Manual

March 25, 2018 | Author: Jose Luis Molina | Category: Motor Oil, Transmission (Mechanics), Machines, Mechanical Engineering, Engineering
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ContentsGeneral Information 1 Specifications 2 Lubrication and Maintenance 3 Installation, Commissioning and Decommissioning 4 Hydraulic System 5 Electrical System In development 6 PH-50 Pipehandler In development 7 Motor Housing, Transmission In development Guide Beams and Carriage 8 9 Preliminary TDS-11SA i Introduction How to Use This Manual This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Where applicable, each section includes: 1. A table of contents, or an illustrated view index showing: • Major assemblies, systems or operations • Page references to descriptions in text 2. Disassembly / assembly information and tools 3. Inspection information 4. Testing / troubleshooting information 5. Repair information 6. Adjustment information 7. Torque values Notes, Cautions and Warnings i ! (Note) Gives helpful information. (Caution) Indicates a possibility of personal injury or equipment damage if instructions are not followed. (Warning) Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. Special Information ! Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains warnings about proceedures which could damage equipment or make it unsafe, and cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized. All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text, figures and tables. REV A © 1998 Varco Systems Top Drive Technical Publications Department All rights reserved ii Varco Systems General Information Major components................................................. 1-2 1 Identification numbers .......................................... 1-3 Lifting points .......................................................... 1-4 Safety wiring .......................................................... 1-5 Torque values ........................................................ 1-6 Basic useage ......................................................... 1-7 Drilling ahead with singles ............................... 1-7 Drilling ahead with triples ................................. 1-8 Backreaming...................................................... 1-9 4 3 2 5 6 7 8 9 Preliminary TDS-11SA 1-1 General Information Major components 1 Motor Cooling System Counterbalance System Hydraulic Disc Brakes (2) Gooseneck (S-Pipe) AC Drilling Motors (2) Guide Beam Transmission/ Motor Housing Electrical System Hydraulic System Rotating Link Adapter PH-50 Pipehandler Front Carriage Rear Right Side Rear Left Side Front 1-2 Varco Systems . ASSY NO.General Information Identification numbers Encoder Instruction Label On the side of brake housing 1 AC Motor Identification Label On the side of each AC motor Warning Label On the side of bonnet Warning Labels On the side of each AC motor Top Drive Identification Plate On the front of motor housing SALES ORDER NO. TRACE CODE DATE OF MANUFACTURE REV Preliminary TDS-11SA 1-3 . 000 lbs (16.500 lbs (15.798 kg) TDS-11SA on skid ! Lifting Points For skid attached to top drive Locking pins Must be in place prior to moving skid with top drive 1-4 Varco Systems .663 kg) TDS-11SA Lifting Point For removal or attachment to the skid ! Bail Lock Must be installed before lifting top drive from the skid or attaching top drive to the skid Lifting Points For skid attached to top drive 37.General Information Lifting points 1 34. General Information Safety wiring 1 2 1 3 4 5 Preliminary TDS-11SA 1-5 . 800 9.310 2.000 87.600 7.000 87.950 16.400 21.176 1.000 psi 1 1/8" to 1 1/2" dia.020 3.600 73.300 29.050 11.7 12.S.382 6. UNF 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 28 24 24 20 20 18 18 16 14 14 12 12 12 12 9.700 12.3 13.1 21.000 psi to 1" dia. Torque (ft lb) Max.300 23.020 3.General Information Torque values 1 Bolts Lubricated with Light Machine Oil Grade 5 Min.0 28 43 71 95 134 236 370 551 693 977 1.700 5.568 7.533 2.940 6.700 5.320 3.400 21.150 1.302 1.550 10.090 10.950 16. Torque (ft lb) Bolts Lubricated with Anti-seize Compound Grade 5 Max.037 2.050 11.528 2. Torque (ft lb) Clamp Force (lb) Diameter Threads per inch Coarse Thread Series.500 59.550 10.178 1.000 psi T.300 53.100 78.5 18 33 52 86 114 162 285 447 665 836 1.320 3.733 2.700 7.S.4 18 32 53 79 116 158 273 452 672 840 1.1 13. = 120.700 12.4 23.5 20 37 58 95 126 179 315 494 735 924 1.400 38.100 78.000 5.596 2.800 32.300 53.300 23.400 38.500 59. = 105.600 42.340 4.400 42.490 6.400 42.300 29.600 14.700 T.600 14.600 42.843 8. Proof Strength = 85. Torque (ft lb) Clamp Force (lb) Min.000 Fine Thread Series.340 4.600 73.800 32.200 47. Proof Strength = 74.040 1.800 64.387 1.197 1.800 9.5 25 39 64 86 121 214 335 499 627 884 1.323 1.000 psi 1-6 Varco Systems .6 39 59 87 118 205 339 504 630 882 1. UNC 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 20 18 16 14 13 12 11 10 9 8 7 7 6 6 7.6 16 29 48 71 105 143 247 409 608 760 1.4 36 53 78 107 185 306 456 570 798 1.764 2.600 7.200 47.064 1.800 64.9 15. General Information Basic useage Drilling ahead with singles 1 Set slips on string Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse) Latch drill pipe elevator around single Release link tilt Stab bottom of single onto string Spin in motor and single Makeup both connections with motor in torque mode Start circulation Begin drilling Tilt links to mousehole Pickup single with elevator Lower block to stab motor into top of single Pull slips Open IBOP 1 2 3 4 5 Makeup Open IBOP Link Tilt Close IBOP Stab Makeup Preliminary TDS-11SA 1-7 . General Information Drilling ahead with triples 1 Set slips on string Stop circulation Breakout connection using pipehandler and drilling motor (in reverse) Raise block Tilt link tilt to derrickman Pickup stand with elevator Stab bottom of stand onto string Lower block to stab motor into top of stand Spin in motor and stand Makeup both connections with motor Pull slips Start circulation Begin drilling 1 2 3 4 5 Link Tilt Makeup Start Circulation Stop Circulation Stab Makeup 1-8 Varco Systems . pull slips. stop rotation and circulation Set slips on string Breakout connection using pipehandler and drilling motor (reverse) Breakout and spinout stand at floor Hoist free stand with elevator Setback stand using link tilt Lower block. hoist and rotate 1 2 3 4 5 Breakout Hoist Setback Hoist and Rotate Breakout Preliminary TDS-11SA 1-9 .General Information Backreaming 1 Hoist while circulating and rotating When 3-rd connection surfaces. stab motor into string Spin in motor and makeup connection with motor Start circulation. General Information 1 1-10 Varco Systems . .................................................... 2-4 Typical mast interface ..............................Specifications Design specifications ........ 2-3 General specifications ................................. 2-2 Size specifications (continued) .......................................... 2-2 Size specifications .................. 2-5 1 2 3 4 5 6 7 8 9 Preliminary TDS-11SA 2-1 ........... (3048 mm) 2 18.0 in. (1826 mm) 2-2 Varco Systems .9 in.798 kg 56. (2235 mm) 233.5 in. (2855 mm) To Center of Gravity 28.0 in. (1588 mm) 71. (5918 mm) To Center of Gravity 112. (1422 mm) 62.2 in.Specifications Design specifications Size specifications Front and side view Bail 120 in. (716 mm) = 37. (470 mm) Bail 88 in.000 lb = 16.5 in.4 in. (579 mm) C L Well 21. (856 mm) 2 33.8 in.7 in.0 in. (660 mm) 36.0 in.6 in.8 in.0 in. (762 mm) Setback (Standard) 22. (561 mm) 31.9 in.1 in.Specifications Size specifications (continued) Plan view Rear 33. (859 mm) 30. (787 mm) 32. (937 mm) C L Well Front Preliminary TDS-11SA 2-3 .1 in. (53 mm) 22. (828 mm) 26. AC motor (1) 6 gpm. height (Siemens) 140. 91. x 84. (4 in.4 in.600 rpm Hydraulic caliper disc brakes IDM Yaskowa Drive (800 hp.500 lb 600 VAC(60 Hz). or 690 VDC(50 Hz) 10 hp.500 lb 17.. 600 VAC) Reliance AC-575 VAC (2 x 400 hp) PH-50 (55. or 600 VAC(50 Hz).0 in.8 ft 700 KVA @ 575-600 VAC.000 ft lb torque) 3-1/2 in.0 in.500 ft lb (800 hp) 55.5:1 (4. (1) 4 gpm 1800 rpm 25 gal Pressure feed 15 gal Single speed.0 in. or 750 VDC. to 5 in.000 ft lb 228 rpm 500 ton Items Description 2 2-4 Varco Systems . 91. height (IDM) 9. double reduction spur gear system (helical gears optional) 10. 575 VAC) or Siemens (800 hp. x 90. 50/60 Hz 800 hp 37. to 6-5/8 in.0 in.2 in.Specifications General specifications Components Top Drive Weight Stack-up Height Power Requirements Horsepower Output torque (continuous) Tool torque (intermittent @ stall) Maximum Speed @ full power Hoisting capacity Drill Pipe Sizes Pipe Handler Type Drilling Motor Type Variable Frequency Drive Type Motor Braking Type Motor Cooling System Type Power Speed Gearcase Type Gear ratio Gearcase Lubrication Type Reservoir capacity Fully internal flow Gear Type Hydraulic System Power Flow Speed Reservoir capacity Oil Type Electrical House Size Type Weight Input requirement 125. OD tool joint) 34..??:1 optional) Local intake pressure blower (2) 5 hp AC motors 3. (28.2 m) Drill Floor AC Cables AC Power and Control Cables 7. (61 m)* * Dimensions are Subject to Verification ** Standard TDS ConfigurationTwo IBOP’s with 108 in. (5.3 m) Level Service Loop 200 ft. (2. (45.0 ft. (22. (24.4 m)** Tool Joint Service Loop Saddle at ~80 ft. (3 m)-Minimum* 2 Custom Spanners On A-Frames or Mast Side Panels (by Customer) Varco Driller’s Control Control Cable with Connectors 150 ft.7 m) Unitized Variable Frequency Inverter & Varco Control Panel Local Power Supply Diesel/Alternator Set/AC Buss C L Beam Service Loop Tool Joint 4. (1.1 m)* Bail Rest TDS Work Height 18. (4. Elevevator Links TDS-11S Varco Portable Top Drive System 2 Sectional Guide Beam Drill Stand Made-up at 4 ft. (22.2 m) Level 93 ft.5 ft.9 m)* Connected to Standpipe at 73 ft. Crown Clearance 13.1 m)** Block Top Stroked-Typ. 13.(by Customer) 10.1 m)-Minimum Preliminary TDS-11SA 2-5 Clear Working Height 142 ft.Specifications Typical mast interface Existing Traveling Equipment 350-ton Hook/Block Combo-Typ. (1.4 m) Level* Mud Hose 75 ft.0 ft.3 m) Portable Torque Reaction Beam “U”.3 m) . (43.5 ft.0 ft.Bolted to Spanners . (4.0 ft. Specifications 2 2-6 Varco Systems . . 3-9 1 2 3 4 5 General purpose lubrication ......................... 3-8 Motor lubrication .... 3-2 Selecting the proper gearbox oil......................................................... 3-7 Motors .................................................................. 3-2 Recommended gear oils ................................................ 3-5 Lubrication schedule ......... 3-5 Recommended hydraulic fluid ................................................ 3-14 General lubrication (continued) ............... 3-13 General lubrication (continued) ....... 3-11 General lubrication ......................................... 3-15 7 6 8 9 Preliminary TDS-11SA 3-1 ...................................Lubrication Transmission ................................ 3-11 Recommended lubricants ...... 3-10 Lubrication schedule .................................... 3-5 Precautions.................. 3-6 Hydraulic lubrication.......................................................................................................... 3-4 Hydraulic system .... 3-3 Gearbox lubrication ......... 3-8 Recommended motor grease .................. 3-8 Lubrication schedule ................... 3-12 General lubrication (continued) .................................................................................................................................................. 3-2 Lubrication schedule ........................................................... 3-2 Varco Systems . Select lubrication for the TDS based on the minimum ambient temperature (surrounding air) to be expected before the next oil change. Introducing an oil viscosity greater than required by the ambient temperature can: t Damage the gearbox due to reduced oil flow t Damage the oil pump because of excessive load 3 Lubrication schedule Description Replace the Gearbox Oil and Perform an Oil Analysis Oil viscosity should be adjusted based on expected ambient conditions for next six months Frequency 1 x every 6 Months 1 x every 3 Months Replace the Gearbox Oil Filter (P/N 111013) The first oil change should be performed after the first month of operation since new units often contain metal contaminates and contaminates caused by initial break-in. Under these conditions oil tends to extrude out of the gear mesh.Lubrication Transmission Selecting the proper gearbox oil TDS transmissions operate under a combination of heavy and shock loads. Varco recommends changing the oil every six months. Under all but the most severe operating conditions. Varco Top Drives also operate under a wide variety of temperatures. and a minimum viscosity of 100 SUS at internal operating temperature. Keeping an effective film of oil on the gear mesh requires oil with an AGMA “extra pressure” rating (EP). Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F. consult Varco engineering. consult Varco engineering. If drilling conditions dictate oil temperatures below 20°F. the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. For minimum temperatures below 20°F.Lubrication Recommended gear oils Ambient Temperature Range -6 to 16 C (20 to 60 F) 7 to 30 C (45 to 85 F) Above 21 C (Above 70 F) Manufacturer Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Loadway EP68 Meropa 68 Carter EP 68 Extra Duty NL2EP Alpha LS-150 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 Extra Duty NL4EP Alpha LS-320 NL Gear 320 Spartan EP320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320 Extra Duty NL6EP 3 Viscosity Index NGLI AGMA ISO Viscosity Grade N/R 2EP 68 N/R 4EP 150 N/R 6EP 320 e z Oils of insufficient viscosity can damage gears by allowing metal to metal contact. Preliminary TDS-11SA 3-3 . If the oil temperature rises above 200°F. 12 point socket to remove plug Gear Oil Sight Gauge Check withTop Drive “OFF” “Pop-up” Dirt Alarm Gear Oil Filter 3-4 Varco Systems .Lubrication Gearbox lubrication 3 Cork Ball (Level Indicator) Sight Glass Gearbox Oil “Fill” Use a 1 3/8 inch. 3 Use care when handling components to prevent nicking close tolerance finishes. and maintain system cleanliness by promptly capping all disconnected lines. thoroughly clean work area. Before opening the hydraulic system. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system.Lubrication Hydraulic system Precautions n n e e Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel. Preliminary TDS-11SA 3-5 . Use care to prevent contamination from entering the hydraulic system during maintenance activities. Lubrication schedule Description Perform Hydraulic System Oil Analysis Replace the Hydraulic Fluid Replace the Hydraulic System Filter (P/N 114416-1) Frequency 1 x every 6 Months 1 x Year. or Earlier Based on Oil Analysis 1 x every 3 Months The first oil change should be performed after the first month of operation since new units often contain metal contaminates and contaminates caused by initial break-in. Hydraulic oil under pressure can penetrate skin and cause serious injury. Lubrication Recommended hydraulic fluid Oil Temperature Range -15 to 75 C (5 to 167 F) -10 to 85 C (14 to 185 F) Manufacturer Castrol Chevron Exxon Gulf Mobil Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 3 Shell Statoil Texaco Total Union Viscosity Index ISO Viscosity Grade 32 46 3-6 Varco Systems . Lubrication Hydraulic lubrication Ensure that the area is clean prior to adding hydraulic fluid Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill Remove dust plug from the female quick disconnect on the lubrication kit Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as shown Red “Pop-up” Dirt Alarm Cork Ball (Level Indicator) Sight Glass Hydraulic Oil Sight Gauge 3 Hydraulic Oil Filter Hydraulic Lubrication Kit 55 gal Drum Lubrication Kit Quick Disconnect Hydraulic Oil Fill Quick Disconnect Hydraulic Oil “Fill” Preliminary TDS-11SA 3-7 . Lubrication schedule Description Lubricate the AC Drilling Motor Lubricate the Blower Motor Lubricate the Hydraulic Pump Motor No. of Points 4 4 2 Frequency 1 x every 3 Months 1 x every 3 Months 1 x every 3 Months Type Motor Grease Motor Grease Motor Grease 3 Recommended motor grease Motor Grease Manufacturer Chevron Black Pearl EP2 (Do Not Substitute) 3-8 Varco Systems .Lubrication Motors n Varco recommends that lubrication of all AC motors should be done by the rig electrician. Lubrication Motor lubrication Apply grease to designated grease fittings with grease gun Grease Fittings 1/8 inch Grease Fitting (Varco P/N 53201) 3 Months AC Blower Motor (2) 3 pumps (2 grease fittings each motor) 3 1/8 inch Pipe Plug (remove and reinstall after lubricating) 3 Months AC Drilling Motor (2) 5 pumps (2 grease fittings each motor) As Viewed From Below 3 Months Hydraulic Pump AC Motor 3 pumps (2 grease fittings each motor) Preliminary TDS-11SA 3-9 . Cylinder Pins IBOP Actuator Cranks Stabilizer Bushing Clamp Cylinder Gate Carriage Assembly Torque Arrestor at Clamp Cylinder Elevator Link Eyes Wireline Adapter No. Severe conditions such as extreme loads or temperature. binding parts. may require more frequent lubrication. of Points 1 1 2 – 2 5 2 4 2 8 4 4 2 Frequency Daily Weekly Weekly Weekly Weekly Daily Daily Daily Daily Weekly Weekly Weekly Weekly Type General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease 3-10 Varco Systems . Be careful not to over lubricate parts. creating a potential slipping hazard for personnel. too much grease forced into a fitting can pop out a bearing seal. rust accumulations. Worn bushings. etc.Lubrication General purpose lubrication e e 3 The lubrication intervals described in this manual are based on lubricant supplier recommendations. corrosive atmosphere. and other abnormal conditions indicate more frequent lubrication is necessary. For example. Over lubrication can also affect safety since over lubricated parts can drip.. Lubrication schedule Description Washpipe Assembly Upper Bonnet Seal Bail Pins Rotating Link Adapter Gear Rotating Link Adapter IBOP Actuator Yoke. Lubrication Recommended lubricants Ambient Temperature Range Below -20 C (Below -4 F) Above -20 C (Above -4 F) Manufacturer Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union N/R Avi-Motive W Lidok EP1 Gulf Crown EP31 Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 MP Grease Avi-Motive Lidok EP2 Gulf Crown EP32 Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 3 Viscosity Index NGLI AGMA ISO Viscosity Grade 1 N/R N/R 2 N/R N/R Preliminary TDS-11SA 3-11 . Lubrication General lubrication 3 Apply general purpose grease to designated grease fittings with grease gun. Daily Wash Pipe Assembly Apply one pump at beginning of tour Weekly Bail Pins (2) Two pumps each side Weekly Upper Bonnet Seal One pump Use Hand Pump Only Weekly Rotating Link Adapter Gear Weekly Rotating Link Adapter Three pumps each Weekly Elevator Link Eyes (4) 3-12 Varco Systems . Use a brush when greasing other parts. 3 Daily IBOP Actuator Yoke One pump (if equipped) Daily IBOP Actuator Yoke One pump each side Daily IBOP Actuator Cylinder Pins One pump each (if equipped) Weekly Torque Arrestor Tubes Daily IBOP Actuator Cranks One pump each side Daily Stabilizer Bushing One pump each side Daily Stabilizer Bushing One pump each Weekly Elevator Link Eyes (4) Daily Clamp Cylinder Gate One pump each side Preliminary TDS-11SA 3-13 . Use a brush when greasing other parts.Lubrication General lubrication (continued) Apply general purpose grease to designated grease fittings with grease gun. Lubrication General lubrication (continued) Apply general purpose grease to designated grease fittings with grease gun 3 Weekly Bogies (4) One pump each side Weekly Rollers (4) One pump each side 3-14 Varco Systems . Lubrication General lubrication (continued) Apply general purpose grease to designated grease fittings with grease gun 3 Weekly Wireline Adapter One pump each Preliminary TDS-11SA 3-15 . Lubrication 3 3-16 Varco Systems . ........... Commissioning and Decommissioning Illustrated index .............................................................. 4-14 Stab and pin the first guide beam section .... 4-27 9 8 7 6 5 4 2 1 Preliminary TDS-11SA 4-1 ................ 4-11 Moving guide beam sections ........... 4-8 Moving the TDS-11SA to the drill floor ............ 4-5 Locating the control house ............................ 4-24 Installing the mud hose ............................................................................................ 4-26 Installing the rotary hose ............ 4-21 Installing the service loop ................................................................................. 4-17 Disengaging the upper carriage latch ........................................................................................... 4-7 3 Installation ............. 4-3 Preparation and preinstallation considerations ................. 4-15 Completing the guide beam installation ........................ 4-10 Disengaging the lower carriage latch .............. 4-9 Removing the TDS-11SA from the skid .. 4-13 Hoist the first guide beam section ........................................................Installation...... 4-19 Installing the intermediate restraints ......... 4-20 Installing derrick termination ....... 4-8 Pre-installation checklist ...................... 4-12 Present and hook the first guide beam section ....... 4-22 Service loop connection diagram ...... 4-16 Hanging the guide beam................................... 4-4 Preinstallation ............................................. 4-6 Installing incoming power cables ............... 4-25 Installing the counterbalance ..... 4-18 Installing the main tieback ....................................................... 4-5 Installing the crown padeye and hang-off link.................................... 4-23 Installing the driller’s console . ...................... 4-39 4 Lowering each guide beam section ............................. 4-35 Removing and storing the electrical cables and service loops ........................ 4-28 Hydraulic system checkout procedure ......................... 4-30 Decommissioning.............. 4-44 4-2 Varco Systems ..... 4-41 Returning the TDS-11SA to the skid ...................................................... 4-43 Long term storage procedures ..........................Installation. Commissioning and Decommissioning Commissioning ............ 4-42 Removing the TDS-11SA from the drill floor............. 4-38 Unpinning each guide beam section .................... 4-35 Securing the TDS-11SA for rig-down .... 4-36 Setting the latches and locking the bail ......... 4-44 Returning the TDS-11SA to service after storage ............................. 4-37 Disconnecting the guide beam ................................. 4-40 Unhooking and removing each guide beam section ..... 4-29 Mechanical checkout procedure ............................................. 4-28 Electrical system checkout procedure .............................................. Commissioning and Decommissioning Illustrated index Crown Padeye and Hang-off Link Page 4-X Counterbalance Page 4-X Rotary Hose Page 4-X Guide Beam Page 4-X Derrick Termination Page 4-X 4 Intermediate Restraints Page 4-X Service Loop Page 4-X Varco Driller’s Console (VDC) Page 4-X Control Cable with Connectors Page 4-X Unitized Variable Frequency Inverter and Varco Control Panel (House) Page 4-X Local Power Supply Diesel/Alternator Set/AC Bus AC Cables Page 4-X AC Power and Control Cables Page 4-X Main Tieback Page 4-X Preliminary TDS-11SA 4-3 .Installation. Derrick Clear Working Height Derrick Crown Clearance 4 152 ft. the required top drive travel is about 100 ft. and opposite the V-door is an ideal arrangement for handling tubulars from the V-door. 136 ft. installing the guide beam on the drawworks side of the derrick.. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. and extend the standpipe height to 70 ft. to ensure proper clearance and to help prevent wear to the service loop and mud hose. Each rig has different crown clearance for efficient tripping. long) with a 75 ft. 9 ft. Commissioning and Decommissioning Preparation and preinstallation considerations The TDS-11SA interfaces with the rig’s hoisting system and electrical power system. or mast. 142 ft. stand typically requires 97 ft. resulting in an overall height from the floor to the top of the traveling block of at least 126 ft. The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes. 20 ft. hose. when using a Kelly. Although many rig floor layouts are possible. Installing the TDS-11SA with existing traveling equipment may require an adapter– further reducing crown clearance. 147 ft. Handling a 93 ft. compared to about 75 ft. Derrick and electrical system modifications are required when installing the TDS-11SA on existing rigs. 25 ft. For derricks that handle triples. 15 ft.Installation. 4-4 Varco Systems . Other important installation considerations include the location of: t The casing stabbing board t Floor and derrick accessories t Drawworks fastline t Guide beam hang-off bracket t Torque reaction beam t Mud stand pipe extension t Varco drillers console location t Variable frequency inverter/Varco control panel location Derrick height is a critical interface requirement. 8 inches 33.0 inches Description Standard height configuration (adustable) Varco’s IDS Top Drive requirements Original setback for TDS-9S C L Well Preliminary TDS-11SA 4-5 .Installation.8 inches 30. Commissioning and Decommissioning Preinstallation Installing the crown padeye and hang-off link Crown Crown Padeye Weld according to table below See Table 4 Shackle Hang-off Link Recommended Installations Dimension 36. (3556 mm) 90.4 mm) Position as close to derrick plate as possible to minimize cable lengths.00 in. Commissioning and Decommissioning Locating the control house Recommended Area for Control House Location Drawworks V-Door Ramp TDS-11SA 4 C L Well Varco Driller’s Console 9.Installation. general exhausts).00 in. diesel engines. Location of the control house must ensure accessibility from all sides. 140.500 lb (4300 kg) Control House C L Well Control House Recommendations Position the control house off the driller’s side or behind the drawworks. (2286 mm) 4-6 Varco Systems . Ensure a safe distance from direct sources of heat (i.00 in. 91. (2311.e. Connect cables in accordance with the electrical schematic provided in the Technical Drawings book. Commissioning and Decommissioning Installing incoming power cables A-C OM POS ITE CON NEC TOR B-S ERIA LC ONN ECT OR Incoming Power Cables D-U INC C-A OM ING 575 VAC E-V INC OM ING UX. Varco Control Panel (House) Preliminary TDS-11SA 4-7 . POW ER Plug Panel CON NEC TOR 4 575 VAC F-W INC OM ING G-U OUT GO ING 575 575 VAC H-V OUT GO ING VAC 575 VAC I-W OUT GO ING 575 VAC Plug Panel Recommendations Connect the incoming power cables with the isolation circuit breaker turned OFF. Grounding locations are at the lower corners of the control house.Installation. Earth the control house with the Varco Ground Rod Kit. with the block over the center of the rotary table. is inspected to ensure that they will not foul with the TDS-11SA. Commissioning and Decommissioning Installation Pre-installation checklist The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and TDS11SA. etc. t Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed and inspected to conform to Varco specifications as detailed in FIP00003. This includes: t Make sure the derrick/mast is vertical. 4 4-8 Varco Systems . The hook should open toward the drawworks. t Rigging of tong lines. t The hook or adaptor becket is installed.Installation. t The control panel and frequency drive are installed. t The service loop bracket is installed in the derrick/mast. 000 lb (16000 kg) TDS-11SA on Skid Drill Floor 2 Backup Line V-Door Ramp 1 Preliminary TDS-11SA 4-9 . Commissioning and Decommissioning Moving the TDS-11SA to the drill floor Lifting Block Hoist using the drawwork Be sure that the Bail Lock Assembly is installed Tube (P/N 113498) U-Bolt (P/N 113497) 2x 3/4" nuts ! TDS-11SA on Skid Lifting Sling Attached to bail for hoisting Lifting Sling 4 ! TDS-11SA In position prior to lifting from skid Be sure that the Top Drive is pinned to the Skid prior to hoisting 3 37.Installation. 500 lb (15700 kg) TDS-11SA Pin 2 Latches Engaged for hoisting 4 Pin Lifting Block Hoist from skid using the drawwork TDS-11SA Lock Pin Remove prior to hoisting from skid TDS-11SA Prior to lifting from skid 1 Drill Floor Skid Remove from drill floor after hoisting TDS-11SA 3 2. Commissioning and Decommissioning Removing the TDS-11SA from the skid ! Be sure that the Bail Lock Assembly is installed. Remove only after installation is complete. TDS-11SA Lifted from skid 34.Installation.500 lb (1100 kg) Skid 4-10 Varco Systems . disengage the lower carriage latch and pin it as shown. 4 Upper Latch Engaged Lower Latch Disengaged Pin As viewed from rear of Carriage TDS-11SA prior to lifting from skid Preliminary TDS-11SA 4-11 .Installation. Commissioning and Decommissioning Disengaging the lower carriage latch Guide Beam Top Section Carriage Guide Beam Wings ! After hoisting the TDS-11SA from the skid. 100 lb (953 kg) Guide Beam Section Sling 4 Lifting Eyes TDS-11SA Drill Floor Guide Beam Section Guide Beam Sections Prior to Installation 4-12 Varco Systems . Commissioning and Decommissioning Moving guide beam sections 2.Installation. Installation. Commissioning and Decommissioning Present and hook the first guide beam section Guide Beam Top Section 1 Present Grease the bores on both joint halves Radius locks joint from unhooking at 8° rotation Guide Surface Hook Pin Hook Pin Saddle Grease the bores on both joint halves 4 2 Hook Guide Beam Top Section Hook Pin In fully engaged position Present and Hook the first guide beam section Guide Beam Section Hooked Drill Floor Preliminary TDS-11SA 4-13 . Installation. Commissioning and Decommissioning Hoist the first guide beam section Hoist Guide Beam Top Section Hoist Using the drawwork Hook Pin First Guide Beam Section Initially hoisted by the hook pin 4 Bar and Radius Locates pin bores for easy insertion of pins Drill Floor 4-14 Varco Systems . Commissioning and Decommissioning Stab and pin the first guide beam section 1 Stab the guide beam joints together Guide Beam Top Section Lynch Pin 4 Secure with the lynch pin 3 Retainer Pin 4 2 Stab and Pin the guide beam joint Joint Pin Install after stabbing Drill Floor Block as Required Preliminary TDS-11SA 4-15 .Installation. 8 in. (2. TDS-11SA Hoisting latches disengaged Crown Padeye Shackle Ensure that the shackle is pinned and the cotter pin is in place Hang-off Link 4 Pin Safety Pin Guide Beam Top Section C L Guide Beam Top Section C L Well Guide Beam Assembled Main Tieback and Spreader Beam Drill Floor Floor Clearance 7 ft.) (858.Installation.) (762 mm) Original TDS-9S or if plate extension (36.52 mm) Varco’s IDS top drive requirements (30.0 in. Commissioning and Decommissioning Completing the guide beam installation Crown Note: Use these pin positions if crown padeye installation is based on: (36.6 mm) 4-16 Varco Systems .) needs to be cut off due to interference.8 in.) (934.133.8 in.72 mm) Standard adjustable height configuration (33. ) needs to be cut off due to interference. (2. (858.8 in.133.52 mm) Varco’s IDS Top Drive requirements 30. Commissioning and Decommissioning Hanging the guide beam Crown Note: Use these pin positions if crown padeye installation is based on: 36.72 mm) Standard adjustable height configuration 33.Installation.8 in. (934. TDS-11SA Crown Padeye Shackle Ensure that the shackle is pinned and the cotter pin is in place Hang-off Link 4 Pin Safety Pin Guide Beam Assembled Guide Beam Top Section C L Guide Beam Top Section C L Well Drill Floor Floor Clearance 7 ft.8 in.0 in.6 mm) Preliminary TDS-11SA 4-17 . (762 mm) Original TDS-9S or if plate extension (36. Commissioning and Decommissioning Disengaging the upper carriage latch Guide Beam Top Section Carriage ! After hanging the guide beam on the hang-off link and prior to lowering the Top Drive. disengage the upper carriage latch and pin it as shown. 4 Pin Upper Latch Disengaged Lower Latch Disengaged As viewed from rear of Carriage Guide Beam Assembled Drill Floor 4-18 Varco Systems .Installation. 0 inches Preliminary TDS-11SA 4-19 .8 inches Description Standard height configuration (adjustable) Varco’s IDS Top Drive requirements Original setback for TDS-9S C L Well 30.8 inches 33.Installation. Commissioning and Decommissioning Installing the main tieback Guide Beam Bottom Section Tieback Link Guide Beam Assembled Tieback Plate 4 Main Spreader Beam Apply Anti-seize Compound Typical Auxiliary Spreader Beam Mast Leg Drill Floor See Table Main Tieback and Spreader Beam Recommended Installations Dimension 36. Commissioning and Decommissioning Installing the intermediate restraints Apply Anti-seize Compound Guide Beam Assembled Intermediate Tieback Plate (2) Girt Padeye (2) (If greater than 3 inches from girt) 4 3 inches 105 Feet Space between girt and guide beam Padeye (1) (If less than 3 inches from girt) Pin and Cotter Pin 55 Feet Guide Beam Assembled Drill Floor Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches 4-20 Varco Systems .Installation. Installation, Commissioning and Decommissioning Installing derrick termination Hoist Line Attachment Point Derrick Leg Plate Derrick/ Mast Leg Hoist Line Attachment Points Service Loop Brackets 4 Mount on the side of the derrick adjacent to the service loop brackets on the TDS-11SA Mount as far as practical from well center, to maintain a 36 inch minimum bend radius. Maintaining a larger radius increases loop life and reduces damage due to “pinching”. Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc. 75 ft/83 ft from Drill Floor Preliminary TDS-11SA 4-21 Installation, Commissioning and Decommissioning Installing the service loop Hoist Derrick Termination 1,000 lbs (454 kg) Service Loop Sling 4 ! To avoid damage to the service loop use care when dragging it near sharp edges and allow room for passing under the V-door TDS Service Loop Lifting Eyes Do not remove Derrick Service Loop Do not unpack the service loops until they are ready to hang Use a sling attached to the lifting eyes to hoist each service loop. Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting. The TDS service loop connects electrical service to the top drive and the derrick service loop connects electrical service to the control house Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package ! To avoid damage to the service loop maintain a 36 inch minimum Service Loop bend radius and Storage Tub 3,600 lbs (1,634.4 kg) 4-22 Varco Systems Installation, Commissioning and Decommissioning Service loop connection diagram 4 Preliminary TDS-11SA 4-23 Installation. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system. 4-24 Varco Systems . Commissioning and Decommissioning Installing the driller’s console Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated Location must ensure that the gauges are easily seen by the driller during drilling operations Location must be visible and readable at night TO RQ UE IBO AK E P BR R Y NC GE ER OP EM ST PIP EH D AN LE 4 C L Well Drawworks V-Door Ramp TDS-11SA C L Well Pigtail Cables Connect to control house Varco Driller’s Console ! Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. as it is specifically made for use with the TDS-11SA. Installation. Commissioning and Decommissioning Installing the mud hose 4 Preliminary TDS-11SA 4-25 . Commissioning and Decommissioning Installing the counterbalance For use with Hooks 4 4-26 Varco Systems .Installation. Installation. Commissioning and Decommissioning Installing the rotary hose 5 4 5 3 4 2 3 1 4 6 6 9 8 10 10 11 12 7 11 8 12 14 13 O Preliminary TDS-11SA 4-27 . Installation. Commissioning and Decommissioning Commissioning Hydraulic system checkout procedure Checking hydraulic fluid level 4 4-28 Varco Systems . Installation. Commissioning and Decommissioning Electrical system checkout procedure Checking connections and motor rotation Operate each control on the Varco driller’s console Assign the cooling motors and inverter by selecting FORWARD or REVERSE on the driller’s console Rotate the drill stem using the THROTTLE on the driller’s console and observe proper operation Check for alarm conditions and resolve any alarms at this time Check all connectors for tightness and lockwire Check operation of meters Check operation of “?” stop Check the latches on the driller’s console for tightness Varco Driller’s Console Latches 4 RP M TO RQ UE TO IB P IBO ED OS CL E BR AK BR N O RQ UE OP MA X AK E Y NC GE ER OP EM ST SE OF R VE SE F 0 DR AR D ILL TO RQ UE PIP RO S OIL OS SL ES EH AN DL ER TA TE RIG LIN HT KT ILT FL OA T P LO IBO C OP EN FO RW MA 0 X E E AK AK BR TO BR ON AU KT F LIN OF ILT TIL F OF T IVE DRULT FA RE Throttle F LE T PR P -U IT KE LIM MAENT RR CU OR OT P L M EM X RIL RT MA DOVE CH EN ILL WR LD DR UE& HO RQ SH TO PU R WE PO N O 0 S OW ER LO SS R YD MP H LA ECK UTO A M CH AR AL NCE ILE AU LIC Forward/Reverse Control / SP DR ILL IN TO RQ BL UE Preliminary TDS-11SA 4-29 . Look for oil level (oil is dark brown).Installation. Commissioning and Decommissioning Mechanical checkout procedure Checking gearbox oil level With the drive motors and hydraulic system off. check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox Always check the oil level after the unit has been running and the transmission oil is warm. Check filter condition “pop” 4 Cork Ball (Level Indicator) Gearbox Oil “Fill” Clean area before removing plug Sight Glass Gear Oil Sight Gauge Check with top drive “OFF” Recommended Lubricants GEAR OIL “Pop-up” Dirt Alarm Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade Ambient Temperature Range -6 to 16 C (20 to 60 F) 7 to 30 C (45 to 85 F) Above 21 C (Above 70 F) Alpha LS-68 Alpha LS-150 Alpha LS-320 NL Gear 68 NL Gear 150 NL Gear 320 Spartan EP68 Spartan EP150 Spartan EP320 EP Lube HD68 EP Lube HD150 EP Lube HD320 MobilGear 626 MobilGear 629 MobilGear 632 Omala 68 Omala 150 Omala 320 Loadway EP68 Loadway EP150 Loadway EP320 Meropa 68 Meropa 150 Meropa 320 Carter EP 68 Carter EP 150 Carter EP 320 Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP N/R 2EP 68 N/R 4EP 150 N/R 6EP 320 Gear Oil Filter 4-30 Varco Systems . not foam level (foam is tan). Commissioning and Decommissioning Adjusting the link tilt Pin inches (mm) Typical Link Tilt Crank Assembly Mousehole Position Cable Pull “up” or “down” to set mousehole position Clamp 4 Latch (inches) (mm) Drill Down Position Bottom of elevator should be above bottom of stabbing guide Link Mousehole Position Derrickman’s Position Well Center (Float Position) Elevator Preliminary TDS-11SA 4-31 .Installation. Installation. Commissioning and Decommissioning Selecting the proper saver sub and clamp cylinder jaws 53 41 42 40 38 39 20 31 34 21 20 21 52 36 37 54 55 25 26 24 13 51 22 23 41 20 40 44 59 60 56 43 4 35 27 29 32 33 14 15 18 19 30 28 57 58 21 45 36 16 17 13 35 11 34 37 50 46 47 18 19 12 12 27 32 2 5 9 8 7 1 33 14 15 28 48 49 16 17 10 6 4 3 S 4-32 Varco Systems . Installation. Commissioning and Decommissioning Removing and installing the saver sub Upper IBOP Lower IBOP 4 Saver Sub Upper Tool Lock Joint Shell Actuator Intermediate Tool Lock Joint Lower Tool Lock Joint Preliminary TDS-11SA 4-33 . Installation. Commissioning and Decommissioning Removing and installing the clamp cylinder jaws 43 42 34 2 35 30 1 32 22 R 27 35 35 33 31 34 34 29 40 28 39 47 53 46 24 57 58 56 37 38 7 R 52 18 4 19 16 17 59 60 64 54 5 68 14 69 80 70 65 13 71 63 6 77 10 10 8 77 79 72 81 74 75 78 55 20 15 61 62 73 51 76 45 48 66 67 52 11 40 42 9 3 36 12 25 41 12 21 23 26 26 9 4 49 44 50 Q 4-34 Varco Systems . Use the swivel at the tugger line attachment to allow each service loop to coil without twisting.634.000 lbs (454 kg) Service Loop Sling 4 ! To avoid damage to the service loop use care when dragging it near sharp edges and allow room for passing under the V-door TDS Service Loop Lifting Eyes Do not remove Derrick Service Loop Do not pack the service loops until the service loop storage tub is in position ! To avoid damage to the service loop maintain a 36 inch minimum Service Loop bend radius and Storage Tub 3.600 lbs (1.4 kg) Use a sling attached to the lifting eyes to lower each service loop. Commissioning and Decommissioning Decommissioning Removing and storing the electrical cables and service loops Lower Derrick Termination 1. Preliminary TDS-11SA 4-35 .Installation. 0 in.5 in.5 in. (470 mm) Bail 88 in. (2855 mm) To Center of Gravity 28. (1588 mm) 71.9 in. (716 mm) = 37. (3048 mm) 18. (2235 mm) 4 233. (5918 mm) To Center of Gravity 112. (1422 mm) 62.4 in. (1826 mm) 4-36 Varco Systems .0 in.Installation.000 lb = 16.798 kg 56. Commissioning and Decommissioning Securing the TDS-11SA for rig-down Bail 120 in.2 in. Installation. Commissioning and Decommissioning Setting the latches and locking the bail 4 Preliminary TDS-11SA 4-37 . Commissioning and Decommissioning Disconnecting the guide beam Crown Crown Padeye Do not remove Shackle TDS-11SA Carriage latches remain engaged Hang-off Link 4 Pin Guide Beam Top Section Be sure that the bail lock assembly is installed Drill Floor Be sure carriage latches remain engaged Disconnect the guide beam from the main tieback and intermediate tiebacks Disconnect the guide beam from the hang-off link 4-38 Varco Systems .Installation. Installation. Commissioning and Decommissioning Unpinning each guide beam section 4 Preliminary TDS-11SA 4-39 . Commissioning and Decommissioning Lowering each guide beam section 4 4-40 Varco Systems .Installation. Installation. Commissioning and Decommissioning Unhooking and removing each guide beam section 4 Preliminary TDS-11SA 4-41 . 500 lbs (15.Installation. Commissioning and Decommissioning Returning the TDS-11SA to the skid Pin Install after lowering TDS-11SA onto the skid 34.500 lbs (1.663 kg) TDS-11SA TDS-11SA 2 TDS-11SA 4 Lifting Block Lock Pin Install after lowering TDS-11SA onto the skid 3 TDS-11SA Lowered onto skid Drill Floor 2. lower the TDS-11SA onto the skid Pin the TDS-11SA to the skid at the top and bottom of the guide beam top section Skid Install pin retainers 1 4-42 Varco Systems .135 kg) Skid Hoist skid to the drill floor Using the drawwork. 798 kg) TDS-11SA On the skid prior to removing from the drill floor 1 Drill Floor 2 Backup Line V-Door Ramp 3 Preliminary TDS-11SA 4-43 .000 lbs (16.Installation. Commissioning and Decommissioning Removing the TDS-11SA from the drill floor ! Be sure that the Bail Lock Assembly is installed Lifting Block Lower using the drawwork Sling 4 Lifting Sling TDS-11SA on Skid 37. During storage. and at one month intervals if stored outdoors. Avoid wide variations in temperature and high humidity. however. 2. Leave enough space around the drilling motors for ventilation. 11. rotate the motors and gear train periodically to distribute lubricant. All exposed unpainted metal surfaces are coated with a rust preventive prior to shipment. Drain the oil from the gearbox prior to rigging down. 6. The preferred environment is clean and dry at 60°F ambient. 3. Perform this at three month intervals if stored indoors. 11. For indoor storage. A cargo container is appropriate for outdoor storage. taking special care with all load carrying components. For long term storage recommendations dealing with the AC drilling motors. 8. cover the TDS-11SA in its shipping and handling skid. verify the following items: 1. Commissioning and Decommissioning Long term storage procedures 1. 4. 7. 5. Release the hook and remove the TDS-11SA. 10. Returning the TDS-11SA to service after storage Before placing the TDS-11SA back into service after storage. Install the TDS-11SA into the skid and pin. 4 9. Do not use silica gel or a dehydrating agent. check these surfaces periodically to be sure that no corrosion is taking place. Remove all rust preventive and any corrosion that may have taken place. Rig down the guide beam. 12. Remove the saver sub. Bring the shipping and handling skid to the drill floor. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent. Disconnect guide beam from lower attachment and connecting link.Installation. Cover all openings to prevent water or dust from entering. see the motor manufacturer’s manual. 4-44 Varco Systems . Follow the return to service procedures in the AC drilling motor manufacturer’s manual. 2. ....................................... 5-3 Inspecting the guide beam joints ... 5-5 Inspecting the intermediate restraints .................. 5-2 1 Inspecting the top section of the guide beam ....... 5-7 3 Illustrated part lists ........................................... Carriage/accumulator (roll) ................Guide Beams and Carriage Inspecting the crown padeye and hang-off link . Carriage assembly.......................................... 5-6 Inspecting the carriage ........................... 5-9 Guide beams (roller) ........................ Tiebacks (sliding) ............... Guide beams (slider) ................................................................................................... right (roller) ..... left (roller) .......... right (skid) ....... Carriage assembly... 5-10 5-12 5-14 5-16 5-18 5-20 5-22 5-24 5-26 5-28 2 4 5 6 7 8 9 Preliminary TDS-11SA 5-1 ....... 5-4 Inspecting the main tieback.... Universal tiebacks ................ left (skid) ...................................................................................... Carriage/accumulator (skid) ........... Carriage assembly.............. Carriage assembly...................... 5" (37 mm) minimum Monthly Hang-off Link Bores Inspect and repair if worn Hang-off Link Bores 5-2 Varco Systems .Guide Beams and Carriage Inspecting the crown padeye and hang-off link Crown Yearly Crown Padeye MPI 2.0" (50 mm) minimum 5 Monthly Shackle Inspect and replace if worn 1.1" (52 mm) minimum Monthly Crown Padeye Visually inspect weld for cracks Monthly Cotter Pin Replace if missing Shackle 2. 5" (37 mm) minimum 5 Bolt Assembly Hang-off Link Bores Monthly Safety Pin Replace if missing Monthly Hang-off Link Bores Inspect and repair if worn Guide Beam Top Section Preliminary TDS-11SA 5-3 .1" (52 mm) minimum 1.Guide Beams and Carriage Inspecting the top section of the guide beam Crown 2. Guide Beams and Carriage Inspecting the guide beam joints Verify that the joint pins, retainer pins and lynch pins are in place and secure. Replace any missing or damaged pins. Secure Weekly Lynch Pin 5 Weekly Joint Pin Yearly Typical Guide Beam Joint Weekly Retainer Pin MPI Monthly Inspect welds for cracks 5-4 Varco Systems Guide Beams and Carriage Inspecting the main tieback Daily Check that the tool is aligned directly over well center Guide Beam Bottom Section Main Spreader Beam Tieback Link Tieback Plate Yearly Typical all welds 5 MPI Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks. Auxiliary Spreader Beam Mast Leg Preliminary TDS-11SA 5-5 Guide Beams and Carriage Inspecting the intermediate restraints Daily Check that the tool is aligned directly over well center Weekly Check for tightness of cotter pins, and double nuts. If there are signs of shifting, verify alignment. 5 Weekly Pin and Cotter Pin Verify that all pins are in place. Replace any missing or damaged pins. Mast Girt Yearly Typical all welds Guide Beam MPI 5-6 Varco Systems Guide Beams and Carriage Inspecting the carriage Weekly Typical all rollers Inspect for uneven wear or damage. Replace yearly or as required. 5 Daily Detent Pins Verify that pins are in place and secure Preliminary TDS-11SA 5-7 . Guide Beams and Carriage 5 5-8 Varco Systems . Guide Beams and Carriage Illustrated part lists On the following pages xxxxxxx 5 Preliminary TDS-11SA 5-9 . Guide Beams and Carriage 8 Rolling Guide Beam/Carriage Configuration Top Section Part of Shipping Package 7 3 2 1 5 4 6 5 E Guide beams (roller) 5-10 Varco Systems . 65" Qty 1 4 1 12 12 12 4 1 5 Preliminary TDS-11SA 5-11 . Bottom Section Guide Beam.Guide Beams and Carriage Key to Guide beams (roller) Item # 1 2 3 4 5 6 7 8 Part # 116414-505 115954 115954-500 116644 116643 51403-8-S 89035-1 99873-650 Description Guide Beam. Special Intermediate Section Retaining Pin Hinge Pin Cotter Pin Shackle. 25 Ton Connection Link. Intermediate Section Guide Beam. Guide Beams and Carriage Sliding Guide Beam/Carriage Configuration 8 9 10 11 12 13 14 3 1 Top Section Part of Shipping Package 5 5 6 4 7 2 F Guide beams (slider) 5-12 Varco Systems . 7 1 1 1 1 1 1 1 5 Preliminary TDS-11SA 5-13 . Intermediate Section (18 ft) Guide Beam.6.5.6 2 3. Bottom Section (36 ft) Guide Beam. Intermediate Section (36 ft) Retainer Pin Joint Pin Lynch Pin Shackle. 25 Ton Hang-Off Link Hang-Off Link Hang-Off Link Hang-Off Link Hang-Off Link Hang-Off Link Qty 1 1 4. Bottom Section (18 ft) Guide Beam.5.6.7 3.6.5.7 3.Guide Beams and Carriage Key to Guide beams (slider) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part # 117618 117618-500 117616 117616-500 117783 117782 117496-1 95523 117788-136 117788-142 117788-147 117788-152 117788-126 117788-156 Description Guide Beam.5. Rolling Configuration) 9 11 12 10 11 4 11 2 14 10 11 7 5 14 1 5 5 15 16 3 8 6 13 11 10 14 4 17 Mast Leg G Universal tiebacks 5-14 Varco Systems .Guide Beams and Carriage Guide Beam (Bottom Section. 1. 1-8 unc Lock Washer. 1-8 x 36" long Plate. 1-8 UNC x 4. 1" Threaded Rod. W 8 x 18 x 144.5 long Flat Washer.0 long Nut. 1" Screw.0 long Beam.0 long Qty 2 2 4 12 6 8 1 20 4 112 72 12 16 28 1 1 2 1 5 117659-DWG Universal Tieback Kit Drawing Preliminary TDS-11SA 5-15 .Guide Beams and Carriage Key to Universal tiebacks Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part # 117698 117699 117700-1 117700-2 117700-3 117701 117702 117731 50016-32-C5 50416-C 50916-C 50016-20-C5 50816-R-C-5 112893-1 117659-15 117659-16 117659-17 Description Tieback Link Attachment Plate Strap Strap Strap Strap Tieback Plate Flange Clamp Screw. W 12 x 72 x 384.00 Thick Beam. 1-8 unc x 2. Sliding Configuration) 10 10 11 5 14 11 15 7 14 5 15 11 10 12 9 3 8 4 14 6 13 11 10 2 Mast Leg H Tiebacks (sliding) 5-16 Varco Systems .Guide Beams and Carriage 16 11 15 1 Guide Beam (Bottom Section. 16 6 5 5 50016-64-C5D Bolt. W 12 x 72 x 384.Guide Beams and Carriage Key to Tiebacks (sliding) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part # 117976 117977-2 117700-1 117700-2 117700-3 117701 117982 117731 117977-9 50416-C 50916-C 117977-12 50816-R-C-5 112893-1 119973 Description Tieback Link Beam. 1-8 x 36" long Strap Qty 1 2 4 8 4 8 1 6. 1" Threaded Rod. W 8 x 18 x 180. 1. 1. 1-8 unc Lock Washer.64 8.00 thick Flat Washer.0 long Nut.00 unc x 8.32 1 16 4.0 long Preliminary TDS-11SA 5-17 .8 1 16. 1" Plate.32.0 long Strap Strap Strap Strap Tieback Plate Flange Clamp Beam.8.20. Guide Beams and Carriage 2 EE Fr on t 3 1 DD 9 5 8 7 4 5 5 6 CC Carriage/accumulator (roll) 5-18 Varco Systems . Regular Socket-head Cap Screw. Lock Washer. Left (30" setback) Hydro-Pneumatic Accumulator.25 Hydro-Pneumatic Accumulator. 6" Accumulator Strap. 4" Align Accumulator Mount Strap Qty 1 1 1 1 6 2 1 2 4 50008-10-C5D Hex-head Cap Screw 5 Preliminary TDS-11SA 5-19 . Right (30" setback) Carriage Assembly. 6" dia.Guide Beams and Carriage Key to Carriage/accumulator (roll) Item # 1 2 3 4 5 6 7 8 9 Part # 113450 113448 110562 113370 50908-C 50108-10-CD 110563 88710 Description Carriage Assembly. 1/2 UNC x 1. Guide Beams and Carriage 5 11 9 8 13 4 Fr on t 1 6 3 8 13 2 4 12 17 16 11 21 10 9 7 22 5 8 13 14 18 19 20 15 DD Carriage assembly. right (roller) 5-20 Varco Systems . Modified Side Roller Bracket Lock Washer. 1/8" NPT 2 1 1 2 Preliminary TDS-11SA 5-21 . Right Bogey Pivot Pin Bogey Shim. 6" dia. 1.75 ID Grease Fitting.. 2. 2" dia.063 dia. 1/8"-27 NPT Sandwich Plate Jam Nut. 1/8" Cam Follower. 1" UNC x 3.Guide Beams and Carriage Key to Carriage assembly. Cable Ferrule Detent Pin. 3/4" Retaining Cable. . Roller. 2"-12 UN-2B Qty 1 2 2 12 2 8 2 12 10 4 12 2 12 3 3 6 6 5 50016-28-C5D Hex-head Cap Screw.75" long Chock Plug.0" dia. right (roller) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part # 113449 112875 112876 109903 113285 80784 109904 51132-C 53000-4-C 109944 53209 10994 80569 Description Carriage. Plug. Crowned.0" long 51012-C 51220-2 51219-2 51221-6-K 109995 53000-2-C Lock Washer. 3/4" UNC x 3. 1/2" dia. 4" dia. Hi-Collar.5" long 51016-C Lock Washer. 1/4" NPT Flanged Bushing. 50012-24-C5D Hex-head Cap Screw. x 2. left (roller) 5-22 Varco Systems .Guide Beams and Carriage 1 Fr on t 13 8 13 8 15 3 6 9 19 11 10 2 17 21 12 14 4 16 20 18 5 9 5 22 4 8 13 7 11 EE Carriage assembly. 4" dia. 1. 2" dia. 2.75 ID Grease Fitting.5" long 51016-C Lock Washer. 1/8"-27 NPT Sandwich Plate Jam Nut.0" long 51012-C 51220-2 51219-2 51221-6-K 109995 53000-2-C Lock Washer. 1/2" dia.063 dia. Roller. 1/4" NPT Flanged Bushing. left (roller) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part # 113447 112875 112876 109903 113285 80784 109904 51132-C 53000-4-C 109944 53209 10994 80569 Description Carriage. 6" dia. Modified Side Roller Bracket Lock Washer. Cable Ferrule Detent Pin. 1" UNC x 3. . Crowned. 1/8" Cam Follower. 3/4" Retaining Cable. Left Bogey Pivot Pin Bogey Shim. 2"-12 UN-2B Qty 1 2 2 12 2 8 2 12 10 4 12 2 12 3 3 6 6 5 50016-28-C5D Hex-head Cap Screw. Plug.75" long Chock Plug. Hi-Collar..0" dia. 1/8" NPT 2 1 1 2 Preliminary TDS-11SA 5-23 . x 2. 50012-24-C5D Hex-head Cap Screw. 3/4" UNC x 3.Guide Beams and Carriage Key to Carriage assembly. Guide Beams and Carriage 2 HH Fr on t 10 1 GG 3 8 5 5 4 9 6 8 7 FF Carriage/accumulator (skid) 5-24 Varco Systems . Long Accumulator Strap. 6" 5 Preliminary TDS-11SA 5-25 . Right Carriage Assembly. Regular Hydro-Pneumatic Accumulator. 4" Hydro-Pneumatic Accumulator. Short Qty 1 1 1 1 4 2 4 8 1 1 50008-10-C5D Hex-head Cap Screw 88710 50008-8-C5D 50908-C 110563 110562 Align Accumulator Mount Strap Hex-head Cap Screw Lock Washer.Guide Beams and Carriage Key to Carriage/accumulator (skid) Item # 1 2 3 4 5 6 7 8 9 10 Part # 117594 117593 117621-1 117621-2 Description Carriage Assembly. Left Accumulator Strap. Guide Beams and Carriage Fr 1 4 on t 4 3 2 4 5 7 6 11 10 5 8 13 9 4 12 4 7 4 5 6 GG Carriage assembly, right (skid) 5-26 Varco Systems Guide Beams and Carriage Key to Carriage assembly, right (skid) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 Part # 117592 117586 117588 51608-8 50912-C Description Carriage, Right (machining) Carriage Angle (machining) Skid Pad Roll Pin Lock Washer, Regular Qty 1 1 6 34 8 8 2 2 2 2 2 4 2 5 50012-14-C5D Hex-head Cap Screw 51608-12 117870 117871 Roll Pin Chock Plunger, Hand Retractable 56412-30-SHP Clevis Pin 51402-10-S 50812-N-C 50310-C Cotter Pin Flat Washer, Narrow Hex-Jam Nut Preliminary TDS-11SA 5-27 Guide Beams and Carriage 1 Fr on t 4 2 5 4 6 4 12 11 7 10 13 5 9 8 7 3 4 4 4 5 6 HH Carriage assembly, left (skid) 5-28 Varco Systems left (skid) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 Part # 117591 117586 117588 51608-8 50912-C Description Carriage. Hand Retractable 56412-29-SHP Clevis Pin 51402-10-S 50812-N-C 50310-C Cotter Pin Flat Washer. Regular Qty 1 1 6 34 8 8 2 2 2 2 2 4 2 5 50012-14-C5D Hex-head Cap Screw 51608-12 117870 117871 Roll Pin Chock Plunger. Narrow Hex-Jam Nut Preliminary TDS-11SA 5-29 .Guide Beams and Carriage Key to Carriage assembly. Left (machining) Carriage Angle (machining) Skid Pad Roll Pin Lock Washer. Guide Beams and Carriage 5 5-30 Varco Systems . ........................................................................ 8-9 Hydraulic reservoir bladder ............................. 8-4 Hydraulic system diagram ............................................................................................................ 8-17 Setting up the circuits ................................ 8-14 Precharging the accumulators . 8-18 Counterbalance circuit and stand-jump circuit .................................................. 8-18 Hydraulic pumps and unloading circuit ........................................... 8-16 IBOP pressure switch ...... 8-35 Shot pin cylinder and clamp cylinder ................................................................. 8-6 Maintenance schedule ..................................... 8-29 Counterbalance and stand jump .......................................Hydraulic System Hydraulic system ............................... 8-12 Heat exchanger ................................................ 8-26 Gearbox lubrication relief circuit .................................................................. 8-24 Shot pin circuit ............ 8-8 Hydraulic fluid level and filter ......................................................................................................... 8-24 Link tilt cylinder circuit ........... 8-27 Rotating link adapter hydraulic motor relief circuit .... 8-39 9 8 7 6 5 4 3 2 1 Preliminary TDS-11SA 8-1 ....................... 8-28 Troubleshooting ....................... 8-31 AC motor brake circuit............. 8-6 Precautions........................ 8-22 AC motor brake circuit. 8-13 Using the hydraulic system test ports ............ 8-37 Link tilt cylinders ......... 8-5 Inspection .......................... 8-29 HPU and reservoir bladder ... 8-15 IBOP timing circuit ........................................................................................ 8-3 Illustrated index .................................. ..................................... 8-41 Rotating link adapter...................Hydraulic System Gearbox lubrication hydraulic system . 8-43 Solenoid valve replacement procedures ......................... 8-46 Double A UL-type valve ........................... 8-46 Atos EEx-type valve .............................. 8-47 Hydraulic schematic symbols ....................... 8-49 8 8-2 Varco Systems ............. 1800 rpm. AC motor. and counterbalance system. Three hydro-pneumatic accumulators are located on the main body. A fixed displacement pump drives the lube oil system motor. A 10-horse power.Hydraulic System Hydraulic system The hydraulic control system is a completely self-contained. A variable displacement pump provides hydraulic power for the AC motor brakes. pressure and flow control valves. remote actuated IBOP. onboard system. 8 Preliminary TDS-11SA 8-3 . The hydraulic manifold attaches to the main body and contains solenoid. The reservoir is mounted between the AC drilling motors and is equipped with strainers and an oil level sight gauge. eliminating the need for draining and refilling during normal rig moves. A sealed stainless steel reservoir supplies hydraulic oil. link tilt. pipe backup clamp cylinder. drives two hydraulic pumps and powers the hydraulic system. powered rotating head. 1.800 rpm. AC motor 25 gal Front Rear Hydraulic Oil Reservoir Page 8-X (Between AC Drilling Motors) Front Rear 8 Rotating Head Motor and Shot Pin Assembly Page 8-X 10 HP AC Motor and Pump Assembly Page 8-X 8-4 Varco Systems .Hydraulic System Illustrated index Specifications Hydraulic Oil Filter Page 8-X Counterbalance Accumulator Page 8-X IBOP Delay Circuit Accumulator Page 8-X Hydraulic Oil “Fill” Page 8-X Variable Displacement Pump Accumulator Page 8-X Hydraulic Manifold Page 8-X Power Reservoir Capacity 10 hp. Motor Variable Displacement Pump Fixed Displacement Pump (Mtr. Lube) Reservoir 8 Preliminary TDS-11SA 8-5 .Hydraulic System Hydraulic system diagram Drilling Motor Brake Upper IBOP Actuator Cylinder Link Tilt Cylinders Pipehandler Clamp Cylinder Counterbalance Accumulator Rotating Head (Elevator Positioner) Counterbalance Cylinders Lock-up Cylinder Rotating Head Motor Lube Oil Distribution System Control Manifold PV PF Low Speed Hydraulic Motor Lube Oil Pump Upper IBOP Unloading Accumulator System Accumulator Gearbox Sump M 10 HP A.C. Read and understand all safety precautions and warnings before performing maintenance procedures. inspection. unless specifically noted in this manual. Use caution when draining lubricant. read and understand the following warnings before performing inspection and maintenance procedures: n n n n n Properly lockout the main power source before performing lubrication. or replacement procedures. n n 8-6 Do not attempt repairs you do not understand. Do not attempt any adjustments while the machine is moving. as well as other hazards. Wear protective glasses to prevent eye injuries from fluids under pressure. n 8 Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system. Varco Systems . It can be hot.Hydraulic System Inspection Precautions To avoid serious injury or death. Never check for hydraulic leaks with your hands. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. n Replace worn or damaged hydraulic system components immediately. and clean any dirt buildup from hydraulic components. Hydraulic oil under pressure can penetrate skin and cause serious injury. Do not tighten hydraulic fittings while they are under pressure. Avoid injury by discharging the three accumulators and relieving pressure before disconnecting hydraulic lines. 8 Preliminary TDS-11SA 8-7 .Hydraulic System n n e Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Inspect the hydraulic system daily for leaks at fittings. Inspect the hydraulic filter located on the upper left AC drilling motor daily. Always search for hydraulic leaks with a piece of cardboard or wood-not with your bare hands. Use care when handling components to prevent nicking close tolerance finishes. Inspect the hydraulic fluid level in the hydraulic reservoir located between the AC drilling motors daily. hard or stiff hoses. during the inspection. In addition. Turn the counterbalance vlave to shutdown mode to bleed the hydraulic system. and damaged or corroded fittings. thoroughly clean work area. Fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Get immediate medical attention for hydraulic fluid injuries. and maintain system cleanliness by promptly capping all disconnected lines. Before opening the hydraulic system. kinked or crushed hoses. tighten or replace any leaking port connections. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel. n Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury. damaged hose covers. Hydraulic System Maintenance schedule Hydraulic System Oil Lubrication Schedule DESCRIPTION FREQUENCY Perform Hydraulic System Oil Analysis Replace Hydraulic Fluid Replace Hydraulic System Filter (P/N 114416-1) 1 x every 6 Months 1 x Year. Check for hydraulic fluid leaks Recommended Lubricants HYDRAULIC OIL Oil Temperature Range -15 to 75 C (5 to 167 F) -10 to 85 C (14 to 185 F) Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 N/R N/R 32 Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 N/R 2 46 8 8-8 Varco Systems . Check hydraulic fluid levels 3. Check condition of the hydraulic filter indicator 2. or Earlier Based on Oil Analysis 1 x every 3 Months Daily Inspections 1. Red “Pop-up” Dirt Alarm Daily Hydraulic Oil Filter Cork Ball (Level Indicator) Sight Glass Hydraulic Oil Sight Gauge Hydraulic Oil Fill Quick Disconnect 8 Hydraulic Oil “Fill” Preliminary TDS-11SA 8-9 . The first oil change should be performed sooner than six months since new installations often contain metal contamination caused by connecting slightly damaged threaded parts. Replace it if the indicator has popped up.Hydraulic System Hydraulic fluid level and filter Check the red “pop-up” alarm on the hydraulic filter daily. Use care to prevent contamination from entering the hydraulic system during maintenance activities. Hydraulic System Adding the hydraulic fluid Cork Ball (Level Indicator) Hydraulic Oil Fill Quick Disconnect Sight Glass Hydraulic Oil Sight Gauge Hydraulic Oil “Fill” Hydraulic Lubrication Kit 55 gal Drum Lubrication Kit Quick Disconnect Specifications Reservoir Capacity 25 gal 8 Ensure that the area is clean prior to adding hydraulic fluid Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill Remove dust plug from the female quick disconnect on the lubrication kit Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm 8-10 Varco Systems . Hydraulic System Draining the hydraulic fluid Pump Inlet/Drain Adapter 10 HP AC Pump Motor Fixed Displacement Pump Variable Displacement Pump 8 Preliminary TDS-11SA 8-11 . wear and cracks Hydraulic Oil Reservoir (Between AC Drilling Motors) Reservoir Cover Yearly Reservoir Bladder (Varco P/N 110191-501 or 110191-500) Check for holes. tears.Hydraulic System Hydraulic reservoir bladder Clean area before inspecting the reservoir bladder Remove the 10 cap screws and lock washers from the cover Remove cover with bladder attached Check yearly for holes. tears. wear and cracks Hydraulic Oil Reservoir Front Rear 8 8-12 Varco Systems . and cleanliness. corrosion. Drill Motor Assembly 8 Preliminary TDS-11SA 8-13 . Replace yearly or as required.Hydraulic System Heat exchanger Blower and Brake Covers Yearly Oil Heat Exchanger (Varco P/N 110170) Inspect for leaks. blockage. As Viewed From Below 8-14 Varco Systems .Hydraulic System Using the hydraulic system test ports Stand Jump SV9 L4 PV PF Brake SV1 P1 IBOP SV4 A4 Clamp/ Shot Pin SV5 Float Link SV8 Tilt SV6 * B8 G5 CB * SA * P * T1 8 C4 SV2 Rotating Link Adapter Z1 B9 B1 C5 B5 A6 B6 * These test ports are on sides or bottom of manifold. System Accumulator (125-cubic inch displacement) 800 psi precharge Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge Bleed the accumulator if the pressure is higher. Verify that all three points measure 0 psi. Note that there is a time delay in pressure decay on port C4. using part number 114446-1. test the hydraulic pressure at CB. Test the precharge pressure on the following three nitrogen filled accumulators. or add nitrogen if the pressure is lower than specified above. and the counterbalance mode valve in the “shut down” position. 8 Preliminary TDS-11SA 8-15 . mounted to the transmission housing. SA and C4 on the hydraulic manifold.Hydraulic System Precharging the accumulators Counterbalance Accumulator IBOP Delay Circuit Accumulator Variable Displacement Pump Accumulator Hydraulic Manifold Front Rear With the hydraulic system shut down. 01.0 2.8 1.5 2.5 FP Full Page 0.8 ARTWORK PLACEHOLDER 1.Hydraulic System IBOP timing circuit 5 10 20 30 40 50 60 70 80 90 0.0 1.5 8 ® DRILLING SYSTEMS REV.B 09.2 0.95 8-16 Varco Systems .0 1.5 0.5 0.1 0.1 0.2 0. 2 0.1 0.B 09.5 FP Full Page 0.0 2.2 0.1 0.8 ARTWORK PLACEHOLDER 1.Hydraulic System IBOP pressure switch 5 10 20 30 40 50 60 70 80 90 0.0 1.95 Preliminary TDS-11SA 8-17 .0 1.01.5 0.5 2.5 8 ® DRILLING SYSTEMS REV.5 0.8 1. Hydraulic System Setting up the circuits Hydraulic pumps and unloading circuit There are two pumps – a fixed displacement pump runs the transmission lubrication system and a variable displacement pump provides hydraulic flow to the hydraulic system. Motor and Pump Assembly Allen Wrench Front Valve As Viewed from Below Variable Displacement Pump Fixed Displacement Pump 10 HP AC Pump Motor 8 8-18 Varco Systems . to maximum pressure. Turn off the electric motor. Disconnect the tube at the manifold end. Increase the pressure by adjusting relief valve RV2 clockwise until the pressure increases to 400 psi at test point PF. Correct as required. check for leaks. 5. Note the full-load amps on the motor nameplate. 10.Hydraulic System 1. 4. 9. z While adjusting valves. 6. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when looking into pump shaft/electric motor fan). 3. Locate the tube connecting manifold port PF to the lubrication motor. Connect a gauge to test point PV. A steel cap is installed over the adjustment screw to discourage unauthorized adjustment. Start the electric motor and allow both hydraulic pumps to circulate oil. which allows the hydraulic system to operate without building up pressure. fully counterclockwise. 11. Restart the hydraulic system electric motor. Set the relief valve RV2 to minimum pressure. verify a linear relationship between turning the adjustment screw and observing the pressure change. Adjust UV1. 7. 8 Preliminary TDS-11SA 8-19 . Connect a gauge to test point PF. fully counterclockwise. Set the counterbalance mode valve to the RUN position. fully clockwise. z Make sure the variable displacement pump case is filled with clean hydraulic oil. Listen for unusual noises that would indicate cavitation. 12. Reconnect the tube between manifold port PF and the lubrication motor. 2. Set the relief valve RV1 for the variable displacement pump to a minimum setting. Note the ammeter reading while RV1 is at minimum setting. Set the jam nut on RV2. Connect an ammeter to the electric motor. cap the tube and plug the PF port using steel fittings. 8. Raise the setting of relief valve RV1 from 0 psi to 1. observe the ammeter. the pressure rapidly rises to the unload pressure.Hydraulic System 13. The point where the current drops is the pump pressure compensator setpoint. and back to 0 psi to verify maximum motor current at 800 psi. If maximum motor current does not occur at 800 psi. Adjust relief valve RV1 to its minimum setting.500 psi at a steady rate. During the pressure rise. After reloading. The motor current should rise to a maximum value at 800 psi. 15. 8 8-20 Varco Systems .000 psi. Adjust relief valve RV1 to 2. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2. 14. 20. Adjust relief valve RV1 again from 0 psi to 1. then an additional two turns counterclockwise. Connect a gauge to test point SA. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off. then drop off and begin to rise again. Install steel cap over the adjustment screw to discourage unauthorized adjustment. The pressure at SA decays until UV1 reloads.200 psi and secure the jam nut.500 psi. 19. 18. adjust the pump pressure compensator as required. 16. and leave the gauge on PV. 17. The pressure cycles like a sawtooth wave. Taking longer increases the temperature of the hydraulic fluid. 22.Hydraulic System 3000 Pressure at PV Pressure at SA 2000 Pressure (PSI) 1700 1000 800 150 0 10 20 30 40 50 60 Approximate Time (Seconds) 21. To verify the setting of UV1. e Perform the adjustment with reasonable speed. 8 Preliminary TDS-11SA 8-21 . Adjust the setting of UV1 as required to a 2. 23. Observe the cycle of loading and unloading of the relief valve. note the difference in pump noise level between the loaded and unloaded condition. Observe several unload-reload cycles to determine the unload pressure.000 psi unload pressure. The process takes no longer than two minutes. 200 psi. 12. 6. To set the relief valve. turn the setting one full turn clockwise beyond the setting and set the jam nut. 8. Install a steel cover over the valve. Rotate the counterbalance mode valve from the RUN position to RIG-UP position. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting. This causes the counterbalance cylinders to slowly extend.Hydraulic System Counterbalance circuit and stand-jump circuit 1. Observe the relationship of turning the relief valve adjustment clockwise to pressure increase. Allen wrench and 9/ 16 in. 5. make sure the pumps are operating. For the counterbalance circuit there are three adjustments: t Relief valve (on counterbalance cylinder) t PCC – operator set t SJR – operator set 2. 8-22 Varco Systems . When the relief valve reaches system pressure. 10. Prepare the hardware to attach the cylinder pear links to the hook. Adjust PCC to 1. 8 e Cylinders stroke to the end of stroke with the mode valve in the RUN position. 4. Increase the pressure clockwise using a 5/32 in. fully clockwise. 3. open-end wrench. 9. 13. 11. Measure pressure at test port CB. Connect a gauge to test port CB. Adjust pressure reducing valve PCC to the maximum setting. 7. 15. Adjust relief valve SJR until the bail lifts off the hook. 16. 8 Preliminary TDS-11SA 8-23 . Switch back to DRILL counterbalance mode and observe the pressure at test point CB. 20. Activate the STAND JUMP mode on the drilling console. The pressure at CB is about 1. Note the pressure at CB. 22.600 psi. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down counterbalance cylinders and system accumulator before shipping or performing maintenance. The gauge at B9 should read about 190 psi. 18. attach hardware to the pear links on the hook. 17. Switch back to STAND JUMP mode and observe the pressure CB increase by 190 psi. Reduce PCC an additional 25 psi. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just begins to lift off of the hook. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the hook. 23. 21. Connect a gauge to test point B9. 19. Rotate the counterbalance mode valve back to the RUN position.Hydraulic System 14. Once cylinders reach end of stroke. Hydraulic System AC motor brake circuit The AC drilling motor brakes are spring released and hydraulic pressure applied at 1. or stop pressure to release the brakes. forcing the pin to stop on the face of the gear. 5. setting the brakes. The force the shot pin exerts is limited until the pin engages a hole. The solenoid valve operates to apply pressure.400 psi. The shot pin often misses the hole in the rotating gear. 2. turn the auto brakes switch on the driller’s console to the ON position. 3. 8 8-24 Varco Systems . The pressure reducing valve regulates the pressure to 1. The pressure reading should be 1. To test the system.400 psi. z The electrical system jogs the rotating head until the pin engages a hole. the SV5 valve is de-energized. Turn the auto brakes switch to the OFF position. Test the pressure at C5. If the reading is not 1. you set the valve by operating solenoid valve SV5 manually. 6. Adjust reducing valve AR5 to 500 psi.400 psi. 4. measure the pressure at B5. If the pressure is high. At rest. When the pin stalls out. To limit the amount of force. The pressure reading should be very low. Set the relief valve pressure to 200 psi. adjust the pressure control reducing valve PC 1 to 1. Tighten the jam nut on the relief valve. Set the adjustable relief valve near the body of the cylinder.400.400 psi. Attach a pressure gauge to B1 in the manifold. Shot pin circuit 1. the solenoid valve might be sticking. Hydraulic System Rotating Link Adapter Drive Motor and Shot Pin Assembly 10 HP AC Motor and Pump Assembly (Simplified for Clarity) Rotating Link Adapter Hydraulic Drive Motor B5 A5 A (Located on far Side) B Position Sensors C5 (Located on far Side) Link Adapter Rotation Gear Shot Pin 8 Preliminary TDS-11SA 8-25 . There is nothing to adjust on the manifold for the link tilt circuit. taking present and decayed pressure readings. 7. 2. This delayed pressure is the setpoint of the counterbalance valve. Adjust the four load holding valves in pairs – the upper pair and lower pair. 11. 3. Command the link tilt to the OFF position and observe the pressure delay at TP. The correct pressure setting is 1. 9. Adjust the valves one at a time. 8-26 Varco Systems . link tilt operation is not synchronized. Repeat steps 6 and 7 until the decayed pressure is 1. From the driller’s console.Hydraulic System Link tilt cylinder circuit 1.500 psi. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise. Adjust all four counterbalance valves fully clockwise. Command the link tilt to the DRILL position and repeat the procedure above to set both counterbalance valves on the DRILL side. 5. 8. z e 8 This is an iterative process.000 psi. then one turn counterclockwise. Continue to set the driller’s console control to the mousehole position and OFF. 4. Repeat the procedure above for the other cylinder at the mousehole position. There is a test point on each loading manifold. z If the valves are not adjusted correctly. The cylinder goes to full extension and the pressure at the test port TP is 2. 10. move the link tilt to go to the mousehole position. Turning the counterbalance valve counterclockwise increases the pressure.500 psi. 6. The procedure is the same for all four valves. sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi. consectetuer adipiscing elit. Lorem ipsum dolor sit amet. vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi. Ut wisi enim ad minim veniam. Lorem ipsum dolor sit amet. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat. Dolor sit amet.Hydraulic System Gearbox lubrication relief circuit Lorem ipsum. sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. consectetuer adipiscing elit. Ut wisi enim ad minim veniam. sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Lorem ipsum dolor sit amet. consectetuer adipiscing elit. quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. consectetuer adipiscing elit. consectetuer adipiscing elit. vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi. quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat. Lorem ipsum dolor sit amet. Duis autem vel eum iriure dolor in hendrerit in vulputate velit esse molestie consequat. 8 Preliminary TDS-11SA 8-27 . 8 8-28 Varco Systems . which locks up the gear.600 psi. The shot pin must go through the hole. 2. Adjust the relief valve to 1. Operate the clamp.Hydraulic System Rotating link adapter hydraulic motor relief circuit 1. 4. 3. Turn the manual override on the SV2-rotation circuit to drive the head in the counterclockwise direction. Test the pressure at A and adjust the relief valve to 1. Set the relief valves mounted on rotation motor. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the clockwise direction and test the pressure at B.600 psi. loose fittings. Counterbalance mode valve left in shut down position too long and pressure bleeds down. No precharge in system accumulator. Check system pressure. Replace the lubrication pump. Adjust as required. Charge system accumulator. Replace the pump. Test pumps and motors. 8 Preliminary TDS-11SA 8-29 . Replace the flexible coupling. Piston pump is not working. worn hoses. Suction valve closed. System pressure is down. Pressure at UV1 is too low. loose cylinders. Hydraulic components do not operate. Unloading valve is not working. Probable cause Relief valves out of adjustment. Inspect hydraulic connections and correct rotation. Check for leaks. Open suction valve. Test and adjust UV1 or replace unloading valve. Test relief valve pressures. Lubrication pump is not working. Pumps are rotating in the wrong direction. Flexible coupling is damaged. Remedy Test pressures and adjust relief valves. Fill hydraulic reservoir.Hydraulic System Troubleshooting HPU and reservoir bladder Problem Hydraulic system overheating. Low oil level in reservoir. Adjust pressure at UV1. fluid levels and seals. Min.00 In^ 3/Rev.10 In^ 3/Rev. 4 PSI -12 T T -16 Filter with Bypass Valve M 10 HP 1800 RPM S L1 Filter (Strainer) Variable Displacement Pump Fixed Displacement Pump Reservoir Assembly Manual Shut-Off Valves 8 8-30 Varco Systems . Max.Hydraulic System HPU and reservoir bladder schematic diagram Hydraulic Fill Disconnect System Pressure 6µm 50 PSID Prefill Valve Pressure Compensator Control 800 PSIG -6 XC B 1.50 In^ 3/Rev. L 1. . run. system pressure is applied to XC and the prefill valve. as the top drive rests on the hook. 8 Preliminary TDS-11SA 8-31 . you make up the mechanical connection to the bail. maintains a hydraulic pressure. Perform the following steps to adjust the force: 1. until the top drive just lifts off the hook. with precharge pressure of 900 psi. In the run mode. In the rig-up mode. a lift of approximately 30.600 psi is needed at the counterbalance cylinders to lift the TDS-11SA off the hook. the hydraulic system bleeds down the system accumulator and the counterbalance accumulator pressure. additional pressure of approximately 300 psi is applied to over the normal counterbalance pressure to lift the TDS-11SA and drill string off the hook.000 lb is achieved with a pressure of 1600 psi at CB. and shut down modes. There should be a 0 psi reading. 4. for counterbalance operation. along with check valve CV3.Hydraulic System Counterbalance and stand jump The accumulator. Refer to the vendor documentation material located in the Vendor Documentation Package. approximately 1. Test the pressure at port CB. When the cylinders extend. Set the pressure control valve PCC to the minimum setting (fully counterclockwise). 2. Set the counterbalance mode valve to the RUN mode. Adjust the pressure at pressure control valve PCC clockwise. observing pressure at CB. In the shutdown mode. The optional stand jump feature is controlled by solenoid valve SV9. Test the pressure at port B9. 3. Counterbalance testing For the counterbalance operation. Back off the pressure 25 psi. With the counterbalance in the run mode and the stand jump switch on. causing both cylinders to extend. A three-position manually operated valve controls counterbalance operation for rig-up. Observe the position of the top drive on the hook. for the gas charging procedure for the accumulator. 8 8-32 Varco Systems . Adjust relief valve SJR fully counterclockwise to the minimum setting. z Adjust relief valve SJR slowly to allow pressure at CB to stabilize.000 lb is achieved with a pressure of approximately 1800 psi at CB. Test the pressure at port CB and B9.Hydraulic System Stand jump testing For the optional stand jump feature. The additional 300 psi pressure over the normal counterbalance pressure is provided by energizing the stand jump solenoid valve SV9. Set the counterbalance mode switch to RUN and engage the stand jump switch. Perform the following steps to adjust the pressure: 1. a lift of about 33. Slowly increase the pressure at CB by adjusting relief valve SJR clockwise until the bail lifts off the hook with a stand of pipe in the elevator. 2. Solenoid valve SV9 is not operating. Seal leaks No hydraulic pressure. Replace the valve. Test electrical and hydraulic operation. Test electrical and hydraulic operation. Replace the valve. PCC is not operating. Charge the accumulator. No hydraulic pressure. Replace or repair as applicable. Relief valve is not operating. Precharge on the accumulator is low. Stand jump does not function. Replace or repair as applicable. Solenoid valve SV9 is not operating. Test pressure and adjust pressure reducing valve. Test pressure and adjust pressure reducing valve. Cylinder damages. Seal leaks. Inspect cylinder and repair or replace seal. 8 Preliminary TDS-11SA 8-33 . Precharge on the accumulator is low. Remedy Inspect cylinder and repair or replace seal. Relief valve is not operating. Replace the valve. Charge the accumulator. Replace the valve.Hydraulic System Problem Counterbalance does not function Probable cause Cylinder damaged. PCC is not operating. 075ø 75 PSI 1 2 T-13A CV2 T -12 . Rod Normally-Open Logic Cartridge Metering Counterbalance Accumulator 728 Cubic Inches 900 PSI Precharge -6 Prefill Valve 25mm .000" Dia.075ø 75 PSI 1 2 T-13A CV1 Counterbalance Cylinders 4.010ø T T 5 PSI XC 90 PSI -16 -12 CP -12 CP CP -12 2 .047ø Cable ID Number Stand Jump Solenoid (Solenoid Valve 9) Counterbalance Mode Rig-up Shut-down Run A B Stand Jump 2 Position Valve B A b C09 3 Position Valve with Detent -6 P D03 XC T MV P CB SV9 D03 T .Hydraulic System Counterbalance and stand jump schematic diagram Pressure Relief Valve 2500 PSI T-3A 1 -4 OR1 ZC OR2 .50" Stroke 2.055ø CV3 75 PSI T-21A Manifold Assembly B9 1 4 3 2 CB CDF 4 PSI DF 2 T-13A 1 Test Port B9 Pressure Relief Valve SJR 190 PSI T-10A 1600 PSI PCC T-21A 2 1 4 3 1 2 8 System Accumulator 126 Cubic Inches 800 PSI Precharge DF 2 TF T-5A 30 PSI 1 CTF System Pressure SA To Tank 8-34 Varco Systems . Bore X 8.000" Dia. Hydraulic System AC motor brake circuit Symptom Mechanical noise in blower. Probable cause Loose impeller. Faulty motor bearings. Remedy Reinstall impeller and hub with threadlocking compound on screws. Repair or replace as needed. Locate and repair as needed. Check for dirt or trash between starter coil. Repair or replace as needed. Use spare service loop conductor. Blower runs intermittently. Faulty or loose wiring. Faulty motor starter Broken service loop conductor. Motor overheating, Incorrect blower rotation. overtemp alarm stays on with blower running. Broken service loop conductor. Verify blower rotation is correct. Use spare service loop conductor. 8 Preliminary TDS-11SA 8-35 Hydraulic System AC motor brake circuit schematic diagram Brake Calipers 2 Position Solenoid Valve Brakes On Cable ID Number b C01 P T -4 A B .071ø SV1 D03 B1 Manifold Assembly Non-Adjustable Orifice P1 Test Point 1400 PSI PC1 1 T-11A 8 Reducing Valve 2 3 System Pressure Tank Drain 8-36 Varco Systems Hydraulic System Shot pin cylinder and clamp cylinder Problem Shot pin does not engage. Probable cause Solenoid valve is not operating or relief valve is not adjusted. Abnormal pressure change at B5 and C5 indicates valve problem. Normal pressure change indicates plumbing or shot pin cylinder are faulty. Remedy Check electrical actuation and test pressure. Adjust as required. Replace directional control valve. Repair plumbing or shot pin cylinder. Test pressures and adjust as required. Shot pin applies excessive force to rotating head gear. Clamp cylinder does not actuate. Relief valve is not operating or out of adjustment. No pressure or reduced pressure at the cylinder. Cylinder is damaged. Test pressures and adjust and repair as required. Inspect cylinder and repair or replace. z To provide high pressure to the clamp Repair plumbing, rotating circuit, pressure at C5 must be 2,000 psi head, or clamp cylinder. and G5 must be less than 100 psi. If this condition is met, pressure at CP should increase from less than 100 psi to higher than 2,000 psi. If not, check the plumbing, rotating link adapter, and clamp cylinder. While clamping, pressure at CR should Clean or repair CNEC valve. be 2.7 times the pressure at CP. When the dies contact the pipe, pressure at CR should be less than 100 psi. If the pressure does not fade, check valve CNEC for contamination. Shot pin engages but clamp cylinder does not activate. Control valve not operating. Check pressure at C5. Replace valve CV5 if required or the regenerate manifold. 8 Preliminary TDS-11SA 8-37 0" Stroke 8. Rod 2 2x .031ø T-11A AR5 Pressure Reducing Valve LC5 Logic Cartridge 2 T-11A .094ø 2 VP 1 T-10A B5 C5 -8 400 PSI 2 30 PSID VR Non-Adjustable Flow Control E5 G5 -8 Clamp A b B -8 E5 G5 -8 Rotating Link Adapter Assembly P SV5 D03 T .039ø .000" Dia. Bore X 2.159ø 50 PSI 1 .Hydraulic System Shot pin cylinder and clamp cylinder schematic diagram Clamp Cylinder 10.031ø 3 A5 B5 C5 E5 G5 1 3 2 . Rod Hydraulic Cylinder Cavity Plug Pilot-to-Close Check Valve CP 1 2 30 PSID 2 1 3 T-2A CR CKEB Shot-Pin Cylinder Relief Valve Shot Pin Cylinder 2 Position Solenoid Valve 5 Clamp/Shot Pin Cable ID Number C05 -6 -6 CNEC 3 T-2A COFA . Bore X 2.31" Stroke 1.500" Dia.000" Dia.000" Dia.047ø 1 T-5A 2.031ø 500 PSI 3 T-21A CV5 1 1 T-11A PC5 2 2 4 75 PSI P5 Externally-Drained Pilot-to-Open Valve 8 Drain System Pressure Tank 3 Drain System Pressure Tank T1 T1 D5 Manifold Assembly 8-38 Varco Systems . Links do not move together. the links do not tilt. Drill pipe elevator does not float back to center position. Load holding relief valves are out of adjustment. Replace the seal. check valve. Test the hydraulic system. 8 Preliminary TDS-11SA 8-39 . Pressure at B8 does not decay Replace the pilot to open to less than 100 psi. Solenoid valve is not shifting. Probable cause Remedy Link clamp incorrectly adjusted. the problem is hydraulic. stuck open. the problem is electrical. Link tilt does not tilt. Replace the pilot to open check valve. Faulty cylinder seal. Pilot to open check valve is stuck open or contaminated. Load holding valves are out of adjustment.Hydraulic System Link tilt cylinders Problem Drill pipe elevator does not reach mouse hole/derrickman position. Readjust. Adjust the pressure for all four valves to 1. If connectors.500 psi. Check electrical continuity. Links drift when valve is released. If the link Test the solenoid and tilts. or contaminated. Use manual override. Adjust or replace the load holding relief valve. Hydraulic System Link tilt cylinders schematic diagram Link Tilt Cylinder 3.3" Stroke 1.031ø . Bore X 10.250" Dia.031ø B6 3 T-11A 1 Link Tilt "Tilt" Solenoid (Solenoid Valve 6) B8 E6 .031ø -8 C07 Drill Down P Logic Cartridge 50 PSI 2 LB6 .380" Dia. Rod Mousehole Drill Down C1 C1 C1 X1 C2 C2 C2 CV1 T-11A 3 V1 V1 1 2 1500 PSI 1 3 2 T-11A CB1 CV2 T-11A 3 1 2 1500 PSI 1 3 2 T-11A CB2 X2 V2 V2 FL X -8 B8 B8 -8 B8 E6 E6 E6 -8 G6 G6 G6 H H J J -8 X Rotating Link Adapter Assembly Link Tilt "Float" Solenoid (Solenoid Valve 8) Link-Tilt Float Cable ID Number A b C08 P SV8 B -6 -8 T D03 -8 Link Tilt "Drill Down" Solenoid (Solenoid Valve 6) Link Tilt b A B T a C06 M'hole D03 .031ø .071ø 4 1 2 75 PSI 3 CA6 T-21A .071ø 4 2 3 Pressure Tank A8 X D1 X 1 CB6 75 PSI T-21A Manifold Assembly 8-40 Varco Systems -8 X X -8 -6 -6 -8 -8 -8 X X X -8 .031ø SV6 G6 Logic Cartridge 8 LA6 T-11A 1 50 PSI 2 3 A6 . Lower oil viscosity. Replace motor. Intermittent operation.Hydraulic System Gearbox lubrication hydraulic system Problem Oil leaking from lower seal. Worn oil seals. Add hydraulic fluid. Remedy Replace seals. Add oil. Check pressure at PF. Adjust oil level to middle of sight glass. Low hydraulic fluid in reservoir. Gearbox oil temperature (less than 230˚F). Probable cause Worn oil seals. Oil level too low or too high. Replace motor. Oil level is too low. Open suction valve. Gear spray nozzle missing. Check recommended lubricants chart and replace as needed. Broken lube pump adapter plate spline. Replace spray nozzel. 8 Preliminary TDS-11SA 8-41 . Oil pump loss alarm is on. Oil overheated. Repair or replace as needed. Oil pump hydraulic motor failure. Damaged gears or bearings. Replace seals. Suction valve closed on fixed displacement pump. Replace adapter plate spline. Excessive oil viscosity. Replace pump if pressure is low. Oil leaking from upper bearing retainer. Faulty motor. Incorrect lubricant used. Faulty fixed displacement pump. 047ø . Metal in oil. Replace oil pump. Probable cause Missing inspection plugs.^ 3/Rev.205ø . Upper Compound Gear 1.10 In.059ø . Lower Compound Gear . Excessively viscous oil.059ø . Clean orifice or nozzle. L1 -16 60µm Lube-Oil Pump -10 A B 8 -10 3. Upper gearbox seals worn.047ø L4 Spray Nozzles (4) Orifices (6) Upper Mainshaft Bearing Lower Radial/Main Thrust Bearings Upper Compound Bearing Lower Compound Bearing Lube-Oil Filter Lube Pump 5.0 GPM Ea. Damaged oil pump. Lower oil viscosity.^ 3/Rev. Restricted oil flow. Excessive foaming. Gearbox lubrication hydraulic system schematic diagram Pressure Switch S04 18 PSI Decreasing -16 1. Replace seals. Water in oil.Hydraulic System Problem Water/mud in oil. Replace gears or bearings. Lube Pump Motor System Pressure Hydraulic Motor Hydraulic Heat Exchanger 8-42 Varco Systems .0 In.5 GPM Ea. Foreign particles blocking orifice or nozzle. Remedy Replace inspection plugs. Cold oil.062ø . Replace oil. Worn gears or damaged bearings. Adjust the pressure at relief valve CBCA to approach 1500 psi. The link tilt float solenoid valve SV8 releases pressure from the cylinder to allow the link tilt to move to the well center position. When you override a directional valve. taking present and delayed pressure readings. TDS-11SA 8-43 . Use the following procedures to test the link tilt cylinder: 1. n Alert all personnel near the shot pin. you bypass the safety interlock and top drive components move. full pressure is applied through E6 to the link tilt cylinder to move the links to the mousehole position. Continue to set the driller’s console control to mousehole and neutral. set the link tilt to the mousehole position. From the drillers console. Set the system to a neutral position and observe the pressure drop. When the solenoid valve SV6 is actuated to the mousehole position. System test For the link tilt circuit. possibly causing serious injury or death. there is nothing to adjust on the manifold. The cylinder goes to full extension and the pressure at test port TP is 2000 psi.Hydraulic System Rotating link adapter Operation The solenoid valve SV6 operates two cylinders with load holding manifolds. and link adapter before overriding a directional valve. Adjusting the valves at the same time assures the link tilt operation is synchronized. clamp. which energizes the solenoid valve SV6 and drives the link tilt cylinder to full extension. two for the rod end and two for the piston end. full pressure is applied through G6 to move the cylinder to the drill down position. 3. 2. When solenoid valve SV6 is actuated to the drill down position. 8 z Preliminary This is an iterative process. The four load-holding valves are adjusted in pairs. Adjust relief control valves CBCA and CWCK for rod and piston pressure at 1. you bypass the safety interlock and top drive components move. Remedy Inspect. 8 If the motor will drive normally. Tool does not return to home Valve is sticking or relief valve position. the cause could be the control system. Mechanical interference. Look n Solenoid valve is not electrically operating. Shot pin is engaged.500 psi. Check electrical connections and valve functions. 4. Inspect and repair. Test pressure left and right. Adjust valves togetherpressure is the same for all four valves. The piston relief valves are set at the pistons fully extended and the rod relief valves are set at the pistons fully retracted. is out of adjustment. Directional valve does not shift. possibly causing serious injury or death. Sensor is broken. Replace hydraulic lines. Adjust the relief valve. When you override a directional valve. Replace sensor. repair or replace the valve. Test pressures and inspect valves. Motor is worn out or gear teeth Replace the motor. but not drive to the home position. Adjust the relief valve as required. Problem Tool does not rotate. Counterbalance valves are out of adjustment. 8-44 Varco Systems . Fixed valve orifice is plugged. Hydraulic lines are damaged. are broken.Hydraulic System e Turning the relief valve counterclockwise increases the pressure. Probable cause Direct control valve or relief valve is sticking. Replace the valve.500 psi for balanced hydraulic system operation. Both system rod and piston relief valve pressures at TP and FL are 1. Links are not synchronized. Checkout control system. Clear orifice or replace the valve. Hydraulic System Rotating link adapter schematic diagram Rotating Head Motor A B Fixed Displacement Motor 2 1 T-10A 1600 PSI 1600 PSI T-10A Pressure Relief Valves 2 1 A B Rotate Left Solenoid Rotating Head Rotate Right Solenoid Cable ID Number C03 Left A b B a C02 Cable ID Number P T Right -6 -6 A2 .071ø SV2 D03 B2 Manifold Assembly 8 Non-Adjustable Orifice Pressure Tank 3 Position Solenoid Valve Preliminary TDS-11SA 8-45 . 5 0.5 FP Full Page 0.01.B 09.8 1.0 1.95 8-46 Varco Systems .2 0.0 1.5 2.2 0.1 0.8 ARTWORK PLACEHOLDER 1.5 ® 8 DRILLING SYSTEMS REV.0 2.1 0.Hydraulic System Solenoid valve replacement procedures Double A UL-type valve 5 10 20 30 40 50 60 70 80 90 0.5 0. B 09.8 1.1 0.95 8 Preliminary TDS-11SA 8-47 .0 1.0 2.1 0.5 2.Hydraulic System Atos EEx-type valve 5 10 20 30 40 50 60 70 80 90 0.5 0.2 0.5 0.0 1.8 ARTWORK PLACEHOLDER 1.5 FP Full Page 0.2 0.5 ® DRILLING SYSTEMS REV.01. Rod Open Close Test Point Typical Hydraulic Cylinder CR LODC 2 1 30 PSI CXCD T-13A 3 50 PSI CP T-11A VR 2 1 Time-Delay Accumulator 30 Cubic Inches 800 PSI Precharge Logic Cartridge Gas Charged Accumulator (Small) -6 A4 B4 A4 B4 -6 IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve Cable ID Number -6 IBOP Close A b C04 P -6 B -6 -6 T -6 A4 .Hydraulic System Solenoid valve schematic diagram IBOP Actuator Cylinder 2.010ø 8 T-11A Flow Control Valve PC4 System Pressure Tank 8-48 Varco Systems . Bore X 4.00" Stroke 1.055ø SV4 D03 B4 C4 Manifold Assembly 500 PSI D4 CV4 1 T-11A 3 2 1 3 2 .500" Dia.750" Dia. Hydraulic System Hydraulic schematic symbols The following hydraulic troubleshooting section provides a schematic diagram and description for each TDS-11SA hydraulic circuit. t The system is preadjusted. n Alert all personnel near the top drive before overriding a solenoid valve. you bypass the safety interlock and top drive components will move possibly causing serious injury or death. When you override a solenoid valve. Following each schematic is a group of troubleshooting charts to help you quickly locate and correct hydraulic system problems.g. When performing hydraulic troubleshooting. Hydraulic problems are usually related to faulty valves. t Test points shown in the hydraulic schematic with a box (e. A4) can be found on the manifold under the main body. There are also test points on the rotating link adapter motor. 8 Preliminary TDS-11SA 8-49 . be aware that: t The electrical control system can be bypassed for troubleshooting by manually overriding the solenoid valve for each operational system. or other damage to the system rather than misadjustments.. contamination. Changes to adjustments should be made only after all other possible causes have been eliminated. CTF. A2R. SV6 33-2 Manual Valve (Rotary) 3 Position 4 Way Valve 33-3 MV Fixed Displacement Pumps Variable Displacement 33-5 33-4 Standard Valve 33-6 RV2. SV5.Hydraulic System Description 2 Position 4 Way Valves (Single Solenoid) Solenoid Operated Valves 3 Position 4 Way Valves (Double Solenoid) Symbol Schematic Reference SV1. SV8. SV9 33-1 SV2. CTR. SJR Pressure Relief Valves Ventable Relief Valve 33-7 RV1 Differential Unloading Valve 33-8 UV1 Pressure Reducing Valve 33-9 PC1. CV2 8-50 Varco Systems . CV2. CXCD Prefill valve assembly CV1. CDR. B2R. SV4. PC4 8 Pressure Reducing/Relieving Valve 33-10 PCC Chack Valve 33-11 CDF. CV4 (Clamp Body) 33-13 1 3 Cavity Plug 2 33-14 PC5 Internal Plug 33-15 Non Adjustable Flow Control Valves 33-16 CV1 Non Adjustable Orifice 33-17 Diameter in inches 3 Port (Internal Drain) Counterbalance Valves 4 Port (External Drain) 33-19 33-18 CBCA (Link Tilt Circuit) CWCK (Link Tilt Circuit) Standard Cartridge Logic Cartridge With Metering 33-21 33-20 LA6. CB6. LC5. CV3. LODC See Prefill Assembly 8 Quick Disconnect Coupling 33-22 Preliminary TDS-11SA 8-51 . LB6.Hydraulic System Description Pilot-To-Open Check Valves Pilot-To-Close Symbol Schematic Reference CKCB (Link Tilt) 33-12 CA6. Hydraulic System Description Non Bypass Filter Symbol Schematic Reference See Lube Oil Circuit 33-23 Filter with Bypass 33-24 See Return Circuit Manual Shutoff Valve 33-25 Thermostat 33-26 Lube Oil Circuit Pressure Switch 33-27 Lube Oil Circuit Heat Exchanger 33-28 Hydraulic Circuit (Inside Brake Housing) Pressure Compensator Control 33-29 Part of the Pump Hydro-Pneumatic Accumulator 33-30 Hydraulic Motor (Bi-Directional) 33-31 Hydraulic Cylinder 33-32 8 Tank (Reservoir) 33-33 Test Point 33-34 8-52 Varco Systems . please select the hand tool. View Page View Bookmarks View Thumbnails Hand Zoom In Select Text Return to First Page Return to Previous Page Go to Next Page Go to Last Page 100% Zoom Fit Page Fit Page Width Inside Window Go Back Go Forward Find . the hand will point. In order to view a document.Adobe Acrobat Navigation Below are the buttons that appear in your toolbar of this document. If a document has been linked.
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