D811000252-MAN-001

Bill of Material Item 1 2 3 4 5

Quantity 1 1 1 1 1

Part Number

Description

SM00620 SM01053

Service Manual, TDS-4S Service Manual, Washpipe Assembly Technical Drawing Package, TDS-4S Mechanical Spares Control Spares

D811000252-DOS-001 30184939 30184734

NEXT ASSY

PRODUCT

M614000012-GEN-001

TDS-4S

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

CURRENT DRAWN CHECKED

Owner’s Manual

Petrobras, P14 TDS-4S

INITIAL J. Kellstrom

SCALE:

WT LBS:

R. Shumski

DATE

10/23/2007

SHT:

AV

K. Schmidt

APPVD

SIZE:

1 OF 1 REV:

D811000252-MAN-001

01 D811000457-GEN-001/01

TDS-4S

Top Drive System Service Manual

SM00620 Revision B

March 8, 2001

ii

TDS-4S Contents

Contents Book 1 – Description Preface/Manual conventions Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6

Chapter 1 Introduction General description .......................................................... 1-7

Chapter 2 Major component description Motor housing assembly ................................................ 1-19 Drilling motor ......................................................... 1-20 Two speed transmission ........................................... 1-20 Integrated swivel bail and swivel washpipe ............... 1-22 Standard rotating head ............................................. 1-24 Powered rotating head ............................................. 1-26 Rotating head controls ....................................... 1-26 Cooling systems ............................................................. 1-28 Local blower ............................................................ 1-28 Closed loop .............................................................. 1-30 Remote blower ......................................................... 1-32 Guide dolly assemblies ................................................... 1-34 Motor alignment system ................................................ 1-37 Pipehandler .................................................................... 1-38 Link adapter ............................................................ 1-39 Safety valves (IBOP) ................................................ 1-40 Saver and crossover subs..................................... 1-40 Safety valve actuator ................................................. 1-40 Torque wrench ........................................................ 1-42

TDS-4S Contents

iii

March 8, 2001

Link tilt mechanisms ................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51 TDS Control System (TDCS) ....................................... 1-53 Varco Driller’s control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62

Chapter 3 Specifications Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower ...................................................... 1-66 Derrick mounted remote blower ........................ 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70

iv

TDS-4S Contents

Book 2 – Installation and Commissioning Preface/Manual conventions Safety information ........................................................... 2-5 Directional references ...................................................... 2-6 Manual layout.................................................................. 2-6

Chapter 1 Preparation Preinstallation checklist.................................................... 2-7

Chapter 2 Installation Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Driller’s controls and instrumentation ........................... 2-23 Varco Driller’s Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27

Chapter 3 Commissioning Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33

TDS-4S Contents

v

March 8, 2001

Book 3 – Operation Preface/Manual conventions Safety information ........................................................... 3-5 Directional references ...................................................... 3-6 Manual layout .................................................................. 3-6

Chapter 1 Operating procedures Start-up procedure ........................................................... 3-7 Stalling the DC motor ..................................................... 3-8 Changing transmission speeds .......................................... 3-9 Pipehandler operation .................................................... 3-11 Standard rotating head ............................................. 3-11 Powered rotating head ............................................. 3-12 Controls............................................................. 3-12 ROTATING HEAD LEFT/RIGHT switch ..... 3-12 AUTO STOP/FREE ROTATE switch ............ 3-12 Safety valves (IBOP) ................................................ 3-14 Torque wrench ........................................................ 3-16 Changing drill string sizes ........................................ 3-19 PH-85 ............................................................... 3-19 PH-60d ............................................................. 3-19 Torque values for load carrying components ............ 3-20 Drilling ahead ................................................................ 3-21 Drilling ahead with triples ....................................... 3-21 Drilling ahead with singles ....................................... 3-24 Drilling ahead on a semi .......................................... 3-26 Tripping ........................................................................ 3-28 Reaming out .................................................................. 3-29 Well control procedures ................................................. 3-31 Running casing .............................................................. 3-32 Handling bottom hole assemblies .................................. 3-32 Post jarring operations ................................................... 3-34

vi

TDS-4S Contents

Book 4 – Maintenance and Troubleshooting Preface/Manual conventions Safety information ........................................................... 4-7 Directional references ...................................................... 4-8 Manual layout.................................................................. 4-8

Chapter 1 Maintenance Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21

Chapter 2 Lubrication Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34 TDS-4S Contents

vii

March 8, 2001

Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45

Chapter 3 Maintenance Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97 viii

TDS-4S Contents

Chapter 4 Troubleshooting Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111

Book 4 – TDS-4S Control System General description .......................................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................................................ 5-7

TDS-4S Contents

ix

March 8, 2001

x

TDS-4S Contents

TDS-4S Top Drive Drilling System

Description SM00620-1 Rev. B

March 8, 2001

1-2

TDS-4S Description

Contents Preface/Manual conventions Safety information ........................................................... 1-5 Directional references ...................................................... 1-6 Manual layout.................................................................. 1-6

Chapter 1 Introduction General description .......................................................... 1-7

Chapter 2 Major component description Motor housing assembly ................................................ 1-19 Drilling motor ......................................................... 1-20 Two speed transmission ........................................... 1-20 Integrated swivel bail and swivel washpipe ............... 1-22 Standard rotating head ............................................. 1-24 Powered rotating head ............................................. 1-26 Rotating head controls ....................................... 1-26 Cooling systems ............................................................. 1-28 Local blower ............................................................ 1-28 Closed loop .............................................................. 1-30 Remote blower ......................................................... 1-32 Guide dolly assemblies ................................................... 1-34 Motor alignment system ................................................ 1-37 Pipehandler .................................................................... 1-38 Link adapter ............................................................ 1-39 Safety valves (IBOP) ................................................ 1-40 Saver and crossover subs..................................... 1-40 Safety valve actuator ................................................. 1-40 Torque wrench ........................................................ 1-42 Link tilt mechanisms................................................ 1-45 Standard and extended reach pneumatic link tilt mechanisms ........................................... 1-45 Hydraulic link tilt mechanism ........................... 1-48 Link tilt controls .......................................... 1-48 Elevator links ................................................................. 1-50 Counterbalance system .................................................. 1-51

TDS-4S Description

1-3

March 8, 2001

TDS Control System (TDCS) ....................................... 1-53 Varco Driller’s control and instrumentation Console (VDC) ....................................................... 1-53 Transfer control panel .............................................. 1-54 Purge control system ................................................ 1-54 Service loops .................................................................. 1-55 Derrick electrical termination kit ................................... 1-56 Auxiliary equipment ...................................................... 1-57 Master bushing ID wear guide ................................. 1-58 Swiveling drill collar dolly ........................................ 1-59 Wireline adapter ...................................................... 1-60 Crown height indicator ............................................ 1-62

Chapter 3 Specifications Drilling motor ......................................................... 1-65 Main gearbox lube system ........................................ 1-65 Cooling systems ....................................................... 1-66 Local blower ...................................................... 1-66 Derrick mounted remote blower ........................ 1-66 Closed loop ........................................................ 1-66 Guide dollies ............................................................ 1-67 Pipehandler .............................................................. 1-67 Service loop kits ....................................................... 1-68 Power loop (non-regulated areas) ....................... 1-68 Control loop ...................................................... 1-68 Fluid loop .......................................................... 1-69 Electrical equipment accessories ............................... 1-70 API Class I, Division II -N.E.C. ........................ 1-70 European standard zone 2 area-EExd ................. 1-70

1-4

TDS-4S Description

Preface Manual conventions

Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information, a warning, or a caution note. See the examples below and pay close attention to these important advisories.

z e

n

Indicates advisories for operational or servicing procedures involving little or no risk of personnel injury or equipment damage. Indicates advisories involving a risk of equipment damage.

Indicates advisories involving a definite risk of injury to rig personnel. Avoid personnel injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.

TDS-4S Description

1-5

March 8, 2001

Directional references References to the right or left and front or back of components described in this manual assume the perspective of the Top Drive Drilling System (TDS-4S), standing behind the TDS-4S as it faces well center.

Manual layout This binder contains several separate books that you can remove individually for convenience.

1-6

TDS-4S Description

Chapter 1 Introduction

General description Oil well drilling with a rotary table, kelly drive bushing, and a 45 ft. kelly was the industry standard for years. For decades, drillers extended the drill string with the “making-a-single-connection” process using the rotary table, kelly, pipe tongs, drawworks cathead, master bushing, bowls, and slips. This method of handling pipe and joint makeup remained unchanged, apart from minor improvements such as kelly spinners, until the advent of top drive drilling systems. Varco produces several Top Drive Drilling Systems (TDS) to rotate the drill string and allow adding entire 93 ft. stands of pipe, eliminating two thirds of the conventional single-pipe drilling connections. This manual describes the function and maintenance of the TDS-4S, which integrates the drill pipe connection handling and drive systems with the drilling swivel. The TDS (Figures 1-1 and 1-2) provides the rotating power of a conventional rotary table drive while eliminating the need to “pick up” the cumbersome swivel/kelly combination. The TDS does not interfere with the existing conventional equipment. It allows tripping, circulation, rotation, and the running of casing as well as providing 90 ft. back reaming capabilities to reduce the chance of stuck pipe. TDS-4S Description

1-7

March 8, 2001

Guide Dolly Assembly

Motor Housing Assembly

LO

Pipehandler Assembly

Figure 1-1. Typical TDS-4S overall view

1-8

TDS-4S Description

The TDS integrated swivel bail connects directly to a drilling hook. Connecting the TDS integrated swivel bail directly to the traveling block or motion compensator frame can eliminate the drilling hook and shorten the TDS working height further.

Integrated Swivel Bail Counterbalance Cylinder (2)

Gooseneck Air Brake

;;; ;;; ;;;;;;;; ;;; ;; ;;; ;; ; ;; ;;;;;;;; ;;; ;; ;;;;;;;; ;;; ;;;; ;;; ;; ;;;;;;;; ; ; ;;; ;; ;;;;;;;; ; ; ;; ; ;; ;;;;;;;; ; ; ; ; ;; ;;;;;;;;;;; ; ; ; ;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;; ;;;;;;;; ; ; ; ; ; ;;;; ;;; ;;;;;;;;;;; ;;;; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;; ; ; ; ; ; ; ; ; ; ; ; ; ;;;; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ; ;;;; ; ;; ; ;; ;; ;; ;; ;; ;;;;;;;; ; ; ; ; ; ; ;;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;;;;; ;;; ; ;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;; ; ; ; ; ;;; ; ; ; ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ; ;

;; ;;

Motor Support Bonnet

; ; ; ;;; ; ;;; ; ;;; ;

; ; ;; ;;; ; ;; ;;; ; ;;; ;;; ;; ;;;;;;;;;;;; ;;; ;;;;;;;;;;;; ; ;; ;;;;;;;;;;;; ; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;;

Swivel Bearing

;;; ; ; ;; ; ;; ; ;; ;;

;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ;;;;;;;; ; ; ; ; ; ; ; ; ; ;;;;;;;;; ;;;;;;;;;; ;; ; ; ; ; ; ; ; ; ; ;;;;;;;; ;;;;;;;; ; ; ; ; ; ; ; ; ; ;;;;;;;; ;; ; ; ; ; ; ; ; ; ; ;;;;;; ;;; ;; ; ; ; ; ; ; ; ; ; ;;;;;;;; ;;; ; ; ; ; ; ; ; ; ; ; ;;;;;;;; ;;;;;;;;;;;;;;; ; ; ; ;;; ;;;;;;;; ;;;;;;;; ;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;; ;; ;; ;; ;;

;;;;;;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;; ;;; ;;; ;;;;;;;;

Bull Gear

;; ;;; ;; ;;; ;; ;;; ;; ;;; ;; ;;; ;; ;;; ;; ;;;

; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;; ;

; ; ; ; ; ; ; ; ; ; ; ;; ;

;;;;; ; ; ;;; ; ; ; ; ; ; ;; ;; ;;; ;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ;;;; ;; ; ; ; ; ; ; ; ; ;; ;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ; ; ; ; ; ;;;;;;;;;;;;;; ;;; ;;;;; ;;;;;;;;;;;;;; ; ; ; ; ; ; ; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ; ; ; ; ; ; ; ;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;; ; ; ; ; ;; ;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;; ;;; ;;;;; ;;;;;;; ;;;;;;;;;;;;;; ; ; ; ; ; ;;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;;;;;;;; ; ; ;;;;; ;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;;; ;;;;; ;;;;;;;; ;;;;;;;; ;; ; ;;; ;; ;; ;; ;; ;; ; ; ;; ;; ;; ;; ; ; ;; ;; ; ;; ;; ; ;; ;; ; ;; ;; ; ;

DC Drilling Motor

;;;;;;;;;;;;; ; ;; ;; ;; ;; ;; ;; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;;;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ;; ;; ;; ;; ;; ;; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ;; ;; ;; ;; ;; ;; ; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ; ; ; ; ; ; ; ; ; ; ; ; ;

Motor Pinion Gear

;;;;;; ;;;;;; ;;;;;; ;;;;;; ;;;;;;; ;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;;

;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;

Standard Washpipe Packing

Upper Gearcase

;; ;;;; ;;

Low Gear (Engaged)

; ;;;;; ;; ;; ; ; ; ; ; ;; ;; ;; ; ; ; ; ; ; ; ; ; ;;;;;;; ;; ; ; ;; ;; ;;; ; ; ; ;; ;; ;; ;; ;; ; ; ; ;;;;;;;;

High Gear (Disengaged) Rotating Head Main Shaft/Drive Stem

Lower Gearcase

Figure 1-2. TDS-4S motor and swivel housing assembly

TDS-4S Description

1-9

March 8, 2001

The integrated drive stem functions as the main output shaft driving the drill string. The electric drilling motor and transmission, located next to the stem, rotates the stem. The DC motor bolts to an upper assembly of the gearcase, called the motor support bonnet. The motor frame/guide dolly attaches to the motor housing assembly. The entire assembly moves vertically on two rails installed in the derrick. The vertical rails react the motor torque during drilling operations and keeps the TDS positioned over wellcenter. The pipehandler assembly (Figures 1-3 and 1-4) can make or break drill pipe at any height in the derrick.

1-10

TDS-4S Description

Rotating Head (Part of the Motor Housing Assembly)

Torque Arrestor (4)

Link Adapter (Also know as: Solid Body Elevator) (Landing Collar Inside on Main Shaft/Drive Stem)

Hydraulic/Pneumatic Link Tilt

Upper IBOP Valve Actuator

Splined Upper IBOP Valve Lower IBOP Valve (Inside Torque Tube)

Torque Wrench

350-Ton 108 in. Link (2) (Optional Varco Equipment)

Manually or Remotely Operated Drill Pipe Elevator (Optional Varco Equipment)

Figure 1-3. Typical 650-Ton, PH-85 pipehandler assembly

TDS-4S Description

1-11

March 8, 2001

Torque Arrestor (4)

650-Ton Rotating Head (Part of Motor Housing Assembly)

Link Adapter (Also known as Solid Body Elevator) (Landing Collar Inside On Main Shaft/Drive Stem)

Pneumatic Link Tilt

Safety Valve Actuator

Lower IBOP Valve (Inside Torque Tube) Splined Upper IBOP Valve

Torque Wrench

108 in. 350-Ton Links (Optional Varco Equipment)


Figure 1-4. 650-Ton, PH-60d pipehandler assembly

1-12

TDS-4S Description

Internal Blow Out Preventor (IBOP) valves connect to the end of the drive stem (Figure 1-5). The driller can close the upper IBOP at any position in the derrick from the driller’s control console. A second, lower IBOP can be manually closed and sent downhole while controlling a kick.

Main Shaft/ Drive Stem Link Adapter (Also known as Solid Body Elevator) Landing Collar

Upper IBOP Valve Actuator Air Cylinder (2)

Actuator Arm (2)

Crank Assembly (2)

Safety Valve Actuator Shell

Upper IBOP

Torque Tube

Lower IBOP

Saver Sub

Drill Pipe

Figure 1-5. Safety valves (IBOPs) and actuator assembly TDS-4S Description

1-13

March 8, 2001

The drive stem passes through the link adapter. The torque arrestors keep the link adapter above the landing collar on the drive stem when drilling (Figures 1-6, 1-7 and 1-8). When hoisting, the link adapter is pulled down onto the landing collar due to the added weight of the drill string. This directs the hoisting load through the drive stem, motor housing assembly, and swivel bail. The fluid service loop provides the hydraulic, pneumatic power, and optional cooling water services to the TDS. The electric service loops provide DC power and AC power/control. A drill pipe elevator hangs from a pair of conventional links that attach to the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up pipe. The Major component description chapter of this book describes each of these assemblies. Subsequent books provide more information on the equipment specific to your rig configuration.

1-14

TDS-4S Description

Rotating Head (Part of Motor Housing Assembly)

Link Adapter (Also known as Solid Body Elevator)

Torque Arrestors (4)

Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors

TDS-4S Description

1-15

March 8, 2001

650/500-Ton Rotating Head (Part of Motor Housing Assembly)

Hydraulic/Pneumatic Link Tilt

650/500-Ton Link Adapter (Also known as Solid Body Elevator)

Torque Arrestor 650-Ton: (4) 500-Ton: (2)

Link Adapter Support Plate

Upper IBOP Valve


Safety Valve Actuator Torque Wrench

Lower IBOP Valve


Saver Sub

Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies

1-16

TDS-4S Description

650-Ton Rotating Head (Part of Motor Housing Assembly)

Pneumatic Link Tilt

650-Ton Link Adapter (Also known as Solid Body Elevator)

Torque Arrestor (4)

Link Adapter Support Plate

Upper IBOP Valve


Safety Valve Actuator Torque Wrench

Lower IBOP Valve


Saver Sub

Figure 1-8. 650-Ton, PH-60d pipehandler in relation to other TDS assemblies

TDS-4S Description

1-17

March 8, 2001

1-18

TDS-4S Description

Chapter 2 Major component description

Motor housing assembly The motor housing assembly is composed of the following: ❏ Drilling motor and brake ❏ Two speed transmission ❏ Rotating head ❏ Integrated swivel and washpipe

TDS-4S Description

1-19

March 8, 2001

Drilling motor The drilling motor on the TDS is a 1,100 hp DC drilling motor. Mechanically, the motor features a double-ended armature shaft and thrust bearings for vertical operation. There is an air brake on the motor to hold torque in the drill string to assist in directional work. It is remotely operated by a solenoid valve. Please refer to the specifications included later in this book for additional details.

Two speed transmission The two speed transmission consists of the following major components: ❏ Bull gears – 96 tooth, 2.0 diametral pitch ❏ High range compound gears – 27 tooth and 30 tooth ❏ Low range compound gears – 23 tooth and 40 tooth ❏ Motor pinion gears – 21 tooth ❏ Geneva transmission shifter mechanism (Figure 1-9) ❏ Main body and lower gearcase ❏ Main shaft/drive stem ❏ Bonnet ❏ Swivel bearing The compound gears mount to their eccentric shafts with a tworow, full complement roller bearing on one end and a spherical roller bearing on the other end.

1-20

TDS-4S Description

Rotating Head Assembly

Shifter Input Shaft

LO

HI External HI / LO Indicator

Compound Gear Shafts

Bottom View

Low Gear Eccentric Shaft (Disengaged)

High Gear Eccentric Shaft (Engaged)

Geneva Mechanism

Shifter Input

Top View

Figure 1-9. Transmission/geneva mechanism

TDS-4S Description

1-21

March 8, 2001

Lubrication to the bearings and gear meshes is force fed by an electrically driven gear pump externally mounted on the gearcase (Figure 1-10). The lower gearcase is a heavy duty steel casting, fully ribbed for added heat dissipation. The transmission shifts gears by rotating two vertical compound gear eccentric shafts. The two compound shafts (high and low) are supported on heavy trunnions between the main body and lower gearcase halves. As the shafts rotate (less than one-half turn), the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. Each compound shaft carries a large, internally splined geneva slave. A common geneva master sequentially unlocks, rotates, and locks both gears. The master rotates using a reduction gear set with a vertical manual input shaft. It carries its own latching mechanism and provides the security of a double lock on the compound shafts. A 1 in. male hex at the bottom of the transmission case (Figure 1-9), rotates the input shaft. After pushing inward on the male hex, it takes five turns of the input shaft to unlock both gear sets, rotate the engaged gear set to full disengagement, rotate the disengaged gear set into full engagement, and lock both gear sets in their proper positions with positive stops in the locked position. An external indicator shows the gear range selection.

Integrated swivel bail and swivel washpipe The integrated swivel bail is a bearing assembly that allows transfer of the rotating load to the lifting components (Figure 1-2). The swivel washpipe is a rotating seal that allows mud to flow to the rotating drill string.

1-22

TDS-4S Description

Lower Radial Shaft Bearing

Motor Pinion Gears

Side View Bull Gears

Inlet

Compound Shafts (Not Visible)

Bull Gears

Motor Pinion Gears

LEGEND Pressure Tap

Fabricated Drilled

Bottom View

Figure 1-10. Transmission lubrication system TDS-4S Description

1-23

March 8, 2001

Standard rotating head The standard rotating head allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head (Figure 1-11). It features two hydraulic passages, three pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2,500 psi). The rotating head assembly consists of: ❏ Stationary flange ❏ Eight rotary glyd rings ❏ Swivel block ❏ Cam ❏ Auto-return cylinder ❏ Cam follower ❏ Swivel block locking mechanism The hydraulic and air lines for the various pipehandler functions (air link tilt, torque wrench, etc.) run from their respective solenoid valves to the stationary flange. The fluids travel from the flange to the swivel block via sealed rotating passages. The glyd rings maintain the seal between the passages. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates relative to the flange without twisting or damaging any hoses. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. There is also an auto-return cylinder mounted on the stationary flange. The auto-return cylinder is hydraulically connected to the counterbalance manifold. The rod end of the cylinder connects to a cam follower assembly that tracks the cam mounted to the swivel block.

1-24

TDS-4S Description

Cam

Stationary Flange

Cam Follower

Locking Lever

Auto-Return Cylinder

Torque Arrestor Location Glyd Ring (8)

Swivel Block Torque Wrench Hanger (Lug not shown)

Figure 1-11. Standard 650-Ton rotating head assembly

TDS-4S Description

1-25

March 8, 2001

Powered rotating head The 10-port powered rotating head (Figure 1-12) allows transferring pneumatic and hydraulic pressure from stationary ports on the drilling motor housing to rotating ports on the rotating head. It features three hydraulic passages, five pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid (all are rated at 2,000 psi). The rotating head assembly consists of the following components: ❏ Stationary flange ❏ Eleven rotary glyd rings ❏ Swivel block ❏ Bull gear ❏ Hydraulic motor assembly ❏ Proximity sensor and adjustable targets The hydraulic and air lines for the various pipehandler functions (hydraulic link tilt, torque wrench, etc.) run from their respective solenoid valves to the stationary flange. The fluids travel from the flange to the swivel block via sealed rotating passages. The glyd rings maintain the seal between the passages. Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates relative to the flange without twisting or damaging any hoses. There is also a lug for mounting the torque wrench hanger and holes for attaching the torque arrestors on the swivel block. The rotating head stationary flange bolts directly to the bottom of the gearcase with the drive stem running through the center. The hydraulic motor assembly mounts to the swivel flange which engages a compound gear, driven by a pinion gear on the hydraulic motor shaft. Two switches on the driller’s control panel control the hydraulic motor.

Rotating head controls The powered rotating head has two switches. The ROTATING HEAD LEFT/RIGHT switch rotates the rotating head, pipe handler, and link tilt to the right or left (same direction as the drill string). The AUTO STOP/FREE ROTATE switch controls the powered rotating head operating mode. 1-26

TDS-4S Description

Stationary Flange

Rotary Glyd Ring (11)

Bull Gear

Torque Arrestor Hanger Swivel Block

A5

H1

S2

A2

H3

PRESSU

A3

RE

A1

S1

H1

Hydraulic Motor Assembly

S2

H2

A4

A1

A4 A5

A2

H3

A3 H2

S1

Figure 1-12. Powered rotating head assembly

TDS-4S Description

1-27

March 8, 2001

Cooling systems Local blower The local blower cooling system with an optional extended intake provides local cooling air to the drilling motor (Figure 1-13). It receives air approximately 27 ft. above the rig floor at the lowest point of the motor’s travel. An explosion-proof 20 hp, 3,450 rpm AC electrical motor directly drives the impeller in the blower housing. An optional flexible duct connects the blower housing to the extended intake mounted on the traveling equipment. Two spark arrestor assemblies are mounted on the exhaust ports of the upper gearcase. These components hinder the egress of any air born sparks from the DC motor.

1-28

TDS-4S Description

Axial Fan 20 hp Blower Motor

Transmission Cooler

Locking Key Oil Fittings (2)

Blower Housing Gasket

Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket Flex Duct Connection Point Mounting Plate

Blower Duct to AC Drilling Motor

Spark Arrestor

Figure 1-13. Typical local blower cooling system

TDS-4S Description

1-29

March 8, 2001

Closed loop The closed loop cooling system (Figure 1-14) consists of two air/ water heat exchangers cooled by twin blowers driven by a double ended AC motor. Ducting directs air out the motor exhaust port to the heat exchangers and back to the blower inlets. The heat exchangers are built from Cupro-Nickel tubes and the headers are pressure tested to 250 psi. The system requires a supply of liquid coolant (sea water, chilled fresh water or glycol) at 100 gpm at a maximum inlet temperature of 90°F. Purge air at a rate of 70 scfm per motor at 1.0 psig is also required to provide positive system pressure, and a purge control system (refer to TDS Control System information provided later in this chapter) monitors system pressure to insure safe operation.

1-30

TDS-4S Description

Dual Shaft 20 hp AC Blower Motor

Blower Mount/ Brake Cover Blower Housing (2)

Impeller (2)

8 in. Flex Connection (2)

Blower Inlet (2)

Water Connections

DC to Motor Exhaust Port on Upper Gear Case Inspection Cover

GE Drilling Motor Heat Exchanger (2)

Figure 1-14. Typical closed loop cooling system

TDS-4S Description

1-31

March 8, 2001

Remote blower The remote blower motor cooling system consists of a motor and pressure blower mounted in the derrick at racking board level (Figure 1-15). Air is drawn in from outside the wind wall, through a flexible duct into the top of the drilling motor, and exits through spark arrestors attached to the air outlets of the motor. A pressure switch monitors the motor air inlet pressure to verify blower operation. The contacts of the pressure switch are usually wired into the SCR assignment logic for the drilling motor. A moisture separator is attached to the blower inlet duct to prevent water from entering the motor.

1-32

TDS-4S Description

Air Inlet

40 hp Explosion Proof Electric Motor (AC) and Centrifugal Pressure Blower

Wind Wall

Racking Platform at Racking Board Level

Rigid Cooling Duct

Spark Arrestor

Motor Dolly Assembly

86' Flex Air Duct

Figure 1-15. Typical remote blower cooling system

TDS-4S Description

1-33

March 8, 2001

Guide dolly assemblies The guide dolly assembly transmits the drilling torque reaction to the guide rails keep the TDS positioned over wellcenter and can provide a method for setting the entire unit aside for maintenance or to allow rig operation without the TDS if necessary. The standard guide dolly assembly consists of two frames connected by hinges on the pivot side and hold-down bolts on the other (Figure 1-16). Non-swing retract guide dollies use hold-down bolts (swing bolts) on both sides (Figure 1-17). One frame attaches to the motor housing assembly and includes attachment points for the service loops and rotary hose. The other frame includes the guide rollers and remains in the guide rails during all normal operations. Centralized lubrication manifolds provide roller lubrication.

1-34

TDS-4S Description

Motor Frame

Guide Dolly Frame

Hinge Pin (2)

Hold-down Bolt (Swing Bolt) (2)

Figure 1-16. Typical swing guide dolly assembly

TDS-4S Description

1-35

March 8, 2001

Upper Stabilizer Arm Motor Frame

Guide Dolly Frame

Retract Cylinder

Lower Extend/Retract Arm

LEGEND Intermediate Frame

45.0"

Figure 1-17. Typical retract guide dolly assembly

1-36

TDS-4S Description

Extended Mode Retracted Mode

Motor alignment system The motor alignment system consists of a duplex cylinder, hydraulic accumulator, pressure reducing valve manifold, and related hardware. The duplex cylinder attaches between the bottom of the lower gearcase and the motor frame. It connects to an accumulator circuit located on the guide dolly. The accumulator is charged with nitrogen and maintained at a predetermined pressure setting by the alignment cylinder manifold. Figure 1-18 shows the motor alignment cylinder installed in a typical motor frame. The duplex cylinder maintains a wellcenter orientation for the swivel stem when disconnected from the drill sting, while allowing the motor housing assembly to float slightly about its trunnions.

Motor Alignment Cylinder

Shipping Brace

Motor Frame Dolly (Ref)

Figure 1-18. Motor alignment cylinder

TDS-4S Description

1-37

March 8, 2001

Pipehandler The main components of the pipehandler include the following (Figures 1-3 and 1-4): ❏ Link adapter ❏ Safety valves (Upper and Lower IBOPs) ❏ IBOP valve actuator ❏ Torque wrench ❏ Link tilt mechanism The pipehandler provides two basic functions for the TDS: ❏ Tripping 93 ft. drilling pipe stands ❏ Providing up to 85,000 ft lb torque for makeup and break-out of connections at any height in the derrick (the PH-60d provides up to 60,000 ft lb torque) The pipehandler can be configured for various tool joint connections. It includes a link adapter and a special-purpose Varco torque wrench assembly. It also incorporates a remote IBOP valve actuator and link tilt mechanism. When not in use, the pipehandler remains stationary and free from the drill string passing through it. When tripping or performing bottom hole operations, the pipehandler is free to rotate 360°, emulating the action of a standard hook.

1-38

TDS-4S Description

Link adapter The link adapter (solid body elevator) and the elevator links (Figures 1-7 and 1-8), working in conjunction with the torque arrestors, transfer the hoisting loads to the drive stem. The drive stem is free to rotate inside the link adapter while drilling. The link adapter does not rotate with the drive stem because torque arrestors raise the link adapter up off the load supporting landing collar located on the drive stem. When hoisting loads, springs inside the torque arrestors compess to transfer the load to the drive stem by pulling the link adapter down onto the landing collar. The link adapter rotates with the rotating head–which is required for tripping operations. The torque arrestors contain compression springs capable of supporting any stand of drill pipe in the full up position.

TDS-4S Description

1-39

March 8, 2001

Safety valves (IBOP) The Varco pipehandler includes two Internal Blowout Preventor safety valves (IBOPs) to provide blowout prevention. For detailed descriptions, installation, operation, maintenance, and parts information, refer to the IBOP Service Manual.

Saver and crossover subs Each pipehandler ships with two saver subs and one crossover sub. Saver subs (Figures 1-7 and 1-8) are dual pin subs used to preserve the threads on the lower IBOP and provide a pin for the box end of the drill string. Saver sub threads can be recut to a minimum shoulder-to-shoulder length of 5 in. before the sub must be discarded. The crossover sub converts the lower IBOP pin to a box connection for well control procedures with standard pipe.

e

Saver subs are load bearing components in the TDS and must be inspected periodically along with other load bearing components. Refer to the Maintenance and Troubleshooting book for more information.

Safety valve actuator The remotely operated upper IBOP valve actuator allows upper IBOP actuation at any height in the derrick. The upper IBOP actuator system consists of the following: ❏ Two pneumatic air cylinders ❏ Two actuator arms ❏ Actuator shell ❏ Two crank assemblies ❏ Two pneumatic solenoid valves Double-acting air cylinders move the actuator arm. The actuator arm connects to the valve actuator shell and moves the actuator shell up or down (Figure 1-19). A slot in the actuator shell engages the crank assemblies, which opens or closes the IBOP. The air cylinders are operated remotely by a solenoid valve controlled by an electrical switch at the VDC. 1-40

TDS-4S Description



Actuator Arm (2)

Crank Assembly (2)


Upper IBOP

Torque Tube

Lower IBOP

Saver Sub

Drill Pipe

Figure 1-19. Safety valve actuator system

TDS-4S Description

1-41

March 8, 2001

Torque wrench The torque wrench provides a means for making and breaking out connections with the drive stem. The torque wrench assembly consists of the following components (Figures 1-20 and 1-21): ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

Hanger Torque tube Torque tube guide ring Two torque cylinders Two clamping jaws Two clamping pistons Control manifold Lift cylinder Two stop tubes Stabbing guide IBOP actuator cylinders and arms

A hanger attached to the rotating head supports the torque wrench. The torque wrench has two torque cylinders connected to the torque tube. The clamping jaw contains a 10 in. diameter clamping piston for gripping the box end of the drill pipe. On the lower section of the upper IBOP, a female spline engages the mating male spline on the lower IBOP contained inside the torque tube. When actuated, the torque wrench rises and engages the splines on the upper IBOP. It then receives sequenced pressure to clamp the clamping piston on the box connection. After the clamping pressure develops, another sequence valve automatically opens and directs pressure to the torque cylinders. The torque cylinders can rotate up to 25° while developing a maximum torque of 85,000 ft lb (60,000 ft lb for PH-60d). One electrical push button on the VDC controls the entire torque wrench operation. The driller simply holds the button down until the connection is made or broken. The driller then releases the button to allow the unit to automatically recycle to the ready position. A two-position, air piloted hydraulic valve located on the counterbalance manifold controls the cycle. The torque wrench can also make up or break out the saver sub or the lower IBOP. A manually operated valve on the rear of the pipehandler selects either the make up or break out function. 1-42

TDS-4S Description

IBOP Actuator Hoses (Air)

Hanger Torque Wrench Hoses (Hydraulic)

IBOP Actuator Air Cylinders Lift Cylinder IBOP Actuator Arms

Torque Tube

Clamping Jaw (Inside Clamp Body)

V a r c o

Stop Tube (2)

Control Manifold (Hidden) Torque Cylinder (2)

Stabbing Guide

Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)

Figure 1-20. PH-85 torque wrench assembly

TDS-4S Description

1-43

March 8, 2001

IBOP Actuator Hoses (Air)

Hanger

Torque Wrench Hoses (Hydraulic)

Lift Cylinder

IBOP Actuator Air Cylinders IBOP Actuator Arms

Torque Tube Stop Tube (2) Clamping Jaws (Inside Clamp Body)

Control Manifold (Hidden) Torque Cylinder (2)

Stabbing Guide

Clamping Piston (Inside Clamp Body Cylinder) Guide Ring (Not Visible)

Figure 1-21. PH-60d torque wrench assembly

1-44

TDS-4S Description

Link tilt mechanisms Standard and extended reach pneumatic link tilt mechanisms The standard (Figure 1-22) and extended reach (Figure 1-23) link tilt assembly allows: ❏ The elevators to move off of well center to pick up a stand in the mousehole. ❏ The derrickman to handle pipe more easily. The link tilt assembly mounts on the front of the solid body elevator (link adapter). This assembly consists of a pivoting lifting frame connected to the drilling elevator links with chains and clamps. A switch on the VDC controls a pneumatic solenoid valve that inflates an air spring within the lifting frame. Inflating the air spring pivots the frame upward, tilting the links outward. Extended reach link tilt mechanisms have two air springs and extend 76 in. A standard reach link tilt will extend links 52 in. Both reaches are based on 108 in. elevator links. An adjustable intermediate stop mechanism provides clearance between the drill pipe elevator and the monkey board to assist the derrickman in racking operations.

TDS-4S Description

1-45

March 8, 2001

Lifting Frame

Intermediate Stop

Air Actuator D/P Elevator Link Clamp

Intermediate Stop Release

Figure 1-22. Standard pneumatic link tilt mechanism

1-46

TDS-4S Description

Lifting Frame

Double Air Actuator

D/P Elevator Link Clamp

Intermediate Stop Intermediate Stop Release

Figure 1-23. Extended reach pneumatic link tilt mechanism

TDS-4S Description

1-47

March 8, 2001

Hydraulic link tilt mechanism The hydraulic link tilt assembly (Figure 1-24) provides lateral movement of the drill pipe elevator to a position above the mousehole or toward the monkeyboard. The link tilt assembly mounts on the front of the link adapter (solid body elevator). The link tilt uses dual hydraulic cylinders. Full link tilt extension moves drill pipe approximately 78 in. from well center, based on 108 in. links. During operation, the operator can stop link tilt movement at any position and hold the supported load in place. The link tilt also enables retracting the open drill pipe elevator from the drill pipe while drilling, tripping, and adding stands (available only on PH-85 models). Link tilt controls

The link tilt is controlled by a four-position switch. The positions are RETRACT, FLOAT, HOLD, and EXTEND. RETRACT

In the RETRACT position, the elevator backs away from well center. FLOAT

FLOAT returns the elevators to well center from the retracted or extended position. A 1/2-second delay is programmed into the FLOAT function to allow the control switch to travel from the RETRACT position to the HOLD position without activating the FLOAT. HOLD

This setting holds the position of the elevators extended or retracted. EXTEND

This setting extends the elevator forward to the mousehole through wellcenter.

1-48

TDS-4S Description

Hydraulic Link Tilt with Passive Stop Passive Stop Assembly (2) Cylinder Assembly (2) Link Tilt Arm

Hydraulic Link Tilt with Intermediate Stop

Intermediate Stop

Stop Adjuster

Figure 1-24. Hydraulic link tilt

TDS-4S Description

1-49

March 8, 2001

Elevator links Varco elevator links attach to the link adapter and support the drill pipe elevator. Elevator link options include: ❏ 108 in., 350-Ton elevator links ❏ 132 in., 350-Ton elevator links ❏ 180 in., 500-Ton elevator links (special long links for running casing, providing 120 in. of clearance for cementing heads)

1-50

TDS-4S Description

Counterbalance system The counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS. It provides cushioned stroke similar to that provided by the hook. The counterbalance system prevents damage to the threads of the saver sub and drill pipe by offsetting the weight of the top drive while stabbing into a connection. The system (Figure 1-27) consists primarily of two hydraulic cylinders, a counterbalance manifold, and two hydraulic accumulators. The hydraulic cylinder assemblies connect the integrated swivel bail and the traveling equipment (hook, block, becket, hook adapter, etc.). When properly adjusted, the counterbalance system supports all but about 800 lb of the weight of the top drive over a full 8 to 10 in. of travel. The system also incorporates a complete backup. The two accumulators, constantly maintained at system pressure, are always able to provide pressure to the counterbalance cylinders if the HPU is “off ” or non-operational for any reason. For normal operation, however, the HPU is “on” when using the torque wrench for breaking out the top drive at the floor and is left on while making up the next stand. When adding a stand to the string during drilling operations, the driller takes a stand in the elevators and stabs it into the box in the rotary table. The driller continues to lower the TDS until the saver sub touches the box of the new stand. At this point, only about 800 lb load is on the saver sub/drill pipe connection. The counterbalance cylinders support the remainder of the TDS weight. The driller then spins in and torques up the connection with the pipehandler assembly and is ready to drill ahead. Note that the driller does not have to do anything extra to get the counterbalance system to function properly. It is a pre-adjusted system. Once drilling resumes, the HPU can be turned off and restarted again for breaking out the connection at the floor after drilling the stand down.

TDS-4S Description

1-51

March 8, 2001

Stabbing Mode: Top Drive Lowered Past Thread Contact Guide Dolly Assembly 18,970 lb

18,970 lb

Hydraulic Cylinders (2)

Hydraulic Accumulators (2)

38,750 lb Typical System Weight

Counterbalance Manifold 810 lb Weight on Threads

Hydraulic Power Supply

Fluids Service Loop

Rig Floor

Figure 1-27. Counterbalance system

1-52

TDS-4S Description

TDS Control System (TDCS) The TDS Control System (TDCS) provides the driller with a control console that operates all of the TDS functions. The components of the TDCS include: ❏ Varco Driller’s control and instrumentation Console (VDC) ❏ Transfer control panel (TP) ❏ Purge control system for closed loop cooling systems

Varco Driller’s control and instrumentation Console (VDC) The Varco driller’s control and instrumentation Console (VDC) consists of a torque meter, an RPM meter and various switches and indicator lights. The basic TDS control functions are: ❏ Link tilt ❏ Remotely controlled upper IBOP valve ❏ Motor brake ❏ Motor spin-torque control ❏ Makeup torque limit ❏ Transfer switch (TDS/ROT) The existing rotary table controls adjust motor speed, torque and direction while drilling. A typical VDC also contains indicator lights for determining the status of: ❏ The brake ❏ The remotely controlled upper IBOP valve ❏ The oil pump ❏ Blower pressure loss ❏ Cooling air temperature ❏ The purge system(s) Optional controls and status indicator lights are available. Refer to Engineering Drawing 98952 for VDC configurations.

TDS-4S Description

1-53

March 8, 2001

Transfer control panel The TDS operates from the same SCR as the rotary table. The Transfer control panel switches power between them. This electrical enclosure contains the DC contacts, the programmable controller, the auxiliary AC components and the rig instrumentation interfaces for recording torque and speed of the TDS. The DC power cables running from the SCR to the rotary table motor are disconnected from the rotary table and connect to the transfer panel. New cables run from the TP to the rotary table motor and to the racking board junction boxes for the TDS. The transfer panel has a purge control system for use in a hazardous area (Zone 2 or Class 1, Div. 2). If the panel is in the SCR room, a purge system is not required. The panel is compatible with all currently installed SCR systems and is configured at installation for the SCR it will control. Logic and alarm functions are connected to the TDS by programming the transfer panel’s Programmable Logic Controller (PLC) to operate the rig’s existing systems. Similarly, TDS interlocks and limits, such as spin-up and makeup speeds, are programmed into the PLC and are the same for all installations.

Purge control system The transfer panel, VDC, and TDS closed loop cooling system have separate purge systems. All systems provide positive internal pressure to prevent hazardous gases from entering areas of potential ignition in Zone 2 or Class 1, Div. 2 hazardous areas. Pressure switches in the protection units monitor the pressure and provide an alarm signal in the event of purge pressure loss. Prior to starting an unpurged system, the purge control unit purges the system for a specific time interval sufficient to remove any trapped hazardous gas. Status lights on the VDC indicate to the driller correct purge pressure, loss of purge and system purging. If purge pressure loss alarms and indicators are ignored for a preset time interval, the isolation unit can be set to shut down the TDS.

1-54

TDS-4S Description

Service loops The service loops transfer the required electric and fluid services between the derrick service standpipes and junction boxes, and the corresponding junction boxes and fluid connections located on the TDS. There are two kinds of loops: one containing the electric cables, and one containing air, hydraulic and water lines (water lines included only on units with a closed loop cooling system). The power electrical loop contains four 646 MCM DC power cables, one 2/0 AWG drilling motor ground cable. The other electrical service loop contains a composite cable consisting of: ❏ 26 14 AWG conductors for auxiliary features ❏ 4

8 AWG conductors for blower motor

❏ 2

5 AWG conductors for series motor field supply

❏ 2

14 AWG shielded pairs for the RPM pickup signal

The power and ground cables are spiral wound and potted inside a protective cover with 7 1/2 in. mounting flanges at each end. The composit cable is pathed in its own smaller service loop. This allows for easy changeout of either the power loop or the composit loop in the event of a failure. The TDS can use optional dual electrical service loops in order to meet certain regulatory agency requirements for power cable current carrying capacity. The fluids loop can consists of any combination of the following: ❏ 3

3/4 in. diameter hoses for hydraulic supplies (one is a spare)

❏ 2

1/2 in. diameter hoses for air supply (one is a spare)

❏ 1

1 in. diameter hoses for purge supply

❏ 2

1 1/4 in. diameter hoses for cooling water (closed loop cooling systems only)

❏ 2

1 in. diameter hoses for retract cylinder supply and return

❏

Additional 7-conductor, 20 AWG cables as required

TDS-4S Description

1-55

March 8, 2001

Derrick electrical termination kit This kit consists of all the necessary electrical junction boxes attached to a bulkhead mounting plate, which is then mounted in the derrick to connect the rig electric supplies to the service loop. There are several J-box configurations, depending upon which electrical system is ordered. Each configuration complies with specific electrical codes and regulatory agency requirements throughout the world.

1-56

TDS-4S Description

Auxiliary equipment Auxiliary equipment is compatible with all TDS models. All of the equipment is selected or adapted for your specific rig. Below is a list of auxiliary equipment available: ❏ Master bushing ID wear guide ❏ Swiveling drill collar dolly ❏ Wireline adapter ❏ Crown height indicator ❏ Driller’s recorder tranducer kit

TDS-4S Description

1-57

March 8, 2001

Master bushing ID wear guide The master bushing ID wear guide centers the rotating drill string and protects the master bushing while drilling ahead (Figure 1-26). It hinges open for removal or when setting manual slips. The bushings can be changed out to accomodate different size drill pipe.

Figure 1-26. Master bushing ID wear guide

1-58

TDS-4S Description

Swiveling drill collar dolly The swiveling drill collar dolly (Figure 1-27) allows the drill collar elevators to turn freely when handling bottom hole assemblies. The drill collar dolly’s upset, which latches in the standard drill pipe elevator, mounts on a bearing which allows it to swivel even under load. A shoulder elevator is suspended from the “perfection” links (or a second drill pipe elevator if lifting subs are used). The collars can be walked in or out with the elevator turning on the drill collar dolly. A Drill Pipe Elevator

A 100 TON VARCO

Drill Collar Dolly

Perfection Links (36")

;;; ;;; ;; ;;; ;; ;;;

91 in. Square Shoulder Elevator

Lifting Sub 37 in.

8 in.

Drill Collar View

A-A

Figure 1-27. Swiveling drill collar dolly

TDS-4S Description

1-59

March 8, 2001

Wireline adapter The wireline adapter (Figures 1-28 and 1-29) attaches to the pipehandler and prevents wireline from interfering and damaging pipe and TDS components. It can be used with a lubricator held in the elevators by using 180 in. casing elevator links.

42.52 in.

26.0 in.

23.1 in.

Typical Section through Sheave

Figure 1-28. Typical PH-85 wireline adapter

1-60

TDS-4S Description

View A-A

9/16 in. Max. Wire Rope Dia.

Top Drive Torque Wrench

Torque Wrench Guard (remove for installation)

20 in. Dia. Sheave

Elevator Links (180 in. longCustomer furnished)

Lubricator

To Mud Manifold

Wireline Adapter installs in place of Torque Wrench Guard using existing Pins

Elevator Links (180 in. or longerCustomer furnished)

View A-A

Figure 1-29. Typical PH-60d wireline adapter

TDS-4S Description

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March 8, 2001

Crown height indicator The crown height position indicator is a self-contained electronic instrument which determines the position of the traveling equipment with respect to the derrick crown. The system contains four major subassemblies: ❏ A metal target typically located on the Varco block dolly assembly ❏ Two hinged sensor bracket assemblies located on the rear of the guide track ❏ A sensor junction box located in the derrick near the above bracket assemblies ❏ A crown height indicator control box, or an integral control in the driller’s control and instrumentation console The Crown Height Indicator Control (CHIC) control box (Figure 1-30) contains three indicator lights and an electronic printed circuit board. Two of the indicators display the position of the top of the traveling equipment relative to the crown. The third indicator displays system power status. The yellow indicator on the CHIC control box illuminates when the top of the traveling equipment is within ten feet of the crown. The red indicator illuminates when the traveling equipment is within five feet of the crown. When the traveling equipment is within two feet of the crown both indicators flash alternately. The green indicator illuminates when correct DC system power is available. This indicator also contains a push-to-test button which simulates the 2 ft. position. The integral crown height indicator controls on the VDC are identical to the separate control box.

1-62

TDS-4S Description

CROWN CLEARANCE 2 FEET WHEN FLASHING

IBOP CLOSE

BRAKE ON

IBOP CLOSE OPEN

BRAKE OFF ON

TORQ. WRENCH PUSH & PULL

LINK TILT OFF ON

R 5 FEET

Y 10 FEET ACTIVE/TEST

G

Integrated Controls

IBOP CLOSE

BRAKE ON

CROWN CLEARANCE 2 FEET WHEN FLASHING

Purge Air in

R 5 FEET

IBOP CLOSE OPEN

BRAKE OFF ON

Y 10 FEET

TORQ. WRENCH PUSH & PULL

G

LINK TILT OFF ON

Purge Air out to Protection Unit

ACTIVE/TEST

VDC

Independent Controls

Figure 1-30. Typical CHIC control box

TDS-4S Description

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March 8, 2001

1-64

TDS-4S Description

Chapter 3 Specifications

Drilling motor Horsepower: 1,100 Maximum stall time at full power is generally about 10 seconds. Refer to the Operation book for details.

Main gearbox lube system Provides lubrication to both the primary gear set and swivel bearing. It includes explosion proof 5 hp AC motor/pump combination, filter/strainer, pressure loss sensor, and oil level sight glass. The TDS-4S main gearbox lube system holds approximately 20 gallons (refer to the Maintenance and Troubleshooting book for details on oil capacity and adding oil to the gearbox).

TDS-4S Description

1-65

March 8, 2001

Cooling systems Local blower * Flow

3,200 cfm

Blower motor

20 hp

Typical voltage

220/460 VAC, 3-phase, 60 Hz

Speed

3,450 rpm

Spark arrestors

Standard style, BASEEFA approved type available

Derrick mounted remote blower * Flow

3,200 cfm

Blower motor

40 hp

Typical voltage

220/460 VAC, 3-phase, 60 Hz

Speed

3,450 rpm

Spark arrestors

Standard style, BASEEFA approved type available

* These systems include an additional oil cooler/heat exchanger mounted on top of the gearcase on the TDS.

Closed loop

1-66

TDS-4S Description

Flow

3,200 cfm

Blower motor

20 hp

Typical voltage

220/460 VAC, 3-phase, 60 Hz

Speed

3,450 rpm

Heat exchanger

220,000 BTU/Hr. for GE motor

Cooling water supply

50 gpm at 250 foot head, measured at rig floor

Oil cooler

6 gpm

Max. inlet temp

90°F

Guide dollies Standard rail setback 30, 39 or 48 in. (Wellcenter to centerline of rails) Standard rail spacing (Centerline of rails)

62, 66 or 72 in.

Recommended rail sizes

W12x53 (land masts), or W14x74, W14x90

Roller size

6 in. flange and 6 in. side

Frame material

ASTM A-500/A-36 steel or equivalent

Pipehandler Break-out torque

PH-85 and PH-85H = 85,000 ft lb PH-60d = 60,000 ft lb

Hydraulic pressure

2,000 psi maximum

Hydraulic flow

30 to 35 gpm

Air pressure

90 psi minimum

TDS-4S Description

1-67

March 8, 2001

Service loop kits Power loop (non-regulated areas) 646 mcm

4 (each)

Standard length

86 ft. (flange to flange)

Diameter

5 in. ID SAE 100-R2 hose outer jacket

Power cable voltage

2,000 maximum (each)

Ground cable

2/0 conductor tinned copper ground

Control composite loop 26 conductor, 14 guage 4 conductor, 8 guage 2 pair, 14 guage twisted and shielded 2 conductor, 5 guage 1 pair, 6 gauge twisted and shielded

1-68

TDS-4S Description

Fluid loop

z

Not all hoses are required for all configurations. Overall length of assembly

86 ft. (flange to flange)

Hydraulic pressure or return hose (3 total)

Size

3/4 in. ID, SAE 100-R9

Maximum working pressure

3,000 psi

Air supply hose (2 each)

Size

1/2 in. ID, SAE 100-R2

Working pressure

150 psi


3,500 psi

Purge air supply hose (2 each)

Size

1 in. ID, SAE 100-R2

Working pressure

150 psi


2,000 psi

Water hose (2)

Size

1 1/4 in. ID, SAE 100-R2

Working pressure

150 psi


1,625 psi

Retract hoses (2)

Size

1 in. ID, SAE 100-R2


3,000 psi

TDS-4S Description

1-69

March 8, 2001

Electrical equipment accessories API Class I, Division II -N.E.C. Derrick J-boxes (2 each)

Cast aluminum, explosion proof

Motor J-boxes (2 each)

Cast aluminum, explosion proof

Solenoid valves (6 each)

1/2 in., 4-way, 2 position

Pressure switches (2 each)

6 in. of H2O sensor

Motor space heaters (2 each) 2 - 200 watt, 110 volt VDC/instrument kit

Various switches

Torque meter

(0 - 1,500 Amps)

RPM meter

(0 - 350 rpm)

European standard zone 2 area-EExd Derrick J-boxes (2 each)

Stainless steel

Motor J-boxes (2 each)

Stainless steel

Solenoid valves (6 each)

1/2 in., 4-way, 2 position

Pressure switches (2 each)

6 in. of H2O sensor

Motor space heaters (2 each) 2 - 200 watt, 220 volt

1-70

TDS-4S Description

TDS-4S TOP DRIVE DRILLING SYSTEM Drill Pipe Torque Vs. Speed GE 752 High Torque Series Motor 60,000 58,200 INTERMITTENT 55,000 1,130 HP LIMIT 50,900 CONTINUOUS

50,000

LOW GEAR 45,000

160 RPM

TORQUE, CONTINUOUS (ft lb)

40,000 37,200 INTERMITTENT

1,130 HP LIMIT

35,000 32,500 CONTINUOUS 30,000

25,000

HIGH GEAR 20,000

15,000 12,000 ft lb 10,000 5,000 ft lb 5,000 120

190

0 0

50

100

150

200

250

300

RPM CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS WITH A 7 SEC. MAX. DURATION JUNE 3, 1991 A.N.

TDS-4S Description

1-71

March 8, 2001

TDS-4S TOP DRIVE DRILLING SYSTEM Drill Pipe Torque Vs. Speed GE 752 High Torque Shunt Motor

TORQUE, CONTINUOUS (ft lb)

55,000

50,000

50,100 INTERMITTENT

45,000

45,500 CONTINUOUS

LOW GEAR

40,000

35,000 32,000 INTERMITTENT

30,000 29,100 CONTINUOUS

HIGH GEAR

25,000

20,000 Reduced Field Required in this Area

15,000

10,000 5,000 130 RPM

205 RPM

0 0

50

100

150

200

250

300

RPM Continuous Torque Values are based on 1250 Armature Amps. Intermittent Torque Values are based on stall at 1400 Amps with a 7 second maximum duration. Reduced Field area is based on a 30 Amps Field.

1-72

TDS-4S Description


Installation and Commissioning SM00620-2

October 20, 1998

2-2

TDS-4S Installation and Commissioning


Chapter 1 Preparation Preinstallation checklist.................................................... 2-7

Chapter 2 Installation Derrick electrical termination kit ..................................... 2-9 Installation ................................................................. 2-9 Wiring ..................................................................... 2-13 Plumbing ....................................................................... 2-15 Hydraulic................................................................. 2-15 Air ........................................................................... 2-15 Water....................................................................... 2-15 Rig-up procedure ........................................................... 2-16 Counterbalance system .................................................. 2-21 Motor alignment cylinder system ................................... 2-22 Driller’s controls and instrumentation ........................... 2-23 Varco Driller’s Console (VDC)................................ 2-23 Throttle and torque limit controls ........................... 2-23 Wiring ..................................................................... 2-23 Service loops .................................................................. 2-24 Installation ............................................................... 2-24 Electrical loop .................................................... 2-25 Fluids loop ......................................................... 2-25 Air loop ....................................................... 2-26 Retract loop ....................................................... 2-27

Chapter 3 Commissioning Checkout procedures ..................................................... 2-29 Long term TDS storage procedures................................ 2-32 Returning the TDS to service after storage ..................... 2-33


2-3

October 20, 1998

2-4




z e

n




2-5

October 20, 1998



2-6


Chapter 1 Preparation

Preinstallation checklist The following assumes that all preinstallation planning and rig-up has been accomplished prior to installation of the TDS. This includes: 1. Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances (Figures 2-1, 2-2, and 2-3). 2. Stops are ready for installation at the bottom of the rails. 3. Hydraulic and air standpipes are installed in the derrick, flushed clean, and pressure tested. Water piping is installed, flushed, and pressure tested as well for configurations with closed loop cooling systems. 4. All electronics are installed up to the derrick junction box: DC power leads, AC leads for blower motor, and control/ alarm signals. 5. The transfer panel is installed. 6. Rigging of the tong lines, etc. are inspected to ensure that they will not foul with the TDS and other rig equipment.


2-7

October 20, 1998

2-8


Chapter 2 Installation

Derrick electrical termination kit Installation Refer to Figures 2-1, 2-2, and 2-3 for typical mounting dimensions of the plate assembly. Mount it at racking board height within 15 ft. of the service loop support bracket. Remember to provide convenient access for wiring and maintenance. Usually, mounting the plate so that the J-box is four to five feet above the walk-around and near the service loop support bracket is adequate. If a walk-around does not exist, then construct a work platform to allow access to the J-boxes. Manufacture appropriate brackets and clamps to attach the plate to the derrick structure.


2-9

October 20, 1998

± 1/4 in.

CL Rail

Over Full Length

CL Rail ± 3/8 in. Over Full Length ± 1/8 in. Within 25 ft. of Floor

CL Rail

CL Rail C L Well Center

± 3/8 in. Over Full Length ± 1/8 in. Within 25 ft. of Floor

C L Well Center

TDS Back Operational Clearance Between Top Drive And Nearest Girt or Fastline Should Be 3 in. Minimum

Guide Rails

Nearest Girt

Splice Clearance

Splice Plates or Bolts Are Not Permissible on Inside Surfaces of Beam

Dolly Overhang

Maximum Rail Support Spacing 16 ft. for W12x53 Rails 25 ft. for W14x74 Rails

6" Rail Stop

10 ft. 6 in. +0/-4 in.

Guide Dolly Config.

Rail Size

39 x 66 48 x 62 30 x 72 30 x 72

W14 x 90 W14 x 90 W12 x 90 W14 x 90

Drill Floor CL Well Center

Figure 2-1. General rail installation data

2-10


Splice Dolly Clear Overhang Inches

3.3 3.3 3.3 2.3

0 0 1.6 0.5

Instrument J-Box **

Clearance Hole For .75 in. Dia. Bolt (4 Places) 36.0 in.

Electrical Supply*

Motor J-Box **

Filter/Regulator Lubrication Assembly**

48.0 in.

800 lb Load

B 18.0 in.

Must Support 4,000 lb

Control Service Loop**

B

Electrical Service Loop**

Hydraulic Air Standpipes Standpipes To Be 1 1/2 in. To Be 1 1/2 in. Sch 40 Pipe* Sch 80 Pipe* Water Standpipes A To Be 2 in. Sch 40 Pipe* 86 ft. Service Loops

Fluids Service Loop**

36.0 in.

View A-A Typical Service Loop Termination

A

Gussets *

75 ft. Mud Hose Ref

73 ft. Mud Hose Connection

Service Loop Bracket** Existing Girt * 5500 lb Load

View B-B 83 ft. Hydraulic, Air and Water Standpipe Height and Service Loop Bracket Location 10 ft. 6 in. +0/-4 in.

7 ft. Ref

* Customer Supplied ** Varco Supplied

Typical Equipment Stack-Up

Figure 2-2. Derrick services/general installation data


2-11

October 20, 1998

Motor Frame Setback Rails

L P

L

9 ft. 3 in. TDS-3S 10 ft. 3 in. TDS-4S, TDS-8S

7 ft. TDS-3S 8 ft. TDS-4S, TDS-6S, TDS-8S

P L Rail Stops

L 42,600 lb for a typical TDS-3S 48,000 lb for a typical TDS-4S 52,000 lb for a typical TDS-7S 48,000 lb for a typical TDS-8S

Rail Loading with TDS in Setback position Load P - lb Rail Spacing

TDS-3S

TDS-4S, TDS-8S

39 in. x 66 in.

18,600

18,900

48 in. x 62 in.

18,600

18,900

30 in. x 72 in.

17,500

17,800

Rail Loading while Drilling - 38,000 ft lb for TDS-3S, 60,000 ft lb for TDS-4S, 68,000 ft lb for TDS-6S, 34,000 ft lb for TDS-7S and 62,250 ft lb for TDS-8S. Load L - lb TDS-6S

TDS-7S

5450

--

3090

3680

5800

--

3290

3170

5000

--

2840

--

3330

3780

--

Rail Spacing

TDS-3S

39 in. x 66 in.

3450

48 in. x 62 in. 30 in. x 72 in. 91/101 in. x 108 in.

TDS-4S, TDS-8S

Figure 2-3. General installation data

2-12


Wiring The electrical installation requires routing power to the transfer panel and then to the TDS through the service loops (Figure 2-4). In addition, control cables are required between the service loop, the transfer panel, the SCR, the TDS Varco Driller’s Console (VDC), the SCR’s driller’s console, the hydraulic and water pumps and the drilling recorder.

Derrick Power J-Box

Transfer Panel

#12AWG/20C #10AWG/4C #14AWG/2 Pr Shld #6AWG/2C* Shunt Field

Derrick AC J-Box

(4)646MCM* Top Drive System

AC Power

HYD Pump #2 #16AWG/10C #16AWG/10C

Existing Driller’s Console

#16AWG/10C

#10AWG/4C #10AWG/4C #6AWG/4C #6AWG/4C

TDS Driller’s Console HYD Pump #1

Rotary Table

RBS Controls #12AWG/3C

E/P RPM

#6AWG/2C* Existing Power Cables

#16AWG/10C

E/P Torq

#14AWG/2 Pr Shld #12AWG/3C #14AWG/37C #12AWG/20C #12AWG/20C #16AWG/10C #12AWG/20C

#10AWG/4C

#14AWG/2 Pr Shld #12AWG/3C

SCR Room

Service Loop

#6AWG/2C* Shunt Field #16AWG/10C

Water Pump #1

Water Pump #2

Figure 2-4. Typical cabling diagram TDS-4S Installation and Commissioning

2-13

October 20, 1998

The cable requirements, depending on options selected are: Cable

Runs

646MCM (4 Shunt)

SCR room to transfer panel

(8 Series)

Transfer panel to derrick J-box Transfer panel to rotary

#6AWG/2C (Shunt only)

SCR Room to transfer panel Transfer panel to derrick J-box Transfer panel to rotary

#6AWG/4C

AC Power to hydraulic pumps

#10AWG/4C

AC Power to water pumps AC Power to transfer panel Transfer panel to derrick J-box

#12AWG/20C

Transfer panel to existing driller’s console Transfer panel to derrick J-box Transfer panel to hydraulic pumps Transfer panel to water pumps

#12AWG/3C

Transfer panel to RBS unit Transfer panel to VDC RBS unit to VDC

#14AWG/37C

Transfer panel to VDC

#14AWG/2PR SHLD

Transfer panel to derrick J-box Transfer panel to VDC Transfer panel to drilling recorder

#16AWG/10C

Transfer panel to SCR console Transfer panel to SCR room Hydraulic pumps to transfer panel Water pumps to transfer panel

Purge control system (not shown) #12AWG/3C

Purge control unit to transfer panel Isolation unit to floor air control unit Transfer panel protection unit to isolation unit

#16AWG/10C

Purge control unit to transfer panel VDC protection unit to isolation unit

#14AWG/2PR SHLD

Transfer panel to derrick J-box

Terminate the J-boxes per the electrical schematic. Follow applicable electrical codes during installation. Cable glands are provided for the service loop cables. Cable glands for the incoming power, control and signal cables are not provided. 2-14


Plumbing The plumbing connections should terminate near the service loop bracket. The mating halves are preassembled on the service loop. Specifications for specific lines are described in the following sections.

Hydraulic Hydraulic lines should be cleaned and pickled, black pipe lines (one pressure and one return) 1 1/2 or 2 in. schedule 80 pipe. Install shut-off valves at the drill floor or racking board level. The derrick connections are reduced to 1 in. NPT female pressure and fluid return for connection to the service loop.

Air Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of the purge supply for the TDS. Install a shut-off valve at drill floor or racking board level. The air lines connect to the filtered and lubricated supply. The derrick connections are reduced to 1 in. NPT female for the purge line (if required) and 1/2 in. for the air line in order for the fluids service loop to match.

z

Do not connect purge air lines to the lubricator. Only use clean, dry air in the purge air system.

Water The two cooling lines should be schedule 40, 2 in. pipe. Install shut-off valves at the drill floor or racking board level. See the cooling system specifications for water supply requirements. The derrick connections are reduced to 1 1/4 in. NPT female pressure and return for connection to the fluids service loop.


2-15

October 20, 1998

Rig-up procedure z

Refer to the engineering drawings to install the TDS. 1. Using four lift slings from the crane, one attached at each corner of the guide dolly, lift the TDS motor and dolly assembly to the V-door. 2. Attach the lifting slings from the hook or block to the pad eyes located at the swivel end of the motor support bonnet and lift the TDS into the guide rails. The slings must be a minimum of 15 ft. long (equal length) and capable of lifting 40,000 lb combined. (BOP stack lift slings are usually adequate.)

z

On some configurations it may be necessary to remove the upper roller brackets from the dolly to allow the unit to engage the guide rails. 3. Once the TDS is fully engaged on the guide rails, install the stops at the bottom of the guide rails and lower the TDS onto the stops. 4. Slide the link adapter onto the drive stem and support it up against the rotating head with adequate rigging and an air winch. Be certain that the link tilt mounting bosses are opposite from the torque wrench mounting clevis on the rotating head. 5. Slide the landing collar retainer onto the drive stem as shown in Figure 2-5. Install the O-ring in the uppermost groove on the stem. Load the O-ring and remaining grooves with a waterproof grease. Place the split landing collar around the grooves of the drive stem, and drive in the remaining roll pin. Grease the OD liberally. Wipe off excess grease. 6. Use the installation procedure in the IBOP Service Manual to install the pipehandler assembly. 7. Use the pipehandler to tighten the connection between the lower IBOP/saver sub assembly to the upper IBOP.

2-16


O-Ring

Roll Pin (4)

Split Landing Collar (2)

Drive Stem

Safety Link (4)

Figure 2-5. Installing the landing collar 8. Use the four bolts, lock washers and safety wire provided to install this assembly to the link adapter. Connect the opposite end of the hose to the quick disconnect on the rotating head assembly. 9. Install the elevator links and drill pipe elevator. Attach the link tilt clamps to the bails (U-bolts on the inside). There should be about 1/2 in. slack in the chains.


2-17

October 20, 1998

10. Install the counterbalance system as illustrated in Figure 2-6. When using chain, use the following procedure to determine the chain length required: a. Install pear links to ears on hook-block. b. With the hook supporting the TDS, measure the distance from the point of contact inside the pear link to the top of the mounting lug on the integrated swivel bail. c. Subtract 37 1/4 in. from the measurement in step b. d. Cut the chain to the length obtained in step c. The tolerance is: +3 1/4 in. or -0 in. e. Assemble remaining components and install per Figures 2-6 and 2-7. 11. Attach the service loops to the bracket on the TDS dolly frame. Using the cable clamps provided on the motor support bonnet, route the electrical cables over the gear box and into the J-boxes. The front guard folds down for access to the Jboxes. Use the electrical schematic (refer to the engineering drawings) to make the connections. Be certain that the cables are securely tied or clamped to the structure along their length. Route the hoses to the bulkhead and plug in the quick disconnects. Follow the stamped code numbers to confirm each type, and identify spares. 12. Attach the S-tube to the swivel gooseneck and the side of the motor frame as follows: a. Make up the upper union just before clamping the S-tube to the side of the motor frame. b. Install the drill pipe rubber onto the S-tube aligned with the mounting saddle on the frame. c. Attach the mud hose to the bottom connection of the S-tube. d. Position the 20° S-tube elbow on the bottom of the S-tube to adjust the hanging direction of mud hose. 13. Remove the exhaust duct shipping covers from the spark arrestors on the air exhaust duct at each side of the DC motor. Save the covers for use during future shipping or storage.

2-18


Pear Link Connecting Link Hydraulic Accumulator (Inside Motor Frame)

Motor Frame and Guide Dolly Assembly

Counterbalance Cylinder Assembly (2)

Counterbalance Manifold (On Guide Dolly)

Counterbalance Lug (Bolted to Bail) Integrated Swivel Bail

Figure 2-6. Typical counterbalance assembly


2-19

October 20, 1998

Loop Assembly

Guide Assembly

Cylinder Assembly

Hose Assemblies

Hydraulic Accumulator (Inside Dolly Tube) Swivel Bail

Counterbalance Operation Switch

Figure 2-7. Optional counterbalance assembly with parking system

n

2-20

Never operate the top drive with the exhaust duct covers attached to the spark arrestors on the air exhaust ducts. Doing so severely restricts air flow through the motor, causing overheating and potential damage. They can also fall off during operation and injure personnel working below. Attach the covers only during shipping and storage.


Counterbalance system Figures 2-6 and 2-7 illustrates the installation arrangement for this system. Please see the Maintenance and Troubleshooting book for the adjustment procedures. This assembly is pre-charged when it is shipped by land or water transport. When this assembly is shipped by air freight, it must be pre-charged according to the instructions in the Maintenance and Troubleshooting book.


2-21

October 20, 1998

Motor alignment cylinder system Figure 2-8 shows the motor alignment cylinder installed on a typical motor frame. The split shipping brace, shown exploded from the cylinder rod, is only removed after unit is fully installed. If the brace is removed before the hydraulic system is powered, the motor will tend to rotate on its trunnions. If the cylinder is removed for service, use the three bleed holes (located along the top of the cylinder barrel) to remove trapped air from the cylinder before operating the unit. Refer to the Maintenance and Troubleshooting book for the adjustment procedure.


Shipping Brace



2-22


Driller’s controls and instrumentation The controls and instrumentation described in the following sections are, or must be, supplied for operation of the TDS system.

Varco Driller’s Console (VDC) Mount the VDC within easy reach and in plain view of the driller while he is operating the drawworks brake and clutches. The gauges must be easily seen by the driller during drilling operations. Provide appropriate cable glands for the electric cables.

Throttle and torque limit controls The throttle and torque limit controls are the standard controls used for the independent rotary drive table. If not using an independent rotary drive, then these controls must be added by the SCR manufacturer.

Wiring Refer to the electrical schematics in the engineering drawings.

n

Customers who choose to use control systems 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 or damage to the system. Other systems must meet Varco requirements. Varco highly recommends the use of its system as it is specifically made for use with the TDS.


2-23

October 20, 1998

Service loops Installation Install the service loops as follows: 1. Fabricate the appropriate brackets and clamps to attach the service loop mounting bracket to the derrick structure. 2. Place the service loop derrick mounting bracket at the height specified on the derrick interface drawing provided in the engineering drawings. Locate the bracket on the side of the derrick adjacent to the hinges on the TDS and as far as practical toward the corner where the guide rail bracing is attached. The bracket must be located far enough from the corner to insure the loops do not catch under the guide rails during operations, but far enough back to provide clearance for tong lines, the stabbing board, tugger lines, etc. 3. Do not unpack the service loops from the shipping protective crate until they are ready to hang in the derrick. Lift the service loops onto the rig floor (still in the crates) and then remove them from the crates with the lifting eyes provided.

e

Use care in lifting gear rigging so as not to damage electrical conductors. Use lifting eyes only. Do not bend the service loops tighter than a three foot bend radius. Tighter bends damage the loops. 4. Attach a sling to the TDS end of the service loop and lift using the lifting eyes only. Allow enough room for the 86 ft. service loop to hang and untwist. 5. Use the lifting eyes to pull the derrick end of the loop through the V-door and attach it to the air tugger. Hoist this end of the loop into the derrick while slacking off at the crane end. Do not drag the loop on any sharp areas on the derrick. Disconnect the crane from the sling and continue hoisting the loop into the derrick. 6. Check that the derrick end of the loop is hanging toward the crown. Attach the derrick end to the derrick service loop bracket and hold in place with flange clamps (Figures 2-2).

2-24


7. Pick up the TDS end of the loops and attach them to the service loop bracket at the bottom of the motor frame. 8. Complete the terminations of the two loops as outlined in the following sections.

Electrical loop 1. Connect the pre-terminated wire ends at the motor J-boxes using the appropriate glands. Refer to the electrical schematic provided to ensure proper terminal block assignments. 2

Cut wires and cables to length and terminate them at the derrick end to attach them to the derrick J-boxes.

Terminal ends and lugs are supplied, but proper assembly equipment (crimping pliers, wire strippers, and hydraulic crimper for the DC power lugs with the correct dies for the cable) must be provided by the installer. Installation practices should comply with applicable electrical codes (i.e., NEC, etc.).

Fluids loop 1. Before connecting the hoses from the service loop, be certain that the service stand pipes have been flushed free of any contamination.

z

Use only 10 wt. hydraulic oil or non-detergent motor oil as a lubricant in the air system. Use of any other type of oil (i.e., Marvel Mystery Oil, etc.) or synthetic additive will cause the seals in the air valves to swell and cease to function. 2. Plug the quick disconnects into the appropriate mating end on the TDS. The quick disconnects are arranged to connect only one way so that the hoses cannot be mixed up. The hydraulic and air lines are identification stamped at both ends so they can be verified and connected properly. An assortment of pipe fittings are supplied with the termination kit to attach the fluid service loop hoses to the top of the standpipes in the derrick (Figure 2-2).


2-25

October 20, 1998

3. Connect the service loop to the standpipes, noting the codes (i.e., A for air, H for hydraulic, etc.) to separate the hoses.

z

The hoses in the fluids loop only extend 11 ft. from the mounting bracket. It may be necessary to make jumper hoses to reach the standpipes. Air loop

e

To reduce the possibility of accidental opening of the air-operated elevator, attach the airlines from the air-operated elevators to the spare port S1 on the rotating head whenever possible. Port S1 is located next to the hydraulic return port in the rotating head. Port S2 is next to the hydraulic press port. Install a pressure relief valve on the elevator and set at 200 psi.

2-26


Retract loop If your rig is equipped with a retract guide dolly, attach the retract loop to the derrick mounting brackets as follows:

z

There are four separate service loops needed for a TDS with retractable dollies: two electrical loops, a fluids loop, and a retract system loop. The electrical and fluids service loops attach to the derrick service loop mounting bracket, the retract loop attaches to the retract system service loop bracket. 1. Lift the crate containing the retract system service loop onto the rig floor. 2. Uncrate the service loop. 3. Attach an air winch to the lifting eyes on the derrick end (derrick end has 8 ft. of hose extending beyond the flange) and hoist to the retract system mounting bracket. 4. Attach the service loop flange to the mounting bracket with the hardware provided. Ensure that the service loop hangs straight in the derrick without any twists or kinks.

e

Use only 10 wt. hydraulic oil or non-detergent motor oil as a lubricant in the air system. Use of any other type of oil (i.e. Marvel Mystery Oil, etc.) or synthetic additive will cause the seals in the air valves to swell and cease to function. 5. Connect the retract service loop hydraulic and pneumatic hoses to the derrick standpipes.

e

Before connecting the hoses from the service loop, be certain that the standpipes have been flushed free of any contamination.


2-27

October 20, 1998

2-28


Chapter 3 Commissioning

Checkout procedures 1. Turn on the hydraulic and air power and check for leaks. Repair as required. 2. Turn on the electric power (driller’s controls only). 3. Check the function of switches and solenoids. There is an audible click when each solenoid is actuated. 4. Actuate the link tilt. Be sure that it operates smoothly and the elevator reaches a joint in the mousehole. 5. Adjust the intermediate stop so that the elevator clears the monkeyboard when actuated. Refer to the Maintenance and Troubleshooting book if a problem occurs. 6. Actuate the motor brake. There is a loud sound as the air escapes when the brake releases. 7. Move the Make/Break valve located on the manifold at the back of the pipehandler torque wrench to the BREAK position. 8. Turn on the hydraulic power supply and adjust the pressure reducing valve (also located on the torque wrench manifold) to the appropriate pressure for the lower IBOP connection.


2-29

October 20, 1998

9. Return the Make/Break valve to the MAKE position. 10. Torque the connection between the upper and lower IBOP valves. The torque wrench automatic sequence is adjusted at the factory, but be sure that it follows the proper sequence. If necessary, refer to the Maintenance and Troubleshooting book for the adjustment procedure. 11. Push and hold the makeup button on the VDC a sufficient number of times to make up the connection. 12. Make up the lower IBOP to the saver sub. 13. Reset pressure to the appropriate setting for drill pipe connections (you can preset the pressure with the Make/Break valve in the MAKE position). 14. Use the procedure outlined in the Maintenance and Troubleshooting book to adjust the safety valve actuator mechanism. 15. Actuate the IBOP valve. Verify that the stroke adjustment is correct and that no binding occurs.

e

It is extremely important to verify that the stroke adjustment is correct and that no binding occurs as the valve will fail prematurely (wash out) if it does not open and close fully. 16. Verify that the indicator light on the VDC lights up when the IBOP valve is closed. 17. Assign the TDS at the driller’s console and check that the blower operates. 18. Advance the throttle and be sure that the motor is operating properly in both directions. 19. Calibrate the Torque meter and RPM meter. 20. With the Hydraulic Power Unit (HPU) off, bleed down the TDS accumulators (HYD SIDE, not gas side). 21. Remove the split shipping brace (Figure 2-7) from the motor alignment cylinder. 22. Open the two flow control valves 1-1/2 turns off their seats. 23. Set a joint of drill pipe in the slips.

2-30


24. Bring the TDS down as if stabbing the saver sub into the box. The pin and box should be in alignment. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with the drill pipe box. b. Turn off the HPU and bleed down the cylinder accumulator (open the needle valve on the back of the manifold). This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions until the integrated swivel bail contacts the motor support bonnet. c. Loosen the lock tab and jam nut on the cylinder clevis. d. With a wrench tightened on the cylinder rod flats, screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. e. Secure the jam nut and lock tab. f. The nominal position of the two cylinder flow control valves is 1-1/2 turn off their seats. If you experience heavy drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface. If motor movement becomes excessive due to continued vibration, (more than 1/2 in. of total cylinder stroke) close the flow controls to 3/4 turn off their seats.


2-31

October 20, 1998

Long term TDS storage procedures 1. Palletize the main unit for indoor storage. A cargo container is appropriate for indoor/outdoor storage. 2. Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60°F ambient. If high humidity is unavoidable, 70°F is recommended. 3. All exposed unpainted metal surfaces are coated with a rust preventive at the factory 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. 4. Cover all openings to prevent water or dust from entering. Leave enough space around the drilling motor to allow the machine to breathe. Do not use silica gel or a dehydrating agent. 5. During storage, lubricant drains from the top half of the roller bearings in the motor, allowing corrosion to take place on the exposed areas. In order to counteract this, rotate the motor and gear train periodically to distribute lubricant over the top of the bearings. Perform this at three month intervals if stored indoors, and at one month intervals if stored outdoors. 6. The drilling motor is equipped with AC space heaters in order to keep the internal motor temperature above ambient, preventing condensation. Connect power to the space heaters at terminals 1 and 2 in the AC motor J-box (see electrical schematic in the back of this section for proper voltage). Be sure to reseal the protective covering after connection. 7. Megger the drilling motor armature and field (static voltage of 1,000 VAC and 2 MOhm minimum) when placed into storage and at three month intervals thereafter (one month if stored outside). Keep a record of the readings, as a drop between readings indicates an increase in moisture in the windings created by inadequate storage protection. If megger readings drop, bake the motor as soon as possible to restore proper resistance and avoid further damage. 8. Varco recommends adding one gallon of Mobilarma 524 Rust Preventive prior to shutdown. Or drain the oil and mix with a rust preventive, then replace the oil, run the oil pump and rotate motor to insure 100% coverage. 2-32


Returning the TDS to service after storage Before placing the TDS back into service, 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 procedure in the drilling motor service manual. To verify the condition of the motor, take note of the following: a. Blow out all dust and dirt that may have accumulated in the windings with clean, dry air. b. Visually inspect for spring corrosion, sticking brushes and general defects. c. Remove the brushes from holders, inspect and replace them as necessary prior to operation. d. Check the winding insulation continuity to ground with a 1,000 volt megger. If the reading is less than two MOhms, bake the winding until the moisture content is sufficiently reduced to produce an acceptable reading. 3. Perform a complete system test and adjustment as detailed in the next section.


2-33

October 20, 1998

2-34



Operation SM00620-3

October 20, 1998

3-2

TDS-4S Operation


Chapter 1 Operating procedures Start-up procedure ........................................................... 3-7 Stalling the DC motor ..................................................... 3-8 Changing transmission speeds .......................................... 3-9 Pipehandler operation .................................................... 3-11 Standard rotating head ............................................. 3-11 Powered rotating head ............................................. 3-12 Controls............................................................. 3-12 ROTATING HEAD LEFT/RIGHT switch ..... 3-12 AUTO STOP/FREE ROTATE switch ............ 3-12 Safety valves (IBOP) ................................................ 3-14 Torque wrench ........................................................ 3-16 Changing drill string sizes ........................................ 3-19 PH-85 ............................................................... 3-19 PH-60d ............................................................. 3-19 Torque values for load carrying components ............ 3-20 Drilling ahead ................................................................ 3-21 Drilling ahead with triples ....................................... 3-21 Drilling ahead with singles ....................................... 3-24 Drilling ahead on a semi .......................................... 3-26 Tripping ........................................................................ 3-28 Reaming out .................................................................. 3-29 Well control procedures ................................................. 3-31 Running casing .............................................................. 3-32 Handling bottom hole assemblies .................................. 3-32 Post jarring operations ................................................... 3-34

TDS-4S Operation

3-3

October 20, 1998

3-4

TDS-4S Operation



z e

n



TDS-4S Operation

3-5

October 20, 1998



3-6

TDS-4S Operation

Chapter 1 Operating procedures

Start-up procedure Use the following procedure to start up the TDS: 1. Place the blower/oil pump switch in the AUTO position. 2. Place the hydraulic power unit (HPU) switch in the PLC position. 3. Place the water pumps switch in the PLC position. 4. Place the motor space heater switch in the ON position. 5. Place the top drive/rotary table (TDS/ROT) lockout switch in the TDS position. 6. Assign a SCR.

TDS-4S Operation

3-7

October 20, 1998

Stalling the DC motor e

The brake on the top end of the TDS drilling motor armature shaft is a static, or parking brake. It is not a running or dynamic brake. It is not intended to, nor is it capable of, slip-releasing the wind-up torque in the drill string. Using the brake to slip-release the drill string wind-up torque causes the brake to heat up and can destroy the brake lining. When the TDS motor brake holds the down-hole torque, Varco recommends using the following procedure to safely release the torque in the string: 1. Use the hand throttle to develop motor torque equal to the wind-up torque held by the parking brake. 2. Release the parking brake. 3. Reduce the drill current, reducing motor torque, as the drill string slowly releases the wind-up torque. 4. Turn the hand throttle off and reset the drill current to the normal operating position after the pipe unwinds completely.

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3-8

TDS-4S Operation

Do not leave the top drive DC motor stalled in a high torque condition generally for more than 10 seconds (refer to the following table): Amps

Stall time (sec)

Amps

Stall time (sec)

280 470 670 820

240 90 45 30

900 1000 1200 1400

25 20 15 10

Changing transmission speeds The transmission shifts gears by rotating two vertical compound gear eccentric shafts (Figure 3-1). The two compound shafts (high and low) are supported between the main body and lower gear case halves on heavy trunnions. As the shafts rotate (less than onehalf turn), the compound gears go into or out of mesh with both the motor pinion gear and the bull gear because the support shaft center axes are offset or eccentric. To change transmission speeds, use a 1 in. wrench to turn the 1 in. male hex, located on the well side of the guide dolly lower cross members at the bottom of the transmission case, to rotate the input shaft. It takes five turns of the input shaft to unlock both gear sets, rotate the engaged gear set to full disengagement, rotate the disengaged gear set into full engagement and lock both gear sets in their proper positions with positive stops in the locked position. An external indicator shows the gear range selection. An optional remote gear shifter is available. It allows the operator to change gears simply by turning a switch to select the desired gear. Refer to the Remote Gear Shifter Supplement for more information.

TDS-4S Operation

3-9

October 20, 1998

Rotating Head Assembly

Shifter Input Shaft

LO

HI External HI / LO Indicator

Compound Gear Shafts

Bottom View

Low Gear Eccentric Shaft (Disengaged)

High Gear Eccentric Shaft (Engaged)

Geneva Mechanism

Shifter Input

Top View

Figure 3-1. Transmission/geneva mechanism

3-10

TDS-4S Operation

Pipehandler operation Standard rotating head The perimeter of the rotating head cam (Figure 3-2) has an indented area where the cam follower normally rests. When the cam follower is in this indented area, the return cylinder rod is fully retracted and hydraulic pressure inside the cylinder is at equilibrium. When the swivel block and cam rotates to another position along with the drill string, the ramp of the cam extends the return cylinder rod, unbalancing hydraulic pressure in the cylinder. When the elevator is released, the system automatically returns to its pre-selected (indented) position (equilibrium). To operate the swivel block locking mechanism, pull down the locking lever, pulling the locking pin out of one of 24 locking slots in the cam. With the locking lever in the vertical position, manually rotate the swivel block to the desired position and release the locking lever, setting the pin.

Cam

Stationary Flange

Cam Follower

Locking Lever




Figure 3-2. Standard 650-Ton rotating head assembly

TDS-4S Operation

3-11

October 20, 1998

Powered rotating head The 10-port powered rotating head (Figure 3-3) functions as a hydraulic slip ring. It provides ten hydraulic and pneumatic passages between the stationary swivel flange and the rotating swivel block and attached pipe handling equipment. The powered rotating head is operated by controls on the driller’s console. The driller can rotate the swivel block and attached pipe handling equipment freely, or to a predesignated AUTO STOP position. The position can be set by locating a target in the bull gear on the rotating head, to align with the proximity sensor mounted on the flange of the rotating head.

Controls The powered rotating head is controlled by two switches. ROTATING HEAD LEFT/RIGHT switch

This switch rotates the powered rotating head, pipe handler, and link tilt to the right or left (same direction as the drill string). Rotation only occurs when the switch is held in the RIGHT or LEFT position. Rotation stops when the switch returns to the center position.

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The ROTATING HEAD function is only active when the LINK TILT switch is in the FLOAT position. AUTO STOP/FREE ROTATE switch

This switch is in the AUTO STOP mode when the light is illuminated (on). In the AUTO STOP mode, a proximity sensor automatically stops rotating head rotation. The AUTO STOP function is independent of the direction of rotation. Rotation continues when the ROTATE switch returns to the center position, then activated again. When the AUTO STOP/FREE ROTATE light is off, the FREE ROTATE mode is active. In this mode, the rotating head rotates as described in the ROTATING LEFT/RIGHT section above.

3-12

TDS-4S Operation

Stationary Flange

Rotary Glyd Ring (11)

Bull Gear

Torque Arrestor Hanger Swivel Block

A5

H1

S2

A2

H3

PRESSU

A3

RE

A1

S1

H1

Hydraulic Motor Assembly

S2

H2

A4

A1

A4 A5

A2

H3

A3 H2

S1

Figure 3-3. Powered rotating head assembly

TDS-4S Operation

3-13

October 20, 1998

Safety valves (IBOP) Operating the switch on the VDC to the IBOP CLOSED position causes the two actuator air cylinder rods to extend, moving the arms and the actuator shell body upward (Figure 3-4). This upward movement causes the crank assemblies to rotate 90°, closing the upper IBOP. Operating the switch to the OPEN position retracts the cylinder rods, drawing the IBOP actuator shell downward-opening the upper IBOP.

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3-14

TDS-4S Operation

Closing the manually operated lower IBOP requires an Allen wrench.



Actuator Arm (2)

Crank Assembly (2)


Upper IBOP

Torque Tube

Lower IBOP

Saver Sub

Drill Pipe

Figure 3-4. Safety valve actuator system

TDS-4S Operation

3-15

October 20, 1998

Torque wrench The primary function of the TDS torque wrench is to breakout the drill string from the saver sub before making a connection. The torque wench can also make connections if necessary (i.e., when replacing the lower IBOP or saver sub, or while backreaming, or when adding a pup joint to the drill stem). The torque wrench has a control manifold with the following components (Figure 3-5): ❏ Hydraulic pressure gauge ❏ Control and sequencing valves ❏ Hydraulic hose inlet and outlet Quick Disconnects (QDs) ❏ Manual Make/Break directional valve The Make/Break valve controls the torque wrench operating direction (makeup/breakout) during operation. A pressure reducing valve (PRV) on the control manifold allows presetting the makeup torque (this valve is bypassed when the torque wrench is in breakout mode). When the driller actuates the torque wrench from the VDC, the lifting cylinder rod retracts, raising the torque tube to engage the splines on the upper IBOP. A sequenced signal from the control manifold then operates the clamping piston, clamping the jaws onto the drill string box connection. Then another sequenced signal from the control manifold automatically directs pressure to the torque cylinders, rotating the torque tube up to 25° while developing a maximum torque of 85,000 ft lb (65,000 ft lb on the PH-60d Pipehandler). The position of the Make/Break valve on the control manifold determines the direction that the torque tube rotates. A two-position, air-piloted, hydraulic valve located on the counterbalance manifold located on top of the TDS guide dolly controls the entire sequenced cycle described above. A push button switch on the VDC operates the hydraulic valve. The driller holds the button down to makeup or breakout a connection, and then releases the button to allow the torque wrench to automatically recycle to the ready position. If the torque developed on the first pass is insufficient, the driller simply operates the button again.

3-16

TDS-4S Operation

Manually switch the Make/Break valve on the torque wrench to the MAKE position to use the top drive torque wrench to make connections. This allows the driller to initiate automatic torque wrench sequences and repeat them until reaching the preset makeup torque.

Make/Break Valve

Recycle Sequence Valve

Clamp Sequence Valve

Torque Sequence Valve

Torque Wrench Manifold

BREAK

MAKE

Hydraulic Pressure Return RECYCLE

CLAMP

TORQUE

PRV

50

60

40

30

1000

1500

70

80

Hydraulic Pressure Inlet

20

LIFT LOWER

500

2000

90

10

®

2500

0

0

PSI Ft.Lbs.

10 0

Lift/Lower Flow Control Valve

x1000

Torque Gauge 0 - 2500 PSI

Figure 3-5. Typical torque wrench control manifold

TDS-4S Operation

3-17

October 20, 1998

n

Failing to apply the correct amount of torque when using the torque wrench to makeup connections can result in equipment damage and injury to rig personnel. Do not switch the Make/Break valve to BREAK until completing the makeup sequence, which may require repeating the makeup sequence several times. Verify the torque pressure regulating valve setting after every makeup sequence before releasing the makeup valve. Repeat the makeup sequence until the torque cylinders do not stroke more than one inch during the final sequence, repeat the sequence if uncertain. Varco recommends that the driller operating the pipehandler verify that the torque cylinders do not stroke more than one inch on the last makeup cycle. Varco also recommends checking the torque gauge on the pipehandler while making connections to make sure the torque wrench applies the correct amount of torque to the connection. Stop and verify correct operation whenever the operator observes unsteady or inconsistent hydraulic pressure readings, or finds it difficult to adjust set points. Varco recommends that a second individual assist the driller when making connections with the torque wrench. The second person can verify that the torque wrench applies the correct torque to connections.

3-18

TDS-4S Operation

Changing drill string sizes PH-85 To operate the torque wrench using drill string sizes that are different from the size specified on your rig’s original configuration, install a separate drill string handling kit. Refer to the following tables when ordering a drill string handling kit for a PH-85:

Drill String Change-Over Kits 750/650 Ton PH-85 Pipehandling Original Part Number

Desired Tool Joint Connection NC 50

5 1/2 F.H.

95497-A-H-N-*-* 95497-A-J-N-*-*

NC 38 91873-650 91873-650

94731-650 94731-650

94730-650 –––

95497-A-K-N-*-*

91873-651

–––

94730-651

95497-B-K-N-*-* 95497-A-L-N-*-*

91873-651 n/a

––– n/a

94730-652 TBD

6 5/8 F.H. –––

2 7/8 F.H.

94729-650 94729-651 94729-652 –––

97219-651 n/a

*These designators do not affect kit choice.

PH-60d To operate the torque wrench with a 3 1/2 in. drill string, install a separate drill string handling kit. The following lists available kits for a PH-60d: ❏ Part No. 78652-1 – Includes stabbing guide assembly, jaw assemblies, saver subs, installation drawing. ❏ Part No. 78652-2 – Includes stabbing guide assembly, jaw assemblies, installation drawing.

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Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No. 78652-2 does not. By purchasing the latter, the user assumes responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver subs separately. Specifications for these are available from the factory or any Varco service center.

TDS-4S Operation

3-19

October 20, 1998

Torque values for load carrying components Proper makeup torque is critical to the function of drill stem components. Table 3-3 only includes components within the TDS. Refer to the API charts for other components. Table 3-3. Torque values for load carrying components Components

ID

Connection

OD

Min. torque Max. torque

Upper IBOP to main stem/main shaft

3 or 3 3/4 in.

6 5/8 in. API Reg. 7 3/4 in.

50,000 ft lb

63,000 ft lb

Lower IBOP valve to upper safety valve

3 or 3 3/4 in.

6 5/8 in. API Reg. 7 3/4 in.

50,000 ft lb

60,000 ft lb

Saver sub to lower IBOP valve

3 or 3 3/4 in.

6 5/8 in. API Reg. 7 3/8 in.

46,000 ft lb

60,000 ft lb

Crossover sub to lower IBOP valve

3 or 3 3/4 in.

6 5/8 in. API Reg. 7 3/8 in.

46,000 ft lb

60,000 ft lb

Upper IBOP valve to main stem/main shaft

3 or 3 3/4 in.

7 5/8 in. API Reg.

9 in.

83,000 ft lb

91,000 ft lb

Lower IBOP valve to upper IBOP valve

3 or 3 3/4 in.

7 5/8 in. API Reg.

9 in.

75,000 ft lb

84,000 ft lb

Saver sub to lower IBOP valve

3 or 3 3/4 in.

7 5/8 in. API Reg. 7 5/8 in.

66,000 ft lb

85,000 ft lb

Crossover sub to lower IBOP valve

3 or 3 3/4 in.

7 5/8 in. API Reg.

75,000 ft lb

91,000 ft lb

3-20

TDS-4S Operation

9 in.

Drilling ahead Drilling ahead with triples Drilling ahead with triples is the common drilling mode for the TDS. There are various sources for triples. On skidding rigs drilling multiple well platforms, drill pipe can be left racked and used to drill the next well. If triples do not currently exist, there are two recommended methods of obtaining them. One is to leave some triples racked in the derrick when tripping back in the hole and finish the trip with singles. Leave enough triples racked to handle anticipated bit life. The second method for obtaining triples is to make up triples in the mousehole while drilling ahead or during idle rig time. For safety reasons a pivoting mousehole is best because it can pivot to a vertical plane to simplify making connections. Use the following procedure to drill ahead with triples (Figure 3-6): 1. Drill down until the saver sub is within three feet of the rotary table. 2. Circulate bottoms up as necessary. 3. Stop the string rotation. 4. Pick up the string and set slips for a connection four feet off the rig floor. 5. Switch the TDS motor from FORWARD to REVERSE. 6. Stop the mud pumps. 7. Close the IBOP. 8. Break out the drill pipe connection using the torque wrench on the pipehandler. 9. Using the TDS motor, spin out of the box while hoisting the TDS with the drawworks (follow with the drawworks, do not lead).

TDS-4S Operation

3-21

October 20, 1998

Set slips on string Stop circulation

Raise block Tilt link tilt to derrickman

Pickup stand with elevator Stab bottom of stand onto string

Breakout connection using pipehandler and drilling motor (in reverse)

Lower block to stab motor into top of stand

Pull slips

Spin in motor and stand

Begin drilling

Start circulation

Makeup both connections with motor

3

2

1 Link Tilt

4

5

Makeup

Start Circulation

Stop Circulation Stab

Makeup

Figure 3-6. Drilling ahead with triples

3-22

TDS-4S Operation

10. Stop the spin out mode. 11. Open the drill pipe elevators. 12. Retract the TDS away from the hole. 13. Hoist the TDS to the racking board level to get the next stand. 14. Latch the backup tong on the box connection. 15. Thoroughly dope the box connection in the rotary table. 16. When the TDS is fully raised, extend the TDS. 17. Tilt the links. 18. Switch the TDS motor from REVERSE to FORWARD. 19. Derrickman latches the elevator on the next stand. 20. Hoist the pin off setback area and clear the box with the stand. 21. Release the link tilt. 22. Stab the connection at the floor. 23. Switch the TDS to SPIN IN mode. 24. Continue to slack off approximately two feet to stab the upper connection of the stand with the TDS. 25. Slack off to allow connection to shoulder up (lead with the drawworks, do not follow). 26. Switch to TORQUE and hold for approximately six seconds. The makeup torque is preset. 27. Verify full makeup to the correct value on the torque meter. 28. Switch to DRILL mode. 29. Unlatch the backup tong. 30. Open the IBOP. 31. Start the mud pumps. 32. Pick up to pull the slips. 33. Drill ahead.

TDS-4S Operation

3-23

October 20, 1998

Drilling ahead with singles Typically there are two situations requiring drilling ahead with singles. One is beginning operations on a new well where there are no triples made up and racked. The other is when making surveys every 30 ft. (i.e., when kicking off using a downhole mud motor). The link tilt feature makes drilling with singles safe and efficient by moving the elevators to the mousehole to pick up the singles. Use the following procedure to drill ahead with singles (Figure 3-7): 1. Drill down the existing single, pull up to the 4 ft. level (approximately), close the IBOP, stop mud circulation, and set the slips. 2. Break the connection between the saver sub and the drill pipe using the torque wrench in the pipehandler. 3. Spin out the connection using the drilling motor. 4. Lift the TDS, opening the drill pipe elevators to allow them to pass over the box setting in the rotary table. 5. Actuate the link tilt to bring the elevator over to the single in the mousehole and latch the elevator around the single. 6. Pull the single out of the mousehole and as the pin clears the floor, deactivate the link tilt to allow the single to come to well center. 7. Stab the connection at the floor and lower the TDS, allowing the added single to enter the stabbing guide until the saver sub pin stabs into the box of the new joint. 8. Using a backup tong to react the torque, spin up and torque the connection using the TDS motors in the TORQUE mode. 9. Pull the slips, start the mud pumps and drill ahead.

3-24

TDS-4S Operation

Set slips on string

Tilt links to mousehole

Pickup single with elevator

Stop circulation

Latch drill pipe elevator around single

Release link tilt

Close IBOP

Stab bottom of single onto string

Lower block to stab motor into top of single

Pull slips

Spin in motor and single

Start circulation

Open IBOP

Begin drilling Makeup both connections with motor in torque mode

Breakout connection using pipehandler and drilling motor (in reverse)

3

2

1

4

5

Makeup

Open IBOP Close IBOP

Link Tilt Stab

Makeup

Figure 3-7. Drilling ahead with singles

TDS-4S Operation

3-25

October 20, 1998

Drilling ahead on a semi Derrick clearances are critical for drilling operations with the TDS on a floater. When making a connection, kelly drilling pulls the bit off bottom far enough to account for vessel heave. The 54 ft. kelly must be pulled all the way up to add the next joint. With the TDS, there is no kelly to pull up. Therefore, you must be able to pull the bit off bottom enough to allow for vessel heave when making a connection. The practical method for doing this is to pull up the pipe string until the bit is sufficiently off bottom, and then set the slips. The distance should equal the maximum expected heave. The TDS pipehandler can break out the drive shaft, and the TDS motor can spin out the connection. Then hoist the TDS into the derrick and add a new 90 ft. stand from the pipe rack in the same manner as on a fixed rig. Because the pin connection of the new stand is about 15 ft. above the floor, a torque backup device is required, as well as a means to assist stabbing. Varco provides a simple, remotely-operated Raised Backup System (RBS) which retracts out of the way when not in use. Use the following procedure to drill ahead with triples on a semi (Figure 3-8): 1. Drill the stand down until the elevator is to the floor. 2. Pull the string up sufficiently off bottom. 3. Set the slips. 4. Breakout the TDS and spinout shaft using the drilling motor. 5. Raise the TDS to the racking platform and latch the elevator on a new stand. 6. Extend the RBS and adjust the height. Clamp the RBS tong on the elevated box of the drill string. 7. Stab the pin of the new stand into the string using the RBS stabbing head if so equipped, or use the lower racking arm. 8. Stab the TDS into the upper end of the stand, spin in, and make up both connections. 9. Retract the RBS. 10. Pull the slips and drill ahead. 3-26

TDS-4S Operation

Drill down stand

Pickup string 10 to 20 ft.

Stop circulation Set slips

Raise block

Spin in stand

Pull slips

Extend RBS and adjust height

Makeup both connections with motor

Retract RBS

Unlatch elevator Breakout/spinout with pipehandler and motor

1

2

Start circulation

Pickup stand Begin drilling 90 ft.

Stab stand using RBS to assist

3

4

5

Makeup

Start Circulation

Stop Circulation Makeup

Figure 3-8. Drilling ahead with triples (floaters)

TDS-4S Operation

3-27

October 20, 1998

Tripping Perform tripping operations in the conventional manner. Use the link tilt feature to tilt the elevator to the derrickman so the derrickman can quickly latch it around the pipe. The hydraulic link tilt allows the elevator to also reach the mousehole. The air actuated link tilt has an intermediate stop which is adjustable to set the elevator at a convenient working distance from the monkeyboard. The intermediate stop tilts out of the way to allow the elevator to reach the mousehole. If a tight spot or key seat is encountered while tripping out of the hole, spin the drilling motor into the stand at any height in the derrick. Establish circulation and rotation immediately to work the pipe through the tight spot.

3-28

TDS-4S Operation

Reaming out The TDS permits reaming out of an open hole to prevent pipe sticking and to reduce key seat formation, without affecting racking functions associated with normal tripping (i.e., there are no singles to contend with). The pipehandler torque wrench can break out 90 ft. stands in the derrick. Use the following procedure to ream out of the hole (Figure 3-9): 1. Hoist the block while circulating and rotating the drilling motor until the third connection appears. 2. Stop circulation and rotation and set the slips. 3. Break out the drilling motor from the top of the stand using the pipehandler torque wrench. Hold a backup at the floor and spin out the drilling motor. 4. Break out the stand at floor level, and spin out using pipe spinners. 5. Pick up the stand with the drill pipe elevator. 6. Rack the stand back. 7. Lower the block and TDS to the floor. 8. Stab the drilling motor into the box, spin up and torque it with the drilling motor. With light slip loads, the pipehandler torque wrench can be used to torque the connection. 9. Resume circulation and continue reaming out of the hole.

TDS-4S Operation

3-29

October 20, 1998

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

Set slips on string

Hoist free stand with elevator

Setback stand using link tilt

Breakout connection using pipehandler and drilling motor (reverse)

Spin in motor and makeup connection with motor

Breakout and spinout stand at floor

Start circulation, pull slips, hoist and rotate

3

2

1

Lower block, stab motor into string

Breakout

Hoist

4

5

Setback

Hoist and Rotate

Breakout

Figure 3-9. Reaming out

3-30

TDS-4S Operation

Well control procedures The TDS can stab into the string in any position in the derrick. While drilling, the remotely controlled IBOP valve is always in the string for immediate use as needed. Use the following TDS well control procedure in conjunction with standard IBOP well control procedures: 1. On indication of a kick, set the slips at the nearest connection and stab the TDS into the string. 2. Spin up and torque the connection using the Spin/Torque control, after setting the backup tong. 3. Remotely close the upper IBOP valve.* 4. Lower the string to the floor and reset the slips. 5. Manually close the lower IBOP valve. 6. Remove the torque wrench vertical travel stops. 7. Breakout the lower IBOP from the upper IBOP. 8. Engage the top drive motor in reverse to spin out the connection. 9. Install the appropriate crossover sub, check valve or circulation sub on top of the lower IBOP valve. 10. Proceed with normal well control procedures. * Operation of the IBOP valves is the same as any standard valve. A 7/8 in. hex wrench is included with the system to operate the upper valves if the remote actuator should fail, or for checking that the valve is functioning correctly.

TDS-4S Operation

3-31

October 20, 1998

Running casing For casing operations, longer elevator links (180 in.) must be used to allow clearance for the cementing head under the torque wrench in the pipehandler. Attach a short piece of hose to the saver sub in the pipehandler to fill the casing while lowering. Use the remotely controlled upper IBOP valve to start and stop the fluid flow. If desired, run casing conventionally using the block and hook and swinging the TDS aside. Use longer bails (180 in.) to prevent the block dolly (if used) from contacting the TDS dolly.

Handling bottom hole assemblies For handling bottom hole assemblies, use the swiveling drill collar dolly (Figure 3-10) to allow the elevators to turn freely. The drill collar dolly’s upset, which latches in the standard drill pipe elevator, is mounted on a bearing allowing it to swivel even while it is under load. A shoulder elevator is suspended from the “perfection” links (or a second drill pipe elevator if lifting subs are used.) The collars can be walked in or out with the elevator turning on the drill collar dolly.

3-32

TDS-4S Operation

A Drill Pipe Elevator

A 100 TON VARCO

Drill Collar Dolly

Perfection Links (36")

;;; ;;; ;; ;;; ;; ;;;

91 in. Square Shoulder Elevator

Lifting Sub 37 in.

8 in.

Drill Collar View

A-A

Figure 3-10. Swiveling drill collar dolly

TDS-4S Operation

3-33

October 20, 1998

Post jarring operations e

Jarring occurs on all drilling rigs. It is not practical to recommend removing the top drive from the drill string during all jarring operations. But the possibility of damage to a top drive during a jarring operation is considerable. Consider removing the top drive from the drill string before performing prolonged jarring. It is imperative to exercise caution when using a top drive after a jarring operation. Safe operation of the TDS is the responsibility of the user and rig crew. Use the Post Jarring Checklist (PI 93-1) and Design Specification, Design Torque Standard (DS00008) to help ensure safe top drive operation. Note that the checklist includes recommended procedures. Do not limit inspections to items on the checklist. The checklist draws attention to specific parts on major subassemblies. Inspection should be rigorous, looking for any wear that could cause a safety or operational risk. Use the Post Jarring Checklist (PI 93-1) and Design Specification, Design Torque Standard (DS00008) after performing any jarring operation while the top drive is in the drill string.

3-34

TDS-4S Operation


Maintenance and Troubleshooting SM00620-4 Rev. B

March 8, 2001

4-2

TDS-4S Maintenance and Troubleshooting


Chapter 1 Maintenance Inspection ........................................................................ 4-9 TDS swing out procedure .......................................... 4-9 DC drilling motor ................................................... 4-12 Motor alignment cylinder ........................................ 4-12 Air exhaust muffler .................................................. 4-12 Derrick termination kit air filter/regulator/ lubricators ................................................................ 4-13 Pipehandler .............................................................. 4-14 Nondestructive Examination (NDE) ....................... 4-14 Visual inspection................................................ 4-14 Landing collar .............................................. 4-16 Drive stem ................................................... 4-18 Magnetic Particle Inspection (MPI) ................... 4-20 Ultrasonic Inspection ......................................... 4-21 Safety valve inspection procedures (IBOP) ... 4-21

Chapter 2 Lubrication Lubricating the motor and motor support bonnet assembly............................................................. 4-23 Gearbox ................................................................... 4-23 Torque setting procedure ................................... 4-25 Other gearbox lubrication and maintenance considerations ............................... 4-27 Initial oil change period ........................................... 4-27 Oil capacity.............................................................. 4-28 Lubricating the DC motor ....................................... 4-29 Lubricating the washpipe and bonnet seal ................ 4-30 Lubricating the rotating head ......................................... 4-31 Lubricating the link adapter ........................................... 4-32 Lubricating the torque wrench ....................................... 4-33 Lubricating the master bushing ID wear guide ............... 4-34 TDS-4S Maintenance and Troubleshooting

4-3

March 8, 2001

Lubricating the safety valve actuator .............................. 4-34 Lubricating the upper safety valve (IBOP) ..................... 4-35 Lubricating the guide dolly assembly ............................. 4-36 Lubricating the bail pins ................................................ 4-41 Lubricating the cooling system ....................................... 4-42 Lubrication schedule ...................................................... 4-44 Lubricant specifications ................................................. 4-45

Chapter 3 Maintenance Adjustment procedures .................................................. 4-49 Adjusting the torque wrench .................................... 4-49 Adjusting the upper safety valve (IBOP) and safety valve actuator system ............................... 4-52 Adjusting the counterbalance system ........................ 4-52 Adjusting the motor alignment cylinder system ....... 4-54 Precharging the counterbalance system .................... 4-60 Assembly and disassembly .............................................. 4-62 Pipehandler .............................................................. 4-62 Torque wrench disassembly ............................... 4-62 Replacing the torque wrench clamping piston seal ..................................... 4-68 Replacing the standard rotating head glyd rings ........................................................... 4-71 Replacing the powered rotating head glyd rings ........................................................... 4-75 Replacing the standard or extended reach link tilt air actuator ............................................ 4-77 Removing the tong dies ........................................... 4-81 Front jaw ........................................................... 4-81 Rear jaw ............................................................. 4-81 Removing the jaws ................................................... 4-82 Front jaw ........................................................... 4-82 Rear jaw ............................................................. 4-82 Upper safety valve (IBOP) ....................................... 4-82 Lower safety valve (IBOP) ....................................... 4-82 Removing the motor assembly from the guide dolly....................................................... 4-83 Disassembly/assembly of the drilling motor and motor support bonnet ....................................... 4-84 Installing the TDS motor pinion ................................... 4-87 Local blower cooling system assembly/disassembly ... 4-89 Closed loop cooling system assembly/disassembly .... 4-92 Replacing the safety wiring ............................................ 4-95 Safety wiring tips ..................................................... 4-97 4-4


Chapter 4 Troubleshooting Troubleshooting the counterbalance .............................. 4-99 Troubleshooting the motor alignment cylinder ...... 4-100 Troubleshooting the drilling motor and guide dolly ..... 4-101 Troubleshooting the motor air brake ..................... 4-101 Troubleshooting the retract guide dolly ................. 4-101 Troubleshooting the transmission .......................... 4-102 Troubleshooting the oil pump ............................... 4-103 Troubleshooting the cooling system ....................... 4-104 Troubleshooting the pipehandler ................................. 4-106 Troubleshooting the torque wrench ....................... 4-106 Troubleshooting the safety valve actuator............... 4-108 Troubleshooting the link tilt .................................. 4-108 Troubleshooting the pipehandler at the counterbalance manifold ........................................ 4-109 Troubleshooting the crown height indicator .......... 4-110 Six-gang air valve assembly illustration ................... 4-111

z

This section contains some information regarding the GE motor. Refer to the GE Motor Service Manual, VDR00023 (included in VDP0001) for specific details such as: ❏ Inspection and maintenance schedule ❏ Recommended storage instructions drilling motors and generators ❏ Removing motors or generators from storage


4-5

March 8, 2001

4-6




z e

n




4-7

March 8, 2001



4-8


Chapter 1 Maintenance

Inspection TDS swing out procedure Varco top drives with swing-out guide dollies can be quickly swung aside on their own dolly frames for inspection, maintenance, running casing, or to allow drilling operations requiring a kelly and rotary table. Electrical, hydraulic, and air supplies do not have to be disconnected. Use the following procedure to swing out the TDS only if your rig has a guide dolly with hinge pins (refer to the engineering drawings for information specific to your rig configuration): 1. If you have a retract system, operate the switch on the VDC to retract the TDS. 2. Slowly lower the TDS until the elevator nears the rig floor. 3. Remove the elevator and elevator links. 4. Lower the TDS guide dolly to the stop.


4-9

March 8, 2001

z

On some rigs, it may be necessary to secure the traveling block frame to the guide dolly frame using chain and/or rope. 5. Turn off the Hydraulic Power Unit (HPU) and bleed down hydraulic pressure by opening the needle valve on the counterbalance manifold. (The counterbalance manifold is located on the upper motor frame.) 6. Detach the counterbalance system cylinders from the hook or block by unhooking the pear links from the ears on the hook or block. 7. Disconnect the air intake hose. 8. Disconnect the mud hose from the TDS S-tube.

n

Unlatching the hook from the integrated swivel bail may cause the TDS motor assembly and/or the hook to lurch suddenly. Always keep adequate tension on the tailing lines to prevent sudden movement of these assemblies. 9. Unlatch the hook. 10. Attach tugger lines to the TDS motor frame, opposite the frame hinges, to assist in swinging out the TDS motor assembly. Use tailing lines on the motor frame to control swing out. 11. Unfasten the two swing-out bolts, opposite the hinges, holding the motor frame to the guide dolly. 12. Operate the air tuggers to slowly pull on the motor frame while unhooking the traveling block from the swivel bail. 13. When the traveling block is disconnected, continue swinging out the TDS 180° and secure the motor assembly to the derrick with chain and/or rope.

4-10


To swing the TDS back in for operation after inspection or maintenance, perform the following procedure: 1. Lower the guide dolly far enough to allow swinging the TDS back into place. 2. Retract the TDS and secure it.

n

While latching the hook to the integrated swivel bail, the swivel and/or the TDS motor assembly may suddenly lurch. Always keep adequate tension on tailing lines to prevent sudden movement of these assemblies. 3. Attach tugger lines to the TDS motor assembly, opposite the hinges, to aid in swinging back the TDS assembly. Use tailing lines on the motor frame to control swing back. 4. Release the chain and/or rope securing the TDS motor assembly to the derrick and slowly swing back the TDS motor assembly to the guide dolly. While swinging it back, latch the hook onto the swivel. 5. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the hinges. 6. Connect the mud hose to the S-tube. 7. Connect the air intake hose. 8. Hook the counterbalance system pear links onto the ears of the hook or block. 9. Turn the HPU on and bleed air out of the system.


4-11

March 8, 2001

DC drilling motor Thoroughly inspect the TDS, motor support bonnet, and guide dolly assembly for loose bolts and fittings daily. If any safety wire or cotter pins were removed to facilitate repairs, replace them immediately.

z

The DC motor has a complete manufacturer’s service manual for your reference provided in the Vendor Documentation Package.

Motor alignment cylinder

e

The alignment cylinder is not intended to be used to align the pin with the box at the well bore. It is a device to counterbalance the offset weight of the DC motor and allow the system to accommodate external forces. It is adjustable to ensure that the mainshaft is straight at well center–to compensate for design tolerances in the guide rails and dolly. To work properly, the guide rails must be properly located, and the dolly must fit within design tolerances. Check alignment cylinder operation weekly. Also, inspect all moving parts and check accumulator pressures on a weekly basis.

Air exhaust muffler Varco installs air exhaust mufflers on the exhaust ports of the multi-gang solenoid valve manifold for noise abatement. All such mufflers reduce noise and collect contaminants that can eventually restrict the air passage. Air passage constriction results in back pressure on all of the solenoid valves and erratic valve operation. It also holds pressure on the air brake. Periodically remove the mufflers and clean or replace them. If noise abatement is not an issue on the rig, replace the mufflers with simple pipe elbows.

4-12


Derrick termination kit air filter/ regulator/lubricators Top drives that rely on rig air to power link tilt, upper IBOP, brake, and torque wrench makeup/breakout sequence pilot signal functions require regular inspection. The air valves, cylinders and actuators for these functions require proper lubrication and moisture-free and particle contaminant-free air. Moisture in the air can cause corrosion on internal cylinder surfaces. Particle contamination can damage the seals in moving parts and cause solenoid valves to stick. Oil, injected by the lubricator and carried by the air, reduces friction between moving parts and increases the life of seals in valves and actuators.

z

Varco supplies a filter/regulator/lubricator in the derrick installation kit and recommends installing it at the fingerboard level in the derrick. Improperly adjusted regulators can cause poor device performance at reduced pressures, or valve and cylinder seals and O-ring extrusion at excessive pressures. Inspect the entire filter/regulator/lubricator monthly for damage to the filter bowl, overall body, or inlet and outlet fittings. Replace any damaged, corroded, or improperly functioning components. Adjust the pressure regulator outlet pressure to 100-120 psig monthly. Clean and drain the filter weekly. Fill the lubricator with petroleum-based hydraulic oil with a fluid viscosity of 100-200 SSU at 100°F (ISO 32/34).

e

Do not use fluids such as Marvel Mystery Oil, motor oil, or Dextron II in the lubricator. Swollen seals may result.


4-13

March 8, 2001

Pipehandler Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire or cotter pins were removed during repairs, replace them immediately. Inspect the hinge bolts daily to make sure they are not separating from the pipehandler. Make sure the hinge pins are not loose due to excessive wear in the bore of the clamp clevis or a broken retaining bolt.

n

Inspect the link tilt intermediate stop and adjustment device for overall integrity weekly. Replace the components if there is excessive looseness of the threaded rod in the threaded hole of the pivot arm (Figures 4-24 and 4-25). An indication of a possible problem is if the two intermediate stops are not adjusted equally (i.e., if the thread engagement differs between the two stops). Failure to perform this inspection and/or component replacement can result in injury to rig personnel.

Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.

z

NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity.

Visual inspection Use calipers on a regular basis to measure the amount of wear on the elevator link eyes (Figure 4-1). Compare the measurements with the Wear Chart (Figure 4-1) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.

4-14


Upper Eye (Hook)

Wear Chart - Forged Links Lower Upper Eye Eye Dimension Dimension A C

C

C

;;;; ;;;; ;;;; ;;;;

Capacity (per set) in Tons

B = 3 1/2 in., 350-Ton 5 in. 4 13/16 in. 4 5/8 in. 4 7/16 in.

2 3/4 in. 2 9/16 in. 2 3/8 in. 2 3/16 in.

350 300 225 175

B

;;; ;;; ;;;

B = 4 1/2 in., 500-Ton 6 in. 5 3/4 in. 5 1/2 in. 5 1/4 in.

3 1/2 in. 3 1/4 in. 3 in. 2 3/4 in.

500 420 325 250

B = 6 1/4 in., 750-Ton 7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in.

7 1/2 in. 7 1/4 in. 7 in. 6 3/4 in.

350 300 225 175

To determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link.

B

A

;;;; ;;;; ;;;;

A Lower Eye (Elevator)

Figure 4-1. Visual inspection of elevator links


4-15

March 8, 2001

Landing collar

Disassemble and inspect the landing collar every six months. Use the following procedure to disassemble the landing collar (Figure 2-5) for inspection: 1. Disconnect the top drive from the drill string. 2. Remove the IBOPs and pipehandler. 3. Raise the solid body elevator to expose the landing collar retainer. 4. Straighten the retainer tabs. 5. Slide the retainer ring above the split landing collar halves. 6. Drive out one roll pin. 7. Remove the landing collar halves. 8. Slide the retainer off the drive stem. After disassembly, inspect all landing collar parts for wear, damage, or corrosion. Check for: ❏ Grooves or other radial wear marks indicating that the bore of the solid body elevator is rubbing on the outside diameter of the landing collar retainer shell ❏ Radial grooves on the inside diameter of the retainer shell ❏ Missing tabs from the retainer shell ❏ Wear or corrosion induced pitting on the retainer shell shoulder ❏ Wear, corrosion, or fatigue cracks on the inside or outside diameter of the landing collar halves ❏ Evidence of drive stem contact with the solid body elevator ❏ Evidence of inside bore wear on the solid body elevator indicating contact with the drive stem or landing collar retainer. Wear on the inside shoulder of the elevator should not exceed 1/8 in. ❏ Evidence of wear, corrosion, or fatigue cracks on the safety links

4-16


Replace the appropriate part(s) if any of the above conditions exist. Use the following procedure to reassemble the landing collar: 1. Replace the existing O-ring in the retainer shell. 2. Grease the inside diameter of the retainer shell. 3. Slide the retainer onto the drive stem above the landing collar grooves. 4. Install one new roll pin and safety links on the split landing collar halves. 5. Coat the landing collar halves with a generous amount of water resistant grease. 6. Place the landing collar halves on the drive stem with 15° taper closest to the top drive. 7. Drive in the remaining roll pin. 8. Slide the retainer shell over the landing collar halves. 9. Use a hammer and drift to bend all 32 retainer tabs to secure the retainer shell. 10. Coat the retainer shell and drive stem with a generous amount of water resistant grease to prevent corrosion. 11. Reinstall the IBOPs and pipehandler.


4-17

March 8, 2001

Drive stem

Regularly inspect and measure the drive stem/main shaft for wear. Remove the drive stem/mainshaft from service if bore wear is greater than the dimensions shown in Figure 4-2. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections. Large Bore 1.30 Minimum @ Landing Collar Grooves (2.45 New) 3.75 Diameter (New)

(1.70 New)

9.000 Diameter

7 5/8 API REG R.N. Pin 7.500-3 ACME-3G Left-hand Thread

Small Bore 1.30 Minimum @ Landing Collar Grooves (2.45 New) 3.00 Diameter (New)

(1.70 New)

9.000 Diameter

7 5/8 API REG R.N. Pin 6.250-3 ACME-2G Left-hand Thread

Figure 4-2. Typical minimum bore wear dimensions (Refer to engineering drawings for exact dimensions)

4-18


Use the following API recommended guidelines (Figures 4-3) to determine the tensile load bearing capacities of the drive stem/ main shaft landing collar. 3800000 3700000

New Condition (3.00 Bore)

3600000 3500000 3400000 3300000

3100000

New Condition (3.82 Bore)

3000000 2900000 2800000 2700000 2600000 2500000 2400000 2300000

1.00

1.05

1.10

1.15

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

2200000

1.75

Load (Lbs)

3200000

Remaining Wall Thickness Under Pin Thread Relief Groove (Inches)

Figure 4-3. 750-Ton and 650-Ton drive stem/main shaft landing collar tensile dimensions


4-19

March 8, 2001

Magnetic Particle Inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components and load collar grooves to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. After approximately five years, or 15,000 operating hours, depending on the severity of operating conditions, Varco recommends performing a MPI of all load carrying components over their entire surface (including internal bores) to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. The load carrying components are: ❏ Drive stem/main shaft (lower portion) ❏ Landing collar ❏ Upper and lower IBOP ❏ 350-Ton BNC drill pipe elevator ❏ Link adapter ❏ Saver, crossover, and spacer subs ❏ Power subs ❏ Power swivels ❏ Elevator links Details on MPI procedures are in the following publications:

4-20

I.A.D.C.

Drilling Manual, 9th Edition

ASTM A-275

Std. Method for Magnetic Particle Inspection of Steel Forgings

ASTM E-709

Std. Recommended Practice for Magnetic Particle Inspection


Ultrasonic Inspection In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings. Safety valve inspection procedures (IBOP)

z

Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).


4-21

March 8, 2001

4-22


Chapter 2 Lubrication

Lubricating the motor and motor support bonnet assembly Gearbox Check oil daily. With the motor off, check to see that the oil level is at the middle of the sight glass located on the side of the main body. Drain and refill the gearbox every 1,500 operating hours or three months, whichever occurs first. (Refer to Oil capacity later in this chapter.) Properly maintaining the TDS gear shifting mechanism increases the operational life of the top drive. Use the following procedure to maintain proper gear lubrication: 1. Shift all top drive two speed gearboxes from one gear to the other and back again at least once a week. This helps to distribute lubricant and prevents contaminant buildup. 2. Remove the gear indicator lever assembly and the indicator gearcase cover.


4-23

March 8, 2001

3. Repack the inside area with grease every six months (refer to Figures 1-9 and 1-10 in the Description book). 4. Inspect the gears for corrosion or damage. Clean, lubricate or replace components as required. There is a “timing mark” on the gears to ensure correct orientation. If these marks are not visible when removing the gears, mark the gears before removal to ensure correct orientation when reinstalling them. If there are problems shifting from one gear to the other, use the following procedure to shift the gears: 1. Turn the drive stem with chain tongs to make sure the gear mesh aligns properly. Do not turn the DC motor while shifting gears. 2. Insert two 3/8 in. bolts in the threaded holes on the bottom of the shafts while shifting the gears and use a bar to turn the shaft in the proper direction. Do not shear the bolts. Eccentric shaft rotation direction is the same as the shifter input shaft when shifting into gear. 3. If the shift input mechanism slips when attempting to shift gears, use a torque wrench to check the torque of the shifter when the clutch begins to slip. If the torque is less than 65 ft lb, then use the Torque setting procedure to adjust the clutch

e

Gearbox oil must be drained before removing clutch. The factory setting of the clutch is 45 ft lb. However, increase the torque if there are persistent problems. 4. Remove the 3 in. inspection plugs on the rear of the gearcase and make sure the compound gears are free to turn with the unit in neutral. If the gears cannot turn, it indicates a larger problem (i.e., contaminants in gears, damaged bearings, etc.).

4-24


Torque setting procedure Use the following procedure to set the torque limit clutch to 45-50 ft lb: 1. Attach any torque indicator to the output stub (Figure 4-4). 2. Hold the body and determine the current torque setting. 3. Remove the snap ring and locking plate. 4. Use a 5/8 in. open end wrench to turn the nut clockwise to increase torque, or to turn the nut counterclockwise to decrease the torque. 5. Check the resulting torque and repeat the above steps if more adjustment is necessary. 6. Replace the locking plate and snap ring.


4-25

March 8, 2001

A

Gear Subplate

Lower Gearcase

Housing Gear Changer

Gear Shaft Changer

Torque Limiter (Clutch)

Detail A

Torque Limit Clutch

Figure 4-4. Torque setting procedure

4-26


Other gearbox lubrication and maintenance considerations ❏ Keep the bottom of the eccentric gear shafts clean and free of corrosion, paint or other contaminants. Keep this area lightly lubricated with oil. ❏ Contaminant build up or corrosion around the upper end of the eccentric shafts can cause persistent shifting problems. Install sealed caps on the top of the shaft to correct the problem. There are two ways to install sealed caps. One way to install sealed caps requires shop installation during top drive overhaul. There is a kit for field installation (P/N 97926). It consists of a rubber gasket, a sealing cap and a stud which threads into an existing tapped hole in the top of the eccentric shaft. The stud holds the cap on top of the gearcase and keeps contaminants away from the shaft. It also adds a secondary seal between the oil in the gearbox and the DC motor cooling air path.

Initial oil change period Drain and refill the gearbox after the first 500 operating hours or four weeks, whichever occurs first. Remove and clean the oil pump suction strainer (or oil filter, depending on the model and configuration) when changing the oil.


4-27

March 8, 2001

Oil capacity The TDS-4S holds approximately 10-20 gallons of oil, but oil capacities vary according to the type of cooling systems, etc. installed. Always fill the transmission to the middle of the sight glass. Use the following procedure to fill the transmission for the first time on a new top drive: 1. Fill the gearbox to the top of the sight glass (approximately 10-20 gallons). 2. Operate the top drive 10-15 minutes and check the sight glass. 3. The oil level should be near the middle of the sight glass. If the oil level is below the middle of the sight glass, add more oil until the level reaches the middle of the sight glass. If the oil level is at, or above the middle of the sight glass, do not add any additional oil to the gearcase. After installation and initial operation of the top drive, always fill the transmission to the middle of the sight glass. When draining oil from the drain plug at the bottom of the gearcase, only the 5-6 gallons of oil at the bottom of the gearcase actually drains. Oil still remains in the rotating head cavity (approximately 1-2 gallons), the oil lube/pump/cooler system (approximately 1-2 gallons), and the wetted surfaces inside the motor housing assembly (approximately 2-3 gallons). Removing the suction hose from the cover plate below the pinion shaft allows more oil to drain and also removes sediment that collects there. Removing the oil drain plug from the rotating head allows more oil to drain.

4-28


Lubricating the DC motor The upper motor armature bearings have grease points located on the brake adapter plate attached to the top of the motor. The lower armature bearing grease point on the G.E. motor is at the end of a small diameter tube projecting toward the back of the tool. The grease points all have plugs or relief fittings installed during operation. Install grease fittings to lubricate and then remove the fittings and replace the plugs for operation. Lubricate the pinion (transmission) end bearing every 750 operating hours, or three months, with two ounce by weight Shell Cyprina RA™. Lubricate the commutator (brake) end bearing every 1,500 operating hours, or six months, with two ounce by weight Shell Cyprina RA™.

e

Excessive lubrication of electric motors can cause motor failure due to shorting or heat buildup from grease coming in contact with the field windings.


4-29

March 8, 2001

Lubricating the washpipe and bonnet seal Apply grease daily to the washpipe grease fitting and the two bonnet seal fittings (located below the washpipe grease fitting) (Figure 4-5).

Grease Fittings Wash Pipe Assembly

Bonnet

Figure 4-5. Lubricating the washpipe and bonnet seal

4-30


Lubricating the rotating head Apply grease daily at the fittings (Figures 4-6 and 4-7). Inspect for seal leakage weekly around the lower bearing retainer.

Grease Fittings Grease Fitting

Grease Fittings

Figure 4-6. Lubricating the standard rotating head

Grease Fitting

Grease Fittings

Figure 4-7. Lubricating the powered rotating head TDS-4S Maintenance and Troubleshooting

4-31

March 8, 2001

Lubricating the link adapter Apply grease to the link adapter fittings weekly as shown in Figure 4-8.

2 Grease Fittings on front, 2 Grease Fittings opposite. (4 places total)

Figure 4-8. Lubricating the link adapter

4-32


Lubricating the torque wrench Apply grease daily to the torque wrench fittings (Figure 4-9). Inspect the stabbing guide for excessive wear or cracks. Replace as necessary.

Grease Fitting (6 on IBOP Actuator Rollers, Cylinder Pins and Arm Pins)

Grease Fitting (6 on Optional Link Stop and Cylinder Assembly)

Grease Fitting (1 each side of Torque Tube on Clevis Pin)

Grease Fitting (8 on Bottom of Clamp)

Figure 4-9. Lubricating the PH-85 torque wrench TDS-4S Maintenance and Troubleshooting

4-33

March 8, 2001

Lubricating the master bushing ID wear guide The master bushing ID wear guide has four fittings (Figure 4-10). Lubricate weekly. Inspect the guide ring periodically for wear or damage and replace it as necessary.

Master Bushing Wear Guide

Grease Fittings (4)

Figure 4-10. Lubricating the master ID bushing wear guide

Lubricating the safety valve actuator Apply grease daily to the fitting in the crank assemblies (Figure 411). Check for worn components and operate the valve to verify correct adjustment weekly.

4-34


Lubricating the upper safety valve (IBOP) Lubricate the upper IBOP valve weekly at the lubrication fittings located directly below the actuator cranks in the recessed counter bores (Figure 4-11). Refer to the IBOP Service Manual for complete IBOP lubrication instructions.

Open Position

Actuator Shell

Grease Fitting

Crank Arm Grease Port

Actuator Arm Groove

Upper IBOP Valve

Figure 4-11. Lubricating the IBOP


4-35

March 8, 2001

Lubricating the guide dolly assembly Lubricate the 20 guide rollers every trip at the four manifolds (5 fittings each) located on each corner of the guide dolly (Figure 4-12). If your rig has a retract system, refer to the Retract Guide Dolly supplement. Check guide rollers weekly for cracks or excessive axial or radial play and replace as necessary. Lubricate the hinges (one place on each hinge) monthly. It is possible to over-grease (too much pressure, not volume) the guide rollers. This can push the plugs out. Visually inspect all of the guide rollers for evidence of grease extruding from the end(s) of the shaft. If you discover over-greasing, perform the following procedure: 1. Remove and disassemble the roller assembly. 2. Thoroughly clean and inspect all parts. 3. If the component parts are still serviceable, drill and tap the shaft end(s) for 1/8 in. NPT threads and install internal wrenching pipe plugs after thoroughly cleaning metal chips from the grease ports in the roller shaft. 4. Pre-grease roller bearings before reassembling and installing the rollers and shaft. 5. Re-grease roller bearings through grease lines to make sure lubricant is pumping through the roller bearings. Some grease should extrude between the rollers and roller shaft. 6. Replace unserviceable assemblies. 7. Improve plug retention on roller assemblies with intact sheet metal plugs by staking the edges of the port(s). To do this: a. Remove the roller or roller bracket assembly to improve accessibility. b. Use a hammer and chisel to stake the port edges.

4-36


A preferred method is to rework the roller assembly for drill and tap operation, but the staking method is also effective. At each bottom corner of the motor frame are the two grease points for the motor trunnions (Figure 4-13). Lubricate these weekly. Lubricate the washpipe packing daily with the mud pump off. Daily, with the hydraulic power on, check the filter gauge on the pressure filter to determine the condition of the filter element. Replace the element when a bypass condition is indicated.

e

Do not weld or torch cut on or near the motor frame without removing hydraulic accumulators.


4-37

March 8, 2001

Grease Fitting (20)

Grease Fittings

(TDS Removed for clarity) Non-Swing Guide Dolly

Grease Fittings

Figure 4-12. Lubricating the non-swing guide dolly assembly

4-38


Grease Fittings Grease Fitting (20)

Swing Guide Dolly

Grease Fitting

Grease Fitting

Grease Fittings

Figure 4-13. Lubricating the swing guide dolly assembly


4-39

March 8, 2001

Grease Fitting (28)

Grease Fittings

Retract Guide Dolly

(TDS Removed for clarity)

Grease Fittings

Figure 4-14. Lubricating the retract guide dolly assembly

4-40


Lubricating the bail pins Lubricate the bail pins weekly, at the same time the dolly rollers are lubricated, at the two fittings, one on each bail pin (Figure 4-15).

Bail

Bail Pin

Bail Pin

Grease Fitting

Grease Fitting

Figure 4-15. Lubricating the bail pins TDS-4S Maintenance and Troubleshooting

4-41

March 8, 2001

Lubricating the cooling system Lubricate AC blower motors every three months (Figure 4-16). On rigs with closed loop cooling systems (Figure 4-17) also check the heat exchangers for water leakage weekly, and remove the access covers and operate the blower to remove dust buildup every 500 operating hours.

Explosion Proof AC Blower Motor Grease Fitting Grease Fitting Motor Cooling Blower

Transmission Cooler

Figure 4-16. Lubricating the local cooling system

4-42


Explosion Proof AC Blower Motor

Grease Fitting

Motor Cooling Blower

Heat Exchanger

Grease Fitting

Motor Cooling Blower

Heat Exchanger

Figure 4-17. Lubricating the closed loop cooling system


4-43

March 8, 2001

Lubrication schedule Frequency Daily Daily Daily Daily Daily Daily Daily

Location Bonnet seal Torque wrench (PH-85) Gearbox oil (check level) Rotating head Safety valve actuator cranks Hydraulic pressure filter † Wash pipe assembly

Lubricant code* 1 1 2 1 1 – 1

Number of points 2 6 1 5 2 – 1

Each trip Each trip

BNC drill pipe elevator Guide dolly rollers (Retract ‡)

1 1

7 20

Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly Weekly

Gearbox (shift gears) Dolly motor trunnions Air filter/regulator/lubricator † IBOP actuator arms Link adapter (650-Ton) Elevator support Master bushing wear guide Link tilt (check condition) Bail pins

1 – 1 1 1 1

2 – 6 4 7 4

1

2

750 hrs/90 days 1,500 hrs/6 mos.

GE drilling motor pinion bearing GE drilling motor commutator bearing

3 3

Monthly Monthly

Motor frame/dolly hinges (Retract ‡) Cooling system cleaning

1 –

4 –

3 months 3 months 3 months

AC blower motor Change gearbox oil Gear oil filter/suction strainer †

1 2 –

2 1 1

* See Table 4-1, Recommended lubricants † Check condition and replace as necessary ‡ Refer to Retract Guide Dolly supplement

e

4-44

Use only 10-wt. hydraulic oil or non-detergent motor oil as a lubricant in the air control system. Using any other type of oil or synthetic additive causes the seals in the air valves to swell and cease to function.


Lubricant specifications TDS-4S 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, and a minimum viscosity of 100 SUS at operating temperature. Varco top drives also operate under a wide variety of temperatures. Select lubrication for the TDS based on the minimum ambient temperature to be expected before the next oil change. Under all but the most severe operating conditions, Varco recommends changing the oil every three months. Introducing an oil viscosity greater than required by the ambient temperature can: ❏ Damage the gearbox due to reduced oil flow ❏ Damage the oil pump because of excessive load All oils change viscosity with temperature and EP oil is no exception. The TDS transmission lubrication system is limited to pumping oils of a maximum of 9,000 SUS viscosity. Varco recommends measuring the oil temperature with a contact thermometer. Measure on the pump discharge fitting on the TDS. The following tables will aid in your lubricant selection and keep your TDS-4S transmission operating properly: Minimum ambient temperature °F °C

Oil type required

Varco P/N

Below 20°

-6°

See note below

See note below

20° to 60°

-6 to 16°

2EP, ISO 68

56004-1

45° to 85°

7° to 30°

4EP, ISO 150

56004-BSC

Above 70°

21°

6EP, ISO 320

56004-2

z

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.


4-45

March 8, 2001

If the oil temperature falls below 20°F, Varco recommends running the TDS at very light loads (less than 100 Amps) until the oil is 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. Table 4-1. Recommended lubricants Lube Code and Description

Ambient temperature range

2

General Purpose Grease

Gear Oil

Above -4°F (-20°C)

Below -4°F (-20°C)

Above 70°F (21°C)

45° to 85°F (7° to 30°C)

20° to 60°F (-6° to 16°C)

Castrol

MP grease

-

Alpha LS-320

Alpha -150

Alpha LS-68

Chevron

Avi-Motive

Avi-Motive W

NL Gear 320

NL Gear 150

NL Gear 68

Exxon

Lidok EP2

Lidok EP1

Spartan EP320

Spartan EP150

Spartan EP68

EP Lube HD320

EP Lube HD150

EP Lube HD68

Gulf

4-46

1

Gulf Crown EP32 Gulf Crown EP31

Mobil

Mobilux EP2

Mobilux EP1

MobilGear 632

MobilGear 629

MobilGear 626

Shell

Alvania EP2

Alvania EP1

Omala 320

Omala 150

Omala 68

Statoil

Uniway EP2N

Uniway EP1N

Loadway EP320

Loadway EP150

Statoil

Texaco

Multifak EP2

Multifak EP1

Meropa 320

Meropa 150

Meropa 68

Total

Multis EP2

Multis EP1

Carter EP 320

Carter EP 150

Carter EP 68

Union

Unoba EP2

Unoba EP1

NGLI

2

1

-

-

-

AGMA

-

-

6EP

4EP

2EP

ISO Viscosity Grade

-

-

320

150

68


Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP

Table 4-1. Recommended lubricants (continued) Lube Code and Description

Ambient temperature range

3

4

5

Motor Grease

Hydraulic Oil

Bio-degradable

All temperatures

14° to 185°F (-10° to 85°C)

5° to 167°F (-15° to 75°C)

N/R

Hyspin AWS-46

Hyspin AWS-32

Black Pearl

AW Hyd oil 46

AW Hyd oil 32

Exxon

N/R

Nuto H46

Nuto H32

Gulf

N/R

Harmony 46AW

Harmony 32AW

Mobil

N/R

DTE 25

DTE 24

Shell

N/R

Tellus 46

Tellus 32

Statoil

N/R

Hydraway HMA 46

Hydraway HMA 32

Texaco

N/R

Rando oil HD46

Rando oil HD32

Total

N/R

Azolla ZS 46

Azolla ZS 32

Union

N/R

Unax AW46

Unax AW32

NGLI

2

-

-

AGMA

-

-

-

ISO Viscosity Grade

-

46

32

Castrol Chevron


4-47

March 8, 2001

4-48


Chapter 3 Maintenance

Adjustment procedures Adjusting the torque wrench Use the following procedure to adjust the pipehandler torque wrench:

e

The pipehandler torque wrench is properly adjusted and tested in the factory before it is shipped. Perform the adjustment procedure after performing maintenance on the torque wrench or if the torque wrench does not function correctly. 1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight. Be sure to use the correct thread compound when making up.

z

When adjusting torque wrench manifold needle valves, loosen the locknut around the valve stem and use a 5/32 in. hex wrench to adjust the valve. After obtaining desired setting tighten locknut around valve stem.


4-49

March 8, 2001

2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUE sequence valves on the torque wrench manifold fully in (Figure 4-18). 3. Fully back out the Pressure Reducing Valve (PRV), then screw in one turn. 4. Turn the LIFT/LOWER flow control valve fully in, and then back it out three turns. 5. Turn on the HPU. 6. If the torque cylinders are in their full clockwise position, set the Make/Break valve to MAKE. If they are in their full counterclockwise position, set Make/Break valve to BREAK. Note that torque cylinders should not move if the recycle sequence valve is fully in. 7. Slowly back out the RECYCLE sequence valve until torque cylinders just start to move, then screw out an additional full turn.

Make/Break Valve

Recycle Sequence Valve

Clamp Sequence Valve

Torque Sequence Valve

Torque Wrench Manifold

BREAK

MAKE

Hydraulic Pressure Return RECYCLE

CLAMP

TORQUE

PRV

50

60

40

30

1000

1500

70

80

Hydraulic Pressure Inlet

20

LIFT LOWER

500

2000

90

10 0

PSI Ft.Lbs.

Torque Gauge 0 - 2500 PSI

Figure 4-18. Torque wrench control manifold 4-50

®

2500

0


x1000

10 0

Lift/Lower Flow Control Valve

8. Move the Make/Break valve to BREAK. Set the PRV to 750 psi. 9. Switch the lever between MAKE and BREAK to adjust the RECYCLE sequence valve until full rotation in each direction takes six to eight seconds. Tighten the locknut around the RECYCLE sequence valve adjustment screw. 10. Set the Make/Break valve to MAKE. 11. Depress and hold the torque wrench operating button on the VDC. The torque wrench should lift and the clamp jaws should remain retracted. 12. Slowly back out the CLAMP sequence valve until the clamp jaws just begin to clamp onto the tool joint. Screw out an additional half turn. Lock the CLAMP sequence valve adjustment screw in position by tightening the locknut. 13. Back out the TORQUE sequence valve until the torque cylinders just begin to stroke, then back out an additional half turn. Tighten the locknut around the TORQUE sequence valve adjustment screw. 14. Release the torque wrench operating button on the VDC. The torque wrench should start to unclamp and drop, then the torque cylinders should recycle. 15. If the torque cylinders recycle before the clamp cylinders retract, screw in the RECYCLE sequence valve until the torque cylinders do not move before clamp cylinders have fully retracted. Tighten the RECYCLE sequence valve adjustment screw locknut. 16. Cycle the torque wrench as many times as required to makeup the connection. 17. Set the Make/Break valve to BREAK. 18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub, without breaking out the saver sub or lower IBOP. 19. The torque wrench is ready for operation.


4-51

March 8, 2001

Adjusting the upper safety valve (IBOP) and safety valve actuator system Refer to the IBOP Service Manual for upper IBOP and safety valve actuator system adjustment procedures.

Adjusting the counterbalance system Leave the HPU on during the entire adjustment procedure, and disconnect the TDS from the drill string near the bottom of the rails, but well off the stops. 1. Remove the caps and loosen the lock nuts on the needle valve and PRV located on the counterbalance manifold (Figure 419). It is not necessary to remove the front guard for access to the manifold. A small amount of oil will leak around the adjusting stems after removing the caps. 2. Open the needle valve and let the stem circulate for two minutes. Crack both upper cylinder fittings and bleed air from system. Tighten the fittings. Close the needle valve. 3. Using a hex wrench, screw in the PRV until the cylinder retracts, raising the TDS. 4. Slowly back out the PRV. The pressure decreases and the cylinder rods begin extending. When the integrated swivel bail contacts the hook, note the pressure on the gauge. Allow the pressure to decrease an additional 25 psi and tighten the locknut. Replace the caps on the valve adjustment stem.

4-52


Needle Valve (on opposite side)

Upper Motor Frame Crossmember

Pressure Reducing Valve

Pressure Gauge

Figure 4-19. Counterbalance manifold


4-53

March 8, 2001

Adjusting the motor alignment cylinder system Once the alignment cylinder is installed, use the following procedure to properly adjust the motor alignment before operating TDS systems that have a separate alignment cylinder accumulator and valve manifold. 1. With the HPU turned off, bleed down the alignment cylinder accumulator by opening the needle valve located at the alignment cylinder valve manifold (Figures 4-20 and 4-21). 2. Remove the split shipping brace from the motor alignment cylinder (Figure 4-22). 3. Turn on the HPU and allow the system to circulate for approximately two minutes. 4. Close the needle valve. 5. Open the two flow control valves located at the alignment cylinder supply return lines 1-1/2 turns off their seats.

4-54


Alignment Cylinder Lug (ref) Pressure Reducing Valve

Needle Valve

Motor Frame (ref)

Alignment Cylinder Manifold Accumulator

Bracket Gas Valve

Figure 4-20. Typical motor alignment cylinder valve manifold


4-55

March 8, 2001

Prefill Valve Assembly

Directional Control Valve (Operation Switch) Pressure Reducing Valve (PRV)

Needle Valve

Motor Frame (ref)

Alignment Cylinder Valve Manifold

Bracket Gas Valve Accumulator

Figure 4-21. Motor alignment cylinder valve manifold

4-56



Shipping Brace




4-57

March 8, 2001

z

The pressure setting is adjusted by screwing the PRV in or out with a hex wrench (Figure 4-19). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the PRV reduces pressure and moves the saver sub away from the rails (see additional notes at the end of this procedure). 6. Verify the correct pressure setting using the following procedure: a. With the HPU on, back down the pressure using the PRV until the saver sub begins to pivot away from the rails. Record this pressure. b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a “dead band” area. c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs. d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by two. The resulting pressure “dead band” provides equal pre-load in each direction – both toward and away from the rails. e. Record the pressure setting for future reference. 7. Set a joint of drill pipe in the slips. 8. Bring the top drive down as if stabbing the saver sub into the box. The pin and the box should be in alignment so that the OD of the pin clears the shoulder of the box. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box. b. Turn off the HPU and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame. c. Loosen the lock tab and jam nut on the cylinder clevis.

4-58


d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4 in. of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2 3/8 ± 1/8 in. gland to rod threads when the system is properly aligned. e. Secure the jam nut and lock tab. f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2 in. of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats. g. Tighten the lock nuts and replace the caps on all valve stems.

z

If the alignment cylinder is removed for service, install the alignment cylinder replacement brace to support the motor housing assembly while continuing to operate the TDS. After reinstalling the alignment cylinder, use the three bleed holes (located along top of cylinder barrel) to remove air trapped in the cylinder. Rail spacing and setback from the centerline of the well must be held within recommended tolerances in order to maintain vertical alignment of the TDS.


4-59

March 8, 2001

Precharging the counterbalance system Please read these instructions completely before precharging, making note of the special cautions at the end of the section. 1. Use an inert gas such as nitrogen for precharging accumulators. If oil-pumped is not available, use dry, waterpumped nitrogen gas. 2. Before precharging, make certain: a. The accumulator end caps are screwed flush into the accumulator body. b. The gas valve is screwed in tight. c. No oil remains trapped in the top end of the accumulator. 3. Remove the gas valve protector and the gas valve cap. 4. Attach the charging hose to the nitrogen bottle and to the gas valve using the following procedure: a. Use thread sealing and lubricating compound on the pipe threads of the gauge. b. Back the gas chuck stem completely out of the way before attaching the assembly to the accumulator gas valve. c. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the bleeder valve. d. Turn the gas chuck stem all of the way down, depressing the core in the accumulator gas valve. e. Only crack open the nitrogen bottle valve to slowly fill the accumulator. Shut it off when the gauge indicates 900 psi. f. If the 900 psi precharge pressure is exceeded, make sure the nitrogen bottle valve is closed, then open the bleeder valve (opposite the gas valve below the gauge) slightly, but only momentarily, to reduce pressure. g. Before loosening the swivel nut, turn the gas chuck stem out all of the way, then open the bleeder valve. h. Prevent the gas valve from turning, loosen swivel nut, and remove the assembly. 5. When precharging is complete, replace the cap on the gas valve and install the gas valve protector.

4-60


e

Do not loop or twist hose as it stiffens when gas pressure is released from nitrogen bottles. Never loosen the swivel nut attached to the gas valve in the accumulator without first backing the gas chuck stem all of the way out. Do not reduce accumulator precharge by depressing valve core (high pressure may rupture rubber valve seat). Instead, slowly turn gas valve out until gas begins to escape through bleed hole drilled through threads of valve. This hole is a safety feature, it warns of stored pressure whenever gas valve is being removed. Install new gas valve O-ring each time gas valve is removed.


4-61

March 8, 2001

Assembly and disassembly Pipehandler Torque wrench disassembly For PH-85, see Figures 4-23, 4-24, 4-25, and 4-26. For PH-60d, see Figure 4-27. 1. Remove the guard. 2. Disconnect the hard plumbing from the quick disconnects near the left torque cylinder. 3. Remove the bolts holding the frame onto the cast body and lift off. 4. Remove the pins holding the torque tube in place and remove. 5. Disconnect and label the hoses from the torque cylinders and remove the cylinders. 6. Disconnect and label the remaining plumbing, and remove the Make/Break manifold assembly. 7. Remove the jaws. 8. Remove the stabbing guide. 9. Remove the retaining bolts, hinge pins and outer body. 10. Remove the cylinder ring from the clamping piston bore. 11. Pressurize the blind end of the clamping cylinder to remove the gland and piston.

e

4-62

Use care in this operation. High pressure air can be explosive.


Torque Tube

V a r c o

Torque Cylinders

Figure 4-23. PH-85 torque wrench assembly/disassembly


4-63

March 8, 2001

Clamping Jaws

Body

Clamp Cylinder Body

Clamp Cylinder Pistons

Stabbing Guide


4-64


Mounting Shaft

Frame

Safety Valve Actuating Cylinder (2)

Vertical Positioning Cylinder

Hanging Height Adjustment

Guard



4-65

March 8, 2001

Figure 4-26. PH-85 torque wrench assembly/disassembly (optional link retractor)

4-66


Frame

Mounting Shaft Safety Valve Actuating Cylinders (2)

Vertical Positing Cylinder

Safety Valve Actuating Arm (2)

Torque Tube Stabilizer

Stop Tube

Hanging Height Adjustment Shim

Torque Tube

Guard

Body Torque Cylinder (2)

Clamp Cylinder Body

Stabbing Guide

Clamping Jaws (2)

Clamping Cylinder Piston Control Manifold

Figure 27. PH-60d torque wrench assembly/disassembly


4-67

March 8, 2001

Reassembly is accomplished in the reverse order of the above procedure. Pay close attention to the following points: 1. Replace all seals. 2. Take great care when installing the clamping piston and gland. If they are not closely aligned with the bore, they may become jammed and could be extremely difficult to remove. 3. Use the following torque values: Cylinder rod end to cylinder rod* 944 ft lb Frame to clamp cylinder body 250 ft lb Stabbing guide to body 250 ft lb Die retainer screws 380 ft lb Body hinge pin retainer screws 150 ft lb Stabbing guide spring retainer screws 75 ft lb Jaw retaining screws 110 ft lb *The torque cylinder rod ends are threaded into the rods with locktite and cross pinned. Replacing the torque wrench clamping piston seal

The following procedures require that the torque wrench be removed from the pipehandler. Replacing the front and rear piston seals

Parts required front and rear piston seal replacement: Qty. 3 2 2

P/N 72219 72220 72221

Description Piston seal Rod seal Rod wiper

Disassembly

1. Remove the slotted hex nut and cotter pin attaching the two halves of the stabbing guide together at the front and swing the guides out to each side. 2. Vent the clamping cylinder as follows: disconnect the hydraulic lines to the clamp port and front unclamp port on the clamp body cylinder at the torque wrench manifold clamp and unclamp ports.

4-68


3. Remove the jaw pins from the rear clamping jaw and remove the jaw. 4. Remove the two screws holding the jaw spacer to the front clamp cylinder piston and remove the spacer and jaw spacer. 5. Remove the two screws holding the clamp clevis to the rear clamp cylinder piston. 6. Remove the pins holding the clamp body to the clamp clevis and remove the clamp clevis. Be sure to remove the spacer from the piston rod slot. 7. Push in the cylinder gland from the rear cylinder head retainer ring and remove the ring with a screwdriver. 8. Attach the sliding hammer to the rear piston rod and carefully pull the piston until the cylinder gland can be removed. 9. Continue to pull until the piston comes out. 10. Using a piece of wood or brass bar, tap the front clamp piston from the front and remove it from the rear. 11. Remove and discard the piston seals, rod seals, and rod wipers. 12. Remove the front piston rod seal and rod wiper from the clamp cylinder body and discard. 13. Inspect the clamp cylinder bore thoroughly for dirt, burrs, nicks, gouges, and pitting. Repair and clean as necessary. Assembly

1. Insert a new front rod seal and rod wiper in the clamp cylinder body and lubricate with clean hydraulic fluid. 2. Install a new piston seal in the front piston groove and lubricate with hydraulic fluid. 3. Insert the front piston into the clamp cylinder body with the two jaw spacer screw holes orientated vertically. 4. Gently and evenly tap the piston into place until the rod appears beyond the front cylinder bore.


4-69

March 8, 2001

5. Install a new piston seal in the rear piston groove and lubricate with hydraulic fluid. 6. Insert the rear piston into the clamp cylinder body with the two screws holes on the rod oriented to the horizontal position. 7. Gently tap piston into place until there is enough space between the piston face and retaining ring groove to insert cylinder gland and retainer ring. 8. Install the rod seal and rod wiper in the inside grooves of the cylinder gland. 9. Install the piston seal in the outside groove. 10. Lubricate all seals with hydraulic fluid. 11. Insert cylinder gland into the bore rod and piston seals first. Push the gland past retainer groove and install the retainer ring. 12. Insert the spacer and attach the clamp clevis to the rear cylinder rod with the two hex head cap screws and flat washers. Tighten firmly and lockwire. 13. Adjust orientation of the clamp clevis and attach to the clamp body using the two clevis pins and cotter pins. 14. Attach the rear clamping jaw spacer to the front piston rod using the spacer and two hex head cap screws and flat washers. Tighten firmly and lockwire. 15. Attach the clamping jaw with the two jaw pins. 16 Swing the stabbing guide back into position and attach with the slotted nut and cotter pin. 17. Reconnect the hydraulic lines from the clamp body cylinder clamp port and front unclamp port at the torque wrench manifold clamp and unclamp ports. 18. Reinstall and adjust the torque wrench (refer to Adjusting the torque wrench earlier in this chapter).

4-70


Replacing the standard rotating head glyd rings

z

Rotary glyd ring replacement is indicated when hydraulic oil is detected in the pipehandler air supply. An indication of oil contaminating the air supply would be an accumulation of oil in the link tilt air actuator (bag). The following disassembly and assembly procedures assume that the TDS is swung out for maintenance in accordance with the TDS swing out procedures (refer to TDS swing out procedure in Chapter 1 of this book). Refer to Figures 4-28 and 4-29, when performing the following procedures.

Cam

Stationary Flange

Cam Follower

Locking Lever




Figure 4-28. 650-Ton rotating head assembly


4-71

March 8, 2001

Disassembly

1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Push the cam follower away from the rotating block cam. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange. 15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket. 4-72


Cam Assembly Locking Handle

Return Cylinder

Return Cylinder Clevis Pin

Return Cylinder Rod End Detail Hex Nut

;;;;

Cotter Pin

Cam

;;;;;; ;;;;;; ;;;;;; ;;;;;; C;;;;;; ;;;;;; ;;;;;; ;;;;;; Cylinder Clevis

Excluder Cap

Detail Retainer Ring

Ball Bearing Glyd Ring (8)

Excluder Cap Gasket

Cam Ball Bearing

C Stationary Flange

Bull Gear Lip Seal

Figure 4-29. Replacing the 650-Ton rotating head glyd rings


4-73

March 8, 2001

Assembly

1. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the quick disconnect hydraulic fittings on the rotating block. 7. Attach the return cylinder rod to the clevis with the clevis pin and install the slotted hex-head nut and cotter pin. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book.

4-74


Replacing the powered rotating head glyd rings Refer to the assembly drawings when performing the following procedures. Disassembly

1. Order eleven replacement glyd rings, two gearcase seals, one flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco Service Center for details about building an appropriate stand for working on the rotating head when removed from the TDS for service or maintenance. 2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the various pipehandler components. 3. Support the torque wrench. 4. Disconnect the IBOP actuator arms and hoses. 5. Remove the pin attaching the hanger to the rotating block clevis, and remove the torque wrench. 6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating block. 7. Remove the torque arrestors, link tilt, and link adapter. 8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests on the stand. 9. Remove the flange nuts and lift the block, leaving the rotating head on the stand. 10. Remove the quick disconnect fittings from the rotating block hydraulic lines and drain the hydraulic fluid from the system. 11. Remove the cotter pin from the return cylinder clevis pin. 12. Remove the hex-slotted nut and remove the clevis pin. 13. Remove the hydraulic motor assembly. 14. Remove the safety wire from the ten hex-head screws attaching the rotating block to the stationary flange.


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March 8, 2001

15. Support the rotating block and remove the ten screws. 16. Remove the rotating block and glyd rings. 17. Remove the excluder cap and gasket. 18. Remove the glyd rings from the rotating block and discard. 19. Remove excluder cap gasket and replace with new gasket. Assembly

1. Lubricate the eleven new glyd rings with hydraulic fluid and insert them into the glyd ring grooves inside the rotating block. 2. Place the excluder cap and gasket on the bottom of the rotating block. 3. Using a tugger or other support, carefully mate the rotating block to the stationary flange. 4. Reinstall the ten hex-head screws and torque to 250 ft lb. 5. Safety wire the screws per standard safety wire procedures. 6. Reinstall the QD hydraulic fittings on the rotating block. 7. Reinstall the hydraulic motor assembly. 8. Reinstall the pipehandler components per the procedures detailed in the Installation and Commissioning book.

4-76


Replacing the standard or extended reach link tilt air actuator The link tilt mechanism has two air actuators. Use the following procedure to replace one air actuator (Figures 4-30 and 4-31). Parts required:

One air actuator (P/N 82353) 18 Button head cap screws (P/N 50186-10-01)

Disassembly

1. Disconnect the air hose from the rotating head rotating block to the link tilt assembly. 2. Support the link tilt and remove the two upper and two lower screws attaching the link tilt to the link adapter. 3. Lower the link tilt to the floor with the air actuator to be replaced facing up. 4. Remove the cotter key and pin from one end of chain connecting the two sealing plates. 5. Remove the safety wire from the four hex-head cap screws holding the air actuator sealing plate to the link tilt base or lever and remove the screws. 6. Lift the lever or base off the air actuator sealing plate, and rotate it 180° on the link tilt pivot pin and lay down. 7. Remove the nuts and washers holding the sealing plate to the air actuator and remove the plate. 8. Using a pry bar or screwdriver, pry the air actuator away from the screws, attach the actuator to the hanger plate and remove the screws using a hex wrench. 9. Remove and discard the air actuator. 10. Remove any burrs or gouges on sealing surfaces of the hanger and sealing plates.


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March 8, 2001

Lever Weldment Pivot Pin Sealing Plate (2)

Nuts, Lock Washers (18)

Pressure Regulator

Air Actuator Base

Sealing Plate Bolt (4) Quick Exhaust Valve Lever Intermediate Stop (2)

Connecting Chain Buttonhead Capscrew (18)

Stop Pivot Arm Elevator Link (Ref) Stop Release Loop

Figure 4-30. Standard reach link tilt assembly/disassembly

4-78


Lever Weldment Pivot Pin Sealing Plate (2)

Nuts, Lock Washers (18)

Pressure Regulator Hanger Plate Air Actuator (2)

Sealing Plate Bolt (4)

Base

Quick Exhaust Valve Lever Intermediate Stop (2)

Connecting Chain Stop Pivot Arm Elevator Link (Ref)

Stop Release Loop

Figure 4-31. Extended reach link tilt assembly/disassembly


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March 8, 2001

Assembly

1. Place a new actuator on the hanger plate. 2. Attach the air actuator to the hanger plate with the 18 buttonhead cap screws. Coat the screw threads with locktite before installation.

e

The air actuator has aluminum neck bead rings on both sealing surfaces. These beads must be compressed equally to ensure a good air seal. This requires more than one tightening pass to accomplish. Over-torquing may cause hex sockets to strip. 4. Torque the cap screws to the hanger plate at 80 ft lb. 5. Insert the 18 bolts into the neck ring of the air actuator. 6. Reinstall the air actuator sealing plate, coat the bolt threads with locktite and fasten with the lockwashers and nuts provided. 7. Torque the nuts to the sealing plate at 80 ft lb. (See Caution above.) 8. Lift and rotate the link tilt lever or base to line up with the air actuator sealing plate. Attach with the four hex-head cap screws and torque to 250 ft lb. 9. Safety wire the four screws. 10. Reconnect the chain between the two sealing plates. 11. Reinstall and adjust the link tilt per the Installation and Commissioning book.

4-80


Removing the tong dies Front jaw 1. Remove the cotter pin from the retaining bolts and slotted nut. 2. Remove the nuts securing the die retainer to the jaw. 3. Remove the die retainer from the jaw. 4. Remove the tong dies from the jaw.

Rear jaw 1. On the rear jaw, remove the cotter pins from the retaining bolts and slotted nuts. 2. Support the retaining bolt while removing the slotted nut. 3. Remove the retaining bolt from the piston jaw. 4. Support the remaining retaining bolt while removing the slotted nut and upper die retainer. 5. Remove the retaining bolt and lower die retainer. 6. Remove the tong dies from the jaw.


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March 8, 2001

Removing the jaws Front jaw 1. Loosen the socket head cap screws securing the jaw assembly to the torque wrench body. 2. Support the jaw and remove the socket-head cap screws and washers from the jaw assembly and the torque wrench body. 3. Remove the front jaw assembly from the torque wrench body.

Rear jaw 1. Loosen the socket head cap screws securing the jaw assembly to the piston. 2. Support the jaw assembly and remove the socket-head cap screws and washers from the jaw assembly and piston. 3. Remove the rear jaw assembly from the piston.

Upper safety valve (IBOP) Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures.

Lower safety valve (IBOP) Refer to the IBOP Service Manual for IBOP valve assembly and disassembly procedures.

4-82


Removing the motor assembly from the guide dolly You can perform some service procedures on top drives (i.e. upper drive stem bearing and seal, air brake or locally mounted cooling system) without removing the drilling motor assembly from the dolly. If service is required on the lower end (i.e. gear set, lower bearings or seals), the drilling motor must be removed from the dolly. 1. Set the TDS down horizontally on a good flat surface. 2. Make sure none of the components protrude past the guide dolly roller brackets before setting the TDS down. If so, block up the guide dolly accordingly. 3. Disconnect all wiring and hoses between transmission and guide dolly frame. 4. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with removing the transmission from guide dolly frame. 5. Use a suitable sling to support the weight of the TDS and motor support bonnet (approximately 10,000 lb). 6. Take up the slack and remove the trunnion blocks that hold the transmission to the guide dolly frame. 7. Hoist the transmission out of the guide dolly frame. 8. Set the TDS and motor support bonnet down on wooden chocks, being careful not to damage components. 9. Disconnect the wiring between the motor and motor support bonnet. 10. Make sure the transmission is in neutral. 11. Remove the dowel pins in the motor feet. 12. Remove the four large motor bolts. 13. Lift the transmission off of the motor, angling the upper end slightly to clear the motor support bonnet, and sliding the housing off of the motor toward the gearcase 14. Remove the blower and brake assemblies. 15. Reverse this procedure for reassembly. TDS-4S Maintenance and Troubleshooting

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March 8, 2001

Disassembly/assembly of the drilling motor and motor support bonnet 1. Remove the upper bearing cover and grease seal (Figure 4-32). 2. Pressurize the air brake to hold the drive mechanism in place. 3. Remove cotter pins, slotted nuts and the rotating head. 4. Remove the lower gearcase, carefully avoiding damage to the lower gearcase locator dowel pins. 5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear sleeves. Do not remove the gear from the shaft unless you are replacing it. 6. Remove the pinion seal and retaining ring. 7. Remove the main body. 8. On the opposite end of the motor, remove the magnetic pickup and brake cover. 9. Remove the brake for service.

4-84


Main Body Air Brake

Low Gear Assembly

DC Drilling Motor

Bull Gear

High Gear Assembly Pinion Gear Manual Shifter Input

Geneva Mechanism

HI

Shaft LO

Oil Level Sight Glass

Motor Pinion Seal

Lower Gear Case Motor Alignment Cylinder

Gear Selection Indicator

Figure 4-32. Drilling motor and motor support bonnet assembly/disassembly


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March 8, 2001

Refer to the GE Electric Motor Manual for procedures to remove the pinion or hub on the armature shaft, or to service the motor itself. Once the unit has been disassembled, inspect the following assemblies for any wear or damage that may be critical: 1. Gear set: Check the teeth and splines for chips or heavy wear. The wear pattern should be even and symmetrical. If not, replace it. Expect some small surface pitting. It is not cause for replacing the gear set. 2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness during rotation. 3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear exceeds 0.090 in. 4. Main shaft: Check fit to bull gear, wear sleeve surfaces, and retaining threads. 5. Seals: Always replace seals and gaskets when removed. 6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the lower gearcase are critical. Clean up any nicks or gouges prior to reassembly. 7. Air brake: Check the brake for air leakage and the pads for wear. 8. Wear sleeves: These should be free of any imperfections on the sealing surface. 9. Blower: Clean any accumulation of dust from the ducting, then operate the unit and correct any interference between the impeller and housing. 10. Air valve assembly: If any air-operated systems are malfunctioning, remove the appropriate valve and repair or replace. Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. Replace all grease seals and O-rings, and refer to the following torque chart for bolt tightening guidelines.

4-86


Torque Chart Motor support/bonnet to main body Main body to motor support/bonnet Bull gear to hub Lower gearcase to main body Rotating head to lower gearcase Brake adapter ring to motor Brake to brake adapter plate Brake drum to hub Brake cover to brake

1100 ft lb 1100 ft lb 580 ft lb 250 ft lb 250 ft lb 250 ft lb 50 ft lb 250 ft lb 50 ft lb

Installing the TDS motor pinion

n

Installing a pinion gear can be dangerous to personnel installing it as well as anyone witnessing the procedure. Exercise caution at all times. Use the following procedure to install a TDS motor pinion: 1. Clean the motor shaft by hand and cover with a thin layer of Engineer’s Blue. 2. Firmly install the pinion on the motor shaft by hand. Mark reference lines on the pinion and the shaft to ensure identical angular orientation each time. 3. There must be a minimum of 75% surface contact between the pinion and motor shaft. Dress the motor shaft/pinion very lightly with a fine emery cloth and repeat the “blueing” procedure if necessary until there is at least 75% surface contact between the pinion and motor shaft. 4. After thoroughly cleaning all blueing, oil, and/or grease from the pinion bore and shaft, trial mount the cold pinion gear on the motor shaft, lining up the reference marks.


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March 8, 2001

5. Make sure the fixture is clean and the “horse shoe” face and bar are parallel. 6. Place the fixture on the motor shaft with the “horse shoe” end against the inner face of the gear and the bar against the outer face of the gear, sandwiching the pinion gear in the fixture. 7. Adjust the adjusting screw to butt against the end of the motor shaft. 8. Attach a calibrated dial indicator gauge to the fixture and set to zero. 9. Back off the adjusting screw until the gauge reads 0.0720.074 in. Then lock the screw in place with a locknut. 10. Remove the fixture from the pinion gear assembly.

e

Do not put the fixture in the oven. 11. Heat the pinion gear to 360-385°F (182-196°C) for three hours in an oven. After heating for three hours, remove the pinion gear assembly and immediately attach the fixture. 12. Place the pinion gear assembly and fixture on the motor shaft, lining up the reference marks. 13. Gently tap the pinion gear assembly and fixture into place until the adjusting screw butts against the motor shaft. 14. Wait 2-3 minutes and back off the nuts holding the fixture in place. There may be some noise as the pinion gear cools. 15. The pinion creeps up the shaft as it cools to the required position of 0.085 ± 0.005 in. advancement. 16. When the pinion is fully cooled, fit the fixture and check final advancement. 17. Complete the required documentation recording pinion advancement.

4-88


Local blower cooling system assembly/disassembly Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-33): 1. Remove the electrical wires from the blower motor. 2. Remove the eight bolts on each side connecting the ducts to the blower housing ducts. 3. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. 4. Remove the four bolts connecting the blower mount to the brake cover. 5. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. 6. Remove the blower inlet ducts on both sides of the blower motor. 7. Remove the taper lock bushings from both blower impellers. 8. Remove both blower impellers. 9. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. 10. Remove the shaft seal assemblies from both sides. 11. Remove the blower housing and inner plate assemblies as units from both sides. Do not separate the blower housing assemblies from the inner plates. 12. Unbolt the four bolts connecting the blower motor feet to the blower mount. 13. Lift the motor out.


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March 8, 2001

Axial Fan 20 hp Blower Motor

Transmission Cooler

Locking Key Oil Fittings (2)

Blower Housing Gasket

Mounting Brackets (2) Blower Impeller Taper Lock Bushing Gasket Flex Duct Connection Point Mounting Plate

Blower Duct to AC Drilling Motor

Spark Arrestor

Figure 4-33. Typical local blower cooling system assembly/disassembly

4-90


Use the following procedure to install a new motor in the local cooling system: 1. Install wear sleeves on the blower motor shaft. 2. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 3. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Use two 3/8 in. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. b. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. 4. Install shaft seal assemblies inside both blower housing assemblies. Make sure the seals are centered. 5. Tighten and safetywire the retainer plates in place on both sides. 6. Install the impellers and taper lock bushings on both sides and safetywire the bolts. 7. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. 8. Hoist the entire cooling system assembly onto the TDS. If the alignment holes were properly used, the cooling system assembly should line up perfectly on the TDS. 9. Install and safetywire the four bolts connecting the blower mount to the brake cover. 10. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. 11. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 12. Connect the electrical wires to the blower motor.


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March 8, 2001

Closed loop cooling system assembly/disassembly Use the following procedure to remove the blower motor in the local blower cooling system (Figure 4-34): 1. Remove the electrical wires from the blower motor. 2. Remove the eight bolts on each side connecting the ducts to the blower housing ducts. 3. Remove the four bolts on each side connecting the duct housing to the blower inlet ducts. 4. Remove the four bolts connecting the blower mount to the brake cover. 5. Hoist the blower assembly off of the TDS and place on a clean work space on the derrick floor. 6. Remove the blower inlet ducts on both sides of the blower motor. 7. Remove the taper lock bushings from both blower impellers. 8. Remove both blower impellers. 9. Remove the bolts connecting the blower housing assemblies on both sides to the blower mount. 10. Remove the shaft seal assemblies from both sides. 11. Remove the blower housing and inner plate assemblies as units from both sides. Do not separate the blower housing assemblies from the inner plates. 12. Unbolt the four bolts connecting the blower motor feet to the blower mount. 13. Lift the motor out.

4-92


Dual Shaft 20 hp AC Blower Motor

Blower Mount/ Brake Cover Blower Housing (2)

Impeller (2)

8 in. Flex Connection (2)

Blower Inlet (2)

Water Connections

DC to Motor Exhaust Port on Upper Gear Case Inspection Cover

GE Drilling Motor Heat Exchanger (2)

Figure 4-34. Typical closed loop cooling system assembly/disassembly


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March 8, 2001

Use the following procedure to install a new motor in the local cooling system: 1. Install wear sleeves on the blower motor shaft. 2. Bolt the blower motor onto the blower motor mount and safetywire the bolts. 3. Install the blower housing and inner plate assemblies on both sides of the blower motor frame as follows: a. Use two 3/8 in. bolts in the threaded alignment bolt holes on both sides to line up the blower housing and inner plate assemblies with the blower motor frame on both sides. b. Gradually insert and tighten the bolts that connect the blower housing and inner plate assemblies on both sides to the blower motor frame. Check the alignment holes as you tighten the bolts to make sure both assemblies line up properly on the blower motor frame. 4. Install shaft seal assemblies inside both blower housing assemblies. Make sure the seals are centered. 5. Tighten and safetywire the retainer plates in place on both sides. 6. Install the impellers and taper lock bushings on both sides and safetywire the bolts. 7. Install the blower inlet duct assemblies to the blower housing on both sides using the same alignment holes used in Step 3a. 8. Hoist the entire cooling system assembly onto the TDS. If the alignment holes were properly used, the cooling system assembly should line up perfectly on the TDS. 9. Install and safetywire the four bolts connecting the blower mount to the brake cover. 10. Install and safetywire the four bolts on each side connecting the heat exchange duct housing assemblies to the blower inlet duct assemblies. 11. Install and safetywire the six bolts on each side connecting the transmission ducts to the blower housing ducts. 12. Connect the electrical wires to the blower motor.

4-94


Replacing the safety wiring Use the following procedures to safety wire screws, nuts, bolts, or other fasteners where applicable.

n

Torque fasteners before safety wiring any screw, nut, plug, or other fastener. Never overtorque or loosen a torqued fastener to align safety wire holes. Use the size and type of safety wire required in the applicable specifications and drawings. Whenever possible, use double-twist safety wiring.

n n

Limit single-twist wiring to the following: small screws located in closely spaced, closed geometrical patterns (e.g., triangles, squares, rectangles, or circles), parts in electrical systems, or parts that are difficult to reach.

Do not reuse safety wire. To install safety wire: 1. Open the jaws of the safety twist pliers. 2. Squeeze the handles of the pliers together and unlock the round, perforated slider in the center of the pliers from the hook lock. 3. Grip both safety wires in the jaw. Squeeze the handles together with one hand and pull the slider toward the rear of the pliers with the other hand to lock the pliers. 4. Twist the safety wire by pulling the aluminum knob and twist the rod out from the pliers. Let the pliers spin free. 5. Return the knob and twist the rod by holding the pliers steady with one hand and pushing against the end of the knob the with other hand (step 4 in Figure 4-35). 6. Repeat the previous twisting cycle.


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March 8, 2001

7. After threading the safety wire through the hole in the fastener, pull the wire straight through without nicking the wire. Twist four to five complete revolutions per inch of wire. 8. Make a pigtail of approximately 1 in. (25 mm) length (four twists minimum) at the end of the wiring and bend back or under to prevent it from becoming a snag.

1 2

5

3

4

Figure 4-35. Safety wiring procedures

4-96


Safety wiring tips ❏ Pull the safety wire firmly, but do not stretch it or let kinks develop. Make twists tight, even, and as taut as possible without weakening the wire by overtwisting (Figure 4-36).

n

Do not nick the wire with the edge of the hole in the fastener. Position the safety wire so the pull exerted by the wire tightens the nut. For best results, let the wire leave the fastener in a clockwise direction ❏ Twist the safety wire so the loop around the bolt or head has sufficient tension to keep it from slipping up and over the bolt head, with resulting slack in the safety wiring.

n

When securing castellated nuts with safety wire, tighten the nut to the low side of the selected torque range, unless otherwise specified. If necessary, continue tightening within specified torque limits until a slot aligns with the hole. ❏ The number of nuts, bolts or screws that can be safety-wired together depends on the application. As a guide, when safetywiring widely spaced bolts by the double-twist method, a group of three, or a 24 in. (610 mm) length of safety wire is usually the maximum.

Figure 4-36. Safety wiring examples TDS-4S Maintenance and Troubleshooting

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March 8, 2001

4-98


Chapter 4 Troubleshooting

Troubleshooting the counterbalance Symptom

Probable cause

Remedy

System does not hold pressure.

Needle valve is not closed.

See adjustment procedure and check needle valve.

Cylinder rod seals leak.

Replace seals.

Fittings or hoses leak.

Tighten or replace as required.

Dirty or defective PRV valve. See adjustment procedure. Clean or replace. Dirty or stuck check valve.

Clean or replace.

Counterbalance control valve Return valve to drilling position. in rig down position. Cylinder rods remain retracted (closed).

e

Pressure setting too high.

Adjust per adjustment procedure.

When activating or reactivating the counterbalance system, never start an empty system with the needle valve closed. Always start the Hydraulic Power Unit (HPU) first, run for 3-5 minutes, then slowly close needle valve with HPU running. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals. TDS-4S Maintenance and Troubleshooting

4-99

March 8, 2001

Troubleshooting the motor alignment cylinder Symptom

Probable cause

Remedy

Alignment cylinder fails to move transmission at trunnion pivot points with recommended pressure setting.

Transmission trunnion pins will not pivot in dolly support brackets, from lack of lubrication.

Free trunnion pins as needed and lubricate area regularly.

Possible problem with Counterbalance system hydraulic system works erratically or does not components. work at all.

Check Troubleshooting the counterbalance section of this book.

Loss of nitrogen precharge in Recharge accumulators as per the procedure in the Troubleshooting the accumulators located in counterbalance section of this book. motor dolly upright frame. System does not hold pressure.

Needle valve is not closed.

See the adjustment procedure.

Cylinder rod seals leak.

Replace seals.

Fittings or hoses leak.

Tighten or replace as required.

Dirty or defective PRV valve. Clean or replace. Saver sub on TDS does not align with drill pipe.

Alignment cylinder pressure too high or too low.

See the adjustment procedure.

Alignment cylinder rod Adjust according to procedure. adjustment too long or short.

Excessive motor movement.

4-100

Rails not properly aligned with centerline of well.

Check to make sure that rotary is in center of floor and then check alignment of rails in relation to rotary.

Alignment cylinder fluid flow not adequately throttled.

See the adjustment procedure. Normal adjustment is 1 1/2 turns from full closed position on flow control valves. If there is excessive movement close to 3/4 turn from full closed position.


Troubleshooting the drilling motor and guide dolly Troubleshooting the motor air brake Symptom

Probable cause

Remedy

Brake does not hold.

Insufficient air supply.

Check air supply pressure, 90 psi minimum required.

Solenoid valve not shifting.

Check electrical continuity. Check lubricator on air supply. Check mechanical operation of solenoid valve.

Brake does not release.

Brake drum contaminated with grease or pads worn or burnt.

Inspect and replace if necessary.

Solenoid valve sticking.

Lubricate, repair with repair kit or replace valve. Check air supply lubricator.

Quick exhaust valve not functioning properly.

Clean or replace.

Troubleshooting the retract guide dolly Symptom

Probable cause

Remedy

Guide dolly retracts too slow or too fast.

Flow control valves on the guide dolly are not properly set.

Set the flow controls to attain desired retract speed.


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March 8, 2001

Troubleshooting the transmission Symptom

Probable cause

Remedy

Oil leaking from lower seal.

Lower gear case seals are dry or damaged.

Apply grease to seal. Grease fitting daily. If problem persists replace gearcase seals and bearing.

Oil leaking from shaft Oil level too high. housing breather.

Gearbox temperature is excessive.

Adjust oil level per recommended specification.

Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Oil is foaming.

Replace oil.

Oil level too low or too high. Adjust oil level to recommended level in sight glass. Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Clogged oil suction screen.

Remove suction screen from oil pump. Check discharge or pressure hoses at outlets to confirm circulation.

Check heat exchangers for air flow Clogged or dirty heat exchangers on unit equipped or water flow to ensure adequate heat transfer and dissipation. with such.

4-102


Troubleshooting the oil pump Symptom

Probable cause

Remedy

OIL PUMP LOSS alarm is on.

Motor is not running.

Check electrical components to ensure power is available to motor. Repair or replace as needed.

Incorrect motor rotation.

Verify proper rotation and correct if necessary.

Dirty or clogged oil pump suction screen.

Remove and clean suction screen making sure to properly seal screen cover when installing.

Oil pump cavitatingevidence of air bubbles in discharge lines.

Check all connections and suction screen cover plate to ensure there are no air leaks on suction side of oil pump. Repair as needed.

Defective or improperly adjusted pressure switch.

Check switch operation. Repair or replace as needed.

Failure of oil pump drive coupling.

Inspect, repair or replace as needed.

Faulty or worn oil pump.

Check relief valve on back of pump. Install test gauge in discharge line and adjust to 10 psi. If unable to make oil pump work after checking all of the above, repair or replace as needed.

Incorrect lubricant used.

Check recommended lubricants chart to make sure proper viscosity of oil is used. Replace as needed.


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March 8, 2001

Troubleshooting the cooling system Symptom

Probable cause

Remedy

Mechanical noise in blower.

Loose impeller.

Reinstall impeller and hub and locktite 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.

Worn or defective seal or wear sleeve.

Replace as needed.

Loose or vibrating blower motor, wearing seals excessively.

Correct blower mounting problem or faulty motor bearing and replace blower shaft seals.

Incorrect blower rotation.

Verify blower rotation. Correct as needed.

Dirty or clogged spark arrestors (local or remote cooling systems).

Remove spark arrestors from motor and clean screens if screens are damaged with holes. Replace as needed.

Blower runs intermittently.

Excessive air loss in blower motor shaft area.

DC MOTOR OVERHEATING, OVERTEMP alarm stays on with blower running.

Clogged water or air passages Remove and clean passages as needed. in water cooled exchangers (closed loop cooling).

4-104


Troubleshooting the cooling system (cont.)

Symptom

Probable cause

Remedy

DC MOTOR OVERHEATING, OVERTEMP alarm stays on with blower running.

Continuous drilling Amps over recommended levels.

Check service manual for continuous Amp motor rating and adjust drilling program accordingly.

Motor being stalled for over recommended periods of time.

DC motor should never be stalled for more than 5 seconds with over 300 Amps applied.

e

Serious damage could occur to the motor if this is done.

Faulty temperature switch or Repair or replace as needed. probe.

z

Do not readjust or raise heat range setting.

Improper cooling water flow See the Installation and or incoming water temp too Commissioning book for recommended or required flow rates high (closed loop cooling). and water temp. Restricted air flow (local or remote cooling).

Check and clean spark arrestors as needed. Check air intake on blower to ensure there are no restrictions. Verify proper blower rotation.

WATER DETECTOR alarm is on (closed loop system).

Moisture in air inside DC motor.

Check for leaks in heat exchanger. Check air purge line filters. Ensure dry air is going into motor.

Dirty or faulty water detector.

Clean or replace as needed.


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March 8, 2001

Troubleshooting the pipehandler Troubleshooting the torque wrench Symptom

Probable cause

Remedy

Tool does not cycle properly.

Valves in manifold out of adjustment.

Readjust.

Supply and return hoses are crossed.

Reconnect hoses correctly.

Improperly connected Quick Check QDs to make sure they are Disconnects (QDs). properly plugged together and flowing in both directions. Needle valve in counterbalance manifold is open.

Close needle valve (always with HPU running).

Defective cartridge valve or PRV valve.

Inspect valves for damaged seals or stuck spools. Replace if necessary.

Improper component or component installation.

Valve cartridge replaced with wrong type.

z

4-106

When changing the Make/Break valve, make sure the valve is properly oriented when installed.

Die retainer and die retainer bolts damaged while breaking.

Improper saver sub length or Saver sub length too long. Sub machining. should also have proper chamfer on both shoulders.

Torque wrench does not lift.

Oil bypass in pipehandler hydraulic components.


Listen for oil bypassing in pipehandler cylinders or manifold. Locate and repair bypass as necessary.

Troubleshooting the torque wrench (cont.)

Symptom

Probable cause

Tool goes up, clamps, Air pilot valve on counterbalance manifold stuck or and cycles, but inoperative. remains clamped on pipe when switch is released.

Remedy Remove air supply line to verify air supply when solenoid valve is activated.

Pilot valve dirty.

If air supply is available remove end cap on pilot valve, clean and lubricate.

Improperly connected quick disconnects.

If air pilot valve is operable, hook both pipehandler hoses together and verify flow in both directions by activating switch with hydraulics on. If there is flow in only one direction, check QDs. If QDs are properly connected, check hydraulic pilot valve for stuck spool.

Hydraulic valve not shifting. Repair or replace. Saver sub breaks out instead of tool joint.

Saver sub not made up properly.

Make up saver sub per procedure described in the IBOP Service Manual, increase previous torque makeup by 10% to maximum torque recommended in the IBOP Service Manual (for original Varco OEM subs).

Tong dies break or score drill pipe.

Valves in manifold out of adjustment.

Readjust per procedure.

Tong dies worn.

Replace tong dies.

Connection overtorqued.

If saver sub is made up to recommended torque and continues to break out instead of drill pipe connection, break out using rig tongs. If saver sub or drill pipe will not break out using pipehandler, remove pipehandler and break out with rig tongs at floor.


4-107

March 8, 2001

Troubleshooting the safety valve actuator Symptom

Probable cause

Remedy

Safety valve leaks.

Internal parts worn out.

Check for washouts or defective parts. Repair as needed.

Actuator out of adjustment.

Check electrical continuity. Check spool mechanical operation. Lubricate if needed. Check actuator cylinder adjustment (see procedure).

Excessive vibration or Actuator support roller wobble while rotating. brackets bent or out of adjustment. Worn cam rollers.

Check actuator shell adjustment and crank assembly operation. Repair or replace rollers and roller brackets, shimming as needed to maintain smooth operation.

Troubleshooting the link tilt Symptom

Probable cause

Remedy

Does not tilt.

Solenoid valve not shifting.

Check electrical continuity. Check spool mechanical operation and lubricate as needed.

Does not reach mousehole.

Improperly adjusted.

Readjust drag link, shorten if necessary.

Retracts slowly, does not make it back to well center.

Pressure setting on float valve too low.

Adjust pressure setting.

Passive stop not in right spot.

Adjust jam not on passive stop to position elevators over well center.

Pressure setting on float valve too high.

Adjust pressure setting.

Passive stop not in right spot.

Adjust jam not on passive stop to position elevators over well center.

Retracts past well center in float mode.

4-108


Troubleshooting the pipehandler at the counterbalance manifold Symptom

Probable cause

Remedy

Pipehandler goes up and clamps when the HPU is turned on without pressing switch.

Improperly connected QDs.

Check all QDs to make sure that they are properly connected, also making sure that each half is intact and not coming apart and restricting fluid.

Solenoid valve stuck or inoperative.

Disconnect air line from solenoid to air pilot valve. If there is a constant air flow, the solenoid valve is stuck in the open position. Remove the solenoid and valve. Clean as needed. Repair or replace valve as needed. Check oil lubricator to make sure valves are being lubricated.

Air pilot valve sticking.

Faulty or loose wiring. IBOP valve actuator remains either in closed or open position. No air supply or air supply incorrect.

If there is no constant air flow from air line, remove end cover on air pilot valve and check spool to see if it is operating freely. Clean as needed and lubricate. Repair or replace valve as needed. Check electrical continuity to switches and solenoids. Check air supply. There must be 90 psi minimum pressure.

Crank assembly, actuator Check crank assembly, actuator arms and cylinders. Repair as needed. arms or cylinders sticking. Solenoid valves stuck in the open position or in center position. IBOP valve does not fully Actuator cylinder out of open or close. adjustment.

Check solenoid valves to see if they are not stuck in the open position or in center position. Repair or replace valve as needed. Check actuator cylinder adjustment and adjust as needed.

Cam follower rollers sticking.

Check cam follower rollers on crank assembly and arms.

Crank assembly retainer bolts loose.

Check crank assembly retainer bolts to assure tightness.

z

Crank assembly retainer bolts should be checked weekly to make sure they remain tight.


4-109

March 8, 2001

Troubleshooting the crown height indicator Symptom Green power indicator does not illuminate.

Probable cause Remedy No AC power being applied. Check Expo purge system and input AC power. Internal AC breaker tripped. Check internal circuit breaker on control electronic module for tripped condition. Failure of DC power supply. Check AC power LED on control electronic module. Replace electronic control module necessary. Replace electronic control module. Depressing the PUSH TO Malfunction of control electronics. TEST indicator does not cause position indicators to flash or illuminate. Misadjusted lower sensor Check proximity switch alignment. Yellow indicator is proximity switch. constantly illuminated while traveling assembly is below ten feet. Defective lower sensor Check mechanical operation of sensor bracket assembly. bracket assembly. Perform cable continuity tests. Defective sensor cable between sensor junction box and control electronics. Defective proximity switch. Replace proximity switch.

Yellow and red indicator constantly flash while traveling assembly is below ten feet.

Malfunction of electronics control module. Misadjusted lower sensor proximity switch.

Defective sensor cable between the sensor junction box and control electronics. Defective upper sensor bracket assemblies. Defective upper proximity switches.

Malfunction of electronics control module.

4-110


Replace electronic control module. Check proximity switch alignment.

Perform cable continuity tests.

Check the mechanical operation of the upper sensor bracket assembly. Check voltages from upper proximity switch by measuring voltage between TB3 and TB2 for upper sensor at the sensor junction box. A measurement of less than 2.0 VDC indicates a working sensor when metal is detected. Replace proximity switches as required. Replace electronic control module.

Six-gang air valve assembly illustration Air Elevator Torque Wrench Brake IBOP Open Link Tilt IBOP Close


4-111

March 8, 2001

4-112



Control System SM00620-5

March 8, 2001

5-2

TDS-4S Control System

Contents TDS-4S Control System General description .......................................................... 5-5 Maintenance and troubleshooting/ checkout procedures ........................................................ 5-7


5-3

March 8, 2001

5-4



General description The Top Drive Drilling System (TDS) typically operates from the same SCR as the rotary table. A panel, located in a Central Electronics Enclosure (CEE), switches power from one to the other. The CEE typically contains the following components: ❏ DC contactors ❏ A programmable logic controller (PLC) ❏ Auxiliary AC components ❏ Rig instrumentation interfaces for recording TDS torque and speed


5-5

March 8, 2001

In dedicated top drive SCR configurations, the SCR runs the top drive only. The panel can feature a purge control system so it can be located in hazardous areas. If the panel is located in the SCR room, a purge system is not required. The panel is designed to be compatible with all presently installed SCR systems and is configured at installation for the specific SCR used on a rig. Logic and alarm functions are connected to the TDS via PLC programming so the TDS can operate existing rig systems. Also, TDS interlocks and limits, such as spin-up and makeup speeds, are programmed into the PLC and are the same for all installations.

5-6


Maintenance and troubleshooting/ checkout procedures The Varco Top Drive Drilling Control System (TDCS) is straightforward in its operation and relatively easy to service. Refer to the following documentation for maintenance, troubleshooting and checkout information: ❏ Periodic control system maintenance schedule (See Table 1 below.) ❏ Rig checklist ❏ PLC manual ❏ Card rack terminal specifications Table 1. Periodic control system maintenance schedule Location

Procedure

Frequency

Indicator lamps

Test using the lamp test switch on the driller’s console.

Each time the TDS is assigned.

Heater

Check operation with an Ohm meter.

Monthly

High voltage connections

Check for discolored or brittle insulation.

Monthly

Check retaining bolt torque (needs to be 25 ft lb).

Monthly

Component mounting

Check fastener tightness, especially in vibration-prone areas.

Monthly

Blower mounting current

Check and record current. (A drop in the current may indicate restriction or blockage of the air intake.)

Monthly

Drilling motor field current

Verify and record.

Weekly

Seals and gaskets

Check for integrity.

Monthly

Apply a light film of silicone lubricant to the transfer panel door.

Every 3 months


5-7

March 8, 2001

5-8


This page left blank intentionally.

WASHPIPE ASSEMBLY

Service Manual

SM01053 Revision A

© Copyright 2004 Varco® LP. All rights reserved. Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This publication is the property of, and contains information proprietary to, Varco International, Inc. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Varco International, Inc. All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. Information in this manual is subject to change without notice.

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intended Audience and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Washpipe Assembly Pressure Ratings . . . . . . . . . . . . . . . . . . . . . 10 General Maintenance Practices . . . . . . . . . . . . . . . . . . . . 11 Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Standard Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . 12 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hammerless Washpipe Assembly . . . . . . . . . . . . . . . . . . 36 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removing the Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Washpipe

3

4

Varco

General Information Intended Audience and Use This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Varco International, Inc., will not be held liable for errors in this material, or for consequences arising from misuse of this material. This manual is intended as a supplement to the service manuals supplied with the Varco Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).

Conventions Notes, Cautions, and Warnings Notes, cautions, and warnings are used throughout this manual to provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note:

i The note symbol indicates that additional information is provided about the current topics.

Caution:

! The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning:

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.

Illustrations Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see the technical drawings included with your Varco documentation.

Washpipe

5

Safety Requirements Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by Varco manuals are the recommended methods of performing those operations.

! To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.

Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.

! During installation, maintenance, or repair of equipment, personnel should wear protective gear. Protective gear must be worn during certain operation.

Contact the Varco training department for more information about equipment operation and maintenance training.

Recommended Tools Service operations may require the use of tools designed specifically for the purpose being described. Varco recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when using service procedures or tools not specifically recommended by Varco.

6

Varco

Safety Requirements General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water.

! Before installing or performing maintenance or repairs on equipment, read the following instructions to avoid endangering exposed persons or damaging equipment.

Isolate all energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.

Wear proper protective equipment during equipment installation, maintenance, or repair.

Replacing Components

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment to ensure correct installment.

Replace failed or damaged components with Varco certified parts. Failure to do so could result in equipment damage, or personal injury.

Routine Maintenance Equipment must be maintained on a regular and routine basis. See the service manual for maintenance recommendations.

! Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Proper Use of Equipment Varco equipment is designed for specific functions and applications, and should be used only for their intended purpose.

Washpipe

7

General Description Washpipe Assembly The washpipe assembly is located between the main shaft and the gooseneck (S-pipe) on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard and hammerless.

8

Varco

General Description Special Tools The standard washpipe assembly has hammer nuts on its washpipe nut and packing box. The hammer nuts are provided so that a special wrench and a hammer can be used to tighten to washpipe nut and packing box during installation. The hammerless washpipe assembly uses gear nuts which are tightened more precisely without a hammer but with a special torque wrench kit. This feature makes the unit easier to install by allowing the unit to swing in and out of its support bonnet before being torqued and does not require the use of a hammer.

Standard Washpipe

Standard Washpipe Wrench

Strike here

Hammerless Washpipe Torque Wrench 30-250 ft lb Hammerless Washpipe Torque Multiplier 3200 ft lb Removable extension not shown

Socket Adapter

Washpipe

9

Specifications Washpipe Assembly Pressure Ratings

i Assembly descriptions are repeated for similar units. Use the assembly part number when referencing pressure ratings.

Standard Washpipe Assembly Description

Part No.

Pressure Rating (psi)

Small Bore (3-inch)

30123290

7,500

Large Bore (4-inch)

30123440

7,500

Large-to-Small Bore

30153491-50

7,500

Hammerless Washpipe Assembly

10

Description

Part No.

Pressure Rating (psi)

Large Bore (4-inch)

30156883

7,500

Large-to-Small Bore

30173058-50

7,500

Varco

General Maintenance Practices Equipment Maintenance Records Keep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.

i Procedures in this chapter relate to Varco only components. See the vendor manuals for maintenance procedures and schedules for the vendor equipment.

Maintenance Schedules Maintenance schedules list preventive maintenance tasks. Inspection schedules assume normal operating conditions. Some conditions (excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent inspection intervals. Perform the procedures indicated, as warranted by the inspection.

Safety Precautions Avoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual. To avoid serious injury or death, read and understand the following Warnings before performing maintenance or troubleshooting procedures:

Unless instructed otherwise, properly lock out the main power source before performing any maintenance procedure. Wear protective glasses to prevent eye injuries. Do not attempt any adjustments while the machine is moving. Read and understand all safety precautions and warnings before performing maintenance procedures.

Washpipe

11

Standard Washpipe Assembly Initial Installation Procedure 1. Install the washpipe assembly on the TDS/IDS and hand-tighten the washpipe nut and packing box, then back off the packing box and washpipe nut by 1/4 turn.

the packing box.

securely tighten.)

i

Nut

12

Varco

Standard Washpipe Assembly Initial Installation

Washpipe

13

Standard Washpipe Assembly Initial Installation Procedure 11. Check washpipe alignment. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 12. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.

Washpipe

Dial Indicator Packing Box

14

Varco

Standard Washpipe Assembly Maintenance Schedules Inspection Schedule Item

Inspect for

Interval

Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck

• Surface should be

TDS/IDS main shaft bearing endplay

Endplay is within specification (refer to TDS/IDS Service Manual)

Once every six months and immediately after jarring

Washpipe Assembly grease fitting

Proper operation

Replace every six months

Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft

Proper alignment between pilots

After TDS/IDS main shaft bearing endplay has been checked and is within specification

All parts

Refer to Disassembly Procedure

Upon disassembly of washpipe assembly

smooth and free of flaws or burrs • ID of stem liners

When washpipe assembly is to be removed from TDS/ IDS

Cleaning Schedule Item TDS/IDS bonnet (inside)

Procedure Remove residual mud

Interval Weekly

Lubrication Schedule Item Washpipe Assembly grease fitting

Washpipe

Procedure Apply 3 to 4 pumps of grease (refer to Lubrication Procedure)

Interval Twice daily or every 10 rotating hours

15

Standard Washpipe Assembly Inspection Procedures When Washpipe is to be Removed from TDS/IDS

Service Limit (inches) 3.090 3.840 3.120

16

Varco

Standard Washpipe Assembly Inspection Procedures Every Six Months Procedure 1. Remove the washpipe assembly and replace the grease fitting. 2. Check the main shaft axial movement by applying an upward force to the main shaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).

Washpipe Grease Fitting Replace

Dial Indicator

Washpipe

17

Standard Washpipe Assembly Inspection Procedures Every Six Months

Gooseneck Pilot

Dial Indicator

0.002 TIR between these two surfaces

Bonnet removed for clarity.

Main Shaft Pilot

18

Varco

Standard Washpipe Assembly Lubrication Procedures Daily Lubrication

Description grease fitting.

Cyprina 2.

Washpipe

19

Standard Washpipe Assembly Troubleshooting

i The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.

Symptom Leakage at threads between packing box and TDS/IDS main shaft

Leakage at grease fitting access hole

20

Probable cause

Remedy

Poly Pak seal failure in main shaft stem liner

Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.

Lower O-ring failure

1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Stem liner not smooth and does not allow O-ring to seal properly

Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.

Stem liner not flat and does not allow O-ring to seal properly


Spacers not flat and prevents packing seals from sealing between spacers proper

Follow inspection procedures as outlined in step 8 of the Disassembly Procedure.





Varco

Standard Washpipe Assembly Troubleshooting Symptom

Remedy

Leakage through grease fitting access hole (cont)


Follow inspection procedures as outlined the Inspection Procedure.

Leakage at grease fitting

Grease fitting failure


Leakage between the washpipe and the packing box

Packing failure

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Leakage between the washpipe and the washpipe nut

Packing failure or packing is improperly seated


Upper O-ring failure

1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Upper O-ring failure Leakage at threads between washpipe nut and gooseneck


Premature failure after greasing

Washpipe

Probable cause



Improper greasing procedure

Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.

21

Standard Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy

Premature failure accompanied by occasional spurts of mud from packing box

Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay

If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment.


Misalignment of gooseneckto-washpipe pilot

Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure.

Installation problems

The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).

Nut not torqued

Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.

Too mush grease during assembly of the unit

Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.

Premature failure due to flanged packing

During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).

22

Varco

Standard Washpipe Assembly Troubleshooting

Washpipe


Washpipe

23

Standard Washpipe Assembly Troubleshooting Symptom Packing is worn out

Probable cause

Remedy

Poor greasing schedule or improper grease.

Follow proper lubrication procedures.

RPM, pressure and mud temperature too high

Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.

Spacers too flat

If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.

Nut not torqued


Blue spacers

Improper torque or grease on the OD of the spacers

Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.

Unable to maintain torque on packing box

Improper assembly or installation

1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.

Packing extruding between spacers

24

Varco

Standard Washpipe Assembly Troubleshooting Symptom Unable to maintain torque on packing box (cont)

Probable cause

Remedy 4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.

Washpipe

25

Standard Washpipe Assembly Disassembly Procedure

Snap Ring

1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.

Holding Ring

Washpipe Nut

O-Ring

Packing Box Grease Fitting

i Washpipe

Discard and replace these non-serviceable parts from the washpipe assembly. Upper Spacer

Packing Set (5 per Set)

Socket Head Dog Nose Screw

Middle Spacer

Middle Spacer

O-Ring

26

Varco

Standard Washpipe Assembly Disassembly Procedure 4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat

ID This surface to be smooth and flat

This edge to be sharp

Spacer

Varco Part No.

Proper ID (inches)

Service Limit ID (inches)

Small Bore

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Large Bore

Upper Middle Lower

30123434 30123435 30123436

4.895 to 4.900 4.895 to 4.900 4.895 to 4.900

4.905 4.905 4.905

Middle Spacer

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Middle Spacer

Washpipe Assembly

Large to Small Bore

Washpipe

Upper Spacer

27

Standard Washpipe Assembly Disassembly Procedure 8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through.

Washpipe Nut

ID Packing Box

Washpipe Assembly

Washpipe Nut Part No.

Proper ID (inches)


Small Bore

123284

3.655 to 3.660

3.665

Large Bore

30123431

4.905 to 4.910

4.915

Large to Small Bore

30153493

3.655 to 3.660

3.665

Washpipe Assembly

Packing Box Part No.

Proper ID (inches)


Small Bore

30123563

3.637 to 3.644

Large Bore

30123626

4.900 to 4.905

Large to Small Bore

30153494

3.637 to 3.644

28

Varco

Standard Washpipe Assembly Disassembly Procedure 10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.

Holding Ring

This surface to be smooth and flat Undercut rease i

This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.

Washpipe

29

Standard Washpipe Assembly Reassembly Procedure 1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer

2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer

Sharp edge of spacer Sharp edge of spacer Sharp edge of spacer

30

Wipe grease from area shown, all the way around on each spacer.

Middle Spacer

Middle Spacer

Varco

Standard Washpipe Assembly Reassembly Procedure 3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Dowel Pin

Grease Fitting

Socket Head Dog Nose Screw Packing Box

Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min

i In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.

Washpipe

31

Standard Washpipe Assembly Reassembly Procedure 7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe.

Washpipe Nut

Washpipe

Packing Box

32

Varco

Standard Washpipe Assembly Reassembly Procedure 9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.

Holding Ring Wipe grease from area shown, all the way around the holding ring.

Packing Seal

Fill with grease to level shown.

Holding Ring

10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings.

Packing Seal

Snap Ring O-ring

13. approximately the length of the washpip pe. 14. Initial Installation Procedure.

Washpipe

33

Standard Washpipe Assembly Illustrated Parts List O-Ring Snap Ring

Holding Ring Upper Spacer Packing Set 5 per set

Washpipe Nut Middle Spacer

Middle Spacer Washpipe

Lower Spacer

Packing Box O-Ring

Grease Fitting Socket Head Dog Nose Screw

Long-Arm Allen Wrench

34

Varco

Standard Washpipe Assembly Illustrated Parts List

Washpipe

Description

Small Bore (3-inch)

Large Bore (4-inch)

Large-to-Small Bore

Washpipe Assembly

30123290

30123440

30153491

O-Ring

51300-348-F

51300-359-F

51300-348-F

Snap Ring

30123562

123634

30123562

Holding Ring

30123288

30123437

30123288

Washpipe Nut

123284

30123431

30153493

Washpipe

30123289 (7,500 psi)

30123438 (7,500 psi)

30123289 (7,500 psi)

Packing Box

30123563

30123626

30153494

Grease Fitting

53219-1

53219-1

53219-1

Socket Head Screw

30123564

30123564

30123564

Upper Spacer

123585

30123434

123585

Middle Spacer

30123286

30123435

30123286

Lower Spacer

123287

30123436

123287

Pressure Seal Kit (Packing Set)

30123290-PK

30123440-PK

30123290-PK

Stem Liners

98290

112871

30153492

Poly Pak Seal

98291

112895

112895

Grease

56005-1

56005-1

56005-1

35

Hammerless Washpipe Assembly Initial Installation Procedure

i During installation the washpipe assembly is brought into place as one unit and handled by a tugger line. Ensure that the washpipe assembly is strapped together securely before lifting.

1. Unlock the TDS/IDS handling yoke from its stored position and swing it out to accept the washpipe assembly.

Makes the washpipe assembly easier to install by allowing it to swing in and out of the motorsupport bonnet.

i

Nut

Yoke

36

2 places

Varco

Hammerless Washpipe Assembly Initial Installation Procedure

the TDS/IDS main shaft. 4. it until it makes contact with the top of the main shaft. 5. packing box and the washpipe nuts. 6. Apply pipe dope to the threads and hand-tighten the washpipe nut and packing box. 7. align the pipe in the packing box. 8. Set the TDS/IDS brake.

Torque Multiplier Ratio – 18.5 to 1 Removable extension

Torque Wrench

9. Loosen the thumb screw on the pinion gear and raise the pinion gear from its stored position and lock the thumb screw in place when it aligns with the gear on the packing box. It may be necessary to rotate the square drive shaft to engage the gears. 10. Install the torque kit assembly over the square shaft. Set the torque wrench to 100 ft-lb and begin applying torque to the packing box gradually until the torque wrench clicks. Torque Wrench Setting-ft.-lbf. 75 100 125 150

Applied Torque to Nut-ft.-lbf. 4,500 6,000 7,500 9,000

11. Disengage the pinion gear from the packing box gear and engage it with the washpipe nut gear and secure it in place. Similarly, apply torque to the washpipe nut, completing the installation of the washpipe assembly. 12. Apply 6 to 8 pumps of grease to the grease fittings. 13. Return the pinion gear to its stored position and secure it with the thumb screw. Secure the handling yoke to its stored position by pinning it with the two pins. 14. Release the TDS/IDS brake and rotate the TDS/IDS at approximately 50 rpm for one minute.

Washpipe

37

Hammerless Washpipe Assembly Maintenance Schedules Inspection Schedule Inspect for

Item

Interval

Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck

• Surface should be

TDS/IDS main shaft bearing endplay

Endplay is within specification (refer to TDS/IDS Service Manual)

Once every six months and immediately after jarring

Washpipe Assembly grease fitting

Proper operation

Replace every six months

Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft

Proper alignment between pilots

After TDS/IDS main shaft bearing endplay has been checked and is within specification

All parts

Refer to Disassembly Procedure

Upon disassembly of washpipe assembly

smooth and free of flaws or burrs • ID of stem liners

When washpipe assembly is to be removed from TDS/ IDS

Cleaning Schedule Procedure

Item TDS bonnet (inside)

Remove residual mud

Interval Weekly

Lubrication Schedule Procedure

Item Washpipe Assembly grease fitting

Apply 3 to 4 pumps of grease

Interval Twice daily or every 10 rotating hours

! To prevent rust from damaging parts, properly clean and grease the following parts before storage: 1. Jacking nut and shaft threads 2. Square shaft from top to bottom 3. Gear teeth on all three gears

38

Varco

Hammerless Washpipe Assembly Inspection Procedures Every Six Months Washpipe Assembly Alignment Satisfactory packing life depends on good washpipe alignment. Use the following procedure to check sleeve-to-gooseneck support alignment: 1. Attach an indicator base to the gooseneck support and place the indicator at the top of the sleeve. 2. Raise and lower the sleeve and record the total indicator reading. 3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or packing box. 4. Rotate the sleeve 360° and record the TIR. Washpipe Assembly Tolerances Use the following procedure to check washpipe assembly tolerances: 1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to 0.003 inch. 2. Check the clearance by raising and lowering the sleeve. The maximum allowable misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum allowable misalignment after complete assembly of the washpipe assembly is 0.010 inch TIR.

i Inspection may indicate misalignment exceeding recommended limits. The packing box assemblies are designed to accommodate misalignment of the sleeve to the gooseneck and can operate with some excessive misalignment. However, to achieve maximum packing life, maintain the misalignment at the washpipe within the recommended limits.

Washpipe

39

Hammerless Washpipe Assembly Inspection Procedures Every Six Months Procedure 1. Remove the washpipe assembly and replace the grease fitting. 2. Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).

Washpipe Grease Fitting Replace

Dial Indicator

40

Varco

Hammerless Washpipe Assembly Inspection Procedures Every Six Months

Gooseneck Pilot

Dial Indicator

0.002 TIR between these two surfaces

Bonnet removed for clarity.

Main Shaft Pilot

Washpipe

41

Hammerless Washpipe Assembly Lubrication Procedures Daily Lubrication Recommended Grease

42

Manufacturer

Description

Shell

Cyprina

Procedure 1. Twice daily or once every 10 hours of rotation, apply 3 to 4 pumps of grease to the washpipe grease fitting. 2. Rotate the TDS/IDS at 50 rpm for one minute with 0 psi standpipe pressure. 3. Turn on the mud pumps and check for leaks.

Varco

Hammerless Washpipe Assembly Troubleshooting

i The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.

Symptom Leakage at threads between packing box and TDS/IDS main shaft

Leakage at grease fitting access hole

Washpipe

Probable cause

Remedy





Stem liner not smooth and does not allow O-ring to seal properly


Stem liner not flat and does not allow O-ring to seal properly








43

Hammerless Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy

Leakage through grease fitting access hole (cont)


Follow inspection procedures as outlined the Inspection Procedure.

Leakage at grease fitting

Grease fitting failure


Leakage between the washpipe and the packing box

Packing failure


Leakage between the washpipe and the washpipe nut



Upper O-ring failure


Upper O-ring failure Leakage at threads between washpipe nut and gooseneck


Premature failure after greasing

44



Improper greasing procedure

Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.

Varco

Hammerless Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy


Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay

If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment.


Misalignment of gooseneckto-washpipe pilot

Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure.

Installation problems

The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).

Nut not torqued


Too mush grease during assembly of the unit

Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.

Premature failure due to flanged packing

During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).

Washpipe

45

Hammerless Washpipe Assembly Troubleshooting

Washpipe


46

Varco

Hammerless Washpipe Assembly Troubleshooting Symptom Packing is worn out

Remedy

Poor greasing schedule or improper grease.

Follow proper lubrication procedures.

RPM, pressure and mud temperature too high

Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.

Spacers too flat

If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.

Nut not torqued


Blue spacers

Improper torque or grease on the OD of the spacers

Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.

Unable to maintain torque on packing box

Improper assembly or installation

1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.

Packing extruding between spacers

Washpipe

Probable cause

47

Hammerless Washpipe Assembly Troubleshooting Symptom Unable to maintain torque on packing box (cont)

Probable cause

Remedy 4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.

48

Varco

Hammerless Washpipe Assembly Removing the Washpipe Assembly Remove the washpipe assembly by reversing the Installation Procedure.

! Once the packing box and washpipe nuts are unscrewed, the assembly must be strapped together as one unit before it is picked up by the handling yoke.

i The hammerless washpipe assembly must always be handled as one unit. Avoid disassembly unless you suspect faulty parts (refer to Troubleshooting).

Washpipe

49

Hammerless Washpipe Assembly Disassembly Procedure

Snap Ring

1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.

Holding Ring

Washpipe Nut

O-Ring

Packing Box

i Washpipe

Discard and replace these non-serviceable parts from the washpipe assembly.

Grease Fitting Socket Head Dog Nose Screw Upper Spacer

Packing Set (5 per Set)

Middle Spacer

Middle Spacer

O-Ring

50

Varco

Hammerless Washpipe Assembly Disassembly Procedure 4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat

ID This surface to be smooth and flat

This edge to be sharp

Spacer

Varco Part No.

Proper ID (inches)


Large Bore

Upper Middle Lower

30123434 30123435 30123436

4.895 to 4.900 4.895 to 4.900 4.895 to 4.900

4.905 4.905 4.905

Large to Small Bore

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Washpipe Assembly

Washpipe

Upper Spacer

Middle Spacer

51

Hammerless Washpipe Assembly Disassembly Procedure 8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through. hpipe ut

ID Packing Box

Washpipe Assembly

Washpipe Nut Part No.

Proper ID (inches)


Large Bore

30123431

4.905 to 4.910

4.915

Large to Small Bore

30153493

3.655 to 3.660

3.665

Washpipe Assembly

Packing Box Part No.

Proper ID (inches)


Large Bore

30123626

4.900 to 4.905

Large to Small Bore

30153494

3.637 to 3.644

52

3 650

Varco

Hammerless Washpipe Assembly Disassembly Procedure 10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.

Holding Ring

This surface to be smooth and flat Undercut Grea Fitti

This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.

Washpipe

53

Hammerless Washpipe Assembly Reassembly Procedure 1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer

2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer

Sharp edge of spacer Sharp edge of spacer

Wipe grease from area shown, all the way around on each spacer.

Middle Spacer

Sharp edge of spacer

54

Varco

Hammerless Washpipe Assembly Reassembly Procedure 3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Dowel Pin

Grease Fitting

Socket Head Dog Nose Screw

Packing Box

Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min

i In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.

Washpipe

55

Hammerless Washpipe Assembly Reassembly Procedure 7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe. Washpipe Nut

Washpipe

Packing Box

56

Varco

Hammerless Washpipe Assembly Reassembly Procedure 9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.

Holding Ring Wipe grease from area shown, all the way around the holding ring.

Packing Seal

Fill with grease to level shown.

Holding Ring

10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings.

Packing Seal

Snap Ring O-ring

13. approximately the length of the washpip pe. 14. Initial Installation Procedure.

Washpipe

57

Hammerless Washpipe Assembly Illustrated Parts List O-Ring Snap Ring

Holding Ring Upper Spacer Packing Set 5 per set

Washpipe Nut Middle Spacer

Middle Spacer

Washpipe

Lower Spacer

Packing Box O-Ring

Grease Fitting

Socket Head Dog Nose Screw Long-Arm Allen Wrench

58

Varco

Hammerless Washpipe Assembly Illustrated Parts List Description

Washpipe

Large Bore (4-inch)

Large-to-Small Bore

Washpipe Assembly

30156883 & 30156883-750

30173058-50 & 30173058-100

O-Ring

51300-359-F

51300-348-F

Snap Ring

123634

30123562

Holding Ring

30123437

30123288

Washpipe Nut

30152547

30173057

Washpipe - Low Pressure

30123438 (7,500 psi)

30123289 (7,500 psi)

Washpipe - High Pressure

30123438-TC (7,500 psi)

30123289-TC (10,000 psi)

Packing Box

30156884

30173056

Grease Fitting

53219-1

53219-1

Socket Head Screw

30123564

30123564

Upper Spacer

30123434

123585

Middle Spacer

30123435

30123286

Lower Spacer

30123436

30123287

Pressure Seal Kit (Packing Set)

30123584-2 (7,500 psi)

123292-2 (7,500 psi)

Stem Liner

112871

30153492

Poly Pak Seal

112895

112895

Grease

56005-1

56005-1

59

Glossary ID - Inner Diameter IDS - Integrated Drilling System OD - Outer Diamaeter TDS - Top Drive System TIR - Total Indicator Reading

60

Varco


Technical Drawing Package TDS-4S Petrobras P14

RIG/PLANT REFERENCE ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER CLIENT DOCUMENT NUMBER

Client Document Number

M614000012-GEN-001

REFERENCE DESCRIPTION

Customer Configuration

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco DOCUMENT NUMBER

D811000252-DOS-001

www.nov.com D811000461-GEN-001/01

National Oilwell Varco RIG SOLUTIONS 12950 West Little York Houston, TX 77041

REV

01

Document number Revision Page

D811000252-DOS-001 01 2

REVISION HISTORY

01

17.04.2008

Rev

Date (dd.mm.yyyy)

First Issue Reason for issue

J. Kellstrom

K. Schmidt

R. Shumski

Prepared

Checked

Approved

CHANGE DESCRIPTION

Revision 01

Change Description New Release

www.nov.com D811000461-GEN-001/01


D811000252-DOS-001 01 3

TECHNICAL DRAWING PACKAGE This document provides a list of drawings for the TDS-4S. The actual drawings are arranged in the binder in numerical order.

Drawings by Assembly General Customer Configuration................................................................... M614000012-GEN-001 General Arrangement, Overall……………………………………….. .D721000114-GAD-001 General Arrangement .......................................................................D721000256-GAD-001 Hydraulic Schematic………………………………………………….. ..D614000084-SCH-001 Single Line Diagram…………………………………………………………………... 30184728 Interconnect Diagram ………………………….. .................................................... 30184729 Cable Schedule………………………………………………… ............................... 30184730 Network Diagram………………………………………………………………………. 30184731 I/O Map………………………………………………… ............................................ 30184732 Hazardous Equipment Index………………………………………………………… 30184733 Hose Kit, CRT to PH-85…………………. ........................................ M614000509-ASM-001 Top Drive Assembly Motor Housing Assembly…………….. ........................................ .121344-SE-088-10-50SB Drilling Motor Assembly………............................................................... 88585-SH-Q Rotating Head Assembly……………………… ........................................ 116417-500 Hydraulic Motor Assembly…………………………………………… .........116418 Washpipe Assembly …………………………….. ........................................ 30123290 Compound Gear Assembly (Helical)……………. ............................ 116804-500/-501 Guide Dolly Assembly......................................... ................................................. 30184932 Cylinder Assembly………………. ............................................................... 30151882 Alignment Cylinder Assembly………… ...................................................... 30172237 Motor Electrical Installation Kit…………………… ..............................M614000217-SE-U24 Motor Power J-Box Assembly………………………....................................... 79073-3 Valve Manifold Assembly……………………............................................116021-C16 J-Box Assembly I.S.………………………….. .............................................. 108616-6 Kit, Weather Seal, Electrical Gland…………………………. .......................... 30156499-500 Motor Cooling System……………………….......................................................109412-1A1 Oil Circulating Kit……………………….. ............................................................... 30181397 Oil Circulating Assembly………………………………… .............................. 30181991 Pump/Motor Assembly……………. .................................................... 30182305

www.nov.com D811000461-GEN-001/01


D811000252-DOS-001 01 4

“S” Pipe Installation Kit………………………........................................................... 94075-1 S-Pipe Assembly……………. .................................................................... 91677-502 Retrofit Kit, Rotating Head Motor Assembly……………………………….. M614000418-500 Gearbox Lubrication Kit………………….................................................................. 92643-1 Counterbalance Kit………………………………………………................................. 95031-1 Dolly Assembly, Block...........................................................................................30184930 Dolly Assembly, Auxiliary……………………………………………………………. . 30184928

Pipe Handler and Adapter Kits Pipe Handler Installation Kit, PH-85…. ....................................................... 30179600-J35A Torque Wrench Assembly…………………………………………..……….95461-AJBX Cylinder, Clevis Assembly…………………………………………………..…91265 Lift Cylinder Assembly…………………………………………. .......……..…90864 Stabbing Guide Assembly…………………………………………….…..30115170 Manifold Assembly, Elevator Rotate………………………..……………...116023 Manifold Assembly, Rectifier……………………………….… ....... 30171689-501 Torque Arrestor Assembly ....................................................................... .90471-1, -2 Stabbing Guide Assembly……………………………………………….…..108362 Jaw Assembly, PH-85………………………………………………………….90851 Hydraulic Link Tilt Assembly………………………………………..………....…..128996 Crank Assembly……. ................................................................................. 30173893 Upper IBOP………………………………………………………………….30173885-500 Lower IBOP………………………………………………………………………90811-500 PH-85 Adapter Kit………………………………….…………………………………....109961-2 Stabbing Guide Assembly, NC50…………………………………………………..99302 Actuator Shell/Crank Assembly……………………………………..………………….141324-1 Kit, Link Tilt Clamp……………………………………….……………………...M614000290-50

Control System Control Panel…………………….. ......................................................................... 30184445

Service Loops, Derrick Terminations, and Miscellaneous Kits Service Loop Kit, Electrical…. ........................................................................ 117933-86-10 Service Loop, Fluids…………....................................................................109179-86-19-10 Derrick Termination Kit………. ..................................................................................123371

www.nov.com D811000461-GEN-001/01


D811000252-DOS-001 01 5

Driller’s Recorder Transducer Kit…………………………….……………………………80149

www.nov.com


D811000252-DOS-001 01 6

Drawings In Numerical Order Motor Power J-Box Assembly………………………................................................. 79073-3 Driller’s Recorder Transducer Kit…………………………….……………………………80149 Drilling Motor Assembly……….. ....................................................................... 88585-SH-Q Torque Arrestor Assembly................................................................................. .90471-1, -2 Lower IBOP………………………………………………………………………..……90811-500 Jaw Assembly, PH-85………………………………………………………………………90851 Lift Cylinder Assembly……………………………………………………............……..…90864 Cylinder, Clevis Assembly………………………………..……………………………..…91265 S-Pipe Assembly……………. .............................................................................. 91677-502 Gearbox Lubrication Kit………………….................................................................. 92643-1 “S” Pipe Installation Kit………………………........................................................... 94075-1 Counterbalance Kit………………………………………………................................. 95031-1 Torque Wrench Assembly……………………………………………………..…...95461-AJBX Stabbing Guide Assembly, NC50…………………………………………… ........ ……..99302 Stabbing Guide Assembly………………………………………………………………..108362 J-Box Assembly I.S.………………………….. ........................................................ 108616-6 Service Loop, Fluids…………....................................................................109179-86-19-10 Motor Cooling System……………………….......................................................109412-1A1 PH-85 Adapter Kit………………………………….…………………………………....109961-2 Valve Manifold Assembly…………………….. ...................................................116021-C16 Manifold Assembly, Elevator Rotate………………………………………….......... …..116023 Rotating Head Assembly……………………… .................................................. 116417-500 Hydraulic Motor Assembly…………………………………………… ...........................116418 Compound Gear Assembly (Helical)……………. ...................................... 116804-500/-501 Service Loop Kit, Electrical…. ........................................................................ 117933-86-10 Motor Housing Assembly…………….. ........................................ .121344-SE-088-10-50SB Derrick Termination Kit………. ..................................................................................123371 Hydraulic Link Tilt Assembly……………………………………………………………..128996 Actuator Shell/Crank Assembly……………………………………..………………….141324-1 Stabbing Guide Assembly………………………………………….……………...…..30115170 Washpipe Assembly …………………………….. .................................................. 30123290 Cylinder Assembly………………. ......................................................................... 30151882 Kit, Weather Seal, Electrical Gland…………………………. .......................... 30156499-500 Manifold Assembly, Rectifier……………………………………………… ........ 30171689-501

www.nov.com D811000461-GEN-001/01


D811000252-DOS-001 01 7

Alignment Cylinder Assembly………… ................................................................ 30172237 Upper IBOP…………………………………………………………..…………….30173885-500 Crank Assembly……. ........................................................................................... 30173893 Pipe Handler Installation Kit, PH-85…. ....................................................... 30179600-J35A Oil Circulating Kit……………………….. ............................................................... 30181397 Oil Circulating Assembly………………………………… ....................................... 30181991 Pump/Motor Assembly……………. ...................................................................... 30182305 Control Panel…………………….. ......................................................................... 30184445 Single Line Diagram…………………………………………………………………... 30184728 Interconnect Diagram ………………………….. .................................................... 30184729 Cable Schedule………………………………………………… ............................... 30184730 Network Diagram………………………………………………………………………. 30184731 I/O Map………………………………………………… ............................................ 30184732 Hazardous Equipment Index………………………………………………………… 30184733 Dolly Assembly, Auxiliary……………………………………………………………. . 30184928 Dolly Assembly, Block...........................................................................................30184930 Guide Dolly Assembly......................................... ................................................. 30184932 Hydraulic Schematic………………………………………………….. ..D614000084-SCH-001 General Arrangement, Overall……………………………………….. .D721000114-GAD-001 General Arrangement .......................................................................D721000256-GAD-001 Customer Configuration................................................................... M614000012-GEN-001 Motor Electrical Installation Kit…………………… ..............................M614000217-SE-U24 Kit, Link Tilt Clamp……………………………………….……………………...M614000290-50 Retrofit Kit, Rotating Head Motor Assembly……………………………….. M614000418-500 Hose Kit, CRT to PH-85…………………. ........................................ M614000509-ASM-001

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MECHANICAL SPARES KIT PETROBRAS – P14 TDS-4S

NOTES: 1. 2. 3. 4.

30184939-1 Recommended Commissioning Spares 30184939-2 Recommended Operational Spares 30184939-3 Recommended Insurance Spares See Customer Configuration M614000012-GEN-001.

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.

CURRENT DRAWN CHECKED APPD DATE

TITLE

MECHANICAL SPARES LIST PETROBRAS – P14 TDS-4S

INITIAL R SHUMSKI D. STEPHENS R SHUMSKI 7 JUL 08

SIZE

DWG NO

REV

A SCALE

30184939 NONE

WT LBS

NONE

SHEET

1

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

Description Where Used

Auxiliary Dolly Assembly, Non-Retract, C-Face Rollers (30184930) 30184930-DWG 76771

Drawing, Aux Dolly Assembly Cam Follower

1 -

1 -

1 8

30184930 30184930

Aux Dolly Assembly Aux Dolly Assembly

Block Dolly Assembly, Non-Retract, C-Face Rollers (30184928) 30184928-DWG 76771

Drawing, Block Dolly Assembly Cam Follower

1 -

1 -

1 8

30184928 30184928

Block Dolly Assembly Block Dolly Assembly

1 1 -

1 1 1

1 1 2 -

96289 96289 94780 94764

Counterbalance Kit Cylinder Assy, C’Bal Cylinder Assy, C’Bal Cylinder Assy, C’Bal

Counterbalance Kit (95031) 95030-DWG 94780-DWG 94764 94764-SK

Drawing, Counterbalance Kit Drawing, Cylinder Assembly Cylinder Seal Kit, Counterbalance Cylinder

SIZE

DWG NO

REV

A SCALE

30184939 NONE

WT LBS

SHEET

6

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

1 1 1 1 1 2 2

1 1 1 1 1 2 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 -

121344-X 30123440 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X

1 1 12 2

116417-500 116417-500 116417-500 116417-500


Motor Housing Assembly (121344-SE-***-10-50SB) 50SB 121344-DWG 30123440-DWG 107138 75981 91255 91046 91923 73302 90133 51300-392-B 51300-349-B 51300-276-B 51300-458-B 89053-V 51300-142-B 88956 88953 74004 88585-SE-Q 30123290 30123290-PK 30173521 30154362 98290 94990 112895

Drawing, Motor Housing Assy Drawing, Washpipe Assembly Sleeve, Wear Gasket Seal Retainer Seal, Housing Bushing, Bail Pin Lip Seal Ring, 3”, Fig 1002 Brake, Air Seal Main Body O-Ring, Bonnet O-Ring, Bail Pin O-Ring, Housing Seal O-Ring, Housing Seal Seal Lip O-Ring, Gear Changer Gasket, Gear Changer Seal, Piston, Gear Changer Sight Gage, Oil Motor, A/C Hi-Torque Washpipe Assembly, SB Packing / Seal Kit Bearing Isolator Shield, Bearing, Washpipe Liner, Upper Stem, Tapered, Wash’p Seal, Oil, Washpipe Seal, Poly Pak, Washpipe

1 1 -

Motor Housing Assembly Washpipe Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Washpipe Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly Motor Housing Assembly

121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 121344-X 30123290 121344-X 121344-X 121344-X 121344-X 121344-X

Rotating Head Assembly (116417-500, Sub Assembly of 121344-**-***-10-****) 116417-DWG 88302 88098 88096

Drawing, Rotating Head Assembly Gasket Glyd Ring Seal, Lip, Bull Gear

1 -

1 1 4 2

SIZE

Rotating Head Assembly Rotating Head Assembly

DWG NO

REV

A SCALE

Rotating Head Assembly Rotating Head Assembly

30184939 NONE

WT LBS

SHEET

2

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used


Guide Dolly Assembly, Non-Retract, Swing, C-Face Rollers (30184932) 30184932-DWG 30172237-DWG 30172237 14783 15208 85195 85678 79862-2 73719 76420-DWG (-3) 77616 76419 76790 76417 77615 76771 82747 82747-N92151 82747-932633Q 88904-DWG 84601-3 82674-SK 82674 82674-SK

Drawing, Guide Dolly Assy Drawing, Motor Align Cyl Assy Motor Align Cylinder Assembly Gauge Valve, Flow Control Motor Alignment Cylinder Seal Kit, Motor Align Cyl Bushing Thrust Bearing Drawing, Counterbalance Manifold Valve, Cartridge, Check Valve, Cartridge, Needle Valve, Directional Control Valve, Directional, Pilot Valve, Pressure Reducing Cam Follower Pressure Filter Seal, Filter Pressure Filter Element Drawing, Accumulator Kit, Align Cyl Accumulator Seal Kit, Accumulator Accumulator, Counterbalance Seal Kit, Accumulator

1 1 1 1 1 1 -

1 1 1 1 2 2 1 1 1

SIZE

1 1 1 1 2 4 1 1 1 1 1 1 1 20 1 1 2 2

Guide Dolly Assembly Guide Dolly Assembly Guide Dolly Assembly Motor Align Cylinder Assy Motor Align Cylinder Assy Motor Align Cylinder Assy Motor Alignment Cylinder Guide Dolly Assembly Guide Dolly Assembly Guide Dolly Assembly Manifold Assy, C’Balance Manifold Assy, C’Balance Manifold Assy, C’Balance Manifold Assy, C’Balance Manifold Assy, C’Balance Guide Dolly Assembly Guide Dolly Assembly Pressure Filter Pressure Filter Guide Dolly Assembly Accumulator Kit Accumulator Guide Dolly Assembly Accumulator

DWG NO

REV

A SCALE

30184932 30184932 30184932 30172237 30172237 30172237 85195 30184932 30184932 30184932 76420-3 76420-3 76420-3 76420-3 76420-3 30184932 30184932 82747 82747 30184932 88904 94601-3 30184932 82674

30184939 NONE

WT LBS

SHEET

3

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used


1 3 2 1 1 1 1 1

1 1 1 1 1 1 1 2 1 1 1 1 -

M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 M614000217 110572-U24 110572-U24 M614000217 110572-U24 92814-U24 85986-U24 85986-U24

Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Motor Electric Kit Manf Assy, 6-Gang w/JBox Manf Assy, 6-Gang w/JBox Motor Electric Kit Manf Assy, 6-Gang w/JBox Manifold Assy, 6-Gang

Motor Electric Kit, UL (M614000217-SE/SH-U24) M614000217-DWG 129991-01A 93939 76842 79388 87541 76841 83095 84882 84665 10743 88083 110572-DWG 92814-DWG 85986-U24 82172 82173

Drawing, Motor Electric Kit Gland, Barrier Proximity Sensor Switch, Differential Pressure Switch, Pressure, IBOP Switch, Pressure, Oil Switch, Pressure, Purge Switch, Pressure, BX Elev Switch, Proximity Switch, Temp Muffler, Short Exhaust Valve, Quick Exhaust Drawing, Air Manifold Assembly Drawing, 6-Gang Valve Assembly Valve, Versa Seal Kit, Valve Body Seal Kit, 4-Way Valve

1 3 2 1 1 1 1 1

Auxiliary Hydraulic Manifold for Hydraulic Link Tilt and BX Elevators 116021-DWG 82695-1 82695-1 82695-1 94518-23IN 82697-10-B16 82695-12-B16 82695-10-B16 93547-2B75N 111664-1EN 94518-13HN 94536-130N 116641-2BN 116585-1N010

Drawing, Hydraulic Manifold Assy Kit, Seal Kit, Seal Kit, Seal Valve, Cartridge, Counterbalance Valve, Solenoid, EEx Valve, Solenoid, EEx Valve, Solenoid, EEx Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Relief Valve, Cartridge, Counterbalance Valve, Cartridge, Check Valve, Cartridge, Relief Valve, Cartridge, Flow Fuse

1 1 1 1 -

1 1 1 1 -

1 1 1 1 1 1 1 1 1 1 1 1 1 1

30181871 82697-10-B16 82695-12-B16 82695-10-B16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16 116021-C16

Motor Electric Kit Solenoid, Hyd Manf Assy Solenoid, Hyd Manf Assy Solenoid, Hyd Manf Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy Hydraulic Manifold Assy

1 -

1 -

1 1 1

109412-2A1 109412-2A1 109412-2A1

Local Cooling Assembly Local Cooling Assembly Local Cooling Assembly

Local Cooling System (109412-2A1) 109412-DWG 109411 88229

Drawing, Motor Cooling System Heat Exchanger Motor Blower, 20HP, UL

SIZE

DWG NO

REV

A SCALE

30184939 NONE

WT LBS

SHEET

4

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

1 4 1 2 4 4 4 2

1 6 2 1 3 6 6 6 3

1 1 1 1 1 1 1 1 1 1 -

30181397 30181397 30181397 30181233 30111013 30111013 30181233 30181397 30181397 30181397 30181397 30175768-MECH 30175768-MECH 30175768-MECH 30175768-MECH 30181233 30181397 30176000

1 1 -

1 1 2 1 1 1

1 1 2 1 1 1 1 1 1

30176118 30176118 30176118 30176118 30176118 30181991 30176118 30176118 30176118

Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Oil Circulating Assembly Motor/Pump Assembly Motor/Pump Assembly Motor/Pump Assembly

1 2 1 2

1 2 1 2

1 2 1 1 2

94075 94075 94075 94075 91677-515 84617-501

S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Installation Kit S-Pipe Assembly Elbow


Oil Circulation Kit, UL, 460VAC (30181397) 30181397-DWG 30177032 115217-1D0 30111013 30111013-1 30111013-5 97575 115217-1F2 30156468-P1D 30176001 30175768-MECH 30175768-15 30175768-1 30173422-14 30156633-10 108216-16 30176000 30176000-3

Drawing, Oil Circulation Kit Thermometer, 3 inch diameter Gage, Pressure Filter Assembly, 60 Microns Dual Element, Filter, 60 Microns Magnetic Separator Valve, Thermostatic Gage, Pressure Switch, Differential Pressure Gage, Differential Pressure Filter, 25 , w/Dirt Alarm Connector Filter Filter Element Magnet Assembly O-Ring Ball Valve, 1 NPTF Strainer, Y-Style Element, Y-Style Strainer

Oil Circulating Kit Oil circulating Kit Oil circulating Kit Oil Circulating Kit Filter Assembly Filter Assembly Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Oil Circulating Kit Filter, 25μ Filter, 25μ Filter, 25μ Filter, 25μ Oil Circulating Kit Oil Circulating Kit Strainer, Y-Style

Oil Circulating Assembly (30181991) 30181991-DWG 30181832-DWG 30176029 30155689-2 30155689-3 30182305 97578-2 30156301-3 30177975

Drawing, Oil Circulating Assembly Drawing, Electrical Interconnect Flowmeter Flow Switch, .25 GPM Flow Switch, 1.2 GPM Motor/Pump Assembly Motor, 5HP, 460VAC, UL Pump, Screw Coupling

S-Pipe Installation Kit (94075-17) 94075-DWG 51300-425-B 91677-DWG 91677-515 84617-501 114833

Drawing, S-Pipe Installation Kit O-Ring Drawing, S-Pipe Assembly S-Pipe Assembly Elbow, 4”, Fig 1002 Seal

SIZE

DWG NO

REV

A SCALE

30184939 NONE

WT LBS

SHEET

5

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used


1 1 1 1 -

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1

30179600-*** 30179600 3017960-W35A 30172885-500 30172885-500 30172885-500 30172885-500 30172885-500 30172885-500 90811 3017960-W35A 90811-500 90811-500

PH-85 Installation Kit Upper IBOP PH-85 Installation Kit Upper IBOP Upper IBOP Upper IBOP Upper IBOP & Lower IBOP Upper IBOP & Lower IBOP Upper IBOP & Lower IBOP Lower IBOP PH-85 Installation Kit Lower IBOP Lower IBOP

1 2 1 1 2 2 2 1 1 1 1

95461-*** 95461-*** 95461-*** 95461-*** 95461-***B & -***BX 95461-***B & -***BX 95461-***B & -***BX 95461-***B & -***BX 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 95461-*** 94518-13HN 94537-175N

Clamp Cylinder Clamp Cylinder Clamp Cylinder Jaw Assembly Manifold, Elevator Tilt Manifold, Elevator Tilt Manifold, Elevator Tilt Manifold, Elevator Tilt Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Torque Wrench Assembly Valve, Cartridge, C’balance Valve, Cartridge, Check

1 2

30116378 30116378

PH-85 Installation Kit (30179600-J35A) 30179600-DWG 30173885-DWG 30173885-500 30177237-DWG 30177237-2 30177237-1 77408 79489-14 89141-18 90811-DWG 90811-500 95385-2 95385-1

Drawing, PH-85 Installation Kit Drawing, UIBOP Upper IBOP Valve Assembly Drawing, Repair Kit Repair Kit, - Complete Repair Kit – Soft Seals Wrench, IBOP Seat Puller Nut Wrench Drawing, LIBOP Lower IBOP Valve Assembly Repair Kit, - Complete Repair Kit – Soft Seals

PH-85 Torque Wrench Assembly (95461-ATBX, Sub Assembly of 30179600-J**) 72221 72219 72220 81788 30116378-DWG 94537-175N 94518-13HN 94521-1DN 91223 91224 90849 91854 71847 91265 95461-DWG 98006-13N 98006-13N

Rod, Wiper Seal, Piston Seal, Rod Die Drawing, Manifold Assy, Elev Tilt Valve, Cartridge, Check Valve, Cartridge, Counterbalance Valve, Cartridge, Shuttle Bushing, Actuator Bushing, Sleeve Bushing, Torque Cylinder Bushing, Torque Cylinder Cam Follower Cylinder, Hydraulic, Clevis Assy Drawing, Torque Wrench Assy Seal Kit, Counterbalance Valve Seal Kit, Check Valve

4 1 1 -

50 1 2 2 2 2 2 1 1 1

Rectifier Manifold Assembly (30116378, Sub Assembly of 95461-***B & -***BX) 30116378-DWG 94536-130N

Drawing, Manifold Valve, Cartridge, Check

1 -

1 -

SIZE

DWG NO

REV

A SCALE

Manifold, Rectifier Manifold, Rectifier

30184939 NONE

WT LBS

SHEET

7

OF

9

DCF0045 (REV B)

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used


RBS-4 Installation Kit (30183592 & -1) 30183592-DWG 126558-DWG 126992-DWG

Drawing, RBS-4 Installation Kit Drawing, Hyd Schematic, RBS-4 Drawing, Elec Interconnect

1 1 1

1 1 1

1 1 1

30183592 30183592 30183592

RBS-4 Installation Kit RBS-4 Installation Kit RBS-4 Installation Kit

127321-DWG 127354 83444-05 86959-5 86959-4 107030-16 94536-330N

Drawing, Bulkhead Plate Assy Assembly, Inlet Manifold Gland Inlet Filter Assembly Element Inlet Filter Assembly Ball Valve Valve, Cartridge, Check

1 2 2 -

1 2 2 -

1 1 2 2 1 1 1

30183592 127321 127321 86959-4 127354 127354 127354

Bulkhead Assembly Bulkhead Assy Bulkhead Assy Bulkhead Assy/Inlet Filter Bulkhead Assy/Inlet Filter Bulkhead Assy/Inlet Manf Bulkhead Assy/Inlet Manf

30126664-DWG 94518-13HN 126663-DWG 108894-B25 108894-P23 108894-R13 108894-G13 108894-Z703 108894-Y2

Drawing, Lift Cylinder Assembly Valve, Cartridge, Counterbalance Drawing, Lift Cylinder SCD Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland

1 -

1 1 1 1 1 1 1

1 1 1 1 1 1 1 1

30183592 30126664 30126664 126663 126663 126663 126663 126663 126663

Lift Cylinder Assembly Lift Cylinder Assy Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl Lift Cylinder Assy/Lift Cyl

140717-DWG

Drawing, Tong Arm Elec/Stab Head (140717-2) Gland Flow Divider Drawing, Regen Clamp Manifold Manifold, Clamp Regen Valve, Cartridge, Fixed Flow Valve, Cartridge, Pilot-Close Drawing, Control Manifold Seal Kit, Solenoid Valve Valve, Cartridge, Check Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Check, Pilot-Open Valve, Cartridge, Logic Valve, Cartridge, Logic Valve, Cartridge, Pilot Operated Valve, Cartridge, Pressure Comp Valve, Cartridge, Reducing Valve, Cartridge, Relief Valve, Cartridge, Remote Pilot Valve, Cartridge, Sequence Valve, Cartridge, Shuttle

30183592

Tong Arm Electrical

83444-01 126811-220 126584-DWG 126584 109302-375NB 94537-375N 126581-DWG 112554-SK 94536-330N 107029-375N 107029-130N 93547-1B75N 94534-3CXN 94534-1CLN 93542-05D 107610-1HN 116641-3AN 94522-1BN 117068-1REN 107236-1AN 94521-1DN

1 1 1 -

2 1 1 1 -

SIZE

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1

Tong Arm Elec/Gland Tong Arm Elec/Flow Divider

140717 126584 126584 140717 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S 126581-SGE-3-S

Tong Arm Elec/Reg Manifold Tong Arm Elec/Reg Manifold Tong Arm Elec/Reg Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Manifold

DWG NO

REV

A SCALE

140717 140717

30184939 NONE

WT LBS

SHEET

8

OF

9

DCF0045 (REV B)

Part Number

112554-D2 112554-J2 126540-DWG 30158598 30158597-DWG 108894-B50 108894-P50 108894-R20 108894-G20 108894-Z677 108894-Y4 30113000 30158763 30158597 124223-3 94518-13HN 108894-B20 30158763-PK 108894-10 108894-G10 108894-Z676 108894-Y1 123305-DWG 118844-24-16 126648-DWG 118844-32-32 118844-28-38 118844-48-48 118844-32-40 118844-48-40 118844-32-28 118844-32-40 30158606-1-DWG 126404-DWG 30126114 126650-DWG

Description

Valve, Directional Valve, Directional Drawing, Tong Arm & Stab Head Hyd (126540-1) Retract Cylinder Assy Drawing, Cylinder Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland Bushing Cylinder, Latch, 1-1/2 Stroke Cylinder, Latch, 1-1/2 Stroke Switch, Limit Valve, Cartridge, Counterbalance Seal Kit, Body Seal Kit, Piston Seal Kit, Rod Seal Kit, Rod & Gland Wrench, Gland Spanner Wrench, Rod Gland Drawing, Stabbing Head Assembly (123305-500) Bushing, Fiberglide Frame Assembly Bushing Bushing Bushing Bushing Bushing Bushing Bushing Drawing, Clamp Cylinder Assembly Drawing, Carriage Assembly Cam Follower, 6 inches Drawing, Retract/Latch Cyl Assy

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

1

1

1 1 1

126581-SGE-3-S 126581-SGE-3-S 140717

1 1

1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

126540 30158598 30158597 30158597 30158597 30158597 30158597 30158597 30158598 30158598 30158598 30158598 30158598 30158763 30158763 30158763 30158763 30158763 30158763 123305

Tong Arm Elec/Ret Cy Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Ret Cyl Tong Arm Elec/Stab Head

1 1 2 1

2 2 2 2 2 2 2 2 2 1 1 2 1

1 1 8 1

30158717 30158592 30178431 30178431 30178431 30178431 30178431 30178431 30158606-1 30178431 126404 126404 30182592

Tong Arm Elec/Stab Head Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Frame Assy Tong Arm Elec/Carriage Tong Arm Elec/Carriage RBS Installation Kit

SIZE

Tong Arm Elec/Manifold Tong Arm Elec/Manifold Tong Arm Elec/Ret Cyl

DWG NO

REV

A SCALE


30184939 NONE

WT LBS

SHEET

9

OF

9

DCF0045 (REV B)


TDS-4S CONTROL SPARES LIST PETROBRAS P-14

NOTES: 1. 30184734-1 Recommended Commissioning Spares 2. 30184734-2 Recommended Operational Spares 3. 30184734-3 Recommended Insurance Spares

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.

CURRENT DRAWN

CONTROL SPARES LIST, TDS-4S, PETROBRAS P-14

INITIAL T. GONZALEZ

CHECKED

T. JORDAN

APPVD

T. JORDAN

DATE

TITLE

11/07/07

SIZE

DWG NO

REV

A SCALE

30184734 NONE

WT LBS

SHEET

1

OF

3

DCF0045 (REV B)

Part No.

Description

-1 Recom. Commission Spare

-2 Recom. Operational Spare

-3 Recom. Insurance Spare

Where Used


92119-6 Barrier, Potentiometer Converter 141611 Power Supply 15VDC, 1A

1

-

1

30184445

Control System Assy.

1

-

1

30184445


122627-02 Power Supply 24VDC, 10A

1

-

1


122627-36 Digital Input Module, 16x24VDC 112627-101 Digital Relay Output Module, SM322 122627-142 Analog Input, SM331, 8Ch

1

-

1

30184445 & P804000014ASM-001 30184445

1

-

1

30184445


2

-

2


1 1 2

-

1 1 2

2

-

2

-

-

1

30184445& P804000014ASM-001 30184445 30184445 30184445 & P804000014ASM-001 30184445 & P804000014ASM-001 30184445

-

-

1

30184445


-

-

1

30184445


1 1 1 -

1

1 1 1 1

30184445 30184445 30184445 30184445

Control System Assy. Control System Assy. Control System Assy. Control System Assy.

-

1

1

30184445


1

10 -

1 1 1 1 2

Control System Assy. Control System Assy. Control System Assy. Control System Assy. Control System Assy.

1 1

-

2 1

92119-8 Barrier, I.S.

1

-

1

30184445 30184445 30184445 30184445 30184445 & P804000014ASM-001 30184445 P804000014ASM-001 P804000014ASM-001

98263 Barrier, I.S.

1

-

1

Remote I/O J-Box

111070 Barrier, I.S.

1

-

1

1

-

1

1

-

1

P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001

122627-19 Analog Output 122627-76 Frequency Counter 112627-101 Digital Relay Output Module, SM322 122627-14 Digital Output

122627-27 Front Connector, Screw Terminal, 20 Pins 122627-75 Front Connector, Screw Terminal, 40 Pins 122627-34 Profibus Connector w/PG Socket . 122627-143 CPU 315-2DP 30123233-10E Isolator, Analog Signal 3071075 Isolator, Analog Signal 30087708-59 Light, Indicator, Clear 24V DC 30087708-39 Light, Indicator, Green 24V DC 30087708-44 Lamp, Bayonet 24V DC 30087708-37 Switch, 3 Position 30087708-27 Switch, 2 Position 81736-2 Potentiometer, 2W, 10K 118910-7 Relay,DPDT, 2NO, 24V

118910-17 Relay,DPDT, 2NO, 120V 30171978 Barrier, .I.S.

122627-01 Power Supply 24VDC, 5A 122627-127

ET200S POWER MODULE

SIZE

Control System Assy. Control System Assy. Control System Assy.



Control System Assy. Remote I/O J-Box Remote I/O J-Box

Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box

DWG NO

REV

A SCALE


30184734 NONE

WT LBS

SHEET

2

OF

3

DCF0045 (REV B)

122627-128 ET2OOS Power Module Base 122627-125 ET200S Counter Module

1

-

1

1

-

1

122627-126 ET200S Counter Module Base 114054-3110 Thermostat

1

-

1

-

-

1

114054-3107 Heater

-

-

1

-

1

1

30156246 Atos Profibus Solenoid Driver

SIZE

Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box Remote I/O J-Box

DWG NO

REV

A SCALE

P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001 P804000014ASM-001

30184734 NONE

WT LBS

SHEET

3

OF

3

DCF0045 (REV B)

D811000252-MAN-001

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