TDS_10S Service Manual

8/9/2019 TDS_10S Service Manual

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TDS-1 0 S

Top DriveDrillingSystem

Service M anual

SM 0 0 4 0 0


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March 2, 1998

ii TDS-10S Contents

Manual conventions

This manual uses conventions that make it easy for the reader tolocate key information and detailed descriptions. Graphics

illustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and its components.

Information pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention. Note the examples belowand pay close attention to these important advisories.

z Note: Indicates advisories for operational or servicing proceduresinvolving no risk of personal injury or equipment damage.

e Caution: Indicates advisories involving a risk of equipment damage.

n Warning: Indicates advisories involving a defi ni te risk of injury to ri g personnel.

Avoid personal injury and equipment damage by reading thismanual and related documents prior to operating or maintainingthe equipment.

About this manual


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TDS-10S Contents ii

Contents

Book 1 – Description, Installation and Operation

Preface

Manual conventions............................................................ 5Safety information .............................................................. 5Directional references ......................................................... 6Illustrations......................................................................... 6Manual layout..................................................................... 6Varco service centers........................................................... 6

Chapter 1 Introduction

Introduction to the TDS-10S............................................. 7

Chapter 2 Description

TDS-10S major components .............................................. 9Motor housing and swivel assembly ............................ 10

Transmission and swivel housing .......................... 10Integrated swivel assembly .................................... 11Drill ing motor and brakes..................................... 11

Motor cooling system ................................................. 12Carriage and guide beam............................................. 14PH-55 pipehandler ..................................................... 14

Powered rotating link adapter ............................... 14Torque backup clamp cylinder.............................. 15Bidirectional l ink tilt ............................................. 16Internal blowout prevention ................................. 18

Hydraulic control system ............................................ 20Counterbalance system ......................................... 22

STAND JUMP feature (optional) ................... 23AC motor and control system ..................................... 24


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iv TDS-10S Contents

Chapter 3 Installation

Installing the TDS-10S..................................................... 27

Chapter 4 Operation

Driller’s interface and driller’s console............................... 33Throttle control .......................................................... 33Torque control............................................................ 34Switches...................................................................... 34Indicators.................................................................... 36Varco control system................................................... 37

Variable frequency inverter ............................................... 38Rectifier and DC link filter ......................................... 38Power modules ........................................................... 38Control section ........................................................... 38

Service loop ...................................................................... 39Drill ing ahead ................................................................... 40

Drilling ahead with triples .......................................... 40Drilling ahead with singles.......................................... 42Tripping in and tripping out ....................................... 44Back reaming .............................................................. 44Well control procedures.............................................. 46Running casing........................................................... 48

Chapter 5 Specifications

General ............................................................................. 49Drilling parameters..................................................... 50

Rated capacities..................................................... 50Drilling motor ...................................................... 50Pipehandler (PH-55) ............................................ 50

Chapter 6 Appendix............................... 51


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TDS-10S Contents v

Book 2 – Maintenance and Troubleshooting

PrefaceManual conventions............................................................ 7Safety information .............................................................. 7Directional references ......................................................... 8Illustrations......................................................................... 8Manual layout..................................................................... 8Varco service centers........................................................... 8

Chapter 1 Introduction

Precautions......................................................................... 9

Chapter 2 Maintenance schedules

Inspection schedules ......................................................... 11Lubrication schedule......................................................... 13Lubricant specifications.................................................... 14

Selecting a lubricating/hydraulic oil ............................ 14Selecting a lubricant .................................................... 15

Chapter 3 InspectionInspecting hardware and fitt ings....................................... 17Inspecting the AC drill ing motor brakes........................... 18Inspecting the AC dril ling motor louvers.......................... 18Inspecting the wash pipe assembly .................................... 18Inspecting the upper stem liner ......................................... 19Inspecting main shaft end play.......................................... 21Inspecting the gearbox oil level ......................................... 22Inspecting the guide beam ................................................ 22Inspecting the IBOPs........................................................ 22

Inspecting the pipehandler ................................................ 23Nondestructive Examination (NDE) ................................ 24

Inspecting the elevator link eyes.................................. 24Inspecting the drive stem ............................................ 26Magnetic particle inspection (MPI) ............................ 27Ultrasonic inspection .................................................. 28

Inspecting the hydraulic system ........................................ 29Inspecting the electrical system ......................................... 29


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vi TDS-10S Contents

Chapter 4 Lubrication

Introduction ..................................................................... 31Lubricating the AC blower motor bearings....................... 32Lubricating the hydraulic pump AC motor ....................... 32

Lubricating the AC drilling motor bearings ...................... 32Lubricating the wash pipe assembly .................................. 34Lubricating the upper main body oil seals......................... 35Replacing the gearbox oil .................................................. 35

Initial oil change......................................................... 35Oil capacity................................................................. 35

Replacing the gearbox oil filter .......................................... 36Lubricating the carriage and guide beam........................... 36Lubricating the rotating link adapter ................................. 36Lubricating the link ti lt and PH-55 stabilizer bushing ...... 38Lubricating the elevator support and

master bushing wear guide................................................ 38Lubricating the wireline adapter ........................................ 38Lubricating the IBOP actuator yoke................................. 39Lubricating the IBOP actuator crank ................................ 40Lubricating the torque arrestor tubes andclamp cylinder gate ........................................................... 41

Chapter 5 Maintenance

General hydraulic system maintenance.............................. 43

Start-up procedure...................................................... 44Accumulator maintenance ................................................ 44

Chapter 6 Troubleshooting

Troubleshooting the AC drilling motor ............................ 45Troubleshooting the AC blower motor ............................. 46Troubleshooting the hydraulic system............................... 47Troubleshooting the ACdrill ing motor brakes......................................................... 51Troubleshooting the rotating link adapter

(rotating head) motor ....................................................... 52Operation ................................................................... 52System test .................................................................. 52

Troubleshooting the IBOP actuator cylinder .................... 54Operation ................................................................... 54System test .................................................................. 55


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Troubleshooting the shot pin cylinderand clamp cylinder............................................................ 57

Operation ................................................................... 57System test .................................................................. 58

Troubleshooting the counterbalance system...................... 60

Counterbalance testing ............................................... 61Stand jump testing...................................................... 62Troubleshooting the hydraulic power unit (HPU)and reservoir ..................................................................... 64


Chapter 7 Disassembly and assembly

Precautions....................................................................... 67PH-55 Pipehandler ........................................................... 69

Disassembling the PH-55 Pipehandler ........................ 69Assembling the PH-55 Pipehandler ............................ 71

Rotating link adapter ........................................................ 72Disassembling the rotating link adapter assembly........ 72Assembling the rotating link adapter assembly ............ 73

Transmission/motor housing ............................................ 75Removing the transmission/motor housing................. 75Install ing the transmission/motor housing .................. 75Disassembling the transmission/motor housing .......... 76

Removing the bonnet and wash pipe .................... 76

Removing the upper bearing retainer plate.................. 77Removing the AC drilling motor .......................... 77Removing transmission components..................... 78

Assembling the transmission/ motor housing ............................................................ 81

Assembling the main body.................................... 81Assembling the main shaft .................................... 82Assembling the gears to the main body ................. 84Installing the AC drilling motor ............................ 87Installing the upper bearing retainer plate............. 89Install ing the wash pipe......................................... 91

Checking the gear train backlash........................... 91AC drill ing motor disassembly/assembly ........................... 92

AC drill ing motor disassembly .................................... 92AC drill ing motor assembly ........................................ 94

Replacing the safety wiring ............................................... 96Safety wiring tips........................................................ 98


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Book 3 – Control System

Chapter 1 DescriptionGeneral description............................................................. 5Major component descriptions........................................... 7

Varco Driller’s Console (VDC)..................................... 7Programmable logic controller (PLC) ..................... 9Variable Frequency Drive (VFD) .......................... 10

Electrical service loops................................................. 12

Chapter 2 Operation

Preoperational checklists ................................................... 13VDC controls................................................................... 17Correcting a drive fault ..................................................... 20

Drive fault while drilling............................................. 20Drive fault while making up ....................................... 21

Chapter 3 Maintenance

Maintaining the control system......................................... 23Troubleshooting ............................................................... 25

VFD ........................................................................... 28

Book 4 – Supplemental Material


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TDS-1 0 S


Description,Installat ion andOperation


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2 TDS-10S Service Manual

March 10, 1998


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TDS-10S Service Manual 3

Contents

Preface

Manual conventions............................................................ 5Safety information .............................................................. 5Directional references ......................................................... 6Illustrations......................................................................... 6Manual layout..................................................................... 6Varco service centers........................................................... 6

Chapter 1 IntroductionIntroduction to the TDS-10S............................................. 7

Chapter 2 Description

TDS-10S major components .............................................. 9Motor housing and swivel assembly ............................ 10

Transmission and swivel housing .......................... 10Integrated swivel assembly .................................... 11Drill ing motor and brakes..................................... 11

Motor cooling system ................................................. 12Carriage and guide beam............................................. 14PH-55 pipehandler ..................................................... 14

Powered rotating link adapter ............................... 14Torque backup clamp cylinder.............................. 15Bidirectional l ink tilt ............................................. 16Internal blowout prevention ................................. 18

Hydraulic control system ............................................ 20Counterbalance system ......................................... 22

STAND JUMP feature (optional) ................... 23AC motor and control system ..................................... 24

Chapter 3 Installation

Installing the TDS-10S..................................................... 27


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Chapter 4 Operation

Driller’s interface and driller’s console............................... 33Throttle control .......................................................... 33Torque control............................................................ 34

Switches...................................................................... 34Indicators.................................................................... 36Varco control system................................................... 37

Variable frequency inverter ............................................... 38Rectifier and DC link filter ......................................... 38Power modules ........................................................... 38Control section ........................................................... 38

Service loop ...................................................................... 39Drill ing ahead ................................................................... 40

Drilling ahead with triples .......................................... 40Drilling ahead with singles.......................................... 42

Tripping in and tripping out ....................................... 44Back reaming .............................................................. 44Well control procedures.............................................. 46Running casing........................................................... 48

Chapter 5 Specifications

General ............................................................................. 49Drilling parameters..................................................... 50

Rated capacities..................................................... 50

Drilling motor ...................................................... 50Pipehandler (PH-55) ............................................ 50

Chapter 6 Appendix............................... 51


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Preface

Manual conventionsThis manual contains conventions that make it easy for the readerto locate key information and detailed descriptions. Graphicsillustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and assemblies to providea better understanding of the equipment’s functionality.

Safety informationInformation pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the symbols belowand pay close attention to these important advisories throughoutthe text.

z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personal injury and equipmentdamage.

e Indi cates advisories involving a risk of equipment damage.

n Indi cates advisories involving a defini te risk of injury to rig personnel.


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March 10, 1998

Avoid personal injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.

Directional references

References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the toolassembly–standing behind the tool as it faces well center.

IllustrationsFigures present a graphical representation of tool components foruse in identifying parts or establishing nomenclature.

Illustrations show measurements with inches (in.), followed bymillimeters (mm).

For more specific component information pertinent to your rigconfiguration, see the drawing index in the Drawingschapter to

obtain the engineering drawing number.

Manual layout

This binder contains several separate chapters that you canremove individually for convenience.

Varco service centers

If you need technical assistance, see the back cover of this manualfor a complete list of Varco’s Worldwide Service Centers.


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Chapter 1

Introduction

Introduction to the TDS-10S

Varco Drilling Systems developed the TDS-10S Top DriveDrilling 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 drillingtorque and 36,500 ft lb of makeup/break out torque. The TDS-10S is compact enough to be safely operated in a standard 136 ft.mast while providing 250 tons of hoisting capacity. Its highlyportable design allows for simple rig-up and rig-down in just afew hours. It easily integrates into existing rigs at minimalinstallation cost and rig modification.


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Chapter 2

Description

TDS-10S major components

The TDS-10S drilling system includes the following assembliesand 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


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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 reductionprovides a 13.1:1 ratio from the motor to the main shaft. Themain body and gear case cover house the transmission, the mainthrust and radial bearings. The gear case cover houses the upper

take-up bearing and supports the AC motor. The bull gearattaches to the load shoulder on the main shaft. All lubrication of the gears and bearing is via a pressurized system integrated intothe main body and cover.


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Integrated swivel assembly

An industry-standard washpipe packing assembly is locatedbetween the main shaft and gooseneck, and allows for therotation of the drill string. The bonnet/gear case cover supportsthe assembly and attaches to the gear case to provide lateral

support.

An alloy steel swivel bail attaches to the main body. The swivelbail can stroke vertically relative to the swivel housing to providean integral counterbalance system. An extended length is availableto allow operator clearance between the gooseneck and hook forwireline 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 casecover with a modified “D-face” to avoid shimming or specialalignment during installation.

The motor has a double-ended shaft with a drive hub mountedon the lower end and a disc brake rotor mounted on the upperend. Two hydraulic caliper disc brakes mount to the top end of the motor, where they can be easily inspected and serviced via theaccess covers around the brake covers. The caliper disc brakes alsoassist in drill string positioning when performing directionalwork. They are remotely operated from the driller’s console.


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Motor cooling system

The motor cooling system (Figure 1) on the TDS-10S is a localintake centrifugal blower consisting of a cooling fan motormounted on top of the AC drilling motor. The system draws air

across the brake and delivers it through rigid ducting to anopening at the top of the motor. The cooling air then passesthrough the inside of the open-frame type AC drilling motor andexits through the louvered openings near the bottom of themotor. This rugged, simple design provides highly reliable servicewith positive ventilation.


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Blower Motor

Louvers

Air Flow

Duct

Centrifugal Blower

Disk Brake Housing

AC Drilling Motor

Intake Air Flow(Between Motor and

Brake Housing)

Exhaust Air Flow

Figure 1. TDS-10S motor cooling system


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Carriage and guide beam

The TDS-10S drilling system travels on a hanging guide beam bymeans of a carriage attached to the gear case. The guide beamhangs from the crown and extends to within seven feet of the drill

floor. There, it attaches to either a lower mast girt or a torquereaction beam mounted across the lower section of the mast orderrick.

The drilling torque is reacted through the carriage and into theguide beam. The guide beam is available in 18-ft. sections(63 lb/ft) and hangs from a pad eye at the crown. The guide beamsections are pinned together making installation easy. Guide beamsections can be assembled one section at a time, at the drill floor,while raising the guide beam to the crown attachment using thedrawworks.

The carriage consists of an angle structure and low friction guidepads. This arrangement maintains alignment of the main shaftwith the drill string while moving up and down on the guidebeam.

PH-55 pipehandler

The PH-55 pipehandler consists of the following majorcomponents:

Powered rotating link adapter

Torque backup clamp cylinder

Bidirectional link ti lt

Remote upper IBOP actuator

Elevator links and drill pipe elevator


The powered rotating link adapter hangs from the stem.Hydraulic pressure applied to an annulus between the stem andthe rotating link adapter supports the weight of the pipe handlerwith 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 seatand, in turn, transfers the load to the main shaft.


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The powered rotating link adapter allows the hydraulic lines toremain connected as the pipehandler rotates with the drill stemcomponents while tripping or when positioning the link tilt.During this operation, the pressurized annulus acts as a hydraulicthrust bearing.

The powered rotating link adapter has a hydraulic drive motor torotate it in either direction. An electric solenoid valve operates thehydraulic motor. A pinion gear on the hydraulic drive motorrotates the positioning gear that is attached to the top of therotating link adapter.

During make or brake operations the rotating link adapter can belocked into any of 24 index positions by selecting the pipehandlerclamp mode which actuates a hydraulically operated shot pin.When the hydraulic drive motor is not powered the link adaptercan rotate freely.

The link t ilt mechanism is integrated into the rotating link adapterThe torque arrestor frame hangs from the rotating link adapter.

Two bushings located toward the top and bottom ends of therotating link adapter and sandwiched radially against the stem,support the radial loads. The internal hydraulic fluid passages inthe stem connect to the respective fluid passages in the rotatinglink adapter.

Fluid is fed from the main manifold into the stem through the radiapassages at the upper end. This fluid is routed from the vertical

passages in the stem to grooves in the rotating link adapter, and outto all actuators on the pipe handler. While rotating or in anystationary position, fluid flows between the two components.


The torque backup clamp cylinder assembly is located below thelower shoulder of the saver sub. It includes two gripping jawswith die inserts and a clamping cylinder for gripping the box endof the drill string when connecting to a saver sub. A torquearrestor frame hanging from the rotating link adapter supports

the torque backup clamp cylinder and allows the clamp cylinderto float up or down to allow for thread engagement anddisengagement. With the torque backup clamp cylinderpressurized to clamp on a tool joint, torque is reacted through thetorque arrestor frame while making and breaking connections.

The torque backup clamp cylinder position is adjustable. Itsposition 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.


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Bidirectional link tilt

The link tilt mechanism consists of two hydraulic cylinders and acrank mounted with a pivot arrangement on the rotating linkadapter (Figure 2). The top end of the crank is connected to therod 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 thederrickman position which is adjustable. Releasing the stop (bypulling a cable) allows the elevator to travel to the mouseholeposition.

The elevator is fully extended in the opposite direction byextending the two hydraulic cylinders. This gives the tool overdrillcapability.

The link tilt operates from a three-position switch located on thedriller’s console. The TILT position moves the links toward themousehole or derrickman by retracting the two hydrauliccylinders. The DRILL position tilts the links back to clear thedrill pipe and raise the elevator to allow drilling down to the floor.The spring centered position holds the link at any intermediateposition. There is a separate float switch which is used to allowthe links to hang free. The DRILL position changes the tiltdirection, which also keeps the elevator off the drill pipe whendrilling or moves it away from the well center to clear the drill

floor when drilling down to the floor. The links may be stoppedat any intermediate position. The links float back to the wellcenter when the FLOAT position button on the driller’s console isoperated.


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108"

76"

Drill Floor

56"

28"

Link Tilt Cylinder (2)

M o u s e h o

l e

D e r r i c k

m a n *

O v e r d r i l l

D r i

l l 34"

36"Typ.

14"

4"

WellCL

All dimensions are true for108" long Elevator Links and

FOR REFERENCE ONLY

* At Monkey Board level (80')and placed into view

FOR CLARITY ONLY

Figure 2. Bidirectional link tilt positions


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Internal blowout prevention

The two ball-type internal blowout prevention (IBOP) valves arefull size, internal opening safety valves (Figure 3). The remotelyoperated upper valve and the manually operated lower valve formthe 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 OPENand CLOSE functions of the upper IBOP valve. When the switchis operated, a hydraulic cylinder through a non-rotating leverarrangement attached to the torque arrestor slides an actuatorshell up and down. This lever arrangement drives a small crankarm on each side of the valve which opens and closes the upperIBOP valve.

Both upper and lower IBOP valves can be broken out and sent

down hole.


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Hydraulic control system

The hydraulic control system (Figure 4) is completely self-contained (on board) and supplies all hydraulic power. Iteliminates the need for an additional service loop. The system

consists of components that operate the following assemblies:


AC motor brakes

Gear/main bearings lubrication system

Powered rotating head

Remotely actuated IBOP


Link tilt

The hydraulic control system is powered by a 10 hp, 1,200 rpmAC motor that is direct coupled to drive a hydraulic pump.

An integral hydraulic manifold mounts to the carriage andcontains all solenoid, pressure, and flow control valves.

There is also a manifold mounted to the shot pin housing forcontrolling the hydraulic rotating link adapter motor.

Hydro-pneumatic accumulators operate the IBOP, pressure

control valves, and counterbalance system.


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M

Reservoir

Hydraulic

Pump

10 HP A.C.Motor

Rotating LinkAdapter Motor

Shot PinCylinder

CounterbalanceAccumulator

DrillingMotor Brake

Upper IBOPActuator

Cylinder

Link TiltCylinders

Torque Backup

ClampCylinder

CounterbalanceCylinders

Lube Oil

Distribution

System

Accumulator

Pipehandler Rotating Link Adapter

(D.P. Elevator Positioner)

System Control Manifold

Upper IBOPTime Delay

Accumulator

Figure 4. TDS-10S hydraulic system


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The integral counterbalance system prevents damage to tool jointthreads 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 betweenthe transmission cover and bail, a hydraulic accumulator, and ahydraulic manifold. The system is integral to the TDS-10S andtherefore does not require any external attachment to the hook.The cylinders are connected to a hydraulic accumulator. Theaccumulator is charged with hydraulic fluid and maintained at apredetermined pressure setting by the counterbalance circuit inthe main hydraulic control system manifold.


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STAND JUMP feature (optional)

The stand jump feature developed for the TDS-9S is available asan option for the TDS-10S. It consists of a switch at the driller’sconsole 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 STANDJUMP feature allows the cylinders to lift the weight of the topdrive off the drill string while breaking out a connection. Thiseases the stress on the threads and avoids damage.


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AC motor and control system

The TDS-10S uses one 350 hp AC motor (Figure 5). It is locatedon top of the gear case, which minimizes the distance from thewell centerline to the rear of the guide beam.

Varco selected an AC drilling motor for use on the TDS-10Sbecause 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 VACmaximum, 3-phase. The TDS-10S includes an air cooling system.

The motor is fed from a PWM inverter that provides variablevoltage 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 from0 to 1,200 motor rpm, with constant power of 350-hp from1,200 rpm up to the maximum rated motor speed of 2,400 rpm.(See the TDS-10S output curve figures in the Appendi x chapter.)


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Thrust Ball Bearing

Air Inlet(1100 CFM)

Air Exhaust

Upper Grease Fitting

Lower Grease Fitting

End Coil

End Coil

Guide Roller Bearing

Stator Assembly(Laminated)

Rotor Assembly(Laminated)

Hub (Ref)

Mounting Base

Motor Frame(Laminated)

Motor Shaft(Vertical Type)

Hydraulic Motor Brake (Ref)

Figure 5. AC drilling motor


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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) provide20,000 ft lb of torque at a drill stem operating speed range of 0 to87 rpm. Maintaining constant 350-hp output, the top driveprovides 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 thecooling air to pass through the inside of the motor, whichprovides more efficient transfer of rotor and winding heat to thecooling air. The motor is manufactured specifically for top driveapplications. 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


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Chapter 3

Installation

Installing the TDS-10S

Electrical, mechanical and structural modifications are necessaryto 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


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All of the above modifications may not be necessary, but all mustbe considered as well as the overall rig floor layout in order toensure that proper installation, t ime utilization and accurate costinformation is made.

The functional operation of a TDS-10S has many considerations;a primary consideration is the mast/derrick height. The workingheight and crown clearance are two primary factors to finalizeprior to ordering and installing your TDS-10S. Working heightand Crown clearance can both vary dependent upon hook, block,bail, elevator links, and coupling chosen. Figure 6 shows a typicalTDS-10S mast interface. A mast/derrick interface requirementsand worksheet is provided in the Appendix chapter.


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3X50 ft(3X15,2 m)

A.C. Cables

Existing Traveling Equipment(250 ton Hook/Block Combo-Typ.)

Varco Portable Top

Drive System TDS-10S

Crown

Block Top

Bail Rest

Tool Joint

Tool Joint

*

**

Dimensions are Subject forVerificationStandard TDS Configuration-One IBOP with 96" elev.LinksOptional TDS Configuration-Two IBOP’s with 108" elev. Links

Beam

Service Loop

CL

Sectional Guide Beam10 X 10" Square Tube

75 ft(22,9 m) Mud Hose* Connectedto Standpipe at 73 ft (22,3 m) Level

200 ft(61 m)* Unitized Service Loop

Service Loop Saddle at ~80 Ft(24,4 M) Level*

Portable Torque Reaction Beam(Varco Universal Clamp on System, or Custormer Supplied)

Varco Driller's Control

150 ft (45,7 m) ControlCable with Connectors

"Local Power Supply"(Diesel/Alternator Set)

Unitized Variable FrequencyInverter & Varco Control Panel

Drill Floor

93 ft(28,4 m)Drill StandMade-up at4 ft(1,2 m)

Level

12.6 ft(3,8 m)-Std.11.6 ft(3,5 m)-Opt.

Clearance**

15.0 ft(4,6 m)-Std.16.0 ft(4,9 m)-Opt.TDS Work Height**

11.4 ft(3,5 m)*Stroked-Typ.

4.0 ft(1,2 m)

1 0

. 0 f t ( 3

, 0 m

) - M i n *

7 . 0

f t ( 2

, 1 m

) - M

i n

1 3 6 f t ( 4 1

, 5 m

) -

C l e a r

W o r k

i n g

H e

i g h t

Figure 6. Typical TDS-10S mast interface


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Another key consideration in selecting and successfully operatinga top drive is how well the top drive fits inside of the mast/ derrick. Given the specific dimensions within the mast/derricklegs, the top drive and its guidance system need to utilize thecomplete 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-55pipehandler connected. In the skid, the top drive is attached tothe 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 connectionand locking-in of the remainder of the guide beam section andthe 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 themast/derrick. Proper attachment and tieback is vital to thetransmission of the system torque to the rig structure.

Additional unit subsystem checkouts and precautions areprovided, all of which must be followed to ensure properfunctionali ty of the TDS-10S unit.


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Carriage Assembly

with Guide Pads

Guide Beam10 X 10 (250 X 250)

Square Tube

20.5 (521)

25.6(650)Ref.

44.0(1118)Ref.

19.5(495)

26.0(660)

28.0 (711)

48.0 (1219) Ref.

Motor Housing Gooseneck Service Loop Bracket

WellCL

CL

CL

CL

Reliance ElectricAC Induction

350 HP Drilling Motor

18.0(457)

24.0 (610)

Dimensionsare in inches (millimeters)

Figure 7. TDS-10S envelope/plan view


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March 10, 1998


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Chapter 4

Operation

Driller’s interface and driller’s console

The driller’s console is manufactured from 300-series stainlesssteel and it uses full-size, oil-tight switches and indicators. It is

designed for purging to meet hazardous area requirements. Byrequest, Varco can supply the console with Pyle-Nationalconnectors.

Throttle control

The throttle uses a design similar to the standard throttle controlused with SCR systems. The handle is robust and includesintegral stops to prevent damage.


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March 10, 1998

Torque control

Two torque limit potentiometers are provided for setting drill andmakeup torque limits.

The drill limit control allows the driller to set the maximumtorque output of the top drive to match the drill pipe size beingused.

The makeup control sets the torque when making up connectionsusing the TDS-10S drilling motor.

Switches

Various switches control the following functions:

Drill/Spin/Torque mode select

Link tilt

Brake

Backup clamp cylinder


IBOP valve

Forward and reverse selection for the drill pipe rotation

Emergency stop

Stand jump (optional)


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VarcoDriller'sConsole

Jumper Cable Assembliescould be used between Mast Termination Plate and Skid (Control House).

*

+

-

VarcoDriller's

Interface

VariableFrequency

Drive /

AC PowerHighline

orDiesel/Alternator

Set

+-

*

*

Top Drive

Solenoids

SystemElectrical PanelElectrical

ServiceLoop

MastSaddle

Sensors

Skid

J-Box

Motor

1 E n c o d e r

*

DC Generator(Alternate)

Figure 8. Electrical interface


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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

R

R

R A

RPMTORQUE

R

MAX0

0 MAX

STOP

EMERGENCY

THROTTLE

RE VER SE FORWAR D

ONBRAKEOFF

ONAUTO

HYDRAULIC POWER

CLOSEOPEN

IBOPAUTO

BRAKE

ONBRAKE

CLOSEDIBOP

SILENCE CHECKALARM LAMP

OVERTEMP

DRILL MOTOR

BLOWER LOSS

MAX0

CURRENT LIMITMAKE-UP

TORQUEDRILL

SPIN

OFFDRIVEFAULT

OILPRESS LOSS

DRILL TORQUE

OFF

LINK TILT FLOAT

PUSH & HOLD

TORQUE WRENCH

ROTATE

DRILL TILT

PIPEHANDLER IBOPBRAKE

LEFT RIGHT

LINK TILT

R

Figure 9. Typical TDS-10S Varco driller’s console (VDC)


45/254


Varco control system

The driller’s interface is integrated with the Variable FrequencyDrive (VFD). The VFD is located in an environmentallycontrolled house.

The driller’s interface integrated with the VFD includes thefollowing 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 toolsstandard for Varco top drive systems.

The driller’s interface receives input from the operator controls onthe driller’s console and processes this information through theprogrammable logic controller (PLC). It controls the responses of the cooling system motor, the solenoid valves, the brakes, IBOPfunctions, and sensors. The PLC reads the status of the sensorsand acts as an interlock to prevent inadvertent tool operations. Itnotifies the driller of the operational status of the TDS-10S andprovides a diagnosis of any inadvertent operational conditions.


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March 10, 1998

Variable frequency inverter

The frequency inverter consists of the following three majorsections:

Rectifier and DC link filter

In this section, the incoming 3-phase AC voltage is converted toDC voltage and filtered by the DC link capacitors. This providesa ripple-free 740 VDC voltage as input for the inverter.Alternately, by bypassing the rectifier section, the inverter can bepowered from a 740 VDC source.

Power modules

AC motor speed control requires variable frequency voltage. Todo this, the DC voltage is converted to an output waveform thatconsists of a series of pulses. The duration of each pulse iscontrolled so that the fundamental voltage applied to the ACmotor has the desired frequency and amplitude. The technique of using pulses to develop a waveform that appears to the motor as asine wave is called pulse width modulation or PWM.

Control section

The control section monitors the performance of the drillingmotor, accepts throttle and torque limit signals from theTDS-10S control system, and controls the firing circuits of thepower modules.

To vary motor speed, the driller uses a hand throttle. The throttlevaries the frequency and voltage to the motor. Because the drillingmotor is frequency synchronous, the motor speed is proportionalto the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200motor rpm).

One of the greatest advantages of an AC variable frequency driveis the quality of the speed and torque control. It allows precisecontrol of the drill pipe speed over the full operational range.


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+

-

Variable Frequency Drive

T D S - 1 0 S

A C

M o t o r s

0 - 5 7 5 V A C , 0 t o 8 0 H z , 3 - P h a s e

Inverter Controller

Data Bus

Resultant Pulse DC

AC Inverter(AC Frequency Drive)

810 VDC20 Hz=600 RPM @ Mtr.

40 Hz=1200 RPM @ Mtr.

0

0

0

ACPowerSource

PLC

Insulated gate Bi-polarTransistors (IGBT)

00

600 VAC, 42 to 62 Hz

3-Phase (350 AMPS)

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 cost-effectiveness of the TDS-10S drilling system and provides a saferwork area.

The TDS-10S has three electrical service loops. One loop consistsof four 313 MCM cables (three for dri lling motor power, one forground). One loop is a composite cable that contains conductorsfor the sensors and actuator (solenoid) control. The third loop

contains power for the smaller AC motors and space heater forthe drive motor.


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March 10, 1998

Drilling ahead

Drilling ahead with triplesThis is the common drilling mode for the TDS-10S. There arevarious sources for triples to drill with. On skidding rigs drillingmultiple wells, or rigs that can move with racked pipe, the drillpipe can be left racked and used to drill the next well. If triples donot currently exist to drill with, there are two recommendedmethods of obtaining them. One is to leave some triples racked inthe derrick when tripping back in the hole and finish the tripwith singles. Enough triples should be left racked to handleanticipated bit life. The second is to make up triples in themousehole while drilling ahead or during rig idle time. For safetyreasons it is best to have a pivoting mousehole so it can be put ina vertical plane to simplify making connections. Note that theconnections just need to be spun up as they will be torqued whenthe 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 drivemotor and backup clamp in the pipehandler.

3 Spin out the connection using the drill ing motor.

4. Lift the top drive.

5. The derrickman latches the triple in the elevator and the floorcrew stabs it in the box.

6. Lower the top drive stabbing the pipe into the stabbing guideuntil 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 reactthe torque.

8. Pull the slips, start the mud pumps and drill ahead.


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Set slips onstring

Stop circulation

Close IBOP

Breakoutconnectionusing pipehandlerand drilling motor(in reverse)

Raise block

Tilt link tiltto derrickman

Pickup stand withelevator

Stab bottom ofstand onto string

Lower block tostab motor intotop of stand

Spin in motorand stand

Makeup bothconnections withmotor

Pull slips

Start circulation

Open IBOP

Begin drilling

1 2 3 4 5

Stab Makeup

Makeup

CloseIBOP

OpenIBOP

LinkTilt

Figure 11. Drilling ahead with triples


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March 10, 1998

Drilling ahead with singles

Typically there are two situations when it is desirable to drillahead with singles. One is beginning operations on a new welland there are no triples made-up and racked back. The other is

when surveys must be made every 30 feet (kicking off using adownhole mud motor). The link tilt feature makes drilling withsingles safe and efficient by moving the elevators to themousehole 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 motorand the backup clamp in the pipehandler.

3. Spin out the connection using the drill ing motor.

4. Lift the top drive until elevators clear box.

5. Actuate the link tilt to bring the elevator over to the single inthe mousehole, lower the top drive and latch the elevatoraround the single in the mousehole.

6. Pull the single out of the mousehole and as the pin clears thefloor, release the link tilt to allow the single to come to wellcenter.

7. Stab the connection at the floor and lower the top driveallowing 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.


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Set slips onstring

Stop circulation

Close IBOP

Breakoutconnectionusing pipehandlerand drilling motor(in reverse)

Tilt links tomousehole

Latch drill pipeelevator aroundsingle

Pickup single withelevator

Release link tilt

Stab bottom ofsingle onto string

Lower block tostab motor intotop of single

Spin in motorand single

Makeup bothconnections withmotor intorque mode

Pull slips

Open IBOP

Start circulation

Begin drilling

Stab Makeup

OpenIBOP

LinkTilt

1 2 3 4 5

Makeup

CloseIBOP

Figure 12. Drilling ahead with singles


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March 10, 1998

Tripping in and tripping out

Tripping is handled in the conventional manner. The link t ilt featurecan be used to tilt the elevator to the derrickman, enhancing hisability to latch it around the pipe thus improving trip times.

The link tilt has an intermediate stop which is adjustable to setthe elevator at a convenient working distance from the monkeyboard. The intermediate stop is tilted out of the way to allow theelevator to reach the mousehole.

If a tight spot or key seat is encountered while tripping out of thehole, the drilling motor may be spun into the stand at any heightin the derrick and circulation and rotation establishedimmediately to work the pipe through the tight spot.

Back reaming

The TDS-10S permits reaming out of open hole to prevent pipesticking and reducing keyseat formation, without affectingracking functions associated with normal tripping; i.e., no singlesto contend with. This is provided by the ability of the top driveand 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 motoruntil 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 thedrilling motor.

4. Break out the drill ing motor from the top of the stand usingthe top drive motor and backup clamp, then spin out withthe 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 thedrilling motor and backup clamp.

9. Resume circulation and continue reaming out of the hole.


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Hoist whilecirculating androtating

When 3-rdconnectionsurfaces, stop

rotation andcirculation

Set slips onstring

Breakout connec-tion using pipehandlerand drilling motor(reverse)

Breakout andspinout standat floor

Hoist free standwith elevator

Setback standusing link tilt

Setback

Lower block,stab motor intostring

Spin in motorand makeupconnection with

motor

Start circulation,pull slips,hoist and rotate

1 2 3 4 5

Breakout

Breakout Hoist

Hoist andRotate

Figure 13. Back reaming


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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 isalways in the string for immediate use as needed.

The lower IBOP valve is the same type as the upper IBOP valveexcept it must be operated manually with a wrench. Both valvesalways remain in the string and are therefore always readilyavailable by connecting the TDS-10S to the drill string.

To attach well control equipment to the drill string the torquearrestor frame assembly can be pulled away from the drill stringby opening the clamp cylinder.

After removing the lower valve from the upper valve, the lowervalve remains connected to the drill string for well control

purposes. The TDS-10S includes crossover subs for connectingthe drill stem to the lower valve.

Use the following procedure for well control during trippingoperations (Figure 14):

1. On indication of a kick, set the slips and stab the top driveinto 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 theupper IBOP valve. I f it becomes necessary to continuetripping in with a dart valve, or another well controlaccessory, the lower IBOP valve can be used to assist theoperation. 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, swingout 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 circulationsub on top of lower IBOP valve.

10. Proceed with normal well control procedures.


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Remote IBOPActuator Cylinder

Upper IBOP Valve

Lower IBOPValve

Insert NewSaver Sub

Add X-Over Sub(Check Valve etc.)

Saver Sub

Drill Pipe

Figure 14. PH-55 pipehandler well control procedures


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March 10, 1998

Running casing

Use longer elevator links (180 in.) to allow clearance forcementing head under the backup clamp in the pipehandler.

Attach a short piece of hose to the saver sub in the pipehandler tofill the casing while lowering. Use the remotely controlled upperIBOP valve to start and stop the fluid flow.


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Chapter 5

Specifications

General

Transmission 13.1:1 high torque/lowspeed, or optional 4.8:1

low torque/high speeddouble reduction helicalgear

Transmission lube Pressure fed, filtered

Powered rotating head Infinitely positionable

System weight 18,000 lb


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March 10, 1998

Drilling parameters

Drilling speed range 0 to 182 rpm continuous

Drilling torque 20,000 ft lb maximumcontinuous (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 aircooled.

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)

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 350tons, API, 96 in. long(108 in. links optional)


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Chapter 6

Appendix


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March 10, 1998

Bail Rest

TDS-10S

250 Ton System350 HP AC Motor

Output Torque20,000 ft-lbs

Drill Floor

Tool Joint

20.8 ft(6,3 m)

TDS-4SWorkingHeight

Bail Rest

TDS-4S

650 Ton System1,100 HP DC Motor

Output Torque29,100(HI)/45,000(LO) ft-lbs

IDS-1

500 Ton System1,000 HP DC Motor

Output Torque34,000 ft-lbs

Bail Rest

Tool Joint Tool Joint

23.0 ft(7,0 m)

IDS-1WorkingHeight

15.0 ft(4,6 m)

TDS-10SWorkingHeight

Varco’s Top Drive Drilling Systems comparison


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50 100 150 20000

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

Drill Pipe RPM

D r i l l P i p e T o r q u e ( F t - L

b s )

350 HP AC Motor - 13.1:1 Tranmission (Standard)

Max. Stall @

36,500 ft lb

TDS-10S output curve (13.1:1)


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March 10, 1998

100 200 300 400 50000

2,500

5,000

7,500

10,000

12,500

15,000

Drill Pipe RPM

D r i l l P i p e T o r q u e ( F t - L

b s )

350 HP AC Motor - 4.8:1 Tranmission (Optional)

Max. Stall @13,390 ft lb

TDS-10S output curve (4.8:1)


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TRAVELINGEQUIPMENT

MAKE MODELWORKING HEIGHT WEIGHT (EST)

in ft mm lbs kg

660B-500 92 7.6 2324 18500 8391

DRECO 760B-650 105 8.7 2654 23800 10795

760B-750 109 9.0 2756 27500 12474

650H500 91 7.5 2299 13500 6266

NATIONAL 660H500 109 9.0 2756 18750 8509

760H650 112 9.3 2832 21800 9888

B500 100 8.3 2543 17900 8119OILWELL

650 104 8.6 2629 20240 9181

A750 120 10.4 3210 34016 15429TRAVELINGTB525-6-60 105 8.8 2670 18200 8255BLOCKS

IDECO TB650-6-60 110 9.2 2794 20500 9299

TB750-7-60 113 9.4 2873 22100 10024

RA52-6-500 92 7.7 2337 13250 6010

CECO RA60-6-650 103 8.6 2621 19158 8690

RA60-7-750 110 9.2 2794 22871 10374

McKISSICK500 91 7.6 2315 21500 9752

650 109 9.1 2769 22590 10246

MH500-1195 92 7.7 2340 21546 10000

650-1090 105 8.7 2664 26932 12500

PYRAMID500 104 8.7 2648 22000 9979

650/750 103 8.5 2604 27000 12247

HOOK-BLOCK 650G500 169 14.1 4293 21250 9639 COMBOS

NATIONAL660G500 184 15.3 4674 26500 12020

(stroked 8") 760G650 192 16.0 4883 31780 14415IDECO UTB 525-6-60 181 15.1 4607 9000 4082

545G350 152 12.6 3861 15260 6922

540G250 137 11.4 3480 11600 5262

5500 117 9.8 2981 9950 4513VARCO BJ5750 138 11.5 3493 18090 8205

51000 158 13.2 4035 32076 14550HOOKS 500 97 8.1 2457 6920 3138

NATIONAL 650 103 8.6 2623 8550 3872

750 113 9.4 2873 9750 4423

WEB WILS. 500 120 10.0 3048 8500 3856

MH500 112 9.3 2845 11850 5500

650/750 138 11.5 3508 18745 8700

P500 92 7.7 2343 5700 2585

NATIONAL P650 94 7.8 2375 6900 3130

P750 116 9.6 2937 11500 5216

OILWELLPC500 94 7.8 2388 5708 2589

PC650 96 8.0 2438 7350 3334

TL-500 91 7.6 2311 5200 2359

IDECO TL-650 101 8.4 2562 6900 3130

TL-750 114 9.5 2899 8200 3719SWIVELS

CECOLB500 91 7.6 2311 5947 2698

LB650 99 8.2 2505 6646 3015

SW550 94 7.8 2381 5700 2585

G.-DENVER S500 98 8.1 2486 5800 2631

S650 101 8.4 2570 6850 3107

500 102 8.5 2578 6100 2767

DRECO 650 109 9.1 2769 7000 3175

750 119 9.9 3001 9100 4128

TDS-3H 214 17.8 5436 32600 14800

TDS-3S 250 20.8 6350 36750 16685

TDS-4H 221 18.4 5613 37000 16798

VARCOTOP DRIVES

TDS-4S 250 20.8 6350 38750 17593

TDS-5H 214 17.8 5436 35200 15981

TDS-6S* 276 23.0 7010 43750 19826

IDS-11S 216 18.0 5486 26500 12020

(stroked 8")

TDS-7S 250 20.8 6350 49000 22742

TDS-9S 214 17.8 5425 24000 10886

5350 106 8.8 2692 6340 2876

5250 104 8.7 2642 5050 2291

TDS-10S 192 16.0 4877 18000 8164

H350 77 6.4 1956 9380 4255

IDS-1** 346 28.8 8788 49000 22742

Block Top

Block

Hook(If Used)

Swivel

DrillingSystem

Hook-BlockCombination

S-TypeDrillingSystem

(IntegratedSwivel)

Tool Joint

IntegratedDrilling System

(IDS)(Integrated Block

and Swivel)

Saddle

Saddle

StemShoulder

Saddle

To short-couple a Swivel Bail/Top Driveto a Traveling Block VARCO offers special

Adapters with a 3 to 4 ft working height.

** With 500 Ton 60-in SheaveVarco Integrated Taveling Block

* Includes 750 Ton Hook Adapter

Top drive worksheet


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March 10, 1998

VFD / Varco Driller's Interface

Drill Floor

4 ft

Beam

.............ft

.............ftMast

Bundle

.............ftMud Hose,[email protected]

ServiceLoop/Mast

BundleSaddle

@..........ft

..................Clearance

Customer:

..........................................

..........................................

Existing

Traveling Equipment:

...........................................

...........................................

Traveling Equipment

Short-Coupling using

Varco Adapter/Becket

(if applicable):

............................................

............................................

............................................

..................(Stroked)

15.0 or 16.0 ftTDS Working Height

SectionalGuide Beam

Tool Joint

Tool Joint

Bail Rest

Block Top

Crown

CL

. . . . . . . . . . . .

f t M a s

t O p e r a

t i n g

H e

i g h t

9 3 f t D r i

l l S t a n

d

TDS-10S Mast interface worksheet (generic)


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TDS-10S


M aintenanceandTroubleshooting


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March 2, 1998

2 TDS-10S Maintenance and Troubleshooting


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TDS-10S Maintenance and Troubleshooting 3

Contents

PrefaceManual conventions............................................................ 7Safety information .............................................................. 7Directional references ......................................................... 8Illustrations......................................................................... 8Manual layout..................................................................... 8Varco service centers........................................................... 8

Chapter 1 IntroductionPrecautions......................................................................... 9

Chapter 2 Maintenance schedulesInspection schedules ......................................................... 11Lubrication schedule......................................................... 13Lubricant specifications.................................................... 14

Selecting a lubricating/hydraulic oil ............................ 14Selecting a lubricant .................................................... 15

Chapter 3 InspectionInspecting hardware and fitt ings....................................... 17Inspecting the AC drill ing motor brakes........................... 18Inspecting the AC dril ling motor louvers.......................... 18Inspecting the wash pipe assembly .................................... 18Inspecting the upper stem liner ......................................... 19Inspecting main shaft end play.......................................... 21Inspecting the gearbox oil level ......................................... 22Inspecting the guide beam ................................................ 22Inspecting the IBOPs........................................................ 22

Inspecting the pipehandler ................................................ 23Nondestructive Examination (NDE) ................................ 24

Inspecting the elevator link eyes.................................. 24Inspecting the drive stem ............................................ 26Magnetic particle inspection (MPI) ............................ 27Ultrasonic inspection .................................................. 28

Inspecting the hydraulic system ........................................ 29Inspecting the electrical system ......................................... 29


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March 2, 1998


Chapter 4 LubricationIntroduction ..................................................................... 31Lubricating the AC blower motor bearings....................... 32Lubricating the hydraulic pump AC motor ....................... 32

Lubricating the AC drilling motor bearings ...................... 32Lubricating the wash pipe assembly .................................. 34Lubricating the upper main body oil seals......................... 35Replacing the gearbox oil .................................................. 35

Initial oil change......................................................... 35Oil capacity................................................................. 35

Replacing the gearbox oil filter .......................................... 36Lubricating the carriage and guide beam........................... 36Lubricating the rotating link adapter ................................. 36Lubricating the link ti lt and PH-55 stabilizer bushing ...... 38Lubricating the elevator support and

master bushing wear guide................................................ 38Lubricating the wireline adapter ........................................ 38Lubricating the IBOP actuator yoke................................. 39Lubricating the IBOP actuator crank ................................ 40Lubricating the torque arrestor tubes andclamp cylinder gate ........................................................... 41

Chapter 5 MaintenanceGeneral hydraulic system maintenance.............................. 43

Start-up procedure...................................................... 44

Accumulator maintenance ................................................ 44

Chapter 6 TroubleshootingTroubleshooting the AC drilling motor ............................ 45Troubleshooting the AC blower motor ............................. 46Troubleshooting the hydraulic system............................... 47Troubleshooting the ACdrill ing motor brakes......................................................... 51Troubleshooting the rotating link adapter(rotating head) motor ....................................................... 52


Troubleshooting the IBOP actuator cylinder .................... 54Operation ................................................................... 54System test .................................................................. 55


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March 2, 1998



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Preface

Manual conventionsThis manual contains conventions that make it easy for the readerto locate key information and detailed descriptions. Graphicsillustrate descriptions of equipment and assemblies to provide abetter understanding of the equipment and assemblies to providea better understanding of the equipment’s functionality.

Safety informationInformation pertaining to possible personnel injury andequipment damage appears throughout this manual and isformatted to draw the reader’s attention to importantinformation, a warning, or a caution note. See the symbols belowand pay close attention to these important advisories throughoutthe text.

z Indicates advisories for operational or servicing proceduresinvolving little or no risk of personal injury and equipmentdamage.

e Indi cates advisories involving a risk of equipment damage.

n Indi cates advisories involving a defini te risk of injury to rig personnel.


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March 2, 1998


Avoid personal injury and equipment damage by reading thismanual and related documents before operating, inspecting, orservicing the equipment.

Directional references

References to the right or left and front or back of componentsdescribed in this manual assume the perspective of the toolassembly–standing behind the tool as it faces well center.

IllustrationsFigures present a graphical representation of tool components foruse in identifying parts or establishing nomenclature.

Illustrations show measurements with inches (in.), followed bymillimeters (mm).

For more specific component information pertinent to your rigconfiguration, see the drawing index in the Drawingschapter to

obtain the engineering drawing number.

Manual layout

This binder contains several separate chapters that you canremove individually for convenience.

Varco service centers

If you need technical assistance, see the back cover of this manualfor a complete list of Varco’s Worldwide Service Centers.


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Chapter 1

Introduction

Precautions

To avoid serious injury or death, read and understand thefollowing warnings before performing maintenance procedures:

n Properly lockout the main power source before performing lubr ication, inspection, or replacement procedures, unless

speci fi cally noted in this manual.

n Wear protective glasses to prevent eye inj ur ies fr om flui ds under pressure, as well as other hazards.

n Do not attempt any adjustments whi le the machine is moving.


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March 2, 1998


n Use cauti on when draining lubri cant. I t can be hot.

nNever check for hydraul ic leaks wi th your hands. Oi l under

pressure escaping from a hole can be nearly invi sible and can

penetrate ski n causing serious inj ury. Always check for leaks wi th

a piece of wood or cardboard and always wear protective eyewear

when worki ng on hydraul ic components.

n Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraul ic system.

n Do not attempt repairs you do not understand.

n Read and understand all safety precautions and warni ngs before performing maintenance procedures.


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Chapter 2

Maintenanceschedules

Inspection schedules

z The service intervals listed in Table 1 on the following page arebased on average operating conditions. Use the schedule as aguide. Some conditions (excessive loadings, dusty or corrosiveatmosphere, temperature extremes, etc.) may warrant morefrequent service intervals.


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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 WeeklyGuide beam wear

Upper stem liner Corrosion Monthly, or whenever thewash 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 connectionsare broken

Load bearing components Magnetic Particle Inspection At three months or 1,500

(MPI) hours on exposed surfacesAt five years overentire surface

Ultrasonic Inspection to beperformed along with MPI


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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

IBOP actuator yoke and pins General purpose grease Daily

IBOP actuator cranks 2 General purpose grease Daily

Stabilizer bushing General purpose grease Daily

Rotating link adapter grease fi ttings 3 General purpose grease WeeklyClamp cylinder gate General purpose grease Weekly

Torque arrestor tubes–at clamp cylinder area 2 General purpose grease Weekly–at clamp cylinder gate 4 General purpose grease 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 WeeklyAC 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

Replace oil Gear oil Three months

Replace oil filter Three months


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March 2, 1998


Lubricant specifications

Selecting a lubricating/hydraulic oilVarco Top Drives operate under a wide variety of temperaturesand conditions. The oil viscosity varies from quite thick at start-up in cold climates to very thin in hot climates during difficultdrilling conditions.

Select gearbox lubrication based on the minimum ambienttemperature to be expected before the next oil change.Introducing an oil viscosity greater than required by the ambienttemperature 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 lubr icant 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 For minimum temperatures below -15°F, warm the TDS-10S upby rotating at a very light load and very slow speeds until the oiltemperature is above -15°F. Contact your local Varco ServiceCenter for specific instructions.


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Selecting a lubricant

Use Table 4 to select the appropriate lubricant for your specificapplication.

Table 4. Recommended lubricants

General Purpose Grease

Above -20˚ Below -20˚CAmbienttemperaturerange

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

NGL1

AGMA

ISO ViscosityGrade

MP grease

Avi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

2

-

-

-

Avi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

1

-

-

Lube Code and Description

1

Use Chevron Black Pearl EP2 grease for all temperatures whereapplicable.


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March 2, 1998



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Chapter 3

Inspection

Inspecting hardware and fittings

Visually inspect the TDS-10S for loose or missing hardware andfittings daily. Make sure all lockwire is undamaged.


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March 2, 1998


Inspecting the AC drilling motor brakes

Remove the brake housing covers to access the drilling motorbrakes.

Inspect the brake shoes for wear, and replace the shoes if wornbelow the allowable lining wear limit given by the manufacturer(approximately 3/32 in.). See the brake manual included in theVendor Documentation Packagefor additional information. If thebrake shoes are wearing unevenly, adjust the brake pads byadjusting the bolts on the brake calipers.

Inspect the brake hydraulic lines for leaks.

n Never check for hydraul ic leaks wi th your hands. Oi l under pressure escaping from a hole can be nearly invi sible and can penetrate ski n causing serious inj ury. Always check for leaks wi th a pi ece of wood or

cardboard.

Inspecting the AC drilling motor louvers

Make sure that no AC drill motor louvers are missing ordamaged.

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.


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Inspecting the upper stem liner

Use the following procedure to inspect the upper stem liner whenreplacing the washpipe assembly.

1. Remove the wash pipe packing (Figure 1).

2. Check the upper stem liner for erosion cause by leaking washpipe packing and replace the liner if erosion is found.

z The 3.875 in. OD polypack seal must also be replaced wheneverthe upper stem liner is replaced. Make sure the O-ring of the sealis facing down when the seal is installed on the liner.


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March 2, 1998


Wash Pipe Assembly

Main Shaft

Polypack Seal

Upper StemLiner

Polypack Seal

Upper Stem Liner

Figure 1. Inspecting the upper stem liner


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Inspec

Documents

TDS_10S Service Manual