Académique Documents
Professionnel Documents
Culture Documents
Top Drive
Drilling
System
Service Manual
SM00400
March 2, 1998
Manual conventions
This manual uses conventions that make it easy for the reader to
locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and its components.
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention. Note the examples below
and pay close attention to these important advisories.
z
e
ii
TDS-10S
About thisContents
manual
Contents
Book 1 Description, Installation and Operation
Preface
Manual conventions............................................................
Safety information ..............................................................
Directional references .........................................................
Illustrations .........................................................................
Manual layout.....................................................................
Varco service centers ...........................................................
5
5
6
6
6
6
Chapter 1 Introduction
Introduction to the TDS-10S ............................................. 7
Chapter 2 Description
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
TDS-10S Contents
iii
March 2, 1998
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
Chapter 4 Operation
Drillers interface and drillers console ...............................
Throttle control ..........................................................
Torque control............................................................
Switches ......................................................................
Indicators ....................................................................
Varco control system ...................................................
Variable frequency inverter ...............................................
Rectifier and DC link filter .........................................
Power modules ...........................................................
Control section ...........................................................
Service loop ......................................................................
Drilling ahead ...................................................................
Drilling ahead with triples ..........................................
Drilling ahead with singles ..........................................
Tripping in and tripping out .......................................
Back reaming ..............................................................
Well control procedures ..............................................
Running casing ...........................................................
33
33
34
34
36
37
38
38
38
38
39
40
40
42
44
44
46
48
Chapter 5 Specifications
General .............................................................................
Drilling parameters .....................................................
Rated capacities.....................................................
Drilling motor ......................................................
Pipehandler (PH-55) ............................................
49
50
50
50
50
Chapter 6 Appendix............................... 51
iv
TDS-10S Contents
7
7
8
8
8
8
Chapter 1 Introduction
Precautions ......................................................................... 9
11
13
14
14
15
Chapter 3 Inspection
Inspecting hardware and fittings .......................................
Inspecting the AC drilling motor brakes ...........................
Inspecting the AC drilling motor louvers ..........................
Inspecting the wash pipe assembly ....................................
Inspecting the upper stem liner .........................................
Inspecting main shaft end play ..........................................
Inspecting the gearbox oil level .........................................
Inspecting the guide beam ................................................
Inspecting the IBOPs ........................................................
Inspecting the pipehandler ................................................
Nondestructive Examination (NDE) ................................
Inspecting the elevator link eyes ..................................
Inspecting the drive stem ............................................
Magnetic particle inspection (MPI) ............................
Ultrasonic inspection ..................................................
Inspecting the hydraulic system ........................................
Inspecting the electrical system .........................................
TDS-10S Contents
17
18
18
18
19
21
22
22
22
23
24
24
26
27
28
29
29
v
March 2, 1998
Chapter 4 Lubrication
Introduction .....................................................................
Lubricating the AC blower motor bearings .......................
Lubricating the hydraulic pump AC motor .......................
Lubricating the AC drilling motor bearings ......................
Lubricating the wash pipe assembly ..................................
Lubricating the upper main body oil seals .........................
Replacing the gearbox oil ..................................................
Initial oil change .........................................................
Oil capacity.................................................................
Replacing the gearbox oil filter ..........................................
Lubricating the carriage and guide beam ...........................
Lubricating the rotating link adapter .................................
Lubricating the link tilt and PH-55 stabilizer bushing ......
Lubricating the elevator support and
master bushing wear guide ................................................
Lubricating the wireline adapter ........................................
Lubricating the IBOP actuator yoke .................................
Lubricating the IBOP actuator crank ................................
Lubricating the torque arrestor tubes and
clamp cylinder gate ...........................................................
31
32
32
32
34
35
35
35
35
36
36
36
38
38
38
39
40
41
Chapter 5 Maintenance
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................
Troubleshooting the AC blower motor .............................
Troubleshooting the hydraulic system ...............................
Troubleshooting the AC
drilling motor brakes .........................................................
Troubleshooting the rotating link adapter
(rotating head) motor .......................................................
Operation ...................................................................
System test ..................................................................
Troubleshooting the IBOP actuator cylinder ....................
Operation ...................................................................
System test ..................................................................
vi
TDS-10S Contents
45
46
47
51
52
52
52
54
54
55
57
57
58
60
61
62
64
64
64
TDS-10S Contents
67
69
69
71
72
72
73
75
75
75
76
76
77
77
78
81
81
82
84
87
89
91
91
92
92
94
96
98
vii
March 2, 1998
Chapter 2 Operation
Preoperational checklists ...................................................
VDC controls ...................................................................
Correcting a drive fault .....................................................
Drive fault while drilling .............................................
Drive fault while making up .......................................
13
17
20
20
21
Chapter 3 Maintenance
Maintaining the control system ......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
viii
TDS-10S Contents
TDS-10S
Top Drive
Drilling
System
Description,
Installation and
Operation
Contents
Preface
Manual conventions............................................................
Safety information ..............................................................
Directional references .........................................................
Illustrations .........................................................................
Manual layout.....................................................................
Varco service centers ...........................................................
5
5
6
6
6
6
Chapter 1 Introduction
Introduction to the TDS-10S ............................................. 7
Chapter 2 Description
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
Chapter 4 Operation
Drillers interface and drillers console ...............................
Throttle control ..........................................................
Torque control............................................................
Switches ......................................................................
Indicators ....................................................................
Varco control system ...................................................
Variable frequency inverter ...............................................
Rectifier and DC link filter .........................................
Power modules ...........................................................
Control section ...........................................................
Service loop ......................................................................
Drilling ahead ...................................................................
Drilling ahead with triples ..........................................
Drilling ahead with singles ..........................................
Tripping in and tripping out .......................................
Back reaming ..............................................................
Well control procedures ..............................................
Running casing ...........................................................
33
33
34
34
36
37
38
38
38
38
39
40
40
42
44
44
46
48
Chapter 5 Specifications
General .............................................................................
Drilling parameters .....................................................
Rated capacities.....................................................
Drilling motor ......................................................
Pipehandler (PH-55) ............................................
49
50
50
50
50
Preface
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and assemblies to provide
a better understanding of the equipments functionality.
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
z
e
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assemblystanding behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Chapter 1
Introduction
Chapter 2
Description
10
11
12
Duct
Blower Motor
Centrifugal Blower
Air Flow
AC Drilling Motor
Louvers
Exhaust Air Flow
13
PH-55 pipehandler
The PH-55 pipehandler consists of the following major
components:
Powered rotating link adapter
Torque backup clamp cylinder
Bidirectional link tilt
Remote upper IBOP actuator
Elevator links and drill pipe elevator
14
15
16
Ov
er
dr
eh
ole
ill
Drill
Derr
ickm
Mo
an *
us
108"
34"
14"
4"
36"
Typ.
28"
76"
56"
CL Well
Drill Floor
17
18
Main Shaft
Saver Sub
Stabbing Guide
19
20
Upper IBOP
Actuator
Cylinder
Link Tilt
Cylinders
Torque Backup
Clamp
Cylinder
Counterbalance
Accumulator
Drilling
Motor Brake
Counterbalance
Cylinders
Shot Pin
Cylinder
Lube Oil
Distribution
Rotating Link
Adapter Motor
10 HP A.C.
Motor
Upper IBOP
Time Delay
Accumulator
Hydraulic
Pump
Reservoir
System
Accumulator
21
Counterbalance system
The integral counterbalance system prevents damage to tool joint
threads while making or breaking connections with the TDS-10S.
It replaces the function of the hook compensator spring.
The system consists of two hydraulic cylinders attached between
the transmission cover and bail, a hydraulic accumulator, and a
hydraulic manifold. The system is integral to the TDS-10S and
therefore does not require any external attachment to the hook.
The cylinders are connected to a hydraulic accumulator. The
accumulator is charged with hydraulic fluid and maintained at a
predetermined pressure setting by the counterbalance circuit in
the main hydraulic control system manifold.
22
23
24
Air Inlet
(1100 CFM)
End Coil
Rotor Assembly
(Laminated)
Motor Frame
(Laminated)
Stator Assembly
(Laminated)
Air Exhaust
Motor Shaft
(Vertical Type)
End Coil
Mounting Base
25
The AC motor (350 hp) and the gear ratios (13.1:1 high torque,
standard speed, or optional 4.8:1 low torque, high speed) provide
20,000 ft lb of torque at a drill stem operating speed range of 0 to
87 rpm. Maintaining constant 350-hp output, the top drive
provides 8,081 ft lb of torque at a maximum drill stem speed of
182 rpm.
The open-frame design of the AC drilling motor allows the
cooling air to pass through the inside of the motor, which
provides more efficient transfer of rotor and winding heat to the
cooling air. The motor is manufactured specifically for top drive
applications. They include:
Internal temperature sensors
Double varnish impregnated glass-served windings
Upgraded bearing/shaft seals
High-capacity bearings
Tapered output shafts
High strength tie bolts
Improved material castings
26
Chapter 3
Installation
27
All of the above modifications may not be necessary, but all must
be considered as well as the overall rig floor layout in order to
ensure that proper installation, time utilization and accurate cost
information is made.
The functional operation of a TDS-10S has many considerations;
a primary consideration is the mast/derrick height. The working
height and crown clearance are two primary factors to finalize
prior to ordering and installing your TDS-10S. Working height
and Crown clearance can both vary dependent upon hook, block,
bail, elevator links, and coupling chosen. Figure 6 shows a typical
TDS-10S mast interface. A mast/derrick interface requirements
and worksheet is provided in the Appendix chapter.
28
Crown
12.6 ft(3,8 m)-Std.
11.6 ft(3,5 m)-Opt.
Clearance**
Block Top
93 ft(28,4 m)
Drill Stand
Made-up at
4 ft(1,2 m)
Level
CL
Beam
Service Loop
Tool Joint
4.0 ft(1,2 m)
Drill Floor
3X50 ft(3X15,2 m)
A.C. Cables
29
30
Guide Beam
10 X 10 (250 X 250)
Square Tube
CL
Well
CL
Reliance Electric
AC Induction
350 HP Drilling Motor
Carriage Assembly
with Guide Pads
20.5 (521)
24.0 (610)
CL
26.0
(660)
25.6
(650)
Ref.
19.5
(495)
44.0
(1118)
Ref.
CL
18.0
(457)
28.0 (711)
Dimensions
are in inches
(millimeters)
Gooseneck
31
32
Chapter 4
Operation
Throttle control
The throttle uses a design similar to the standard throttle control
used with SCR systems. The handle is robust and includes
integral stops to prevent damage.
33
Torque control
Two torque limit potentiometers are provided for setting drill and
makeup torque limits.
The drill limit control allows the driller to set the maximum
torque output of the top drive to match the drill pipe size being
used.
The makeup control sets the torque when making up connections
using the TDS-10S drilling motor.
Switches
Various switches control the following functions:
Drill/Spin/Torque mode select
Link tilt
Brake
Backup clamp cylinder
Powered rotating link adapter
IBOP valve
Forward and reverse selection for the drill pipe rotation
Emergency stop
Stand jump (optional)
34
Top Drive
DC Generator
(Alternate)
-
Encoder
Skid
* Mast
Saddle
Motor
1
+
+
* Variable
Frequency
Drive /
* Varco
Driller's
Interface
Electrical
Service
Loop
System
Electrical Panel
Solenoids
J-Box
Sensors
AC Power
Highline
or
Diesel/Alternator
Set
Varco
Driller's
Console
35
Indicators
Various indicators report status/faults to the driller:
Oil pressure loss
Drill motor over temp
Blower loss
Rotating link adapter
IBOP closed
Brake
Drive fault
PIPEHANDLER
MAKE-UP
CURRENT LIMIT
OIL
PRESS LOSS
BRAKE
IBOP
CLOSED
THROTTLE
RIGHT
IBOP
BRAKE
ON
ROTATE
LEFT
MAX
DRILL MOTOR
OVERTEMP
LINK TILT
OFF
TORQUE WRENCH
PUSH & HOLD
DRILL
BRAKE
AUTO
OFF
EMERGENCY
STOP
IBOP
OPEN
TILT
CLOSE
BRAKE
ON
R
0
SPIN
DRILL
BLOWER LOSS
TORQUE
ALARM LAMP
SILENCE CHECK
HYDRAULIC POWER
AUTO
DRIVE
FAULT
MAX
DRILL TORQUE
OFF
REVERSE
FORWARD
ON
TORQUE
R
0
MAX
36
RPM
37
Power modules
AC motor speed control requires variable frequency voltage. To
do this, the DC voltage is converted to an output waveform that
consists of a series of pulses. The duration of each pulse is
controlled so that the fundamental voltage applied to the AC
motor has the desired frequency and amplitude. The technique of
using pulses to develop a waveform that appears to the motor as a
sine wave is called pulse width modulation or PWM.
Control section
The control section monitors the performance of the drilling
motor, accepts throttle and torque limit signals from the
TDS-10S control system, and controls the firing circuits of the
power modules.
To vary motor speed, the driller uses a hand throttle. The throttle
varies the frequency and voltage to the motor. Because the drilling
motor is frequency synchronous, the motor speed is proportional
to the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200
motor rpm).
One of the greatest advantages of an AC variable frequency drive
is the quality of the speed and torque control. It allows precise
control of the drill pipe speed over the full operational range.
38
Resultant Pulse DC
TDS-10S AC Motors
+
AC
Power
Source
AC Inverter
(AC Frequency Drive)
Inverter Controller
600 VAC, 42 to 62 Hz
3-Phase (350 AMPS)
0
40 Hz=1200 RPM @ Mtr.
PLC
Data Bus
Service loop
The TDS-10S has an on board hydraulic system and, therefore,
does not need a fluids service loop. This adds to the costeffectiveness of the TDS-10S drilling system and provides a safer
work area.
The TDS-10S has three electrical service loops. One loop consists
of four 313 MCM cables (three for drilling motor power, one for
ground). One loop is a composite cable that contains conductors
for the sensors and actuator (solenoid) control. The third loop
contains power for the smaller AC motors and space heater for
the drive motor.
39
Drilling ahead
Drilling ahead with triples
This is the common drilling mode for the TDS-10S. There are
various sources for triples to drill with. On skidding rigs drilling
multiple wells, or rigs that can move with racked pipe, the drill
pipe can be left racked and used to drill the next well. If triples do
not currently exist to drill with, 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. Enough triples should be left racked to handle
anticipated bit life. The second is to make up triples in the
mousehole while drilling ahead or during rig idle time. For safety
reasons it is best to have a pivoting mousehole so it can be put in
a vertical plane to simplify making connections. Note that the
connections just need to be spun up as they will be torqued when
the Top drive motor applies the makeup torque.
Use the following procedure for drilling ahead with triples
(Figure 11):
1. Drill down the existing stand and set slips.
2. Break out the saver sub from the drill pipe using the top drive
motor and backup clamp in the pipehandler.
3
40
Set slips on
string
Stop circulation
Raise block
Tilt link tilt
to derrickman
Close IBOP
Lower block to
stab motor into
top of stand
Pull slips
Spin in motor
and stand
Open IBOP
Start circulation
Begin drilling
Makeup both
connections with
motor
Breakout
connection
using pipehandler
and drilling motor
(in reverse)
1
Link
Tilt
Makeup
Open
IBOP
Close
IBOP
Stab
Makeup
41
42
Set slips on
string
Tilt links to
mousehole
Stop circulation
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)
Makeup
Open
IBOP
Close
IBOP
Link
Tilt
Stab
Makeup
43
Back reaming
The TDS-10S permits reaming out of open hole to prevent pipe
sticking and reducing keyseat formation, without affecting
racking functions associated with normal tripping; i.e., no singles
to contend with. This is provided by the ability of the top drive
and backup clamp to break out 93 ft. stands in the derrick/mast.
Use the following procedures for reaming out of the hole
(Figure 13):
1. Hoist the block while circulating and rotating the drill motor
until the third connection appears.
2. Stop circulation and rotation, and set the slips.
3. Break out the stand at floor level, and spin out using the
drilling motor.
4. Break out the drilling motor from the top of the stand using
the top drive motor and backup clamp, then spin out with
the drilling motor.
5. Pick up the stand with the drill pipe elevator.
6. Rack stand back.
7. Lower the top drive to the floor.
8. Stab drilling motor into box, spin-up and torque with the
drilling motor and backup clamp.
9. Resume circulation and continue reaming out of the hole.
44
Hoist while
circulating and
rotating
When 3-rd
connection
surfaces, stop
rotation and
circulation
Set slips on
string
Setback stand
using link tilt
Spin in motor
and makeup
connection with
motor
Breakout and
spinout stand
at floor
Start circulation,
pull slips,
hoist and rotate
Lower block,
stab motor into
string
Breakout
Hoist
Setback
Hoist and
Rotate
Breakout
45
46
Remote IBOP
Actuator Cylinder
Lower IBOP
Valve
Saver Sub
Insert New
Saver Sub
Drill Pipe
47
Running casing
Use longer elevator links (180 in.) to allow clearance for
cementing head under the backup clamp in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.
48
Chapter 5
Specifications
General
Transmission
Transmission lube
Infinitely positionable
System weight
18,000 lb
49
Drilling parameters
Drilling speed range
Drilling torque
20,000 ft lb maximum
continuous (27115 Nm)
Breakout torque
Drilling horsepower
Rated capacities
Hoisting
Drilling (rotating)
250 Tons
Drilling motor
Type
Rating
350 hp
Rated speed
1,200 rpm
Maximum speed
2,400 rpm
1,550 ft lb
2,790 ft lb
Pipehandler (PH-55)
50
Torque capacity
Elevator links
Chapter 6
Appendix
51
TDS-4S
IDS-1
TDS-10S
Output Torque
29,100(HI)/45,000(LO) ft-lbs
Output Torque
34,000 ft-lbs
Output Torque
20,000 ft-lbs
Bail Rest
Bail Rest
Bail Rest
20.8 ft
(6,3 m)
TDS-4S
Working
Height
Tool Joint
23.0 ft
(7,0 m)
IDS-1
Working
Height
Tool Joint
15.0 ft
(4,6 m)
TDS-10S
Working
Height
Tool Joint
Drill Floor
52
Max. Stall @
36,500 ft lb
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
0
50
100
150
200
53
Max. Stall @
13,390 ft lb
12,500
10,000
7,500
5,000
2,500
0
0
100
200
300
54
400
500
Block Top
TRAVELING
EQUIPMENT
MAKE
DRECO
Block
Saddle
NATIONAL
OILWELL
Hook-Block
Combination
TRAVELING
BLOCKS
IDECO
CECO
Hook
(If Used)
Saddle
Integrated
Drilling System
(IDS)
(Integrated Block
and Swivel)
McKISSICK
MH
PYRAMID
Saddle
HOOK-BLOCK
COMBOS
(stroked 8")
NATIONAL
IDECO
Swivel
Stem
Shoulder
VARCO BJ
S-Type
Drilling
System
(Integrated
Swivel)
HOOKS
(stroked 8")
NATIONAL
WEB WILS.
MH
NATIONAL
Drilling
System
OILWELL
IDECO
SWIVELS
CECO
G.-DENVER
Tool Joint
DRECO
VARCO
TOP DRIVES
MODEL
660B-500
760B-650
760B-750
650H500
660H500
760H650
H350
B500
650
A750
TB525-6-60
TB650-6-60
TB750-7-60
RA52-6-500
RA60-6-650
RA60-7-750
500
650
500-1195
650-1090
500
650/750
540G250
545G350
650G500
660G500
760G650
UTB 525-6-60
5250
5350
5500
5750
51000
500
650
750
500
500
650/750
P500
P650
P750
PC500
PC650
TL-500
TL-650
TL-750
LB500
LB650
SW550
S500
S650
500
650
750
TDS-3H
TDS-3S
TDS-4H
TDS-4S
TDS-5H
TDS-6S*
TDS-7S
TDS-9S
TDS-10S
IDS-11S
IDS-1**
WORKING HEIGHT
WEIGHT (EST)
in
ft
mm
lbs
kg
92
105
109
91
109
112
77
100
104
120
105
110
113
92
103
110
91
109
92
105
104
103
137
152
169
184
192
181
104
106
117
138
158
97
103
113
120
112
138
92
94
116
94
96
91
101
114
91
99
94
98
101
102
109
119
214
250
221
250
214
276
250
214
192
216
346
7.6
8.7
9.0
7.5
9.0
9.3
6.4
8.3
8.6
10.4
8.8
9.2
9.4
7.7
8.6
9.2
7.6
9.1
7.7
8.7
8.7
8.5
11.4
12.6
14.1
15.3
16.0
15.1
8.7
8.8
9.8
11.5
13.2
8.1
8.6
9.4
10.0
9.3
11.5
7.7
7.8
9.6
7.8
8.0
7.6
8.4
9.5
7.6
8.2
7.8
8.1
8.4
8.5
9.1
9.9
17.8
20.8
18.4
20.8
17.8
23.0
20.8
17.8
16.0
18.0
28.8
2324
2654
2756
2299
2756
2832
1956
2543
2629
3210
2670
2794
2873
2337
2621
2794
2315
2769
2340
2664
2648
2604
3480
3861
4293
4674
4883
4607
2642
2692
2981
3493
4035
2457
2623
2873
3048
2845
3508
2343
2375
2937
2388
2438
2311
2562
2899
2311
2505
2381
2486
2570
2578
2769
3001
5436
6350
5613
6350
5436
7010
6350
5425
4877
5486
8788
18500
23800
27500
13500
18750
21800
9380
17900
20240
34016
18200
20500
22100
13250
19158
22871
21500
22590
21546
26932
22000
27000
11600
15260
21250
26500
31780
9000
5050
6340
9950
18090
32076
6920
8550
9750
8500
11850
18745
5700
6900
11500
5708
7350
5200
6900
8200
5947
6646
5700
5800
6850
6100
7000
9100
32600
36750
37000
38750
35200
43750
49000
24000
18000
26500
49000
8391
10795
12474
6266
8509
9888
4255
8119
9181
15429
8255
9299
10024
6010
8690
10374
9752
10246
10000
12500
9979
12247
5262
6922
9639
12020
14415
4082
2291
2876
4513
8205
14550
3138
3872
4423
3856
5500
8700
2585
3130
5216
2589
3334
2359
3130
3719
2698
3015
2585
2631
3107
2767
3175
4128
14800
16685
16798
17593
15981
19826
22742
10886
8164
12020
22742
55
Crown
Customer:
..................
Clearance
Block Top
..........................................
..........................................
...........................................
15.0 or 16.0 ft
TDS Working Height
Tool Joint
Service
Loop/Mast
Bundle
Saddle
@..........ft
Traveling Equipment
Short-Coupling using
Varco Adapter/Becket
(if applicable):
.............ft
Mud Hose,
Standpipe
@..........ft
............................................
............................................
............................................
Sectional
Guide Beam
...........................................
Bail Rest
93 ft Drill Stand
Existing
Traveling Equipment:
..................
(Stroked)
.............ft
Mast
Bundle
.............ft
CL
Beam
Tool Joint
4 ft
Drill Floor
56
TDS-10S
Top Drive
Drilling
System
Maintenance
and
Troubleshooting
March 2, 1998
Contents
Preface
Manual conventions............................................................
Safety information ..............................................................
Directional references .........................................................
Illustrations .........................................................................
Manual layout.....................................................................
Varco service centers ...........................................................
7
7
8
8
8
8
Chapter 1 Introduction
Precautions ......................................................................... 9
11
13
14
14
15
Chapter 3 Inspection
Inspecting hardware and fittings .......................................
Inspecting the AC drilling motor brakes ...........................
Inspecting the AC drilling motor louvers ..........................
Inspecting the wash pipe assembly ....................................
Inspecting the upper stem liner .........................................
Inspecting main shaft end play ..........................................
Inspecting the gearbox oil level .........................................
Inspecting the guide beam ................................................
Inspecting the IBOPs ........................................................
Inspecting the pipehandler ................................................
Nondestructive Examination (NDE) ................................
Inspecting the elevator link eyes ..................................
Inspecting the drive stem ............................................
Magnetic particle inspection (MPI) ............................
Ultrasonic inspection ..................................................
Inspecting the hydraulic system ........................................
Inspecting the electrical system .........................................
TDS-10S Maintenance and Troubleshooting
17
18
18
18
19
21
22
22
22
23
24
24
26
27
28
29
29
3
March 2, 1998
Chapter 4 Lubrication
Introduction .....................................................................
Lubricating the AC blower motor bearings .......................
Lubricating the hydraulic pump AC motor .......................
Lubricating the AC drilling motor bearings ......................
Lubricating the wash pipe assembly ..................................
Lubricating the upper main body oil seals .........................
Replacing the gearbox oil ..................................................
Initial oil change .........................................................
Oil capacity.................................................................
Replacing the gearbox oil filter ..........................................
Lubricating the carriage and guide beam ...........................
Lubricating the rotating link adapter .................................
Lubricating the link tilt and PH-55 stabilizer bushing ......
Lubricating the elevator support and
master bushing wear guide ................................................
Lubricating the wireline adapter ........................................
Lubricating the IBOP actuator yoke .................................
Lubricating the IBOP actuator crank ................................
Lubricating the torque arrestor tubes and
clamp cylinder gate ...........................................................
31
32
32
32
34
35
35
35
35
36
36
36
38
38
38
39
40
41
Chapter 5 Maintenance
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................
Troubleshooting the AC blower motor .............................
Troubleshooting the hydraulic system ...............................
Troubleshooting the AC
drilling motor brakes .........................................................
Troubleshooting the rotating link adapter
(rotating head) motor .......................................................
Operation ...................................................................
System test ..................................................................
Troubleshooting the IBOP actuator cylinder ....................
Operation ...................................................................
System test ..................................................................
45
46
47
51
52
52
52
54
54
55
57
57
58
60
61
62
64
64
64
67
69
69
71
72
72
73
75
75
75
76
76
77
77
78
81
81
82
84
87
89
91
91
92
92
94
96
98
March 2, 1998
Preface
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and assemblies to provide
a better understanding of the equipments functionality.
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
z
e
March 2, 1998
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assemblystanding behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Chapter 1
Introduction
Precautions
To avoid serious injury or death, read and understand the
following warnings before performing maintenance procedures:
n
n
n
March 2, 1998
n
n
n
n
n
10
Never check for hydraulic leaks with your hands. Oil under
pressure escaping from a hole can be nearly invisible and can
penetrate skin causing serious injury. Always check for leaks with
a piece of wood or cardboard and always wear protective eyewear
when working on hydraulic components.
Chapter 2
Maintenance
schedules
Inspection schedules
z
11
March 2, 1998
Check for
Frequency
Gearbox/Hydraulic reservoir
Oil level
Daily
Looseness
Daily
Leaks
Daily
Main body
Weekly
AC drilling motor
Louvers/screens
Weekly
Guide beam
Weekly
Corrosion
Elevator link
Eye diameter
Monthly
Monthly
Main shaft
Accumulators (3)
Charge
Gooseneck
Wear
IBOPs
Damage
Whenever connections
are broken
12
Lubrication schedule
Table 2. Lubrication schedule
Component
Fittings
Type
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly
Weekly
Weekly
Weekly
Link tilt
Weekly
Elevator support
Weekly
Weekly
Wireline adapter
Weekly
Stabilizer bushing
Rotating link adapter grease fittings
2
4
Three months
AC blower motor
Three months
Three months
Gear oil
Three months
Replace oil
Replace oil filter
Three months
13
March 2, 1998
Lubricant specifications
Selecting a lubricating/hydraulic oil
Varco Top Drives operate under a wide variety of temperatures
and conditions. The oil viscosity varies from quite thick at startup in cold climates to very thin in hot climates during difficult
drilling conditions.
Select gearbox lubrication based on the minimum ambient
temperature to be expected before the next oil change.
Introducing an oil viscosity greater than required by the ambient
temperature could damage the gearbox due to reduced oil flow, or
damage the oil pump with an excessive load.
Use the following table to select the proper lubricant:
The TDS-10S uses the same lubricant for both the transmission and
hydraulic reservoir.
Varco P/N
ISO 32
56008-1
ISO 68
56008-2
40 to 85F (4 to 29C)
ISO 100
56008-3
ISO 150
56008-4
14
Selecting a lubricant
Use Table 4 to select the appropriate lubricant for your specific
application.
Above -20
Below -20C
Castrol
MP grease
Chevron
Avi-Motive
Avi-Motive W
Exxon
Lidok EP2
Lidok EP1
Gulf
Mobil
Mobilux EP2
Mobilux EP1
Shell
Alvania EP2
Alvania EP1
Statoil
Uniway EP2N
Uniway EP1N
Texaco
Multifak EP2
Multifak EP1
Total
Multis EP2
Multis EP1
Union
Unoba EP2
Unoba EP1
NGL1
AGMA
ISO Viscosity
Grade
Use Chevron Black Pearl EP2 grease for all temperatures where
applicable.
15
March 2, 1998
16
Chapter 3
Inspection
17
March 2, 1998
Never check for hydraulic leaks with your hands. Oil under pressure
escaping from a hole can be nearly invisible and can penetrate skin
causing serious injury. Always check for leaks with a piece of wood or
cardboard.
18
19
March 2, 1998
Polypack Seal
Upper Stem Liner
Upper Stem
Liner
Polypack Seal
Main Shaft
20
z
z
Align the shims so that the upper bearing lube tube bore is not
blocked.
Refer to Installing the upper bearing retainer plate in the
Disassembly and assembly section of this book for further details
on this adjustment.
21
March 2, 1998
z
z
22
23
March 2, 1998
24
Upper
Eye
(Hook)
C
Lower
Eye
Dimension A
Capacity
(Per Set)
In
Tons
2-1/4
2-1/8
2-1/16
1-3/4
250
210
188
137
B
B = 3-1/2 in., 350 Ton
5
4-13/16
4-5/8
4-7/16
2-3/4
2-9/16
2-3/8
2-3/16
350
300
225
175
A
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.
A
Lower
Eye
(Elevator)
25
March 2, 1998
26
27
March 2, 1998
Ultrasonic inspection
In addition to MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the loadcarrying capacity of the part. Any subsurface irregularity can also
compromise a components integrity.
Details on Ultrasonic Inspection procedures are in the following
publications:
I.A.D.C., Drilling Manual, 9th Edition
ASTM A-388, Standard Practice for Ultrasonic Examination of
Heavy Steel Forgings
28
29
March 2, 1998
30
Chapter 4
Lubrication
Introduction
The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.
31
March 2, 1998
32
AC Drilling Motor
33
March 2, 1998
Grease Fitting
Washpipe Assembly
34
Grease the main body oil seals daily to prevent abrasive drilling
mud from leaking into the main body.
After every oil change, check for proper lubrication oil flow.
Oil capacity
The TDS-10S main body holds approximately 17-19 gallons of
oil. Always fill the transmission to the middle of the upper sight
glass. Use the following procedure to fill the transmission for the
first time:
1. Use a hand pump to fill the gearbox to the top of the sight
glass (approximately 17-19 gallons).
2. Operate the TDS and hydraulic systems 10-15 minutes and
then check the sight glass.
3. If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass.
35
March 2, 1998
36
250 TON
Grease
Fitting
Grease
Fitting
Front
A4
B4
E5
E6
E6
G6
B8
G6
A4
G5
B4
Grease Fittings
E5
H
Back
37
March 2, 1998
38
IBOP Actuator
Yoke
Upper IBOP
Actuator Shell
39
March 2, 1998
Closed
Position
Open
Position
Crank Arm
Grease Fitting
Upper IBOP
Valve
40
Torque Arrestor
Grease Fitting (2)
Grease Locations
(Each side)
Grease Fittings
(Each side)
Figure 8. Lubricating the torque arrestor tubes and clamp cylinder gate
41
March 2, 1998
42
Chapter 5
Maintenance
n
n
e
43
March 2, 1998
Start-up procedure
Accumulator maintenance
The Vendor Documentation Package contains the accumulator
manufacturers instructions for the TDS-10S hydraulic
accumulators (Bulletin SB1630-M1). This bulletin contains all
necessary maintenance, removal and replacement, and precharging instructions for the TDS-10S accumulators.
44
Chapter 6
Troubleshooting
45
March 2, 1998
Probable cause
Remedy
Loose impeller.
46
Alert all personnel near the top drive before overriding a solenoid
valve. When you override a solenoid valve, you bypass the safety
interlock and top drive components will move possibly causing
serious injury or death.
Test points shown in the hydraulic schematic with a box
(e.g., A4) can be found on the manifold under the main body.
There are also test points on the rotating link adapter motor.
The system is preadjusted. Hydraulic problems are usually
related to faulty valves, contamination, or other damage to
the system rather than misadjustments. Changes to
adjustments should be made only after all other possible
causes have been eliminated.
Table 6 identifies the schematic symbols used in this section.
47
March 2, 1998
Symbol
A
Schematic Reference
SV2, SV6
P
Manual
Valve
(Rotary)
T
A B
MV
P T
Pump
Fixed Displacement
Pressure
Relief
Valves
Standard Valve
2
3
RV1
UV1
Pressure
Reducing
Valve
PC1, PC4
Pressure
Reducing/Relieving
Vavle
PCC
Check
Valve
48
Symbol
Schematic Reference
1
3
Cavity Plug
PC5
2
Internal Plug
CV1
Diameter in Inches
Counterbalance
Valves
Logic Cartridges
49
March 2, 1998
Symbol
Schematic Reference
Thermostat
Pressure Switch
Heat Exchanger
Hydraulic Circuit
(Inside Brake Housing)
Hydro-Pneumatic Accumulator
Hydraulic Cylinder
Tank (Reservoir)
Test Point
50
Troubleshooting the AC
drilling motor brakes
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 2,000 psi. The solenoid valve operates to apply
pressure, setting the brakes, or stop pressure to release the brakes.
Probable cause
Remedy
Brakes release but still drags. Check valve is blocked or the Replace the check valve or
tube is pinched.
tube as required.
Mechanical problems with
brakes.
Brakes do not engage or slip. There is hydraulic oil on the Check for hydraulic leaks
brake pads.
and repair.
Delay in the brakes actuating The hydraulic oil is
contaminated.
after the console switch is
turned on.
51
March 2, 1998
System test
To test the system, operate the rotating head switch on the
control panel. Verify both directions of rotation. The rotation
speed is limited by the nonadjustable orifice. The torque is
limited by the two relief valves.
52
Probable cause
Remedy
Mechanical interference.
53
March 2, 1998
Probable cause
Remedy
54
System test
Refer to the hydraulic circuit schematic in the Technical Drawing
book for the IBOP actuator cylinder. The IBOP is normally
open.
Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
To test the system, engage the IBOP and measure the pressure at
B4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open the
IBOP and test the pressure at A4, which increases to 2,000 psi.
The pressure at B4 and C4 drops to 500 psi.
55
March 2, 1998
11.5 IN^ 3
500 PSI
PRECHARGE
N07
IBOP CLOSE
b
N12
A4
SV4 D03
B4
.055
FC4
T-13A
500 PSI
T-11A
PC4
C4
.016
3
1
30 PSI
400 PSI
T-21A
A4
B4
SQ4
A4
B4
A4
B4
OPEN
CLOSE
Hydraulic Cylinder
56
57
March 2, 1998
System test
At rest, the pressure at C5 is 2,000 psi, B5 is less than 100 psi,
CP is less than 100 psi, and CR is 500 psi.
Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
When you energize solenoid valve SV5, using the manual
override, pressure increases to the barrel of the shot pin cylinder.
The pressure is controlled by a .031 pressure reducing valve that
prevents the shot pin from putting full force on the rotating head
surface until the pin engages in one of the holes.
Pressure at B5 is 200 psi (limited by the relief valve), C5 is less
than 100 psi, G5 is less than 100 psi, CP is less than 100 psi, and
CR is less than 100 psi.
Once the shot pin engages the hole, full pressure is applied in C5
to control valve CV5 open for clamp. Pressure at B5 is 2000 psi,
C5 is 2000 psi (forces valve CV5 open for clamp), G5 is less than
100 psi, CP is 2,000 psi, and CR is less than 100 psi.
When solenoid valve SV5 is de-energized, the shot pin cylinder
withdraws the shot pin, and the clamp disengages at the same
time. The circuit returns to rest conditions.
58
Table 10. Troubleshooting the shot pin cylinder and clamp cylinder
Problem
Probable cause
Remedy
Shot pin does not engage. Solenoid valve is not operating or Check the electrical actuation
relief valve is not adjusted.
and test pressure. Adjust as
required.
Abnormal pressure change at B5 Replace the directional control
and C5 indicates valve problem. valve.
Normal pressure change
indicates plumbing or shot pin
cylinder are faulty.
Shot pin applies excessive Relief valve is not operating or
out of adjustment.
force to rotating head
gear.
Clamp cylinder does not No pressure or reduced pressure Test pressures and adjust and
actuate.
at the cylinder.
repair as required.
Cylinder is damaged.
provide high pressure to the
z To
clamp circuit, pressure at C5
59
March 2, 1998
60
Counterbalance testing
For the counterbalance operation, a lift of approximately
30,000 lb is achieved with a pressure of 1,600 psi at CB.
Perform the following steps to adjust the force:
1. Set the COUNTERBALANCE MODE switch to the RUN
mode. Set the pressure control valve PCC to the minimum
setting (fully counterclockwise).
2. Test the pressure at port B9. There should be a 0 psi reading.
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
4. Adjust the pressure at pressure control valve PCC clockwise,
observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on
the hook.
61
March 2, 1998
62
Problem
Probable cause
Remedy
No hydraulic pressure.
Precharge on accumulator
is low.
No hydraulic pressure.
Precharge on accumulator
is low.
63
March 2, 1998
System test
Test the circuit pressure at port PV. Relief valves RV1 and UV1
are a part of the circuit. UV1 is a differential unloading valve,
which can be pressure checked at port Z1.
RV2 is set at 400 psi and can be tested at PF. Test the pressure at
PV to confirm the relief valve RV1 is set at 800 psi. The
differential unloading valve UV1 is tested at Z1 to confirm the
pressure is 2,000 psi.
64
IN
10 Micron
No Bypass Out
30
PSI
N08
PF
Y1
Upper Compound
Gear
10 HP
1200 RPM
1.5
GPM
1.40 in3/rev
Lower Compound Gear
Upper Mainshaft Bearing
Lower Radial/Main Thrust Bearings
Upper Compound Bearing
Lower Compound Bearing
65
March 2, 1998
Table 12. Troubleshooting the hydraulic power unit (HPU) and reservoir
Problem
Probable cause
Remedy
Hydraulic system
overheating.
Counterbalance mode
valve left in shut down
position too long and
pressure bleeds down.
No precharge in system
accumulator.
Flexible coupling is
damaged.
Hydraulic components
do not operate.
66
Chapter 7
Disassembly and
assembly
Precautions
e
67
March 2, 1998
68
PH-55 Pipehandler
Disassembling the PH-55
Pipehandler
Remove the PH-55 Pipehandler to service the following
components:
Stem
Stem seals
Rotating link adapter upper and lower wear bushings
Rotating link adapter rotary seals
n
n
z
z
69
March 2, 1998
70
Always install new main shaft seals and use care not to damage seal
lips or case.
2. Install the new O-rings on the stem flange.
3. Grease the walls of the bore in the main body, the stem main
shaft seals, and the O-rings on the rotating link adapter
assembly.
4. Position the rotating link adapter assembly, supporting it with
the same stand or block used in the disassembly procedure.
5. Using three 5/8-11 UNC bolts, pull the rotating link adapter
to the main body and completely seat the rotating link
adapter into the bore.
6. Install screws to secure the rotating link adapter to the main
body.
7. Replace the drain plug.
8. Install the upper IBOP, lower IBOP, and saver sub.
9. Install the upper tool joint lock and tighten the bolts to
180 to 190 ft lb.
10. Install the IBOP actuator shell.
11. Install the intermediate tool joint lock and tighten the bolts to
180 to 190 ft lb.
12. Install the lower tool joint lock.
13. Install the upper IBOP crank assembly.
14. Pin the torque arrestor to the rotating link adapter.
71
March 2, 1998
Protect the internal surfaces of the rotating link adapter body and the
surfaces of the stem when separating the two components. When
removing the rotating link adapter from the stem, carefully tap with a
mallet to remove the rotating link adapter from the stem. There can
be resistance from misalignment between the two bores when rasing
the stem and gear assembly.
7. Prepare a work area to stand up the stem and gear assembly
on the bottom surface of the stem.
8. Remove the retainer ring under the piston ring from the stem
and gear assembly.
9. Remove the piston ring and the gear. This may require light
tapping on top of the gear with the gear sitting on the piston
ring.
72
The piston ring is assembled with a light press fit. Provide a support
under the gear so that it does not drop when it breaks loose.
10. Remove and discard all rotary seals, o-rings, the thrust ring,
and two wear bushings from inside the rotating link adapter
and gear inside dimension.
11. Remove and discard the stem flange O-rings and stem bore
shaft seals.
73
March 2, 1998
Always install a new mainshaft seal and use care not to damage the
seal or the case.
20. Install new stem flange O-ring.
z
e
74
Transmission/motor housing
Removing the transmission/motor
housing
Remove the transmission/motor housing to service the following
components:
Compound gear and bearings
Main shaft
Main thrust bearing
Bull gear
The AC drive motor can be removed with the TDS-10S left in
place. To remove this component, skip to the applicable removal
section below.
To remove the transmission/motor housing:
1. Remove the PH-55 pipehandler components as described
above.
2. Remove the saver sub and the lower and upper IBOPs. See
the IBOP Service Manual, included in the Supplemental
Materials book for the procedure.
3. Disconnect the service loop, rig down the tool, and transport
the transmission/motor housing to a suitable work area.
75
March 2, 1998
76
Use the two jacking holes in the upper bearing retainer plate as
required to help remove the plate.
2. Remove the lube tube from the lube tube bore of the cover,
and remove the lube tube O-rings.
3. Remove and discard the two lip seals in the bearing retainer
plate.
4. Remove the bearing retainer plate shims.
5. Remove the taper roller bearing outer race from the cover
bore.
77
March 2, 1998
When raising the main shaft, the main thrust bearing separates.
Lift the main shaft slowly.
7. Use the lifting eye on the end of the compound shaft to lift
out the compound gear.
78
Do not use a steel hammer when removing the gears. It can damage
components.
10. Remove the mainshaft upper wear sleeve by heating the sleeve
to 250F (121C). Check the sleeve for wear after removing
it.
11. Remove and discard the upper taper bearing inner race by
heating the race to 250F (121C).
If replacing the bull gear, perform steps 12, 13, and 14. If not,
proceed to step 15 and remove the bull gear along with the main
shaft.
12. Remove the 10 lockwired cap screws that hold the bull gear in
place.
13. Install two 5/8-11 UNC forged eyebolts in the bull gear
pickup holes and heat the bull gear to between 150F (66C)
and 200F (93C), then remove the bull gear by lifting the
gear straight up off the alignment pin.
14. Inspect the bull gear alignment dowel pin, and remove and
discard the pin if damaged.
15. Remove the main shaft wear sleeve by heating the sleeve to
250F (121C), then pulling the sleeve off shaft. Check the
sleeve for wear grooves after it is removed.
16. Remove the lower radial bearing inner race by heating the
race to 250F (121C), then pulling the race off the main
shaft.
79
March 2, 1998
17. Remove the main shaft sleeve by heating the sleeve to between
200F (93C) and 250F (121C) and pulling the sleeve off
the shaft.
18. Remove half of the thrust bearing race, the bearings, and the
cage of the thrust bearing.
19. Remove the other half of the thrust bearing race by heating
the race to 200F (93C) and pulling the race off the main
shaft.
20. Remove the four lockwired cap screws that hold the lower
radial bearing ring retainers in place and remove the retainers.
21. Remove the outer race of the lower radial bearing from the
bore in the housing with a bearing puller.
22. Remove the retainer nut and washer from the pinion shaft to
separate the bearing from the pinion gear. Heat the bearing to
200F (93C) and pull the bearing from the shaft.
23. Heat the inner bearing races to 200F (93C) and pull it off
the journals to remove the inner bearing races (cones) from
the compound gear journals.
24. When replacing the thrust bearing or radial bearing inner
race, turn the main shaft assembly upside down with the
6 5/8 in. pin connection pointed up. In order to turn the
assembly upside down, raise the lower race of the thrust
bearing until the rollers contact the upper race. Use two large
C-clamps and clamp the lower race and rollers to the main
shaft shoulder. Once the shaft is inverted, remove the clamps.
80
Do not drop the races or rollers during this tipping over process.
e
z
81
March 2, 1998
82
Lower Race
Rollers and Cage
Tapered Roller
Thrust Bearing
Upper Race
Heat to 200F (93C)
Bottom End of Shaft
Main Shaft
Stem
Shaft Shoulder
18" Diameter
Load Plate
Rest
83
March 2, 1998
84
11. Liberally apply oil to the lower radial bearing and inner race
of same bearing. Before lowering the main shaft, slowly loosen
the C-clamps until the lower race of the thrust bearing rests
on the inner race of the main radial bearing. Remove the Cclamps.
Loosen the C-clamps slowly to prevent the rollers from fallong out.
Lower the main shaft assembly through the main bore of the
main body until both the main thrust bearing races contact
the rollers and the main shaft rotates easily.
12. Heat the bull gear to between 150F (66C) and 200F
(93C). Install two 5/8-11 UNC forged eyebolts in the gear
pickup holes, making sure the stamping TOP SIDE is up.
13. Carefully lower the bull gear into position until it seats. If the
old dowel pin has been removed, rotate the gear until the
1 in. dowel pin hole is aligned.
If the bull gear dowel pin has been removed, chill the new dowel
pin to at least 0F (-18C), but no lower than -60F
(-51C) as the bull gear is being placed into position. Then drive
the dowel pin into the alignment hole using a bronze hammer.
The pin will sit flush to 1/4 in. high.
14. Apply an anti-seize compound to the threads of the ten 1 in.
hex-head cap screws that hold the bull gear in place, and
install the cap screws and lockwashers in place. Tighten the
cap screws in a star pattern to 610-670 ft lb.
15. Safety wire the cap screws with .051 in. diameter lockwire.
16. Heat the upper taper bearing inner race to between 225F
(107C) and 250F (121C). Install the bearing rotating the
race until it seats.
17. Inspect the upper wear sleeve. If the sleeve shows signs of wear
or damage, replace it.
18. Heat the upper wear sleeve to between 200F (93C) and
250F (121C). Install the sleeve and rotate the sleeve until it
seats.
85
March 2, 1998
19. Install dowel pins in the main body cover and keys in the
main body.
20. Apply a thin layer of sealant to the mating surfaces of the
main body and main body cover.
21. Install O-rings around the oil galleys in the back wall of the
main body.
22. Liberally apply oil to the upper cone of compound gear and
cup in cover. Lower the cover onto the main body, making
certain the compound gear bearing halves are aligned.
23. Install and tighten the cover bolts.
24. Lightly tighten the screws to the compound retainer and
measure the gap between the retainer and the main body.
25. Install a stack of shims between the retainer and the main
body that exceeds the gap by approximately .002 in.
26. Tighten the screws to 75 ft lb. Check the end play by
inserting a dial indicator through the hole in the bearing
retainer and moving the compound up and down using a pry
bar.
27. Disassemble the retainer and remove or add shims to obtain
an end play of .001 to .002 in.
28. Clean the mating faces, then apply a thin layer of sealant to
the mating faces. Install the reservoir.
29. Place the O-ring in the groove on the top face of the main
body cover where the hydraulic pump assembly attaches.
30. Install the hydraulic pump assembly.
86
Take care to not damage the inlet filter when lowering the pump
into place.
Make sure the brake end with mounting feet faces the rear, and
the blower duct faces the hydraulic pump when installing the AC
drilling motor.
3. Install the four cap screws and lockwashers that hold the AC
drilling motor to the main body.
4. Apply an anti-seize compound to the threads of the four main
body cover bolts for the motor. Tighten the four main body
cover bolts to 250-270 ft lb.
5. Install the tie rods by first inserting the end of the rod with
the greatest length of thread into the holes in the brake
adapter plate.
a. Raise the tie rod until the lower end clears the top of the
main body cover.
b. Install the tie rod into the threaded holes.
c. Tighten the tie rods until the lower end shoulders against
the main body cover.
d. Install the flat washer and locknut onto the remaining end
of the tie rod and torque to 325 ft lb.
87
March 2, 1998
AC Motor
Pilot Bore
O-Ring
88
Align the shims so that the upper bearing lube tube bore is not
blocked.
4. Remove the bearing retainer plate cap screws and the bearing
retainer plate.
5. Install the two new upper bonnet oil seals in the bearing
retainer plate with the lips facing up.
Use care not to damage the seals. Be careful to install the seals with
the lips facing up since these seals function to keep mud from entering
the main body.
6. Using a center punch, stake the last seal in place on eight
points.
7. Install the O-ring on the bearing retainer plate and coat the
O-ring with grease.
8. Install two O-rings on the upper bearing lube tube and coat
the O-rings with grease.
9. Install the lube tube into the lube tube bore in the cover with
the .060 in. diameter hole facing up.
89
March 2, 1998
10. Install the bearing retainer plate, being careful to align the
lube tube bore in the retainer with the lube tube protruding
from the cover.
11. Carefully tap the bearing retainer plate to seat the plate on
top of the cover.
12. Apply an anti-seize compound to the threads of the six
bearing retainer plate cap screws, install the six cap screws and
lockwashers, and tighten to 250-270 ft lb. Safety wire the cap
screws.
13. Recheck the main shaft axial movement by applying a force to
the main shaft and measuring the amount of axial movement
with a dial indicator. The main shaft movement must be
between .001 and .002 in. If the movement falls outside of
this specification, readjust the number of shims under the
bearing retainer plate.
14. Install two new grease fittings into the bearing retainer plate.
90
91
March 2, 1998
92
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Brake Hub
AC Motor
Pressure Gauge
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Hub
93
March 2, 1998
94
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
5.029
Ref
Brake Hub
AC Motor
5.975
Ref
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
Lap to 85% Contact
,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
Pinion Hub
95
March 2, 1998
n
n
96
1
2
97
March 2, 1998
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.
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.
TDS-10S
Top Drive
Drilling
System
Control System
March 2, 1998
Contents
Chapter 1 Description
General description ............................................................. 5
Major component descriptions ........................................... 7
Varco Drillers Console (VDC)..................................... 7
Programmable logic controller (PLC) ..................... 9
Variable Frequency Drive (VFD) .......................... 10
Electrical service loops................................................. 12
Chapter 2 Operation
Preoperational checklists ...................................................
VDC controls ...................................................................
Correcting a drive fault .....................................................
Drive fault while drilling .............................................
Drive fault while making up .......................................
13
17
20
20
21
Chapter 3 Maintenance
Maintaining the control system......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
March 2, 1998
Chapter 1
Description
General description
The TDS-10S control system consists of the following three
major components:
Varco Drillers Console (VDC)
Varco Electrical House (VEH)
Electrical Service Loops
These components directly interface to control and provide safety
interlocks for the TDS-10S (Figure 1).
March 2, 1998
Variable
Frequency Drive
(VFD)
3-Phase Power
Control
Signals
Varco
Driller's Console
(VDC)
Data
Bus
Remote I/O
PLC
Control
Signals
TDS-10S
IBOP
BRAKE
IBOP
CLOSED
BRAKE
ON
PIPEHANDLER
MAKE-UP
CURRENT LIMIT
OIL
PRESS LOSS
ROTATE
LEFT
R
0
MAX
VDC
PRESS LOSS
DRILL MOTOR
OVERTEMP
LINK TILT
OFF
TORQUE WRENCH
PUSH & HOLD
DRILL
R
BRAKE
AUTO
IBOP
TILT
OPEN
CLOSE OFF
BRAKE
ON
EMERGENCY
STOP
SPIN
DRILL
THROTTLE
RIGHT
BLOWER LOSS
TORQUE
ALARM LAMP
SILENCE CHECK
HYDRAULIC POWER
AUTO
ON
DRIVE
FAULT
MAX
DRILL TORQUE
OFF
REVERSE
FORWARD
TORQUE
R
RPM
R
0
MAX
March 2, 1998
March 2, 1998
10
810 VDC
Resultant Pulse DC
TDS-10S AC Motors
+
AC
Power
Source
AC Inverter
(AC Frequency Drive)
PLC
Inverter Controller
600 VAC, 42 to 62 Hz
3-Phase (350 AMPS)
0
40 Hz=1200 RPM @ Mtr.
Data Bus
VFD
11
March 2, 1998
12
Chapter 2
Operation
Preoperational checklists
The tables on the subsequent pages provide the following
preoperational checklists:
Drive control system function checks (Table 1)
Top Drive control system function checks (Table 2)
Top Drive control system interlock checks (Table 3)
Top Drive control system alarm checks (Table 4)
13
March 2, 1998
Function
Indicator
Display Lamp
Physical
Check
Forward
N/A
Blower on
Reverse
N/A
Blower on
Off
N/A
Blower off
Forward
N/A
Oil pump on
Reverse
N/A
Oil pump on
Off
N/A
Closed
On
Actuator shell up
Open
Off
Actuator shell
down
Drill
N/A
Links to drill
down position
Off
N/A
No movement
Tilt
N/A
Links extended
to mousehole
Push
N/A
Links float to
w/c
Rotating head
(manual)
Left
N/A
Rotates left
Right
N/A
Rotates right
Counterbalance
Drill
N/A
Balance TDS
weight
Stand Jump
(opt.)
N/A
Lifts TDS
weight
Blowers
Oil pump
IBOP
Link tilt
14
Switch
Position
Check OK
Function
Indicator
Display Lamp
Physical
Check
Off
Off
Brake released
On
On
Brake set
Auto/throttle on
Off
Brake released
Auto/throttle off
On
Brake set
Off
N/A
Jaws unclamped
Clamp
N/A
Jaws clamped
Alarm silence
Push
On
Horn silenced
Lamp check
Push
All lamps on
On
(after 2 seconds) (after 2 seconds)
Brake
Torque wrench
Check OK
Function
Rotating head
Torque wrench
clamp
Control
Sequence
Action
No rotation
After 5 seconds
actuate rotate
left/right.
After 5 seconds,
rotating head
rotates.
Check OK
No torque wrench
With
clamp
drill/spin/torque
switch in drill mode
and throttle on,
actuate torque
wrench clamp.
15
March 2, 1998
Blower differential
press
16
Disconnect aux.
power loop
Blower Press
Alarm flashes and
horn sounds
Disconnect aux.
power loop
Blower Press
Alarm flashes and
horn sounds
Check OK
VDC controls
Table 5 describes each of the VDC controls in detail (Figure 4).
24
20
21
OIL
DRILL MOTOR
PRESS LOSS OVERTEMP BLOWER LOSS
12
DRIVE
FAULT
PURGE
LOSS
13
3
RPM
TORQUE
5
IBOP
IBOP
CLOSED
10
BRAKE
OPEN
BRAKE
AUTO
BRAKE ON
IBOP
CLOSE
OFF
BRAKE
ON
EMERGENCY
STOP
16
THROTTLE
PIPE HANDLER
MAKE-UP
CURRENT LMIT
ROTATE
LEFT
MAX
0
HYDRAULIC
POWER
OFF
ON
DRILL
LINK TILT
OFF
TILT
TORQUE WRENCH
PUSH & HOLD
MAX
DRILL TORQUE
COUNTERBALANCE
DRILL
23
STAND
JUMP
DRILL
SPIN
TORQUE
ALARM/LAMP TEST
(PRESS TO SILENCE)
MAX
OFF
REVERSE
FORWARD
19
9
11
15
14
18
17
22
17
March 2, 1998
DRIVE FAULT
Red indicator light flashes and horn sounds when a VFD fault
is detected. Pressing the alarm silence button stops the horn.
The alarm indicator light stays on while the switch is timed
for 5 minutes. The alarm returns if the fault is not fixed,
otherwise, the alarm light turns off.
BLOWER LOSS
BRAKE ON
DRILL MOTOR
OVERTEMP
IBOP CLOSED
ALARM /LAMP TEST When the alarm indicator light illuminates and the horn
switch
sounds, press the switch to silence the horn. The alarm light
BRAKE switch
DRILL TORQUE
Limit Potentiometer
10 ROTATE
18
12 EMERGENCY STOP Emergency stop shuts down all operations. Emergency stop
switch
switch is hardwired to the VFD. Pressing the stop button
deselects the drive and sets the brake, causing the top drive
rotation to stop regardless of throttle position. Auxiliary
cooling motors remain on.
13 IBOP switch
Activates the upper IBOP valve. Turning the switch to the left
retracts the IBOP actuator cylinder to close the valve. Turning
the switch to the right extends the cylinder to open the valve.
16 MAKE-UP CURRENT A potentiometer sets the torque limit in the VFD when using
LIMIT Potentiometer the top drive to makeup connections. Torque is displayed on
the torque meter. Adjust the torque by setting the brake and
turning the potentiometer to increase or decrease the torque.
17 REVERSE /OFF/
FORWARD switch
18 TORQUE WRENCH
PUSH & HOLD
switch
21 RPM meter
23 THROTTLE
24 TORQUE meter
19
March 2, 1998
20
The top drive must not be deassigned (hydraulic pump and blower
motors running) for more than 10 minutes to maintain maximum
braking. Brakes are applied by hydraulic caliper pressure actuated by
accumulator pressure. When the hydraulic pump is off, the
accumulator pressure drops due to normal system leakage, resulting in
a decrease in braking. The decrease in braking is gradual until the
accumulator precharge pressure is reached. If the drill string torque is
low, there may be noticeable rotation due to a gradual decrease in
braking since the required brake holding pressure is low. In this
situation, the brakes release once hydraulic pressure reaches the
accumulator precharge pressure.
Floor hands should stay clear of back-up tong and long line
during this operation due to the possibility that a sudden release
of torque might cause the tong to recoil and fall to the floor.
21
March 2, 1998
22
Chapter 3
Maintenance
23
March 2, 1998
Procedure
Interval
Indicator lamps
Daily
Heater
Monthly
High voltage
connections
Monthly
Monthly
24
Component
mounting
Monthly
Monthly
Troubleshooting
The figures in the subsequent pages show the following PLC
modules during normal operations:
S7-300 CPU (Figure 5)
Input module (Figure 6)
Output module (Figure 7)
Remote I/O (Figure 8)
CPU315-2 DP
SF
BATF
BUSF
DC5V
FRCE
RUN
Memory card
receptacle
STOP
RUN-P
RUN
Mode Selector
STOP
MRES
Battery Compartment
MPI port
Jumper (removable)
Terminals for
power supply and
functional ground
PROFIBUS-DP
interface
M
L+
DC
M 24V
X1 MPI
X2 DP
25
March 2, 1998
RUN
BF
DIA
ET 200B -4AI
0 1
RUN
STOP
RUN
BF
DIA
ET 200B -4AO
0 4
RUN
STOP
26
RUN
BF
DIA
0 5
RUN
STOP
27
March 2, 1998
VFD
The VFD has an LCD panel that can be used for troubleshooting
(Figure 9).
Output current
Actual value
Setpoint
Mode number
15,2A
120V
#
14.00Hz
*
14.00Hz
014=Operation
Output voltage
Mode name
Fault
Run
P
Jog
+/-
Reset
28
TDS-10S
Top Drive
Drilling
System
Supplemental
Material
March 2, 1998
Contents
Supplemental Material
Supplement list ................................................................ 8-5
March 2, 1998
Supplemental
Material
Supplement list
This chapter contains the following supplements:
Design Specification, Design Torque Standard (DS00008)
IBOP Service Manual
March 2, 1998
Safety Valve
(IBOP)
Service Manual
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the drillers console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
V
a
r
c
o
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
OPE
CL SD
Back-up
Rings
O-Ring
O-Ring
Ball
Sleeve
Seal Ring
Stabilizer
Ring
Crank
Grease/
Mud Seal
Seat
Wave
Spring
Back-up Ring
O-Ring
Thread
Protector
Feb. 2, 1994
PRINCIPLE FEATURES
The upper IBOP valves (2 ea.) are equipped with:
PH-85 style dual-path operating systems
New low-stress inside body contours
Completely redesigned long-life internals
The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides.
The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
5. Screw the stem/main shaft and upper IBOP together.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
a. Torque up to the recommended torque value (Table 1).
b. Back off the connection and inspect the threads and face.
c. Torque up to the recommended torque value (Table 1).
Feb. 2, 1994
I.D.
Connection
O.D.
Torque (ft-lb)
(min.)
(max.)
Mainshaft to Upper
IBOP Safety Valve*
3"
7-3/4
60,000
70,000
3"
7-3/4
50,000
70,000
3"
7-3/8
46,000
64,000
Crossover Sub to
Lower IBOP Safety
Valve
3"
7-3/8
46,000
60,000
Mainshaft to Upper
IBOP Safety
Valve**
3"
83,000
91,000
3"
75,000
91,000
3"
8-5/8
66,000
85,000
Crossover Sub to
Lower IBOP Valve
3"
75,000
91,000
* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a.
b.
c.
d.
e.
f.
Carefully grind off any raised tong marks on the O.D. of the safety valves.
Open the valve exactly halfway (45 degree rotation of the actuator).
Orient the levers on the crank assemblies horizontally as shown.
Slide the shell up onto the valve with the actuator arm groove on the bottom.
Hold the shell in position relative to the valve operating sockets.
Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90 of crank travel.
10
Feb. 2, 1994
Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90 of crank travel.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Groove
Lock Tabs
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open
Position
Closed
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Roller
Assembly (3)
Crank Assembly
Retaining Screw
Crank
Assembly
Slot
Roller
Assembly
(3)
Actuator
Shell
Crank*
Roller
Assembly (3)
Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove
Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Closed
Position
Open
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the drillers console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
16
Feb. 2, 1994
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
1. Breakout and remove the lower IBOP.
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
4. Re-assemble the valves.
5. Reinstall and torque the lower valve.
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
1. To verify the integrity of the grease seal.
2. To lubricate the floating seat.
3. To flush mud and debris from the spring cavity.
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly
the valve should be serviced.
2. Install a suitable grease fitting.
3. Open the valve.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT
19
C
L
BALL
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
GREASE PORT
Feb. 2, 1994
PRESSURE PLUG
WAVE SPRING
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
Feb. 2, 1994
VALVE
BODY
PRESSURE PLUG
GREASE PORT
20
C
L
BALL
Figure 11. Lubricating a Typical Lower IBOP
FIXED SEAT
Feb. 2, 1994
INSPECTION
Magnetic Particle Inspection
After approximately three to six months (depending on the severity of operating conditions)
Varco recommends performing a Magnetic Particle Inspection of all load bearing components
including IBOPs over their entire surface and internal bores to reveal any fatigue or crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C.
ASTM A-275
ASTM E-709
21
Feb. 2, 1994
Recommended
Inspection Areas
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.
VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Adapter
Cylinder
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2)
*1 Inch
Actuator
Arm
Cylinder
in OPEN
Position
Rod
End
Cylinder
Gland
Upper IBOP
Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &
Single Crank PH-60
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13
17
19
10
18
14
15
20
16
8
2X 4
3
9
12
11
12
7/8" Hex
25
Feb. 2, 1994
Parts List
ITEM
QYT. / KIT
DESCRIPTION
PART NUMBERS
90939-5
RETAINING RING
89141-1
O'RING
90441-9
BACK-UP RING
90441-10
90939-5
90939-5
POLYSEAL
96439
BACK-UP RING
89141-13
CROWN SEAL
89141-8
10
SLEEVE
11
O'RING
89141-11
12
BACKING RING
89141-12
13
14
WAVE SPRING
89141-9
15
BODY
16
O'RING
17
NYLON PLUG
18
19
PLUG
20
89141-3
93806-11
96438
Feb. 2, 1994
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Nut Wrench for DSV Models
Varco Part No. 89141-18
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or
clamp to hold the valve
securely (Figure 16).
Figure 16
2. Engage the seat puller in
the inside groove of the
lower seat (Figure 17).
3. Using the load bar across
the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).
Figure 17
28
Feb. 2, 1994
Figure 18
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat
counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the
upper seat (Figure 20).
Figure 20
29
Feb. 2, 1994
Figure 21
12. From the outside of the
valve, push the crank into
the valve body and remove
them (Figure 22).
Figure 22
13. Remove the pulling tool
from the lower seat.
14. Insert the pulling tool from
the opposite end of the
valve and engage the
groove on the I.D. of the
lower seat (Figure 23).
Figure 23
30
Feb. 2, 1994
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
Figure 26
Figure 27
32
Feb. 2, 1994
Figure 28
7. Inspect the ball valve for
corrosion, pitting and
gaulling (Figure 29).
Figure 29
33
Feb. 2, 1994
Figure 30
9. Make sure the snap ring is
not broken or damaged
(Figure 31).
Figure 31
34
Feb. 2, 1994
Figure 32
13. Thoroughly lubricate the
valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the
pulling tool until it seats on
the spring surface of the
lower seat (Figure 33).
Figure 33
Feb. 2, 1994
Figure 34
19. Apply a generous coat of
grease to the outside of the
sleeve and crank.
20. From the inside of the valve
body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).
Figure 35
21. Make sure the crank moves
90 to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the
Closed position.
23. Apply a generous coat of
grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).
Figure 36
36
Feb. 2, 1994
Figure 37
Figure 38
37
Feb. 2, 1994
Figure 39
36. Install the 1/4" N.P.T. plug
into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.
38
Feb. 2, 1994
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP
PART NO.
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
94769-500
94769-502
94769-501
STD
H2S
NAM
Upper Valve-PH60
6 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94770-500
94770-502
94770-501
STD
H2S
NAM
Upper Valve-PH60
7 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94099-500
94099-502
94099-501
STD
H2S
NAM
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94100-500
94100-502
94100-501
STD
H2S
NAM
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90815
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90814
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90813
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
90812
-
STD
H2S
NAM
93806
-
93806-1
-
90939-5
-
94206-500
94206-501
94206-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94205-500
94205-501
94205-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94204-500
94204-501
94204-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
40
Feb. 2, 1994
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
94203-500
94203-501
94203-502
STD
H2S
NAM
93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
91138
-
STD
H2S
NAM
95384
-
91137-SP
-
91137-1
-
89451-501
89491-503
86434
STD
H2S
NAM
Lower Valve
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-1
-
90939-5
89453-15
89452-501
89492-502
-
STD
H2S
NAM
Lower Valve-Stepped
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90811
-
STD
H2S
NAM
Lower Valve
7 5/8 Pin X 7 5/8 Box
93807
-
93807-1
-
90939-5
-
91138
-
STD
H2S
NAM
94385
-
91137-SP
-
91137-1
-
105629
-
STD
H2S
NAM
90939-5
-
103220
-
STD
H2S
NAM
90939-2
-
90939-1
-
90939-5
-
98977-500
98977-502
98977-501
STD
H2S
NAM
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
99461-500
STD
H2S
NAM
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
41
Feb. 2, 1994
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46
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