TDS-10S Top Drive Drilling System Service Manual SM00400 March 2, 1998 Manual conventions This manual uses conventions that make it easy for the reader to locate key information and detailed descriptions. Graphics illustrate descriptions of equipment and assemblies to provide a better understanding of the equipment and its components. Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention. Note the examples below and pay close attention to these important advisories. z e n Note: Indicates advisories for operational or servicing procedures involving no risk of personal injury or equipment damage. Caution: Indicates advisories involving a risk of equipment damage. Warning: Indicates advisories involving a definite risk of injury to rig personnel. Avoid personal injury and equipment damage by reading this manual and related documents prior to operating or maintaining the equipment. ii TDS-10S About thisContents manual Contents Book 1 – Description, Installation and Operation Preface Manual conventions............................................................ Safety information .............................................................. Directional references ......................................................... Illustrations ......................................................................... Manual layout..................................................................... Varco service centers ........................................................... 5 5 6 6 6 6 Chapter 1 Introduction Introduction to the TDS-10S ............................................. 7 Chapter 2 Description TDS-10S major components .............................................. 9 Motor housing and swivel assembly ............................ 10 Transmission and swivel housing .......................... 10 Integrated swivel assembly .................................... 11 Drilling motor and brakes ..................................... 11 Motor cooling system ................................................. 12 Carriage and guide beam............................................. 14 PH-55 pipehandler ..................................................... 14 Powered rotating link adapter ............................... 14 Torque backup clamp cylinder .............................. 15 Bidirectional link tilt ............................................. 16 Internal blowout prevention ................................. 18 Hydraulic control system ............................................ 20 Counterbalance system ......................................... 22 STAND JUMP feature (optional) ................... 23 AC motor and control system ..................................... 24 TDS-10S Contents iii March 2, 1998 Chapter 3 Installation Installing the TDS-10S ..................................................... 27 Chapter 4 Operation Driller’s interface and driller’s console ............................... Throttle control .......................................................... Torque control............................................................ Switches ...................................................................... Indicators .................................................................... Varco control system ................................................... Variable frequency inverter ............................................... Rectifier and DC link filter ......................................... Power modules ........................................................... Control section ........................................................... Service loop ...................................................................... Drilling ahead ................................................................... Drilling ahead with triples .......................................... Drilling ahead with singles .......................................... Tripping in and tripping out ....................................... Back reaming .............................................................. Well control procedures .............................................. Running casing ........................................................... 33 33 34 34 36 37 38 38 38 38 39 40 40 42 44 44 46 48 Chapter 5 Specifications General ............................................................................. Drilling parameters ..................................................... Rated capacities..................................................... Drilling motor ...................................................... Pipehandler (PH-55) ............................................ 49 50 50 50 50 Chapter 6 Appendix............................... 51 iv TDS-10S Contents Book 2 – Maintenance and Troubleshooting Preface Manual conventions............................................................ Safety information .............................................................. Directional references ......................................................... Illustrations ......................................................................... Manual layout..................................................................... Varco service centers ........................................................... 7 7 8 8 8 8 Chapter 1 Introduction Precautions ......................................................................... 9 Chapter 2 Maintenance schedules Inspection schedules ......................................................... Lubrication schedule ......................................................... Lubricant specifications .................................................... Selecting a lubricating/hydraulic oil ............................ Selecting a lubricant .................................................... 11 13 14 14 15 Chapter 3 Inspection Inspecting hardware and fittings ....................................... Inspecting the AC drilling motor brakes ........................... Inspecting the AC drilling motor louvers .......................... Inspecting the wash pipe assembly .................................... Inspecting the upper stem liner ......................................... Inspecting main shaft end play .......................................... Inspecting the gearbox oil level ......................................... Inspecting the guide beam ................................................ Inspecting the IBOPs ........................................................ Inspecting the pipehandler ................................................ Nondestructive Examination (NDE) ................................ Inspecting the elevator link eyes .................................. Inspecting the drive stem ............................................ Magnetic particle inspection (MPI) ............................ Ultrasonic inspection .................................................. Inspecting the hydraulic system ........................................ Inspecting the electrical system ......................................... TDS-10S Contents 17 18 18 18 19 21 22 22 22 23 24 24 26 27 28 29 29 v March 2, 1998 Chapter 4 Lubrication Introduction ..................................................................... Lubricating the AC blower motor bearings ....................... Lubricating the hydraulic pump AC motor ....................... Lubricating the AC drilling motor bearings ...................... Lubricating the wash pipe assembly .................................. Lubricating the upper main body oil seals ......................... Replacing the gearbox oil .................................................. Initial oil change ......................................................... Oil capacity................................................................. Replacing the gearbox oil filter .......................................... Lubricating the carriage and guide beam ........................... Lubricating the rotating link adapter ................................. Lubricating the link tilt and PH-55 stabilizer bushing ...... Lubricating the elevator support and master bushing wear guide ................................................ Lubricating the wireline adapter ........................................ Lubricating the IBOP actuator yoke ................................. Lubricating the IBOP actuator crank ................................ Lubricating the torque arrestor tubes and clamp cylinder gate ........................................................... 31 32 32 32 34 35 35 35 35 36 36 36 38 38 38 39 40 41 Chapter 5 Maintenance General hydraulic system maintenance.............................. 43 Start-up procedure ...................................................... 44 Accumulator maintenance ................................................ 44 Chapter 6 Troubleshooting Troubleshooting the AC drilling motor ............................ Troubleshooting the AC blower motor ............................. Troubleshooting the hydraulic system ............................... Troubleshooting the AC drilling motor brakes ......................................................... Troubleshooting the rotating link adapter (rotating head) motor ....................................................... Operation ................................................................... System test .................................................................. Troubleshooting the IBOP actuator cylinder .................... Operation ................................................................... System test .................................................................. vi TDS-10S Contents 45 46 47 51 52 52 52 54 54 55 Troubleshooting the shot pin cylinder and clamp cylinder ............................................................ Operation ................................................................... System test .................................................................. Troubleshooting the counterbalance system ...................... Counterbalance testing ............................................... Stand jump testing ...................................................... Troubleshooting the hydraulic power unit (HPU) and reservoir ..................................................................... Operation ................................................................... System test .................................................................. 57 57 58 60 61 62 64 64 64 Chapter 7 Disassembly and assembly Precautions ....................................................................... PH-55 Pipehandler ........................................................... Disassembling the PH-55 Pipehandler ........................ Assembling the PH-55 Pipehandler ............................ Rotating link adapter ........................................................ Disassembling the rotating link adapter assembly ........ Assembling the rotating link adapter assembly ............ Transmission/motor housing ............................................ Removing the transmission/motor housing ................. Installing the transmission/motor housing .................. Disassembling the transmission/motor housing .......... Removing the bonnet and wash pipe .................... Removing the upper bearing retainer plate .................. Removing the AC drilling motor .......................... Removing transmission components ..................... Assembling the transmission/ motor housing ............................................................ Assembling the main body .................................... Assembling the main shaft .................................... Assembling the gears to the main body ................. Installing the AC drilling motor ............................ Installing the upper bearing retainer plate ............. Installing the wash pipe......................................... Checking the gear train backlash ........................... AC drilling motor disassembly/assembly ........................... AC drilling motor disassembly .................................... AC drilling motor assembly ........................................ Replacing the safety wiring ............................................... Safety wiring tips ........................................................ TDS-10S Contents 67 69 69 71 72 72 73 75 75 75 76 76 77 77 78 81 81 82 84 87 89 91 91 92 92 94 96 98 vii March 2, 1998 Book 3 – Control System Chapter 1 Description General description ............................................................. 5 Major component descriptions ........................................... 7 Varco Driller’s Console (VDC) ..................................... 7 Programmable logic controller (PLC) ..................... 9 Variable Frequency Drive (VFD) .......................... 10 Electrical service loops................................................. 12 Chapter 2 Operation Preoperational checklists ................................................... VDC controls ................................................................... Correcting a drive fault ..................................................... Drive fault while drilling ............................................. Drive fault while making up ....................................... 13 17 20 20 21 Chapter 3 Maintenance Maintaining the control system ......................................... 23 Troubleshooting ............................................................... 25 VFD ........................................................................... 28 Book 4 – Supplemental Material viii TDS-10S Contents TDS-10S Top Drive Drilling System Description, Installation and Operation March 10, 1998 2 TDS-10S Service Manual Contents Preface Manual conventions............................................................ Safety information .............................................................. Directional references ......................................................... Illustrations ......................................................................... Manual layout..................................................................... Varco service centers ........................................................... 5 5 6 6 6 6 Chapter 1 Introduction Introduction to the TDS-10S ............................................. 7 Chapter 2 Description TDS-10S major components .............................................. 9 Motor housing and swivel assembly ............................ 10 Transmission and swivel housing .......................... 10 Integrated swivel assembly .................................... 11 Drilling motor and brakes ..................................... 11 Motor cooling system ................................................. 12 Carriage and guide beam............................................. 14 PH-55 pipehandler ..................................................... 14 Powered rotating link adapter ............................... 14 Torque backup clamp cylinder .............................. 15 Bidirectional link tilt ............................................. 16 Internal blowout prevention ................................. 18 Hydraulic control system ............................................ 20 Counterbalance system ......................................... 22 STAND JUMP feature (optional) ................... 23 AC motor and control system ..................................... 24 Chapter 3 Installation Installing the TDS-10S ..................................................... 27 TDS-10S Service Manual 3 March 10, 1998 Chapter 4 Operation Driller’s interface and driller’s console ............................... Throttle control .......................................................... Torque control............................................................ Switches ...................................................................... Indicators .................................................................... Varco control system ................................................... Variable frequency inverter ............................................... Rectifier and DC link filter ......................................... Power modules ........................................................... Control section ........................................................... Service loop ...................................................................... Drilling ahead ................................................................... Drilling ahead with triples .......................................... Drilling ahead with singles .......................................... Tripping in and tripping out ....................................... Back reaming .............................................................. Well control procedures .............................................. Running casing ........................................................... 33 33 34 34 36 37 38 38 38 38 39 40 40 42 44 44 46 48 Chapter 5 Specifications General ............................................................................. Drilling parameters ..................................................... Rated capacities..................................................... Drilling motor ...................................................... Pipehandler (PH-55) ............................................ 49 50 50 50 50 Chapter 6 Appendix ............................... 51 4 TDS-10S Service Manual Preface Manual conventions This manual contains conventions that make it easy for the reader to locate key information and detailed descriptions. Graphics illustrate descriptions of equipment and assemblies to provide a better understanding of the equipment and assemblies to provide a better understanding of the equipment’s functionality. Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information, a warning, or a caution note. See the symbols below and pay close attention to these important advisories throughout the text. z e n Indicates advisories for operational or servicing procedures involving little or no risk of personal injury and equipment damage. Indicates advisories involving a risk of equipment damage. Indicates advisories involving a definite risk of injury to rig personnel. TDS-10S Service Manual 5 March 10, 1998 Avoid personal injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment. Directional references References to the right or left and front or back of components described in this manual assume the perspective of the tool assembly–standing behind the tool as it faces well center. Illustrations Figures present a graphical representation of tool components for use in identifying parts or establishing nomenclature. Illustrations show measurements with inches (in.), followed by millimeters (mm). For more specific component information pertinent to your rig configuration, see the drawing index in the Drawings chapter to obtain the engineering drawing number. Manual layout This binder contains several separate chapters that you can remove individually for convenience. Varco service centers If you need technical assistance, see the back cover of this manual for a complete list of Varco’s Worldwide Service Centers. 6 TDS-10S Service Manual Chapter 1 Introduction Introduction to the TDS-10S Varco Drilling Systems developed the TDS-10S Top Drive Drilling System primarily for smaller land rigs. Varco made use of the recent advancements in AC technology, designing the TDS-10S to use one 350-hp AC drilling motor. This 350-hp system produces 20,000 ft lb of continuous drilling torque and 36,500 ft lb of makeup/break out torque. The TDS10S is compact enough to be safely operated in a standard 136 ft. mast while providing 250 tons of hoisting capacity. Its highly portable design allows for simple rig-up and rig-down in just a few hours. It easily integrates into existing rigs at minimal installation cost and rig modification. TDS-10S Service Manual 7 March 10, 1998 8 TDS-10S Service Manual Chapter 2 Description TDS-10S major components The TDS-10S drilling system includes the following assemblies and subassemblies: ❏ Motor housing and swivel assembly ❏ Motor cooling system ❏ Guide beam ❏ PH-55 pipehandler ❏ Hydraulic control system ❏ Counterbalance system ❏ AC drilling motor ❏ Electrical control system TDS-10S Service Manual 9 March 10, 1998 Motor housing and swivel assembly This assembly is comprised of the following subassemblies: ❏ Transmission and swivel housing ❏ Integrated swivel assembly ❏ Drilling motor and brakes Transmission and swivel housing The assembly consists of the following components: ❏ Bonnet/cover ❏ Main body ❏ Motor pinion ❏ Compound gear ❏ Bull gear ❏ Main shaft ❏ Lubrication system The single-speed helical gear transmission with double reduction provides a 13.1:1 ratio from the motor to the main shaft. The main body and gear case cover house the transmission, the main thrust and radial bearings. The gear case cover houses the upper take-up bearing and supports the AC motor. The bull gear attaches to the load shoulder on the main shaft. All lubrication of the gears and bearing is via a pressurized system integrated into the main body and cover. 10 TDS-10S Service Manual Integrated swivel assembly An industry-standard washpipe packing assembly is located between the main shaft and gooseneck, and allows for the rotation of the drill string. The bonnet/gear case cover supports the assembly and attaches to the gear case to provide lateral support. An alloy steel swivel bail attaches to the main body. The swivel bail can stroke vertically relative to the swivel housing to provide an integral counterbalance system. An extended length is available to allow operator clearance between the gooseneck and hook for wireline packing assemblies. Drilling motor and brakes A 350 hp AC drilling motor supplies power to the TDS-10S. The motor mounts vertically on top of the transmission gear case cover with a modified “D-face” to avoid shimming or special alignment during installation. The motor has a double-ended shaft with a drive hub mounted on the lower end and a disc brake rotor mounted on the upper end. Two hydraulic caliper disc brakes mount to the top end of the motor, where they can be easily inspected and serviced via the access covers around the brake covers. The caliper disc brakes also assist in drill string positioning when performing directional work. They are remotely operated from the driller’s console. TDS-10S Service Manual 11 March 10, 1998 Motor cooling system The motor cooling system (Figure 1) on the TDS-10S is a local intake centrifugal blower consisting of a cooling fan motor mounted on top of the AC drilling motor. The system draws air across the brake and delivers it through rigid ducting to an opening at the top of the motor. The cooling air then passes through the inside of the open-frame type AC drilling motor and exits through the louvered openings near the bottom of the motor. This rugged, simple design provides highly reliable service with positive ventilation. 12 TDS-10S Service Manual Duct Blower Motor Centrifugal Blower Air Flow Disk Brake Housing AC Drilling Motor Intake Air Flow (Between Motor and Brake Housing) Louvers Exhaust Air Flow Figure 1. TDS-10S motor cooling system TDS-10S Service Manual 13 March 10, 1998 Carriage and guide beam The TDS-10S drilling system travels on a hanging guide beam by means of a carriage attached to the gear case. The guide beam hangs from the crown and extends to within seven feet of the drill floor. There, it attaches to either a lower mast girt or a torque reaction beam mounted across the lower section of the mast or derrick. The drilling torque is reacted through the carriage and into the guide beam. The guide beam is available in 18-ft. sections (63 lb/ft) and hangs from a pad eye at the crown. The guide beam sections are pinned together making installation easy. Guide beam sections can be assembled one section at a time, at the drill floor, while raising the guide beam to the crown attachment using the drawworks. The carriage consists of an angle structure and low friction guide pads. This arrangement maintains alignment of the main shaft with the drill string while moving up and down on the guide beam. PH-55 pipehandler The PH-55 pipehandler consists of the following major components: ❏ Powered rotating link adapter ❏ Torque backup clamp cylinder ❏ Bidirectional link tilt ❏ Remote upper IBOP actuator ❏ Elevator links and drill pipe elevator Powered rotating link adapter The powered rotating link adapter hangs from the stem. Hydraulic pressure applied to an annulus between the stem and the rotating link adapter supports the weight of the pipe handler with links and drill pipe elevator during drilling. During tripping, when the drill pipe elevator supports the weight of the drill string, the rotating link adapter strokes down to the landing collar seat and, in turn, transfers the load to the main shaft. 14 TDS-10S Service Manual The powered rotating link adapter allows the hydraulic lines to remain connected as the pipehandler rotates with the drill stem components while tripping or when positioning the link tilt. During this operation, the pressurized annulus acts as a hydraulic thrust bearing. The powered rotating link adapter has a hydraulic drive motor to rotate it in either direction. An electric solenoid valve operates the hydraulic motor. A pinion gear on the hydraulic drive motor rotates the positioning gear that is attached to the top of the rotating link adapter. During make or brake operations the rotating link adapter can be locked into any of 24 index positions by selecting the pipehandler clamp mode which actuates a hydraulically operated shot pin. When the hydraulic drive motor is not powered the link adapter can rotate freely. The link tilt mechanism is integrated into the rotating link adapter. The torque arrestor frame hangs from the rotating link adapter. Two bushings located toward the top and bottom ends of the rotating link adapter and sandwiched radially against the stem, support the radial loads. The internal hydraulic fluid passages in the stem connect to the respective fluid passages in the rotating link adapter. Fluid is fed from the main manifold into the stem through the radial passages at the upper end. This fluid is routed from the vertical passages in the stem to grooves in the rotating link adapter, and out to all actuators on the pipe handler. While rotating or in any stationary position, fluid flows between the two components. Torque backup clamp cylinder The torque backup clamp cylinder assembly is located below the lower shoulder of the saver sub. It includes two gripping jaws with die inserts and a clamping cylinder for gripping the box end of the drill string when connecting to a saver sub. A torque arrestor frame hanging from the rotating link adapter supports the torque backup clamp cylinder and allows the clamp cylinder to float up or down to allow for thread engagement and disengagement. With the torque backup clamp cylinder pressurized to clamp on a tool joint, torque is reacted through the torque arrestor frame while making and breaking connections. The torque backup clamp cylinder position is adjustable. Its position is adjusted so that the top of the dies are 3/8 to 1/2 in. below the top of the box end of the tool joint. TDS-10S Service Manual 15 March 10, 1998 Bidirectional link tilt The link tilt mechanism consists of two hydraulic cylinders and a crank mounted with a pivot arrangement on the rotating link adapter (Figure 2). The top end of the crank is connected to the rod end clevises of the two hydraulic cylinders. The bottom end of the crank is connected to the elevator links through two levers, attached to the links with U-bolts and link clamps. The stop mechanism limits the travel of the elevator to the derrickman position which is adjustable. Releasing the stop (by pulling a cable) allows the elevator to travel to the mousehole position. The elevator is fully extended in the opposite direction by extending the two hydraulic cylinders. This gives the tool overdrill capability. The link tilt operates from a three-position switch located on the driller’s console. The TILT position moves the links toward the mousehole or derrickman by retracting the two hydraulic cylinders. The DRILL position tilts the links back to clear the drill pipe and raise the elevator to allow drilling down to the floor. The spring centered position holds the link at any intermediate position. There is a separate float switch which is used to allow the links to hang free. The DRILL position changes the tilt direction, which also keeps the elevator off the drill pipe when drilling or moves it away from the well center to clear the drill floor when drilling down to the floor. The links may be stopped at any intermediate position. The links float back to the well center when the FLOAT position button on the driller’s console is operated. 16 TDS-10S Service Manual Link Tilt Cylinder (2) All dimensions are true for 108" long Elevator Links and FOR REFERENCE ONLY * At Monkey Board level (80') and placed into view FOR CLARITY ONLY Ov er dr eh ole ill Drill Derr ickm Mo an * us 108" 34" 14" 4" 36" Typ. 28" 76" 56" CL Well Drill Floor Figure 2. Bidirectional link tilt positions TDS-10S Service Manual 17 March 10, 1998 Internal blowout prevention The two ball-type internal blowout prevention (IBOP) valves are full size, internal opening safety valves (Figure 3). The remotely operated upper valve and the manually operated lower valve form the well control system. Both valves have 6 5/8 in. regular RH connections and 15,000 psi pressure ratings. A two-position switch at the driller’s console operates the OPEN and CLOSE functions of the upper IBOP valve. When the switch is operated, a hydraulic cylinder through a non-rotating lever arrangement attached to the torque arrestor slides an actuator shell up and down. This lever arrangement drives a small crank arm on each side of the valve which opens and closes the upper IBOP valve. Both upper and lower IBOP valves can be broken out and sent down hole. 18 TDS-10S Service Manual Main Shaft Tool Joint Lock Upper IBOP Actuator Cylinder Upper IBOP and Actuator (Remote) Tool Joint Lock Torque Arrestor Frame Manual Lower IBOP (Optional) Tool Joint Lock Saver Sub Back-up Clamp Cylinder Assembly Stabbing Guide Figure 3. TDS-10S drill stem assembly TDS-10S Service Manual 19 March 10, 1998 Hydraulic control system The hydraulic control system (Figure 4) is completely selfcontained (on board) and supplies all hydraulic power. It eliminates the need for an additional service loop. The system consists of components that operate the following assemblies: ❏ Counterbalance system ❏ AC motor brakes ❏ Gear/main bearings lubrication system ❏ Powered rotating head ❏ Remotely actuated IBOP ❏ Torque backup clamp cylinder ❏ Link tilt The hydraulic control system is powered by a 10 hp, 1,200 rpm AC motor that is direct coupled to drive a hydraulic pump. An integral hydraulic manifold mounts to the carriage and contains all solenoid, pressure, and flow control valves. There is also a manifold mounted to the shot pin housing for controlling the hydraulic rotating link adapter motor. Hydro-pneumatic accumulators operate the IBOP, pressure control valves, and counterbalance system. 20 TDS-10S Service Manual Upper IBOP Actuator Cylinder Link Tilt Cylinders Torque Backup Clamp Cylinder Counterbalance Accumulator Drilling Motor Brake Pipehandler Rotating Link Adapter (D.P. Elevator Positioner) Counterbalance Cylinders Shot Pin Cylinder Lube Oil Distribution Rotating Link Adapter Motor System Control Manifold 10 HP A.C. Motor M Upper IBOP Time Delay Accumulator Hydraulic Pump Reservoir System Accumulator Figure 4. TDS-10S hydraulic system TDS-10S Service Manual 21 March 10, 1998 Counterbalance system The integral counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS-10S. It replaces the function of the hook compensator spring. The system consists of two hydraulic cylinders attached between the transmission cover and bail, a hydraulic accumulator, and a hydraulic manifold. The system is integral to the TDS-10S and therefore does not require any external attachment to the hook. The cylinders are connected to a hydraulic accumulator. The accumulator is charged with hydraulic fluid and maintained at a predetermined pressure setting by the counterbalance circuit in the main hydraulic control system manifold. 22 TDS-10S Service Manual STAND JUMP feature (optional) The stand jump feature developed for the TDS-9S is available as an option for the TDS-10S. It consists of a switch at the driller’s console allowing the operator to change the mode of operation of the counterbalance cylinders from DRILL, which is a standard counterbalance condition, to STAND JUMP. The STAND JUMP feature allows the cylinders to lift the weight of the top drive off the drill string while breaking out a connection. This eases the stress on the threads and avoids damage. TDS-10S Service Manual 23 March 10, 1998 AC motor and control system The TDS-10S uses one 350 hp AC motor (Figure 5). It is located on top of the gear case, which minimizes the distance from the well centerline to the rear of the guide beam. Varco selected an AC drilling motor for use on the TDS-10S because it provides the following benefits: ❏ Reliability ❏ Low maintenance ❏ Nonpolluting ❏ Wide operational range ❏ May be stalled indefinitely at full torque ❏ 180% overload capability for up to one minute ❏ Brushless ❏ Nonsparking One AC induction motor powers the TDS-10S at 550 VAC maximum, 3-phase. The TDS-10S includes an air cooling system. The motor is fed from a PWM inverter that provides variable voltage at variable frequency for speed and torque control. The motor is rated at 350 hp with a maximum constant output torque of 1,550 ft lb. Maximum constant torque is available from 0 to 1,200 motor rpm, with constant power of 350-hp from 1,200 rpm up to the maximum rated motor speed of 2,400 rpm. (See the TDS-10S output curve figures in the Appendix chapter.) 24 TDS-10S Service Manual Hydraulic Motor Brake (Ref) Upper Grease Fitting Thrust Ball Bearing Air Inlet (1100 CFM) End Coil Rotor Assembly (Laminated) Motor Frame (Laminated) Stator Assembly (Laminated) Air Exhaust Motor Shaft (Vertical Type) End Coil Mounting Base Lower Grease Fitting Hub (Ref) Guide Roller Bearing Figure 5. AC drilling motor TDS-10S Service Manual 25 March 10, 1998 The AC motor (350 hp) and the gear ratios (13.1:1 high torque, standard speed, or optional 4.8:1 low torque, high speed) provide 20,000 ft lb of torque at a drill stem operating speed range of 0 to 87 rpm. Maintaining constant 350-hp output, the top drive provides 8,081 ft lb of torque at a maximum drill stem speed of 182 rpm. The open-frame design of the AC drilling motor allows the cooling air to pass through the inside of the motor, which provides more efficient transfer of rotor and winding heat to the cooling air. The motor is manufactured specifically for top drive applications. They include: ❏ Internal temperature sensors ❏ Double varnish impregnated glass-served windings ❏ Upgraded bearing/shaft seals ❏ High-capacity bearings ❏ Tapered output shafts ❏ High strength tie bolts ❏ Improved material castings 26 TDS-10S Service Manual Chapter 3 Installation Installing the TDS-10S Electrical, mechanical and structural modifications are necessary to install a TDS-10S on an existing rig. Dependent upon the specific rig characteristics, possible modifications can include: ❏ Extending the standpipe to 73 ft. ❏ Replacing the rotary hose (75 ft.) ❏ Installing an AC drive electrical generator (new or upgrade) ❏ Tie-back for the guide beam ❏ Crown pad eye for the guide beam ❏ Attachment pad eye for service loop/bundle saddle installation at the 80 ft. level ❏ Location of tongs, pipe spinner, mud bucket and trigger lines ❏ Guide beam clearance to girts and fastline ❏ Location of the casing stabbing board TDS-10S Service Manual 27 March 10, 1998 All of the above modifications may not be necessary, but all must be considered as well as the overall rig floor layout in order to ensure that proper installation, time utilization and accurate cost information is made. The functional operation of a TDS-10S has many considerations; a primary consideration is the mast/derrick height. The working height and crown clearance are two primary factors to finalize prior to ordering and installing your TDS-10S. Working height and Crown clearance can both vary dependent upon hook, block, bail, elevator links, and coupling chosen. Figure 6 shows a typical TDS-10S mast interface. A mast/derrick interface requirements and worksheet is provided in the Appendix chapter. 28 TDS-10S Service Manual Existing Traveling Equipment (250 ton Hook/Block Combo-Typ.) Crown 12.6 ft(3,8 m)-Std. 11.6 ft(3,5 m)-Opt. Clearance** Block Top Varco Portable Top Drive System TDS-10S 11.4 ft(3,5 m)* Stroked-Typ. Bail Rest Sectional Guide Beam 10 X 10" Square Tube 15.0 ft(4,6 m)-Std. 16.0 ft(4,9 m)-Opt. TDS Work Height** Tool Joint 75 ft(22,9 m) Mud Hose* Connected to Standpipe at 73 ft (22,3 m) Level 200 ft(61 m)* Unitized Service Loop 10.0 ft(3,0 m)-Min* Portable Torque Reaction Beam (Varco Universal Clamp on System, or Custormer Supplied) Varco Driller's Control 150 ft (45,7 m) Control Cable with Connectors Unitized Variable Frequency Inverter & Varco Control Panel "Local Power Supply" (Diesel/Alternator Set) 7.0 ft(2,1 m)-Min 93 ft(28,4 m) Drill Stand Made-up at 4 ft(1,2 m) Level 136 ft(41,5 m) - Clear Working Height Service Loop Saddle at ~80 Ft(24,4 M) Level* CL Beam Service Loop Tool Joint 4.0 ft(1,2 m) Drill Floor * Dimensions are Subject for Verification ** Standard TDS ConfigurationOne IBOP with 96" elev.Links Optional TDS ConfigurationTwo IBOP’s with 108" elev. Links 3X50 ft(3X15,2 m) A.C. Cables Figure 6. Typical TDS-10S mast interface TDS-10S Service Manual 29 March 10, 1998 Another key consideration in selecting and successfully operating a top drive is how well the top drive fits inside of the mast/ derrick. Given the specific dimensions within the mast/derrick legs, the top drive and its guidance system need to utilize the complete working height. Figure 7 shows a detailed top view of the TDS-10S. The TDS-10S is shipped on a transportation skid with the PH-55 pipehandler connected. In the skid, the top drive is attached to the upper section of the guide beam. Using the hook or a crane, the TDS-10S and skid is moved to the rig floor. Following the directions provided will allow for easy connection and locking-in of the remainder of the guide beam section and the attachment to the upper support brackets. Once the guide beam is secured at the top, the lower end of the guide beam is attached to the spreader beam and tied back to the mast/derrick. Proper attachment and tieback is vital to the transmission of the system torque to the rig structure. Additional unit subsystem checkouts and precautions are provided, all of which must be followed to ensure proper functionality of the TDS-10S unit. 30 TDS-10S Service Manual Guide Beam 10 X 10 (250 X 250) Square Tube CL Well CL Reliance Electric AC Induction 350 HP Drilling Motor Carriage Assembly with Guide Pads 20.5 (521) 24.0 (610) CL 26.0 (660) 25.6 (650) Ref. 19.5 (495) 44.0 (1118) Ref. CL 18.0 (457) 28.0 (711) Dimensions are in inches (millimeters) 48.0 (1219) Ref. Motor Housing Gooseneck Service Loop Bracket Figure 7. TDS-10S envelope/plan view TDS-10S Service Manual 31 March 10, 1998 32 TDS-10S Service Manual Chapter 4 Operation Driller’s interface and driller’s console The driller’s console is manufactured from 300-series stainless steel and it uses full-size, oil-tight switches and indicators. It is designed for purging to meet hazardous area requirements. By request, Varco can supply the console with Pyle-National connectors. Throttle control The throttle uses a design similar to the standard throttle control used with SCR systems. The handle is robust and includes integral stops to prevent damage. TDS-10S Service Manual 33 March 10, 1998 Torque control Two torque limit potentiometers are provided for setting drill and makeup torque limits. The drill limit control allows the driller to set the maximum torque output of the top drive to match the drill pipe size being used. The makeup control sets the torque when making up connections using the TDS-10S drilling motor. Switches Various switches control the following functions: ❏ Drill/Spin/Torque mode select ❏ Link tilt ❏ Brake ❏ Backup clamp cylinder ❏ Powered rotating link adapter ❏ IBOP valve ❏ Forward and reverse selection for the drill pipe rotation ❏ Emergency stop ❏ Stand jump (optional) 34 TDS-10S Service Manual Top Drive DC Generator (Alternate) - Encoder Skid * Mast Saddle Motor 1 + + * Variable Frequency Drive / * Varco Driller's Interface Electrical Service Loop System Electrical Panel Solenoids J-Box Sensors AC Power Highline or Diesel/Alternator Set Varco Driller's Console * Jumper Cable Assemblies could be used between Mast Termination Plate and Skid (Control House). Figure 8. Electrical interface TDS-10S Service Manual 35 March 10, 1998 Indicators Various indicators report status/faults to the driller: ❏ Oil pressure loss ❏ Drill motor over temp ❏ Blower loss ❏ Rotating link adapter ❏ IBOP closed ❏ Brake ❏ Drive fault PIPEHANDLER MAKE-UP CURRENT LIMIT OIL PRESS LOSS BRAKE IBOP CLOSED THROTTLE RIGHT R R 0 IBOP BRAKE ON LINK TILT FLOAT ROTATE LEFT A MAX DRILL MOTOR OVERTEMP LINK TILT OFF TORQUE WRENCH PUSH & HOLD DRILL BRAKE AUTO OFF EMERGENCY STOP IBOP OPEN TILT CLOSE BRAKE ON R 0 SPIN DRILL BLOWER LOSS TORQUE ALARM LAMP SILENCE CHECK HYDRAULIC POWER AUTO DRIVE FAULT MAX DRILL TORQUE OFF REVERSE FORWARD ON R TORQUE R 0 MAX Figure 9. Typical TDS-10S Varco driller’s console (VDC) 36 TDS-10S Service Manual RPM Varco control system The driller’s interface is integrated with the Variable Frequency Drive (VFD). The VFD is located in an environmentally controlled house. The driller’s interface integrated with the VFD includes the following components: ❏ Control logic for system interlocks ❏ Blower and oil pump motor starters ❏ Control circuitry for pipehandler functions ❏ Power supply for TDS-10S solenoids and VDC indicators ❏ AC inverter ❏ Programmable Logic Controller (PLC) The driller’s interface to the VFD is via a common data bus. Function changes are implemented with programming tools standard for Varco top drive systems. The driller’s interface receives input from the operator controls on the driller’s console and processes this information through the programmable logic controller (PLC). It controls the responses of the cooling system motor, the solenoid valves, the brakes, IBOP functions, and sensors. The PLC reads the status of the sensors and acts as an interlock to prevent inadvertent tool operations. It notifies the driller of the operational status of the TDS-10S and provides a diagnosis of any inadvertent operational conditions. TDS-10S Service Manual 37 March 10, 1998 Variable frequency inverter The frequency inverter consists of the following three major sections: Rectifier and DC link filter In this section, the incoming 3-phase AC voltage is converted to DC voltage and filtered by the DC link capacitors. This provides a ripple-free 740 VDC voltage as input for the inverter. Alternately, by bypassing the rectifier section, the inverter can be powered from a 740 VDC source. Power modules AC motor speed control requires variable frequency voltage. To do this, the DC voltage is converted to an output waveform that consists of a series of pulses. The duration of each pulse is controlled so that the fundamental voltage applied to the AC motor has the desired frequency and amplitude. The technique of using pulses to develop a waveform that appears to the motor as a sine wave is called pulse width modulation or PWM. Control section The control section monitors the performance of the drilling motor, accepts throttle and torque limit signals from the TDS-10S control system, and controls the firing circuits of the power modules. To vary motor speed, the driller uses a hand throttle. The throttle varies the frequency and voltage to the motor. Because the drilling motor is frequency synchronous, the motor speed is proportional to the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200 motor rpm). One of the greatest advantages of an AC variable frequency drive is the quality of the speed and torque control. It allows precise control of the drill pipe speed over the full operational range. 38 TDS-10S Service Manual Variable Frequency Drive 810 VDC Resultant Pulse DC 20 Hz=600 RPM @ Mtr. 0 0 0 0 TDS-10S AC Motors Insulated gate Bi-polar Transistors (IGBT) + AC Power Source AC Inverter (AC Frequency Drive) Inverter Controller 0-575VAC, 0 to 80 Hz, 3-Phase 600 VAC, 42 to 62 Hz 3-Phase (350 AMPS) 0 40 Hz=1200 RPM @ Mtr. PLC Data Bus Figure 9. AC power conversion to variable frequency Service loop The TDS-10S has an on board hydraulic system and, therefore, does not need a fluids service loop. This adds to the costeffectiveness of the TDS-10S drilling system and provides a safer work area. The TDS-10S has three electrical service loops. One loop consists of four 313 MCM cables (three for drilling motor power, one for ground). One loop is a composite cable that contains conductors for the sensors and actuator (solenoid) control. The third loop contains power for the smaller AC motors and space heater for the drive motor. TDS-10S Service Manual 39 March 10, 1998 Drilling ahead Drilling ahead with triples This is the common drilling mode for the TDS-10S. There are various sources for triples to drill with. On skidding rigs drilling multiple wells, or rigs that can move with racked pipe, the drill pipe can be left racked and used to drill the next well. If triples do not currently exist to drill with, there are two recommended methods of obtaining them. One is to leave some triples racked in the derrick when tripping back in the hole and finish the trip with singles. Enough triples should be left racked to handle anticipated bit life. The second is to make up triples in the mousehole while drilling ahead or during rig idle time. For safety reasons it is best to have a pivoting mousehole so it can be put in a vertical plane to simplify making connections. Note that the connections just need to be spun up as they will be torqued when the Top drive motor applies the makeup torque. Use the following procedure for drilling ahead with triples (Figure 11): 1. Drill down the existing stand and set slips. 2. Break out the saver sub from the drill pipe using the top drive motor and backup clamp in the pipehandler. 3 Spin out the connection using the drilling motor. 4. Lift the top drive. 5. The derrickman latches the triple in the elevator and the floor crew stabs it in the box. 6. Lower the top drive stabbing the pipe into the stabbing guide until the pin of the saver sub enters the box. 7. Spin-up and torque the connection using the drilling motor (makeup torque must be preset). Use a backup tong to react the torque. 8. Pull the slips, start the mud pumps and drill ahead. 40 TDS-10S Service Manual Set slips on string Stop circulation Raise block Tilt link tilt to derrickman Pickup stand with elevator Stab bottom of stand onto string Close IBOP Lower block to stab motor into top of stand Pull slips Spin in motor and stand Open IBOP Start circulation Begin drilling Makeup both connections with motor Breakout connection using pipehandler and drilling motor (in reverse) 3 2 1 Link Tilt 4 5 Makeup Open IBOP Close IBOP Stab Makeup Figure 11. Drilling ahead with triples TDS-10S Service Manual 41 March 10, 1998 Drilling ahead with singles Typically there are two situations when it is desirable to drill ahead with singles. One is beginning operations on a new well and there are no triples made-up and racked back. The other is when surveys must be made every 30 feet (kicking off using a downhole mud motor). The link tilt feature makes drilling with singles safe and efficient by moving the elevators to the mousehole to pick up the singles. Use the following procedure for drilling ahead with singles (Figure 12): 1. Drill down existing joint and set the slips. 2. Break out the saver sub from the using the top drive motor and the backup clamp in the pipehandler. 3. Spin out the connection using the drilling motor. 4. Lift the top drive until elevators clear box. 5. Actuate the link tilt to bring the elevator over to the single in the mousehole, lower the top drive and latch the elevator around the single in the mousehole. 6. Pull the single out of the mousehole and as the pin clears the floor, release the link tilt to allow the single to come to well center. 7. Stab the connection at the floor and lower the top drive allowing the added single to enter the stabbing guide. 8. Spin-up and torque the connection using the drilling motor (torque mode). Set a backup tong to react the torque. 9. Pull the slips, start the mud pumps and drill ahead. 42 TDS-10S Service Manual Set slips on string Tilt links to mousehole Pickup single with elevator Stop circulation Latch drill pipe elevator around single Release link tilt Close IBOP Stab bottom of single onto string Lower block to stab motor into top of single Pull slips Spin in motor and single Start circulation Open IBOP Begin drilling Makeup both connections with motor in torque mode Breakout connection using pipehandler and drilling motor (in reverse) 3 2 1 4 5 Makeup Open IBOP Close IBOP Link Tilt Stab Makeup Figure 12. Drilling ahead with singles TDS-10S Service Manual 43 March 10, 1998 Tripping in and tripping out Tripping is handled in the conventional manner. The link tilt feature can be used to tilt the elevator to the derrickman, enhancing his ability to latch it around the pipe thus improving trip times. The link tilt has an intermediate stop which is adjustable to set the elevator at a convenient working distance from the monkey board. The intermediate stop is tilted out of the way to allow the elevator to reach the mousehole. If a tight spot or key seat is encountered while tripping out of the hole, the drilling motor may be spun into the stand at any height in the derrick and circulation and rotation established immediately to work the pipe through the tight spot. Back reaming The TDS-10S permits reaming out of open hole to prevent pipe sticking and reducing keyseat formation, without affecting racking functions associated with normal tripping; i.e., no singles to contend with. This is provided by the ability of the top drive and backup clamp to break out 93 ft. stands in the derrick/mast. Use the following procedures for reaming out of the hole (Figure 13): 1. Hoist the block while circulating and rotating the drill motor until the third connection appears. 2. Stop circulation and rotation, and set the slips. 3. Break out the stand at floor level, and spin out using the drilling motor. 4. Break out the drilling motor from the top of the stand using the top drive motor and backup clamp, then spin out with the drilling motor. 5. Pick up the stand with the drill pipe elevator. 6. Rack stand back. 7. Lower the top drive to the floor. 8. Stab drilling motor into box, spin-up and torque with the drilling motor and backup clamp. 9. Resume circulation and continue reaming out of the hole. 44 TDS-10S Service Manual Hoist while circulating and rotating When 3-rd connection surfaces, stop rotation and circulation Set slips on string Hoist free stand with elevator Setback stand using link tilt Breakout connection using pipehandler and drilling motor (reverse) Spin in motor and makeup connection with motor Breakout and spinout stand at floor Start circulation, pull slips, hoist and rotate 3 2 1 Lower block, stab motor into string Breakout Hoist 4 5 Setback Hoist and Rotate Breakout Figure 13. Back reaming TDS-10S Service Manual 45 March 10, 1998 Well control procedures The TDS-10S can stab into the string at any point in the derrick. While drilling, the remotely controlled upper IBOP valve is always in the string for immediate use as needed. The lower IBOP valve is the same type as the upper IBOP valve except it must be operated manually with a wrench. Both valves always remain in the string and are therefore always readily available by connecting the TDS-10S to the drill string. To attach well control equipment to the drill string the torque arrestor frame assembly can be pulled away from the drill string by opening the clamp cylinder. After removing the lower valve from the upper valve, the lower valve remains connected to the drill string for well control purposes. The TDS-10S includes crossover subs for connecting the drill stem to the lower valve. Use the following procedure for well control during tripping operations (Figure 14): 1. On indication of a kick, set the slips and stab the top drive into the string. 2. Spin-up and torque the connection. 3. Close the remote upper IBOP. Internal pipe pressure of up to 15,000 psi is now held by the upper IBOP valve. If it becomes necessary to continue tripping in with a dart valve, or another well control accessory, the lower IBOP valve can be used to assist the operation. In this case, the following steps may be followed: 4. Lower string to the floor and reset the slips. 5. Manually close the lower IBOP valve. 6. With the tugger line attached to the back of the unit, swing out the torque arrestor clamp cylinder assembly. 7. Remove the lower and intermediate tool joint locks. 8. Break out lower IBOP and saver sub from upper IBOP using tongs. 9. Install appropriate crossover sub, check valve or circulation sub on top of lower IBOP valve. 10. Proceed with normal well control procedures. 46 TDS-10S Service Manual Add X-Over Sub (Check Valve etc.) Remote IBOP Actuator Cylinder Upper IBOP Valve Lower IBOP Valve Saver Sub Insert New Saver Sub Drill Pipe Figure 14. PH-55 pipehandler well control procedures TDS-10S Service Manual 47 March 10, 1998 Running casing Use longer elevator links (180 in.) to allow clearance for cementing head under the backup clamp in the pipehandler. Attach a short piece of hose to the saver sub in the pipehandler to fill the casing while lowering. Use the remotely controlled upper IBOP valve to start and stop the fluid flow. 48 TDS-10S Service Manual Chapter 5 Specifications General Transmission 13.1:1 high torque/low speed, or optional 4.8:1 low torque/high speed double reduction helical gear Transmission lube Pressure fed, filtered Powered rotating head Infinitely positionable System weight 18,000 lb TDS-10S Service Manual 49 March 10, 1998 Drilling parameters Drilling speed range 0 to 182 rpm continuous Drilling torque 20,000 ft lb maximum continuous (27115 Nm) Breakout torque 36,500 ft lb max. int. Drilling horsepower 350 maximum continuous Static locking brake 35,000 ft lb (47455 Nm) Rated capacities Hoisting 250 Tons, API-8C, PSL-1 Drilling (rotating) 250 Tons Water course (main shaft bore) 5,000 psi CWP (3 in.) Drilling motor Type AC induction, forced air cooled. Rating 350 hp Rated speed 1,200 rpm Maximum speed 2,400 rpm Maximum continuous torque 1,550 ft lb Maximum intermittent torque 2,790 ft lb Pipehandler (PH-55) 50 TDS-10S Service Manual Torque capacity 50,000 ft lb @ 2,000 psi Drill pipe range (OD) 2 7/8 in. through 5 in. (4 in. through 6 5/8 in. OD tool joint) Upper IBOP (remote) 6 5/8 in. API Reg. RH, Box Lower IBOP (manual) 6 5/8 in. API Reg . RH, Box and Pin (optional) IBOP pressure rating 15,000 psi CWP Elevator links 175 tons, 250 tons, or 350 tons, API, 96 in. long (108 in. links optional) Chapter 6 Appendix TDS-10S Service Manual 51 March 10, 1998 TDS-4S IDS-1 TDS-10S 650 Ton System 1,100 HP DC Motor 500 Ton System 1,000 HP DC Motor 250 Ton System 350 HP AC Motor Output Torque 29,100(HI)/45,000(LO) ft-lbs Output Torque 34,000 ft-lbs Output Torque 20,000 ft-lbs Bail Rest Bail Rest Bail Rest 20.8 ft (6,3 m) TDS-4S Working Height Tool Joint 23.0 ft (7,0 m) IDS-1 Working Height Tool Joint 15.0 ft (4,6 m) TDS-10S Working Height Tool Joint Drill Floor Varco’s Top Drive Drilling Systems comparison 52 TDS-10S Service Manual 350 HP AC Motor - 13.1:1 Tranmission (Standard) 40,000 Max. Stall @ 36,500 ft lb 35,000 Drill Pipe Torque (Ft-Lbs) 30,000 25,000 20,000 15,000 10,000 5,000 0 0 50 100 150 200 Drill Pipe RPM TDS-10S output curve (13.1:1) TDS-10S Service Manual 53 March 10, 1998 350 HP AC Motor - 4.8:1 Tranmission (Optional) 15,000 Max. Stall @ 13,390 ft lb 12,500 Drill Pipe Torque (Ft-Lbs) 10,000 7,500 5,000 2,500 0 0 100 200 300 Drill Pipe RPM TDS-10S output curve (4.8:1) 54 TDS-10S Service Manual 400 500 Block Top TRAVELING EQUIPMENT MAKE DRECO Block Saddle NATIONAL OILWELL Hook-Block Combination TRAVELING BLOCKS IDECO CECO Hook (If Used) Saddle Integrated Drilling System (IDS) (Integrated Block and Swivel) McKISSICK MH PYRAMID Saddle HOOK-BLOCK COMBOS (stroked 8") NATIONAL IDECO Swivel Stem Shoulder VARCO BJ S-Type Drilling System (Integrated Swivel) HOOKS (stroked 8") NATIONAL WEB WILS. MH NATIONAL Drilling System OILWELL IDECO SWIVELS CECO G.-DENVER Tool Joint DRECO To short-couple a Swivel Bail/Top Drive to a Traveling Block VARCO offers special Adapters with a 3 to 4 ft working height. VARCO TOP DRIVES * Includes 750 Ton Hook Adapter ** With 500 Ton 60-in Sheave Varco Integrated Taveling Block MODEL 660B-500 760B-650 760B-750 650H500 660H500 760H650 H350 B500 650 A750 TB525-6-60 TB650-6-60 TB750-7-60 RA52-6-500 RA60-6-650 RA60-7-750 500 650 500-1195 650-1090 500 650/750 540G250 545G350 650G500 660G500 760G650 UTB 525-6-60 5250 5350 5500 5750 51000 500 650 750 500 500 650/750 P500 P650 P750 PC500 PC650 TL-500 TL-650 TL-750 LB500 LB650 SW550 S500 S650 500 650 750 TDS-3H TDS-3S TDS-4H TDS-4S TDS-5H TDS-6S* TDS-7S TDS-9S TDS-10S IDS-11S IDS-1** WORKING HEIGHT WEIGHT (EST) in ft mm lbs kg 92 105 109 91 109 112 77 100 104 120 105 110 113 92 103 110 91 109 92 105 104 103 137 152 169 184 192 181 104 106 117 138 158 97 103 113 120 112 138 92 94 116 94 96 91 101 114 91 99 94 98 101 102 109 119 214 250 221 250 214 276 250 214 192 216 346 7.6 8.7 9.0 7.5 9.0 9.3 6.4 8.3 8.6 10.4 8.8 9.2 9.4 7.7 8.6 9.2 7.6 9.1 7.7 8.7 8.7 8.5 11.4 12.6 14.1 15.3 16.0 15.1 8.7 8.8 9.8 11.5 13.2 8.1 8.6 9.4 10.0 9.3 11.5 7.7 7.8 9.6 7.8 8.0 7.6 8.4 9.5 7.6 8.2 7.8 8.1 8.4 8.5 9.1 9.9 17.8 20.8 18.4 20.8 17.8 23.0 20.8 17.8 16.0 18.0 28.8 2324 2654 2756 2299 2756 2832 1956 2543 2629 3210 2670 2794 2873 2337 2621 2794 2315 2769 2340 2664 2648 2604 3480 3861 4293 4674 4883 4607 2642 2692 2981 3493 4035 2457 2623 2873 3048 2845 3508 2343 2375 2937 2388 2438 2311 2562 2899 2311 2505 2381 2486 2570 2578 2769 3001 5436 6350 5613 6350 5436 7010 6350 5425 4877 5486 8788 18500 23800 27500 13500 18750 21800 9380 17900 20240 34016 18200 20500 22100 13250 19158 22871 21500 22590 21546 26932 22000 27000 11600 15260 21250 26500 31780 9000 5050 6340 9950 18090 32076 6920 8550 9750 8500 11850 18745 5700 6900 11500 5708 7350 5200 6900 8200 5947 6646 5700 5800 6850 6100 7000 9100 32600 36750 37000 38750 35200 43750 49000 24000 18000 26500 49000 8391 10795 12474 6266 8509 9888 4255 8119 9181 15429 8255 9299 10024 6010 8690 10374 9752 10246 10000 12500 9979 12247 5262 6922 9639 12020 14415 4082 2291 2876 4513 8205 14550 3138 3872 4423 3856 5500 8700 2585 3130 5216 2589 3334 2359 3130 3719 2698 3015 2585 2631 3107 2767 3175 4128 14800 16685 16798 17593 15981 19826 22742 10886 8164 12020 22742 Top drive worksheet TDS-10S Service Manual 55 March 10, 1998 Crown Customer: .................. Clearance Block Top .......................................... .......................................... ........................................... 15.0 or 16.0 ft TDS Working Height Tool Joint Service Loop/Mast Bundle Saddle @..........ft Traveling Equipment Short-Coupling using Varco Adapter/Becket (if applicable): .............ft Mud Hose, Standpipe @..........ft ............................................ ............................................ ............................................ Sectional Guide Beam ............ft Mast Operating Height ........................................... Bail Rest 93 ft Drill Stand Existing Traveling Equipment: .................. (Stroked) .............ft Mast Bundle .............ft CL Beam VFD / Varco Driller's Interface Tool Joint 4 ft Drill Floor TDS-10S Mast interface worksheet (generic) 56 TDS-10S Service Manual TDS-10S Top Drive Drilling System Maintenance and Troubleshooting March 2, 1998 2 TDS-10S Maintenance and Troubleshooting Contents Preface Manual conventions............................................................ Safety information .............................................................. Directional references ......................................................... Illustrations ......................................................................... Manual layout ..................................................................... Varco service centers ........................................................... 7 7 8 8 8 8 Chapter 1 Introduction Precautions ......................................................................... 9 Chapter 2 Maintenance schedules Inspection schedules ......................................................... Lubrication schedule ......................................................... Lubricant specifications .................................................... Selecting a lubricating/hydraulic oil ............................ Selecting a lubricant .................................................... 11 13 14 14 15 Chapter 3 Inspection Inspecting hardware and fittings ....................................... Inspecting the AC drilling motor brakes ........................... Inspecting the AC drilling motor louvers .......................... Inspecting the wash pipe assembly .................................... Inspecting the upper stem liner ......................................... Inspecting main shaft end play .......................................... Inspecting the gearbox oil level ......................................... Inspecting the guide beam ................................................ Inspecting the IBOPs ........................................................ Inspecting the pipehandler ................................................ Nondestructive Examination (NDE) ................................ Inspecting the elevator link eyes .................................. Inspecting the drive stem ............................................ Magnetic particle inspection (MPI) ............................ Ultrasonic inspection .................................................. Inspecting the hydraulic system ........................................ Inspecting the electrical system ......................................... TDS-10S Maintenance and Troubleshooting 17 18 18 18 19 21 22 22 22 23 24 24 26 27 28 29 29 3 March 2, 1998 Chapter 4 Lubrication Introduction ..................................................................... Lubricating the AC blower motor bearings ....................... Lubricating the hydraulic pump AC motor ....................... Lubricating the AC drilling motor bearings ...................... Lubricating the wash pipe assembly .................................. Lubricating the upper main body oil seals ......................... Replacing the gearbox oil .................................................. Initial oil change ......................................................... Oil capacity................................................................. Replacing the gearbox oil filter .......................................... Lubricating the carriage and guide beam ........................... Lubricating the rotating link adapter ................................. Lubricating the link tilt and PH-55 stabilizer bushing ...... Lubricating the elevator support and master bushing wear guide ................................................ Lubricating the wireline adapter ........................................ Lubricating the IBOP actuator yoke ................................. Lubricating the IBOP actuator crank ................................ Lubricating the torque arrestor tubes and clamp cylinder gate ........................................................... 31 32 32 32 34 35 35 35 35 36 36 36 38 38 38 39 40 41 Chapter 5 Maintenance General hydraulic system maintenance.............................. 43 Start-up procedure ...................................................... 44 Accumulator maintenance ................................................ 44 Chapter 6 Troubleshooting Troubleshooting the AC drilling motor ............................ Troubleshooting the AC blower motor ............................. Troubleshooting the hydraulic system ............................... Troubleshooting the AC drilling motor brakes......................................................... Troubleshooting the rotating link adapter (rotating head) motor ....................................................... Operation ................................................................... System test .................................................................. Troubleshooting the IBOP actuator cylinder .................... Operation ................................................................... System test .................................................................. 4 TDS-10S Maintenance and Troubleshooting 45 46 47 51 52 52 52 54 54 55 Troubleshooting the shot pin cylinder and clamp cylinder ............................................................ Operation ................................................................... System test .................................................................. Troubleshooting the counterbalance system ...................... Counterbalance testing ............................................... Stand jump testing ...................................................... Troubleshooting the hydraulic power unit (HPU) and reservoir ..................................................................... Operation ................................................................... System test .................................................................. 57 57 58 60 61 62 64 64 64 Chapter 7 Disassembly and assembly Precautions ....................................................................... PH-55 Pipehandler ........................................................... Disassembling the PH-55 Pipehandler ........................ Assembling the PH-55 Pipehandler ............................ Rotating link adapter ........................................................ Disassembling the rotating link adapter assembly ........ Assembling the rotating link adapter assembly ............ Transmission/motor housing ............................................ Removing the transmission/motor housing ................. Installing the transmission/motor housing .................. Disassembling the transmission/motor housing .......... Removing the bonnet and wash pipe .................... Removing the upper bearing retainer plate .................. Removing the AC drilling motor .......................... Removing transmission components ..................... Assembling the transmission/ motor housing ............................................................ Assembling the main body .................................... Assembling the main shaft .................................... Assembling the gears to the main body ................. Installing the AC drilling motor ............................ Installing the upper bearing retainer plate ............. Installing the wash pipe......................................... Checking the gear train backlash ........................... AC drilling motor disassembly/assembly ........................... AC drilling motor disassembly .................................... AC drilling motor assembly ........................................ Replacing the safety wiring ............................................... Safety wiring tips ........................................................ TDS-10S Maintenance and Troubleshooting 67 69 69 71 72 72 73 75 75 75 76 76 77 77 78 81 81 82 84 87 89 91 91 92 92 94 96 98 5 March 2, 1998 6 TDS-10S Maintenance and Troubleshooting Preface Manual conventions This manual contains conventions that make it easy for the reader to locate key information and detailed descriptions. Graphics illustrate descriptions of equipment and assemblies to provide a better understanding of the equipment and assemblies to provide a better understanding of the equipment’s functionality. Safety information Information pertaining to possible personnel injury and equipment damage appears throughout this manual and is formatted to draw the reader’s attention to important information, a warning, or a caution note. See the symbols below and pay close attention to these important advisories throughout the text. z e n Indicates advisories for operational or servicing procedures involving little or no risk of personal injury and equipment damage. Indicates advisories involving a risk of equipment damage. Indicates advisories involving a definite risk of injury to rig personnel. TDS-10S Maintenance and Troubleshooting 7 March 2, 1998 Avoid personal injury and equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment. Directional references References to the right or left and front or back of components described in this manual assume the perspective of the tool assembly–standing behind the tool as it faces well center. Illustrations Figures present a graphical representation of tool components for use in identifying parts or establishing nomenclature. Illustrations show measurements with inches (in.), followed by millimeters (mm). For more specific component information pertinent to your rig configuration, see the drawing index in the Drawings chapter to obtain the engineering drawing number. Manual layout This binder contains several separate chapters that you can remove individually for convenience. Varco service centers If you need technical assistance, see the back cover of this manual for a complete list of Varco’s Worldwide Service Centers. 8 TDS-10S Maintenance and Troubleshooting Chapter 1 Introduction Precautions To avoid serious injury or death, read and understand the following warnings before performing maintenance procedures: n n n Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual. Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards. Do not attempt any adjustments while the machine is moving. TDS-10S Maintenance and Troubleshooting 9 March 2, 1998 n n n n n 10 Use caution when draining lubricant. It can be hot. Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components. Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system. Do not attempt repairs you do not understand. Read and understand all safety precautions and warnings before performing maintenance procedures. TDS-10S Maintenance and Troubleshooting Chapter 2 Maintenance schedules Inspection schedules z The service intervals listed in Table 1 on the following page are based on average operating conditions. Use the schedule as a guide. Some conditions (excessive loadings, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent service intervals. TDS-10S Maintenance and Troubleshooting 11 March 2, 1998 Table 1. Inspection schedule Component Check for Frequency Gearbox/Hydraulic reservoir Oil level Daily Hardware and fittings Looseness Daily Wash pipe assembly Leaks Daily Main body Lubrication oil spray/flow Weekly AC drilling motor Louvers/screens Weekly Guide beam Hinge pin retainers Guide beam wear Weekly Upper stem liner Corrosion Monthly, or whenever the wash pipe packing is serviced Elevator link Eye diameter Monthly AC drilling motor brakes Wear and hydraulic leaks Monthly Main shaft Axial movement (end play) Every three months Accumulators (3) Charge Every three months Gooseneck Wear Every six months IBOPs Damage Whenever connections are broken Load bearing components Magnetic Particle Inspection (MPI) At three months or 1,500 hours on exposed surfaces At five years over entire surface Ultrasonic Inspection to be performed along with MPI 12 TDS-10S Maintenance and Troubleshooting Lubrication schedule Table 2. Lubrication schedule Component Fittings Type Frequency Wash pipe assembly 1 General purpose grease Daily Upper main body oil seal grease fittings 2 General purpose grease Daily General purpose grease Daily General purpose grease Daily General purpose grease Daily General purpose grease Weekly General purpose grease Weekly General purpose grease General purpose grease Weekly Weekly Link tilt General purpose grease Weekly Elevator support General purpose grease Weekly Master bushing wear guide General purpose grease Weekly Wireline adapter General purpose grease Weekly IBOP actuator yoke and pins IBOP actuator cranks 2 Stabilizer bushing Rotating link adapter grease fittings 3 Clamp cylinder gate Torque arrestor tubes –at clamp cylinder area –at clamp cylinder gate 2 4 AC drilling motor bearings 2 Chevron Black Pearl EP2 Three months AC blower motor 2 Chevron Black Pearl EP2 Three months Hydraulic pump motor 2 Chevron Black Pearl EP2 Three months Gear oil Three months Replace oil Replace oil filter Three months TDS-10S Maintenance and Troubleshooting 13 March 2, 1998 Lubricant specifications Selecting a lubricating/hydraulic oil Varco Top Drives operate under a wide variety of temperatures and conditions. The oil viscosity varies from quite thick at startup in cold climates to very thin in hot climates during difficult drilling conditions. Select gearbox lubrication based on the minimum ambient temperature to be expected before the next oil change. Introducing an oil viscosity greater than required by the ambient temperature could damage the gearbox due to reduced oil flow, or damage the oil pump with an excessive load. Use the following table to select the proper lubricant: e The TDS-10S uses the same lubricant for both the transmission and hydraulic reservoir. Table 3. Selecting a lubricating/hydraulic oil Minimum ambient temp Oil type required Varco P/N Below -15°F (-26°C) See note below See note below -15 to 35°F (-26 to 2°C) ISO 32 56008-1 20 to 65°F (-7 to 18°C) ISO 68 56008-2 40 to 85°F (4 to 29°C) ISO 100 56008-3 65 to 100° (18 to 38°C) ISO 150 56008-4 z 14 For minimum temperatures below -15°F, warm the TDS-10S up by rotating at a very light load and very slow speeds until the oil temperature is above -15°F. Contact your local Varco Service Center for specific instructions. TDS-10S Maintenance and Troubleshooting Selecting a lubricant Use Table 4 to select the appropriate lubricant for your specific application. Table 4. Recommended lubricants Lube Code and Description 1 General Purpose Grease Ambient temperature range Above -20˚ Below -20˚C Castrol MP grease - Chevron Avi-Motive Avi-Motive W Exxon Lidok EP2 Lidok EP1 Gulf Gulf Crown EP32 Gulf Crown EP31 Mobil Mobilux EP2 Mobilux EP1 Shell Alvania EP2 Alvania EP1 Statoil Uniway EP2N Uniway EP1N Texaco Multifak EP2 Multifak EP1 Total Multis EP2 Multis EP1 Union Unoba EP2 Unoba EP1 NGL1 2 1 AGMA - - ISO Viscosity Grade - - Use Chevron Black Pearl EP2 grease for all temperatures where applicable. TDS-10S Maintenance and Troubleshooting 15 March 2, 1998 16 TDS-10S Maintenance and Troubleshooting Chapter 3 Inspection Inspecting hardware and fittings Visually inspect the TDS-10S for loose or missing hardware and fittings daily. Make sure all lockwire is undamaged. TDS-10S Maintenance and Troubleshooting 17 March 2, 1998 Inspecting the AC drilling motor brakes Remove the brake housing covers to access the drilling motor brakes. Inspect the brake shoes for wear, and replace the shoes if worn below the allowable lining wear limit given by the manufacturer (approximately 3/32 in.). See the brake manual included in the Vendor Documentation Package for additional information. If the brake shoes are wearing unevenly, adjust the brake pads by adjusting the bolts on the brake calipers. Inspect the brake hydraulic lines for leaks. n Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard. Inspecting the AC drilling motor louvers Make sure that no AC drill motor louvers are missing or damaged. Make sure that the screens inside the louvers are clean and free of contaminates and allow for adequate ventilation. Inspecting the wash pipe assembly Visually inspect the wash pipe assembly daily for leaks. 18 TDS-10S Maintenance and Troubleshooting Inspecting the upper stem liner Use the following procedure to inspect the upper stem liner when replacing the washpipe assembly. 1. Remove the wash pipe packing (Figure 1). 2. Check the upper stem liner for erosion cause by leaking wash pipe packing and replace the liner if erosion is found. z The 3.875 in. OD polypack seal must also be replaced whenever the upper stem liner is replaced. Make sure the O-ring of the seal is facing down when the seal is installed on the liner. TDS-10S Maintenance and Troubleshooting 19 March 2, 1998 Wash Pipe Assembly Polypack Seal Upper Stem Liner Upper Stem Liner Polypack Seal Main Shaft Figure 1. Inspecting the upper stem liner 20 TDS-10S Maintenance and Troubleshooting Inspecting main shaft end play Use the following procedure to check for main shaft end play: 1. Remove the wash pipe packing. 2. Check the main shaft axial movement by applying an upward force to the main shaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 to .002 in., remove the upper bearing retainer plate and adjust the number of shims under the bearing retainer plate as required to allow .001 to .002 in. of axial shaft movement (end play) with the retainer plate cap screws tightened to 250-270 ft lb. z z Align the shims so that the upper bearing lube tube bore is not blocked. Refer to Installing the upper bearing retainer plate in the Disassembly and assembly section of this book for further details on this adjustment. TDS-10S Maintenance and Troubleshooting 21 March 2, 1998 Inspecting the gearbox oil level With the drive motor and hydraulic system off, check to see that the oil level is at the middle of the sight glass located on the lube pump adapter plate mounted on the side of the gearbox. z z Oil level is identified by three sight glasses. Oil level should be at the top of the upper sight glass. Always check the oil level after the unit has been running and the transmission oil is warm. Look for oil level (oil is dark brown); not foam level (foam is tan). Inspecting the guide beam Inspect the guide beam components weekly. Verify that the hinge pins and retainer pins are in place. Re-torque tieback clamp nuts. Inspecting the IBOPs z 22 Upper and lower safety valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the safety valves on a frequent basis. Read and use the safety valve inspection procedures described in the IBOP Service Manual included in this manual. TDS-10S Maintenance and Troubleshooting Inspecting the pipehandler Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire or cotter pins were removed during repairs, replace them immediately. Inspect the hinge pins and retainer bolts daily to make sure they are not separating from the pipehandler. Make sure the hinge pins are not loose because of excessive wear in either the bore of the gate or clamp body. TDS-10S Maintenance and Troubleshooting 23 March 2, 1998 Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items. z NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection (MPI), ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity. Inspecting the elevator link eyes Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare the measurements with the Wear Chart (Figure 2) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link. 24 TDS-10S Maintenance and Troubleshooting Upper Eye (Hook) C , C Wear Chart - Forged Links Upper Eye Dimension C Lower Eye Dimension A Capacity (Per Set) In Tons , B = 2-7/8 in., 250 Ton 5 4-7/8 4-5/8 4-3/8 2-1/4 2-1/8 2-1/16 1-3/4 250 210 188 137 B B B = 3-1/2 in., 350 Ton 5 4-13/16 4-5/8 4-7/16 2-3/4 2-9/16 2-3/8 2-3/16 350 300 225 175 , A To Determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link. A Lower Eye (Elevator) Figure 2. Visual inspection of elevator links TDS-10S Maintenance and Troubleshooting 25 March 2, 1998 Inspecting the drive stem Regularly inspect and measure the drive stem/main shaft for wear. Determine inspection frequency according to API Recommended Practice 8B, Section 2 for power swivels and power subs. Varco recommends the use of API RP 7G and API RP 8B as guidelines for interpreting and performing inspections. Measurement techniques are specified in API RP 7G, Section 10. Use API Bulletin 5T1 to identify and define imperfections found during inspections. 26 TDS-10S Maintenance and Troubleshooting Magnetic particle inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a MPI of the exposed surfaces of all load bearing components and load collar grooves to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are a cause for replacing the suspect component. After approximately five years or 15,000 operating hours, depending on the severity of operating conditions, Varco recommends performing a MPI of all load bearing components over the entire surface (including internal bores) to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are a cause for replacing the suspect component. The load bearing components are: ❏ Bail ❏ Rotating link adapter ❏ Main body casting ❏ Landing collar ❏ Main shaft ❏ Upper and lower IBOPs ❏ Saver sub ❏ Elevator ❏ Elevator links Details on MPI Inspection procedures are in the following publications: ❏ ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings ❏ ASTM E-709, Standard Recommended Practice for Magnetic Particle Inspection ❏ I.A.D.C., Drilling Manual, 9th Edition TDS-10S Maintenance and Troubleshooting 27 March 2, 1998 Ultrasonic inspection In addition to MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capacity of the part. Any subsurface irregularity can also compromise a component’s integrity. Details on Ultrasonic Inspection procedures are in the following publications: ❏ I.A.D.C., Drilling Manual, 9th Edition ❏ ASTM A-388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings z 28 Upper and lower safety valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the safety valves on a frequent basis. Read and use the safety valve inspection procedures described in the IBOP Service Manual included in this manual. TDS-10S Maintenance and Troubleshooting Inspecting the hydraulic system n Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury. Avoid injury by discharging the three accumulators and relieving pressure before disconnecting hydraulic lines. Always search for hydraulic leaks with a piece of cardboard or wood-not with your bare hands. Get immediate medical attention for hydraulic fluid injuries. Fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Do not tighten hydraulic fittings while they are under pressure. Inspect the hydraulic system weekly for leaks at fittings, damaged hose covers, kinked or crushed hoses, hard or stiff hoses, and damaged or corroded fittings. In addition, during the inspection, tighten or replace any leaking port connections, and clean any dirt buildup from hydraulic components. e Keep in mind that a loss of hydraulic oil is also a loss of gear lubrication Inspecting the electrical system Periodically, depending on severity of service, check all electrical lines, connectors, and related electrical hardware for loose connections and damage, and replace components and tighten connections as necessary. Also, inspect electrical sensors for exterior damage and replace components as required. TDS-10S Maintenance and Troubleshooting 29 March 2, 1998 30 TDS-10S Maintenance and Troubleshooting Chapter 4 Lubrication Introduction The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, etc., may require more frequent lubrication. Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Be careful not to over lubricate parts. For example, too much grease forced into a fitting can pop out a bearing seal. Over lubrication can also affect safety since over lubricated parts can drip, creating a potential slipping hazard for personnel. TDS-10S Maintenance and Troubleshooting 31 March 2, 1998 Lubricating the AC blower motor bearings Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings. Apply grease every three months to the grease fittings for the bearings in the AC blower motor located on top of the AC drilling motor, and to the grease fittings for the bearings in the AC motor that powers the hydraulic system. All fittings are located on the ends of the motor. After greasing, remove the fittings and reinstall the plugs. Lubricating the hydraulic pump AC motor Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings. Apply grease every three months to the grease fittings for the bearings in the hydraulic pump AC motor located on top of the AC drilling motor, and to the grease fittings for the bearings in the AC motor that powers the hydraulic system. All fittings are located on the ends of the motor. After greasing, remove the fittings and reinstall the plugs. Lubricating the AC drilling motor bearings Use the following procedure to lubricate the AC drilling motor bearings at the locations indicated every three months with the shaft stationary and the motor warm. 1. Locate the grease inlet at the top of the motor frame (Figure 3). 2. Clean the area and replace the 1/8 in. pipe plug with a grease fitting and remove the grease drain plug located opposite the grease inlet. 3. Repeat steps 1 and 2 for the bottom of the motor frame 32 TDS-10S Maintenance and Troubleshooting 4. Add grease to the bearing with a manual grease gun. The motor manufacturer’s manual located in the Vendor Documentation Package, contains information on the proper amount and type of grease to use. 5. Clean any excess grease from the grease drain and replace the pipe plugs at the inlet and the drain. 0.375" Drain Hole Grease Inlet For .125-27 NPT Grease Fitting AC Drilling Motor Grease Inlet For .125-27 NPT Grease Fitting 0.375" Drain Hole Figure 3. Lubricating the AC drilling motor TDS-10S Maintenance and Troubleshooting 33 March 2, 1998 Lubricating the wash pipe assembly Apply grease daily to the wash pipe assembly grease fitting with the mud pump shut off (Figure 4). Grease Fitting Washpipe Assembly Upper Main Body Oil Seal Grease Fittings Figure 4. Lubricating the wash pipe assembly 34 TDS-10S Maintenance and Troubleshooting Lubricating the upper main body oil seals Apply grease daily to the two grease fittings for the main body upper oil seals located inside the bonnet. z Grease the main body oil seals daily to prevent abrasive drilling mud from leaking into the main body. Replacing the gearbox oil Initial oil change Drain and refill the gearbox after the first four weeks, or 500 hours of operation, whichever comes first. Replace the oil filter when changing the oil. z After every oil change, check for proper lubrication oil flow. Oil capacity The TDS-10S main body holds approximately 17-19 gallons of oil. Always fill the transmission to the middle of the upper sight glass. Use the following procedure to fill the transmission for the first time: 1. Use a hand pump to fill the gearbox to the top of the sight glass (approximately 17-19 gallons). 2. Operate the TDS and hydraulic systems 10-15 minutes and then check the sight glass. 3. If the oil level is below the middle of the sight glass, add more oil until the level reaches the middle of the sight glass. TDS-10S Maintenance and Troubleshooting 35 March 2, 1998 Replacing the gearbox oil filter Replace the gearbox oil filter at the same time the oil is changed. The filter is located on a bracket attached to the carriage. Lubricating the carriage and guide beam Apply a thin film of grease to the running surfaces of the guide beam once a week. Lubricating the rotating link adapter Apply grease weekly to the three grease fittings on the rotating link adapter (Figure 5). 36 TDS-10S Maintenance and Troubleshooting Rotating Link Adapter 250 TON Grease Fitting Grease Fitting Front L H J A4 B4 E5 Rotating Link Adapter J E6 E6 G6 B8 G6 A4 G5 B4 Grease Fittings E5 H Back Figure 5. Lubricating the rotating link adapter TDS-10S Maintenance and Troubleshooting 37 March 2, 1998 Lubricating the link tilt and PH-55 stabilizer bushing Apply grease to the four link tilt grease fittings weekly. Lubricate the stabilizer bushing daily. Lubricating the elevator support and master bushing wear guide Apply grease to the seven fittings on the elevator support weekly. The master bushing wear guide has four fittings. Lubricate weekly. Inspect the guide ring periodically for wear or damage and replace it as necessary. Lubricating the wireline adapter Apply grease to the wireline adapter weekly. The wireline adapter has one fitting. Inspect the sheaves periodically for wear or damage and replace as necessary. 38 TDS-10S Maintenance and Troubleshooting Lubricating the IBOP actuator yoke Apply grease to the five grease fittings on the IBOP actuator daily (Figure 6). IBOP Actuator Cylinder Grease Fitting (2) IBOP Actuator Yoke Upper IBOP Actuator Shell Figure 6. Lubricating the IBOP actuator yoke TDS-10S Maintenance and Troubleshooting 39 March 2, 1998 Lubricating the IBOP actuator crank Apply grease daily to the two IBOP actuator crank grease fittings (Figure 7). Closed Position Open Position Actuator Arm Groove Actuator Shell Crank Arm Grease Fitting Upper IBOP Valve Figure 7. Lubricating the IBOP actuator crank 40 TDS-10S Maintenance and Troubleshooting Lubricating the torque arrestor tubes and clamp cylinder gate Apply grease with a brush to the torque arrestor tubes and apply grease to the four clamp cylinder gate fittings weekly (Figure 8). Torque Arrestor Grease Fitting (2) Grease Locations (Each side) Clamp Cylinder Gate Grease Fittings (Each side) Figure 8. Lubricating the torque arrestor tubes and clamp cylinder gate TDS-10S Maintenance and Troubleshooting 41 March 2, 1998 42 TDS-10S Maintenance and Troubleshooting Chapter 5 Maintenance General hydraulic system maintenance n n e Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Allow several minutes after the hydraulic system is turned off prior to attempting any service which would involve opening hydraulic lines. Hydraulic oil under pressure can penetrate skin and cause serious injury. Before opening hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel. Use care when handling components to prevent nicking close tolerance finishes. TDS-10S Maintenance and Troubleshooting 43 March 2, 1998 Start-up procedure e Only operate the hydraulic system when the TDS-10S is in the vertical position. Perform the following start-up procedure whenever restarting a hydraulic system in which a motor or pump has been removed and reinstalled: 1. Inspect all hydraulic system components (reservoir, hoses, valves, fittings, etc.) to make sure they are clean prior to filling with fluid. 2. Fill the gear case oil reservoir with the recommended lubricating oil passed through a 10 micron (nominal, no bypass) filter. 3. Check the oil level and add filtered fluid if necessary. 4. Jog start the AC drilling motor to verify correct rotation direction. Accumulator maintenance The Vendor Documentation Package contains the accumulator manufacturer’s instructions for the TDS-10S hydraulic accumulators (Bulletin SB1630-M1). This bulletin contains all necessary maintenance, removal and replacement, and precharging instructions for the TDS-10S accumulators. 44 TDS-10S Maintenance and Troubleshooting Chapter 6 Troubleshooting Troubleshooting the AC drilling motor Refer to the AC motor manufacturer service manual in the Vendor Documentation Package. TDS-10S Maintenance and Troubleshooting 45 March 2, 1998 Troubleshooting the AC blower motor The AC blower motor is located on top of the AC drilling motor. The Table 5 describes problems, probable causes and remedies. Table 5. Troubleshooting the AC blower motor Problem Probable cause Remedy Mechanical noise in blower. Loose impeller. Reinstall impeller and hub with threadlocking compound on screws. Faulty motor bearings. Repair or replace as needed. Faulty or loose wiring. Locate and repair as needed. Faulty motor starter. Check for dirt or trash between starter coil. Repair or replace as needed. Broken service loop conductor. Use spare service loop conductor. Blower runs intermittently. Motor overheating, overtemp Incorrect blower rotation. alarm stays on with blower running. Broken service loop conductor. 46 TDS-10S Maintenance and Troubleshooting Verify blower rotation correct. Use spare service loop conductor. Troubleshooting the hydraulic system The following hydraulic troubleshooting section provides a schematic diagram and description for each TDS-10S hydraulic circuit. Following each schematic is a group of troubleshooting charts to help you quickly locate and correct hydraulic system problems. When performing hydraulic troubleshooting, be aware that: ❏ The electrical control system can be bypassed for troubleshooting by manually overriding the solenoid valve for each operational system. n Alert all personnel near the top drive before overriding a solenoid valve. When you override a solenoid valve, you bypass the safety interlock and top drive components will move possibly causing serious injury or death. ❏ Test points shown in the hydraulic schematic with a box (e.g., A4) can be found on the manifold under the main body. There are also test points on the rotating link adapter motor. ❏ The system is preadjusted. Hydraulic problems are usually related to faulty valves, contamination, or other damage to the system rather than misadjustments. Changes to adjustments should be made only after all other possible causes have been eliminated. ❏ Table 6 identifies the schematic symbols used in this section. TDS-10S Maintenance and Troubleshooting 47 March 2, 1998 Table 6. Hydraulic schematic symbols Description Solenoid Operated Valves Symbol A Schematic Reference B 2 Position 4 way Valves (Single Solenoid) SV1, SV4, SV5, SV8, SV9 P A T B 3 Position 4 way Valves (Double Solenoid) SV2, SV6 P Manual Valve (Rotary) T A B 3 Position 4 way Valve MV P T Pump Fixed Displacement 1 Pressure Relief Valves RV2, A2R, B2R, SJR Standard Valve 2 3 Ventable Relief Valve Differential Unloading Valve 2 RV1 UV1 Pressure Reducing Valve PC1, PC4 Pressure Reducing/Relieving Vavle PCC Check Valve 48 1 TDS-10S Maintenance and Troubleshooting CDF, CTF, CV2, CTR, CDR, CXCD Prefill valve assembly CV1, CV2 Table 6. Hydraulic schematic symbols (continued) Description Symbol Schematic Reference Pilot-To-Open Check Valve CKCB (Link Tilt) Pilot-To-Close Check Valve CA6, CB6, CV3, CV4 (Clamp Body) 1 3 Cavity Plug PC5 2 Internal Plug Non Adjustable Flow Control Valves CV1 Non Adjustable Orifice Diameter in Inches 3 Port (Internal Drain) CBCA (Link Tilt Circuit) 4 Port (Internal Drain) CWCK (Link Tilt Circuit) Counterbalance Valves Logic Cartridges LA6, LB6, LC5, LODC Logic Cartridge With Metering See Prefill Assembly Quick Disconnect Coupling TDS-10S Maintenance and Troubleshooting 49 March 2, 1998 Table 6. Hydraulic schematic symbols (continued) Description Symbol Schematic Reference Non Bypass Filter See Lube Oil Circuit Filter With Bypass See Return Circuit Manual Shutoff Valve Thermostat Lube Oil Circuit Pressure Switch Lube Oil Circuit Heat Exchanger Hydraulic Circuit (Inside Brake Housing) Pressure Compensator Control Part of the Pump Hydro-Pneumatic Accumulator Hydraulic Motor (Bi-Directional) Hydraulic Cylinder Tank (Reservoir) Test Point 50 TDS-10S Maintenance and Troubleshooting Troubleshooting the AC drilling motor brakes The AC drilling motor brakes are spring released and hydraulic pressure applied at 2,000 psi. The solenoid valve operates to apply pressure, setting the brakes, or stop pressure to release the brakes. Table 7. Troubleshooting the AC drilling motor brakes Problem Probable cause Remedy Brake does not release. Directional valve is stuck. Test the valve and replace if necessary. Brakes release but still drags. Check valve is blocked or the Replace the check valve or tube is pinched. tube as required. Mechanical problems with brakes. Repair the brake mechanism. Brakes do not engage or slip. There is hydraulic oil on the Check for hydraulic leaks brake pads. and repair. Delay in the brakes actuating The hydraulic oil is contaminated. after the console switch is turned on. Replace the hydraulic oil. The pressure reducing valve is faulty. Replace the valve. To test the system, turn the AUTO BRAKES switch on the driller’s console to the ON position. Attach a pressure gauge to B1 in the manifold. The pressure reading should be 2,000 psi. Turn the AUTO BRAKES switch to the OFF position. The pressure reading should be very low. If the pressure is high, the solenoid valve could be sticking. TDS-10S Maintenance and Troubleshooting 51 March 2, 1998 Troubleshooting the rotating link adapter (rotating head) motor Operation The three position directional valve controls the direction of the rotating head to the left or right. The pressure is applied to the A or B port of the hydraulic motor, depending on the selected direction. The auto return function is controlled by the processor and returns the tool to the home position. System test To test the system, operate the rotating head switch on the control panel. Verify both directions of rotation. The rotation speed is limited by the nonadjustable orifice. The torque is limited by the two relief valves. z 52 The 1,600 psi test pressure at ports A and B is maximum load pressure. If the rotating link adapter is free to rotate, the load pressure will be less than maximum. The shot pin must be engaged to achieve full load pressure. TDS-10S Maintenance and Troubleshooting Table 8. Troubleshooting the rotating link adapter (rotating head) motor Problem Probable cause Remedy Tool does not rotate. Direct control valve or relief valve is sticking. Inspect, repair or replace the valve. Look for pressure changes when solenoid is energized. If there is no pressure change, try the manual overide on the valve. you overide a directional n When valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death. Solenoid valve is not electrically operating. Check the electrical connections and valve functions. Motor is worn out or gear teeth are broken. Replace the motor. Shot pin is engaged. Adjust the relief valve. Mechanical interference. Inspect and repair. Directional valve does not shift. Test pressure the left and right. Replace the valve. Fixed valve orifice is plugged. Clear the orifice or replace the valve. Hydraulic lines are damaged. Replace the hydraulic lines. TDS-10S Maintenance and Troubleshooting 53 March 2, 1998 Troubleshooting the IBOP actuator cylinder Operation The IBOP is in the open position under low hydraulic pressure, A4 = 500 psi, B4 and C4 = less than 100 psi. When you close the IBOP, high pressure is applied to the cylinder. A4 is less than 100 psi; B4 and C4 are 2000 psi. When the solenoid is deenergized, for opening the IBOP, A4 goes to 500 psi after a small time delay. B4 is less than 100 psi and C4 reaches 2,000 psi after a small time delay. The time delay is operated by the time delay accumulator. Table 9. Troubleshooting the IBOP actuator cylinder Problem Probable cause Remedy Safety valve leaks. Internal parts are worn out. Check for washouts or defective parts and repair or replace as needed. Actuator is not functioning properly. Check the mechanical operation of actuator. Check the reducing valves. Excessive vibration or wobble Yoke bushings or actuator while rotating. bushings are worn out. Cylinder does not actuate. Replace the bushings. Worn cam rollers. Repair or replace the rollers and roller brackets. Pressure reducing valve plugged orifice. Test pressures and adjust or replace the pressure reducing valve. Accumulator is not charged. Test the accumulator pressure and charge as required. No system pressure. 54 TDS-10S Maintenance and Troubleshooting Check the hydraulic system operation. System test Refer to the hydraulic circuit schematic in the Technical Drawing book for the IBOP actuator cylinder. The IBOP is normally open. n Alert all personnel near the shot pin, clamp, and rotating head before overriding a directional valve. When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death. To test the system, engage the IBOP and measure the pressure at B4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open the IBOP and test the pressure at A4, which increases to 2,000 psi. The pressure at B4 and C4 drops to 500 psi. TDS-10S Maintenance and Troubleshooting 55 March 2, 1998 11.5 IN^ 3 500 PSI PRECHARGE N07 IBOP CLOSE A B P T b N12 A4 SV4 D03 B4 .055Ø FC4 T-13A 2 500 PSI T-11A PC4 1 C4 .016Ø 3 1 30 PSI 2 2 3 4 1 400 PSI T-21A A4 B4 SQ4 A4 B4 A4 B4 OPEN CLOSE Hydraulic Cylinder IBOP ACTUATOR CYLINDER 2.500 DIA. BORE X 2.00 STROKE 1.375 DIA. DOUBLE ROD Figure 9. Hydraulic circuit for the IBOP actuator cylinder 56 TDS-10S Maintenance and Troubleshooting Troubleshooting the shot pin cylinder and clamp cylinder Operation The shot pin cylinder and clamp cylinder operation are interrelated and complex. The shot pin cylinder is different in that it has an extra port called the barrel port. The barrel port is back from the end of stroke which creates a valving effect. When the shot pin and clamp cylinders are not activated, the shot pin is fully retracted with full pressure and the clamp cylinder is retracted with 500 psi. When you energize the clamp cylinder, the shot pin cylinder is actuated against the rotating gear and it may miss one of the 24 holes. The control system starts pulsing the rotating head to move slowly until the shot pin engages a hole on the rotating gear. The shot pin cylinder pressure is limited by the relief valve until the cylinder passes through one of the holes. Once the pin engages the hole, full system pressure is applied to C5 which opens valve CV5, applying full pressure to the clamp cylinder to close. When the clamp cylinder is de-energized, the clamp releases and the shot pin pulls out. TDS-10S Maintenance and Troubleshooting 57 March 2, 1998 System test At rest, the pressure at C5 is 2,000 psi, B5 is less than 100 psi, CP is less than 100 psi, and CR is 500 psi. n Alert all personnel near the shot pin, clamp, and rotating head before overriding a directional valve. When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death. When you energize solenoid valve SV5, using the manual override, pressure increases to the barrel of the shot pin cylinder. The pressure is controlled by a .031 pressure reducing valve that prevents the shot pin from putting full force on the rotating head surface until the pin engages in one of the holes. Pressure at B5 is 200 psi (limited by the relief valve), C5 is less than 100 psi, G5 is less than 100 psi, CP is less than 100 psi, and CR is less than 100 psi. Once the shot pin engages the hole, full pressure is applied in C5 to control valve CV5 open for clamp. Pressure at B5 is 2000 psi, C5 is 2000 psi (forces valve CV5 open for clamp), G5 is less than 100 psi, CP is 2,000 psi, and CR is less than 100 psi. When solenoid valve SV5 is de-energized, the shot pin cylinder withdraws the shot pin, and the clamp disengages at the same time. The circuit returns to rest conditions. 58 TDS-10S Maintenance and Troubleshooting Table 10. Troubleshooting the shot pin cylinder and clamp cylinder Problem Probable cause Remedy Shot pin does not engage. Solenoid valve is not operating or Check the electrical actuation relief valve is not adjusted. and test pressure. Adjust as required. Abnormal pressure change at B5 Replace the directional control and C5 indicates valve problem. valve. Normal pressure change indicates plumbing or shot pin cylinder are faulty. Shot pin applies excessive Relief valve is not operating or out of adjustment. force to rotating head gear. Repair the plumbing or shot pin cylinder. Test pressures and adjust as required. Clamp cylinder does not No pressure or reduced pressure Test pressures and adjust and actuate. at the cylinder. repair as required. Cylinder is damaged. provide high pressure to the z To clamp circuit, pressure at C5 Inspect the cylinder and repair or replace. Repair plumbing, rotating head, or clamp cylinder. must be 2,000 psi 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 head, and clamp cylinder. While clamping, pressure at CR Clean or repair the CNEC valve. should 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. Control valve not operating. Shot pin engages but clamp cylinder does not activate. Check the pressure at C5. Replace valve CV5 if required or the regenerate manifold. TDS-10S Maintenance and Troubleshooting 59 March 2, 1998 Troubleshooting the counterbalance system The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a hydraulic pressure. Refer to the manufacturer's documentation in the Vendor Documentation Package for the gas charging procedure for the accumulator. A three-position manually operated valve controls counterbalance operation for rig-up, run, and shut down modes. In the rig-up mode, system pressure is applied to XC and the prefill valve, causing both cylinders to extend. When the cylinders extend, you make up the mechanical connection to the bail. In the run mode, for counterbalance operation, approximately 1,600 psi is needed at the counterbalance cylinders to lift the TDS-10S off the hook. Stand jump operation is controlled by solenoid valve SV9. With the counterbalance in the run mode and the stand jump switch on, additional pressure of approximately 300 psi is applied to over the normal counterbalance pressure to lift the TDS-10S and drill string off the hook. In the shutdown mode, the hydraulic system bleeds down the system accumulator and the counterbalance accumulator pressure. 60 TDS-10S Maintenance and Troubleshooting Counterbalance testing For the counterbalance operation, a lift of approximately 30,000 lb is achieved with a pressure of 1,600 psi at CB. Perform the following steps to adjust the force: 1. Set the COUNTERBALANCE MODE switch to the RUN mode. Set the pressure control valve PCC to the minimum setting (fully counterclockwise). 2. Test the pressure at port B9. There should be a 0 psi reading. 3. Test the pressure at port CB. Observe the position of the top drive on the hook. 4. Adjust the pressure at pressure control valve PCC clockwise, observing pressure at CB, until the top drive just lifts off the hook. Back off the pressure 25 psi, as the top drive rests on the hook. TDS-10S Maintenance and Troubleshooting 61 March 2, 1998 Stand jump testing For the stand jump operation, a lift of about 33,000 lb is achieved with a pressure of approximately 1,800 psi at CB. The additional 300 psi pressure over the normal counterbalance pressure is provided by energizing the stand jump solenoid valve SV9. Perform the following steps to adjust the pressure: 1. Set the counterbalance mode switch to Run and engage the stand jump switch. Test the pressure at port CB and B9. Adjust relief valve SJR fully counterclockwise to the minimum setting. 2. 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. z 62 Adjust relief valve SJR slowly to allow pressure at CB to stabilize. TDS-10S Maintenance and Troubleshooting Table 11. Troubleshooting the counterbalance system Problem Probable cause Remedy Counterbalance does Cylinder damaged. Seal leaks. not function. Inspect the cylinder and repair or replace the seal. No hydraulic pressure. Test the pressure and adjust the pressure reducing valve. Solenoid valve SV9 is not operating. Test the electrical and hydraulic operation. Replace or repair as applicable. PCC is not operating. Replace the valve. Relief valve is not operating. Replace the valve. Precharge on accumulator is low. Charge the accumulator. Stand jump does not Cylinder damaged. Seal leaks. function. Inspect the cylinder and repair or replace the seal. No hydraulic pressure. Test the pressure and adjust the pressure reducing valve. Solenoid valve SV9 is not operating. Test the electrical and hydraulic operation. Replace or repair as applicable. PCC is not operating. Replace the valve. Relief valve is not operating. Replace the valve. Precharge on accumulator is low. Charge the accumulator. TDS-10S Maintenance and Troubleshooting 63 March 2, 1998 Troubleshooting the hydraulic power unit (HPU) and reservoir Operation Figure 10 shows the onboard HPU schematic. A 10 hp electric motor drives the fixed displacement pump. The fixed displacement pump provides hydraulic power to operate the lubrication pump motor. Pressure can be tested at port PF. Relief valve RV2 limits the driving pressure of the lube oil circuit. System test Test the circuit pressure at port PV. Relief valves RV1 and UV1 are a part of the circuit. UV1 is a differential unloading valve, which can be pressure checked at port Z1. RV2 is set at 400 psi and can be tested at PF. Test the pressure at PV to confirm the relief valve RV1 is set at 800 psi. The differential unloading valve UV1 is tested at Z1 to confirm the pressure is 2,000 psi. 64 TDS-10S Maintenance and Troubleshooting IN 10 Micron No Bypass Out 30 PSI N08 PF Y1 D .062Ø .205Ø .059Ø .047Ø 1.0 GPM Upper Compound Gear M 10 HP 1200 RPM 1.5 GPM 1.40 in3/rev Lower Compound Gear Upper Mainshaft Bearing Lower Radial/Main Thrust Bearings Upper Compound Bearing Lower Compound Bearing Figure 10. Hydraulic circuit for the HPU and reservoir TDS-10S Maintenance and Troubleshooting 65 March 2, 1998 Table 12. Troubleshooting the hydraulic power unit (HPU) and reservoir Problem Probable cause Remedy Hydraulic system overheating. Relief valves out of adjustment. Test the pressures and adjust the relief valves. Unloading valve is not working. Test and adjust the UV1 or replace the unloading valve. Counterbalance mode valve left in shut down position too long and pressure bleeds down. Check the system pressure. No precharge in system accumulator. Charge the system accumulator. System pressure is down. Test the pump and motor. Test the relief valve pressures. Adjust as required. Check for leaks, loose fittings, loose cylinders, worn hoses, fluid levels and seals. Flexible coupling is damaged. Replace the flexible coupling. Pressure at UV1 is too low. Adjust the pressure at UV1. Pump is rotating in the wrong direction. Inspect the hydraulic connections and correct rotation. Low oil level in reservoir. Fill the hydraulic reservoir. Hydraulic components do not operate. 66 TDS-10S Maintenance and Troubleshooting Chapter 7 Disassembly and assembly Precautions e Only authorized Varco repair technicians should perform the following major disassembly and assembly procedures. e Transport hydraulic components to a clean, dust-free service area before disassembling for service. TDS-10S Maintenance and Troubleshooting 67 March 2, 1998 z Disassembly procedures are usually performed when replacing damaged components that are causing a tool function to fail. Whenever performing a disassembly, practice preventive maintenance by: ❏ Cleaning and inspecting all disassembled parts. ❏ Replacing all worn and damaged parts before they can cause another failure. ❏ Installing thread protectors on exposed threads. e 68 Torque all fasteners to the limits given in DS00008 (Design Specification Design Torque Standard), located in the Supplemental Materials book, unless an alternative torque value is given in the procedure. TDS-10S Maintenance and Troubleshooting PH-55 Pipehandler Disassembling the PH-55 Pipehandler Remove the PH-55 Pipehandler to service the following components: ❏ Stem ❏ Stem seals ❏ Rotating link adapter upper and lower wear bushings ❏ Rotating link adapter rotary seals n n z z Release all hydraulic oil pressure before disconnecting hydraulic lines. Hydraulic oil under pressure can penetrate skin and cause serious injury. Before opening the hydraulic system, thoroughly clean the work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel. To protect the rotating link adapter seals and inner surfaces, remove the stem along with the rotating link adapter. Contact the nearest Varco Service Center for details about building an appropriate stand for removing the rotating link adapter. TDS-10S Maintenance and Troubleshooting 69 March 2, 1998 Use the following procedures to disassemble the pipehandler: 1. Remove the elevator links and the elevator. 2. Disengage and remove the shot pin. 3. Disconnect the hydraulic lines and cap all connections. 4. Remove one of the backup clamp cylinder gate hinge pins and open the gate. z The link tilt brackets remain attached to the links. 5. Remove the two pins that attach the link tilt crank to the link tilt lever. 6. Remove the pin attaching the torque arrestor to the rotating link adapter and remove the torque arrestor with the clamp cylinder assembly. 7. Remove the upper IBOP crank assembly. 8. Remove the lower tool joint lock. 9. Remove the intermediate joint lock. 10. Remove the IBOP actuator shell. 11. Remove the upper tool joint lock. 12. Remove the saver sub, lower IBOP, and upper IBOP. 13. Remove the pipe plug from the stem flange and drain the transmission oil from the housing. 14. Lower the top drive until the bottom of the rotating link adapter just rests on a stand or blocks. 15. Remove the landing collar assembly from the main shaft. 16. Remove the screws holding the rotating link adapter to the main housing. 17. Raise the top drive slowly, leaving the rotating link adapter on the stand or blocks. 70 TDS-10S Maintenance and Troubleshooting Assembling the PH-55 Pipehandler Use the following procedures to assemble the pipehandler: 1. Install the new main shaft seals inside the stem bore. e Always install new main shaft seals and use care not to damage seal lips or case. 2. Install the new O-rings on the stem flange. 3. Grease the walls of the bore in the main body, the stem main shaft seals, and the O-rings on the rotating link adapter assembly. 4. Position the rotating link adapter assembly, supporting it with the same stand or block used in the disassembly procedure. 5. Using three 5/8-11 UNC bolts, pull the rotating link adapter to the main body and completely seat the rotating link adapter into the bore. 6. Install screws to secure the rotating link adapter to the main body. 7. Replace the drain plug. 8. Install the upper IBOP, lower IBOP, and saver sub. 9. Install the upper tool joint lock and tighten the bolts to 180 to 190 ft lb. 10. Install the IBOP actuator shell. 11. Install the intermediate tool joint lock and tighten the bolts to 180 to 190 ft lb. 12. Install the lower tool joint lock. 13. Install the upper IBOP crank assembly. 14. Pin the torque arrestor to the rotating link adapter. z The link clamp assembly remains attached to the torque arrestor. 15. Position the drill pipe elevator and links, and pin the link tilt levers to the link clamp assemblies. 16. Close and pin the torque backup clamp cylinder gate. 17. Connect all hydraulic lines. TDS-10S Maintenance and Troubleshooting 71 March 2, 1998 Rotating link adapter Disassembling the rotating link adapter assembly Use the following procedures to disassemble the rotating link adapter assembly: 1. Remove the pipehandler as described above and transport the rotating link adapter assembly to a suitable work area. 2. Support the rotating link adapter assembly on a work table so that the link tilt crank hangs down. 3. Remove the hose assemblies, link tilt crank and the two cylinders. 4. Remove the lock wire and screws that hold the gear and stem assembly to the rotating link adapter body. 5. Attach three lifting slings symmetrically to the top of the stem flange and slowly raise the stem and gear assembly to separate it from the rotating link adapter body. 6. Set the stem and gear assembly on a suitably protected surface. e Protect the internal surfaces of the rotating link adapter body and the surfaces of the stem when separating the two components. When removing the rotating link adapter from the stem, carefully tap with a mallet to remove the rotating link adapter from the stem. There can be resistance from misalignment between the two bores when rasing the stem and gear assembly. 7. Prepare a work area to stand up the stem and gear assembly on the bottom surface of the stem. 8. Remove the retainer ring under the piston ring from the stem and gear assembly. 9. Remove the piston ring and the gear. This may require light tapping on top of the gear with the gear sitting on the piston ring. 72 TDS-10S Maintenance and Troubleshooting e The piston ring is assembled with a light press fit. Provide a support under the gear so that it does not drop when it breaks loose. 10. Remove and discard all rotary seals, o-rings, the thrust ring, and two wear bushings from inside the rotating link adapter and gear inside dimension. 11. Remove and discard the stem flange O-rings and stem bore shaft seals. Assembling the rotating link adapter assembly Use the following procedures to assemble the rotating link adapter assembly: 1. Orient the stem so the stem flange (top of the stem) is down on a suitably protected surface. 2. Install the gear with it's rotating seal and wiper in place. Note the orientation. 3. Install the o-ring for the piston ring. 4. Install the piston ring. It requires light tapping to press it into place. 5. Install the retainer ring. 6. Install all of the rotary seals on the rotating link adapter (nine of one size and one larger), and an o-ring on the top surface. 7. Install the two wear bushings and the thrust ring in the rotating link adapter. 8. Rest the rotating link adapter on its bottom surface. 9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the inside diameter of the rotating link adapter. TDS-10S Maintenance and Troubleshooting 73 March 2, 1998 10. Attach three lifting slings symmetrically through the holes on the top of the stem flange and slowly lower the assembly into the rotating link adapter body. e Make sure the seals do not twist in the grooves. 11. Line up the dowel pin holes and replace all of the screws and safety wire. 12. Install the link tilt cylinders; pin and secure in place. 13. Install the link tilt crank; pin and secure in place. 14. Install all hose assemblies. 15. Invert the rotating link adapter assembly so that the stem flange is up. 19. Install a new main shaft seal inside the stem bore with the seal lip facing up. e Always install a new mainshaft seal and use care not to damage the seal or the case. 20. Install new stem flange O-ring. z e 74 A light coating of grease applied to the O-ring helps in installing the rotating link adapter assembly into the TDS main body. Always install new stem O-ring and use care not to damage the O-ring or the case. TDS-10S Maintenance and Troubleshooting Transmission/motor housing Removing the transmission/motor housing Remove the transmission/motor housing to service the following components: ❏ Compound gear and bearings ❏ Main shaft ❏ Main thrust bearing ❏ Bull gear The AC drive motor can be removed with the TDS-10S left in place. To remove this component, skip to the applicable removal section below. To remove the transmission/motor housing: 1. Remove the PH-55 pipehandler components as described above. 2. Remove the saver sub and the lower and upper IBOPs. See the IBOP Service Manual, included in the Supplemental Materials book for the procedure. 3. Disconnect the service loop, rig down the tool, and transport the transmission/motor housing to a suitable work area. Installing the transmission/motor housing Perform the rig up procedures in the Installation chapter. TDS-10S Maintenance and Troubleshooting 75 March 2, 1998 Disassembling the transmission/ motor housing z Drain the oil from the transmission/motor housing before disassembling components. Removing the bonnet and wash pipe Use the following procedures to disassemble the transmission/ motor housing assembly upper component: 1. Remove the bail (see steps a through g). e An installation tool is required to safely remove the bail from the TDS-10S. a. Remove the bail retainers from the main body. b. Disconnect the counterbalance cylinders from the bail and main body cover. c. Attach two swivel lifting eyes (rated for 10,000 lb minimum), one on each side, 2 in. up from the bottom of the bail. d. Using shackles rated for 10,000 lb minimum, attach the swivel eyes to the installation tool. e. Tighten the nut on the turnbuckle shaft until the distance between the tips of the bail have increased by approximately 3.5 in. over the beginning position. f. The bail can be removed by leaving one end engaged in the pocket and rocking the other end around the pocket in the main body until it is fully clear. g. Move the bail until it is clear of the main body and then remove the installation tool. 2. Remove the wash pipe packing box assembly. 3. Remove the upper stem liner on top of the main shaft using the two pry points, and remove and discard the liner seal. 4. Remove the bearing shield from the top of the main shaft. 76 TDS-10S Maintenance and Troubleshooting Removing the upper bearing retainer plate Use the following procedures to remove the upper bearing retainer plate: 1. Remove the six cap screws and lockwashers that attach the bearing retainer plate to the main body cover and remove the plate. z Use the two jacking holes in the upper bearing retainer plate as required to help remove the plate. 2. Remove the lube tube from the lube tube bore of the cover, and remove the lube tube O-rings. 3. Remove and discard the two lip seals in the bearing retainer plate. 4. Remove the bearing retainer plate shims. 5. Remove the taper roller bearing outer race from the cover bore. Removing the AC drilling motor Use the following procedures to remove the AC drilling motor: 1. Remove the four nuts and tie rods between the brake adapter plate at the top of the motor, and the top of the main body cover. 2. Remove the four cap screws and lockwashers that attach the AC drilling motor to the main body cover. Attach handling gear to the brake end of the motor and lift the motor off the main body cover. The pinion hub separates from the pinion shaft as the motor rises. 3. Remove the O-ring that seals the AC drilling motor to the main body cover. TDS-10S Maintenance and Troubleshooting 77 March 2, 1998 Removing transmission components e Heat the bearings with an induction heater to facilitate bearing removal. Because this method heats quickly and could possibly damage bearings, always use a Tempilstik or pyrometer to monitor bearing temperature. Use the following procedures to disassemble the transmission/ motor housing: 1. Remove the oil reservoir by removing all but four attachment screws. Leave four screws (one on each edge) loosened approximately 1/8 in. Using screws to jack the reservoir apart, thread the screws into the threaded holes located around the reservoir flange. Tighten the screws until the sealant separates. Remove the last four screws after providing suitable support for the weight of the reservoir. 2. Mark, disconnect and plug all hoses attached to the hydraulic pump/motor assembly. Remove the hydraulic pump/motor assembly. Disconnect the electrical cable attached to the electric motor. 3. Remove the screws that attach the pump assembly to the main body cover. Use jack screws around the perimeter of the flange to remove the pump assembly. 4. Remove the cap screws that attach the cover to the main body. Use jack screws around the perimeter of the main body cover to separate the cover from the main body and remove the cover. 5. Remove the oil gallery O-rings. 6. Carefully lift the main shaft/bull gear assembly straight up. e When raising the main shaft, the main thrust bearing separates. Lift the main shaft slowly. 7. Use the lifting eye on the end of the compound shaft to lift out the compound gear. 78 TDS-10S Maintenance and Troubleshooting 8. Install a lifting eye in the bottom of the internal splined area and apply tension to remove the pinion gear. Remove all hoses that attach to the pinion shaft retainer. Remove the attachment screws and use jack screws, if necessary, to remove the pinion shaft retainer from the bottom side of the main body. Lower the pinion and bearing assembly out of the bottom of the main body. 9. Remove and inspect the main body orifices and the pipe plugs. e Do not use a steel hammer when removing the gears. It can damage components. 10. Remove the mainshaft upper wear sleeve by heating the sleeve to 250°F (121°C). Check the sleeve for wear after removing it. 11. Remove and discard the upper taper bearing inner race by heating the race to 250°F (121°C). z If replacing the bull gear, perform steps 12, 13, and 14. If not, proceed to step 15 and remove the bull gear along with the main shaft. 12. Remove the 10 lockwired cap screws that hold the bull gear in place. 13. Install two 5/8-11 UNC forged eyebolts in the bull gear pickup holes and heat the bull gear to between 150°F (66°C) and 200°F (93°C), then remove the bull gear by lifting the gear straight up off the alignment pin. 14. Inspect the bull gear alignment dowel pin, and remove and discard the pin if damaged. 15. Remove the main shaft wear sleeve by heating the sleeve to 250°F (121°C), then pulling the sleeve off shaft. Check the sleeve for wear grooves after it is removed. 16. Remove the lower radial bearing inner race by heating the race to 250°F (121°C), then pulling the race off the main shaft. TDS-10S Maintenance and Troubleshooting 79 March 2, 1998 17. Remove the main shaft sleeve by heating the sleeve to between 200°F (93°C) and 250°F (121°C) and pulling the sleeve off the shaft. 18. Remove half of the thrust bearing race, the bearings, and the cage of the thrust bearing. 19. Remove the other half of the thrust bearing race by heating the race to 200°F (93°C) and pulling the race off the main shaft. 20. Remove the four lockwired cap screws that hold the lower radial bearing ring retainers in place and remove the retainers. 21. Remove the outer race of the lower radial bearing from the bore in the housing with a bearing puller. 22. Remove the retainer nut and washer from the pinion shaft to separate the bearing from the pinion gear. Heat the bearing to 200°F (93°C) and pull the bearing from the shaft. 23. Heat the inner bearing races to 200°F (93°C) and pull it off the journals to remove the inner bearing races (cones) from the compound gear journals. 24. When replacing the thrust bearing or radial bearing inner race, turn the main shaft assembly upside down with the 6 5/8 in. pin connection pointed up. In order to turn the assembly upside down, raise the lower race of the thrust bearing until the rollers contact the upper race. Use two large C-clamps and clamp the lower race and rollers to the main shaft shoulder. Once the shaft is inverted, remove the clamps. e 80 Do not drop the races or rollers during this tipping over process. TDS-10S Maintenance and Troubleshooting Assembling the transmission/ motor housing e z Keep the transmission bearings, shafts, and housing free of chips, burrs, and dirt during the following assembly process to prevent damage to transmission parts. Varco strongly recommends replacing any bearing or gear where even the slightest wear is indicated. It is usually less expensive to replace any questionable parts found during disassembly than risk having to rebuilt the gearbox later. Assembling the main body Use the following procedures to assemble the main body: 1. Steam clean the main body, blowing out all passages (make sure all the plugs and spray nozzles are removed). Apply a protective coating, such as WD-40, to all unpainted internal surfaces. z Do not apply any thread sealant to the orifice. 2. Chill the outer race of the lower radial bearing to at least 0°F (-18°C), but no lower than -60°F (-51°C), then install the bearing into the bore of the main body. Immediately after installing the bearing, spray the bearing with WD-40 to prevent corrosion. e Do not use liquid nitrogen to cool parts. Temperatures below -60°F (-51°C) can affect the composition of certain metals and lead to the weakening of parts. 3. Install the two lower radial bearing ring retainers. 4. Apply an anti-seize compound to the threads of the four 1/2 in. hex-head cap screws that hold the bearing ring retainers in place, and install the cap screws and lockwashers in place. Tighten the cap screws in a star pattern to 71-79 ft lb. 5. Safety wire the cap screws with .047 in. diameter lockwire. 6. Turn the main body over. TDS-10S Maintenance and Troubleshooting 81 March 2, 1998 Assembling the main shaft 1. Remove any burrs, steam clean, and coat the main shaft with a protective coating such as WD-40. e C-clamps must be used when the main shaft assembly is inverted. 2. Restrain the main shaft in a vertical position with the bottom facing up (Figure 11). 3. Heat the upper race of the main thrust bearing to 200°F (93°C) and install the race on top of the 18 in. diameter load plate machined into the shaft. Rotate the race until it seats flat on the plate. 4. Install the thrust bearing’s roller bearings and cage and liberally apply oil to the bearing rollers. 5. Install the other half of the thrust bearing race. 6. Heat the lower radial bearing inner race to between 225°F (107°C) and 250°F (121°C) and install the race onto the main shaft sleeve by rotating the race until it seats. 7. Inspect the lower wear sleeve. If the sleeve shows signs of wear or damage, replace it. 8. Heat the wear sleeve to 250°F (121°C) and install the sleeve. 82 TDS-10S Maintenance and Troubleshooting Lower Race Rollers and Cage Tapered Roller Thrust Bearing Upper Race Heat to 200°F (93°C) Bottom End of Shaft Main Shaft Stem Shaft Shoulder 18" Diameter Load Plate Rest Top End of Shaft Figure 11. Assembling transmission/motor housing TDS-10S Maintenance and Troubleshooting 83 March 2, 1998 Assembling the gears to the main body 1. Reinstall the pipe plugs, orifices, and nozzles. Apply thread sealant (not Teflon tape) to the plugs and Loctite 232 Threadlocker (blue) to orifices and nozzles. 2. Ensure that the lower radial bearings and bearing ring retainers are installed before proceeding (see Assembling the main body). 3. Heat the inner races of compound (cones) bearings to 200°F (93°C) and install on each end of the compound gear. 4. Heat the pinion shaft bearing to 200°F (93°C) and install on the pinion shaft until the inner race shoulders against the pinion shaft. 5. Install the lockwasher and nut. Tighten the nut to 200 ft lb and continue tightening until the tab from the washer aligns with the slot. Bend the tab up into the slot. 6. Using a lifting eye installed in the bottom of the internal splined area, raise the pinion/bearing assembly from the bottom into the main housing. 7. Install the pinion shaft retainer using the six bolts. e Support the pinion shaft in a vertical attitude–do not allow it to tilt. Otherwise the bearing will bind when attempting to return the pinion shaft to vertical. 8. Loosely install the compound bearing retainer into the main body, leaving 3/16 in. gap between the mating surfaces of the retainer and the main body. 9. Install cups of compound bearings in the bores of the main body and main body cover. Chill 30°F if needed. 10. Position the compound gear in the main body using the lifting hole in the end of the compound gear to aid in handling. 84 TDS-10S Maintenance and Troubleshooting 11. Liberally apply oil to the lower radial bearing and inner race of same bearing. Before lowering the main shaft, slowly loosen the C-clamps until the lower race of the thrust bearing rests on the inner race of the main radial bearing. Remove the Cclamps. e Loosen the C-clamps slowly to prevent the rollers from fallong out. Lower the main shaft assembly through the main bore of the main body until both the main thrust bearing races contact the rollers and the main shaft rotates easily. 12. Heat the bull gear to between 150°F (66°C) and 200°F (93°C). Install two 5/8-11 UNC forged eyebolts in the gear pickup holes, making sure the stamping “TOP SIDE” is up. 13. Carefully lower the bull gear into position until it seats. If the old dowel pin has been removed, rotate the gear until the 1 in. dowel pin hole is aligned. z If the bull gear dowel pin has been removed, chill the new dowel pin to at least 0°F (-18°C), but no lower than -60°F (-51°C) as the bull gear is being placed into position. Then drive the dowel pin into the alignment hole using a bronze hammer. The pin will sit flush to 1/4 in. high. 14. Apply an anti-seize compound to the threads of the ten 1 in. hex-head cap screws that hold the bull gear in place, and install the cap screws and lockwashers in place. Tighten the cap screws in a star pattern to 610-670 ft lb. 15. Safety wire the cap screws with .051 in. diameter lockwire. 16. Heat the upper taper bearing inner race to between 225°F (107°C) and 250°F (121°C). Install the bearing rotating the race until it seats. 17. Inspect the upper wear sleeve. If the sleeve shows signs of wear or damage, replace it. 18. Heat the upper wear sleeve to between 200°F (93°C) and 250°F (121°C). Install the sleeve and rotate the sleeve until it seats. TDS-10S Maintenance and Troubleshooting 85 March 2, 1998 19. Install dowel pins in the main body cover and keys in the main body. 20. Apply a thin layer of sealant to the mating surfaces of the main body and main body cover. 21. Install O-rings around the oil galleys in the back wall of the main body. 22. Liberally apply oil to the upper cone of compound gear and cup in cover. Lower the cover onto the main body, making certain the compound gear bearing halves are aligned. 23. Install and tighten the cover bolts. 24. Lightly tighten the screws to the compound retainer and measure the gap between the retainer and the main body. 25. Install a stack of shims between the retainer and the main body that exceeds the gap by approximately .002 in. 26. Tighten the screws to 75 ft lb. Check the end play by inserting a dial indicator through the hole in the bearing retainer and moving the compound up and down using a pry bar. 27. Disassemble the retainer and remove or add shims to obtain an end play of .001 to .002 in. 28. Clean the mating faces, then apply a thin layer of sealant to the mating faces. Install the reservoir. 29. Place the O-ring in the groove on the top face of the main body cover where the hydraulic pump assembly attaches. 30. Install the hydraulic pump assembly. e 86 Take care to not damage the inlet filter when lowering the pump into place. TDS-10S Maintenance and Troubleshooting Installing the AC drilling motor z This procedure assumes the brake and cooling system is installed on the AC drilling motor as well as the pinion hub. See AC drilling motor assembly for instructions on installing the brake hub and pinion hub to the AC motor shaft. Use the following procedures to assemble the transmission/motor housing upper component: 1. Inspect the O-ring that seals the AC drilling motor to the main body joint and replace any O-ring that has flat spots, nicks, or other damage. Place the O-ring on the pilot bore diameters and apply grease (Figure 12). 2. Pick up the AC motor by the brake end (using lifting straps placed under the brake adapter) and lower it into position on the pilot bore being careful not to move or crush the O-ring. z Make sure the brake end with mounting feet faces the rear, and the blower duct faces the hydraulic pump when installing the AC drilling motor. 3. Install the four cap screws and lockwashers that hold the AC drilling motor to the main body. 4. Apply an anti-seize compound to the threads of the four main body cover bolts for the motor. Tighten the four main body cover bolts to 250-270 ft lb. 5. Install the tie rods by first inserting the end of the rod with the greatest length of thread into the holes in the brake adapter plate. a. Raise the tie rod until the lower end clears the top of the main body cover. b. Install the tie rod into the threaded holes. c. Tighten the tie rods until the lower end shoulders against the main body cover. d. Install the flat washer and locknut onto the remaining end of the tie rod and torque to 325 ft lb. TDS-10S Maintenance and Troubleshooting 87 March 2, 1998 AC Motor Pilot Bore O-Ring Figure 12. Installing the AC drilling motor 88 TDS-10S Maintenance and Troubleshooting Installing the upper bearing retainer plate 1. Oil the taper roller bearing on top of the main shaft. Chill the taper roller bearing outer race to at least 0°F (-18°C), then install the race into the cover bore. 2. Clean the retainer plate pipe plugs, apply thread sealer (not Teflon tape) to the pipe plug threads, and install the plugs into the retainer plate. 3. Determine the proper number of shims required under the bearing retainer plate by installing shims, installing the retainer plate, and checking the main shaft axial movement. Check main shaft axial movement by applying a force to the end of the main shaft and measuring the amount of axial movement at the other end with a dial indicator. Add or delete shims as necessary to obtain .001 to .002 in. of axial shaft movement (end play) with the retainer plate cap screws tightened to 250-270 ft lb. z Align the shims so that the upper bearing lube tube bore is not blocked. 4. Remove the bearing retainer plate cap screws and the bearing retainer plate. 5. Install the two new upper bonnet oil seals in the bearing retainer plate with the lips facing up. e Use care not to damage the seals. Be careful to install the seals with the lips facing up since these seals function to keep mud from entering the main body. 6. Using a center punch, stake the last seal in place on eight points. 7. Install the O-ring on the bearing retainer plate and coat the O-ring with grease. 8. Install two O-rings on the upper bearing lube tube and coat the O-rings with grease. 9. Install the lube tube into the lube tube bore in the cover with the .060 in. diameter hole facing up. TDS-10S Maintenance and Troubleshooting 89 March 2, 1998 10. Install the bearing retainer plate, being careful to align the lube tube bore in the retainer with the lube tube protruding from the cover. 11. Carefully tap the bearing retainer plate to seat the plate on top of the cover. 12. Apply an anti-seize compound to the threads of the six bearing retainer plate cap screws, install the six cap screws and lockwashers, and tighten to 250-270 ft lb. Safety wire the cap screws. 13. Recheck the main shaft axial movement by applying a force to the main shaft and measuring the amount of axial movement with a dial indicator. The main shaft movement must be between .001 and .002 in. If the movement falls outside of this specification, readjust the number of shims under the bearing retainer plate. 14. Install two new grease fittings into the bearing retainer plate. 90 TDS-10S Maintenance and Troubleshooting Installing the wash pipe 1. Install the new bearing shield on top of the main shaft. Hold the shield in place with the worm clamp. 2. Install the 3.875 in. OD polypack seal onto the upper stem liner with the O-ring facing away from the flange of the stem liner. 3. Lubricate the upper stem liner with grease and tap the liner in place on top of the main shaft. 4. Using a dial indicator, measure the main shaft to adapter wash pipe pilot on the gooseneck. The TIR should not exceed .006 in. 5. Install the wash pipe packing and tighten. 6. Grease the wash pipe packing and the bearing retainer plate seals. Checking the gear train backlash Using feeler gauges, check the backlash of the primary and secondary gears through the access covers on the right side and left side of the main body (you can also use 3 in. NPT ports for access). z Backlash for the primary gears should be .010 to .020 in. (.024 in. maximum). Backlash for the secondary gears should be .010 to .024 in. (.030 in. maximum). TDS-10S Maintenance and Troubleshooting 91 March 2, 1998 AC drilling motor disassembly/assembly AC drilling motor disassembly Each AC drilling motor has a brake hub on the top of the motor shaft, and a pinion hub at the bottom of the motor shaft as shown in Figure 13. When disassembling the brake hub and pinion hub from the motor shaft: 1. Obtain special tool 110026, a hydraulic hand pump with a gauge and high pressure hose, and connect as shown in Figure 13. 2. Increase the pressure to 35,000 psi and remove the brake hub. 3. Use the same procedure described in steps one and two, to remove the pinion hub. 92 TDS-10S Maintenance and Troubleshooting ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, Brake Hub AC Motor Pressure Gauge ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, Hub Hydraulic Hand Pump Tool # 110026 High Pressure Hose Figure 13. AC drilling motor disassembly TDS-10S Maintenance and Troubleshooting 93 March 2, 1998 AC drilling motor assembly Each AC drilling motor has a brake hub installed on the top of the motor shaft, and a pinion hub installed at the bottom of the motor shaft as shown in Figure 14. When assembling the brake hub and pinion hub to the motor shaft: 1. Lap the brake hub and pinion hub to their respective ends of the motor shaft until the contact area between them is at least 85%. 2. Lightly install the brake hub and pinion hub onto the motor shaft and measure the gap to the motor (dimension A). 3. Remove the brake hub and pinion hub and heat them in an oven to between 400°F and 425°F. 4. Reinstall the brake hub and pinion hub onto the motor shaft advancing the pinion hub .068 ± .005 in. and the brake hub .054 ± .005 in. past the original dimension A. This ensures they remain securely fastened to the motor shaft. 94 TDS-10S Maintenance and Troubleshooting Lap to 85% Contact ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, 5.029 Ref Brake Hub A AC Motor A 5.975 Ref ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,, ,,,,,,,,,,, ,,,,,,,,,,, ,,,,,,,,,,, ,,,,,,,,,,, Lap to 85% Contact ,,,,,,,,,,, ,,,,,,,,,,, ,,,,,,,,,,, Pinion Hub Figure 14. AC drilling motor assembly TDS-10S Maintenance and Troubleshooting 95 March 2, 1998 Replacing the safety wiring Use the following procedures to safety wire screws, nuts, bolts, or other fasteners where applicable. n Torque fasteners before safety wiring any screw, nut, plug, or other fastener. Never overtorque or loosen a torqued fastener to align safety wire holes. Use the size and type of safety wire required in the applicable specifications and drawings. Whenever possible, use double-twist safety wiring. n n Limit single-twist wiring to the following: small screws located in closely spaced, closed geometrical patterns (e.g., triangle, square, rectangle, circle), parts in electrical systems, or parts that are difficult to reach. Do not reuse safety wire. To install safety wire: 1. Open the jaws of the safety twist pliers: 2. Squeeze the handles of the pliers together and unlock the round, perforated slider in the center of the pliers from the hook lock. 3. Grip both safety wires in the jaw. Squeeze the handles together with one hand and pull the slider toward the rear of the pliers with the other hand to lock the pliers. 4. Twist the safety wire by pulling the aluminum knob and twist the rod out from the pliers. Let the pliers spin free. 5. Return the knob and twist the rod by holding the pliers steady with one hand and pushing against the end of the knob the with other hand (step 4 in Figure 15). 6. Repeat the previous twisting cycle. 96 TDS-10S Maintenance and Troubleshooting 7. After threading the safety wire through the hole in the fastener, pull the wire straight through without nicking the wire. Twist four to five complete revolutions per inch of wire. 8. Make a pigtail of approximately 1 in. (25 mm) length (four twists minimum) at the end of the wiring and bend back or under to prevent it from becoming a snag. 1 2 5 3 4 Figure 15. Safety wiring procedures TDS-10S Maintenance and Troubleshooting 97 March 2, 1998 Safety wiring tips ❏ Pull the safety wire firmly, but do not stretch it or let kinks develop. Make twists tight, even, and as taut as possible without weakening the wire by overtwisting (Figure 16). n Do not nick the wire with the edge of the hole in the fastener. Position the safety wire so the pull exerted by the wire tightens the nut. For best results, let the wire leave the fastener in a clockwise direction ❏ Twist the safety wire so the loop around the bolt or head has sufficient tension to keep it from slipping up and over the bolt head, with resulting slack in the safety wiring. n When securing castellated nuts with safety wire, tighten the nut to the low side of the selected torque range, unless otherwise specified. If necessary, continue tightening within specified torque limits until a slot aligns with the hole. ❏ The number of nuts, bolts or screws that can be safety-wired together depends on the application. As a guide, when safetywiring widely spaced bolts by the double-twist method, a group of three, or a 24 in. (610 mm) length of safety wire is usually the maximum. Figure 16. Safety wiring examples 98 TDS-10S Maintenance and Troubleshooting TDS-10S Top Drive Drilling System Control System March 2, 1998 2 TDS-10S Control System Contents Chapter 1 Description General description ............................................................. 5 Major component descriptions ........................................... 7 Varco Driller’s Console (VDC)..................................... 7 Programmable logic controller (PLC) ..................... 9 Variable Frequency Drive (VFD) .......................... 10 Electrical service loops................................................. 12 Chapter 2 Operation Preoperational checklists ................................................... VDC controls ................................................................... Correcting a drive fault ..................................................... Drive fault while drilling ............................................. Drive fault while making up ....................................... 13 17 20 20 21 Chapter 3 Maintenance Maintaining the control system......................................... 23 Troubleshooting ............................................................... 25 VFD ........................................................................... 28 TDS-10S Control System 3 March 2, 1998 4 TDS-10S Control System Chapter 1 Description The following chapter describes the TDS-10S Control System in general and its major components in detail. General description The TDS-10S control system consists of the following three major components: ❏ Varco Driller’s Console (VDC) ❏ Varco Electrical House (VEH) ❏ Electrical Service Loops These components directly interface to control and provide safety interlocks for the TDS-10S (Figure 1). TDS-10S Control System 5 March 2, 1998 Variable Frequency Drive (VFD) 3-Phase Power Control Signals Varco Driller's Console (VDC) Data Bus Remote I/O PLC Control Signals Varco Electrical House (VEH) Figure 1. TDS-10S control system interface 6 TDS-10S Control System TDS-10S Major component descriptions Varco Driller’s Console (VDC) The VDC, made from 300-series stainless steel, uses full size oil tight switches and indicators, and is designed for purging to meet hazardous area requirements (Figure 2). IBOP BRAKE LINK TILT FLOAT IBOP CLOSED BRAKE ON G A PIPEHANDLER MAKE-UP CURRENT LIMIT OIL PRESS LOSS ROTATE LEFT R 0 MAX VDC PRESS LOSS DRILL MOTOR OVERTEMP LINK TILT OFF TORQUE WRENCH PUSH & HOLD DRILL R R BRAKE AUTO IBOP TILT OPEN CLOSE OFF BRAKE ON EMERGENCY STOP R SPIN DRILL THROTTLE RIGHT BLOWER LOSS TORQUE 0 ALARM LAMP SILENCE CHECK HYDRAULIC POWER AUTO ON DRIVE FAULT MAX DRILL TORQUE OFF REVERSE FORWARD TORQUE R RPM R 0 MAX Figure 2. Varco Driller’s Console (VDC) TDS-10S Control System 7 March 2, 1998 It is equipped with the following items to directly interface with the programmable logic controller (PLC): ❏ Throttle ❏ Torque limit potentiometer ❏ Makeup limit potentiometer ❏ Switches and buttons ❏ Indicator lights The throttle uses a design similar to a standard throttle control supplied with Silicone Controlled Rectifier (SCR) systems. The handle includes integral stops to prevent damage. The torque limit potentiometer is also similar to the design used on SCR systems. The maximum torque output of the drive is limited to the continuous torque rating of the drive and motors. The makeup limit potentiometer controls the makeup torque when using the drilling motor to makeup connections. Switches and buttons control the following: ❏ Drill, Spin, Torque mode select ❏ Link tilt ❏ AC drilling motor brakes ❏ Backup clamp ❏ Rotating link adapter ❏ Remote IBOP valve ❏ Drill pipe forward/reverse select ❏ Emergency stop Indicator lights show the following conditions: ❏ Oil pressure loss ❏ Drill motor overtemperature ❏ Blower loss ❏ IBOP closed ❏ Brake ❏ Drive fault 8 TDS-10S Control System Programmable logic controller (PLC) The Variable Frequency Drive (VFD) cabinet encloses the following electrical components: ❏ Master programmable logic controller (PLC) ❏ Circuit breakers ❏ 24 Volt DC power supply for solenoids and VDC ❏ Motor starters for blower and oil pump With the PLC functioning as the central control unit for the TDS-10S, interface to the variable frequency drive (VFD) is limited to a digital communication buss. Input signals from the PLC to the drive include the following: ❏ Control word 1 (On/Off, fwd/rev) ❏ Control word 2 (set point data set selection) ❏ Speed ❏ Torque forward ❏ Torque reverse Communication from the drive to the PLC includes rpm, torque and status word (fault). Any changes to alarm or interlock functions have no effect on the VFD. The remote I/O receives input from the operator controls on the VDC and processes this information through the PLC. The PLC controls the responses of the cooling system motor, solenoid valves, brakes, IBOP functions, and sensors. It reads the status of the sensors and creates interlock conditions to prevent inadvertent tool operations. The PLC also notifies the operator of the operational status of the TDS-10S using alarm indicators which provide diagnosis of inadvertent operational conditions. TDS-10S Control System 9 March 2, 1998 Variable Frequency Drive (VFD) The VFD, used to operate the TDS-10S AC drilling motors, consists of three major parts: ❏ Rectifier section ❏ Control section ❏ Power inverter section The rectifier section converts incoming 3-phase AC power to DC for use by the power devices. The control section monitors the performance of the drilling motor, accepts throttle and torque limit signals from the driller, and controls the firing circuits of the power modules. The power inverter section converts DC power into a simulated AC signal using pulse-width-modulation (PWM) field vector control techniques. The driller controls the speed of the AC drilling motors with a hand throttle. The throttle varies the frequency and voltage to the motor. The speed of the drilling motor is proportional to the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1200 motor rpm). 10 TDS-10S Control System 810 VDC Resultant Pulse DC 20 Hz=600 RPM @ Mtr. 0 0 0 0 TDS-10S AC Motors Insulated gate Bi-polar Transistors (IGBT) + AC Power Source AC Inverter (AC Frequency Drive) PLC Inverter Controller 0-575VAC, 0 to 80 Hz, 3-Phase 600 VAC, 42 to 62 Hz 3-Phase (350 AMPS) 0 40 Hz=1200 RPM @ Mtr. Data Bus VFD Figure 3. Variable Frequency Drive (VFD) TDS-10S Control System 11 March 2, 1998 Electrical service loops The TDS-10S requires three electrical service loops. The main loop consists of four 313 MCM power conductors (three for drilling motor power, one for ground); and a composite cable that contains all of the conductors for sensors and actuator (solenoid) control. This encoder signal is contained in three of four twisted pair shielded wire in the composit cable. An auxiliary power loop provides power for the auxiliary AC motors and heater. 12 TDS-10S Control System Chapter 2 Operation The following chapter contains the TDS-10S Control System preoperational checklists and detailed descriptions of the VDC controls. Preoperational checklists The tables on the subsequent pages provide the following preoperational checklists: ❏ Drive control system function checks (Table 1) ❏ Top Drive control system function checks (Table 2) ❏ Top Drive control system interlock checks (Table 3) ❏ Top Drive control system alarm checks (Table 4) TDS-10S Control System 13 March 2, 1998 Table 1. Drive control system function checks Function Indicator Display Lamp Physical Check Forward N/A Blower on Reverse N/A Blower on Off N/A Blower off Forward N/A Oil pump on Reverse N/A Oil pump on Off N/A Oil pump off Closed On Actuator shell up Open Off Actuator shell down Drill N/A Links to drill down position Off N/A No movement Tilt N/A Links extended to mousehole Link tilt float Push N/A Links float to w/c Rotating head (manual) Left N/A Rotates left Right N/A Rotates right Counterbalance Drill N/A Balance TDS weight Stand Jump (opt.) N/A Lifts TDS weight Blowers Oil pump IBOP Link tilt 14 Switch Position TDS-10S Control System Check OK Table 2. Top Drive control system function checks Switch Position Function Indicator Display Lamp Physical Check Off Off Brake released On On Brake set Auto/throttle on Off Brake released Auto/throttle off On Brake set Off N/A Jaws unclamped Clamp N/A Jaws clamped Alarm silence Push On Horn silenced Lamp check Push All lamps on On (after 2 seconds) (after 2 seconds) Brake Torque wrench Check OK Table 3. Top Drive control system interlock checks Function Rotating head Torque wrench clamp Control Sequence Action With links in tilt or drill position, actuate rotate left/right. No rotation With links in tilt or drill position, actuate float push button. Links float toward wrench clamp. After 5 seconds actuate rotate left/right. After 5 seconds, rotating head rotates. Check OK No torque wrench With clamp drill/spin/torque switch in drill mode and throttle on, actuate torque wrench clamp. TDS-10S Control System 15 March 2, 1998 Table 4. Top Drive control system alarm checks Alarm Function Oil pressure loss Blower differential press 16 TDS-10S Control System Action to Initiate Display Indication Remove/cap oil Press line to oil Press switch “Oil Pressure Alarm” flashes and horn sounds Disconnect aux. power loop “Oil Pressure Alarm” flashes and horn sounds Remove line to left differential press switch “Blower Press Alarm” flashes and horn sounds Disconnect aux. power loop “Blower Press Alarm” flashes and horn sounds Check OK VDC controls Table 5 describes each of the VDC controls in detail (Figure 4). 1 24 6 4 2 20 21 OIL DRILL MOTOR PRESS LOSS OVERTEMP BLOWER LOSS 12 DRIVE FAULT PURGE LOSS 13 3 RPM TORQUE 5 IBOP IBOP CLOSED 10 8 BRAKE OPEN BRAKE AUTO BRAKE ON IBOP CLOSE OFF BRAKE ON EMERGENCY STOP 16 THROTTLE PIPE HANDLER MAKE-UP CURRENT LMIT ROTATE LEFT 0 LINK TILT FLOAT RIGHT MAX 0 HYDRAULIC POWER OFF ON DRILL LINK TILT OFF TILT TORQUE WRENCH PUSH & HOLD MAX DRILL TORQUE COUNTERBALANCE DRILL 23 STAND JUMP 0 DRILL SPIN TORQUE ALARM/LAMP TEST (PRESS TO SILENCE) MAX OFF REVERSE FORWARD 19 9 11 15 7 14 18 17 22 Figure 4. VDC controls TDS-10S Control System 17 March 2, 1998 Table 5. VDC controls Control/Indicator Name Description and Function 1 DRIVE FAULT Red indicator light flashes and horn sounds when a VFD fault is detected. Pressing the alarm silence button stops the horn. The alarm indicator light stays on while the switch is timed for 5 minutes. The alarm returns if the fault is not fixed, otherwise, the alarm light turns off. 2 BLOWER LOSS Red indicator light illuminates in case of a failure in air cooling motor. 3 BRAKE ON Red indicator light illuminates when the brake solenoid valve is energized. 4 DRILL MOTOR OVERTEMP Red indicator light illuminates in case of an overtemperature condition in the 350 hp AC drilling motor. 5 IBOP CLOSED Amber indicator light illuminates when there is hydraulic pressure to the cylinder that closes the IBOP valve. 6 OIL PRESS LOSS Red indicator light illuminates when there is an oil pressure loss in the gearcase lubrication system. 7 ALARM /LAMP TEST When the alarm indicator light illuminates and the horn switch sounds, press the switch to silence the horn. The alarm light stays on until the fault is corrected. If it is not corrected in 5 minutes, the alarm repeats. The switch is also a lamp check for all lights on the VDC. The switch must be pushed and held for two seconds to obtain a lamp check. 8 BRAKE switch There are three brake switch positions: OFF, AUTO, and ON. Turning the switch to the ON position turns the brake on and lights the indicator light above the switch. In the AUTO position, the brake automatically turns on when the throttle is turned off. Turning the switch to the OFF position turns the brake off. After a DRIVE FAULT or emergency stop, the BRAKE SWITCH must be turned ON and then OFF to reset the brake. 9 DRILL TORQUE Limit Potentiometer A potentiometer sets the current limit in the VFD during drilling operations. This sets the torque for normal drilling operations in the drill position. Torque and rpm are displayed and can be adjusted. Adjust the torque by setting the brake and turning the potentiometer to increase or decrease the torque. 10 ROTATE There are three switch positions: OFF, LEFT, and RIGHT. Turn the spring-loaded switch to the left to rotate the head to the left, and turn the switch to the right to rotate the head to the right. NOTE: Works only after the link tilt float switch is pressed. 18 TDS-10S Control System Table 5. VDC controls (continued) Control/Indicator Name 11 DRILL/SPIN,/ TORQUE switch Description and Function There are three switch positions: DRILL, SPIN, and TORQUE. The switch is in the DRILL mode during normal drilling. SPIN mode is a fixed speed of the AC drilling motors. TORQUE mode is a slower fixed speed of the AC drilling motors. It generates a gradual increase in torque to the make-up limit. 12 EMERGENCY STOP Emergency stop shuts down all operations. Emergency stop switch switch is hardwired to the VFD. Pressing the stop button deselects the drive and sets the brake, causing the top drive rotation to stop regardless of throttle position. Auxiliary cooling motors remain on. 13 IBOP switch Activates the upper IBOP valve. Turning the switch to the left retracts the IBOP actuator cylinder to close the valve. Turning the switch to the right extends the cylinder to open the valve. 14 LINK TILT FLOAT The links “float” to the center (NEUTRAL) position when the pushbutton is depressed. 15 LINK TILT switch Activates the link tilt cylinder. The center position is OFF; turning the switch to the left extends the cylinder to the mousehole; and turning the switch to the right retracts the cylinder for drill down. This is a maintained switch that holds the position of the cylinder when returned to OFF. 16 MAKE-UP CURRENT A potentiometer sets the torque limit in the VFD when using LIMIT Potentiometer the top drive to makeup connections. Torque is displayed on the torque meter. Adjust the torque by setting the brake and turning the potentiometer to increase or decrease the torque. 17 REVERSE /OFF/ FORWARD switch 18 TORQUE WRENCH PUSH & HOLD switch There are three switch positions: OFF, FORWARD, and REVERSE. In the OFF position, the top drive cannot operate. FORWARD and REVERSE are used when drilling or making/breaking connections. This switch acts as the drive assignment. Pushing this button engages the pipe clamp and shot pin lock. The rotating head rotates until the shop pin engages. The pipe clamp operates after the shot pin is engaged. 19 HYDRAULIC POWER Turns the tool hydraulics on or off. 20 PURGE LOSS Indicates that the VDC has lost purge pressure. 21 RPM meter Displays the rpm of drill pipe. 23 THROTTLE Controls the speed of the AC drilling motors. Motor rpm is displayed on the rpm meter. 24 TORQUE meter Displays the drill pipe torque in ft lb. TDS-10S Control System 19 March 2, 1998 Correcting a drive fault When a drive fault occurs, the brake automatically sets regardless of the brake switch position. The brake sets at less than 5 rpm. Use the following procedure to release the brakes and unwind the drill string torque in a controlled operation. Drive fault while drilling 1. Turn the brake switch on, if it is not already there. This sets the top drive brakes and keeps the drill string from rotating. 2. Rest the drive. If there is torque build up on the string, open the throttle. The torque meter indicates the preset drill torque limit. If the torque meter reading is different from the drill torque limit prior to the drive fault, readjust the drill torque limit before releasing the brake. 3. Turn the brake control switch off to release the brakes. 4. Rotate the drill torque limit control slowly to unwind the drill string torque. 5. If the drive does not reset and there is torque build up in the drill string, toggle the brake switch from on to off repeatedly. This releases a little torque each time, until it is safe to completely release the brakes. e 20 TDS-10S Control System The top drive must not be deassigned (hydraulic pump and blower motors running) for more than 10 minutes to maintain maximum braking. Brakes are applied by hydraulic caliper pressure actuated by accumulator pressure. When the hydraulic pump is off, the accumulator pressure drops due to normal system leakage, resulting in a decrease in braking. The decrease in braking is gradual until the accumulator precharge pressure is reached. If the drill string torque is low, there may be noticeable rotation due to a gradual decrease in braking since the required brake holding pressure is low. In this situation, the brakes release once hydraulic pressure reaches the accumulator precharge pressure. Drive fault while making up 1. Turn the brake switch on, if it not already there. This sets the top drive brakes and keeps the drive stem from rotating. 2. Toggle the brake switch from on to off repeatedly. This releases a little torque in the drive stem each time until there is slack in the back-up tong line and it is safe to completely release the brakes. n Floor hands should stay clear of back-up tong and long line during this operation due to the possibility that a sudden release of torque might cause the tong to recoil and fall to the floor. TDS-10S Control System 21 March 2, 1998 22 TDS-10S Control System Chapter 3 Maintenance The following chapter contains the TDS-10S Control System maintenance guide. Maintaining the control system Refer to the following documentation for maintenance information: ❏ Periodic control system maintenance schedule (Table 6) ❏ Preoperational checklists (Chapter 2) ❏ PLC manufacturer’s manual ❏ VFD manufacturer’s manual TDS-10S Control System 23 March 2, 1998 Table 6. Periodic control system maintenance schedule Location Procedure Interval Indicator lamps Test using the lamp test switch on the VDC. Daily Heater Check operation with an ohmmeter. Monthly High voltage connections Check for discolored or brittle insulation. Monthly Monthly Check retaining bolt torque (25 ft lb). 24 Component mounting Check fastener tightness, especially in vibration-prone areas. Monthly Seals and gaskets Check for integrity. Monthly TDS-10S Control System Troubleshooting The figures in the subsequent pages show the following PLC modules during normal operations: ❏ S7-300 CPU (Figure 5) ❏ Input module (Figure 6) ❏ Output module (Figure 7) ❏ Remote I/O (Figure 8) CPU315-2 DP SF BATF BUSF DC5V Status and fault LEDs FRCE RUN Memory card receptacle STOP RUN-P RUN Mode Selector STOP MRES Battery Compartment MPI port Jumper (removable) Terminals for power supply and functional ground PROFIBUS-DP interface M L+ DC M 24V X1 MPI X2 DP (Cover removed for clarity) Figure 5. S7-300 CPU during normal operations TDS-10S Control System 25 March 2, 1998 RUN BF DIA ET 200B -4AI 0 1 RUN STOP Figure 6. Input module during normal operations RUN BF DIA ET 200B -4AO 0 4 RUN STOP Figure 7. Output modules during normal operations 26 TDS-10S Control System RUN BF DIA 0 5 RUN STOP Figure 8. Remote I/O during normal operations TDS-10S Control System 27 March 2, 1998 VFD The VFD has an LCD panel that can be used for troubleshooting (Figure 9). Output current Actual value Setpoint Mode number 15,2A 120V # 14.00Hz * 14.00Hz °014=Operation Output voltage Mode name Fault Run P Jog 7 8 9 4 5 6 1 2 3 0 +/- Reset Figure 9. LCD panel 28 TDS-10S Control System TDS-10S Top Drive Drilling System Supplemental Material March 2, 1998 2 TDS-10S Supplemental Material Contents Supplemental Material Supplement list ................................................................ 8-5 TDS-10S Supplemental Material 3 March 2, 1998 4 TDS-10S Supplemental Material Supplemental Material Supplement list This chapter contains the following supplements: ❏ Design Specification, Design Torque Standard (DS00008) ❏ IBOP Service Manual TDS-10S Supplemental Material 5 March 2, 1998 6 TDS-10S Supplemental Material Safety Valve (IBOP) Service Manual ® ™ DRILLING SYSTEMS Feb. 2, 1994 Feb. 2, 1994 Feb. 2, 1994 Contents GENERAL DESCRIPTION.............................................................................. 1 PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5 Introduction .................................................................................................. 5 Principle Features ................................................................................... 5 Remote IBOP Actuator Improvements ........................................................ 7 Internal Valve Mechanism Improvements.................................................... 8 INSTALLATION ............................................................................................ 9 OPERATION .............................................................................................. 16 Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17 LUBRICATION ........................................................................................... 18 INSPECTION ............................................................................................ 21 Magnetic Particle Inspection ...................................................................... 21 Safety Valve Inspection Procedures .......................................................... 21 Visual Inspection ................................................................................... 22 ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23 MAINTENANCE ......................................................................................... 25 Seal Replacement ..................................................................................... 25 Shop Assembly and Disassembly ............................................................. 27 Disassembly.......................................................................................... 28 Assembly .............................................................................................. 32 IBOP Valve Testing in the Shop ............................................................ 39 APPENDIX ................................................................................................ 40 i Feb. 2, 1994 ii Feb. 2, 1994 Varco/BJ Safety Valves (IBOPs) GENERAL DESCRIPTION The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi working pressure. If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left in the string if required. The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System (Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated at any height in the derrick from the driller’s console. The upper IBOP can also be operated manually using a 7/8" hex wrench. There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing for purging any debris that may get in the wave spring area. 1 Feb. 2, 1994 Link Tilt Rotating Head (Ref.) Link Adapter Torque Arrestor Link Adapter Support Plate Splined Upper Safety Valve Safety Valve Actuator 350 Ton 108" Links (Ref.) Torque Wrench Plain Lower Safety Valve Saver Sub 350 Ton Center-Latch Drill Pipe Elevator (Ref.) Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60) 2 Feb. 2, 1994 Link Tilt Rotating Head (Ref.) Link Adapter Torque Arrestor Link Adapter Support Plate Splined Upper Safety Valve V a r c o Safety Valve Actuator 350 Ton 108" Links (Ref.) Torque Wrench Plain Lower Safety Valve Saver Sub 350 Ton Center-Latch Drill Pipe Elevator (Ref.) Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d) 3 Feb. 2, 1994 Thread Protector Body Retaining Ring Upper Seat Plug Back-up Rings OPE CL SD Back-up Rings N O-Ring O-Ring Ball Sleeve Seal Ring Stabilizer Ring Crank Grease/ Mud Seal Seat Wave Spring Back-up Ring O-Ring Figure 3. Typical Upper Safety Valve (IBOP) 4 Thread Protector Feb. 2, 1994 PH-60 IBOP/Actuator Upgrade Kit Introduction Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both as a primary safety valve and as a mud saver while drilling ahead. Maintenance and operating costs will be greatly reduced, allowing a minimum planned maintenance interval of six months for the upper IBOP. PRINCIPLE FEATURES ❏ The upper IBOP valves (2 ea.) are equipped with: • PH-85 style dual-path operating systems • New low-stress inside body contours • Completely redesigned long-life internals ❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides. ❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and they eliminate the need for periodic adjustment. ❏ The dual external crank assemblies share the operating loads. Each is reinforced, with improved sealing and retention. ❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening. 5 Feb. 2, 1994 ACTUATOR CYLINDER MOUNTING BRACKET REQUIRES NO ADJUSTMENT LARGE BORE, LONG STROKE IBOP ACTUATOR CYLINDERS (2) SOLID, ONE-PIECE, JOURNAL-GUIDED IBOP ACTUATOR SHELL REINFORCED DUAL EXTERNAL CRANKS AND HOUSINGS WITH IMPROVED BALL ROTATION STOPS IMPROVED DESIGN DUAL-CRANK UPPER IBOP VALVE Aug. 9, 1993. A.N. Figure 4. PH-60 Upgrade Kit 6 Feb. 2, 1994 Remote IBOP Actuator Improvements (Refer to Drawing 99261 in the Appendix) 1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45% larger piston area ensures positive, complete ball rotation under the most arduous conditions. A 60% increase in available cylinder stroke eliminates the need for sensitive position adjustments, both at initial rig-up as well as over the life of the system. 2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable) guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides directly on the IBOP outer diameter. The new design is very robust, requires no adjustments, and is able to withstand punishing environments without damage. 3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This change reduces the operating and environmental forces on the internal and external components by 50%. It also provides a balanced reaction force to the actuating levers. This force balance allows elimination of the bolt-on guide roller assemblies. Each of the two external crank housings is anchored to the IBOP body with 1/2" screws instead of the 3/8" screws used in the previous design. The crank housings are also secured to react the ball stop torque using a close-tolerance fit between the base of the housing and the machined recess in the IBOP valve body. When required, jacking screws make removing the housings easier. 7 Feb. 2, 1994 Internal Valve Mechanism Improvements 1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They are replaced with a smooth bore through the ball and seat region. This significantly lowers the maximum stress in the valve body and effectively eliminates the possibility of leaks caused by cracking at the crank bores under corrosive mud conditions. 2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball rotation stop in the previous design. The crank was easily replaced, but the body was not repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over extended use could eventually allow the ball to over-travel, leading to washouts. In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal cranks (2) and external crank housings (2) need replacement should they ever become worn. The external crank housings in the new design serve as the ball rotation stops. Each external crank housing has two struts which contact the internal crank to stop the ball precisely at the open or closed position. The torque required to stop the ball is then shared by four surfaces rather than the previous design’s single surface. The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated regions beneath the external cranks. This eliminates the presence of caked drilling fluid around the stop mechanism and is more reliable. 3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler, the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and locating components, decreasing wear and eliminating mechanical failure. 8 Feb. 2, 1994 INSTALLATION The following installation procedure assumes that all other rig components are already installed. 1. Use slips to install a joint of drill pipe into the rotary table. 2. Install the saver sub hand tight onto the drill pipe. 3. Install the lower IBOP hand tight onto the saver sub. 4. Install the upper IBOP hand tight onto the lower IBOP. 5. Screw the stem/main shaft and upper IBOP together. CAUTION The same care should be taken with these valves as would be any other threaded valve. Be sure to use a thread compound with 60% lead by weight or Kopper Kote. Varco does not recommend using a zinc thread compound. If making up new threads for the first time, use the following procedure: a. Torque up to the recommended torque value (Table 1). b. Back off the connection and inspect the threads and face. c. Torque up to the recommended torque value (Table 1). 9 Feb. 2, 1994 Table 1. Make-Up Torque Values Components I.D. Connection O.D. Torque (ft-lb) (min.) (max.) Mainshaft to Upper IBOP Safety Valve* 3" 6-5/8 API Reg. 7-3/4 60,000 70,000 Upper IBOP Safety Valve to Lower IBOP Valve 3" 6-5/8 API Reg. 7-3/4 50,000 70,000 Lower IBOP Valve to Saver Sub 3" 6-5/8 API Reg. 7-3/8 46,000 64,000 Crossover Sub to Lower IBOP Safety Valve 3" 6-5/8 API Reg. 7-3/8 46,000 60,000 Mainshaft to Upper IBOP Safety Valve** 3" 7-5/8 API Reg. 9 83,000 91,000 Upper IBOP Safety Valve to Lower IBOP 3" 7-5/8 API Reg. 9 75,000 91,000 Lower IBOP Valve to Saver Sub 3" 7-5/8 API Reg. 8-5/8 66,000 85,000 Crossover Sub to Lower IBOP Valve 3" 7-5/8 API Reg. 9 75,000 91,000 * 500 Ton ** 650 Ton 6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows (Figures 5 & 6): a. b. c. d. e. f. Carefully grind off any raised tong marks on the O.D. of the safety valves. Open the valve exactly halfway (45 degree rotation of the actuator). Orient the levers on the crank assemblies horizontally as shown. Slide the shell up onto the valve with the actuator arm groove on the bottom. Hold the shell in position relative to the valve operating sockets. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws and locktite on the bolt threads to secure the assemblies. g. Manually operate the actuator to ensure free movement though a full 90° of crank travel. 10 Feb. 2, 1994 Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8): a. Carefully grind off any raised tong marks on O.D. of the safety valves. b. Open the valve exactly halfway (45 degree rotation of actuator). c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire groove on side of crank body is to the right and the safety tab is on the left). d. Slide the shell up onto the valve with the roller groove at the bottom. e. Hold the shell in position relative to the valve operating socket. f. Using the two bolts provided, install the crank assembly, sliding the safety tab through and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire the bolt heads, routing lock wire around the right side of the crank body through the safety wire groove. g. Install the two roller assemblies nearest the crank slot, and then using shims provided, install the third roller assembly, maintaining .005" to .010" clearance between the third roller assembly and the safety valve body with the shell vertically centered on the valve. h. Manually operate the actuator to ensure free movement through full 90° of crank travel. NOTE When the actuator is in the lowest position, the valve should be open. 7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual for the installation and adjustment procedures). 8. Use the torque wrench to make up the saver sub to the lower IBOP. 9. Use the torque wrench to make up the lower IBOP to the upper IBOP. 11 Feb. 2, 1994 Crank Assembly Retaining Screw And Lock Tabs Crank Assembly Slot Actuator Shell Crank Arm* Actuator Arm Groove Lock Tabs Crank Assembly Safety Wire Groove Upper IBOP Valve 7/8" Allen Crank *Note Orientation Cam Follower Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d 12 Feb. 2, 1994 Open Position Closed Position Actuator Shell Crank Arm Grease Port Actuator Arm Groove Upper IBOP Valve Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions 13 Feb. 2, 1994 Roller Assembly (3) Crank Assembly Retaining Screw Crank Assembly Slot Roller Assembly (3) Actuator Shell Crank* Roller Assembly (3) Actuator Arm Groove Safety Valve Safety Wire Groove Shim Crank Assembly *Note Orientation Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the PH-60 14 Feb. 2, 1994 Closed Position Open Position Actuator Shell Crank Arm Grease Port Actuator Arm Groove Upper IBOP Valve Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions 15 Feb. 2, 1994 OPERATION Operating the switch on the driller’s console to the IBOP Close position causes the two (2) actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This upward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve. Operating the switch to the Open position retracts the cylinder rods and opens the IBOP. 16 Feb. 2, 1994 Erosion Prevention of the Ball and Seats in the Lower IBOP Valve To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully closed at least one time each shift change. The valves can partially open without being externally actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends removing the lip seal from the spring loaded (floating) seat to correct this problem. Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9): 1. Breakout and remove the lower IBOP. 2. Disassemble the valve and remove the lip seal from the floating (pin end) seat. 3. Replace the O-rings and back-up rings on the fixed and floating seats. 4. Re-assemble the valves. 5. Reinstall and torque the lower valve. Figure 9. Lower IBOP Seal Removal 17 Feb. 2, 1994 LUBRICATION Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank in the recessed counter bore. There are three reasons for lubricating the valve: 1. To verify the integrity of the grease seal. 2. To lubricate the floating seat. 3. To flush mud and debris from the spring cavity. Use the following procedure to lubricate the IBOP valves (Figures 10 & 11): 1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of pressure. A release of pressure indicates the mud/grease seal is not functioning properly — the valve should be serviced. 2. Install a suitable grease fitting. 3. Open the valve. 4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an equivalent amount from an air powered grease injector. The grease pressure should not exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into the clearance between the floating seat and the valve body. 5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug, tightening securely. CAUTION The plug must be replaced in the valve prior to use to maintain pressure integrity. 18 WAVE SPRING MUD/ GREASE SEAL SEAL RING STABILIZER FIXED SEAT 19 Figure 10. Lubricating a Typical Upper IBOP C L BALL C L FLOATING SEAT PRESSURE SEALS SPRING CAVITY VALVE BODY GREASE PORT Feb. 2, 1994 PRESSURE PLUG WAVE SPRING C L FLOATING SEAT PRESSURE SEALS SPRING CAVITY Feb. 2, 1994 VALVE BODY PRESSURE PLUG GREASE PORT 20 C L BALL Figure 11. Lubricating a Typical Lower IBOP FIXED SEAT Feb. 2, 1994 INSPECTION Magnetic Particle Inspection After approximately three to six months (depending on the severity of operating conditions) Varco recommends performing a Magnetic Particle Inspection of all load bearing components – including IBOPs – over their entire surface and internal bores to reveal any fatigue or crack indications (Figure 11). Any indications found are a potential cause for the replacement of the suspect component. Details on Magnetic Particle Inspection procedures are in the following publications: I.A.D.C. ASTM A-275 ASTM E-709 Drilling Manual, 9th Edition Std. Method for Magnetic Particle Inspection of Steel Forgings Std. Recommended Practice for Magnetic Particle Safety Valve Inspection Procedures Upper and lower safety valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack may begin at the root of the pit. Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse cracks every three to six months, depending on the severity of the exposure. Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be hidden under corrosion products. Use the magnetic particle inspection procedure. Concentrate attention on (Figure 12): ❏ ❏ ❏ ❏ The area inside the operating crank window The fillet radii of internal grooves and shoulders The last engaged threads of box connections The IBOP actuator shell 21 Feb. 2, 1994 Recommended Inspection Areas Figure 12. IBOP Inspection Points NOTE Repairing valve body cracks is not practical because of the close tolerances of internal components and the metallurgy of the valve material. Remove from service and scrap any safety valve body showing positive crack indications. VISUAL INSPECTION Whenever connections are broken, clean and check them for the following: 1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other abnormal conditions. Check shoulders for any marks, gouges or other damage. 2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper safety valve for wear. NOTE Remove any surface imperfections on upper (splined) safety valves after the valve is made up into string to prevent remote actuator malfunctions, causing the valve to wash out. 22 Feb. 2, 1994 ADJUSTING THE SAFETY VALVE ACTUATOR Proper safety valve actuator installation and adjustment is essential to assure proper action of the mechanism and to minimize mechanical component wear. The actuator shell installs over the upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13) adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator shell as follows: 1. After removing the crank assemblies, make sure the actuator shell easily moves up and down over the upper IBOP. NOTE There is only one crank on upper IBOPs for the PH-60 pipehandler. There are also three roller assemblies. 2. With the IBOP valve at mid-stroke, reinstall the crank assemblies. 3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab. 4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check for signs of binding. Make sure the shell travels freely throughout its full range of travel. If binding exists, troubleshoot to eliminate any problems before returning to service. 5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders should retract and the actuator ring should be down. 6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch. 7. Actuate the valve to make sure it opens and closes fully. 23 Feb. 2, 1994 DriveStem (Ref.) Link Adapter Cylinder Adjustment Bolts (4) Landing Collar Eye Bolts (2) Upper IBOP Valve Actuator Shell Upper IBOP Valve Actuator Air Cylinders (2) Crank Assy(Shown with Valve OPEN. Note Crank Assy Position CLOSE OPEN *1 Inch Actuator Arm Cylinder in OPEN Position Rod End Cylinder Gland Upper IBOP Torque Tube *IMPORTANT Lower IBOP Saver Sub Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d & Single Crank PH-60 24 Feb. 2, 1994 MAINTENANCE Seal Replacement Replace seals at six month intervals under normal operating conditions (Figure 14). If there are signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or high salt content drilling fluids, shorter intervals may be necessary. 13 2 17 6 1 19 10 18 5 14 15 20 7 16 8 2X 4 3 9 12 11 12 7/8" Hex Note: Dual Crank Remote IBOP Shown Single Crank Remote and Lower IBOP have similar construction. Figure 14. IBOP Safety Valve Illustrated Parts List 25 Feb. 2, 1994 Parts List ITEM QYT. / KIT DESCRIPTION PART NUMBERS 1 BALL, DUAL CRANK (SET) 90939-5 1 1 - 2 RETAINING RING 89141-1 1 1 - 3 O'RING 90441-9 1 1 1 4 BACK-UP RING 90441-10 1 1 1 5 LOWER SEAT (SET) 90939-5 1 1 - 1 6 UPPER SEAT (SET) 90939-5 1 1 - 1 7 POLYSEAL 96439 1 1 1 8 BACK-UP RING 89141-13 2 2 2 9 CROWN SEAL 89141-8 1 2 2 10 SLEEVE 90441-7 (93806-12 for Dual Crank) 1 2 - 11 O'RING 89141-11 1 2 2 12 BACKING RING 89141-12 2 4 4 13 CRANK, RIGHT HAND 89141-7 (93806-10 for Dual Crank) 1 1 - 14 WAVE SPRING 89141-9 1 1 - 15 BODY - - - 16 O'RING 1 1 1 17 NYLON PLUG 2 2 2 18 CRANK, LEFT HAND - 1 - 19 PLUG 1 1 - 20 SEAL RING STABILIZER 1 1 1 89141-3 93806-11 96438 REPAIR KIT - SINGLE CRANK Refer to the Appendix for Part Numbers REPAIR KIT - DUAL CRANK Refer to the Appendix for Part Numbers REPAIR KIT - SOFT SEAL ONLY (For either Single or Dual Crank) Refer to the Appendix for Part Numbers BALL/SEAT SET Refer to the Appendix for Part Numbers Figure 14. IBOP Illustrated Parts List (Cont.) 26 1 2 Feb. 2, 1994 Shop Assembly and Disassembly The following tools are required (Figure 15): Crank wrench Varco Part No. 77408 Seat puller Varco Part No. 79489-14 Nut wrench (for internal nut) Varco Part No. 89141-18 Bushing installation tool Open end or adjustable wrenches Two large flat screwdrivers or light pry bars 1/4" and 3/4" allen wrenches Pipe vise or suitable holding device to hold valve secure Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve, but also serves to loosen internal components. Follow these general rules while working on the valve: 1. Take proper precautions while working with the components of the valve to make sure precision matched surfaces and seal contact surfaces are not damaged. 2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts as they are removed. 7.5" 3" 22" Load Bar 15.25" 3" Maximum Nut Wrench for DSV Models Varco Part No. 89141-18 Seat Puller For All Models Varco Part No. 79489-14 7/8" Hex Wrench For All Models Varco Part No. 89141-18 Figure 15. IBOP Tools 27 Feb. 2, 1994 DISASSEMBLY Starting with the valve in the closed position, disassemble the IBOP as follows: 1. Place the valve in a vise or clamp to hold the valve securely (Figure 16). Figure 16 2. Engage the seat puller in the inside groove of the lower seat (Figure 17). 3. Using the load bar across the face of the connection, tighten the nut against the load bar to compress the wave spring approximately 0.030" (Figure 17). Figure 17 28 Feb. 2, 1994 4. At the other end of the valve, insert the upper seat wrench, P/N 89141-18, into the upper seat engaging the wrench lugs into the mating slots (Figure 18). 5. Using the crank wrench, P/N 77408, as a lever in the hole provided in the upper seat wrench, rotate the upper seat clockwise until it stops (Figure 18). Figure 18 6. Remove the wrench. 7. Remove the retainer ring from the groove in the valve body by using a screwdriver to pry one end of the retainer ring out of the groove. The ring can then be removed by hand (Figure 19). Figure 19 8. Re-insert the upper seat wrench into the upper seat. 9. Rotate the upper seat counterclockwise until it disengages from the body threads. 10. Remove the wrench and the upper seat (Figure 20). Figure 20 29 Feb. 2, 1994 11. Remove the ball valve (Figure 21). Figure 21 12. From the outside of the valve, push the crank into the valve body and remove them (Figure 22). Figure 22 13. Remove the pulling tool from the lower seat. 14. Insert the pulling tool from the opposite end of the valve and engage the groove on the I.D. of the lower seat (Figure 23). Figure 23 30 Feb. 2, 1994 15. Using the load bar across the face of the connection, tighten the nut against it to remove the lower seat and the wave spring (Figures 24 and 25). 16. Remove and discard the seals from all IBOP components. 17. Thoroughly clean and inspect each item. Figure 24 Figure 25 31 Feb. 2, 1994 ASSEMBLY 1. Inspect the lower seat. Look carefully for signs of corrosion, pitting and gaulling – especially in the sealing areas (Figure 26). 2. Make sure the wave spring is not broken or damaged (Figure 26). 3. Inspect the steel stabilizer ring, making sure it is not worn, pitted or damaged (Figure 26). Figure 26 4. Replace all O-rings, backup rings and seals (Figure 26). 5. Install the steel stabilizer and seal on the lower seat (floating seat), by placing the steel stabilizer in the groove of the U-cup seal and, starting on one side of the seat, work the stabilizer and seal around the seat using a screw driver (Figure 27). NOTE The steel stabilizer ring should be inside the seal when properly installed. Figure 27 32 Feb. 2, 1994 6. Install the wave spring on the lower seat (Figure 28). Figure 28 7. Inspect the ball valve for corrosion, pitting and gaulling (Figure 29). Figure 29 33 Feb. 2, 1994 8. Install new nylon plugs on the upper stationary seat (Figure 30). Figure 30 9. Make sure the snap ring is not broken or damaged (Figure 31). Figure 31 34 Feb. 2, 1994 10. Make sure the crank assembly notches are not worn and there is no pitting on the outside (Figure 32). Check for a sliding fit with the slots in the ball. 11. Install the seals on the crank assembly. 12. Inspect the crank sleeve for wear and washouts. Replace as necessary. Figure 32 13. Thoroughly lubricate the valve bore with a thin film of multipurpose grease of NLGI Grade 2. 14. Insert the pulling tool into the O-ring end of the lower seat engaging the I.D. groove (Figure 33). 15. Apply a generous coat of grease to the O.D. of the lower seat. 16. Slide the wave spring down the threaded rod of the pulling tool until it seats on the spring surface of the lower seat (Figure 33). Figure 33 17. Insert the threaded rod of the pulling tool first into the box opposite the splined end of the upper valve, pulling the lower seat into place in the valve body (Figure 33). 35 Feb. 2, 1994 18. Using the load bar against the face of the connection, tighten the nut to firmly seat the lower seat in the valve body (Figure 34). Figure 34 19. Apply a generous coat of grease to the outside of the sleeve and crank. 20. From the inside of the valve body, install the crank sleeve in the body. Insert the crank into the sleeve (Figure 35). Figure 35 21. Make sure the crank moves 90° to the Open and Closed position (the flat sides of the crank are parallel to the valve body). 22. Position the crank in the Closed position. 23. Apply a generous coat of grease to the entire outside of the ball, but make sure the holes are clear (Figure 36). Figure 36 36 Feb. 2, 1994 24. Slide the ball onto the crank inside the valve body. The keyway must be in the Closed position, or parallel to the key of the crank. 25. Apply a generous coat of grease to the outside threads and seal of the upper seat. 26. Insert the upper seat into the valve body, engaging the threads (Figure 37). Figure 37 27. Insert the upper seat wrench into the mating slots of the upper seat. 28. Rotate the wrench clockwise until the upper seat sets firmly against the ball. 29. Remove the upper seat wrench and install the retainer ring firmly into the groove of the body (Figure 38). Figure 38 30. Insert the upper seat wrench into the mating slots of the upper seat. 31. Rotate the upper seat counterclockwise until the seat is firmly against the retainer ring. 32. Remove the puller and use an allen wrench to make sure the valve functions properly. 33. Leave the valve in the Open position. 34. Remove the wrench. 37 Feb. 2, 1994 35. Grease the valve through the pressure plug until grease extrudes from inside the valve (Figure 39). NOTE The grease pressure should not exceed 300 psi. Excess pressure can cause the mud/grease seal to extrude. Figure 39 36. Install the 1/4" N.P.T. plug into the lubrication port of the body. Torque this plug to approximately 15 to 20 ft.-lbs. Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times to assure smooth operation. Test the valve according to the procedure in the following section. 38 Feb. 2, 1994 IBOP VALVE TESTING IN THE SHOP Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the following procedure to test IBOPs: 1. Rotate the valve crank to the Open position. 2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve to the plug in the opposite end. 3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for lower IBOP) with the ball and the bleed valve in the Open position. 4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical, but using water increases the liklihood of corrosion in the valve body—especially when the valve is not in use for a prolonged period of time. NOTE Open and close the valve five times to release trapped air and overflow through the bleed valve for approximately 30 seconds to assure complete filling of the valve cavity. 5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed position. 6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test. 7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper IBOP, box end up for lower IBOP). 8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP (pin end of the lower IBOP). 9. Fill the valve cavity with water while rotating the ball full open to closed five times to release trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the duration of the test. 10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to insure smooth operation. 11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is acceptable. 12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to release trapped fluid. When testing with water, coat the valve internals with a preservative to prevent oxidation and install thread protectors. 39 Feb. 2, 1994 APPENDIX IBOP Part Numbers IBOP PART NO. TYPE OF SERVICE DESCRIPTION REPAIR KIT PART NO. SOFT SEALS BALL/SEAT PART NO. PART NO. 94769-500 94769-502 94769-501 STD H2S NAM Upper Valve-PH60 6 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design 90939-2 89453-SP 90939-2 90939-1 90939-1 90939-5 89453-15 90939-5 94770-500 94770-502 94770-501 STD H2S NAM Upper Valve-PH60 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design 90939-2 89453-SP 90939-2 90939-1 90939-1 90939-5 89453-15 90939-5 94099-500 94099-502 94099-501 STD H2S NAM Upper Valve - PH60 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design 90939-2 89453-SP 90939-2 90939-1 90939-1 90939-5 89453-15 90939-5 94100-500 94100-502 94100-501 STD H2S NAM Upper Valve - PH60 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design 90939-2 89453-SP 90939-2 90939-1 90939-1 90939-5 89453-15 90939-5 90815 - STD H2S NAM Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Land Collar Design 93806 - 93806-1 - 90939-5 - 90814 - STD H2S NAM Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design 93806 - 93806-1 - 90939-5 - 90813 - STD H2S NAM Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design 93806 - 93806-1 - 90939-5 - 90812 - STD H2S NAM Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design 93806 - 93806-1 - 90939-5 - 94206-500 94206-501 94206-502 STD H2S NAM Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design 93806 89453-SP 93806 93806-1 93806-1 90939-5 89453-15 90939-5 94205-500 94205-501 94205-502 STD H2S NAM Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design 93806 89453-SP 93806 93806-1 93806-1 90939-5 89453-15 90939-5 94204-500 94204-501 94204-502 STD H2S NAM Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design 93806 89453-SP 93806 93806-1 93806-1 90939-5 89453-15 90939-5 40 Feb. 2, 1994 IBOP Part Numbers (Cont.) IBOP PART NO. TYPE OF SERVICE DESCRIPTION REPAIR KIT PART NO. SOFT SEALS BALL/SEAT PART NO. PART NO. 94203-500 94203-501 94203-502 STD H2S NAM Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design 93806 89453-SP 93806 93806-1 93806-1 90939-5 89453-15 90939-5 91138 - STD H2S NAM Upper Valve - PH85 - Big Bore 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design 95384 - 91137-SP - 91137-1 - 89451-501 89491-503 86434 STD H2S NAM Lower Valve 6 5/8 Pin X 6 5/8 Box 90939-2 89453-SP 90939-1 - 90939-5 89453-15 89452-501 89492-502 - STD H2S NAM Lower Valve-Stepped 6 5/8 Pin X 6 5/8 Box 90939-2 89453-SP 90939-2 90939-1 90939-1 90939-5 89453-15 90939-5 90811 - STD H2S NAM Lower Valve 7 5/8 Pin X 7 5/8 Box 93807 - 93807-1 - 90939-5 - 91138 - STD H2S NAM Lower Valve - Big Bore 7 5/8 Pin X 7 5/8 Box 94385 - 91137-SP - 91137-1 - 105629 - STD H2S NAM Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For Ids Only - - 90939-5 - 103220 - STD H2S NAM Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For TDS and SDS 90939-2 - 90939-1 - 90939-5 - 98977-500 98977-502 98977-501 STD H2S NAM Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design 99468-2 99469-SP 99468-2 99468-1 99468-1 65170014 98966 65170014 99461-500 STD H2S NAM Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design 99468-2 99469-SP 99468-2 99468-1 99468-1 65170014 98966 65170014 41 Feb. 2, 1994 Identifying Varco Safety Valves 42 Feb. 2, 1994 43 Feb. 2, 1994 44 Feb. 2, 1994 45 Feb. 2, 1994 46 Adobe Acrobat Navigation Below are the buttons that appear in your toolbar of this document. 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