... 18
Inspecting the wash pipe assembly .................................... 18
Inspecting the upper stem liner ......................................... 19
Inspecting main shaft end play .......................................... 21
Inspecting the gearbox oil level ......................................... 22
Inspecting the guide beam ................................................ 22
Inspecting the IBOPs ........................................................ 22
Inspecting the pipehandler ................................................ 23
Nondestructive Examination (NDE) ................................ 24
Inspecting the elevator link eyes .................................. 24
Inspecting the drive stem ............................................ 26
Magnetic particle inspection (MPI) ............................ 27
Ultrasonic inspection .................................................. 28
Inspecting the hydraulic system ........................................ 29
Inspecting the electrical system ......................................... 29
TDS-10S Contents v
March 2, 1998
Chapter 4 Lubrication
Introduction ..................................................................... 31
Lubricating the AC blower motor bearings ....................... 32
Lubricating the hydraulic pump AC motor ....................... 32
Lubricating the AC drilling motor bearings ...................... 32
Lubricating the wash pipe assembly .................................. 34
Lubricating the upper main body oil seals ......................... 35
Replacing the gearbox oil .................................................. 35
Initial oil change ......................................................... 35
Oil capacity................................................................. 35
Replacing the gearbox oil filter .......................................... 36
Lubricating the carriage and guide beam ........................... 36
Lubricating the rotating link adapter ................................. 36
Lubricating the link tilt and PH-55 stabilizer bushing ...... 38
Lubricating the elevator support and
master bushing wear guide ................................................ 38
Lubricating the wireline adapter ........................................ 38
Lubricating the IBOP actuator yoke ................................. 39
Lubricating the IBOP actuator crank ................................ 40
Lubricating the torque arrestor tubes and
clamp cylinder gate ........................................................... 41
Chapter 5 Maintenance
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................ 45
Troubleshooting the AC blower motor ............................. 46
Troubleshooting the hydraulic system ............................... 47
Troubleshooting the AC
drilling motor brakes ......................................................... 51
Troubleshooting the rotating link adapter
(rotating head) motor ....................................................... 52
Operation ................................................................... 52
System test .................................................................. 52
Troubleshooting the IBOP actuator cylinder .................... 54
Operation ................................................................... 54
System test .................................................................. 55
vi TDS-10S Contents
Troubleshooting the shot pin cylinder
and clamp cylinder ............................................................ 57
Operation ................................................................... 57
System test .................................................................. 58
Troubleshooting the counterbalance system ...................... 60
Counterbalance testing ............................................... 61
Stand jump testing ...................................................... 62
Troubleshooting the hydraulic power unit (HPU)
and reservoir ..................................................................... 64
Operation ................................................................... 64
System test .................................................................. 64
Chapter 1 Description
General description ............................................................. 5
Major component descriptions ........................................... 7
Varco Driller’s Console (VDC) ..................................... 7
Programmable logic controller (PLC) ..................... 9
Variable Frequency Drive (VFD) .......................... 10
Electrical service loops................................................. 12
Chapter 2 Operation
Preoperational checklists ................................................... 13
VDC controls ................................................................... 17
Correcting a drive fault ..................................................... 20
Drive fault while drilling ............................................. 20
Drive fault while making up ....................................... 21
Chapter 3 Maintenance
Maintaining the control system ......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
Description,
Installation and
Operation
March 10, 1998
Chapter 1 Introduction
Introduction to the TDS-10S ............................................. 7
Chapter 2 Description
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
Chapter 4 Operation
Driller’s interface and driller’s console ............................... 33
Throttle control .......................................................... 33
Torque control............................................................ 34
Switches ...................................................................... 34
Indicators .................................................................... 36
Varco control system ................................................... 37
Variable frequency inverter ............................................... 38
Rectifier and DC link filter ......................................... 38
Power modules ........................................................... 38
Control section ........................................................... 38
Service loop ...................................................................... 39
Drilling ahead ................................................................... 40
Drilling ahead with triples .......................................... 40
Drilling ahead with singles .......................................... 42
Tripping in and tripping out ....................................... 44
Back reaming .............................................................. 44
Well control procedures .............................................. 46
Running casing ........................................................... 48
Chapter 5 Specifications
General ............................................................................. 49
Drilling parameters ..................................................... 50
Rated capacities..................................................... 50
Drilling motor ...................................................... 50
Pipehandler (PH-55) ............................................ 50
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and assemblies to provide
a better understanding of the equipment’s functionality.
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assembly–standing behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Introduction
Description
❏ Bonnet/cover
❏ Main body
❏ Motor pinion
❏ Compound gear
❏ Bull gear
❏ Main shaft
❏ Lubrication system
The single-speed helical gear transmission with double reduction
provides a 13.1:1 ratio from the motor to the main shaft. The
main body and gear case cover house the transmission, the main
thrust and radial bearings. The gear case cover houses the upper
take-up bearing and supports the AC motor. The bull gear
attaches to the load shoulder on the main shaft. All lubrication of
the gears and bearing is via a pressurized system integrated into
the main body and cover.
Blower Motor
Centrifugal Blower
Air Flow
AC Drilling Motor
Louvers
PH-55 pipehandler
The PH-55 pipehandler consists of the following major
components:
Ov
er
dr
ill
ole
eh
108"
us
an *
Mo
ickm
Derr
Drill
34"
14"
4"
28" 36"
Typ.
56" 76"
Saver Sub
❏ Counterbalance system
❏ AC motor brakes
❏ Gear/main bearings lubrication system
❏ Powered rotating head
❏ Remotely actuated IBOP
❏ Torque backup clamp cylinder
❏ Link tilt
The hydraulic control system is powered by a 10 hp, 1,200 rpm
AC motor that is direct coupled to drive a hydraulic pump.
An integral hydraulic manifold mounts to the carriage and
contains all solenoid, pressure, and flow control valves.
There is also a manifold mounted to the shot pin housing for
controlling the hydraulic rotating link adapter motor.
Hydro-pneumatic accumulators operate the IBOP, pressure
control valves, and counterbalance system.
Counterbalance
Accumulator
Drilling
Motor Brake
Lube Oil
Distribution
Rotating Link
Adapter Motor
10 HP A.C.
Motor
Hydraulic
Upper IBOP
M Pump
Time Delay
Accumulator
Reservoir
System
Accumulator
Counterbalance system
The integral counterbalance system prevents damage to tool joint
threads while making or breaking connections with the TDS-10S.
It replaces the function of the hook compensator spring.
The system consists of two hydraulic cylinders attached between
the transmission cover and bail, a hydraulic accumulator, and a
hydraulic manifold. The system is integral to the TDS-10S and
therefore does not require any external attachment to the hook.
The cylinders are connected to a hydraulic accumulator. The
accumulator is charged with hydraulic fluid and maintained at a
predetermined pressure setting by the counterbalance circuit in
the main hydraulic control system manifold.
❏ Reliability
❏ Low maintenance
❏ Nonpolluting
❏ Wide operational range
❏ May be stalled indefinitely at full torque
❏ 180% overload capability for up to one minute
❏ Brushless
❏ Nonsparking
One AC induction motor powers the TDS-10S at 550 VAC
maximum, 3-phase. The TDS-10S includes an air cooling system.
The motor is fed from a PWM inverter that provides variable
voltage at variable frequency for speed and torque control.
The motor is rated at 350 hp with a maximum constant output
torque of 1,550 ft lb. Maximum constant torque is available from
0 to 1,200 motor rpm, with constant power of 350-hp from
1,200 rpm up to the maximum rated motor speed of 2,400 rpm.
(See the TDS-10S output curve figures in the Appendix chapter.)
Air Inlet
(1100 CFM)
End Coil
Rotor Assembly
(Laminated)
Motor Frame
(Laminated) Stator Assembly
(Laminated)
Air Exhaust
Motor Shaft
(Vertical Type)
End Coil
Mounting Base
Hub (Ref)
The AC motor (350 hp) and the gear ratios (13.1:1 high torque,
standard speed, or optional 4.8:1 low torque, high speed) provide
20,000 ft lb of torque at a drill stem operating speed range of 0 to
87 rpm. Maintaining constant 350-hp output, the top drive
provides 8,081 ft lb of torque at a maximum drill stem speed of
182 rpm.
The open-frame design of the AC drilling motor allows the
cooling air to pass through the inside of the motor, which
provides more efficient transfer of rotor and winding heat to the
cooling air. The motor is manufactured specifically for top drive
applications. They include:
Installation
All of the above modifications may not be necessary, but all must
be considered as well as the overall rig floor layout in order to
ensure that proper installation, time utilization and accurate cost
information is made.
The functional operation of a TDS-10S has many considerations;
a primary consideration is the mast/derrick height. The working
height and crown clearance are two primary factors to finalize
prior to ordering and installing your TDS-10S. Working height
and Crown clearance can both vary dependent upon hook, block,
bail, elevator links, and coupling chosen. Figure 6 shows a typical
TDS-10S mast interface. A mast/derrick interface requirements
and worksheet is provided in the Appendix chapter.
CL
25.6 26.0
(650) (660)
Ref. 19.5
(495)
44.0
(1118)
Ref.
CL
18.0
(457)
28.0 (711)
Dimensions
are in inches
48.0 (1219) Ref. (millimeters)
Operation
Throttle control
The throttle uses a design similar to the standard throttle control
used with SCR systems. The handle is robust and includes
integral stops to prevent damage.
Torque control
Two torque limit potentiometers are provided for setting drill and
makeup torque limits.
The drill limit control allows the driller to set the maximum
torque output of the top drive to match the drill pipe size being
used.
The makeup control sets the torque when making up connections
using the TDS-10S drilling motor.
Switches
Various switches control the following functions:
DC Generator
Encoder
(Alternate) Motor
* Mast 1
Saddle
- +
-
* Variable
System
Frequency Electrical
Drive / Electrical Panel
Service
* Varco Loop Solenoids
Driller's J-Box
Interface
Sensors
AC Power
Highline
or
Diesel/Alternator
Set
Varco
* Jumper Cable Assemblies
Driller's
Console could be used between
Mast Termination Plate
and Skid (Control House).
Indicators
Various indicators report status/faults to the driller:
R R A
0 MAX
DRILL MOTOR TORQUE WRENCH LINK TILT BRAKE EMERGENCY
OVERTEMP PUSH & HOLD OFF AUTO IBOP
DRILL TILT OPEN CLOSE
STOP
OFF BRAKE
ON
R
0 MAX
0 MAX
Power modules
AC motor speed control requires variable frequency voltage. To
do this, the DC voltage is converted to an output waveform that
consists of a series of pulses. The duration of each pulse is
controlled so that the fundamental voltage applied to the AC
motor has the desired frequency and amplitude. The technique of
using pulses to develop a waveform that appears to the motor as a
sine wave is called pulse width modulation or PWM.
Control section
The control section monitors the performance of the drilling
motor, accepts throttle and torque limit signals from the
TDS-10S control system, and controls the firing circuits of the
power modules.
To vary motor speed, the driller uses a hand throttle. The throttle
varies the frequency and voltage to the motor. Because the drilling
motor is frequency synchronous, the motor speed is proportional
to the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200
motor rpm).
One of the greatest advantages of an AC variable frequency drive
is the quality of the speed and torque control. It allows precise
control of the drill pipe speed over the full operational range.
600 VAC, 42 to 62 Hz
810 VDC
Resultant Pulse DC 20 Hz=600 RPM @ Mtr.
3-Phase (350 AMPS) 0
0 0
TDS-10S AC Motors
+
AC
Power
Source
-
AC Inverter
(AC Frequency Drive) Inverter Controller
0
40 Hz=1200 RPM @ Mtr.
PLC
Data Bus
Service loop
The TDS-10S has an on board hydraulic system and, therefore,
does not need a fluids service loop. This adds to the cost-
effectiveness of the TDS-10S drilling system and provides a safer
work area.
The TDS-10S has three electrical service loops. One loop consists
of four 313 MCM cables (three for drilling motor power, one for
ground). One loop is a composite cable that contains conductors
for the sensors and actuator (solenoid) control. The third loop
contains power for the smaller AC motors and space heater for
the drive motor.
Drilling ahead
1 2 3 4 5
Link
Makeup
Tilt
Open
IBOP
Close
IBOP
Stab Makeup
1 2 3 4 5
Makeup
Open
IBOP
Close Link
IBOP Tilt
Stab Makeup
Back reaming
The TDS-10S permits reaming out of open hole to prevent pipe
sticking and reducing keyseat formation, without affecting
racking functions associated with normal tripping; i.e., no singles
to contend with. This is provided by the ability of the top drive
and backup clamp to break out 93 ft. stands in the derrick/mast.
Use the following procedures for reaming out of the hole
(Figure 13):
1. Hoist the block while circulating and rotating the drill motor
until the third connection appears.
2. Stop circulation and rotation, and set the slips.
3. Break out the stand at floor level, and spin out using the
drilling motor.
4. Break out the drilling motor from the top of the stand using
the top drive motor and backup clamp, then spin out with
the drilling motor.
5. Pick up the stand with the drill pipe elevator.
6. Rack stand back.
7. Lower the top drive to the floor.
8. Stab drilling motor into box, spin-up and torque with the
drilling motor and backup clamp.
9. Resume circulation and continue reaming out of the hole.
1 2 3 4 5
Hoist and
Rotate
Breakout
Remote IBOP
Actuator Cylinder
Lower IBOP
Valve
Saver Sub
Insert New
Saver Sub
Drill Pipe
Running casing
Use longer elevator links (180 in.) to allow clearance for
cementing head under the backup clamp in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.
Specifications
General
Transmission 13.1:1 high torque/low
speed, or optional 4.8:1
low torque/high speed
double reduction helical
gear
Transmission lube Pressure fed, filtered
Powered rotating head Infinitely positionable
System weight 18,000 lb
Drilling parameters
Drilling speed range 0 to 182 rpm continuous
Drilling torque 20,000 ft lb maximum
continuous (27115 Nm)
Breakout torque 36,500 ft lb max. int.
Drilling horsepower 350 maximum continuous
Static locking brake 35,000 ft lb (47455 Nm)
Rated capacities
Hoisting 250 Tons, API-8C, PSL-1
Drilling (rotating) 250 Tons
Water course (main shaft bore) 5,000 psi CWP (3 in.)
Drilling motor
Type AC induction, forced air
cooled.
Rating 350 hp
Rated speed 1,200 rpm
Maximum speed 2,400 rpm
Maximum continuous torque 1,550 ft lb
Maximum intermittent torque 2,790 ft lb
Pipehandler (PH-55)
Torque capacity 50,000 ft lb @ 2,000 psi
Drill pipe range (OD) 2 7/8 in. through 5 in.
(4 in. through 6 5/8 in.
OD tool joint)
Upper IBOP (remote) 6 5/8 in. API Reg. RH,
Box
Lower IBOP (manual) 6 5/8 in. API Reg . RH,
Box and Pin (optional)
IBOP pressure rating 15,000 psi CWP
Elevator links 175 tons, 250 tons, or 350
tons, API, 96 in. long
(108 in. links optional)
50 TDS-10S Service Manual
Chapter 6
Appendix
Bail Rest
Bail Rest
Bail Rest
23.0 ft
20.8 ft (7,0 m)
(6,3 m) IDS-1
TDS-4S Working
Working Height
Height 15.0 ft
(4,6 m)
TDS-10S
Working
Height
Drill Floor
Max. Stall @
36,500 ft lb
35,000
30,000
Drill Pipe Torque (Ft-Lbs)
25,000
20,000
15,000
10,000
5,000
0
0 50 100 150 200
Drill Pipe RPM
Max. Stall @
13,390 ft lb
12,500
10,000
Drill Pipe Torque (Ft-Lbs)
7,500
5,000
2,500
0
0 100 200 300 400 500
Drill Pipe RPM
Crown
Customer: ..................
Clearance
Block Top
..........................................
.......................................... ..................
(Stroked)
Bail Rest
Existing
Traveling Equipment:
15.0 or 16.0 ft
TDS Working Height
...........................................
Tool Joint
...........................................
Service
Traveling Equipment Loop/Mast
Short-Coupling using Bundle
.............ft
............................................
Mud Hose,
............................................ Standpipe
@..........ft
93 ft Drill Stand
............................................
Sectional
Guide Beam
.............ft
Mast
Bundle
.............ft
CL
Beam
Tool Joint
VFD / Varco Driller's Interface
4 ft
Drill Floor
Maintenance
and
Troubleshooting
March 2, 1998
Chapter 1 Introduction
Precautions ......................................................................... 9
Chapter 3 Inspection
Inspecting hardware and fittings ....................................... 17
Inspecting the AC drilling motor brakes ........................... 18
Inspecting the AC drilling motor louvers .......................... 18
Inspecting the wash pipe assembly .................................... 18
Inspecting the upper stem liner ......................................... 19
Inspecting main shaft end play .......................................... 21
Inspecting the gearbox oil level ......................................... 22
Inspecting the guide beam ................................................ 22
Inspecting the IBOPs ........................................................ 22
Inspecting the pipehandler ................................................ 23
Nondestructive Examination (NDE) ................................ 24
Inspecting the elevator link eyes .................................. 24
Inspecting the drive stem ............................................ 26
Magnetic particle inspection (MPI) ............................ 27
Ultrasonic inspection .................................................. 28
Inspecting the hydraulic system ........................................ 29
Inspecting the electrical system ......................................... 29
Chapter 4 Lubrication
Introduction ..................................................................... 31
Lubricating the AC blower motor bearings ....................... 32
Lubricating the hydraulic pump AC motor ....................... 32
Lubricating the AC drilling motor bearings ...................... 32
Lubricating the wash pipe assembly .................................. 34
Lubricating the upper main body oil seals ......................... 35
Replacing the gearbox oil .................................................. 35
Initial oil change ......................................................... 35
Oil capacity................................................................. 35
Replacing the gearbox oil filter .......................................... 36
Lubricating the carriage and guide beam ........................... 36
Lubricating the rotating link adapter ................................. 36
Lubricating the link tilt and PH-55 stabilizer bushing ...... 38
Lubricating the elevator support and
master bushing wear guide ................................................ 38
Lubricating the wireline adapter ........................................ 38
Lubricating the IBOP actuator yoke ................................. 39
Lubricating the IBOP actuator crank ................................ 40
Lubricating the torque arrestor tubes and
clamp cylinder gate ........................................................... 41
Chapter 5 Maintenance
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................ 45
Troubleshooting the AC blower motor ............................. 46
Troubleshooting the hydraulic system ............................... 47
Troubleshooting the AC
drilling motor brakes......................................................... 51
Troubleshooting the rotating link adapter
(rotating head) motor ....................................................... 52
Operation ................................................................... 52
System test .................................................................. 52
Troubleshooting the IBOP actuator cylinder .................... 54
Operation ................................................................... 54
System test .................................................................. 55
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and assemblies to provide
a better understanding of the equipment’s functionality.
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assembly–standing behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Introduction
Precautions
To avoid serious injury or death, read and understand the
following warnings before performing maintenance procedures:
n 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.
Maintenance
schedules
Inspection schedules
Lubricant specifications
e The TDS-10S uses the same lubricant for both the transmission and
hydraulic reservoir.
1
General Purpose Grease
Ambient
temperature Above -20˚ Below -20˚C
range
Castrol MP grease -
NGL1 2 1
AGMA - -
ISO Viscosity - -
Grade
Use Chevron Black Pearl EP2 grease for all temperatures where
applicable.
Inspection
n 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.
Polypack Seal
Upper Stem Liner
Main Shaft
z Align the shims so that the upper bearing lube tube bore is not
blocked.
z Always check the oil level after the unit has been running and the
transmission oil is warm. Look for oil level (oil is dark brown);
not foam level (foam is tan).
,
C
(Hook)
C
,
B = 2-7/8 in., 250 Ton
5 2-1/4 250
4-7/8 2-1/8 210
4-5/8 2-1/16 188
4-3/8 1-3/4 137 B
B
B = 3-1/2 in., 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
❏ Bail
❏ Rotating link adapter
❏ Main body casting
❏ Landing collar
❏ Main shaft
❏ Upper and lower IBOPs
❏ Saver sub
❏ Elevator
❏ Elevator links
Ultrasonic inspection
In addition to 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 capacity of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the following
publications:
Lubrication
Introduction
The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.
AC Drilling Motor
Grease Fitting
Washpipe Assembly
z Grease the main body oil seals daily to prevent abrasive drilling
mud from leaking into the main body.
z After every oil change, check for proper lubrication oil flow.
Oil capacity
The TDS-10S main body holds approximately 17-19 gallons of
oil. Always fill the transmission to the middle of the upper sight
glass. Use the following procedure to fill the transmission for the
first time:
1. Use a hand pump to fill the gearbox to the top of the sight
glass (approximately 17-19 gallons).
2. Operate the TDS and hydraulic systems 10-15 minutes and
then check the sight glass.
3. If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass.
250 TON
Grease Grease
Fitting Fitting
Front
J
E6
E6
G6
B8 G6
A4 G5
B4
E5
Grease Fittings H
Back
IBOP Actuator
Yoke
Upper IBOP
Actuator Shell
Closed
Position
Open
Position
Actuator Shell
Crank Arm
Grease Fitting
Upper IBOP
Valve
Torque Arrestor
Grease Locations
(Each side)
Grease Fittings
(Each side)
Figure 8. Lubricating the torque arrestor tubes and clamp cylinder gate
Maintenance
Start-up procedure
Accumulator maintenance
The Vendor Documentation Package contains the accumulator
manufacturer’s instructions for the TDS-10S hydraulic
accumulators (Bulletin SB1630-M1). This bulletin contains all
necessary maintenance, removal and replacement, and pre-
charging instructions for the TDS-10S accumulators.
Troubleshooting
n 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.
A B
Manual A B
Valve 3 Position 4 way Valve MV
(Rotary) P T
Pump
Fixed Displacement
1
Pressure
Relief
Valves Standard Valve RV2, A2R, B2R, SJR
2
3
Pressure
Reducing
Valve PC1, PC4
Pressure
Reducing/Relieving
Vavle PCC
1
3
Cavity Plug PC5
2
Internal Plug
Counterbalance
Valves
Hydraulic Circuit
Heat Exchanger
(Inside Brake Housing)
Hydro-Pneumatic Accumulator
Hydraulic Cylinder
Tank (Reservoir)
Test Point
Operation
The three position directional valve controls the direction of the
rotating head to the left or right. The pressure is applied to the A
or B port of the hydraulic motor, depending on the selected
direction. The auto return function is controlled by the processor
and returns the tool to the home position.
System test
To test the system, operate the rotating head switch on the
control panel. Verify both directions of rotation. The rotation
speed is limited by the nonadjustable orifice. The torque is
limited by the two relief valves.
Operation
The IBOP is in the open position under low hydraulic pressure,
A4 = 500 psi, B4 and C4 = less than 100 psi. When you close
the IBOP, high pressure is applied to the cylinder. A4 is less than
100 psi; B4 and C4 are 2000 psi. When the solenoid is de-
energized, for opening the IBOP, A4 goes to 500 psi after a small
time delay. B4 is less than 100 psi and C4 reaches 2,000 psi after
a small time delay. The time delay is operated by the time delay
accumulator.
n Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
To test the system, engage the IBOP and measure the pressure at
B4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open the
IBOP and test the pressure at A4, which increases to 2,000 psi.
The pressure at B4 and C4 drops to 500 psi.
11.5 IN^ 3
500 PSI
PRECHARGE
N07
IBOP CLOSE
A B
b
N12
P T
A4 SV4 D03 B4 C4
.055Ø FC4
T-11A 1 PC4
.016Ø
3
1 30 PSI
2
2 3
4 1
A4 SQ4 B4
A4 B4
A4 B4
OPEN
CLOSE Hydraulic Cylinder
Operation
The shot pin cylinder and clamp cylinder operation are
interrelated and complex. The shot pin cylinder is different in
that it has an extra port called the barrel port. The barrel port is
back from the end of stroke which creates a valving effect. When
the shot pin and clamp cylinders are not activated, the shot pin is
fully retracted with full pressure and the clamp cylinder is
retracted with 500 psi.
When you energize the clamp cylinder, the shot pin cylinder is
actuated against the rotating gear and it may miss one of the 24
holes. The control system starts pulsing the rotating head to move
slowly until the shot pin engages a hole on the rotating gear. The
shot pin cylinder pressure is limited by the relief valve until the
cylinder passes through one of the holes. Once the pin engages
the hole, full system pressure is applied to C5 which opens valve
CV5, applying full pressure to the clamp cylinder to close.
When the clamp cylinder is de-energized, the clamp releases and
the shot pin pulls out.
System test
At rest, the pressure at C5 is 2,000 psi, B5 is less than 100 psi,
CP is less than 100 psi, and CR is 500 psi.
n Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
Operation
Figure 10 shows the onboard HPU schematic. A 10 hp electric
motor drives the fixed displacement pump.
The fixed displacement pump provides hydraulic power to
operate the lubrication pump motor. Pressure can be tested at
port PF. Relief valve RV2 limits the driving pressure of the lube
oil circuit.
System test
Test the circuit pressure at port PV. Relief valves RV1 and UV1
are a part of the circuit. UV1 is a differential unloading valve,
which can be pressure checked at port Z1.
RV2 is set at 400 psi and can be tested at PF. Test the pressure at
PV to confirm the relief valve RV1 is set at 800 psi. The
differential unloading valve UV1 is tested at Z1 to confirm the
pressure is 2,000 psi.
30 PSI
N08
Upper Compound
M Gear
10 HP 1.40 in3/rev
1200 RPM Lower Compound Gear
Upper Mainshaft Bearing
Lower Radial/Main Thrust Bearings
Upper Compound Bearing
Lower Compound Bearing
Table 12. Troubleshooting the hydraulic power unit (HPU) and reservoir
Disassembly and
assembly
Precautions
❏ Stem
❏ Stem seals
❏ Rotating link adapter upper and lower wear bushings
❏ Rotating link adapter rotary seals
e Always install new main shaft seals and use care not to damage seal
lips or case.
e Protect the internal surfaces of the rotating link adapter body and the
surfaces of the stem when separating the two components. When
removing the rotating link adapter from the stem, carefully tap with a
mallet to remove the rotating link adapter from the stem. There can
be resistance from misalignment between the two bores when rasing
the stem and gear assembly.
10. Remove and discard all rotary seals, o-rings, the thrust ring,
and two wear bushings from inside the rotating link adapter
and gear inside dimension.
11. Remove and discard the stem flange O-rings and stem bore
shaft seals.
11. Line up the dowel pin holes and replace all of the screws and
safety wire.
12. Install the link tilt cylinders; pin and secure in place.
13. Install the link tilt crank; pin and secure in place.
14. Install all hose assemblies.
15. Invert the rotating link adapter assembly so that the stem
flange is up.
19. Install a new main shaft seal inside the stem bore with the seal
lip facing up.
e Always install a new mainshaft seal and use care not to damage the
seal or the case.
e Always install new stem O-ring and use care not to damage the
O-ring or the case.
z Use the two jacking holes in the upper bearing retainer plate as
required to help remove the plate.
2. Remove the lube tube from the lube tube bore of the cover,
and remove the lube tube O-rings.
3. Remove and discard the two lip seals in the bearing retainer
plate.
4. Remove the bearing retainer plate shims.
5. Remove the taper roller bearing outer race from the cover
bore.
e When raising the main shaft, the main thrust bearing separates.
Lift the main shaft slowly.
7. Use the lifting eye on the end of the compound shaft to lift
out the compound gear.
e Do not use a steel hammer when removing the gears. It can damage
components.
10. Remove the mainshaft upper wear sleeve by heating the sleeve
to 250°F (121°C). Check the sleeve for wear after removing
it.
11. Remove and discard the upper taper bearing inner race by
heating the race to 250°F (121°C).
z If replacing the bull gear, perform steps 12, 13, and 14. If not,
proceed to step 15 and remove the bull gear along with the main
shaft.
12. Remove the 10 lockwired cap screws that hold the bull gear in
place.
13. Install two 5/8-11 UNC forged eyebolts in the bull gear
pickup holes and heat the bull gear to between 150°F (66°C)
and 200°F (93°C), then remove the bull gear by lifting the
gear straight up off the alignment pin.
14. Inspect the bull gear alignment dowel pin, and remove and
discard the pin if damaged.
15. Remove the main shaft wear sleeve by heating the sleeve to
250°F (121°C), then pulling the sleeve off shaft. Check the
sleeve for wear grooves after it is removed.
16. Remove the lower radial bearing inner race by heating the
race to 250°F (121°C), then pulling the race off the main
shaft.
17. Remove the main shaft sleeve by heating the sleeve to between
200°F (93°C) and 250°F (121°C) and pulling the sleeve off
the shaft.
18. Remove half of the thrust bearing race, the bearings, and the
cage of the thrust bearing.
19. Remove the other half of the thrust bearing race by heating
the race to 200°F (93°C) and pulling the race off the main
shaft.
20. Remove the four lockwired cap screws that hold the lower
radial bearing ring retainers in place and remove the retainers.
21. Remove the outer race of the lower radial bearing from the
bore in the housing with a bearing puller.
22. Remove the retainer nut and washer from the pinion shaft to
separate the bearing from the pinion gear. Heat the bearing to
200°F (93°C) and pull the bearing from the shaft.
23. Heat the inner bearing races to 200°F (93°C) and pull it off
the journals to remove the inner bearing races (cones) from
the compound gear journals.
24. When replacing the thrust bearing or radial bearing inner
race, turn the main shaft assembly upside down with the
6 5/8 in. pin connection pointed up. In order to turn the
assembly upside down, raise the lower race of the thrust
bearing until the rollers contact the upper race. Use two large
C-clamps and clamp the lower race and rollers to the main
shaft shoulder. Once the shaft is inverted, remove the clamps.
e Do not drop the races or rollers during this tipping over process.
Main Shaft
Stem
Shaft Shoulder
18" Diameter
Load Plate
Rest
e Loosen the C-clamps slowly to prevent the rollers from fallong out.
Lower the main shaft assembly through the main bore of the
main body until both the main thrust bearing races contact
the rollers and the main shaft rotates easily.
12. Heat the bull gear to between 150°F (66°C) and 200°F
(93°C). Install two 5/8-11 UNC forged eyebolts in the gear
pickup holes, making sure the stamping “TOP SIDE” is up.
13. Carefully lower the bull gear into position until it seats. If the
old dowel pin has been removed, rotate the gear until the
1 in. dowel pin hole is aligned.
z If the bull gear dowel pin has been removed, chill the new dowel
pin to at least 0°F (-18°C), but no lower than -60°F
(-51°C) as the bull gear is being placed into position. Then drive
the dowel pin into the alignment hole using a bronze hammer.
The pin will sit flush to 1/4 in. high.
19. Install dowel pins in the main body cover and keys in the
main body.
20. Apply a thin layer of sealant to the mating surfaces of the
main body and main body cover.
21. Install O-rings around the oil galleys in the back wall of the
main body.
22. Liberally apply oil to the upper cone of compound gear and
cup in cover. Lower the cover onto the main body, making
certain the compound gear bearing halves are aligned.
23. Install and tighten the cover bolts.
24. Lightly tighten the screws to the compound retainer and
measure the gap between the retainer and the main body.
25. Install a stack of shims between the retainer and the main
body that exceeds the gap by approximately .002 in.
26. Tighten the screws to 75 ft lb. Check the end play by
inserting a dial indicator through the hole in the bearing
retainer and moving the compound up and down using a pry
bar.
27. Disassemble the retainer and remove or add shims to obtain
an end play of .001 to .002 in.
28. Clean the mating faces, then apply a thin layer of sealant to
the mating faces. Install the reservoir.
29. Place the O-ring in the groove on the top face of the main
body cover where the hydraulic pump assembly attaches.
30. Install the hydraulic pump assembly.
e Take care to not damage the inlet filter when lowering the pump
into place.
z Make sure the brake end with mounting feet faces the rear, and
the blower duct faces the hydraulic pump when installing the AC
drilling motor.
3. Install the four cap screws and lockwashers that hold the AC
drilling motor to the main body.
4. Apply an anti-seize compound to the threads of the four main
body cover bolts for the motor. Tighten the four main body
cover bolts to 250-270 ft lb.
5. Install the tie rods by first inserting the end of the rod with
the greatest length of thread into the holes in the brake
adapter plate.
a. Raise the tie rod until the lower end clears the top of the
main body cover.
b. Install the tie rod into the threaded holes.
c. Tighten the tie rods until the lower end shoulders against
the main body cover.
d. Install the flat washer and locknut onto the remaining end
of the tie rod and torque to 325 ft lb.
AC Motor
Pilot Bore
O-Ring
z Align the shims so that the upper bearing lube tube bore is not
blocked.
4. Remove the bearing retainer plate cap screws and the bearing
retainer plate.
5. Install the two new upper bonnet oil seals in the bearing
retainer plate with the lips facing up.
e Use care not to damage the seals. Be careful to install the seals with
the lips facing up since these seals function to keep mud from entering
the main body.
10. Install the bearing retainer plate, being careful to align the
lube tube bore in the retainer with the lube tube protruding
from the cover.
11. Carefully tap the bearing retainer plate to seat the plate on
top of the cover.
12. Apply an anti-seize compound to the threads of the six
bearing retainer plate cap screws, install the six cap screws and
lockwashers, and tighten to 250-270 ft lb. Safety wire the cap
screws.
13. Recheck the main shaft axial movement by applying a force to
the main shaft and measuring the amount of axial movement
with a dial indicator. The main shaft movement must be
between .001 and .002 in. If the movement falls outside of
this specification, readjust the number of shims under the
bearing retainer plate.
14. Install two new grease fittings into the bearing retainer plate.
AC Motor
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Pressure Gauge ,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Hub
Hydraulic Hand Pump
Tool # 110026
AC Motor
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
5.975 ,,,,,,,,,,,
,,,,,,,,,,,
Ref ,,,,,,,,,,,
,,,,,,,,,,, Lap to 85% Contact
,,,,,,,,,,,
,,,,,,,,,,,
Pinion Hub
Use the size and type of safety wire required in the applicable
specifications and drawings. Whenever possible, use double-twist
safety wiring.
1
2
3 4
n Do not nick the wire with the edge of the hole in the fastener.
Position the safety wire so the pull exerted by the wire tightens the
nut. For best results, let the wire leave the fastener in a clockwise
direction
❏ Twist the safety wire so the loop around the bolt or head has
sufficient tension to keep it from slipping up and over the
bolt head, with resulting slack in the safety wiring.
n When securing castellated nuts with safety wire, tighten the nut to
the low side of the selected torque range, unless otherwise specified.
If necessary, continue tightening within specified torque limits
until a slot aligns with the hole.
Control System
March 2, 1998
Chapter 2 Operation
Preoperational checklists ................................................... 13
VDC controls ................................................................... 17
Correcting a drive fault ..................................................... 20
Drive fault while drilling ............................................. 20
Drive fault while making up ....................................... 21
Chapter 3 Maintenance
Maintaining the control system......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
Description
General description
The TDS-10S control system consists of the following three
major components:
Variable
Frequency Drive 3-Phase Power
(VFD)
Control
Varco Signals
Driller's Console Data Control
(VDC) PLC TDS-10S
Bus Signals
Remote I/O
Varco Electrical House (VEH)
R G A R
0 MAX
VDC
PRESS LOSS
DRILL MOTOR
OVERTEMP
TORQUE WRENCH
PUSH & HOLD
LINK TILT
OFF IBOP
BRAKE
AUTO
EMERGENCY
DRILL TILT OPEN CLOSE OFF BRAKE STOP
ON
R R 0 MAX
TORQUE RPM
R R
0 MAX
❏ Rectifier section
❏ Control section
❏ Power inverter section
The rectifier section converts incoming 3-phase AC power to DC
for use by the power devices.
The control section monitors the performance of the drilling
motor, accepts throttle and torque limit signals from the driller,
and controls the firing circuits of the power modules.
The power inverter section converts DC power into a simulated
AC signal using pulse-width-modulation (PWM) field vector
control techniques.
The driller controls the speed of the AC drilling motors with a
hand throttle. The throttle varies the frequency and voltage to the
motor. The speed of the drilling motor is proportional to the
frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1200 motor
rpm).
TDS-10S AC Motors
+
AC
Power
Source
-
AC Inverter
(AC Frequency Drive) Inverter Controller
0
40 Hz=1200 RPM @ Mtr.
PLC
Data Bus
VFD
Operation
Preoperational checklists
The tables on the subsequent pages provide the following
preoperational checklists:
Control
Function Sequence Action Check OK
Rotating head With links in tilt or No rotation
drill position,
actuate rotate
left/right.
With links in tilt or Links float toward
drill position, wrench clamp.
actuate float push
button.
After 5 seconds After 5 seconds,
actuate rotate rotating head
left/right. rotates.
Torque wrench With No torque wrench
clamp drill/spin/torque clamp
switch in drill mode
and throttle on,
actuate torque
wrench clamp.
24 1 6 4 2 20
21
DRIVE PURGE
FAULT LOSS
13
3
TORQUE RPM
IBOP BRAKE 8
IBOP
BRAKE ON BRAKE
CLOSED IBOP AUTO
10 OPEN CLOSE OFF BRAKE
ON
EMERGENCY
STOP
16
THROTTLE
PIPE HANDLER
MAKE-UP
CURRENT LMIT ROTATE LINK TILT FLOAT
LEFT RIGHT
0 MAX
0 MAX
HYDRAULIC LINK TILT TORQUE WRENCH DRILL TORQUE
POWER OFF PUSH & HOLD COUNTERBALANCE
OFF ON DRILL TILT
DRILL STAND 23
JUMP
0 MAX
ALARM/LAMP TEST
OFF
SPIN (PRESS TO SILENCE)
DRILL TORQUE REVERSE FORWARD
19
9
11 15 7 14 18 17 22
Control/Indicator
Name Description and Function
1 DRIVE FAULT Red indicator light flashes and horn sounds when a VFD fault
is detected. Pressing the alarm silence button stops the horn.
The alarm indicator light stays on while the switch is timed
for 5 minutes. The alarm returns if the fault is not fixed,
otherwise, the alarm light turns off.
2 BLOWER LOSS Red indicator light illuminates in case of a failure in air
cooling motor.
3 BRAKE ON Red indicator light illuminates when the brake solenoid valve
is energized.
4 DRILL MOTOR Red indicator light illuminates in case of an overtemperature
OVERTEMP condition in the 350 hp AC drilling motor.
5 IBOP CLOSED Amber indicator light illuminates when there is hydraulic
pressure to the cylinder that closes the IBOP valve.
6 OIL PRESS LOSS Red indicator light illuminates when there is an oil pressure
loss in the gearcase lubrication system.
7 ALARM /LAMP TEST When the alarm indicator light illuminates and the horn
switch sounds, press the switch to silence the horn. The alarm light
stays on until the fault is corrected. If it is not corrected in 5
minutes, the alarm repeats. The switch is also a lamp check for
all lights on the VDC. The switch must be pushed and held
for two seconds to obtain a lamp check.
8 BRAKE switch There are three brake switch positions: OFF, AUTO, and
ON. Turning the switch to the ON position turns the brake
on and lights the indicator light above the switch. In the
AUTO position, the brake automatically turns on when the
throttle is turned off. Turning the switch to the OFF position
turns the brake off. After a DRIVE FAULT or emergency
stop, the BRAKE SWITCH must be turned ON and then
OFF to reset the brake.
9 DRILL TORQUE A potentiometer sets the current limit in the VFD during
Limit Potentiometer drilling operations. This sets the torque for normal drilling
operations in the drill position. Torque and rpm are displayed
and can be adjusted. Adjust the torque by setting the brake
and turning the potentiometer to increase or decrease the
torque.
10 ROTATE There are three switch positions: OFF, LEFT, and RIGHT.
Turn the spring-loaded switch to the left to rotate the head to
the left, and turn the switch to the right to rotate the head to
the right.
NOTE: Works only after the link tilt float switch is pressed.
Control/Indicator
Name Description and Function
11 DRILL/SPIN,/ There are three switch positions: DRILL, SPIN, and
TORQUE switch TORQUE. The switch is in the DRILL mode during normal
drilling. SPIN mode is a fixed speed of the AC drilling
motors. TORQUE mode is a slower fixed speed of the AC
drilling motors. It generates a gradual increase in torque to the
make-up limit.
12 EMERGENCY STOP Emergency stop shuts down all operations. Emergency stop
switch switch is hardwired to the VFD. Pressing the stop button
deselects the drive and sets the brake, causing the top drive
rotation to stop regardless of throttle position. Auxiliary
cooling motors remain on.
13 IBOP switch Activates the upper IBOP valve. Turning the switch to the left
retracts the IBOP actuator cylinder to close the valve. Turning
the switch to the right extends the cylinder to open the valve.
14 LINK TILT FLOAT The links “float” to the center (NEUTRAL) position when the
pushbutton is depressed.
15 LINK TILT switch Activates the link tilt cylinder. The center position is OFF;
turning the switch to the left extends the cylinder to the
mousehole; and turning the switch to the right retracts the
cylinder for drill down. This is a maintained switch that holds
the position of the cylinder when returned to OFF.
16 MAKE-UP CURRENT A potentiometer sets the torque limit in the VFD when using
LIMIT Potentiometer the top drive to makeup connections. Torque is displayed on
the torque meter. Adjust the torque by setting the brake and
turning the potentiometer to increase or decrease the torque.
17 REVERSE /OFF/ There are three switch positions: OFF, FORWARD, and
FORWARD switch REVERSE. In the OFF position, the top drive cannot
operate. FORWARD and REVERSE are used when drilling
or making/breaking connections. This switch acts as the drive
assignment.
18 TORQUE WRENCH Pushing this button engages the pipe clamp and shot pin lock.
PUSH & HOLD The rotating head rotates until the shop pin engages. The pipe
switch clamp operates after the shot pin is engaged.
19 HYDRAULIC POWER Turns the tool hydraulics on or off.
20 PURGE LOSS Indicates that the VDC has lost purge pressure.
e The top drive must not be deassigned (hydraulic pump and blower
motors running) for more than 10 minutes to maintain maximum
braking. Brakes are applied by hydraulic caliper pressure actuated by
accumulator pressure. When the hydraulic pump is off, the
accumulator pressure drops due to normal system leakage, resulting in
a decrease in braking. The decrease in braking is gradual until the
accumulator precharge pressure is reached. If the drill string torque is
low, there may be noticeable rotation due to a gradual decrease in
braking since the required brake holding pressure is low. In this
situation, the brakes release once hydraulic pressure reaches the
accumulator precharge pressure.
n Floor hands should stay clear of back-up tong and long line
during this operation due to the possibility that a sudden release
of torque might cause the tong to recoil and fall to the floor.
Maintenance
CPU315-2 DP
SF
BATF BUSF
DC5V
Status and fault LEDs FRCE
RUN
Battery Compartment
MPI port
RUN
BF
DIA
ET 200B -4AI
0 1
RUN STOP
RUN
BF
DIA
ET 200B -4AO
0 4
RUN STOP
0 5
RUN STOP
VFD
The VFD has an LCD panel that can be used for troubleshooting
(Figure 9).
Fault
Run
Jog 7 8 9
4 5 6
1 2 3
0 +/- Reset
Supplemental
Material
March 2, 1998
Supplement list
This chapter contains the following supplements:
® ™
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
i
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the driller’s console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
1
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Splined Adapter
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
2
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
V
Link a
r
Splined Adapter c
o
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
N
OPE
Back-up
CL SD
Rings
O-Ring
O-Ring
Ball
Sleeve
Grease/
Mud Seal
Seat
Wave Thread
Spring Protector
Back-up Ring
O-Ring
4
Feb. 2, 1994
Introduction
Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing
PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both
as a primary safety valve and as a mud saver while drilling ahead.
Maintenance and operating costs will be greatly reduced, allowing a minimum planned
maintenance interval of six months for the upper IBOP.
PRINCIPLE FEATURES
❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides.
❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
❏ The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, grease-
packed, and completely isolated from mud caking and corrosion to ensure full bore opening.
5
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
6
Feb. 2, 1994
1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%
larger piston area ensures positive, complete ball rotation under the most arduous conditions.
A 60% increase in available cylinder stroke eliminates the need for sensitive position
adjustments, both at initial rig-up as well as over the life of the system.
2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current
multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable)
guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides
directly on the IBOP outer diameter. The new design is very robust, requires no adjustments,
and is able to withstand punishing environments without damage.
3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This
change reduces the operating and environmental forces on the internal and external components
by 50%. It also provides a balanced reaction force to the actuating levers. This force balance
allows elimination of the bolt-on guide roller assemblies.
Each of the two external crank housings is anchored to the IBOP body with 1/2" screws
instead of the 3/8" screws used in the previous design. The crank housings are also secured
to react the ball stop torque using a close-tolerance fit between the base of the housing and
the machined recess in the IBOP valve body. When required, jacking screws make removing
the housings easier.
7
Feb. 2, 1994
1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They are
replaced with a smooth bore through the ball and seat region. This significantly lowers the
maximum stress in the valve body and effectively eliminates the possibility of leaks caused
by cracking at the crank bores under corrosive mud conditions.
2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball
rotation stop in the previous design. The crank was easily replaced, but the body was not
repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over
extended use could eventually allow the ball to over-travel, leading to washouts.
In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal
cranks (2) and external crank housings (2) need replacement should they ever become worn.
The external crank housings in the new design serve as the ball rotation stops. Each external
crank housing has two struts which contact the internal crank to stop the ball precisely at the
open or closed position. The torque required to stop the ball is then shared by four surfaces
rather than the previous design’s single surface.
The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated
regions beneath the external cranks. This eliminates the presence of caked drilling fluid
around the stop mechanism and is more reliable.
3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,
the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and
locating components, decreasing wear and eliminating mechanical failure.
8
Feb. 2, 1994
INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
9
Feb. 2, 1994
Torque (ft-lb)
Components I.D. Connection O.D. (min.) (max.)
Upper IBOP Safety 3" 6-5/8 API Reg. 7-3/4 50,000 70,000
Valve to Lower
IBOP Valve
Lower IBOP Valve 3" 6-5/8 API Reg. 7-3/8 46,000 64,000
to Saver Sub
Lower IBOP Valve 3" 7-5/8 API Reg. 8-5/8 66,000 85,000
to Saver Sub
* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a. Carefully grind off any raised tong marks on the O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of the actuator).
c. Orient the levers on the crank assemblies horizontally as shown.
d. Slide the shell up onto the valve with the actuator arm groove on the bottom.
e. Hold the shell in position relative to the valve operating sockets.
f. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90° of crank travel.
10
Feb. 2, 1994
Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90° of crank travel.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Lock Tabs Groove
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Crank
Crank Assembly Assembly
Roller Retaining Screw
Assembly (3)
Slot
Roller
Assembly
Actuator (3)
Shell
Crank*
Roller
Assembly (3) Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the driller’s console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
16
Feb. 2, 1994
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly —
the valve should be serviced.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
L L
FLOATING
SEAT
19
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
WAVE SPRING
FLOATING
SEAT
20
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
Feb. 2, 1994
INSPECTION
21
Feb. 2, 1994
Recommended
Inspection Areas
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.
VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
NOTE
There is only one crank on upper IBOPs for the PH-60 pipehandler.
There are also three roller assemblies.
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Cylinder Adapter
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2) Upper IBOP Valve
Actuator Shell
Upper IBOP Valve
Actuator Air Cylinders (2) Crank Assy(Shown with
Valve OPEN. Note Crank
Assy Position
CLOSE
OPEN
*1 Inch Actuator
Arm
Cylinder
Gland Upper IBOP
Cylinder Rod
in OPEN End
Position Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &
Single Crank PH-60
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13 19
2 17 6 1 10 18 5 14 15
20 7 16
8
2X 4
9
12
11
12 7/8" Hex
Note: Dual Crank Remote IBOP Shown
Single Crank Remote and Lower IBOP
have similar construction.
25
Feb. 2, 1994
Parts List
ITEM DESCRIPTION PART NUMBERS QYT. / KIT
3 O'RING 90441-9 1 1 1
7 POLYSEAL 96439 1 1 1
11 O'RING 89141-11 1 2 2
15 BODY - - -
16 O'RING 89141-3 1 1 1
17 NYLON PLUG 2 2 2 2
19 PLUG 1 1 -
BALL/SEAT SET
Refer to the Appendix for Part Numbers
26
Feb. 2, 1994
Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or
mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,
but also serves to loosen internal components. Follow these general rules while working on the
valve:
1. Take proper precautions while working with the components of the valve to make sure
precision matched surfaces and seal contact surfaces are not damaged.
2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts
as they are removed.
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Seat Puller For All Models Nut Wrench for DSV Models
Varco Part No. 79489-14 Varco Part No. 89141-18
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
Figure 16
Figure 17
28
Feb. 2, 1994
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
Figure 20
29
Feb. 2, 1994
Figure 21
Figure 22
Figure 23
30
Feb. 2, 1994
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
NOTE
The steel stabilizer ring
should be inside the seal
when properly installed.
Figure 27
32
Feb. 2, 1994
Figure 28
Figure 29
33
Feb. 2, 1994
Figure 30
Figure 31
34
Feb. 2, 1994
Figure 32
35
Feb. 2, 1994
Figure 34
Figure 35
Figure 36
36
Feb. 2, 1994
37
Feb. 2, 1994
NOTE
The grease pressure should not exceed
300 psi. Excess pressure can cause the
mud/grease seal to extrude.
Figure 39
38
Feb. 2, 1994
Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test
pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the
following procedure to test IBOPs:
1. Rotate the valve crank to the Open position.
2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug
in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve
to the plug in the opposite end.
3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for
lower IBOP) with the ball and the bleed valve in the Open position.
4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,
but using water increases the liklihood of corrosion in the valve body—especially when the
valve is not in use for a prolonged period of time.
NOTE
Open and close the valve five times to release trapped air and
overflow through the bleed valve for approximately 30 seconds to
assure complete filling of the valve cavity.
5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed
position.
6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus
1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.
7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic
test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper
IBOP, box end up for lower IBOP).
8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP
(pin end of the lower IBOP).
9. Fill the valve cavity with water while rotating the ball full open to closed five times to release
trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working
pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the
duration of the test.
10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to
insure smooth operation.
11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is
acceptable.
12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to
release trapped fluid. When testing with water, coat the valve internals with a preservative
to prevent oxidation and install thread protectors.
39
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
40
Feb. 2, 1994
98977-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
98977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
98977-501 NAM Landing Collar Design 99468-2 99468-1 65170014
99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
NAM Landing Collar Design 99468-2 99468-1 65170014
41
Feb. 2, 1994
42
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46
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