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- 2. TDS 11 MechanicalSystems Safety! Top Drive Development Lubrication Guide Beams & Carriage Motor Housing & Transmission PH-50 Pipehandler On-Board Hydraulics Program Contents
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- 5. History of TopDrive Development
- 6. The Advantages ofTop Drives • Reaming in or out in sloughing formations • Minimized Stuck Pipe, Jarring & Lost Wells • Higher Average ROPs (drilling with stands) • Reduced Tool face re-orientation times • Improved well control while tripping (IBOPs) • More Precise Torque Control on Connections
- 7. The Advantages ofTop Drives + INCREASED SAFETY
- 8. A brief historyof Top Drives Since the advent rotary drilling in the early 1900s, drilling technology has made steady and, in some cases, spectacular progress. In a little over 100 years, well depths have gone from the 70- foot depth of Drake's Well to over 40,000 feet at the rig on Kola Peninsula east of Finland. To accomplish this, advances were necessary in rig design, equipment, bits, materials and drilling techniques. Varco International, Inc., is proud of its part in advancing the technology of drilling. In 1982 they introduced the industry's first top drive drilling system. By replacing the traditional rotary drive and kelly with an advanced system that rotates the drill string and handles entire 93-ft. stands of pipe, Varco was able to reduce drilling time by up to 25% while increasing the overall capability and efficiency of the drilling operation. As a result, Varco Top Drive Drilling Systems have now become the new performance standard for the drilling industry. And Varco continues to extend the threshold of Top drive technology with the introduction of a complete line of AC top drive systems.
- 9. A new thresholdin AC technology For years the backbone of oil industry power has been the 1000 hp DC traction motor adapted from locomotives. They are used extensively to power a variety drilling operations including drawworks, rotary tables and mud pumps. DC traction motors area rugged, dependable, readily available source of high torque electric power. These characteristics made them the ideal choice for the conversion of drilling equipment from direct drive diesel to electric power. In developing its Top Drive systems, Varco first turned to these DC motors to power its new technology. And while they were appropriate for some applications, it became evident that smaller, more compact motors were needed for today's performance requirements. There was a need for an efficient,high performance alternative to traditional DC systems. As part of Varco’s ongoing development effort, various AC motors and drives were reviewed in an effort to satisfy the specific requirements of drilling applications. Varco design engineers determined that rapid developments in adjustable frequency technology made AC drives and motors a better solution for certain applications traditionally served by DC systems. These modern AC motor/control combinations are uniquely suited for the requirements of the drilling industry. By optimizing various components, rugged, reliable AC drives and motors now can produce superior power density for a given frame size. The result - compact, efficient power plants that extend the performance envelope of drilling operations.
- 10. 9,000 10,000 11,000 12,000 13,000 14,000 15,000 0 2 46 8 10 12 14 16 18 20 Drilling Days Depth Drilled (ft) Typical Horizontal Comparisons ~ 14,000’ Wells No Top Drive Top Drive Installed Deviated Wells
- 11. Typical Horizontal Comparisons~ 16,500’ Wells 11,000 12,000 13,000 14,000 15,000 16,000 17,000 0 2 4 6 8 10 12 14 16 18 20 Drilling Days Depth Drilled (ft) 22 24 No Top Drive Top Drive Installed Deviated Wells
- 12. New High TorqueMotors are Introduced Integrated Swivel Reduces System Height The IDS –1 becomes Varco’s First Portable Drive TDS-7 becomes the First AC Top Drive TDS-9 becomes the First Dual AC Motor Top Drive TDS-1 uses a Locomotive Motor TDS-3 becomes the Industry Standard TDS-4 becomes the NEW Industry Standard 1981 1983 1988 1989 1990 1991 1993 1994 1996 1997 TDS-3 TDS-3H TDS-4H TDS-1 TDS-2 Single Speed 5.33:1 TDS-4 TDS-5 Two Speed - 7.95 & 5.08:1 Single Speed - 6.67:1 TDS-3S TDS-4S TDS-6S Single Speed - 5.33:1 Single Speed - 5.33:1 Two Speed DC - 5.33:1 @ 2,200hp TDS-6SB IDS-1 Single Speed Planetary - 6:1 @ 1,150hp TDS-7S Single Speed AC - 5.3:1 @ 990hp TDS-9S Dual Motor AC - 10.5:1 @ 700hp TDS-10S Single AC - 13.1 or 4.8:1 Ratio @ 350hp TDS-8S TDS-3/4SAC TDS-11S Single Motor AC – 9.0:1 @ 1,150hp 1,150hp AC Upgrades Dual Motor AC - 10.5:1 @ 820hp DC to AC Upgrades are Offered Top Drive Development
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- 14. Small, CompactTop Drive Land Rigs Small Platform Rigs Small Jack-Up Rigs Portable & Mobile Reduced Size & Weight Quick Rig-Up & Rig-Down Low Maintenance Cost Precise Torque Control TDS- 9/11S Top Drive
- 15. Large Top DriveFeatures……. Full Torque Capability Remote Break-Out Reverse Link-Tilt Rotating Head Dual IBOP …..Plus Many Other Features….. Remote (Powered) Elevator Positioning On-Board Hydraulic Power Integrated Mousehole Kick-Out Self-Locking Guide Beam Precision AC Control Higher Stall Without Overheating No Brush Maintenance TDS- 9/11S Top Drive
- 16. 500 Ton,700 hp or 800 hp Versions Integrated Swivel and Counterbalance Dual AC Drilling Motors 10.5 : 1 Single Speed Transmission 32,500 or 37,500 ft.lbs Continuous Torque 46,000 or 55,000 ft.lbs Intermittent Torque 0-228 rpm Drilling Speed PH-50 Pipehandler 50,000 ft.lbs Torque 15,000 psi Rated Dual IBOPs Compact Link Tilt Mousehole Kick-Out Self-Locking Guide Beam Ex and UL Electrical Models 25,250 lbs Unit Weight TDS- 9/11S Top Drive
- 17. 0 50 100150 200 250 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 Rotating Speed (rpm) Torque (ft.lbs) 800hp Version 700hp Version Torque/Speed Curves
- 18. 350 or 400hp AC Drilling Motor (2) Cooling System Air Duct (2) Drive Stem Gooseneck ( S-Pipe) Washpipe Packing Assembly Bonnet 10.5 : 1 Transmission Hydraulic Brake (2) Cooling Fan Motor (2) System Bail TDS- 9/11S Power Train
- 19. Air Inlet (550 CFM) AirExhaust Motor Brake Motor Frame (Laminated) Motor Shaft Pinion Gear Rotor Assembly (Laminated) End Coil Guide Roller Bearing End Coil Stator Assembly (Laminated) Thrust Ball Bearing Alternating Current Motor
- 20. Powered Elevator Positioner (360º) Link-TiltAssembly Lower IBOP Valve Back-Up Clamp Adjustable Stabbing Guide Rotating Link Adapter Upper IBOP & Accumulator Assembly Torque Arrester Frame 350T - 108” Elevator Links 350 or 500T Elevators PH-50 Pipe Handler
- 21. PH-50 - Link-TiltPositions
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- 23. Main Shaft Upper IBOP &Dual Crank Actuator Lower IBOP (Manual) Saver Sub Upper IBOP Actuator Cylinder Assembly Tool Joint Clamps (3) Drill Stem Assembly
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- 25. Cables Service Connections J-Boxes 700hp 800hp UL Ex Quick Disconnects 1 set (3)444 MCM + 1 x Composite N/A Hardwire Connections 1 set (3) 646 MCM + 1 x Composite 1 x Power + 1 x Composite Hardwire Connections Hardwire Connections UL Ex 1 x Power + 1 x Composite 2 x Power + 1 x Composite 1 set (3) 646 MCM + 1 x Composite 2 sets (3) 444 MCM + 1 x Composite Quick Disconnects 1 set (4) 646 MCM + 1 x Composite N/A Hardwire Connections 2 sets (3) 444 MCM + 1 x Composite 2 x Power + 1 x Composite Hardwire Connections Hardwire Connections 1 set (4) 646 MCM + 1 x Composite 2 sets (3) 444 MCM + 1 x Composite 1 x Power + 1 x Composite 2 x Power + 1 x Composite Service Loop Configurations Land/ Portable Land/ Portable Land/ Portable Land/ Portable Offshore/ Fixed Offshore/ Fixed Offshore/ Fixed Offshore/ Fixed
- 26. Variable Frequency Drive AC Power Source 600VAC 3-phase, 42-62Hz Rectifier Resultant DC Pulse Capacitors 810 VDC Inverter Controller IGB Transistors 20Hz = 600rpm 40Hz = 1,200rpm TDS-11S 600 VAC 3-Phase, 0-80Hz Variable Frequency Drive
- 27. Typical Floor Layout Driller’s Console Universal Spreader Beam Sectional Guide Beam MastSaddle @ 80ft TDS-11S 86’ Service Loop 75’ Rotary Hose Rathole Mousehole
- 28. Unit Identification Top Drive IdentificationPlate Located on the front of the motor housing Warning Label Located on the side of the bonnet Warning Labels Located on the side of each AC motor AC Motor Identification Label Located on the side of each AC motor Encoder Instruction Label Located on the side of the brake housing
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- 31. Insert the groundingrod into the soil (the rod must be in contact with ground water) Connect the rod to the control house (connection must be clean) Grounding Points Located at opposite corners of the house floor Ground Rod Kit P/N 116004 For offshore installations the control house must be grounded to the ground point on the rig structure Installation The control house must be properly grounded to prevent injury to personnel
- 32. Installation TDS LiftingPoints Lifting Point For lowering/hoisting the Top Drive to/from the skid Bail Lock Must be installed before lowering/hoisting the Top Drive to/from the skid Locking Pins Must be in place prior to moving the skid with the Top Drive attached !Locking Pins Must be in place prior to moving the skid with the Top Drive attached Lifting Points For Lifting the Skid with the Top Drive Attached Lifting Points For Lifting the Skid with the Top Drive Attached Net Weight = 27,000 lb (12,300 kg) With Skid = 30,000 lb (13,600 kg)
- 34. TDS-11S - Consumables TongDies 4 16781 Stabilizer - Front 1 118368 Stabilizer - Rear Flippers – Stabbing Guide Wash Pipe Wash Pipe Tungsten Coated Wash Pipe Packing Kit (Standard) Wash Pipe Packing Kit (HP) Hydraulic Oil Filter Gear Oil Filter 1 118367 1 76442 1 123289 1 123289-TC 1 123290-PK 1 123290-PK-1 1 114416-1 1 111013-1 Part Qty Part No. Stabbing Guide Tong Dies Stabilizers Wash Pipe Hydraulic Oil Filter Gear Oil Filter
- 35. TDS-11S - Dimensions 28” 0.71m 56” 1.42m 62” 1.58m 18.5” 0.47m 214.0” 5.43m 120”Bail 88” Bail 112” 2.85m 233” 5.82m 72” 1.83m 37” 0.94m
- 36. TDS-11S - Envelope 26”(660mm) 36.9” (937mm) 32.6” (828mm) 31.0” (787mm) 33.7” (856mm) 33.8” (859mm) 32.0” (762mm) Standard Setback 22.1” (660mm) 21.1” (536mm) 22.8” (579mm) Front Rear
- 37. Typical Mast Interface ExistingTravelling Equipment 500 ton Hook/Block Combo Type Crown Block Top Bail Rest Tool Joint 13.5’ 4.1m 13.5’ 4.1m 18.0’ 5.4m Clear Working Height 142.0’ (43.3m) Drill Stand Made Up @ 4’ (1.2m) 93.0’ (28.3m) To CL of Beam 10.0’ (3m) min. To Service Loop 7.0’ (2.1m) min. Drill Floor TDS-11S Varco Portable Top Drive System Sectional Guide Beam Assembled On Site Derrick Termination @ ~80’ (24.4m) Mud Hose Connected to Standpipe @ 73’ (22.3m Level) Service Loop Portable Torque Reaction Beam U-Bolted to Spanners 2 x Custom Spanners On A-Frames or Mast Side Panels Varco Driller’s Console Control Cable with Connectors 150’ (45.7m) Unitized Variable Frequency Drive & Control Panel Power Supply AC Cables Power & Control Cables
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- 40. Lubrication Schedule Replace GearboxOil Following Initial Break-In Following 1st Month of Operation Replace Gearbox Oil and Perform Oil Analysis Every 6 Months Replace Gearbox Oil Filter Every 3 Months Remove, Clean and Replace Magnetic Drain Plug Annually Action Frequency Transmission
- 41. Lubrication Schedule Sight Glass CorkBall Gear Oil Filter Pop-Up Dirt Alarm Gearbox Drain Gearbox Oil Drain Transmission Gearbox Oil Fill Check oil level, prior to adding oil (do not mistake the tan colored foam for the dark brown oil) Magnetic Drain Plug YEARLY Remove and clean contamination
- 42. Lubrication Schedule Perform HydraulicSystem Analysis Every 6 Months Replace the Hydraulic Fluid Annually (or depending on analysis) Replace the Hydraulic System Filter Every 3 Months Action Frequency Hydraulics
- 43. Lubrication Schedule Sight Glass CorkBall Hydraulic Oil Filter Pop-Up Dirt Alarm Hydraulic Oil Drain Hydraulics Hydraulic Oil Fill Male Quick-Connect Dust Plug Hydraulic Lubrication Kit Female Quick-Connect
- 44. Lubrication Schedule Motors Lubricate theAC Drilling Motors Every 3 Months 4 Lubricate the Blower Motors Every 3 Months 4 Action Frequency Points Lubricate the Hydraulic Pump Motor Every 3 Months 4
- 45. Lubrication Schedule Motors Grease Fittings PipePlug (1/8”) Grease Fitting (1/8”) Hydraulic Pump AC Motor Grease Fittings AC Blower Motors (2) AC Drilling Motors (2)
- 46. Lubrication Schedule General Lubrication UpperBonnet Seal Weekly 1 Bail Pins Weekly 2 Rotating Link Adaptor Gear Weekly - IBOP Actuator Yoke & Cylinder Pins Daily 5 IBOP Actuator Cranks Daily 2 Upper IBOP Valve Weekly 1 Stabilizer Bushing Daily 4 Clamp Cylinder Gate Daily 2 Carriage Assembly Weekly 8 Torque Arrester @ Clamp Cylinder Weekly 4 Wireline Adaptor Weekly 2 Wash Pipe Assembly Daily 1 Elevator Link Eyes Weekly 4 Action Frequency Points
- 47. Lubrication Schedule General Lubrication RotatingLink Adaptor Upper Bonnet Seal Wash Pipe Assembly Bail Pins (2) Rotating Link Adaptor Gear
- 48. Lubrication Schedule General Lubrication IBOPActuator Cylinder Pins IBOP Actuator Yoke IBOP Actuator Yoke IBOP Actuator Cranks Torque Arrester Tubes Clamp Cylinder Gate Clamp Cylinder Gate Stabilizer Bushing Stabilizer Bushing Upper IBOP Valve ¼” NPT Plug
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- 52. Hang-Off Link Bores GuideBeams & Carriage Inspecting the Crown Padeye & Hang-Off Link Shackle 2.1” (52mm) min 2.0” (50mm) min 1.5” (15mm) min Annually Crown Padeye MPI Monthly Crown Padeye Visual Monthly Cotter Pin Visual Monthly Shackle Inspect Monthly Hang Off Links Inspect
- 53. Guide Beams &Carriage Inspecting the Crown Padeye & Hang-Off Link Monthly Bolt Assembly Inspect Monthly Safety Pin Inspect Hang-Off Link Bores 1.5” (15mm) min Bolt Assembly 2.1” (52mm) min Monthly Hang-Off Link Inspect
- 54. Guide Beams &Carriage Inspecting the Guide Beam Joints Annually Beam Joints MPI Monthly Beam Joints Inspect Lynch Pin Daily Retainer Pin Inspect Weekly Beam Joints Inspect Daily Lynch Pin Inspect
- 55. Guide Beams &Carriage Inspecting the Main Tie-Back Bolted Connections Annually All Welds MPI Daily Alignment Inspect Weekly All Welds Inspect Weekly All Bolts Inspect Auxiliary Spreader Beam Mast Leg Tie-Back Link Guide Beam Bottom Section Tie-Back Plate Main Spreader Beam
- 56. Guide Beams &Carriage Inspecting the Intermediate Restraints Guide Beam Main Girt Weekly Studs/Nuts Inspect Weekly Pin/Cotter Pin Inspect Annually All Welds MPI Daily Alignment Inspect
- 57. Guide Beams &Carriage Inspecting the Carriage Weekly Rollers Inspect Daily Detent Pins Inspect
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- 59. Motor Housing &Transmission Internal Lubrication Flow Pipe Plugs Monthly Pipe Plugs Inspect Monthly Spillway Inspect Monthly Gear Drain Inspect
- 60. Motor Housing &Transmission Adjusting the Encoder(s) Encoder Belt Belt Tension Spring Belt Tension Spring Sled Hold-Down Screws (4) Sled Hold-Down Screws (4) Sled Sled Electrical Connector
- 61. Motor Housing &Transmission Inspecting the Gearbox Lube Pump Hydraulic Motor O-Ring Main Body CapScrew (10) Pump Adaptor Plate Roller Bearings (4) Gear Set Body Seal Gear Housing Thrust Plate Ring Seal End Cover
- 62. Motor Housing &Transmission Inspecting Gear Backlash Dim A + Dim B = Backlash A A B B Solid Wire Solder 6 Monthly Gear Backlash Inspect
- 63. Motor Housing &Transmission Inspecting Bail & Main Body Annually Bail Inspect Annually Bushings (2) Inspect 5 Yearly Main Body Cover MPI 5 Yearly Main Body MPI Annually Bail Pin Inspect Component Minimum Dimension Bushing ID < 4.45” Bail Pin ID < 4.125”
- 64. Motor Housing &Transmission Inspecting S-Pipe Wing Nut Seal Ring Plug Clamp Bolts Seal Ring Wing Nut Monthly S-Pipe Inspect Monthly S-Pipe Pressure Test
- 65. Motor Housing &Transmission Inspecting Main Shaft Liner PolyPack Seal Wash Pipe Assembly Monthly Main Shaft Liner Inspect Polypack Seal Main Shaft
- 66. Motor Housing &Transmission Inspecting Wash Pipe Assembly Wash Pipe Nut Packing Box 3” Bore Wash Pipe Wrench Dowel Pin LEFT HAND THREADS! Socket Head Screw
- 67. Motor Housing &Transmission Inspecting Wash Pipe Assembly Daily Wash Pipe Inspect Upper Spacer Middle Spacer Middle Spacer Lower Spacer O-Ring O-Ring Snap Ring Holding Ring Packing Seal Wash Pipe Nut Wash Pipe Packing Assembly Box Straight Grease Fitting Socket Head Screw
- 68. Motor Housing &Transmission Inspecting Upper Bonnet Seals Cap Screw (6) Bearing Shield Bearing Retainer Lube Tube Lube Tube O-Ring Shims Annually Retainer O-Ring Inspect Annually Bearing Isolator Inspect Annually Oil Seal Inspect Lube Tube O-Ring Bearing Shield Bearing Retainer Cap Screws (6) Bearing Isolator Oil Seal
- 69. Motor Housing &Transmission Inspecting Main Shaft <0.65” Radial Grooves <0.62” 5 Yearly Stem MPI 5 Yearly Split Load Collar MPI Annually Radial Grooves Inspect Retainer Ring
- 70. Motor Housing &Transmission Inspecting Main Shaft End-Play Bearing Retainer Shims Cap Screws (6) Dial Indicator Annually Main Shaft Inspect
- 71. Motor Housing &Transmission Inspecting Blower Motor Assemblies Monthly Loose Bolts Inspect Bolts (4) Bolts (4) Drip Shield Fan Motor Cover Motor Fan Bolts (6) Top Bearing Housing
- 72. Motor Housing &Transmission Inspecting Motor Brakes Monthly Calipers & Pads Inspect Caliper Mounting Bolts (2) Steel Plate 0.09” Adjust Caliper Mounting Bracket Brake Pads
- 73. Motor Housing &Transmission Inspecting Drilling Motors Weekly Motor Cables Inspect Weekly Louvers Inspect Weekly Screens Inspect
- 74. Motor Housing &Transmission Transmission Assembly/Disassembly Stem Sleeve Taper Roller Bearing Dowel Pin Bull Gear Upper Stem Liner Poly Pack Seal Main Shaft Stem Tapered Roller Thrust Bearing Main Shaft Sleeve Main Roller Bearing Wear Sleeve Cap Screw Lock Washer Dowel Pin Bearing Retainer Lower Main Bearing Cap Screw Lock Washer Main Body Main Body O-Ring Internal Locknut Retainer Bearing Lock Washer Lower Compound Roller Bearing Spacer Ring Internal Retaining Ring Compound Gear Internal Retaining Ring Upper Compound Roller Bearing Main Body Cover Upper Spray Nozzles Lube Oil Pump Assembly
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- 76. Varco Driller’s Console PH-50 PipeHandler Inspecting Elevator Links Clevis Pin 26” (635mm) Typical Link Upper Catch Link Link Tilt Catch Link Pin Recess in Motor Guard 2 Weekly Link Clamps Inspect 1 ROTATE LIFT & REMOVE Rear Front Monthly Link Eyes Inspect
- 77. PH-50 Pipe Handler InspectingElevator Links 4 13/16” 5” Upper Eye Dimension (C) Lower Eye Dimension (A) 4 5/8” 4 7/16” 2 3/4” 2 9/16” 2 3/8” 2 3/16” Capacity per Set (Tons) B = 3½” (350 Ton) B = 4½” (500 Ton) B = 6¼” (750 Ton) 5 3/4” 6” 5 1/2” 5 1/4” 3 1/2” 3 1/4” 3” 2 3/4” 7 1/4” 7 1/2” 7” 6 3/4” ? ? ? ? 350 300 225 175 500 420 325 250 ? ? ? ? Upper Eye (Hook) Lower Eye (Elevator) A A C C B B
- 78. PH-50 Pipe Handler InspectingLink-Tilt Monthly Bushings Inspect Monthly Cylinders Inspect Monthly Pins Inspect Monthly Bushings Inspect
- 79. PH-50 Pipe Handler InspectingLink-Tilt Hydraulic Manifold Torque Arrestor Spring Spring Spacer Spring Shims End Cap Clamp Cylinder Body Rig-Up/Run/ Shutdown Valve
- 80. Body Seals Jaw Assembly Hex Head Screws Rear Stabilizer PH-50Pipe Handler Torque Wrench Assembly Manifold Hinge Pin Retainer Front Stabilizer Spring Cylinder Head Ring Cylinder Head Piston Seals Piston Wear Bushing Hinge Pin Stabilizer Spring Retaining Plate Rear/Front Stabbing Guides Gate Tong Dies Clamp Cylinder Body
- 81. PH-50 Pipe Handler Inspectingthe Torque Wrench Assembly Tugger Liner Clamp Cylinder Gate (shown open) Swing Clear Weekly Stabilizers (F/R) Inspect Daily Tong Dies Inspect Weekly Flippers Inspect Weekly Stabbing Guide Inspect Part Replace When Stabilizer Wear > 1/8” Flipper Wear > 1/8”
- 82. PH-50 Pipe Handler Inspectingthe Torque Wrench Assembly Cotter Pin Stabilizer Springs Monthly Stabilizer Springs Inspect
- 83. PH-50 Pipe Handler Inspectingthe IBOP Actuator Weekly Actuator Cylinder Inspect Weekly Actuator Yoke Inspect Monthly Pins & Bushings Inspect Daily Hoses Inspect Part Replace When Pins Wear > 0.3” Bushings Metal Backing Visible
- 84. PH-50 Pipe Handler Inspectingthe Tool Lock Joints Daily Tool Lock Bolts Inspect 1.4” 1.4” 1” 1” 1.4” 1.4”
- 85. PH-50 Pipe Handler Inspectingthe IBOP Valves & Saver Sub Daily Upper IBOP Valve Pressure Test Weekly Upper IBOP Inspect Weekly IBOP Crank Inspect Daily Lower IBOP Valve Pressure Test Weekly Lower IBOP Inspect 5 Yearly Upper & Lower IBOPs MPI Part Replace When Saver Sub Threads have been recut to minimum shoulder-to-shoulder length of 5”
- 86. Shot Pin Bushing PH-50 PipeHandler Shot-Pin Assembly Dowel Pin Shot Pin Rod Seal Assembly Shot Pin Sleeve O-Ring Shot Pin Base Rod Seal Assembly Hydraulic Motor Dual Port Manifold Shot Pin Cap Pinion Gear Shot Pin Cover Shot Pin OD < 1.375” Shot Pin Sleeve ID > 1.510” Shot Pin Bushing ID > 1.475” Part Replace When
- 87. PH-50 Pipe Handler RotatingLink Adaptor Rotary Link Adaptor Retainer Ring O-Ring Rotary GLYD Ring Wiper Seal LEVEL WORKING SURFACE Annually Rotary GLYD Ring Replace Annually O-Ring Replace Annually Thrust Ring Replace Annually Turcite Bushing Replace Annually Piston Ring Inspect Annually Stem Inspect Annually Stem O-Ring Replace Rotating Link Adaptor Gear Index Mark Part Replace When Thrust Ring Less than 0.105” Turcite Bushing Less than 0.112”
- 88. PH-50 Pipe Handler WirelineAdaptor Sheaves Inspect Each Use
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- 90. On-Board Hydraulics Hydraulic Oil Filter Counterbalance Accumulator UpperIBOP Time Delay Accumulator Hydraulic Oil Fill Oil Pressure Switch System Accumulator IBOP Pressure Switch Upper IBOP Actuator Cylinder Counterbalance Manifold Main Hydraulic Manifold Link Tilt Manifold Link Tilt Cylinders Counterbalance Cylinders Hydraulic Oil Reservoir Rotating Head Motor and Shot-Pin Assembly Motor and Pump Assembly Reservoir Capacity 10hp, 1,800rpm Pump Motor 25 Gallons Specifications
- 91. On Board Hydraulics MainHydraulic Manifold Reservoir M 10hp AC Motor Variable Displacement Pump Fixed Displacement Pump System Accumulator IBOP Accumulator Counterbalance Accumulator Counterbalance Cylinders Counterbalance Manifold Drilling Motor Brake Shot-Pin Cylinder Rotating Link Adaptor Lift Rotating Head Motor Rotating Head Piphandler Clamp Cylinder Link-Tilt Cylinders Link-Tilt Manifold Upper IBOP Actuator Cylinder Lube Oil Distribution Hydraulic Motor Lube Oil Pump Sump
- 92. Hydraulic System Maintenance DailyInspections Check Hydraulic Fluid Levels Check for Hydraulic Fluid Leaks Check Condition of All Hydraulic Hoses Check Condition of the Hydraulic Filter Indicator Description
- 93. Hydraulic System Maintenance MaintenanceSchedule Analyze Hydraulic System Oil Once Every 6 Months Replace Hydraulic Fluid Annually (or Depending on Analysis) Inspect Reservoir Bladder Annually Replace Reservoir Bladder Bi-Annually Replace Hydraulic System Filter Once Every 3 Months Description Frequency
- 94. Viscosity Index 3246 Hydraulic System Maintenance Recommended Hydraulic Oils Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union Castrol Manufacturer AW Hyd Oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando Oil HD 32 Azolla ZS 32 Unax AW32 Hyspin AWS-32 -15ºC to 75ºC -10ºC to 85ºC AW Hyd Oil 46 Nuto H46 Harmony 46AW DTE 245 Tellus 46 Hydraway HMA 46 Rando Oil HD 46 Azolla ZS 46 Unax AW46 Hyspin AWS-46
- 95. Hydraulic System Maintenance SightGlass Cork Ball Hydraulic Oil Filter Pop-Up Dirt Alarm Adding & Draining Hydraulic Oil Fill Male Quick-Connect Dust Plug Hydraulic Lubrication Kit Female Quick-Connect Hydraulic Pump Pump Inlet Drain Adaptor
- 96. Hydraulic System Maintenance HydraulicReservoir Bladder Reservoir Breather Reservoir Cover Gasket Hydraulic Oil Reservoir Reservoir Bladder Annually Reservoir Bladder Inspect Reservoir Bladder
- 97. Hydraulic System Maintenance ReservoirBladder Blower & Brake Covers Oil Heat Exchanger Drill Motor Assy. (LHS) Monthly Oil Heat Exchanger Inspect
- 98. Hydraulic System Maintenance SystemTest Ports
- 99. Hydraulic System Maintenance Pre-chargingthe Accumulators Accumulator Setting Port Counterbalance Accumulator (728in³ Displacement) 900psi Discharge CB Time Delay Accumulator (30in³ Displacement) 800psi Discharge C4 System Accumulator (125in³ Displacement) 800psi Discharge SA Counterbalance Accumulator Upper BOP Time Delay Accumulator System Accumulator
- 100. Hydraulic System Maintenance IBOPTiming Circuit
- 101. Hydraulic System Maintenance IBOPand Oil Pressure Switch IBOP Pressure Switch Configuration Oil Pressure Switch Configuration Pressure Adjusting Screw Wires Hoses Annually Hoses Inspect Annually Wires Inspect IBOP Pressure Switch 1500psi (102.0 bar) rising Oil Pressure Switch 18.0psi (+0/-1) decreasing Component Factory Setting
- 102. Hydraulic System Maintenance Settingup the Circuits 10hp AC Pump Motor Fixed Displacement Pump Variable Displacement Pump Guide Beam Pump/Motor Pump Pressure Compensator
- 103. Hydraulic System Maintenance Settingup the Circuits Reading @ PV Reading @ SA 10 20 30 40 50 60 0 150 1000 800 1700 2000 3000 Approximate Time (s) Pressure (psi)
- 104. Hydraulic System Maintenance Settingup the Circuits Manifold Bottom View Manifold Side View RV2 RV1 PF
- 105. Hydraulic System Maintenance Settingup the Circuits
- 106. Hydraulic System Maintenance Settingup the Circuits PCC CB Manifold Bottom View Manifold Side View Manifold End View
- 107. Hydraulic System Maintenance Settingup the Circuits
- 108. Hydraulic System Maintenance Settingup the Circuits Manifold Bottom View Manifold Side View RV2 B1
- 109. Hydraulic System Maintenance Settingup the Circuits Shot Pin Link Adaptor Rotation Gear Hydraulic Motor C5 SV5
- 110. Hydraulic System Maintenance Settingup the Circuits Shot Pin Hydraulic Motor Link Adaptor Rotation Gear A5 C5 B5 Motor Relief Valve Motor Relief Valve Shot Pin Relief Valve A B Test Points
- 111. Hydraulics Troubleshooting HPU &Reservoir Bladder Hydraulic System Overheating Unloading Valve not working Test & adjust UV1 (or replace) Relief Valves RV1 & RV2 improperly set Test pressures & re-set valves Pressure has bled down due to counter- balance mode valve in shut-down too long Check System Pressure No pre-charge in System Accumulator Charge System Accumulator Hydraulic Components Don’t Operate System pressure is too low Test Pumps & Motors Test Relief Valves Check for leaks, loose valves, loose cylinders or worn hoses Piston Pump not working Replace Piston Pump Flexible Coupling damaged Replace Flexible Coupling Lubrication Pump not working Replace Lubrication Pump Pressure at UV1 is too low Adjust UV1 Pumps rotating in wrong direction Check connections & rotation Suction Valve closed Open Suction Valve Low Reservoir oil Fill Reservoir Problem Probable Causes Remedy
- 112. Hydraulics Troubleshooting HPU &Reservoir Bladder
- 113. Hydraulics Troubleshooting Counterbalance &Stand-Jump Counterbalance Does Not Function No hydraulic pressure Test pressure & adjust reducing valve Cylinder damaged or seals leaking Inspect & repair cylinder/seals Solenoid Valve SV9 is not operating Test electrical/hydraulic connection – repair as required PCC not operating Replace valve Stand-Jump Does Not Function Pre-charge too low Charge the accumulator Relief valve not operating Replace valve Cylinder damaged or seals leaking Inspect & repair cylinder/seals No hydraulic pressure Test pressure & adjust reducing valve Problem Probable Causes Remedy Solenoid Valve SV9 is not operating Test electrical/hydraulic connection – repair as required PCC not operating Replace valve Relief valve not operating Replace valve Pre-charge too low Charge the accumulator
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- 115. Hydraulics Troubleshooting Brakes Brake DoesNot Release Directional Valve stuck Test valve and replace if necessary Check Valve is blocked or tube is pinched Check valve & tube Delay in Brakes Actuating Pressure < 1,400psi or does not rise quickly to 1,400psi Adjust or replace reducing valve Hydraulic oil on brake Check for leaks Directional Valve stuck (check pressure at B1) Replace valve or check electrical signal Hydraulic oil contaminated Replace oil Pressure Reducing Valve faulty Replace valve Brake Releases But Drags Mechanic problem with brake Check brake mechanism Problem Probable Causes Remedy Brake Does Not Engage or Slips
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- 117. Hydraulics Troubleshooting Shot-Pin &Clamp Cylinder Shot-Pin Does Not Release Solenoid Valve not operating or needs adjustment Check electrical actuation & test pressure Abnormal pressure change at B5/C5 indicates valve problem Replace Directional Control Valve Relief Valve not operating or needs adjustment Test pressures & adjust No/low pressure at cylinder Test pressures & adjust/repair Shot-Pin Applies Excessive Force Normal pressure change at B5/C5 indicates plumbing or faulty cylinder Repair plumbing or shot-pin cylinder Clamp Cylinder Does Not Actuate Cylinder is damaged Inspect/repair/replace cylinder To provide high pressure to the clamp circuit, pressure at C5 must be 2,000psi and G5 must be less than 100psi. If this condition is met, pressure at CP should increase from less than 100psi to higher than 2,000psi. If not, check the plumbing, rotating link adapter, and clamp cylinder.i Repair plumbing, rotating head, or clamp cylinder. Problem Probable Causes Remedy
- 118. Hydraulics Troubleshooting Shot-Pin &Clamp Cylinder (contd) While clamping, pressure at CR should be 2.7 times the pressure at CP When the dies contact the pipe, pressure at CR should be less than 100psi If the pressure does not fade, check valve CNEC for contamination Clean or repair CNEC valve Control valve not operating Check pressure at C5. Replace valve CV5 if required or the regenerate manifold Shot-Pin Engages But Cylinder Does Not Activate Clamp Cylinder Does Not Actuate
- 119. Hydraulics Troubleshooting Shot-Pin &Clamp Cylinder
- 120. Hydraulics Troubleshooting Link TiltCylinders Elevator Does Not Reach Mousehole or Derrickman Pressure at B1 does not decay to less than 100psi Replace the pilot to open check valve Links Drift When Valve is Released Pilot to open check valve is contaminated or stuck in open position Replace the pilot to open check valve Elevator Does Not Float Back to Center Position Use manual override If the link tilts, the problem is electrical If the links do not tilt, the problem is hydraulic Test the solenoid & connectors Test the hydraulic system Link clamp incorrectly adjusted Check & readjust Faulty cylinder seal Replace cylinder seal Load holding relief valves are stuck open, contaminated or need adjustment Replace or adjust the load holding relief valve Link Tilt Does Not Tilt Solenoid Valve is not shifting Check electrical continuity Problem Probable Causes Remedy Links Do Not Move Together Load holding valves need adjustment Adjust all (4) valves to 1,500psi
- 121. Hydraulics Troubleshooting Link TiltCylinders
- 122. Hydraulics Troubleshooting Gearbox LubricationSystem Oil Leaking From Lower Seal Oil Pump Loss Alarm is On Worn oil seals Replace seals Oil viscosity too high Lower oil viscosity Oil Leaking From Upper Bearing Retainer Worn oil seals Replace seals Gearbox Oil Temperature less than 230ºF Oil level too low or too high Adjust oil level Incorrect oil Replace with recommended oil Damaged gears or bearings Repair or replace Oil level too low or oil overheating Add oil Oil pressure switch needs adjustment Adjust Gear spray nozzle missing Replace spray nozzle Faulty motor Replace motor Oil pump hydraulic motor faulty Replace motor Broken lube pump adaptor plate spline Replace adaptor plate spline Problem Probable Causes Remedy
- 123. Hydraulics Troubleshooting Gearbox LubricationSystem (contd) Oil Pump Loss Alarm is On Restricted Oil Flow Faulty fixed displacement pump. Check pressure at PF and replace pump if pressure is low Oil viscosity too high or oil too cold Lower oil viscosity Low hydraulic fluid in reservoir Add hydraulic fluid Water/Mud in Oil Missing inspection plugs Replace inspection plugs Water in oil Replace oil Worn gears or damaged bearings Replace gears or bearings Foreign particles blocking orifice/ nozzle Clean orifice/nozzle Suction valve closed on fixed displacement pump Open suction valve Upper gearbox seals worn Replace seals Excessive Foaming Metal in Oil Damaged oil pump Replace oil pump
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- 125. Hydraulics Troubleshooting Rotating LinkAdaptor Tool Does Not Rotate Tool Does Not Return to Home Direct control valve or relief valve is sticking Inspect, repair or replace the valve Valve sticking or relief valve needs adjustment Test pressures & inspect valves Adjust relief valves as required Solenoid valve not electrically operating Check electrical/valve functions Shot-pin engaged Adjust the relief valve Mechanical interference Inspect and repair Directional valve does not shift Test pressure left and right Replace valve if necessary Broken sensor Replace sensor Faulty control system Check control system Counterbalance valves need adjustment Adjust valves Motor worn or gear teeth broken Replace the motor Fixed valve orifice plugged Clear orifice or replace valve Hydraulic valves damaged Replace hydraulic lines Problem Probable Causes Remedy Links Not Syncronized
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- 135. PCC CV3 MODE VALVE ACCUMULATOR PRECHARGE 900PSI COUNTERBALANCE CYLINDERS
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- 153. Locate the TopDrive at the bottom of the V-Door ramp Ensure that the bail lock assembly is installed Attach a lifting sling to the bail Attach backup lines to the skid Hoist the Top Drive and skid to the drill floor Ensure the safety of all personnel The Bail Lock Assembly must be installed Tube (P/N 113498) U-Bolt (P/N 113497) 2x 3/4" nuts Be sure that Top Drive is pinned to skid before hoisting to drill floor