6. The Advantages of Top Drives
• Reaming in or out in sloughing formations
• Minimized Stuck Pipe, Jarring & Lost Wells
• Higher Average ROPs (drilling with stands)
• Reduced Tool face re-orientation times
• Improved well control while tripping (IBOPs)
• More Precise Torque Control on Connections
8. A brief history of 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 threshold in 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.
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 Torque Motors 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
14. Small, Compact Top Drive
Land Rigs
Small Platform Rigs
Small Jack-Up Rigs
Portable & Mobile
Reduced Size & Weight
Quick Rig-Up & Rig-Down
Low Maintenance Cost
Precise Torque Control
TDS- 9/11S Top Drive
15. Large Top Drive Features…….
Full Torque Capability
Remote Break-Out
Reverse Link-Tilt
Rotating Head
Dual IBOP
…..Plus Many Other Features…..
Remote (Powered) Elevator Positioning
On-Board Hydraulic Power
Integrated Mousehole Kick-Out
Self-Locking Guide Beam
Precision AC Control
Higher Stall Without Overheating
No Brush Maintenance
TDS- 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
18. 350 or 400 hp 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)
Air Exhaust
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-Tilt Assembly
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
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
600 VAC
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
28. Unit Identification
Top Drive
Identification Plate
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
31. Insert the grounding rod 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 Lifting Points
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)
37. Typical Mast Interface
Existing Travelling 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
40. Lubrication Schedule
Replace Gearbox Oil Following Initial Break-In Following 1st Month of Operation
Replace Gearbox Oil and Perform Oil Analysis Every 6 Months
Replace Gearbox Oil Filter Every 3 Months
Remove, Clean and Replace Magnetic Drain Plug Annually
Action Frequency
Transmission
41. Lubrication Schedule
Sight Glass
Cork Ball
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 Hydraulic System Analysis Every 6 Months
Replace the Hydraulic Fluid Annually (or depending on analysis)
Replace the Hydraulic System Filter Every 3 Months
Action Frequency
Hydraulics
44. Lubrication Schedule
Motors
Lubricate the AC 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
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
76. Varco
Driller’s Console
PH-50 Pipe Handler
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
Inspecting Elevator 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
79. PH-50 Pipe Handler
Inspecting Link-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-50 Pipe 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
85. PH-50 Pipe Handler
Inspecting the 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 Pipe Handler
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
Rotating Link 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”
90. On-Board Hydraulics
Hydraulic Oil
Filter
Counterbalance
Accumulator
Upper IBOP
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
Main Hydraulic 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
Daily Inspections
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
Maintenance Schedule
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 32 46
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
102. Hydraulic System Maintenance
Setting up the Circuits
10hp AC Pump
Motor
Fixed Displacement
Pump
Variable Displacement
Pump
Guide Beam
Pump/Motor
Pump Pressure
Compensator
103. Hydraulic System Maintenance
Setting up the Circuits
Reading @ PV
Reading @ SA
10 20 30 40 50 60
0
150
1000
800
1700
2000
3000
Approximate Time (s)
Pressure
(psi)
110. Hydraulic System Maintenance
Setting up 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
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
115. Hydraulics Troubleshooting
Brakes
Brake Does Not
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
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
120. Hydraulics Troubleshooting
Link Tilt Cylinders
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
122. Hydraulics Troubleshooting
Gearbox Lubrication System
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 Lubrication System (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
125. Hydraulics Troubleshooting
Rotating Link Adaptor
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
153. Locate the Top Drive 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
