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iTDS-11SAPreliminary
Lubrication and Maintenance 3
4Installation, Commissioning
and Decommissioning
Hydraulic System 5
Electrical System 6
PH-50 Pipehandler 7
8
9
1
Specifications
General Information
2
Motor Housing,Transmission
Guide Beamsand CarriageC
on
ten
tsC
on
ten
tsC
on
ten
ts
All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text, figures and tables.
This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system.
Where applicable, each section includes:
1. A table of contents, or an illustrated view index showing: Major assemblies, systems or operations Page references to descriptions in text
2. Disassembly / assembly information and tools3. Inspection information4. Testing / troubleshooting information5. Repair information6. Adjustment information7. Torque values
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains warnings about proceedures which could damage equipment or make it unsafe, and cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized.
Special Information
Notes, Cautions and Warnings
REV A 1998 Varco Systems Top Drive Technical Publications Department All rights reserved
How to Use This Manual
i
!
!
(Note) Gives helpful information.
(Caution) Indicates a possibility of personal injury or equipment damage if instructionsare not followed.
(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructionsare not followed.
ii Varco Systems
Introduction
34
5
6
7
8
9
1
General Information
2
1-1TDS-11SAPreliminary
Major components................................................. 1-2
Identification numbers .......................................... 1-3
Lifting points .......................................................... 1-4
Safety wiring .......................................................... 1-5
Torque values ........................................................ 1-6
Basic useage ......................................................... 1-7Drilling ahead with singles ............................... 1-7Drilling ahead with triples................................. 1-8Backreaming...................................................... 1-9
1-2 Varco Systems
1
General Information
Major components
AC DrillingMotors (2)
Hydraulic DiscBrakes (2)
Motor CoolingSystem
Carriage
GuideBeam
HydraulicSystem
ElectricalSystem
PH-50Pipehandler
Gooseneck(S-Pipe)
CounterbalanceSystem
Transmission/Motor Housing
Rotating LinkAdapter
Left Side Front
Rear
Rear
Right Side Front
1General Information
1-3TDS-11SAPreliminary
Identification numbers
SALES ORDER NO.ASSY NO. REVTRACE CODEDATE OF MANUFACTURE
Encoder Instruction LabelOn the side of brake housing
Warning LabelOn the side of bonnet
Warning LabelsOn the side of each AC motor
AC Motor Identification LabelOn the side of each AC motor
Top DriveIdentification Plate
On the front of motor housing
1-4 Varco Systems
1
General Information
Lifting points
!
!
Bail LockMust be installed
before lifting top drivefrom the skid or attaching
top drive to the skid
Lifting PointFor removal or
attachment to the skid
37,000 lbs(16,798 kg)
TDS-11SA on skid
34,500 lbs(15,663 kg)
TDS-11SA
Lifting PointsFor skid attached to top drive
Lifting PointsFor skid attached to top drive
Locking pinsMust be in place
prior to moving skidwith top drive
1General Information
1-5TDS-11SAPreliminary
Safety wiring
3 4 5
21
1-6 Varco Systems
1
General Information
Torque values
Diameter
1/45/163/8
7/161/2
9/165/83/47/81
1 1/81 1/41 3/81 1/2
1/45/163/8
7/161/2
9/165/83/47/81
1 1/81 1/41 3/81 1/2
2018161413121110
987766
Threadsper inch
2824242020181816141412121212
Bolts Lubricated withLight Machine Oil
Grade 5
7.616294871
105143247409608760
1,0641,3871,843
Min.Torque(ft lb)
9.518335286
114162285447665836
1,1781,5962,090
8.418325379
116158273452672840
1,1761,5332,037
Max.Torque(ft lb)
10.520375895
126179315494735924
1,3021,7642,310
2,0203,3404,9406,8009,050
11,60014,40021,30029,40038,60042,30053,80064,10078,000
ClampForce
(lb)
2,3203,7005,6007,550
10,70012,95016,30023,80032,40042,20047,50059,60073,00087,700
5.712.121.4
365378
107185306456570798
1,0401,382
Min.Torque(ft lb)
7.113.5
25396486
121214335499627884
1,1971,568
6.313.423.6
395987
118205339504630882
1,1501,528
Max.Torque(ft lb)
7.915.0
28437195
134236370551693977
1,3231,733
2,0203,3404,4906,8009,050
11,60014,40021,30029,40038,60042,30053,80064,10078,000
ClampForce
(lb)
2,3203,7005,6007,550
10,70012,95016,30023,80032,40042,20047,50059,60073,00087,700
Bolts Lubricated withAnti-seize Compound
Grade 5
Coarse Thread Series, UNC
Fine Thread Series, UNF
T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psiT.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi
1General Information
1-7TDS-11SAPreliminary
Basic useage
Drilling ahead with singles
1 2 3 4 5
n Set slips on string
n Stop circulation
n Close IBOP
n Breakout connection using pipehandler and drilling motor (in reverse)
n Lower block to stab motor into top of single
n Spin in motor and single
n Makeup both connections with motor in torque mode
n Pull slips
n Open IBOP
n Start circulation
n Begin drilling
n Tilt links to mousehole
n Latch drill pipe elevator around single
n Pickup single with elevator
n Release link tilt
n Stab bottom of single onto string
Stab
OpenIBOP
Makeup
Close IBOPLink Tilt
Makeup
1-8 Varco Systems
1
General Information
Drilling ahead with triples
1 2 3 4 5
n Set slips on string
n Stop circulation
n Breakout connection using pipehandler and drilling motor (in reverse)
n Raise block
n Tilt link tilt to derrickman
n Pickup stand with elevator
n Stab bottom of stand onto string
n Lower block to stab motor into top of stand
n Spin in motor and stand
n Makeup both connections with motor
n Pull slips
n Start circulation
n Begin drilling
Stab
StopCirculation
Link Tilt
Makeup
Makeup
StartCirculation
1General Information
1-9TDS-11SAPreliminary
Backreaming
1 2 3 4 5
n Hoist while circulating and rotating
n When 3-rd connection surfaces, stop rotation and circulation
n Setback standusing link tilt
n Lower block, stab motor into string
n Spin in motor and makeup connection with motor
n Start circulation, pull slips, hoist and rotate
n Hoist free stand with elevator
n Set slips on string
n Breakout connection using pipehandler and drilling motor (reverse)
n Breakout and spinout stand at floor
Setback
Breakout
Breakout Hoist
Hoist andRotate
1-10 Varco Systems
1
General Information
34
5
6
7
8
9
1
Specifications
2
2-1TDS-11SAPreliminary
Design specifications............................................ 2-2Size specifications ............................................ 2-2Size specifications (continued) ........................ 2-3General specifications ...................................... 2-4
Typical mast interface ........................................... 2-5
2-2 Varco Systems
2
Specifications
Design specifications
Size specifications
Front and side view
233.0 in.(5918 mm)
= 37,000 lb= 16,798 kg
To Centerof Gravity
112.4 in.(2855 mm)
71.9 in. (1826 mm) 62.5 in.(1588 mm)
56.0 in.(1422 mm)
To Centerof Gravity
28.2 in.(716 mm)
18.5 in. (470 mm)
Bail120 in.
(3048 mm)
Bail88 in.
(2235 mm)
2-3TDS-11SA
2
Specifications
Preliminary
Size specifications (continued)
Plan view
33.7 in. (856 mm)
31.0 in. (787 mm)32.6 in. (828 mm)36.9 in. (937 mm)26.0 in. (660 mm)
22.8 in.(579 mm)
Well
Front
Rear
33.8 in.(859 mm)
21.1 in.(53 mm)
22.1 in.(561 mm)
30.0 in.(762 mm)Setback
(Standard)
CL
WellCL
2-4 Varco Systems
2
Specifications
General specifications
Top Drive
Drilling Motor
Pipe Handler
Drill Pipe
Variable Frequency Drive
Motor Braking
Motor Cooling System
Gearcase
Gearcase Lubrication
Hydraulic System
Electrical House
WeightStack-up HeightPower RequirementsHorsepowerOutput torque (continuous)Tool torque (intermittent @ stall)Maximum Speed @ full powerHoisting capacity
Sizes
Type
Type
Type
Type
TypePowerSpeed
Type
Gear ratio
TypeReservoir capacityFully internal flowGear Type
PowerFlowSpeedReservoir capacityOil Type
SizeTypeWeightInput requirement
Items
34,500 lb17.8 ft700 KVA @ 575-600 VAC, 50/60 Hz800 hp37,500 ft lb (800 hp)55,000 ft lb228 rpm500 ton
3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
PH-50 (55,000 ft lb torque)
Reliance AC-575 VAC (2 x 400 hp)
IDM Yaskowa Drive (800 hp, 575 VAC) orSiemens (800 hp, 600 VAC)
Hydraulic caliper disc brakes
Local intake pressure blower(2) 5 hp AC motors3,600 rpm
Single speed, double reduction spur gearsystem (helical gears optional)10.5:1 (4.??:1 optional)
Pressure feed15 gal
10 hp, AC motor(1) 6 gpm, (1) 4 gpm1800 rpm25 gal
125.4 in. x 84.0 in., 91.2 in. height (Siemens)140.0 in. x 90.0 in., 91.0 in. height (IDM)9,500 lb600 VAC(60 Hz), or 600 VAC(50 Hz),or 750 VDC, or 690 VDC(50 Hz)
DescriptionComponents
2-5TDS-11SA
2
Specifications
Preliminary
Typical mast interface
*
**
Dimensions are Subject to Verification
Standard TDS Configuration-Two IBOPs with 108 in. Elevevator Links
AC Cables
Existing Traveling Equipment350-ton Hook/Block Combo-Typ.
TDS-11SVarco Portable
Top Drive System
Crown
Block Top
Bail Rest
Tool Joint
Tool Joint
BeamService Loop
CL
Sectional Guide Beam
Mud Hose75 ft. (22,9 m)*
Connected to Standpipeat 73 ft. (22,3 m) Level
Service Loop200 ft. (61 m)*
Service Loop Saddle at ~80 ft. (24,4 m) Level*
Portable Torque Reaction BeamU- Bolted to Spanners - (by Customer)
2 Custom SpannersOn A-Frames or Mast Side Panels (by Customer)
Varco Drillers Control
Control Cable with Connectors150 ft. (45,7 m)
Local Power SupplyDiesel/Alternator Set/AC Buss
Unitized Variable FrequencyInverter & Varco Control Panel
Drill Floor
AC Power andControl Cables
Drill StandMade-up at4 ft. (1,2 m)
Level93 ft. (28,3 m)
Clearance13.5 ft. (4,1 m)**
TDS Work Height18.0 ft. (5,4 m)**
Stroked-Typ.13.5 ft. (4,1 m)*
4.0 ft. (1,2 m)
10.0
ft. (3
m)-M
inimu
m*
7.0
ft. (2,
1 m)-M
inimu
m
Cle
ar
Wo
rkin
g H
eig
ht
142
ft. (43
,3 m)
2-6 Varco Systems
2
Specifications
Lubrication
3
4
5
6
7
8
9
1
2
3-1TDS-11SAPreliminary
Transmission ......................................................... 3-2Selecting the proper gearbox oil...................... 3-2Lubrication schedule ........................................ 3-2Recommended gear oils ................................... 3-3Gearbox lubrication .......................................... 3-4
Hydraulic system................................................... 3-5Precautions........................................................ 3-5Lubrication schedule ........................................ 3-5Recommended hydraulic fluid ......................... 3-6Hydraulic lubrication......................................... 3-7
Motors .................................................................... 3-8Lubrication schedule ........................................ 3-8Recommended motor grease ........................... 3-8Motor lubrication ............................................... 3-9
General purpose lubrication ................................. 3-10Lubrication schedule ........................................ 3-11Recommended lubricants ................................ 3-11General lubrication ........................................... 3-12General lubrication (continued) ....................... 3-13General lubrication (continued) ....................... 3-14General lubrication (continued) ....................... 3-15
3-2 Varco Systems
3
Lubrication
Transmission
Selecting the proper gearbox oilTDS transmissions operate under a combination of heavy and shockloads. Under these conditions oil tends to extrude out of the gear mesh.Keeping an effective film of oil on the gear mesh requires oil with anAGMA extra pressure rating (EP), and a minimum viscosity of 100 SUSat internal operating temperature.
Varco Top Drives also operate under a wide variety of temperatures.Select lubrication for the TDS based on the minimum ambienttemperature (surrounding air) to be expected before the next oil change.Under all but the most severe operating conditions, Varco recommendschanging the oil every six months. Introducing an oil viscosity greaterthan required by the ambient temperature can:
o Damage the gearbox due to reduced oil flow
o Damage the oil pump because of excessive load
Lubrication schedule
Replace the Gearbox Oil and Perform an Oil AnalysisOil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 111013)
1 x every 6 Months
1 x every 3 Months
Description Frequency
The first oil change should be performed after the first month ofoperation since new units often contain metal contaminates andcontaminates caused by initial break-in.
3-3TDS-11SA
3
Lubrication
Preliminary
Recommended gear oils
Ambient Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
NGLI
AGMA
ISO Viscosity Grade
Above 21 C(Above 70 F)
Alpha LS-320NL Gear 320
Spartan EP320EP Lube HD320MobilGear 632
Omala 320Loadway EP320
Meropa 320Carter EP 320
Extra Duty NL6EP
N/R6EP320
7 to 30 C(45 to 85 F)
Alpha LS-150NL Gear 150
Spartan EP150EP Lube HD150MobilGear 629
Omala 150Loadway EP150
Meropa 150Carter EP 150
Extra Duty NL4EP
N/R4EP150
-6 to 16 C(20 to 60 F)
Alpha LS-68NL Gear 68
Spartan EP68EP Lube HD68MobilGear 626
Omala 68Loadway EP68
Meropa 68Carter EP 68
Extra Duty NL2EP
N/R2EP68
e Oils of insufficient viscosity can damage gears by allowing metal tometal contact.
z For minimum temperatures below 20F, the TDS must be warmed up byrotating at a very light load (less than 200 Amps) and at very slowspeeds (less than 50 rpm) until the oil temperature climbs above 20F. Ifdrilling conditions dictate oil temperatures below 20F, consult Varcoengineering.
If the oil temperature rises above 200F, Varco recommends shuttingdown or reducing drilling loads to stabilize the oil temperature below200F If drilling conditions dictate oil temperatures above 200F, consultVarco engineering.
3-4 Varco Systems
3
Lubrication
Gearbox lubrication
Gear OilSight Gauge
Check withTop DriveOFF
Gearbox Oil FillUse a 1 3/8 inch, 12 point
socket to remove plug
Cork Ball(Level Indicator)
SightGlass
Pop-upDirt Alarm
Gear Oil Filter
3-5TDS-11SA
3
Lubrication
Preliminary
Hydraulic system
Precautions
n Release all hydraulic oil pressure by bleeding accumulators beforedisconnecting hydraulic lines. Turn the counterbalance valve toshutdown mode to bleed the hydraulic system. Hydraulic oil underpressure can penetrate skin and cause serious injury.
n Before opening the hydraulic system, thoroughly clean work area,and maintain system cleanliness by promptly capping alldisconnected lines. Dirt is extremely harmful to hydraulic systemcomponents and can cause equipment failure and subsequentinjury to personnel.
e Use care when handling components to prevent nicking close tolerancefinishes.
e Use care to prevent contamination from entering the hydraulic systemduring maintenance activities.
Lubrication schedule
Perform Hydraulic System Oil Analysis
Replace the Hydraulic Fluid
Replace the Hydraulic System Filter (P/N 114416-1)
1 x every 6 Months1 x Year, or Earlier Based on Oil Analysis
1 x every 3 Months
Description Frequency
The first oil change should be performed after the first month ofoperation since new units often contain metal contaminates andcontaminates caused by initial break-in.
3-6 Varco Systems
3
Lubrication
Recommended hydraulic fluid
Hyspin AWS-46AW Hyd oil 46
Nuto H46Harmony 46AW
DTE 25Tellus 46
Hydraway HMA 46Rando oil HD46
Azolla ZS 46Unax AW46
46
Hyspin AWS-32AW Hyd oil 32
Nuto H32Harmony 32AW
DTE 24Tellus 32
Hydraway HMA 32Rando oil HD32
Azolla ZS 32Unax AW32
32
-10 to 85 C(14 to 185 F)
-15 to 75 C(5 to 167 F)
Oil Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
ISO Viscosity Grade
3-7TDS-11SA
3
Lubrication
Preliminary
Hydraulic lubrication
Red Pop-upDirt Alarm
Hydraulic Oil Filter
Hydraulic Oil Fill
HydraulicOil SightGauge
Cork Ball(Level Indicator)
SightGlass
Hydraulic OilFill Quick
Disconnect
LubricationKit Quick
Disconnect
n Ensure that the area is clean prior to adding hydraulic fluid
n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill
n Remove dust plug from the female quick disconnect on the lubrication kit
n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as shown
HydraulicLubrication Kit
55 gal Drum
3-8 Varco Systems
3
Lubrication
Motors
n Varco recommends that lubrication of all AC motors should bedone by the rig electrician.
Lubrication schedule
Description No. of Points Frequency Type
Lubricate the AC Drilling Motor
Lubricate the Blower Motor
Lubricate the Hydraulic Pump Motor
Motor GreaseMotor GreaseMotor Grease
1 x every 3 Months1 x every 3 Months1 x every 3 Months
442
Recommended motor grease
Black Pearl EP2 (Do Not Substitute)
Motor Grease
Manufacturer
Chevron
3-9TDS-11SA
3
Lubrication
Preliminary
Motor lubrication
AC BlowerMotor (2)
3 pumps(2 grease fittings
each motor)
AC DrillingMotor (2)
5 pumps(2 grease fittings
each motor)
1/8 inchPipe Plug(remove andreinstall afterlubricating)
1/8 inchGrease Fitting
(Varco P/N53201)
3 Months
3 Months
3 Months
Hydraulic PumpAC Motor
3 pumps(2 grease fittings
each motor)
As Viewed From Below
Grease Fittings
Apply grease to designatedgrease fittings with grease gun
3-10 Varco Systems
3
Lubrication
General purpose lubrication
e The lubrication intervals described in this manual are based on lubricantsupplier recommendations. Severe conditions such as extreme loads ortemperature, corrosive atmosphere, etc., may require more frequentlubrication.
e Worn bushings, binding parts, rust accumulations, and other abnormalconditions indicate more frequent lubrication is necessary. Be careful notto over lubricate parts. For example, too much grease forced into a fittingcan pop out a bearing seal. Over lubrication can also affect safety sinceover lubricated parts can drip, creating a potential slipping hazard forpersonnel.
Lubrication schedule
Washpipe Assembly
Upper Bonnet Seal
Bail Pins
Rotating Link Adapter Gear
Rotating Link Adapter
IBOP Actuator Yoke, Cylinder Pins
IBOP Actuator Cranks
Stabilizer Bushing
Clamp Cylinder Gate
Carriage Assembly
Torque Arrestor at Clamp Cylinder
Elevator Link Eyes
Wireline Adapter
General Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose GreaseGeneral Purpose Grease
112
252428442
DailyWeeklyWeeklyWeeklyWeeklyDailyDailyDailyDaily
WeeklyWeeklyWeeklyWeekly
Description No. of Points Frequency Type
3-11TDS-11SA
3
Lubrication
Preliminary
Recommended lubricants
Above -20 C(Above -4 F)
Below -20 C(Below -4 F)
MP GreaseAvi-MotiveLidok EP2
Gulf Crown EP32Mobilux EP2Alvania EP2
Uniway EP2NMultifak EP2Multis EP2Unoba EP2
2N/RN/R
N/RAvi-Motive W
Lidok EP1Gulf Crown EP31
Mobilux EP1Alvania EP1
Uniway EP1NMultifak EP1Multis EP1Unoba EP1
1N/RN/R
Ambient Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
NGLI
AGMA
ISO Viscosity Grade
3-12 Varco Systems
3
Lubrication
General lubrication
Wash PipeAssembly
Apply one pumpat beginning of tour
Apply general purposegrease to designatedgrease fittings with
grease gun. Use a brushwhen greasing other parts.
Daily
Upper Bonnet SealOne pump
Use Hand Pump Only
Weekly
Bail Pins (2)Two pumps each side
Weekly
Rotating LinkAdapter Gear
Weekly
Elevator Link Eyes (4)
Weekly
Rotating Link AdapterThree pumps each
Weekly
3-13TDS-11SA
3
Lubrication
Preliminary
General lubrication (continued)
IBOP Actuator Cylinder PinsOne pump each
(if equipped)
Daily
IBOPActuator Yoke
One pump(if equipped)
Daily
IBOPActuator Yoke
One pump each side
Daily
IBOP Actuator CranksOne pump each side
Daily
Stabilizer BushingOne pump each
DailyStabilizer Bushing
One pump each side
Daily
Clamp Cylinder GateOne pump each side
Daily
ElevatorLink Eyes (4)
Weekly
TorqueArrestor Tubes
Weekly
Apply general purpose greaseto designated grease fittingswith grease gun. Use a brushwhen greasing other parts.
3-14 Varco Systems
3
Lubrication
General lubrication (continued)
Rollers (4)One pumpeach side
Weekly
Bogies (4)One pumpeach side
Weekly
Apply general purpose greaseto designated grease fittings
with grease gun
3-15TDS-11SA
3
Lubrication
Preliminary
General lubrication (continued)
Wireline AdapterOne pump each
Weekly
Apply general purpose grease to designated grease
fittings with grease gun
3-16 Varco Systems
3
Lubrication
34
Installation, Commissioningand Decommissioning
5
6
7
8
9
1
2
4-1TDS-11SAPreliminary
Illustrated index................................................. 4-3Preparation and preinstallationconsiderations................................................... 4-4
Preinstallation........................................................ 4-5Installing the crown padeye andhang-off link....................................................... 4-5Locating the control house .............................. 4-6Installing incoming power cables .................... 4-7
Installation ............................................................. 4-8Pre-installation checklist .................................. 4-8Moving the TDS-11SA to the drill floor ............ 4-9Removing the TDS-11SA from the skid ........... 4-10Disengaging the lower carriage latch .............. 4-11Moving guide beam sections ........................... 4-12Present and hook the firstguide beam section........................................... 4-13Hoist the first guide beam section ................... 4-14Stab and pin the first guide beam section ...... 4-15Completing the guide beam installation ......... 4-16Hanging the guide beam................................... 4-17Disengaging the upper carriage latch ............. 4-18Installing the main tieback ............................... 4-19Installing the intermediate restraints............... 4-20Installing derrick termination ........................... 4-21Installing the service loop ................................ 4-22Service loop connection diagram .................... 4-23Installing the drillers console .......................... 4-24Installing the mud hose .................................... 4-25Installing the counterbalance........................... 4-26Installing the rotary hose.................................. 4-27
4-2 Varco Systems
4
Installation, Commissioningand Decommissioning
Commissioning ..................................................... 4-28Hydraulic system checkout procedure ........... 4-28Electrical system checkout procedure ............ 4-29Mechanical checkout procedure...................... 4-30
Decommissioning.................................................. 4-35Removing and storing the electrical cablesand service loops .............................................. 4-35Securing the TDS-11SA for rig-down .............. 4-36Setting the latches and locking the bail .......... 4-37Disconnecting the guide beam ........................ 4-38Unpinning each guide beam section ............... 4-39Lowering each guide beam section................. 4-40Unhooking and removing eachguide beam section........................................... 4-41Returning the TDS-11SA to the skid ................ 4-42Removing the TDS-11SA from the drill floor... 4-43Long term storage procedures ........................ 4-44Returning the TDS-11SA to serviceafter storage ...................................................... 4-44
4-3TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Illustrated index
AC CablesPage 4-X
VarcoDrillers Console
(VDC)Page 4-X
Control Cablewith Connectors
Page 4-X
Local Power SupplyDiesel/Alternator Set/AC Bus
Unitized VariableFrequency Inverter and
Varco Control Panel (House)Page 4-X
AC Power andControl Cables
Page 4-X
DerrickTermination
Page 4-X
Main TiebackPage 4-X
Service LoopPage 4-X
Rotary HosePage 4-X
Crown Padeye andHang-off Link
Page 4-X
CounterbalancePage 4-X
IntermediateRestraints
Page 4-X
Guide BeamPage 4-X
4-4 Varco Systems
4
Installation, Commissioningand Decommissioning
Preparation and preinstallation considerationsThe TDS-11SA interfaces with the rigs hoisting system and electricalpower system. Derrick and electrical system modifications are requiredwhen installing the TDS-11SA on existing rigs.
For derricks that handle triples, the required top drive travel is about 100ft. compared to about 75 ft. when using a Kelly. It is generally necessaryto replace the regular rotary hose (which is normally 60 ft. long) with a 75ft. hose, and extend the standpipe height to 70 ft.
Although many rig floor layouts are possible, installing the guide beamon the drawworks side of the derrick, or mast, and opposite the V-door isan ideal arrangement for handling tubulars from the V-door.
The location of the electrical loop and mud hose is an importantinstallation consideration for pipe setback purposes, to ensure properclearance and to help prevent wear to the service loop and mud hose.Other important installation considerations include the location of:
o The casing stabbing board
o Floor and derrick accessories
o Drawworks fastline
o Guide beam hang-off bracket
o Torque reaction beam
o Mud stand pipe extension
o Varco drillers console location
o Variable frequency inverter/Varco control panel location
Derrick height is a critical interface requirement. Handling a93 ft. stand typically requires 97 ft., resulting in an overall height from thefloor to the top of the traveling block of at least 126 ft.
Derrick Clear Working Height Derrick Crown Clearance152 ft. 25 ft.147 ft. 20 ft.142 ft. 15 ft.136 ft. 9 ft.
Each rig has different crown clearance for efficient tripping. Installing theTDS-11SA with existing traveling equipment may require an adapterfurther reducing crown clearance.
4-5TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Preinstallation
Installing the crown padeye and hang-off link
See Table
Well
CL
Crown PadeyeWeld accordingto table below
Crown
Shackle
Hang-off Link
36.8 inches
33.8 inches
30.0 inches
Standard height configuration (adustable)Varcos IDS Top Drive requirementsOriginal setback for TDS-9S
DescriptionDimension
Recommended Installations
4-6 Varco Systems
4
Installation, Commissioningand Decommissioning
Locating the control house
VarcoDrillersConsole
ControlHouse
Recommended Area forControl House Location
9,500 lb(4300 kg)
Control House
V-DoorRamp
TDS-11SA
Dra
ww
ork
s
Well
CL
Well
CL
91.00 in.(2311.4 mm)
90.00 in.(2286 mm)
140.00 in.(3556 mm)
Recommendations
n Position the control house off the drillers side or behind the drawworks.
n Position as close to derrick plate as possible to minimize cable lengths.
n Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts).
n Location of the control house must ensure accessibility from all sides.
4-7TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Installing incoming power cables
F-W INCOMING 575VAC
C-AUX. POWER CONNECTOR
B-SERIAL CONNECTOR
G-U OUTGOING 575VACH-V OUTGOING 575VAC
I-W OUTGOING 575VAC
D-U INCOMING 575VACE-V INCOMING 575VAC
A-COMPOSITE CONNECTOR
Plug Panel
Plug PanelIncoming
PowerCables
Varco Control Panel(House)
Recommendations
n Connect the incoming power cables with the isolation circuit breaker turned OFF.
n Connect cables in accordance with the electrical schematic provided in the Technical Drawings book.
n Earth the control house with the Varco Ground Rod Kit. Grounding locations are at the lower corners of the control house.
4-8 Varco Systems
4
Installation, Commissioningand Decommissioning
Installation
Pre-installation checklist
The following assumes that all pre-installation planning and rig-up iscomplete prior to installation of the guide beam assembly and TDS-11SA. This includes:
o Make sure the derrick/mast is vertical, with the block over the centerof the rotary table.
o Derrick/mast modifications are completed (if required) and the guidebean support bracket and torque reaction beam are installed andinspected to conform to Varco specifications as detailed in FIP00003.
o The service loop bracket is installed in the derrick/mast.
o The control panel and frequency drive are installed.
o Rigging of tong lines, etc. is inspected to ensure that they will not foulwith the TDS-11SA.
o The hook or adaptor becket is installed. The hook should opentoward the drawworks.
4-9TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Moving the TDS-11SA to the drill floor
!
!
V-DoorRamp
LiftingSling
Backup Line
TDS-11SAIn position
prior to liftingfrom skid
2
Be sure that theBail Lock Assembly
is installedTube (P/N 113498)U-Bolt (P/N 113497)
2x 3/4" nuts
Be sure thatthe Top Driveis pinned to
the Skid priorto hoisting
Lifting SlingAttached to bail
for hoisting
TDS-11SAon Skid
3
1
DrillFloor
LiftingBlock
Hoist usingthe drawwork
37,000 lb(16000 kg)
TDS-11SA on Skid
4-10 Varco Systems
4
Installation, Commissioningand Decommissioning
Removing the TDS-11SA from the skid
!
SkidRemove from drill floor
after hoisting TDS-11SA
Lock PinRemove prior to
hoisting from skid
TDS-11SALifted from
skid
TDS-11SAPrior to lifting
from skid
2
1
3
LiftingBlock
Hoist fromskid using
the drawwork
DrillFloor
Be sure that the Bail Lock Assemblyis installed. Remove only after
installation is complete.
TDS-11SA
2,500 lb(1100 kg)
Skid
34,500 lb(15700 kg)
TDS-11SA
Pin
Pin
LatchesEngaged
for hoisting
4-11TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Disengaging the lower carriage latch
!
As viewed fromrear of Carriage
Pin
Guide BeamWings
Guide BeamTop Section
Carriage
Upper Latch
Engaged
Lower Latch
Disengaged
After hoisting the TDS-11SA from the skid, disengage the lower carriage latch and pin it as shown.
TDS-11SAprior to lifting from skid
4-12 Varco Systems
4
Installation, Commissioningand Decommissioning
Moving guide beam sections
Guide Beam SectionsPrior to Installation
DrillFloor
TDS-11SA
Sling
Lifting Eyes
Guide BeamSection
2,100 lb(953 kg)
Guide Beam Section
4-13TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Present and hook the first guide beam section
DrillFloor
Guide BeamSection
Hooked
Present and Hookthe first guidebeam section
Hook Pin Saddle
Hook Pin
Hook PinIn fully
engagedposition
Present
Hook
Guide Surface
Greasethe bores on
both joint halves Greasethe bores on
both joint halves
Guide BeamTop Section
Guide BeamTop Section
Radius locks joint fromunhooking at 8 rotation
1
2
4-14 Varco Systems
4
Installation, Commissioningand Decommissioning
Hoist the first guide beam section
Bar and RadiusLocates pin bores foreasy insertion of pins
Hook Pin
First GuideBeam Section
Initially hoistedby the hook pin
Hoist
DrillFloor
HoistUsing the drawwork
Guide BeamTop Section
4-15TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Stab and pin the first guide beam section
Stab and Pinthe guide beam joint
Block asRequiredDrill
Floor
Stabthe guide beamjoints together
Joint PinInstall after
stabbing
RetainerPin
LynchPin
Guide BeamTop Section
Securewith thelynch pin
1
2
34
4-16 Varco Systems
4
Installation, Commissioningand Decommissioning
Completing the guide beam installation
(36.8 in.)(934.72 mm)
Standard adjustableheight configuration
Note:Use these pin positionsif crown padeyeinstallation is based on:
(33.8 in.)(858.52 mm)Varcos IDS
top driverequirements
(30.0 in.)(762 mm)Original
TDS-9S or ifplate extension(36.8 in.) needsto be cut off dueto interference.
Well
CLGuide BeamTop Section
CL
CrownPadeye
ShackleEnsure that the shackle
is pinned and thecotter pin is in place
Crown
TDS-11SAHoistinglatches
disengaged
Guide BeamTop Section
Safety Pin
Hang-offLink
Pin
DrillFloor
Main Tieback andSpreader Beam
FloorClearance
7 ft.(2,133.6 mm)
Guide BeamAssembled
4-17TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Hanging the guide beam
36.8 in.(934.72 mm)
Standard adjustableheight configuration
Note:Use these pin positions ifcrown padeye installationis based on:
33.8 in.(858.52 mm)
Varcos IDS Top Driverequirements
30.0 in.(762 mm)
Original TDS-9S or ifplate extension (36.8 in.)needs to be cut off due
to interference.
Well
CLGuide BeamTop Section
CL
CrownPadeye
ShackleEnsure that the
shackle is pinnedand the cotter pin
is in place
Crown
TDS-11SA
Guide BeamTop Section
Safety Pin
Hang-offLink
Pin
DrillFloor
FloorClearance
7 ft.(2,133.6 mm)
GuideBeam
Assembled
4-18 Varco Systems
4
Installation, Commissioningand Decommissioning
Disengaging the upper carriage latch
!
As viewed fromrear of Carriage
Guide BeamTop Section
Carriage
Upper Latch
Disengaged
Pin
Lower Latch
Disengaged
After hanging the guide beam on the
hang-off link and prior to lowering the Top Drive, disengage the upper carriage latch and pin it as shown.
DrillFloor
Guide BeamAssembled
4-19TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Installing the main tieback
Mast Leg
AuxiliarySpreader Beam
Guide BeamBottom Section
MainSpreader
Beam
Apply Anti-seizeCompound
Typical
Tieback Link
TiebackPlate
DrillFloor
Main Tieback andSpreader Beam
SeeTable
GuideBeam
Assembled
36.8 inches Standard height configuration (adjustable)
33.8 inches Varcos IDS Top Drive requirements
30.0 inches Original setback for TDS-9S
Dimension Description
Recommended Installations
Well
CL
4-20 Varco Systems
4
Installation, Commissioningand Decommissioning
Installing the intermediate restraints
DrillFloor
105Feet
55Feet
Guide BeamAssembled
Guide BeamAssembled
Girt
IntermediateTieback Plate
(2)
Apply Anti-seizeCompound
Padeye (2)(If greater than
3 inches from girt)
Padeye (1)(If less than
3 inches from girt)
Pin andCotter Pin
Space between girtand guide beam
3 inches
n Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor
n Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches
n Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches
4-21TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Installing derrick termination
Hoist LineAttachment
Points
Service LoopBrackets
75 ft/83 ftfrom Drill Floor
Hoist LineAttachment
Point
Derrick/Mast Leg
DerrickLeg Plate
n Mount on the side of the derrick adjacent to the service loop brackets on the TDS-11SA
n Mount as far as practical from well center, to maintain a 36 inch minimum bend radius. Maintaining a larger radius increases loop life and reduces damage due to pinching.
n Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc.
4-22 Varco Systems
4
Installation, Commissioningand Decommissioning
Installing the service loop
!
!
Service Loopand Storage Tub
3,600 lbs(1,634.4 kg)
DerrickService Loop
Lifting EyesDo not remove
TDSService Loop
DerrickTermination
To avoid damage to theservice loop maintain a36 inch minimum
bend radius
To avoid damage to the service loop
use care when dragging it near sharp edges
and allow room for passing under the
V-door
Hoist
Sling
n Do not unpack the service loops until they are ready to hang
n Use a sling attached to the lifting eyes to hoist each service loop. Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting.
n The TDS service loop connects electrical service to the top drive and the derrick service loop connects electrical service to the control house
n Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package
1,000 lbs(454 kg)
Service Loop
4-23TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Service loop connection diagram
4-24 Varco Systems
4
Installation, Commissioningand Decommissioning
Installing the drillers console
PIPEHA
NDLER
IBOP
TORQUE
BRAK
EEM
ERGENC
Y
STOP
!
VarcoDrillersConsole
V-DoorRamp
Pigtail CablesConnect to
control house
TDS-11SA
Dra
ww
ork
s
Well
CL
Well
CL
Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system, as it is specifically made for use with the TDS-11SA.
n Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated
n Location must ensure that the gauges are easily seen by the driller during drilling operations
n Location must be visible and readable at night
4-25TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Installing the mud hose
4-26 Varco Systems
4
Installation, Commissioningand Decommissioning
Installing the counterbalance
For use withHooks
4-27TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Installing the rotary hose
8
5
4
3
1
5
4
3
2
69
7
8
10
10
11
12
11
12
6
13
14
O
4-28 Varco Systems
4
Installation, Commissioningand Decommissioning
Commissioning
Hydraulic system checkout procedure
Checking hydraulic fluid level
4-29TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Electrical system checkout procedure
Checking connections and motor rotation
PIPEHA
NDLER
IBOP
BRAK
EEM
ERGENC
Y
STOP
TORQUE
OFF
MAKE-
UP
CURREN
T LIMIT
OIL
PRESS
LOSS
LINK T
ILT FL
OAT
DRILL
MOTOR
OVERTE
MP
TORQUE
WRENC
H
PUSH &
HOLD
LINK T
ILT
OFF
BLOWE
R LOSS
ROTATE
LEFT
DRILL
TILT
RIGHT
SPIN
DRILL
TORQUE
HYDRAU
LIC PO
WER
AUTO
ON
IBOP
CLOSED
ALARM
SILENCE
LAMP
CHECK
BRAKE
ON
BRAKE
AUTO DRI
VE
FAULT
IBOP
OPEN
CLOSE
BRAKE
ON
/
OFF
DRILL
TORQUE
0
0
MAX
TORQUE
RPM
MAX
0
MAX
REVERS
E
FORWA
RD
n Operate each control on the Varco drillers console
n Assign the cooling motors and inverter by selecting FORWARD or REVERSE on the drillers console
n Rotate the drill stem using the THROTTLE on the drillers console and observe proper operation
n Check for alarm conditions and resolve any alarms at this time
n Check all connectors for tightness and lockwire
n Check operation of meters
n Check operation of ? stop
n Check the latches on the drillers console for tightness
Throttle
Latches
VarcoDrillers Console
Forward/ReverseControl
4-30 Varco Systems
4
Installation, Commissioningand Decommissioning
Mechanical checkout procedure
Checking gearbox oil level
Pop-upDirt Alarm
GearOil Filter
Gear OilSight Gauge
Check withtop driveOFF
Cork Ball(Level Indicator)
SightGlass
GearboxOil Fill
Clean area beforeremoving plug
Ambient Temperature Range
CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion
NGLIAGMAISO ViscosityGrade
Above 21 C(Above 70 F)
Alpha LS-320NL Gear 320
Spartan EP320EP Lube HD320MobilGear 632
Omala 320Loadway EP320
Meropa 320Carter EP 320
Extra Duty NL6EP
N/R6EP320
7 to 30 C(45 to 85 F)
Alpha LS-150NL Gear 150
Spartan EP150EP Lube HD150MobilGear 629
Omala 150Loadway EP150
Meropa 150Carter EP 150
Extra Duty NL4EP
N/R4EP150
-6 to 16 C(20 to 60 F)
Alpha LS-68NL Gear 68
Spartan EP68EP Lube HD68MobilGear 626
Omala 68Loadway EP68
Meropa 68Carter EP 68
Extra Duty NL2EP
N/R2EP68
GEAR OIL
Recommended Lubricants
n With the drive motors and hydraulic system off, check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox
n 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).
n Check filter condition pop
4-31TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Adjusting the link tilt
Link TiltCrank Assembly
inches(mm)
Typical
Pin
Latch
Link
ClampMousehole
Position CablePull up or downto set mousehole
position
Elevator
Drill DownPosition
Bottom of elevatorshould be above
bottom ofstabbing guide
(inches)(mm)
MouseholePosition
DerrickmansPosition
Well Center(Float Position)
4-32 Varco Systems
4
Installation, Commissioningand Decommissioning
Selecting the proper saver sub and clamp cylinder jaws
53
43
21
20
37
36
23
22
26
25
21
20
19
18
17
16
11
12
1
24
45
44
37
36
51
13
3550
34
33
32 28
27 49
48
35
31
13
57
58
12
34
33
32 30
29 28
27
15
10 6 4 3
2
5
9
8
7
14
15
14
41
60
59
47
46
19
18
17
16
40
39
38
21
20
40
42
41
52
54
55
56
S
4-33TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Removing and installing the saver sub
Upper IBOP
Lower IBOP
Saver Sub
Upper Tool Lock Joint
Shell Actuator
Intermediate Tool Lock Joint
Lower Tool Lock Joint
4-34 Varco Systems
4
Installation, Commissioningand Decommissioning
Removing and installing the clamp cylinder jaws
9
21
24
25
23
26
28
29
34
27
35
9
42
41
26
3
36
11
12
40
56
58
57
64
60
59
17
20
16
18
19
67
66
61
62
15
65
63
54
5552
52
50
45
48
7673
757472
10
69
68
80
71
70
51
6
8
10
13
14
5
44
7
38
37
4
49
47
53
46
35
30
34
31
35
32
22
34
331
43
42
2
12
39
40
Q
R
R
81
77
7879
77
4-35TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Decommissioning
Removing and storing the electrical cablesand service loops
!
!
Lower
Service Loopand Storage Tub
3,600 lbs(1,634.4 kg)
DerrickService Loop
Lifting EyesDo not remove
TDSService Loop
DerrickTermination
To avoid damage to theservice loop maintain a36 inch minimum
bend radius
To avoid damage to the service loop
use care when dragging it near sharp edges
and allow room for passing under the
V-door
n Do not pack the service loops until the service loop storage tub is in position
n Use a sling attached to the lifting eyes to lower each service loop. Use the swivel at the tugger line attachment to allow each service loop to coil without twisting.
Sling1,000 lbs(454 kg)
Service Loop
4-36 Varco Systems
4
Installation, Commissioningand Decommissioning
Securing the TDS-11SA for rig-down
233.0 in.(5918 mm)
= 37,000 lb= 16,798 kg
To Centerof Gravity
112.4 in.(2855 mm)
71.9 in. (1826 mm) 62.5 in.(1588 mm)
56.0 in.(1422 mm)
To Centerof Gravity
28.2 in.(716 mm)
18.5 in. (470 mm)
Bail120 in.
(3048 mm)
Bail88 in.
(2235 mm)
4-37TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Setting the latches and locking the bail
4-38 Varco Systems
4
Installation, Commissioningand Decommissioning
Disconnecting the guide beam
CrownPadeye
Do not remove
Crown
TDS-11SACarriage latchesremain engaged
Guide BeamTop Section
Shackle
Hang-offLink
Pin
DrillFloor
n Be sure that the bail lock assembly is installed
n Be sure carriage latches remain engaged
n Disconnect the guide beam from the main tieback and intermediate tiebacks
n Disconnect the guide beam from the hang-off link
4-39TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Unpinning each guide beam section
4-40 Varco Systems
4
Installation, Commissioningand Decommissioning
Lowering each guide beam section
4-41TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Unhooking and removing each guide beam section
4-42 Varco Systems
4
Installation, Commissioningand Decommissioning
Returning the TDS-11SA to the skid
Lock PinInstall after lowering
TDS-11SA onto the skid
TDS-11SA
TDS-11SALoweredonto skid
2,500 lbs(1,135 kg)
Skid
Skid
2
3
1
LiftingBlock
DrillFloor
PinInstall after lowering
TDS-11SA onto the skid
n Hoist skid to the drill floor
n Using the drawwork, lower the TDS-11SA onto the skid
n Pin the TDS-11SA to the skid at the top and bottom of the guide beam top section
n Install pin retainers
TDS-11SA
34,500 lbs(15,663 kg)
TDS-11SA
4-43TDS-11SA
4
Installation, Commissioningand Decommissioning
Preliminary
Removing the TDS-11SA from the drill floor
!
V-DoorRamp
LiftingSling
Backup Line
TDS-11SAOn the skid priorto removing from
the drill floor
2
1
3
DrillFloor
LiftingBlock
Lower usingthe drawwork
Be sure that theBail Lock Assembly
is installed
Sling
TDS-11SAon Skid37,000 lbs(16,798 kg)
4-44 Varco Systems
4
Installation, Commissioningand Decommissioning
Long term storage procedures
1. Drain the oil from the gearbox prior to rigging down.
2. Remove the saver sub.
3. Disconnect guide beam from lower attachment and connecting link.
4. Rig down the guide beam.
5. Bring the shipping and handling skid to the drill floor.
6. Install the TDS-11SA into the skid and pin.
7. Release the hook and remove the TDS-11SA.
8. For indoor storage, cover the TDS-11SA in its shipping and handlingskid. A cargo container is appropriate for outdoor storage.
9. Avoid wide variations in temperature and high humidity. The preferredenvironment is clean and dry at 60F ambient.
10. All exposed unpainted metal surfaces are coated with a rustpreventive prior to shipment; however, check these surfacesperiodically to be sure that no corrosion is taking place. Therecommended rust preventive (slushing compound) for bare metalsurfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.
11. Cover all openings to prevent water or dust from entering. Leaveenough space around the drilling motors for ventilation. Do not usesilica gel or a dehydrating agent.
11. During storage, rotate the motors and gear train periodically todistribute lubricant. Perform this at three month intervals if storedindoors, and at one month intervals if stored outdoors.
12. For long term storage recommendations dealing with the AC drillingmotors, see the motor manufacturers manual.
Returning the TDS-11SA to service after storage
Before placing the TDS-11SA back into service after storage, verify thefollowing items:
1. Remove all rust preventive and any corrosion that may have takenplace, taking special care with all load carrying components.
2. Follow the return to service procedures in the AC drilling motormanufacturers manual.
34
5
6
7
8
9
1
2
Guide Beamsand Carriage
5-1TDS-11SAPreliminary
Inspecting the crown padeye and hang-off link.. 5-2
Inspecting the top section of the guide beam..... 5-3
Inspecting the guide beam joints ......................... 5-4
Inspecting the main tieback.................................. 5-5
Inspecting the intermediate restraints ................. 5-6
Inspecting the carriage ......................................... 5-7
Illustrated part lists ............................................... 5-9Guide beams (roller) ........................................... 5-10Guide beams (slider) .......................................... 5-12Universal tiebacks ............................................. 5-14Tiebacks (sliding) ............................................... 5-16Carriage/accumulator (roll) ................................ 5-18Carriage assembly, right (roller) ........................ 5-20Carriage assembly, left (roller) .......................... 5-22Carriage/accumulator (skid) .............................. 5-24Carriage assembly, right (skid) .......................... 5-26Carriage assembly, left (skid) ............................ 5-28
5Guide Beamsand Carriage
5-2 Varco Systems
Inspecting the crown padeye and hang-off link
Crown PadeyeVisually inspect weld for cracks
Monthly
Crown Padeye
Crown
Yearly
ShackleInspect and replace if worn
Shackle
Monthly
Hang-off Link BoresInspect and repair if worn
Hang-off Link Bores
Monthly
MPI
Cotter PinReplace if missing
Monthly
2.1"(52 mm)minimum
2.0"(50 mm)minimum
1.5"(37 mm)minimum
5Guide Beamsand Carriage
5-3TDS-11SAPreliminary
Inspecting the top section of the guide beam
Guide BeamTop Section
Crown
Bolt Assembly
Hang-off Link BoresInspect and repair if worn
Hang-off Link Bores
MonthlySafety Pin
Replace if missing
Monthly
2.1"(52 mm)minimum
1.5"(37 mm)minimum
5Guide Beamsand Carriage
5-4 Varco Systems
Inspecting the guide beam joints
Retainer Pin
Weekly
Lynch Pin
Verify that the joint pins,retainer pins and lynch pins are
in place and secure. Replaceany missing or damaged pins.
Secure
Weekly
Joint Pin
Weekly
Typical GuideBeam Joint
Yearly
MPI
Inspect weldsfor cracks
Monthly
5Guide Beamsand Carriage
5-5TDS-11SAPreliminary
Inspecting the main tieback
Mast Leg
Auxiliary Spreader Beam
Guide BeamBottom Section
Check that the tool is aligneddirectly over well center
MainSpreader Beam
TiebackLinkTieback Plate
Weekly
Yearly
MPI
Daily
Typical all weldsand connections
Inspect clamped connectionsfor tightness and double nuts.
Inspect welds for cracks.
Typical all welds
5Guide Beamsand Carriage
5-6 Varco Systems
Inspecting the intermediate restraints
Pin and Cotter PinVerify that all pins arein place. Replace any
missing or damaged pins.
Guide Beam
Mast Girt
Weekly
Check for tightnessof cotter pins, and
double nuts. If thereare signs of shifting,
verify alignment.
Weekly
Yearly
MPITypical all welds
Check that the toolis aligned directlyover well center
Daily
5Guide Beamsand Carriage
5-7TDS-11SAPreliminary
Inspecting the carriage
Typicalall rollers
Inspect for unevenwear or damage.Replace yearlyor as required.
Weekly
Detent PinsVerify that pins
are in placeand secure
Daily
5Guide Beamsand Carriage
5-8 Varco Systems
5Guide Beamsand Carriage
5-9TDS-11SAPreliminary
Illustrated part lists
On the following pages xxxxxxx
5Guide Beamsand Carriage
5-10 Varco Systems
E
4 6 5
2
3
8
7
1
Top SectionPart of
Shipping Package
RollingGuide Beam/Carriage
Configuration
Guide beams (roller)
5Guide Beamsand Carriage
5-11TDS-11SAPreliminary
Key to Guide beams (roller)
Item # Part # Description Qty
1 116414-505 Guide Beam, Bottom Section 1
2 115954 Guide Beam, Intermediate Section 4
3 115954-500 Guide Beam, Special Intermediate Section 1
4 116644 Retaining Pin 12
5 116643 Hinge Pin 12
6 51403-8-S Cotter Pin 12
7 89035-1 Shackle, 25 Ton 4
8 99873-650 Connection Link, 65" 1
5Guide Beamsand Carriage
5-12 Varco Systems
F
1
2
3
9
10
11
12
13
14
8
4
5 6
7
Top SectionPart of
Shipping Package
SlidingGuide Beam/Carriage
Configuration
Guide beams (slider)
5Guide Beamsand Carriage
5-13TDS-11SAPreliminary
Key to Guide beams (slider)
Item # Part # Description Qty
1 117618 Guide Beam, Bottom Section (18 ft) 1
2 117618-500 Guide Beam, Bottom Section (36 ft) 1
3 117616 Guide Beam, Intermediate Section (18 ft) 4,5,6
4 117616-500 Guide Beam, Intermediate Section (36 ft) 2
5 117783 Retainer Pin 3,5,6,7
6 117782 Joint Pin 3,5,6,7
7 117496-1 Lynch Pin 3,5,6,7
8 95523 Shackle, 25 Ton 1
9 117788-136 Hang-Off Link 1
10 117788-142 Hang-Off Link 1
11 117788-147 Hang-Off Link 1
12 117788-152 Hang-Off Link 1
13 117788-126 Hang-Off Link 1
14 117788-156 Hang-Off Link 1
5Guide Beamsand Carriage
5-14 Varco Systems
G
9
11
10
11
4
7
14
10
11
5
14
3
16
15
8
10
11
13
6
14
17
4
5
1
2
11
12
Mast Leg
Guide Beam(Bottom Section,
Rolling Configuration)
Universal tiebacks
5Guide Beamsand Carriage
5-15TDS-11SAPreliminary
Key to Universal tiebacks
Item # Part # Description Qty
1 117698 Tieback Link 2
2 117699 Attachment Plate 2
3 117700-1 Strap 4
4 117700-2 Strap 12
5 117700-3 Strap 6
6 117701 Strap 8
7 117702 Tieback Plate 1
8 117731 Flange Clamp 20
9 50016-32-C5 Screw, 1-8 UNC x 4.0 long 4
10 50416-C Nut, 1-8 unc 112
11 50916-C Lock Washer, 1" 72
12 50016-20-C5 Screw, 1-8 unc x 2.5 long 12
13 50816-R-C-5 Flat Washer, 1" 16
14 112893-1 Threaded Rod, 1-8 x 36" long 28
15 117659-15 Plate, 1.00 Thick 1
16 117659-16 Beam, W 12 x 72 x 384.0 long 1
17 117659-17 Beam, W 8 x 18 x 144.0 long 2
18 117659-DWG Universal Tieback Kit Drawing 1
5Guide Beamsand Carriage
5-16 Varco Systems
H
10
16
11
15
1
10
11
15
7
14
15
11
10
11
5
14
3
9
12
8
6
13
11
10
142
4
Mast Leg
Guide Beam(Bottom Section,
Sliding Configuration)
Tiebacks (sliding)
5Guide Beamsand Carriage
5-17TDS-11SAPreliminary
Key to Tiebacks (sliding)
Item # Part # Description Qty
1 117976 Tieback Link 1
2 117977-2 Beam, W 8 x 18 x 180.0 long 2
3 117700-1 Strap 4
4 117700-2 Strap 8
5 117700-3 Strap 4
6 117701 Strap 8
7 117982 Tieback Plate 1
8 117731 Flange Clamp 6,8
9 117977-9 Beam, W 12 x 72 x 384.0 long 1
10 50416-C Nut, 1-8 unc 16,32,64
11 50916-C Lock Washer, 1" 8,20,32
12 117977-12 Plate, 1.00 thick 1
13 50816-R-C-5 Flat Washer, 1" 16
14 112893-1 Threaded Rod, 1-8 x 36" long 4,8,16
15 119973 Strap 6
16 50016-64-C5D Bolt, 1.00 unc x 8.0 long 5
5Guide Beamsand Carriage
5-18 Varco Systems
Front
CC
9
2
1
3
4
5
6
5
8
7
EE
DD
Carriage/accumulator (roll)
5Guide Beamsand Carriage
5-19TDS-11SAPreliminary
Key to Carriage/accumulator (roll)
Item # Part # Description Qty
1 113450 Carriage Assembly, Right (30" setback) 1
2 113448 Carriage Assembly, Left (30" setback) 1
3 110562 Hydro-Pneumatic Accumulator, 6" 1
4 113370 Accumulator Strap, 6" dia. 1
5 50908-C Lock Washer, Regular 6
6 50108-10-CD Socket-head Cap Screw, 1/2 UNC x 1.25 2
7 110563 Hydro-Pneumatic Accumulator, 4" 1
8 88710 Align Accumulator Mount Strap 2
9 50008-10-C5D Hex-head Cap Screw 4
5Guide Beamsand Carriage
5-20 Varco Systems
Front
DD
4
1
12
17
16
4
5
9
9
722
8
11
13
13
8
3
6
2
10
21
8
13
15
14
11
18
19
20
Carriage assembly, right (roller)
5Guide Beamsand Carriage
5-21TDS-11SAPreliminary
Key to Carriage assembly, right (roller)
Item # Part # Description Qty
1 113449 Carriage, Right 1
2 112875 Bogey Pivot Pin 2
3 112876 Bogey 2
4 109903 Shim, 1/8" 12
5 113285 Cam Follower, 6" dia. 2
6 80784 Roller, 4" dia., Crowned, Modified 8
7 109904 Side Roller Bracket 2
8 51132-C Lock Washer, Hi-Collar, 2" dia. 12
9 53000-4-C Plug, 1/4" NPT 10
10 109944 Flanged Bushing, 2.75 ID 4
11 53209 Grease Fitting, 1/8"-27 NPT 12
12 10994 Sandwich Plate 2
13 80569 Jam Nut, 2"-12 UN-2B 12
14 50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long 3
15 51016-C Lock Washer, 1.0" dia. 3
16 50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long 6
17 51012-C Lock Washer, 3/4" 6
18 51220-2 Retaining Cable, .063 dia.
19 51219-2 Cable Ferrule 2
20 51221-6-K Detent Pin, 1/2" dia. x 2.75" long 1
21 109995 Chock 1
22 53000-2-C Plug, 1/8" NPT 2
5Guide Beamsand Carriage
5-22 Varco Systems
Front
EE
5
14
2
10
21
9
11
7
8
22
4
13
11
9
6
3
8
13
8
13
15
1
18
19
20
4
12
17
16
Carriage assembly, left (roller)
5Guide Beamsand Carriage
5-23TDS-11SAPreliminary
Key to Carriage assembly, left (roller)
Item # Part # Description Qty
1 113447 Carriage, Left 1
2 112875 Bogey Pivot Pin 2
3 112876 Bogey 2
4 109903 Shim, 1/8" 12
5 113285 Cam Follower, 6" dia. 2
6 80784 Roller, 4" dia., Crowned, Modified 8
7 109904 Side Roller Bracket 2
8 51132-C Lock Washer, Hi-Collar, 2" dia. 12
9 53000-4-C Plug, 1/4" NPT 10
10 109944 Flanged Bushing, 2.75 ID 4
11 53209 Grease Fitting, 1/8"-27 NPT 12
12 10994 Sandwich Plate 2
13 80569 Jam Nut, 2"-12 UN-2B 12
14 50016-28-C5D Hex-head Cap Screw, 1" UNC x 3.5" long 3
15 51016-C Lock Washer, 1.0" dia. 3
16 50012-24-C5D Hex-head Cap Screw, 3/4" UNC x 3.0" long 6
17 51012-C Lock Washer, 3/4" 6
18 51220-2 Retaining Cable, .063 dia.
19 51219-2 Cable Ferrule 2
20 51221-6-K Detent Pin, 1/2" dia. x 2.75" long 1
21 109995 Chock 1
22 53000-2-C Plug, 1/8" NPT 2
5Guide Beamsand Carriage
5-24 Varco Systems
Front
HH
GG
FF
7
8
6
5
8
4
3
101
2
9
Carriage/accumulator (skid)
5Guide Beamsand Carriage
5-25TDS-11SAPreliminary
Key to Carriage/accumulator (skid)
Item # Part # Description Qty
1 117594 Carriage Assembly, Right 1
2 117593 Carriage Assembly, Left 1
3 117621-1 Accumulator Strap, Long 1
4 117621-2 Accumulator Strap, Short 1
5 50008-10-C5D Hex-head Cap Screw 4
6 88710 Align Accumulator Mount Strap 2
7 50008-8-C5D Hex-head Cap Screw 4
8 50908-C Lock Washer, Regular 8
9 110563 Hydro-Pneumatic Accumulator, 4" 1
10 110562 Hydro-Pneumatic Accumulator, 6" 1
5Guide Beamsand Carriage
5-26 Varco Systems
Front1
2
3
4
4
4
4
7
7
4
4
12
813
11
10
9
5
6
5
6 GG
Carriage assembly, right (skid)
5Guide Beamsand Carriage
5-27TDS-11SAPreliminary
Key to Carriage assembly, right (skid)
Item # Part # Description Qty
1 117592 Carriage, Right (machining) 1
2 117586 Carriage Angle (machining) 1
3 117588 Skid Pad 6
4 51608-8 Roll Pin 34
5 50912-C Lock Washer, Regular 8
6 50012-14-C5D Hex-head Cap Screw 8
7 51608-12 Roll Pin 2
8 117870 Chock 2
9 117871 Plunger, Hand Retractable 2
10 56412-30-SHP Clevis Pin 2
11 51402-10-S Cotter Pin 2
12 50812-N-C Flat Washer, Narrow 4
13 50310-C Hex-Jam Nut 2
5Guide Beamsand Carriage
5-28 Varco Systems
Front
1
2
4
5
6
5
64
3
4
11
10
7 12
13
9
8
4
7
4
4
HH
Carriage assembly, left (skid)
5Guide Beamsand Carriage
5-29TDS-11SAPreliminary
Key to Carriage assembly, left (skid)
Item # Part # Description Qty
1 117591 Carriage, Left (machining) 1
2 117586 Carriage Angle (machining) 1
3 117588 Skid Pad 6
4 51608-8 Roll Pin 34
5 50912-C Lock Washer, Regular 8
6 50012-14-C5D Hex-head Cap Screw 8
7 51608-12 Roll Pin 2
8 117870 Chock 2
9 117871 Plunger, Hand Retractable 2
10 56412-29-SHP Clevis Pin 2
11 51402-10-S Cotter Pin 2
12 50812-N-C Flat Washer, Narrow 4
13 50310-C Hex-Jam Nut 2
5Guide Beamsand Carriage
5-30 Varco Systems
34
Hydraulic System
5
6
7
8
9
1
2
8-1TDS-11SAPreliminary
Hydraulic system................................................... 8-3
Illustrated index ..................................................... 8-4
Hydraulic system diagram .................................... 8-5
Inspection .............................................................. 8-6Precautions........................................................ 8-6Maintenance schedule ...................................... 8-8Hydraulic fluid level and filter .......................... 8-9Hydraulic reservoir bladder.............................. 8-12Heat exchanger ................................................. 8-13Using the hydraulic system test ports ............ 8-14Precharging the accumulators......................... 8-15IBOP timing circuit ............................................ 8-16IBOP pressure switch ....................................... 8-17
Setting up the circuits ........................................... 8-18Hydraulic pumps and unloading circuit .......... 8-18Counterbalance circuit andstand-jump circuit ............................................. 8-22AC motor brake circuit...................................... 8-24Shot pin circuit .................................................. 8-24Link tilt cylinder circuit ..................................... 8-26Gearbox lubrication relief circuit ..................... 8-27Rotating link adapter hydraulicmotor relief circuit ............................................. 8-28
Troubleshooting .................................................... 8-29HPU and reservoir bladder ............................... 8-29Counterbalance and stand jump...................... 8-31AC motor brake circuit...................................... 8-35Shot pin cylinder and clamp cylinder .............. 8-37Link tilt cylinders............................................... 8-39
8Hydraulic System
8-2 Varco Systems
Gearbox lubrication hydraulic system ............ 8-41Rotating link adapter......................................... 8-43
Solenoid valve replacement procedures ............. 8-46Double A UL-type valve .................................... 8-46Atos EEx-type valve .......................................... 8-47
Hydraulic schematic symbols .............................. 8-49
8Hydraulic System
8-3TDS-11SAPreliminary
Hydraulic system
The hydraulic control system is a completely self-contained, onboardsystem. A 10-horse power, 1800 rpm, AC motor, drives two hydraulicpumps and powers the hydraulic system. A fixed displacement pumpdrives the lube oil system motor. A variable displacement pump provideshydraulic power for the AC motor brakes, powered rotating head, remoteactuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalancesystem. Three hydro-pneumatic accumulators are located on the mainbody.
The hydraulic manifold attaches to the main body and contains solenoid,pressure and flow control valves.
A sealed stainless steel reservoir supplies hydraulic oil, eliminating theneed for draining and refilling during normal rig moves. The reservoir ismounted between the AC drilling motors and is equipped with strainersand an oil level sight gauge.
8Hydraulic System
8-4 Varco Systems
Illustrated index
Power
Reservoir Capacity
10 hp, 1,800 rpm, AC motor
25 gal
Specifications
10 HP ACMotor and
Pump AssemblyPage 8-X
Rotating HeadMotor andShot Pin
AssemblyPage 8-X
IBOPDelay CircuitAccumulator
Page 8-X
HydraulicOil FillPage 8-X
HydraulicManifoldPage 8-X
VariableDisplacement
PumpAccumulator
Page 8-X
CounterbalanceAccumulator
Page 8-X
HydraulicOil FilterPage 8-X
Hydraulic OilReservoir
Page 8-X(Between AC
Drilling Motors)
Front
Rear
Front
Rear
8Hydraulic System
8-5TDS-11SAPreliminary
Hydraulic system diagram
MReservoir
FixedDisplacement
Pump (Mtr. Lube)
VariableDisplacement
Pump
10 HP A.C.Motor
RotatingHeadMotor
Lock-upCylinder
CounterbalanceAccumulator
DrillingMotor Brake
Upper IBOPActuator Cylinder
Link TiltCylinders
PipehandlerClamp Cylinder
CounterbalanceCylinders
Lube OilDistribution
SystemAccumulator
Lube OilPump
PV PF
Rotating Head(Elevator Positioner)
System Control Manifold
Low SpeedHydraulic
Motor
Upper IBOPUnloading
Accumulator
Gearbox Sump
8Hydraulic System
8-6 Varco Systems
Inspection
PrecautionsTo avoid serious injury or death, read and understand the followingwarnings before performing inspection and maintenance procedures:
n Properly lockout the main power source before performinglubrication, inspection, or replacement procedures, unlessspecifically noted in this manual.
n Wear protective glasses to prevent eye injuries from fluids underpressure, as well as other hazards.
n Do not attempt any adjustments while the machine is moving.
n Use caution when draining lubricant. It can be hot.
n Never check for hydraulic leaks with your hands. Oil underpressure escaping from a hole can be nearly invisible and canpenetrate skin causing serious injury. Always check for leaks with apiece of wood or cardboard and always wear protective eyewearwhen working on hydraulic components.
n Always discharge the three hydro pneumatic accumulators beforeperforming repairs on the hydraulic system.
n Do not attempt repairs you do not understand.
n Read and understand all safety precautions and warnings beforeperforming maintenance procedures.
8Hydraulic System
8-7TDS-11SAPreliminary
n Release all hydraulic oil pressure by bleeding accumulators beforedisconnecting hydraulic lines. Turn the counterbalance vlave toshutdown mode to bleed the hydraulic system. Hydraulic oil underpressure can penetrate skin and cause serious injury.
n Before opening the hydraulic system, thoroughly clean work area,and maintain system cleanliness by promptly capping alldisconnected lines. Dirt is extremely harmful to hydraulic systemcomponents and can cause equipment failure and subsequentinjury to personnel.
e Use care when handling components to prevent nicking close tolerancefinishes.
n Hydraulic fluid escaping under pressure can penetrate the skincausing serious injury. Avoid injury by discharging the threeaccumulators and relieving pressure before disconnectinghydraulic lines. Always search for hydraulic leaks with a piece ofcardboard or wood-not with your bare hands. Get immediatemedical attention for hydraulic fluid injuries. Fluid injected into theskin must be surgically removed within a few hours or gangrenemay result. Do not tighten hydraulic fittings while they are underpressure.
Inspect the hydraulic system daily for leaks at fittings, damaged hosecovers, kinked or crushed hoses, hard or stiff hoses, and damaged orcorroded fittings. In addition, during the inspection, tighten or replace anyleaking port connections, and clean any dirt buildup from hydrauliccomponents.
n Replace worn or damaged hydraulic system componentsimmediately.
Inspect the hydraulic fluid level in the hydraulic reservoir located betweenthe AC drilling motors daily. Inspect the hydraulic filter located on theupper left AC drilling motor daily.
8Hydraulic System
8-8 Varco Systems
Maintenance schedule
Oil Temperature Range
CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion
NGLIAGMAISO ViscosityGrade
-10 to 85 C(14 to 185 F)
HYDRAULIC OIL
Hyspin AWS-46AW Hyd oil 46
Nuto H46Harmony 46AW
DTE 25Tellus 46
Hydraway HMA 46Rando oil HD46
Azolla ZS 46Unax AW46
N/R246
-15 to 75 C(5 to 167 F)
Hyspin AWS-32AW Hyd oil 32
Nuto H32Harmony 32AW
DTE 24Tellus 32
Hydraway HMA 32Rando oil HD32
Azolla ZS 32Unax AW32
N/RN/R32
DESCRIPTION FREQUENCY
Perform Hydraulic SystemOil Analysis
Replace Hydraulic Fluid
Replace Hydraulic SystemFilter (P/N 114416-1)
1 x every 6 Months
1 x Year, or EarlierBased on Oil Analysis
1 x every 3 Months
Hydraulic System OilLubrication Schedule
Recommended Lubricants
1.
2.
3.
Check condition of the hydraulic filter indicator
Check hydraulic fluid levels
Check for hydraulic fluid leaks
Daily Inspections
8Hydraulic System
8-9TDS-11SAPreliminary
Hydraulic fluid level and filter
HydraulicOil Fill
RedPop-up
Dirt Alarm
HydraulicOil Filter
HydraulicOil SightGauge
Cork Ball(Level Indicator)
SightGlass
Hydraulic OilFill Quick
Disconnect
n Check the red pop-up alarm on the hydraulic filter daily. Replace it if the indicator has popped up.
n Use care to prevent contamination from entering the hydraulic system during maintenance activities.
n The first oil change should be performed sooner than six months since new installations often contain metal contamination caused by connecting slightly damaged threaded parts.
Daily
8Hydraulic System
8-10 Varco Systems
Adding the hydraulic fluid
HydraulicOil Fill
HydraulicOil SightGauge
Cork Ball(Level Indicator)
SightGlassHydraulic OilFill Quick
Disconnect
LubricationKit Quick
Disconnect
n Ensure that the area is clean prior to adding hydraulic fluid
n Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill
n Remove dust plug from the female quick disconnect on the lubrication kit
n Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm
Reservoir Capacity
HydraulicLubrication Kit
55 gal Drum
25 gal
Specifications
8Hydraulic System
8-11TDS-11SAPreliminary
Draining the hydraulic fluid
VariableDisplacement
Pump
FixedDisplacement
Pump
10 HP ACPump Motor
PumpInlet/Drain
Adapter
8Hydraulic System
8-12 Varco Systems
Hydraulic reservoir bladder
Hydraulic Oil Reservoir(Between AC Drilling Motors)
ReservoirCover
Reservoir Bladder(Varco P/N 110191-501
or 110191-500)Check for holes, tears,
wear and cracks
Hydraulic OilReservoir
Front
Rear
n Clean area before inspecting the reservoir bladder
n Remove the 10 cap screws and lock washers from the cover
n Remove cover with bladder attached
n Check yearly for holes, tears, wear and cracks
Yearly
8Hydraulic System
8-13TDS-11SAPreliminary
Heat exchanger
Drill MotorAssembly
Blower andBrake Covers
Oil HeatExchanger
(Varco P/N 110170)Inspect for leaks, corrosion,blockage, and cleanliness.
Replace yearly or as required.
Yearly
8Hydraulic System
8-14 Varco Systems
Using the hydraulic system test ports
* These test ports are on sides or bottom of manifold.
T1
SA
P
PV
P1
A4SV4
SV5
Clamp/Shot Pin Float Link
TiltSV8SV6
G5
B8
B6
A6
B5C5
C4
L4
B1
SV2Rotating
LinkAdapter
Z1 B9
PF
SV1SV9Stand Jump Brake
IBOP*
*
*
*
As Viewed From Below
CB
8Hydraulic System
8-15TDS-11SAPreliminary
Precharging the accumulators
n System Accumulator (125-cubic inch displacement) 800 psi precharge
n Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge
n Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge
Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above.
With the hydraulic system shut down, and the counterbalance mode valve in the shut down position, test the hydraulic pressure at CB, SA and C4 on the hydraulic manifold, mounted to the transmission housing. Verify that all three points measure 0 psi.
Note that there is a time delay in pressure decay on port C4.
Test the precharge pressure on the following three nitrogen filled accumulators, using part number 114446-1.
IBOPDelay CircuitAccumulator
HydraulicManifold
VariableDisplacement
PumpAccumulator
CounterbalanceAccumulator
Front
Rear
8Hydraulic System
8-16 Varco Systems
IBOP timing circuit
Full Page
ARTWORK PLACEHOLDER
FP
105 20 30 40 50 60 70 80 90 0.1 0.2 0.5 0.8 1.0 1.5 2.0 2.5
0.1
0.2
0.5
0.8
1.0
1.5
REV.B 09.01.95
DRILLING SYSTEMS
8Hydraulic System
8-17TDS-11SAPreliminary
IBOP pressure switch
Full Page
ARTWORK PLACEHOLDER
FP
105 20 30 40 50 60 70 80 90 0.1 0.2 0.5 0.8 1.0 1.5 2.0 2.5
0.1
0.2
0.5
0.8
1.0
1.5
REV.B 09.01.95
DRILLING SYSTEMS
8Hydraulic System
8-18 Varco Systems
Setting up the circuits
Hydraulic pumps and unloading circuitThere are two pumps a fixed displacement pump runs the transmissionlubrication system and a variable displacement pump provides hydraulicflow to the hydraulic system.
VariableDisplacement
Pump
FixedDisplacement
Pump
10 HP ACPump Motor
Motor and PumpAssembly
Allen Wrench
Valve
Front
As Viewed from Below
8Hydraulic System
8-19TDS-11SAPreliminary
1. Locate the tube connecting manifold port PF to the lubrication motor.Disconnect the tube at the manifold end, cap the tube and plug thePF port using steel fittings.
2. Set the relief valve RV1 for the variable displacement pump to aminimum setting, fully counterclockwise, which allows the hydraulicsystem to operate without building up pressure.
3. Set the relief valve RV2 to minimum pressure, fully counterclockwise.
z Make sure the variable displacement pump case is filled with cleanhydraulic oil.
4. Jog-start the electric motor to make sure the direction of rotation iscorrect (clockwise when looking into pump shaft/electric motor fan).Correct as required.
5. Start the electric motor and allow both hydraulic pumps to circulateoil. Listen for unusual noises that would indicate cavitation; check forleaks.
6. Connect a gauge to test point PF. Increase the pressure by adjustingrelief valve RV2 clockwise until the pressure increases to 400 psi attest point PF. Set the jam nut on RV2. A steel cap is installed over theadjustment screw to discourage unauthorized adjustment.
z While adjusting valves, verify a linear relationship between turning theadjustment screw and observing the pressure change.
7. Turn off the electric motor. Reconnect the tube between manifold portPF and the lubrication motor.
8. Connect an ammeter to the electric motor. Note the full-load amps onthe motor nameplate.
9. Restart the hydraulic system electric motor.
10. Set the counterbalance mode valve to the RUN position.
11. Adjust UV1, fully clockwise, to maximum pressure.12. Connect a gauge to test point PV. Note the ammeter reading while
RV1 is at minimum setting.
8Hydraulic System
8-20 Varco Systems
13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at asteady rate. During the pressure rise, observe the ammeter. Themotor current should rise to a maximum value at 800 psi, then dropoff and begin to rise again. The point where the current drops is thepump pressure compensator setpoint.
14. Adjust relief valve RV1 to its minimum setting. If maximum motorcurrent does not occur at 800 psi, adjust the pump pressurecompensator as required.
15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0psi to verify maximum motor current at 800 psi.
16. Connect a gauge to test point SA, and leave the gauge on PV.
17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.18. Install steel cap over the adjustment screw to discourage
unauthorized adjustment.19. Adjust unloading valve UV1 counterclockwise until the pressure at
PV drops off, then an additional two turns counterclockwise. Thepressure cycles like a sawtooth wave.
20. Observe the unloaded pressure at PV (about 0 psi) while SA readsabout 2,000 psi. The pressure at SA decays until UV1 reloads. Afterreloading, the pressure rapidly rises to the unload pressure.
8Hydraulic System
8-21TDS-11SAPreliminary
Pressure at SA
Approximate Time (Seconds)
Pressu