Manual

Contents Preliminary

General Information

1

Specifications

2

Lubrication and Maintenance

3

Installation, Commissioning and Decommissioning

4

Hydraulic System

5

Electrical System

6

In development

PH-50 Pipehandler In development

7

Motor Housing, Transmission In development

8

Guide Beams and Carriage

TDS-11SA

9

i

Introduction How to Use This Manual This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Where applicable, each section includes: 1. A table of contents, or an illustrated view index showing: • Major assemblies, systems or operations • Page references to descriptions in text 2. Disassembly / assembly information and tools 3. Inspection information 4. Testing / troubleshooting information 5. Repair information 6. Adjustment information 7. Torque values

Notes, Cautions and Warnings

i !

(Note)

Gives helpful information.

(Caution)

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

Special Information

!

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains warnings about proceedures which could damage equipment or make it unsafe, and cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized.

All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text, figures and tables. REV A © 1998 Varco Systems Top Drive Technical Publications Department All rights reserved

ii

Varco Systems

General Information

Major components................................................. 1-2 1 Identification numbers .......................................... 1-3 Lifting points .......................................................... 1-4 Safety wiring .......................................................... 1-5

2

Torque values ........................................................ 1-6 Basic useage ......................................................... 1-7 3

Drilling ahead with singles ............................... 1-7 Drilling ahead with triples ................................. 1-8 Backreaming...................................................... 1-9

4

5

6

7

8

9

Preliminary

TDS-11SA

1-1

General Information

Major components 1

Counterbalance System

Motor Cooling System

Hydraulic Disc Brakes (2) Gooseneck (S-Pipe)

AC Drilling Motors (2)

Guide Beam

Transmission/ Motor Housing

Electrical System

Rotating Link Adapter

Hydraulic System

PH-50 Pipehandler

Front

Carriage

Rear

Right Side

Rear Left Side

1-2

Varco Systems

Front

General Information

Identification numbers Encoder Instruction Label On the side of brake housing

AC Motor Identification Label On the side of each AC motor

Warning Label On the side of bonnet

Warning Labels On the side of each AC motor Top Drive Identification Plate On the front of motor housing

SALES ORDER NO. ASSY NO. TRACE CODE DATE OF MANUFACTURE

Preliminary

TDS-11SA

REV

1-3

1

General Information

Lifting points 34,500 lbs (15,663 kg) TDS-11SA

1

Lifting Point For removal or attachment to the skid

! Bail Lock Must be installed before lifting top drive from the skid or attaching top drive to the skid

Lifting Points For skid attached to top drive

37,000 lbs (16,798 kg) TDS-11SA on skid

! Lifting Points For skid attached to top drive

1-4

Varco Systems

Locking pins Must be in place prior to moving skid with top drive

General Information

Safety wiring 1

3

Preliminary

2

4

1

5

TDS-11SA

1-5

General Information

Torque values 1

Diameter

Threads per inch

Bolts Lubricated with Light Machine Oil

Bolts Lubricated with Anti-seize Compound

Grade 5

Grade 5

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Coarse Thread Series, UNC 20

7.6

8.4

2,020

5.7

6.3

2,020

5/16

18

16

18

3,340

12.1

13.4

3,340

3/8

16

29

32

4,940

21.4

23.6

4,490

7/16

14

48

53

6,800

36

39

6,800

1/2

53

59

9,050

1/4

13

71

79

9,050

9/16

12

105

116

11,600

78

87

11,600

5/8

11

143

158

14,400

107

118

14,400

3/4

10

247

273

21,300

185

205

21,300

7/8

9

409

452

29,400

306

339

29,400

1

8

608

672

38,600

456

504

38,600

1 1/8

7

760

840

42,300

570

630

42,300

1 1/4

7

1,064

1,176

53,800

798

882

53,800

1 3/8

6

1,387

1,533

64,100

1,040

1,150

64,100

6

1,843

2,037

78,000

1,382

1,528

78,000

1 1/2

Fine Thread Series, UNF 1/4

28

9.5

10.5

2,320

7.1

7.9

2,320

5/16

24

18

20

3,700

13.5

15.0

3,700 5,600

3/8

24

33

37

5,600

25

28

7/16

20

52

58

7,550

39

43

7,550

1/2

20

86

95

10,700

64

71

10,700

9/16

18

114

126

12,950

86

95

12,950

5/8

18

162

179

16,300

121

134

16,300

3/4

16

285

315

23,800

214

236

23,800

7/8

14

447

494

32,400

335

370

32,400

1

14

665

735

42,200

499

551

42,200

1 1/8

12

836

924

47,500

627

693

47,500

1 1/4

12

1,178

1,302

59,600

884

977

59,600

1 3/8

12

1,596

1,764

73,000

1,197

1,323

73,000

1 1/2

12

2,090

2,310

87,700

1,568

1,733

87,700

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi T.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi

1-6

Varco Systems

General Information

Basic useage Drilling ahead with singles 1 n Set slips on string n Stop circulation n Close IBOP n Breakout connection using pipehandler and drilling motor (in reverse)

1

n Tilt links to mousehole

n Pickup single with elevator

n Latch drill pipe elevator around single

n Release link tilt

2

n Stab bottom of single onto string

3

n Lower block to stab motor into top of single

n Pull slips

n Spin in motor and single

n Start circulation

n Makeup both connections with motor in torque mode

4

n Open IBOP

n Begin drilling

5

Makeup

Open IBOP Link Tilt Close IBOP Stab

Preliminary

Makeup

TDS-11SA

1-7

General Information

Drilling ahead with triples 1

n Set slips on string

n Raise block

n Stop circulation

n Tilt link tilt to derrickman

n Breakout connection using pipehandler and drilling motor (in reverse)

n Pickup stand with elevator n Stab bottom of stand onto string

n Lower block to stab motor into top of stand

n Pull slips

n Spin in motor and stand

n Begin drilling

n Start circulation

n Makeup both connections with motor

1

2

3

4

5

Makeup

Link Tilt

Start Circulation

Stop Circulation Stab

1-8

Varco Systems

Makeup

General Information

Backreaming n Hoist while circulating and rotating n When 3-rd connection surfaces, stop rotation and circulation

1

n Set slips on string n Breakout connection using pipehandler and drilling motor (reverse)

n Hoist free stand with elevator

n Setback stand using link tilt

n Spin in motor and makeup connection with motor

n Breakout and spinout stand at floor

2

Breakout

n Lower block, stab motor into string

n Start circulation, pull slips, hoist and rotate

3

Hoist

4

5

Setback

Hoist and Rotate Breakout

Preliminary

TDS-11SA

1-9

1

General Information

1

1-10

Varco Systems

Specifications

Design specifications ............................................ 2-2

1

Size specifications ............................................ 2-2 Size specifications (continued) ........................ 2-3 General specifications ...................................... 2-4

2

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

3

4

5

6

7

8

9

Preliminary

TDS-11SA

2-1

Specifications

Design specifications Size specifications Front and side view Bail 120 in. (3048 mm)

2

18.5 in. (470 mm)

Bail 88 in. (2235 mm)

233.0 in. (5918 mm)

To Center of Gravity 112.4 in. (2855 mm)

To Center of Gravity 28.2 in. (716 mm) = 37,000 lb = 16,798 kg

2-2

71.9 in. (1826 mm)

Varco Systems

56.0 in. (1422 mm) 62.5 in. (1588 mm)

Specifications

Size specifications (continued) Plan view Rear

2

33.7 in. (856 mm)

33.8 in. (859 mm) 30.0 in. (762 mm) Setback (Standard)

22.8 in. (579 mm)

C L Well 21.1 in. (53 mm) 22.1 in. (561 mm)

31.0 in. (787 mm) 32.6 in. (828 mm) 26.0 in. (660 mm)

36.9 in. (937 mm)

C L Well

Front

Preliminary

TDS-11SA

2-3

Specifications

General specifications Components

Items

Description

Top Drive

2

Weight Stack-up Height Power Requirements Horsepower Output torque (continuous) Tool torque (intermittent @ stall) Maximum Speed @ full power Hoisting capacity

34,500 lb 17.8 ft 700 KVA @ 575-600 VAC, 50/60 Hz 800 hp 37,500 ft lb (800 hp) 55,000 ft lb 228 rpm 500 ton

Sizes

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

Type

PH-50 (55,000 ft lb torque)

Type

Reliance AC-575 VAC (2 x 400 hp)

Type

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

Type

Hydraulic caliper disc brakes

Type Power Speed

Local intake pressure blower (2) 5 hp AC motors 3,600 rpm

Type

Single speed, double reduction spur gear system (helical gears optional) 10.5:1 (4.??:1 optional)

Drill Pipe Pipe Handler Drilling Motor Variable Frequency Drive

Motor Braking Motor Cooling System

Gearcase

Gear ratio Gearcase Lubrication Type Reservoir capacity Fully internal flow Gear Type

Pressure feed 15 gal

Power Flow Speed Reservoir capacity Oil Type

10 hp, AC motor (1) 6 gpm, (1) 4 gpm 1800 rpm 25 gal

Size Type Weight Input requirement

125.4 in. x 84.0 in., 91.2 in. height (Siemens) 140.0 in. x 90.0 in., 91.0 in. height (IDM) 9,500 lb 600 VAC(60 Hz), or 600 VAC(50 Hz), or 750 VDC, or 690 VDC(50 Hz)

Hydraulic System

Electrical House

2-4

Varco Systems

Specifications

Typical mast interface Existing Traveling Equipment 350-ton Hook/Block Combo-Typ.

TDS-11S Varco Portable Top Drive System

* Dimensions are Subject to Verification ** Standard TDS ConfigurationTwo IBOP’s with 108 in. Elevevator Links

Sectional Guide Beam

Crown Clearance 13.5 ft. (4,1 m)** Block Top Stroked-Typ. 13.5 ft. (4,1 m)* Bail Rest

2

TDS Work Height 18.0 ft. (5,4 m)** Tool Joint

Service Loop Saddle at ~80 ft. (24,4 m) Level* Mud Hose 75 ft. (22,9 m)* Connected to Standpipe at 73 ft. (22,3 m) Level Service Loop 200 ft. (61 m)*

Varco Driller’s Control

Control Cable with Connectors 150 ft. (45,7 m)

Unitized Variable Frequency Inverter & Varco Control Panel Local Power Supply Diesel/Alternator Set/AC Buss

AC Cables

Preliminary

7.0 ft. (2,1 m)-Minimum

2 Custom Spanners On A-Frames or Mast Side Panels (by Customer)

10.0 ft. (3 m)-Minimum*

Portable Torque Reaction Beam “U”- Bolted to Spanners - (by Customer)

Clear Working Height 142 ft. (43,3 m)

Drill Stand Made-up at 4 ft. (1,2 m) Level 93 ft. (28,3 m)

C L Beam Service Loop Tool Joint 4.0 ft. (1,2 m) Drill Floor

AC Power and Control Cables

TDS-11SA

2-5

Specifications

2

2-6

Varco Systems

Lubrication

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

1

Selecting the proper gearbox oil...................... 3-2 Lubrication schedule ........................................ 3-2 Recommended gear oils ................................... 3-3 Gearbox lubrication .......................................... 3-4

2

Hydraulic system ................................................... 3-5 Precautions........................................................ 3-5 Lubrication schedule ........................................ 3-5

3

Recommended hydraulic fluid ......................... 3-6 Hydraulic lubrication......................................... 3-7 Motors .................................................................... 3-8

4

Lubrication schedule ........................................ 3-8 Recommended motor grease ........................... 3-8 Motor lubrication ............................................... 3-9 5 General purpose lubrication ................................. 3-10 Lubrication schedule ........................................ 3-11 Recommended lubricants ................................ 3-11 General lubrication ........................................... 3-12

6

General lubrication (continued) ....................... 3-13 General lubrication (continued) ....................... 3-14 General lubrication (continued) ....................... 3-15 7

8

9

Preliminary

TDS-11SA

3-1

Lubrication

Transmission Selecting the proper gearbox oil TDS transmissions operate under a combination of heavy and shock loads. Under these conditions oil tends to extrude out of the gear mesh. Keeping an effective film of oil on the gear mesh requires oil with an AGMA “extra pressure” rating (EP), and a minimum viscosity of 100 SUS at internal operating temperature. Varco Top Drives also operate under a wide variety of temperatures. Select lubrication for the TDS based on the minimum ambient temperature (surrounding air) to be expected before the next oil change. Under all but the most severe operating conditions, Varco recommends changing the oil every six months. Introducing an oil viscosity greater than required by the ambient temperature can:

3

❏ Damage the gearbox due to reduced oil flow ❏ Damage the oil pump because of excessive load

Lubrication schedule Description Replace the Gearbox Oil and Perform an Oil Analysis

Frequency 1 x every 6 Months

Oil viscosity should be adjusted based on expected ambient conditions for next six months

Replace the Gearbox Oil Filter (P/N 111013)

1 x every 3 Months

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

3-2

Varco Systems

Lubrication

Recommended gear oils Ambient Temperature Range -6 to 16 C

7 to 30 C

Above 21 C

(20 to 60 F)

(45 to 85 F)

(Above 70 F)

Alpha LS-68

Alpha LS-150

Alpha LS-320

Manufacturer Castrol Chevron

NL Gear 68

NL Gear 150

NL Gear 320

Exxon

Spartan EP68

Spartan EP150

Spartan EP320

Gulf

EP Lube HD68

EP Lube HD150

EP Lube HD320

Mobil

MobilGear 626

MobilGear 629

MobilGear 632

Shell

Omala 68

Omala 150

Omala 320

Statoil

Loadway EP68

Loadway EP150

Loadway EP320

Texaco

Meropa 68

Meropa 150

Meropa 320

Total

Carter EP 68

Carter EP 150

Carter EP 320

Union

Extra Duty NL2EP

Extra Duty NL4EP

Extra Duty NL6EP

NGLI

N/R

N/R

N/R

AGMA

2EP

4EP

6EP

68

150

320

3

Viscosity Index

ISO Viscosity Grade

e z

Oils of insufficient viscosity can damage gears by allowing metal to metal contact.

For minimum temperatures below 20°F, the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. If drilling conditions dictate oil temperatures below 20°F, consult Varco engineering. If the oil temperature rises above 200°F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F, consult Varco engineering.

Preliminary

TDS-11SA

3-3

Lubrication

Gearbox lubrication

3

Cork Ball (Level Indicator)

Sight Glass

Gear Oil Sight Gauge Check withTop Drive “OFF”

“Pop-up” Dirt Alarm

Gear Oil Filter

3-4

Varco Systems

Gearbox Oil “Fill” Use a 1 3/8 inch, 12 point socket to remove plug

Lubrication

Hydraulic system Precautions

n n

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

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

e

Use care when handling components to prevent nicking close tolerance finishes.

e

Use care to prevent contamination from entering the hydraulic system during maintenance activities.

Lubrication schedule Description Perform Hydraulic System Oil Analysis Replace the Hydraulic Fluid

Frequency 1 x every 6 Months 1 x Year, or Earlier Based on Oil Analysis

Replace the Hydraulic System Filter (P/N 114416-1)

1 x every 3 Months

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

Preliminary

TDS-11SA

3-5

3

Lubrication

Recommended hydraulic fluid Oil Temperature Range -15 to 75 C

-10 to 85 C

(5 to 167 F)

(14 to 185 F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Harmony 32AW

Harmony 46AW

DTE 24

DTE 25

Manufacturer Castrol Chevron Exxon Gulf Mobil

3

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

32

46

Shell

Viscosity Index ISO Viscosity Grade

3-6

Varco Systems

Lubrication

Hydraulic lubrication n Ensure that the area is clean prior to adding hydraulic fluid Cork Ball (Level Indicator)

n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill n Remove dust plug from the female quick disconnect on the lubrication kit n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as shown

Sight Glass

Red “Pop-up” Dirt Alarm

Hydraulic Oil Sight Gauge

Hydraulic Oil Filter

Hydraulic Lubrication Kit 55 gal Drum Lubrication Kit Quick Disconnect

Hydraulic Oil Fill Quick Disconnect

Hydraulic Oil “Fill”

Preliminary

TDS-11SA

3-7

3

Lubrication

Motors

n

Varco recommends that lubrication of all AC motors should be done by the rig electrician.

Lubrication schedule Description

No. of Points

Frequency

Type

Lubricate the AC Drilling Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Blower Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Hydraulic Pump Motor

2

1 x every 3 Months

Motor Grease

3

Recommended motor grease Motor Grease

Manufacturer Black Pearl EP2 (Do Not Substitute)

Chevron

3-8

Varco Systems

Lubrication

Motor lubrication Apply grease to designated grease fittings with grease gun

Grease Fittings 1/8 inch Grease Fitting (Varco P/N 53201)

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

3

1/8 inch Pipe Plug (remove and reinstall after lubricating)

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

As Viewed From Below

3 Months Hydraulic Pump AC Motor 3 pumps (2 grease fittings each motor)

Preliminary

TDS-11SA

3-9

Lubrication

General purpose lubrication

e e 3

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.

Lubrication schedule Description

No. of Points

Frequency

Type

Washpipe Assembly

1

Daily

General Purpose Grease

Upper Bonnet Seal

1

Weekly


Bail Pins

2

Weekly


Rotating Link Adapter Gear

–

Weekly



2

Weekly


IBOP Actuator Yoke, Cylinder Pins

5

Daily


IBOP Actuator Cranks

2

Daily


Stabilizer Bushing

4

Daily


Clamp Cylinder Gate

2

Daily


Carriage Assembly

8

Weekly


Torque Arrestor at Clamp Cylinder

4

Weekly


Elevator Link Eyes

4

Weekly


Wireline Adapter

2

Weekly


3-10

Varco Systems

Lubrication

Recommended lubricants Ambient Temperature Range Below -20 C

Above -20 C

(Below -4 F)

(Above -4 F)

N/R

MP Grease

Avi-Motive W

Avi-Motive

Lidok EP1

Lidok EP2

Gulf Crown EP31

Gulf Crown EP32

Mobil

Mobilux EP1

Mobilux EP2

Shell

Alvania EP1

Alvania EP2

Statoil

Uniway EP1N

Uniway EP2N

Texaco

Multifak EP1

Multifak EP2

Total

Multis EP1

Multis EP2

Union

Unoba EP1

Unoba EP2

1

2

AGMA

N/R

N/R

ISO Viscosity Grade

N/R

N/R

Manufacturer Castrol Chevron Exxon Gulf

3

Viscosity Index NGLI

Preliminary

TDS-11SA

3-11

Lubrication

General lubrication

3

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

Daily Wash Pipe Assembly Apply one pump at beginning of tour

Weekly

Weekly

Bail Pins (2) Two pumps each side

Upper Bonnet Seal One pump Use Hand Pump Only

Weekly

Weekly

Rotating Link Adapter Gear

Rotating Link Adapter Three pumps each

Weekly Elevator Link Eyes (4)

3-12

Varco Systems

Lubrication

General lubrication (continued)

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

Daily IBOP Actuator Yoke One pump (if equipped)

Daily IBOP Actuator Yoke One pump each side

Daily IBOP Actuator Cylinder Pins One pump each (if equipped)

Weekly

Daily

Torque Arrestor Tubes

IBOP Actuator Cranks One pump each side

Daily Stabilizer Bushing One pump each side

Daily Stabilizer Bushing One pump each

Weekly

Daily

Elevator Link Eyes (4)

Clamp Cylinder Gate One pump each side

Preliminary

TDS-11SA

3-13

3

Lubrication

General lubrication (continued) Apply general purpose grease to designated grease fittings with grease gun

3

Weekly

Weekly

Bogies (4) One pump each side

Rollers (4) One pump each side

3-14

Varco Systems

Lubrication

General lubrication (continued)

Apply general purpose grease to designated grease fittings with grease gun

3

Weekly Wireline Adapter One pump each

Preliminary

TDS-11SA

3-15

Lubrication

3

3-16

Varco Systems


Illustrated index ................................................. 4-3 1

Preparation and preinstallation considerations ................................................... 4-4 Preinstallation ........................................................ 4-5 Installing the crown padeye and

2

hang-off link....................................................... 4-5 Locating the control house .............................. 4-6 Installing incoming power cables .................... 4-7 3 Installation ............................................................. 4-8 Pre-installation checklist .................................. 4-8 Moving the TDS-11SA to the drill floor ............ 4-9 4

Removing the TDS-11SA from the skid ........... 4-10 Disengaging the lower carriage latch .............. 4-11 Moving guide beam sections ........................... 4-12 Present and hook the first

5

guide beam section ........................................... 4-13 Hoist the first guide beam section ................... 4-14 Stab and pin the first guide beam section ...... 4-15 6

Completing the guide beam installation ......... 4-16 Hanging the guide beam................................... 4-17 Disengaging the upper carriage latch ............. 4-18 Installing the main tieback ............................... 4-19

7

Installing the intermediate restraints ............... 4-20 Installing derrick termination ........................... 4-21 Installing the service loop ................................ 4-22 Service loop connection diagram .................... 4-23

8

Installing the driller’s console .......................... 4-24 Installing the mud hose .................................... 4-25 Installing the counterbalance ........................... 4-26 9

Installing the rotary hose .................................. 4-27

Preliminary

TDS-11SA

4-1


Commissioning ..................................................... 4-28 Hydraulic system checkout procedure ........... 4-28 Electrical system checkout procedure ............ 4-29 Mechanical checkout procedure ...................... 4-30 Decommissioning.................................................. 4-35 Removing and storing the electrical cables and service loops .............................................. 4-35 Securing the TDS-11SA for rig-down .............. 4-36 Setting the latches and locking the bail .......... 4-37 Disconnecting the guide beam ........................ 4-38 Unpinning each guide beam section ............... 4-39 4

Lowering each guide beam section ................. 4-40 Unhooking and removing each guide beam section ........................................... 4-41 Returning the TDS-11SA to the skid ................ 4-42 Removing the TDS-11SA from the drill floor... 4-43 Long term storage procedures ........................ 4-44 Returning the TDS-11SA to service after storage ...................................................... 4-44

4-2

Varco Systems


Illustrated index Crown Padeye and Hang-off Link Page 4-X

Counterbalance Page 4-X

Rotary Hose Page 4-X

Derrick Termination Page 4-X

Guide Beam Page 4-X

4

Service Loop Page 4-X

Intermediate Restraints Page 4-X

Varco Driller’s Console (VDC) Page 4-X Control Cable with Connectors Page 4-X

Main Tieback Page 4-X

Unitized Variable Frequency Inverter and Varco Control Panel (House) Page 4-X Local Power Supply Diesel/Alternator Set/AC Bus AC Cables Page 4-X AC Power and Control Cables Page 4-X

Preliminary

TDS-11SA

4-3


Preparation and preinstallation considerations The TDS-11SA interfaces with the rig’s hoisting system and electrical power system. Derrick and electrical system modifications are required when installing the TDS-11SA on existing rigs. For derricks that handle triples, the required top drive travel is about 100 ft. compared to about 75 ft. when using a Kelly. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. long) with a 75 ft. hose, and extend the standpipe height to 70 ft. Although many rig floor layouts are possible, installing the guide beam on the drawworks side of the derrick, or mast, and opposite the V-door is an ideal arrangement for handling tubulars from the V-door. The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop and mud hose. Other important installation considerations include the location of:

4

❏ The casing stabbing board ❏ Floor and derrick accessories ❏ Drawworks fastline ❏ Guide beam hang-off bracket ❏ Torque reaction beam ❏ Mud stand pipe extension ❏ Varco drillers console location ❏ Variable frequency inverter/Varco control panel location Derrick height is a critical interface requirement. Handling a 93 ft. stand typically requires 97 ft., resulting in an overall height from the floor to the top of the traveling block of at least 126 ft. Derrick Clear Working Height

Derrick Crown Clearance

152 ft. 147 ft. 142 ft. 136 ft.

25 ft. 20 ft. 15 ft. 9 ft.

Each rig has different crown clearance for efficient tripping. Installing the TDS-11SA with existing traveling equipment may require an adapter– further reducing crown clearance.

4-4

Varco Systems


Preinstallation Installing the crown padeye and hang-off link Crown

Crown Padeye Weld according to table below

See Table

4 Shackle

Hang-off Link

Recommended Installations Dimension

Description

36.8 inches

Standard height configuration (adustable)

33.8 inches

Varco’s IDS Top Drive requirements

30.0 inches

Original setback for TDS-9S

Preliminary

C L Well

TDS-11SA

4-5


Locating the control house

C L Well

4

Drawworks

Recommended Area for Control House Location

V-Door Ramp TDS-11SA

Varco Driller’s Console

9,500 lb (4300 kg) Control House C L Well

Recommendations

Control House

n Position the control house off the driller’s side or behind the drawworks. 91.00 in. (2311.4 mm)

n Position as close to derrick plate as possible to minimize cable lengths. n Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts). n Location of the control house must ensure accessibility from all sides.

140.00 in. (3556 mm)

4-6

Varco Systems

90.00 in. (2286 mm)


Installing incoming power cables

A-C

OM

POS

ITE

CON

NEC

TOR

B-S

ERIA

LC

ONN

ECT

Incoming Power Cables

D-U

C-A

INC

UX.

OM

ING

ER

INC

4

TOR

OM

ING

575

VAC F-W

OUT

Plug Panel CON

NEC

VAC E-V

G-U

POW

575

OR

INC

OM

GO

ING

ING

575

575

VAC

VAC H-V

OUT

GO

ING

575

VAC I-W

OUT

GO

ING

575

VAC

Plug Panel

Recommendations n Connect the incoming power cables with the isolation circuit breaker turned OFF. n Connect cables in accordance with the electrical schematic provided in the Technical Drawings book.

Varco Control Panel (House)

n Earth the control house with the Varco Ground Rod Kit. Grounding locations are at the lower corners of the control house.

Preliminary

TDS-11SA

4-7


Installation Pre-installation checklist The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and TDS11SA. This includes: ❏ Make sure the derrick/mast is vertical, with the block over the center of the rotary table. ❏ Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed and inspected to conform to Varco specifications as detailed in FIP00003. ❏ The service loop bracket is installed in the derrick/mast. ❏ The control panel and frequency drive are installed. ❏ Rigging of tong lines, etc. is inspected to ensure that they will not foul with the TDS-11SA.

4

❏ The hook or adaptor becket is installed. The hook should open toward the drawworks.

4-8

Varco Systems


Moving the TDS-11SA to the drill floor Lifting Block Hoist using the drawwork

Be sure that the Bail Lock Assembly is installed Tube (P/N 113498) U-Bolt (P/N 113497) 2x 3/4" nuts

!

TDS-11SA on Skid

Lifting Sling Attached to bail for hoisting

4

Lifting Sling

! TDS-11SA In position prior to lifting from skid

Be sure that the Top Drive is pinned to the Skid prior to hoisting

3 37,000 lb (16000 kg) TDS-11SA on Skid

Drill Floor

2

Backup Line V-Door Ramp

Preliminary

1

TDS-11SA

4-9


Removing the TDS-11SA from the skid 34,500 lb (15700 kg) TDS-11SA

! Be sure that the Bail Lock Assembly is installed. Remove only after installation is complete. TDS-11SA Lifted from skid

Pin

2 Latches Engaged for hoisting

4 Pin Lifting Block Hoist from skid using the drawwork

TDS-11SA

Lock Pin Remove prior to hoisting from skid TDS-11SA Prior to lifting from skid

1

Drill Floor Skid Remove from drill floor after hoisting TDS-11SA

3

4-10

Varco Systems

2,500 lb (1100 kg) Skid


Disengaging the lower carriage latch Guide Beam Top Section

Carriage

Guide Beam Wings

! After hoisting the TDS-11SA from the skid, disengage the lower carriage latch and pin it as shown.

Upper Latch Engaged

Lower Latch Disengaged Pin

As viewed from rear of Carriage

TDS-11SA prior to lifting from skid

Preliminary

TDS-11SA

4-11

4


Moving guide beam sections 2,100 lb (953 kg) Guide Beam Section

Sling

4

Lifting Eyes

TDS-11SA

Guide Beam Section

Drill Floor

Guide Beam Sections Prior to Installation

4-12

Varco Systems


Present and hook the first guide beam section Guide Beam Top Section

1 Present

Hook Pin Saddle

Grease the bores on both joint halves

Grease the bores on both joint halves

Radius locks joint from unhooking at 8° rotation Guide Surface Hook Pin

4 Hook Pin In fully engaged position

Guide Beam Top Section

2 Hook

Present and Hook the first guide beam section

Guide Beam Section Hooked Drill Floor

Preliminary

TDS-11SA

4-13


Hoist the first guide beam section

Hoist Guide Beam Top Section Hoist Using the drawwork Hook Pin

First Guide Beam Section Initially hoisted by the hook pin

4

Bar and Radius Locates pin bores for easy insertion of pins

Drill Floor

4-14

Varco Systems


Stab and pin the first guide beam section

1 Stab the guide beam joints together


Lynch Pin

4

3

Secure with the lynch pin

Retainer Pin

4 2 Joint Pin Install after stabbing

Stab and Pin the guide beam joint

Drill Floor

Preliminary

Block as Required

TDS-11SA

4-15


Completing the guide beam installation Note: Use these pin positions if crown padeye installation is based on:

Crown

TDS-11SA Hoisting latches disengaged

(36.8 in.) (934.72 mm) Standard adjustable height configuration

Crown Padeye

(33.8 in.) (858.52 mm) Varco’s IDS top drive requirements

Shackle Ensure that the shackle is pinned and the cotter pin is in place

(30.0 in.) (762 mm) Original TDS-9S or if plate extension (36.8 in.) needs to be cut off due to interference.

Hang-off Link

4 Pin

Safety Pin


Guide Beam Assembled Main Tieback and Spreader Beam Drill Floor

Floor Clearance 7 ft. (2,133.6 mm)

4-16

Varco Systems

C L

C L


Well


Hanging the guide beam Note: Use these pin positions if crown padeye installation is based on:

Crown

TDS-11SA

36.8 in. (934.72 mm) Standard adjustable height configuration

Crown Padeye

33.8 in. (858.52 mm) Varco’s IDS Top Drive requirements

Shackle Ensure that the shackle is pinned and the cotter pin is in place

30.0 in. (762 mm) Original TDS-9S or if plate extension (36.8 in.) needs to be cut off due to interference.

Hang-off Link

Pin

Safety Pin

Guide Beam Assembled


C L

C L


Well

Drill Floor

Floor Clearance 7 ft. (2,133.6 mm)

Preliminary

TDS-11SA

4-17

4


Disengaging the upper carriage latch Guide Beam Top Section

Carriage

! After hanging the guide beam on the hang-off link and prior to lowering the Top Drive, disengage the upper carriage latch and pin it as shown.

4 Pin

Upper Latch Disengaged Lower Latch Disengaged

As viewed from rear of Carriage

Guide Beam Assembled Drill Floor

4-18

Varco Systems


Installing the main tieback Guide Beam Bottom Section

Tieback Link


Tieback Plate

4 Main Spreader Beam

Apply Anti-seize Compound Typical Auxiliary Spreader Beam

Mast Leg

Drill Floor

Main Tieback and Spreader Beam See Table

C L Well

Preliminary

Recommended Installations Dimension

Description

36.8 inches

Standard height configuration (adjustable)

33.8 inches

Varco’s IDS Top Drive requirements

30.0 inches

Original setback for TDS-9S

TDS-11SA

4-19


Installing the intermediate restraints Apply Anti-seize Compound


Intermediate Tieback Plate (2)

Girt Padeye (2) (If greater than 3 inches from girt)

4 3 inches

105 Feet Space between girt and guide beam

Padeye (1) (If less than 3 inches from girt)

Pin and Cotter Pin


55 Feet

Drill Floor

n Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor n Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches n Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches

4-20

Varco Systems


Installing derrick termination Hoist Line Attachment Point

Derrick Leg Plate

Derrick/ Mast Leg

Hoist Line Attachment Points

Service Loop Brackets

4

n Mount on the side of the derrick adjacent to the service loop brackets on the TDS-11SA n Mount as far as practical from well center, to maintain a 36 inch minimum bend radius. Maintaining a larger radius increases loop life and reduces damage due to “pinching”. n Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc.

Preliminary

75 ft/83 ft from Drill Floor

TDS-11SA

4-21


Installing the service loop Hoist Derrick Termination 1,000 lbs (454 kg) Service Loop

Sling

4

! To avoid damage to the service loop use care when dragging it near sharp edges and allow room for passing under the V-door

TDS Service Loop Lifting Eyes Do not remove Derrick Service Loop

n Do not unpack the service loops until they are ready to hang n Use a sling attached to the lifting eyes to hoist each service loop. Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting.

! To avoid damage to the service loop maintain a 36 inch minimum Service Loop bend radius and Storage Tub 3,600 lbs (1,634.4 kg)

4-22

Varco Systems

n The TDS service loop connects electrical service to the top drive and the derrick service loop connects electrical service to the control house n Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package


Service loop connection diagram

4

Preliminary

TDS-11SA

4-23


Installing the driller’s console

n Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated n Location must ensure that the gauges are easily seen by the driller during drilling operations

UE

RQ

TO

P

IBO E

AK

BR

n Location must be visible and readable at night

Y NC GE ER OP EM ST

R

LE

D AN

EH

PIP

C L Well

Drawworks

4

C L Well

TDS-11SA


Pigtail Cables Connect to control house

!

4-24

V-Door Ramp

Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system, as it is specifically made for use with the TDS-11SA.

Varco Systems


Installing the mud hose

4

Preliminary

TDS-11SA

4-25


Installing the counterbalance

For use with Hooks

4

4-26

Varco Systems


Installing the rotary hose 5

4 5

3

4

2

3

1

4 6

6

9

8

11

10

12

10

7 11 8

12 14

13

O

Preliminary

TDS-11SA

4-27


Commissioning Hydraulic system checkout procedure Checking hydraulic fluid level

4

4-28

Varco Systems


Electrical system checkout procedure Checking connections and motor rotation n Operate each control on the Varco driller’s console n Assign the cooling motors and inverter by selecting FORWARD or REVERSE on the driller’s console


n Rotate the drill stem using the THROTTLE on the driller’s console and observe proper operation

Latches

n Check for alarm conditions and resolve any alarms at this time n Check all connectors for tightness and lockwire n Check operation of meters n Check operation of “?” stop n Check the latches on the driller’s console for tightness

4

M

RP

UE

RQ

TO

UE

RQ

TO X

MA

OP

IB P IBOSED O CL

Y NC GE ER OP EM ST

E

AK

BRAKE BR N O ER

DL

AN

EH

PIP

PR P -U IT KE LIM MAENT RR

CU

OR OT P L M EM X RIL RT MA DOVE

T

F LE

LIC

AU

0

IVE DRULT FA

RE

R VE

AR

RW

FO

X

MA

Throttle

0

T

TIL

CH EN ILL WR LD DR UE HO RQ H & TOPUS

R YD MP H LA ECK UTO A M CH AR AL NCE ILE

F

OF SE

OP

F OF

ILT

KT LINOFF

TO

D

P LO IBO C EN

E E AK AK BR TO BRON AU

ILL

DR

SE

T

OA

FL

KT

LIN HT

TE RIG

TA

RO S OILLOS S ES

ILT

UE

RQ

0

R WE PO N O

Forward/Reverse Control

/

S SS

ER

LO

OW

BL UE

IN

SP

RQ

TO

ILL

DR

Preliminary

TDS-11SA

4-29


Mechanical checkout procedure Checking gearbox oil level n With the drive motors and hydraulic system off, check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox n 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). n Check filter condition “pop”

4

Cork Ball (Level Indicator) Gearbox Oil “Fill” Clean area before removing plug

Sight Glass Gear Oil Sight Gauge Check with top drive “OFF”

Recommended Lubricants GEAR OIL Ambient Temperature Range

“Pop-up” Dirt Alarm Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade

Gear Oil Filter

4-30

Varco Systems

-6 to 16 C

7 to 30 C

Above 21 C

(20 to 60 F)

(45 to 85 F)

(Above 70 F)

Alpha LS-68 Alpha LS-150 Alpha LS-320 NL Gear 68 NL Gear 150 NL Gear 320 Spartan EP68 Spartan EP150 Spartan EP320 EP Lube HD68 EP Lube HD150 EP Lube HD320 MobilGear 626 MobilGear 629 MobilGear 632 Omala 68 Omala 150 Omala 320 Loadway EP68 Loadway EP150 Loadway EP320 Meropa 68 Meropa 150 Meropa 320 Carter EP 68 Carter EP 150 Carter EP 320 Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP N/R 2EP 68

N/R 4EP 150

N/R 6EP 320


Adjusting the link tilt

Pin

inches (mm) Typical

Link Tilt Crank Assembly

4 Clamp

Mousehole Position Cable Pull “up” or “down” to set mousehole position

Latch

(inches) (mm)

Drill Down Position

Link

Bottom of elevator should be above bottom of stabbing guide

Mousehole Position Derrickman’s Position

Preliminary

Well Center (Float Position)

Elevator

TDS-11SA

4-31


Selecting the proper saver sub and clamp cylinder jaws

53

41

20

42

21

40

36

38

37

52

39

54 55

20 31

25

21

34

4

43

26

35 24

51

27 29 32

28

13

22 23

30

41

33

20 14

57

59

40

56

60

21 44

15

58

18

45

19 36 16 17

46

37 34

13

47 50

35

18

11 19 12 12

48 27 32 1

2 5

49

16 17

28

33 14

9

15

8 7

10

4-32

6

4

3

Varco Systems

S


Removing and installing the saver sub Upper IBOP

Lower IBOP

4

Saver Sub

Upper Tool Lock Joint

Shell Actuator

Intermediate Tool Lock Joint

Lower Tool Lock Joint

Preliminary

TDS-11SA

4-33


Removing and installing the clamp cylinder jaws 43 42 34 2

31 35

34

30

33

1

35 32

35

22 27

R

34 29 28

40

4

9

39

49

12

47

26

21 53

23

26

25

46

41

24 57 58

42

37 38

9

7

56

3

R

36 12

52 18 4

19

44

16

59

17

60

11

64

40

54 5

66 55

68 14

69

20

70

61

65 13

62

63

73

6 77

10

52

15 80

71

10

50

67

51 76

78

45 48

79 72

74

75

81 8 77

4-34

Varco Systems

Q


Decommissioning Removing and storing the electrical cables and service loops Lower Derrick Termination 1,000 lbs (454 kg) Service Loop

Sling

4

! To avoid damage to the service loop use care when dragging it near sharp edges and allow room for passing under the V-door

TDS Service Loop Lifting Eyes Do not remove Derrick Service Loop

n Do not pack the service loops until the service loop storage tub is in position

! To avoid damage to the service loop maintain a 36 inch minimum Service Loop bend radius and Storage Tub 3,600 lbs (1,634.4 kg)

Preliminary

n Use a sling attached to the lifting eyes to lower each service loop. Use the swivel at the tugger line attachment to allow each service loop to coil without twisting.

TDS-11SA

4-35


Securing the TDS-11SA for rig-down Bail 120 in. (3048 mm) 18.5 in. (470 mm)

Bail 88 in. (2235 mm)

4

233.0 in. (5918 mm)

To Center of Gravity 112.4 in. (2855 mm)

To Center of Gravity 28.2 in. (716 mm) = 37,000 lb = 16,798 kg

4-36

71.9 in. (1826 mm)

Varco Systems

56.0 in. (1422 mm) 62.5 in. (1588 mm)


Setting the latches and locking the bail

4

Preliminary

TDS-11SA

4-37


Disconnecting the guide beam Crown

Crown Padeye Do not remove Shackle

TDS-11SA Carriage latches remain engaged

Hang-off Link

4 Pin


n Be sure that the bail lock assembly is installed Drill Floor

n Be sure carriage latches remain engaged n Disconnect the guide beam from the main tieback and intermediate tiebacks n Disconnect the guide beam from the hang-off link

4-38

Varco Systems


Unpinning each guide beam section

4

Preliminary

TDS-11SA

4-39


Lowering each guide beam section

4

4-40

Varco Systems


Unhooking and removing each guide beam section

4

Preliminary

TDS-11SA

4-41


Returning the TDS-11SA to the skid Pin Install after lowering TDS-11SA onto the skid

34,500 lbs (15,663 kg) TDS-11SA

TDS-11SA

2

TDS-11SA

4

Lifting Block

Lock Pin Install after lowering TDS-11SA onto the skid

3 TDS-11SA Lowered onto skid

Drill Floor

2,500 lbs (1,135 kg) Skid

n Hoist skid to the drill floor n Using the drawwork, lower the TDS-11SA onto the skid

1

n Pin the TDS-11SA to the skid at the top and bottom of the guide beam top section Skid

4-42

Varco Systems

n Install pin retainers


Removing the TDS-11SA from the drill floor

!

Sling

Be sure that the Bail Lock Assembly is installed Lifting Block Lower using the drawwork

4

TDS-11SA on Skid 37,000 lbs (16,798 kg)

Lifting Sling

TDS-11SA On the skid prior to removing from the drill floor

Drill Floor

1

2

Backup Line V-Door Ramp

Preliminary

3

TDS-11SA

4-43


Long term storage procedures 1. Drain the oil from the gearbox prior to rigging down. 2. Remove the saver sub. 3. Disconnect guide beam from lower attachment and connecting link. 4. Rig down the guide beam. 5. Bring the shipping and handling skid to the drill floor. 6. Install the TDS-11SA into the skid and pin. 7. Release the hook and remove the TDS-11SA. 8. For indoor storage, cover the TDS-11SA in its shipping and handling skid. A cargo container is appropriate for outdoor storage.

4

9. Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60°F ambient. 10. All exposed unpainted metal surfaces are coated with a rust preventive prior to shipment; however, check these surfaces periodically to be sure that no corrosion is taking place. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent. 11. Cover all openings to prevent water or dust from entering. Leave enough space around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent. 11. During storage, rotate the motors and gear train periodically to distribute lubricant. Perform this at three month intervals if stored indoors, and at one month intervals if stored outdoors. 12. For long term storage recommendations dealing with the AC drilling motors, see the motor manufacturer’s manual.

Returning the TDS-11SA to service after storage Before placing the TDS-11SA back into service after storage, verify the following items: 1. Remove all rust preventive and any corrosion that may have taken place, taking special care with all load carrying components. 2. Follow the return to service procedures in the AC drilling motor manufacturer’s manual.

4-44

Varco Systems


Inspecting the crown padeye and hang-off link .. 5-2 1 Inspecting the top section of the guide beam ..... 5-3 Inspecting the guide beam joints ......................... 5-4 Inspecting the main tieback.................................. 5-5

2

Inspecting the intermediate restraints ................. 5-6 Inspecting the carriage ......................................... 5-7 3 Illustrated part lists ............................................... 5-9 Guide beams (roller) ........................................... Guide beams (slider) .......................................... Universal tiebacks ............................................. Tiebacks (sliding) ............................................... Carriage/accumulator (roll) ................................ Carriage assembly, right (roller) ........................ Carriage assembly, left (roller) .......................... Carriage/accumulator (skid) .............................. Carriage assembly, right (skid) .......................... Carriage assembly, left (skid) ............................

5-10 5-12 5-14 5-16 5-18 5-20 5-22 5-24 5-26 5-28

4

5

6

7

8

9

Preliminary

TDS-11SA

5-1


Inspecting the crown padeye and hang-off link Crown

Yearly Crown Padeye

MPI

2.1" (52 mm) minimum

Monthly Crown Padeye Visually inspect weld for cracks

Monthly Cotter Pin Replace if missing

5

Shackle 2.0" (50 mm) minimum

Monthly Shackle Inspect and replace if worn 1.5" (37 mm) minimum

Monthly Hang-off Link Bores Inspect and repair if worn Hang-off Link Bores

5-2

Varco Systems


Inspecting the top section of the guide beam Crown

2.1" (52 mm) minimum 1.5" (37 mm) minimum

5 Bolt Assembly

Hang-off Link Bores

Monthly Safety Pin Replace if missing

Monthly Hang-off Link Bores Inspect and repair if worn


Preliminary

TDS-11SA

5-3


Inspecting the guide beam joints

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

Secure

Weekly Lynch Pin

5

Weekly Joint Pin

Yearly Typical Guide Beam Joint

Weekly

MPI

Retainer Pin

Monthly Inspect welds for cracks

5-4

Varco Systems


Inspecting the main tieback Guide Beam Bottom Section

Daily Check that the tool is aligned directly over well center

Main Spreader Beam Tieback Link

Tieback Plate

5

Yearly Typical all welds

MPI

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

Auxiliary Spreader Beam

Mast Leg

Preliminary

TDS-11SA

5-5


Inspecting the intermediate restraints

Daily Check that the tool is aligned directly over well center

Weekly Check for tightness of cotter pins, and double nuts. If there are signs of shifting, verify alignment.

5 Weekly Pin and Cotter Pin Verify that all pins are in place. Replace any missing or damaged pins.

Mast Girt

Yearly Typical all welds Guide Beam

5-6

Varco Systems

MPI


Inspecting the carriage

Weekly Typical all rollers Inspect for uneven wear or damage. Replace yearly or as required.

5

Daily Detent Pins Verify that pins are in place and secure

Preliminary

TDS-11SA

5-7


5

5-8

Varco Systems


Illustrated part lists On the following pages xxxxxxx

5

Preliminary

TDS-11SA

5-9


8

Rolling Guide Beam/Carriage Configuration

Top Section Part of Shipping Package

3 7

2

1

5

4

6

5

E

Guide beams (roller)

5-10

Varco Systems


Key to Guide beams (roller) Item #

Part #

Description

Qty

1

116414-505

Guide Beam, Bottom Section

1

2

115954

Guide Beam, Intermediate Section

4

3

115954-500

Guide Beam, Special Intermediate Section

1

4

116644

Retaining Pin

12

5

116643

Hinge Pin

12

6

51403-8-S

Cotter Pin

12

7

89035-1

Shackle, 25 Ton

4

8

99873-650

Connection Link, 65"

1

5

Preliminary

TDS-11SA

5-11


Sliding Guide Beam/Carriage Configuration

8

9 10 11 3

12

1

13 14

Top Section Part of Shipping Package

5

5

6

4

2 7

F

Guide beams (slider)

5-12

Varco Systems


Key to Guide beams (slider) Item #

Part #

Description

1

117618

Guide Beam, Bottom Section (18 ft)

1

2

117618-500

Guide Beam, Bottom Section (36 ft)

1

3

117616

Guide Beam, Intermediate Section (18 ft)

4,5,6

4

117616-500

Guide Beam, Intermediate Section (36 ft)

2

5

117783

Retainer Pin

3,5,6,7

6

117782

Joint Pin

3,5,6,7

7

117496-1

Lynch Pin

3,5,6,7

8

95523

Shackle, 25 Ton

1

9

117788-136

Hang-Off Link

1

10

117788-142

Hang-Off Link

1

11

117788-147

Hang-Off Link

1

12

117788-152

Hang-Off Link

1

13

117788-126

Hang-Off Link

1

14

117788-156

Hang-Off Link

1

Preliminary

Qty

TDS-11SA

5

5-13


Guide Beam (Bottom Section, Rolling Configuration)

9 11 12 10

11 2

11 4

14 10 11 7 5 14

1

5

5

15 16 3 14

8

4

6 13

17

11 10

Mast Leg

G

Universal tiebacks

5-14

Varco Systems


Key to Universal tiebacks Item #

Part #

Description

Qty

1

117698

Tieback Link

2

2

117699

Attachment Plate

2

3

117700-1

Strap

4

4

117700-2

Strap

12

5

117700-3

Strap

6

6

117701

Strap

8

7

117702

Tieback Plate

1

8

117731

Flange Clamp

20

9

50016-32-C5

Screw, 1-8 UNC x 4.0 long

4

10

50416-C

Nut, 1-8 unc

112

11

50916-C

Lock Washer, 1"

72

12

50016-20-C5

Screw, 1-8 unc x 2.5 long

12

13

50816-R-C-5

Flat Washer, 1"

16

14

112893-1

Threaded Rod, 1-8 x 36" long

28

15

117659-15

Plate, 1.00 Thick

1

16

117659-16

Beam, W 12 x 72 x 384.0 long

1

17

117659-17

Beam, W 8 x 18 x 144.0 long

2

18

117659-DWG Universal Tieback Kit Drawing

Preliminary

5

1

TDS-11SA

5-15


Guide Beam (Bottom Section, Sliding Configuration)

16 11 15 1

10 10 11 5

11 15 7

14

14 15

5

11 10 12 9 3 8 4 14

2

6 13 11 10

Mast Leg

Tiebacks (sliding)

5-16

Varco Systems

H


Key to Tiebacks (sliding) Item #

Part #

Description

Qty

1

117976

Tieback Link

1

2

117977-2

Beam, W 8 x 18 x 180.0 long

2

3

117700-1

Strap

4

4

117700-2

Strap

8

5

117700-3

Strap

4

6

117701

Strap

8

7

117982

Tieback Plate

1

8

117731

Flange Clamp

6,8

9

117977-9

Beam, W 12 x 72 x 384.0 long

10

50416-C

Nut, 1-8 unc

16,32,64

11

50916-C

Lock Washer, 1"

8,20,32

12

117977-12

Plate, 1.00 thick

1

13

50816-R-C-5

Flat Washer, 1"

16

14

112893-1

Threaded Rod, 1-8 x 36" long

15

119973

Strap

16

50016-64-C5D Bolt, 1.00 unc x 8.0 long

Preliminary

1

5

4,8,16 6 5

TDS-11SA

5-17

Guide Beams and Carriage 2 EE

Fr

on

t

3

1 DD 9 5 8 7

4 5

5

6

CC

Carriage/accumulator (roll)

5-18

Varco Systems


Key to Carriage/accumulator (roll) Item #

Part #

Description

Qty

1

113450

Carriage Assembly, Right (30" setback)

1

2

113448

Carriage Assembly, Left (30" setback)

1

3

110562

Hydro-Pneumatic Accumulator, 6"

1

4

113370

Accumulator Strap, 6" dia.

1

5

50908-C

Lock Washer, Regular

6

6

50108-10-CD

Socket-head Cap Screw, 1/2 UNC x 1.25

2

7

110563


1

8

88710

Align Accumulator Mount Strap

2

9

50008-10-C5D Hex-head Cap Screw

4

5

Preliminary

TDS-11SA

5-19

Guide Beams and Carriage 5 11 9

8 13

4 Fr

on

t

1 7

6

22

3 9

8 13

2 4 12

10

17 16 11 21

5 8

14

13

18 19 20 15

DD

Carriage assembly, right (roller)

5-20

Varco Systems


Key to Carriage assembly, right (roller) Item #

Part #

Description

Qty

1

113449

Carriage, Right

1

2

112875

Bogey Pivot Pin

2

3

112876

Bogey

2

4

109903

Shim, 1/8"

12

5

113285

Cam Follower, 6" dia.

2

6

80784

Roller, 4" dia., Crowned, Modified

8

7

109904

Side Roller Bracket

2

8

51132-C

Lock Washer, Hi-Collar, 2" dia.

12

9

53000-4-C

Plug, 1/4" NPT

10

10

109944

Flanged Bushing, 2.75 ID

4

11

53209

Grease Fitting, 1/8"-27 NPT

12

12

10994

Sandwich Plate

2

13

80569

Jam Nut, 2"-12 UN-2B

12

14

50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long

3

15

51016-C

3

16

50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long

6

17

51012-C

Lock Washer, 3/4"

6

18

51220-2

Retaining Cable, .063 dia.

19

51219-2

Cable Ferrule

2

20

51221-6-K

Detent Pin, 1/2" dia. x 2.75" long

1

21

109995

Chock

1

22

53000-2-C

Plug, 1/8" NPT

2

Preliminary

Lock Washer, 1.0" dia.

TDS-11SA

5

5-21

Guide Beams and Carriage 1

Fr

on

8

t 13

13 8 15 3 6

18

9 19 11

20

10 16

2 17 21 12 14

4

5

9 4

5 22

8 13 7 11

EE

Carriage assembly, left (roller)

5-22

Varco Systems


Key to Carriage assembly, left (roller) Item #

Part #

Description

Qty

1

113447

Carriage, Left

1

2

112875

Bogey Pivot Pin

2

3

112876

Bogey

2

4

109903

Shim, 1/8"

12

5

113285

Cam Follower, 6" dia.

2

6

80784

Roller, 4" dia., Crowned, Modified

8

7

109904

Side Roller Bracket

2

8

51132-C

Lock Washer, Hi-Collar, 2" dia.

12

9

53000-4-C

Plug, 1/4" NPT

10

10

109944

Flanged Bushing, 2.75 ID

4

11

53209

Grease Fitting, 1/8"-27 NPT

12

12

10994

Sandwich Plate

2

13

80569

Jam Nut, 2"-12 UN-2B

12

14

50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long

3

15

51016-C

3

16

50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long

6

17

51012-C

Lock Washer, 3/4"

6

18

51220-2

Retaining Cable, .063 dia.

19

51219-2

Cable Ferrule

2

20

51221-6-K

Detent Pin, 1/2" dia. x 2.75" long

1

21

109995

Chock

1

22

53000-2-C

Plug, 1/8" NPT

2

Preliminary

Lock Washer, 1.0" dia.

TDS-11SA

5

5-23


2 HH

Fr

on

t 10

1 GG

3

8 5

5

4

9

6 8 7

FF

Carriage/accumulator (skid)

5-24

Varco Systems


Key to Carriage/accumulator (skid) Item #

Part #

Description

Qty

1

117594

Carriage Assembly, Right

1

2

117593

Carriage Assembly, Left

1

3

117621-1

Accumulator Strap, Long

1

4

117621-2

Accumulator Strap, Short

1

5


4

6

88710

Align Accumulator Mount Strap

2

7

50008-8-C5D

Hex-head Cap Screw

4

8

50908-C


8

9

110563


1

10

110562


1

5

Preliminary

TDS-11SA

5-25


Fr 1

on

4

t 4 3

2

4 5 7

6

11

10

5 8

13

4

12

9

4

7

4

5

6

Carriage assembly, right (skid)

5-26

Varco Systems

GG


Key to Carriage assembly, right (skid) Item #

Part #

Description

1

117592

Carriage, Right (machining)

1

2

117586

Carriage Angle (machining)

1

3

117588

Skid Pad

6

4

51608-8

Roll Pin

34

5

50912-C


8

6


8

7

51608-12

Roll Pin

2

8

117870

Chock

2

9

117871

Plunger, Hand Retractable

2

10

56412-30-SHP Clevis Pin

2

11

51402-10-S

Cotter Pin

2

12

50812-N-C

Flat Washer, Narrow

4

13

50310-C

Hex-Jam Nut

2

Preliminary

Qty

TDS-11SA

5

5-27

Guide Beams and Carriage 1

Fr

on

t

4

2

5 4 6

4

7

12 11

10

13

5 9

8

7

4

3

4

5 4

Carriage assembly, left (skid)

5-28

Varco Systems

6

HH


Key to Carriage assembly, left (skid) Item #

Part #

Description

1

117591

Carriage, Left (machining)

1

2

117586

Carriage Angle (machining)

1

3

117588

Skid Pad

6

4

51608-8

Roll Pin

34

5

50912-C


8

6


8

7

51608-12

Roll Pin

2

8

117870

Chock

2

9

117871

Plunger, Hand Retractable

2

10

56412-29-SHP Clevis Pin

2

11

51402-10-S

Cotter Pin

2

12

50812-N-C

Flat Washer, Narrow

4

13

50310-C

Hex-Jam Nut

2

Preliminary

Qty

TDS-11SA

5

5-29


5

5-30

Varco Systems

Hydraulic System

Hydraulic system ................................................... 8-3 1

Illustrated index ..................................................... 8-4 Hydraulic system diagram .................................... 8-5 Inspection .............................................................. 8-6

2

Precautions........................................................ 8-6 Maintenance schedule ...................................... 8-8 Hydraulic fluid level and filter .......................... 8-9 3

Hydraulic reservoir bladder .............................. 8-12 Heat exchanger ................................................. 8-13 Using the hydraulic system test ports ............ 8-14 Precharging the accumulators ......................... 8-15

4

IBOP timing circuit ............................................ 8-16 IBOP pressure switch ....................................... 8-17 Setting up the circuits ........................................... 8-18

5

Hydraulic pumps and unloading circuit .......... 8-18 Counterbalance circuit and stand-jump circuit ............................................. 8-22 AC motor brake circuit...................................... 8-24

6

Shot pin circuit .................................................. 8-24 Link tilt cylinder circuit ..................................... 8-26 Gearbox lubrication relief circuit ..................... 8-27 7

Rotating link adapter hydraulic motor relief circuit ............................................. 8-28 Troubleshooting .................................................... 8-29

8

HPU and reservoir bladder ............................... 8-29 Counterbalance and stand jump ...................... 8-31 AC motor brake circuit...................................... 8-35 Shot pin cylinder and clamp cylinder .............. 8-37

9

Link tilt cylinders ............................................... 8-39

Preliminary

TDS-11SA

8-1

Hydraulic System

Gearbox lubrication hydraulic system ............ 8-41 Rotating link adapter......................................... 8-43 Solenoid valve replacement procedures ............. 8-46 Double A UL-type valve .................................... 8-46 Atos EEx-type valve .......................................... 8-47 Hydraulic schematic symbols .............................. 8-49

8

8-2

Varco Systems

Hydraulic System

Hydraulic system The hydraulic control system is a completely self-contained, onboard system. A 10-horse power, 1800 rpm, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalance system. Three hydro-pneumatic accumulators are located on the main body. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the AC drilling motors and is equipped with strainers and an oil level sight gauge.

8

Preliminary

TDS-11SA

8-3

Hydraulic System

Illustrated index Specifications Power

Hydraulic Oil Filter Page 8-X

Reservoir Capacity

10 hp, 1,800 rpm, AC motor 25 gal

Counterbalance Accumulator Page 8-X IBOP Delay Circuit Accumulator Page 8-X Hydraulic Oil “Fill” Page 8-X Variable Displacement Pump Accumulator Page 8-X Hydraulic Manifold Page 8-X

Front

Rear

Hydraulic Oil Reservoir Page 8-X (Between AC Drilling Motors)

Front

Rear

8 Rotating Head Motor and Shot Pin Assembly Page 8-X

8-4

Varco Systems

10 HP AC Motor and Pump Assembly Page 8-X

Hydraulic System

Hydraulic system diagram Drilling Motor Brake

Upper IBOP Actuator Cylinder

Link Tilt Cylinders

Pipehandler Clamp Cylinder

Counterbalance Accumulator Rotating Head (Elevator Positioner)

Counterbalance Cylinders

Lock-up Cylinder

Lube Oil Distribution

Rotating Head Motor

System Control Manifold

PV

PF Low Speed Hydraulic Motor

Upper IBOP Unloading Accumulator

Lube Oil Pump

Gearbox Sump

System Accumulator

M

8

10 HP A.C. Motor

Reservoir Variable Displacement Pump

Preliminary

Fixed Displacement Pump (Mtr. Lube)

TDS-11SA

8-5

Hydraulic System

Inspection Precautions To avoid serious injury or death, read and understand the following warnings before performing inspection and maintenance procedures:

n n

Do not attempt any adjustments while the machine is moving.

n

Use caution when draining lubricant. It can be hot.

n n n 8-6

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

n n

8

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components.

Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system.

Do not attempt repairs you do not understand.

Read and understand all safety precautions and warnings before performing maintenance procedures.

Varco Systems

Hydraulic System

n n e

n

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

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

Use care when handling components to prevent nicking close tolerance finishes.

Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury. Avoid injury by discharging the three accumulators and relieving pressure before disconnecting hydraulic lines. Always search for hydraulic leaks with a piece of cardboard or wood-not with your bare hands. Get immediate medical attention for hydraulic fluid injuries. Fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Do not tighten hydraulic fittings while they are under pressure. Inspect the hydraulic system daily for leaks at fittings, damaged hose covers, kinked or crushed hoses, hard or stiff hoses, and damaged or corroded fittings. In addition, during the inspection, tighten or replace any leaking port connections, and clean any dirt buildup from hydraulic components.

n

Replace worn or damaged hydraulic system components immediately.

8

Inspect the hydraulic fluid level in the hydraulic reservoir located between the AC drilling motors daily. Inspect the hydraulic filter located on the upper left AC drilling motor daily.

Preliminary

TDS-11SA

8-7

Hydraulic System

Maintenance schedule Hydraulic System Oil Lubrication Schedule DESCRIPTION

FREQUENCY

Perform Hydraulic System Oil Analysis

1 x every 6 Months 1 x Year, or Earlier Based on Oil Analysis

Replace Hydraulic Fluid Replace Hydraulic System Filter (P/N 114416-1)

1 x every 3 Months

Daily Inspections 1. Check condition of the hydraulic filter indicator 2. Check hydraulic fluid levels 3. Check for hydraulic fluid leaks

Recommended Lubricants HYDRAULIC OIL Oil Temperature Range

Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade

8

8-8

Varco Systems

-15 to 75 C

-10 to 85 C

(5 to 167 F)

(14 to 185 F)

Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32

Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46

N/R N/R 32

N/R 2 46

Hydraulic System

Hydraulic fluid level and filter

Red “Pop-up” Dirt Alarm

Daily

n Check the red “pop-up” alarm on the hydraulic filter daily. Replace it if the indicator has popped up. n Use care to prevent contamination from entering the hydraulic system during maintenance activities. n The first oil change should be performed sooner than six months since new installations often contain metal contamination caused by connecting slightly damaged threaded parts.

Hydraulic Oil Filter


Sight Glass Hydraulic Oil Sight Gauge Hydraulic Oil Fill Quick Disconnect

8 Hydraulic Oil “Fill”

Preliminary

TDS-11SA

8-9

Hydraulic System

Adding the hydraulic fluid


Sight Glass

Hydraulic Oil Fill Quick Disconnect

Hydraulic Oil Sight Gauge

Hydraulic Oil “Fill”

Hydraulic Lubrication Kit 55 gal Drum

Lubrication Kit Quick Disconnect

Specifications Reservoir Capacity

8

25 gal

n Ensure that the area is clean prior to adding hydraulic fluid n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill n Remove dust plug from the female quick disconnect on the lubrication kit n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm

8-10

Varco Systems

Hydraulic System

Draining the hydraulic fluid

Pump Inlet/Drain Adapter

10 HP AC Pump Motor

Fixed Displacement Pump Variable Displacement Pump

8

Preliminary

TDS-11SA

8-11

Hydraulic System

Hydraulic reservoir bladder n Clean area before inspecting the reservoir bladder n Remove the 10 cap screws and lock washers from the cover n Remove cover with bladder attached Hydraulic Oil Reservoir (Between AC Drilling Motors)

n Check yearly for holes, tears, wear and cracks

Reservoir Cover

Yearly Reservoir Bladder (Varco P/N 110191-501 or 110191-500) Check for holes, tears, wear and cracks

Hydraulic Oil Reservoir

Front

Rear

8

8-12

Varco Systems

Hydraulic System

Heat exchanger

Blower and Brake Covers

Yearly Oil Heat Exchanger (Varco P/N 110170) Inspect for leaks, corrosion, blockage, and cleanliness. Replace yearly or as required.

Drill Motor Assembly

8

Preliminary

TDS-11SA

8-13

Hydraulic System

Using the hydraulic system test ports

Stand Jump SV9 L4

PV

Brake SV1

Clamp/ Shot Pin SV5

P1 IBOP SV4

PF

Float Link SV8 Tilt SV6

G5

A4 CB

* SA * P

* T1

C4

8

SV2 Rotating Link Adapter Z1

B9 B1

A6 C5 B5

* These test ports are on sides or bottom of manifold.

As Viewed From Below

8-14

Varco Systems

B6

* B8

Hydraulic System

Precharging the accumulators

Counterbalance Accumulator

IBOP Delay Circuit Accumulator

Variable Displacement Pump Accumulator

Hydraulic Manifold

Front

Rear

With the hydraulic system shut down, and the counterbalance mode valve in the “shut down” position, test the hydraulic pressure at CB, SA and C4 on the hydraulic manifold, mounted to the transmission housing. Verify that all three points measure 0 psi. Note that there is a time delay in pressure decay on port C4. Test the precharge pressure on the following three nitrogen filled accumulators, using part number 114446-1. n System Accumulator (125-cubic inch displacement) 800 psi precharge n Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge n Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above.

Preliminary

TDS-11SA

8-15

8

Hydraulic System

IBOP timing circuit 5

10 20 30 40 50 60 70 80 90

0.1 0.2 0.5 0.8 1.0

1.5

2.0

2.5

0.1

FP

0.2

Full Page

0.5 0.8 1.0

ARTWORK PLACEHOLDER

1.5

8

®

DRILLING SYSTEMS REV.B 09.01.95

8-16

Varco Systems

Hydraulic System

IBOP pressure switch 5

10 20 30 40 50 60 70 80 90

0.1 0.2 0.5 0.8 1.0

1.5

2.0

2.5

0.1

FP

0.2

Full Page

0.5 0.8 1.0

ARTWORK PLACEHOLDER

1.5

8

®


Preliminary

TDS-11SA

8-17

Hydraulic System

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

Motor and Pump Assembly

Front

Allen Wrench

Valve As Viewed from Below

Variable Displacement Pump

8

8-18

Varco Systems

Fixed Displacement Pump

10 HP AC Pump Motor

Hydraulic System

1. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end, cap the tube and plug the PF port using steel fittings. 2. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise, which allows the hydraulic system to operate without building up pressure. 3. Set the relief valve RV2 to minimum pressure, fully counterclockwise.

z

Make sure the variable displacement pump case is filled with clean hydraulic oil. 4. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when looking into pump shaft/electric motor fan). Correct as required. 5. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would indicate cavitation; check for leaks. 6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the pressure increases to 400 psi at test point PF. Set the jam nut on RV2. A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.

z

While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the pressure change. 7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor. 8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate. 9. Restart the hydraulic system electric motor. 10. Set the counterbalance mode valve to the RUN position. 11. Adjust UV1, fully clockwise, to maximum pressure.

8

12. Connect a gauge to test point PV. Note the ammeter reading while RV1 is at minimum setting.

Preliminary

TDS-11SA

8-19

Hydraulic System

13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a steady rate. During the pressure rise, observe the ammeter. The motor current should rise to a maximum value at 800 psi, then drop off and begin to rise again. The point where the current drops is the pump pressure compensator setpoint. 14. Adjust relief valve RV1 to its minimum setting. If maximum motor current does not occur at 800 psi, adjust the pump pressure compensator as required. 15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0 psi to verify maximum motor current at 800 psi. 16. Connect a gauge to test point SA, and leave the gauge on PV. 17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut. 18. Install steel cap over the adjustment screw to discourage unauthorized adjustment. 19. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off, then an additional two turns counterclockwise. The pressure cycles like a sawtooth wave. 20. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2,000 psi. The pressure at SA decays until UV1 reloads. After reloading, the pressure rapidly rises to the unload pressure.

8

8-20

Varco Systems

Hydraulic System

Pressure at PV

3000

Pressure at SA

2000 Pressure (PSI)

1700

1000 800

150 10

0

20

30

40

60

50

Approximate Time (Seconds)

21. Observe several unload-reload cycles to determine the unload pressure. 22. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.

e

Perform the adjustment with reasonable speed. The process takes no longer than two minutes. Taking longer increases the temperature of the hydraulic fluid. 23. Observe the cycle of loading and unloading of the relief valve. To verify the setting of UV1, note the difference in pump noise level between the loaded and unloaded condition.

8

Preliminary

TDS-11SA

8-21

Hydraulic System

Counterbalance circuit and stand-jump circuit 1. For the counterbalance circuit there are three adjustments: ❏ Relief valve (on counterbalance cylinder) ❏ PCC – operator set ❏ SJR – operator set 2. To set the relief valve, make sure the pumps are operating. 3. Adjust pressure reducing valve PCC to the maximum setting, fully clockwise. 4. Connect a gauge to test port CB. 5. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting. 6. Increase the pressure clockwise using a 5/32 in. Allen wrench and 9/ 16 in. open-end wrench. 7. Observe the relationship of turning the relief valve adjustment clockwise to pressure increase. 8. When the relief valve reaches system pressure, turn the setting one full turn clockwise beyond the setting and set the jam nut. 9. Install a steel cover over the valve. 10. Adjust PCC to 1,200 psi. 11. Measure pressure at test port CB. 12. Prepare the hardware to attach the cylinder pear links to the hook. 13. Rotate the counterbalance mode valve from the RUN position to RIG-UP position. This causes the counterbalance cylinders to slowly extend.

e

8

8-22

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

Varco Systems

Hydraulic System

14. Once cylinders reach end of stroke, attach hardware to the pear links on the hook. 15. Rotate the counterbalance mode valve back to the RUN position. 16. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just begins to lift off of the hook. 17. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize. 18. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down counterbalance cylinders and system accumulator before shipping or performing maintenance. 19. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the hook. Note the pressure at CB. 20. Reduce PCC an additional 25 psi. The pressure at CB is about 1,600 psi. 21. Connect a gauge to test point B9. Activate the STAND JUMP mode on the drilling console. Adjust relief valve SJR until the bail lifts off the hook. The gauge at B9 should read about 190 psi. 22. Switch back to DRILL counterbalance mode and observe the pressure at test point CB. 23. Switch back to STAND JUMP mode and observe the pressure CB increase by 190 psi.

8

Preliminary

TDS-11SA

8-23

Hydraulic System

AC motor brake circuit The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,400 psi. The pressure reducing valve regulates the pressure to 1,400 psi. The solenoid valve operates to apply pressure, setting the brakes, or stop pressure to release the brakes. To test the system, turn the auto brakes switch on the driller’s console to the ON position. Attach a pressure gauge to B1 in the manifold. The pressure reading should be 1,400 psi. If the reading is not 1,400 psi, adjust the pressure control reducing valve PC 1 to 1,400. Turn the auto brakes switch to the OFF position. The pressure reading should be very low. If the pressure is high, the solenoid valve might be sticking.

Shot pin circuit 1. Set the adjustable relief valve near the body of the cylinder. The shot pin often misses the hole in the rotating gear. The force the shot pin exerts is limited until the pin engages a hole.

z

The electrical system jogs the rotating head until the pin engages a hole. 2. To limit the amount of force, you set the valve by operating solenoid valve SV5 manually, forcing the pin to stop on the face of the gear. 3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to 200 psi. 4. Tighten the jam nut on the relief valve. 5. At rest, the SV5 valve is de-energized. 6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi.

8

8-24

Varco Systems

Hydraulic System

Rotating Link Adapter Drive Motor and Shot Pin Assembly

10 HP AC Motor and Pump Assembly

(Simplified for Clarity)

Hydraulic Drive Motor


B5

Position Sensors

A (Located on far Side) B

A5

C5 (Located on far Side)

Link Adapter Rotation Gear

Shot Pin

8

Preliminary

TDS-11SA

8-25

Hydraulic System

Link tilt cylinder circuit 1. There is nothing to adjust on the manifold for the link tilt circuit. 2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all four counterbalance valves fully clockwise, then one turn counterclockwise.

z

If the valves are not adjusted correctly, link tilt operation is not synchronized. 3. The correct pressure setting is 1,500 psi. The procedure is the same for all four valves. Adjust the valves one at a time. 4. There is a test point on each loading manifold. 5. From the driller’s console, move the link tilt to go to the mousehole position. 6. The cylinder goes to full extension and the pressure at the test port TP is 2,000 psi. 7. Command the link tilt to the OFF position and observe the pressure delay at TP. This delayed pressure is the setpoint of the counterbalance valve. 8. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise. 9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

z e

This is an iterative process. Continue to set the driller’s console control to the mousehole position and OFF, taking present and decayed pressure readings.

Turning the counterbalance valve counterclockwise increases the pressure.

8 10. Repeat the procedure above for the other cylinder at the mousehole position. 11. Command the link tilt to the DRILL position and repeat the procedure above to set both counterbalance valves on the DRILL side.

8-26

Varco Systems

Hydraulic System

Gearbox lubrication relief circuit Lorem ipsum, Dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Ut wisi enim ad minim veniam, quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat, vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi. Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat, vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi. Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Ut wisi enim ad minim veniam, quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat, vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi.

8

Preliminary

TDS-11SA

8-27

Hydraulic System

Rotating link adapter hydraulic motor relief circuit 1. Set the relief valves mounted on rotation motor. 2. Operate the clamp. The shot pin must go through the hole, which locks up the gear. 3. Turn the manual override on the SV2-rotation circuit to drive the head in the counterclockwise direction. Test the pressure at A and adjust the relief valve to 1,600 psi. 4. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the clockwise direction and test the pressure at B. Adjust the relief valve to 1,600 psi.

8

8-28

Varco Systems

Hydraulic System

Troubleshooting HPU and reservoir bladder Problem

Probable cause

Remedy

Hydraulic system overheating.

Relief valves out of adjustment.

Test pressures and adjust relief valves.

Unloading valve is not working.

Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down position too long and pressure bleeds down.

Check system pressure.

No precharge in system accumulator.

Charge system accumulator.

System pressure is down.

Test pumps and motors. Test relief valve pressures. Adjust as required. Check for leaks, loose fittings, loose cylinders, worn hoses, fluid levels and seals.

Piston pump is not working.

Replace the pump.

Flexible coupling is damaged.

Replace the flexible coupling.

Lubrication pump is not working.

Replace the lubrication pump.

Pressure at UV1 is too low.

Adjust pressure at UV1.

Pumps are rotating in the wrong direction.

Inspect hydraulic connections and correct rotation.

Suction valve closed.

Open suction valve.

Low oil level in reservoir.

Fill hydraulic reservoir.

Hydraulic components do not operate.

8

Preliminary

TDS-11SA

8-29

Hydraulic System

HPU and reservoir bladder schematic diagram

Hydraulic Fill Disconnect System Pressure 6µm

50 PSID

Prefill Valve -12

Pressure Compensator Control

T

Filter with Bypass Valve

T -16

800 PSIG -6 XC B 1.00 In^ 3/Rev. L 1.10 In^ 3/Rev. Max. .50 In^ 3/Rev. Min.

M 10 HP 1800 RPM S

Variable Displacement Pump

Filter (Strainer)

L1

Fixed Displacement Pump

Reservoir Assembly Manual Shut-Off Valves

8

8-30

Varco Systems

4 PSI

Hydraulic System

Counterbalance and stand jump The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a hydraulic pressure. Refer to the vendor documentation material located in the Vendor Documentation Package, for the gas charging procedure for the accumulator. A three-position manually operated valve controls counterbalance operation for rig-up, run, and shut down modes. In the rig-up mode, system pressure is applied to XC and the prefill valve, causing both cylinders to extend. When the cylinders extend, you make up the mechanical connection to the bail. In the run mode, for counterbalance operation, approximately 1,600 psi is needed at the counterbalance cylinders to lift the TDS-11SA off the hook. The optional stand jump feature is controlled by solenoid valve SV9. With the counterbalance in the run mode and the stand jump switch on, additional pressure of approximately 300 psi is applied to over the normal counterbalance pressure to lift the TDS-11SA and drill string off the hook. In the shutdown mode, the hydraulic system bleeds down the system accumulator and the counterbalance accumulator pressure.

Counterbalance testing For the counterbalance operation, a lift of approximately 30,000 lb is achieved with a pressure of 1600 psi at CB. Perform the following steps to adjust the force: 1. Set the counterbalance mode valve to the RUN mode. Set the pressure control valve PCC to the minimum setting (fully counterclockwise). 2. Test the pressure at port B9. There should be a 0 psi reading. 3. Test the pressure at port CB. Observe the position of the top drive on the hook. 4. Adjust the pressure at pressure control valve PCC clockwise, observing pressure at CB, until the top drive just lifts off the hook. Back off the pressure 25 psi, as the top drive rests on the hook.

Preliminary

TDS-11SA

8-31

8

Hydraulic System

Stand jump testing For the optional stand jump feature, a lift of about 33,000 lb is achieved with a pressure of approximately 1800 psi at CB. The additional 300 psi pressure over the normal counterbalance pressure is provided by energizing the stand jump solenoid valve SV9. Perform the following steps to adjust the pressure: 1. Set the counterbalance mode switch to RUN and engage the stand jump switch. Test the pressure at port CB and B9. Adjust relief valve SJR fully counterclockwise to the minimum setting. 2. Slowly increase the pressure at CB by adjusting relief valve SJR clockwise until the bail lifts off the hook with a stand of pipe in the elevator.

z

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

8

8-32

Varco Systems

Hydraulic System

Problem

Probable cause

Remedy

Counterbalance does not function

Cylinder damaged. Seal leaks

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Cylinder damages. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Stand jump does not function.

8

Preliminary

TDS-11SA

8-33

Hydraulic System

Counterbalance and stand jump schematic diagram Pressure Relief Valve

2500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 T

.010ø

T

Counterbalance Accumulator

Normally-Open Logic Cartridge Metering

728 Cubic Inches 900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

8

System Accumulator

2 2

TF

T-5A 30 PSI

1

2

190 PSI

3

System Pressure CTF

SA

8-34

SJR 4

PCC T-21A

DF


1

1600 PSI

T-13A

Pressure Relief Valve

1

Varco Systems

To Tank

Hydraulic System

AC motor brake circuit Symptom

Probable cause

Remedy

Mechanical noise in blower.

Loose impeller.

Reinstall impeller and hub with threadlocking compound on screws.

Faulty motor bearings.

Repair or replace as needed.

Faulty or loose wiring.

Locate and repair as needed.

Faulty motor starter

Check for dirt or trash between starter coil. Repair or replace as needed.

Broken service loop conductor.

Use spare service loop conductor.

Blower runs intermittently.

Motor overheating, Incorrect blower rotation. overtemp alarm stays on with blower running. Broken service loop conductor.

Verify blower rotation is correct.

Use spare service loop conductor.

8

Preliminary

TDS-11SA

8-35

Hydraulic System

AC motor brake circuit schematic diagram Brake Calipers

2 Position Solenoid Valve Brakes On Cable ID Number

A

B

P

T

b

-4

C01

B1

SV1

.071ø

Manifold Assembly

D03

Non-Adjustable Orifice P1

Test Point

1400 PSI PC1

8

Reducing Valve

1

T-11A

2

System Pressure

8-36

Varco Systems

3

Tank

Drain

Hydraulic System

Shot pin cylinder and clamp cylinder Problem

Probable cause

Remedy

Shot pin does not engage.

Solenoid valve is not operating or relief valve is not adjusted.

Check electrical actuation and test pressure. Adjust as required.

Abnormal pressure change at B5 and C5 indicates valve problem.

Replace directional control valve.

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

Repair plumbing or shot pin cylinder.

Shot pin applies excessive force to rotating head gear.

Relief valve is not operating or out of adjustment.

Test pressures and adjust as required.

Clamp cylinder does not actuate.

No pressure or reduced pressure at the cylinder.

Test pressures and adjust and repair as required.

Cylinder is damaged.

Inspect cylinder and repair or replace.

z

To provide high pressure to the clamp Repair plumbing, rotating circuit, pressure at C5 must be 2,000 psi head, or clamp cylinder. and G5 must be less than 100 psi. If this condition is met, pressure at CP should increase from less than 100 psi to higher than 2,000 psi. If not, check the plumbing, rotating link adapter, and clamp cylinder. While clamping, pressure at CR should Clean or repair CNEC valve. be 2.7 times the pressure at CP. When the dies contact the pipe, pressure at CR should be less than 100 psi. If the pressure does not fade, check valve CNEC for contamination.

Shot pin engages but clamp cylinder does not activate.

Control valve not operating.

Check pressure at C5. Replace valve CV5 if required or the regenerate manifold.

8

Preliminary

TDS-11SA

8-37

Hydraulic System

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

Hydraulic Cylinder Cavity Plug

CP

CR

1

Pilot-to-Close Check Valve

3 T-2A

CKEB

2 30 PSID 2 1 CNEC

Shot-Pin Cylinder

3

2.000" Dia. Bore X 2.31" Stroke 1.500" Dia. Rod

Relief Valve

T-2A

1 T-5A

COFA .047ø

2

Shot Pin Cylinder

400 PSI

2

30 PSID

2

2x .094ø

VR

VP 1

2 Position Solenoid Valve 5 Clamp/Shot Pin

Non-Adjustable Flow Control

Cable ID Number

A

B

P

T

b

A5

.159ø

SV5 D03

E5

G5

E5

G5

-8

G5

.039ø

B5

.031ø

C5

AR5 1

LC5

1

T-11A

.031ø

50 PSI 3

Logic Cartridge

Rotating Link Adapter Assembly

-6

-6

C05

E5

-8

Clamp

-8

-8

T-10A B5 C5

2

3

Pressure Reducing Valve

2 .031ø

500 PSI

T-11A

3

2

T-21A CV5

Externally-Drained Pilot-to-Open Valve

1

4 75 PSI P5

Drain

8

1 3

T-11A

System Pressure

PC5

2

Tank

Drain System Pressure Tank T1

8-38

Varco Systems

T1

D5

Manifold Assembly

Hydraulic System

Link tilt cylinders Problem

Probable cause

Remedy

Drill pipe elevator does not reach mouse hole/derrickman position.

Link clamp incorrectly adjusted. Readjust.

Links drift when valve is released.

Pressure at B8 does not decay Replace the pilot to open to less than 100 psi. check valve. Pilot to open check valve is stuck open or contaminated.

Replace the pilot to open check valve.

Faulty cylinder seal.

Replace the seal.

Load holding relief valves are out of adjustment, stuck open, or contaminated.

Adjust or replace the load holding relief valve.

Drill pipe elevator does not float back to center position.

Use manual override. If the link Test the solenoid and tilts, the problem is electrical. If connectors. the links do not tilt, the problem is hydraulic. Test the hydraulic system.

Link tilt does not tilt.

Solenoid valve is not shifting.

Check electrical continuity.

Links do not move together.

Load holding valves are out of adjustment.

Adjust the pressure for all four valves to 1,500 psi.

8

Preliminary

TDS-11SA

8-39

Hydraulic System

Link tilt cylinders schematic diagram Link Tilt Cylinder 3.250" Dia. Bore X 10.3" Stroke 1.380" Dia. Rod

Mousehole Drill Down

C1

C1

1500 PSI

CV1 T-11A 1

X1

C2

CV2 T-11A 3

1

2

C2

T-11A CB2

1

3

2

C2

1500 PSI

T-11A CB1

1

3

C1

X2

3 2

2

V1

V2

H

J

Link Tilt "Tilt" Solenoid (Solenoid Valve 6)

Link Tilt "Drill Down" Solenoid (Solenoid Valve 6)

P

T

SV8

Logic Cartridge

D03

B8

LA6 T-11A 1 50 PSI 2

8

A

B

C07 Drill Down P

T

b

3 A6

E6 .031ø

.071ø

1

D03 .031ø

75 PSI

.031ø B6

3

3

2

4

.031ø

SV6

Logic Cartridge

a C06 M'hole

-8

B -8

A

Link Tilt

-6

b C08

CA6 T-21A .031ø

G6

T-11A 1

50 PSI 2 LB6

.071ø 4

2

3

1 CB6 75 PSI T-21A

Pressure Tank

Manifold Assembly X

D1 X

A8

Varco Systems

X -8

X -8

G6

Rotating Link Adapter Assembly

Link-Tilt Float

8-40

J

-8 X

-8

Link Tilt "Float" Solenoid (Solenoid Valve 8)

H

-8 X

E6

G6

-8

B8 -8

E6

Cable ID Number

-8

-8 G6

X

-8

-8

E6

X

-6 B8

X

-6 B8

V2

V1

FL

Hydraulic System

Gearbox lubrication hydraulic system Problem

Probable cause

Remedy

Oil leaking from lower seal.

Worn oil seals.

Replace seals.

Oil leaking from upper bearing retainer.

Worn oil seals.

Replace seals.

Gearbox oil temperature (less than 230˚F).

Oil level too low or too high.

Adjust oil level to middle of sight glass.

Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Damaged gears or bearings.

Repair or replace as needed.

Oil level is too low. Oil overheated.

Add oil.

Gear spray nozzle missing.

Replace spray nozzel.

Excessive oil viscosity.

Lower oil viscosity.

Faulty motor. Intermittent operation.

Replace motor.

Oil pump hydraulic motor failure.

Replace motor.

Broken lube pump adapter plate spline.

Replace adapter plate spline.

Faulty fixed displacement pump.

Check pressure at PF. Replace pump if pressure is low.

Low hydraulic fluid in reservoir.

Add hydraulic fluid.

Suction valve closed on fixed displacement pump.

Open suction valve.

Oil pump loss alarm is on.

8

Preliminary

TDS-11SA

8-41

Hydraulic System

Problem

Probable cause

Remedy

Water/mud in oil.

Missing inspection plugs.

Replace inspection plugs.

Upper gearbox seals worn.

Replace seals.

Water in oil.

Replace oil.

Excessively viscous oil. Cold oil.

Lower oil viscosity.

Worn gears or damaged bearings.

Replace gears or bearings.

Damaged oil pump.

Replace oil pump.

Foreign particles blocking orifice or nozzle.

Clean orifice or nozzle.

Excessive foaming.

Metal in oil.

Restricted oil flow.

Gearbox lubrication hydraulic system schematic diagram Pressure Switch

Spray Nozzles (4)

Orifices (6)

18 PSI Decreasing

S04

-16 1.0 GPM Ea.

1.5 GPM Ea.

Upper Compound Gear

Lower Compound Gear

.205ø

.062ø

Upper Mainshaft Bearing

.059ø .059ø

Lower Radial/Main Thrust Bearings

Upper Compound Bearing

.047ø .047ø

L4

Lower Compound Bearing

Lube-Oil Filter Lube Pump

60µm

5.10 In.^ 3/Rev. L1 -16

Lube-Oil Pump -10 A

8

B

System Pressure

3.0 In.^ 3/Rev. -10

Lube Pump Motor

Hydraulic Motor

8-42

Varco Systems

Hydraulic Heat Exchanger

Hydraulic System

Rotating link adapter Operation The solenoid valve SV6 operates two cylinders with load holding manifolds. When the solenoid valve SV6 is actuated to the mousehole position, full pressure is applied through E6 to the link tilt cylinder to move the links to the mousehole position. When solenoid valve SV6 is actuated to the drill down position, full pressure is applied through G6 to move the cylinder to the drill down position. The link tilt float solenoid valve SV8 releases pressure from the cylinder to allow the link tilt to move to the well center position.

System test For the link tilt circuit, there is nothing to adjust on the manifold. The four load-holding valves are adjusted in pairs, two for the rod end and two for the piston end. Adjusting the valves at the same time assures the link tilt operation is synchronized.

n

Alert all personnel near the shot pin, clamp, and link adapter 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. Use the following procedures to test the link tilt cylinder: 1. From the drillers console, set the link tilt to the mousehole position, which energizes the solenoid valve SV6 and drives the link tilt cylinder to full extension. 2. The cylinder goes to full extension and the pressure at test port TP is 2000 psi. 3. Set the system to a neutral position and observe the pressure drop. Adjust the pressure at relief valve CBCA to approach 1500 psi.

z Preliminary

This is an iterative process. Continue to set the driller’s console control to mousehole and neutral, taking present and delayed pressure readings.

TDS-11SA

8-43

8

Hydraulic System

e

Turning the relief valve counterclockwise increases the pressure. 4. Both system rod and piston relief valve pressures at TP and FL are 1,500 psi for balanced hydraulic system operation. Adjust relief control valves CBCA and CWCK for rod and piston pressure at 1,500 psi. The piston relief valves are set at the pistons fully extended and the rod relief valves are set at the pistons fully retracted.

Problem

Probable cause

Remedy

Tool does not rotate.

Direct control valve or relief valve is sticking.

Inspect, repair or replace the valve. Look

n Solenoid valve is not electrically operating.

When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death. Check electrical connections and valve functions.

Motor is worn out or gear teeth Replace the motor. are broken. Shot pin is engaged.

Adjust the relief valve.

Mechanical interference.

Inspect and repair.

Directional valve does not shift. Test pressure left and right. Replace the valve. Fixed valve orifice is plugged.

Clear orifice or replace the valve.

Hydraulic lines are damaged.

Replace hydraulic lines.

Tool does not return to home Valve is sticking or relief valve position. is out of adjustment.

8

Links are not synchronized.

8-44

Test pressures and inspect valves. Adjust the relief valve as required.

Sensor is broken.

Replace sensor.

If the motor will drive normally, but not drive to the home position, the cause could be the control system.

Checkout control system.

Counterbalance valves are out of adjustment.

Adjust valves togetherpressure is the same for all four valves.

Varco Systems

Hydraulic System

Rotating link adapter schematic diagram Rotating Head Motor

A

B

Fixed Displacement Motor 2

1

T-10A

Pressure Relief Valves

1600 PSI

1600 PSI

T-10A

2

1

A

B

Rotate Left Solenoid

Rotate Right Solenoid

Rotating Head

Cable ID Number

A

Cable ID Number

B

b

a

C03

C02 P

T

-6

Right

-6

Left

A2

SV2 .071ø

Non-Adjustable Orifice

Preliminary

B2

D03

Pressure

Tank

Manifold Assembly

3 Position Solenoid Valve

TDS-11SA

8-45

8

Hydraulic System

Solenoid valve replacement procedures Double A UL-type valve 5

10

20

30

40

50

60

70

80

90

0.1 0.2 0.5 0.8

1.0

1.5

2.0

2.5

0.1

FP

0.2

Full Page

0.5 0.8 1.0

ARTWORK PLACEHOLDER

1.5

®

DRILLING SYSTEMS

8

REV.B 09.01.95

8-46

Varco Systems

Hydraulic System

Atos EEx-type valve 5

10

20

30

40

50

60

70

80

90

0.1 0.2 0.5 0.8

1.0

1.5

2.0

2.5

0.1

FP

0.2

Full Page

0.5 0.8 1.0

ARTWORK PLACEHOLDER

1.5

®

8


Preliminary

TDS-11SA

8-47

Hydraulic System

Solenoid valve schematic diagram IBOP Actuator Cylinder 2.500" Dia. Bore X 4.00" Stroke 1.750" Dia. Rod Open

Test Point Typical

Close

Hydraulic Cylinder CR LODC

30 PSI CXCD

2

Time-Delay Accumulator

1

T-13A

1

Logic Cartridge


2

3 50 PSI CP

VR

T-11A

Gas Charged Accumulator

A4

B4

A4

B4 -6

-6

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055ø D03

500 PSI

CV4

Flow Control Valve

D4 1

8

T-11A 3

T-11A

2

1

.010ø 2

3

PC4

System Pressure

8-48

Varco Systems

Tank

Hydraulic System

Hydraulic schematic symbols The following hydraulic troubleshooting section provides a schematic diagram and description for each TDS-11SA hydraulic circuit. Following each schematic is a group of troubleshooting charts to help you quickly locate and correct hydraulic system problems. When performing hydraulic troubleshooting, be aware that: ❏ The electrical control system can be bypassed for troubleshooting by manually overriding the solenoid valve for each operational system.

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. ❏ Test points shown in the hydraulic schematic with a box (e.g., A4) can be found on the manifold under the main body. There are also test points on the rotating link adapter motor. ❏ The system is preadjusted. Hydraulic problems are usually related to faulty valves, contamination, or other damage to the system rather than misadjustments. Changes to adjustments should be made only after all other possible causes have been eliminated.

8

Preliminary

TDS-11SA

8-49

Hydraulic System

Description

Symbol

Schematic Reference

2 Position 4 Way Valves (Single Solenoid) Solenoid Operated Valves

SV1, SV4, SV5, SV8, SV9 33-1

3 Position 4 Way Valves (Double Solenoid)

SV2, SV6 33-2

Manual Valve (Rotary)

3 Position 4 Way Valve

MV 33-3

Fixed Displacement 33-4

Pumps Variable Displacement

33-5

RV2, A2R, B2R, SJR

Standard Valve 33-6

Pressure Relief Valves

Ventable Relief Valve

RV1 33-7

UV1

Differential Unloading Valve 33-8

Pressure Reducing Valve

PC1, PC4 33-9

8

PCC

Pressure Reducing/Relieving Valve 33-10

Chack Valve 33-11

8-50

Varco Systems

CDF, CTF, CV2, CTR, CDR, CXCD Prefill valve assembly CV1, CV2

Hydraulic System

Description

Symbol

Schematic Reference CKCB (Link Tilt)

Pilot-To-Open Check Valves

33-12

CA6, CB6, CV3, CV4 (Clamp Body)

Pilot-To-Close 33-13

1 3

PC5

Cavity Plug 2 33-14

Internal Plug 33-15

CV1

Non Adjustable Flow Control Valves 33-16

Non Adjustable Orifice

Diameter in inches 33-17

CBCA (Link Tilt Circuit)

3 Port (Internal Drain) Counterbalance Valves

33-18

CWCK (Link Tilt Circuit)

4 Port (External Drain) 33-19

Standard Cartridge Logic Cartridge

LA6, LB6, LC5, LODC 33-20

With Metering

See Prefill Assembly

8 33-21

Quick Disconnect Coupling 33-22

Preliminary

TDS-11SA

8-51

Hydraulic System

Description

Symbol

Schematic Reference See Lube Oil Circuit

Non Bypass Filter 33-23

Filter with Bypass

See Return Circuit 33-24

Manual Shutoff Valve 33-25

Lube Oil Circuit

Thermostat 33-26

Pressure Switch

Lube Oil Circuit 33-27

Hydraulic Circuit (Inside Brake Housing)

Heat Exchanger 33-28

Pressure Compensator Control

Part of the Pump 33-29

Hydro-Pneumatic Accumulator 33-30

Hydraulic Motor (Bi-Directional) 33-31

Hydraulic Cylinder 33-32

8

Tank (Reservoir) 33-33

Test Point 33-34

8-52

Varco Systems

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