Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Introduction
Major Components.
Sections
Section 1 - General Information
Section 2 – Specifications
Section 3 - Lubrication and Maintenance
Section 4 - Installation, Commissioning and Decommissioning
Section 5 - Guide Beams and Carriage
Section 6 - Motor Housing, Transmission
Section 7 - PH-50 Pipehandler
Section 8 - Hydraulic System
Section 9 - Varco Driller's Console
Section 10 - System Interconnect
Section 11 - Siemens Step 7 PLC
Section 12 - Basics of AC Motors
Section 13 - Basics of AC Drives
Section 14 - Seimens 70 Series Drive Chassis AC to AC
Section 15 - Parameter Listing
Section 16 - Encoder Troubleshooting Instructions
Section 17 - Simovis Version 5
AC Drilling Motors (2) Hydraulic Disc Brakes (2) Motor Cooling System Guide Beam and Carriage Hydraulic System Electrical System PH-50 Pipehandler Gooseneck (S-Pipe) Counterbalance System Transmission/ Motor Housing Rotating Link Adapter
Left Side Front
A brief history of Top Drives
Since the advent rotary drilling in the early 1900s, drilling
technology has made steady and, in some cases, spectacular
progress. In a little over 100 years, well depths have gone from
the 70-foot depth of Drake's Well to over 40,000 feet at the rig
on Kola Peninsula east of Finland. To accomplish this,
advances were necessary in rig design, equipment, bits,
materials and drilling techniques.
Varco International, Inc., is proud of its part in advancing the
technology of drilling. In 1982 they introduced the industry's
first top drive drilling system. By replacing the traditional rotary
drive and kelly with an advanced system that rotates the drill
string and handles entire 93-ft. stands of pipe, Varco was able
to reduce drilling time by up to 25% while increasing the overall
capability and efficiency of the drilling operation.
As a result, Varco Top Drive Drilling Systems have now
become the new performance standard for the drilling industry.
And Varco continues to extend the threshold of Top drive
technology with the introduction of a complete line of AC top
drive systems.
A new threshold in AC technology
For years the backbone of oil industry power has been the
1000 hp DC traction motor adapted from locomotives. They are
used extensively to power a variety drilling operations including
drawworks, rotary tables and mud pumps. DC traction motors
area rugged, dependable, readily available source of high
torque electric power. These characteristics made them the
ideal choice for the conversion of drilling equipment from direct
drive diesel to electric power.
In developing its Top Drive systems, Varco first turned to these
DC motors to power its new technology. And while they were
appropriate for some applications, it became evident that
smaller, more compact motors were needed for today's
perfor-mance requirements. There was a need for an efficient,
high-performance alternative to traditional DC systems. As part of
Varco’s ongoing development effort, various AC motors and
drives were reviewed in an effort to satisfy the specific
require-ments of drilling applications. Varco design engineers
deter-mined that rapid developments in adjustable frequency
technology made AC drives and motors a better solution for
certain applications traditionally served by DC systems. These
modern AC motor/control combinations are uniquely suited for
the requirements of the drilling industry. By optimising various
components, rugged, reliable AC drives and motors now can
produce superior power density for a given frame size. The
result - compact, efficient power plants that extend the
performance envelope of drilling operations.
A performance paradigm
By utilising highly efficient AC motors with the latest variable
frequency drives, Varco has defined a new category of
performance top drive systems. These new AC drives can stall
at full torque for extended periods of time, provide significantly
higher intermittent torque and offer more precise control at all
speeds. An additional benefit of the advanced AC technology
of Varco top drives is constant, useable horsepower over a
greater range of speed and torque. This means that you can
run faster with more torque - an ideal condition for maximising
the potential of diamond and polycrystalline diamond compact
(PDC) bits. In the competitive world of drilling and production,
Varco has developed technology that is defining a new
performance paradigm. Their AC top drive systems combine
increased performance, reduced maintenance, lower power
consumption, and flexible drive parameters into an unbeatable
combination over a wide variety of applications.
Portable Top Drive
Comparison
Specifications Comparison
IDS-1
TDS-9S
TDS-10S TDS-11S
(DC SHUNT)
(AC)
(AC)
(AC)
Working
Height-Ft
23.0
17.8
16.0
18.0
Weight-Lbs.
30,700
24,000
18,000
28,000
Cont. Torque.
34,900
32,500
20,000
38,000
Ft-Lbs.
@155 RPM
@114 RPM @89 RPM @114 RPM
Horse Pwr.
1,000
700
350
800
Rated Ton.
500
400
250
500
TDS Training Manual
AC Electrical
TOP DRIVE COMPONENTS
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
TRANSMISSION/MOTOR HOUSING
AND SWIVEL ASSEMBLY
TDS Training Manual
AC Electrical
Transmission/Motor Housing (Main Body) and
Swivel Assembly
The transmission/motor housing and swivel assembly transfers the power produced
by AC drilling motors to the drill string. Inside the transmission/motor housing main
body is a single-speed double-reduction spur gear system that provides a 10.5:1
ratio from the motors to the main shaft. The main thrust bearing located inside the
motor housing supports drilling loads, while the load stem, which bypasses the
thrust bearing and provides support for the rotating link adapter and pipe handler,
carries the tripping loads. The main body of the motor housing provides a sealed oil
lubrication reservoir for the transmission gears and bearings. Bearings and gears
are force fed by an oil pump that is integral with the main body. A low speed
hydraulic motor drives the oil pump. The filtered lubrication oil constantly circulates
through the main thrust bearing, take-up bearing, lower radial and compound gear
bearings and over the gear meshes. An industry standard wash pipe packing box
assembly is located between the main shaft/swivel stem and the S-pipe weldment.
The bonnet supports the S-pipe weldment. The forged alloy steel bail swings
forward for attaching to standard rotary drilling hooks. The bail is fitted with bronze
bushings that are grease lubricated.
TDS Training Manual
AC Electrical
MOTOR COOLING SYSTEM
The motor cooling system on the AC TDS is a local intake pressure blower
type. It consists of two 5 HP AC motors integrally mounted on top of each AC
drilling motor. Air is drawn in from the combination brake cover/air intake and
delivered through rigid ducting to an opening in the top of each motor. The
cooling air then passes through the inside of the open-frame type AC drilling
motors and exits out of two louver openings near the bottom of the motors.
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
The hydraulic control system is a completely self-contained, onboard system. A
10-horsepower, 1800 RPM, AC motor, drives two hydraulic pumps and powers the
hydraulic system. A fixed displacement pump drives the Lube oil system motor. A
variable displacement pump provides hydraulic power for the AC motor brakes,
powered rotating head, remote actuated IBOP, pipe backup clamp cylinder link tilt
and counterbalance system.
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 the need for
draining and refilling during normal rig moves. The reservoir is mounted between the
two AC drilling motors and is equipped with strainers and oil level sight gauges.
Three hydro-pneumatic accumulators are located on the main body. The
counterbalance system uses the largest accumulator. The medium size accumulator
unloads the variable displacement pump and the smallest accumulator activates the
delay circuit on the IBOP actuator.
TDS Training Manual
AC Electrical
AC DRILLING MOTOR BRAKES
A modified U-face attaches the motors to the main body. This mounting
method allows installation of the motors without shimming or special
alignment. Each motor has double-ended shafts with a drive pinion mounted
on the lower end and disc brake rotor mounted on the upper end. Two
hydraulic calliper disc brakes mounted to the top end of each motor, hold
torque in the drill string and assist in positioning during directional work. An
electrical solenoid valve remotely operates the hydraulic calliper disc brakes.
The AC drilling motors are an open-frame type, meaning that the cooling air
passes through the inside of the motion The drilling motors, manufactured
specifically for top drive applications, have internal temperature sensors,
vacuum varnish impregnated windings, high capacity bearings, and tapered
output shafts to improve serviceability of the pinion gear and brake hubs.
TDS Training Manual
AC Electrical
Powered Rotating link
The powered rotating link adapter located at the top of the pipe handler is a slip ring
assembly. It allows the hydraulic lines to remain connected as the pipe handler
rotates with the drill stem components while tripping out or positioning the link tilt.
The rotating link adapter also provides an attachment for the link tilt, pipe backup
clamp cylinder and remote IBOP actuator assembly. Grooves in the rotating link
adapter align with radial holes in the load stem, allowing hydraulic fluid to flow
between the rotating link adapter and the load stem as they rotate. The radial
passages at the upper end of the load stem intersect with each hose attachment that
runs to the hydraulic manifold. The radial passages in the lower end of the load
stem intersect sealed grooves in the rotating link adapter that, in turn, connect with
hose attachments that run to all the actuators on the pipe handler. The rotating link
adapter can be powered in either direction by a hydraulic drive motor. A pinion gear
on the hydraulic drive motor engages a ring gear attached to the top of the rotating
link adapter. An electric solenoid valve operates the rotating link adapter hydraulic
motor.
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
TWO WAY LINK TILT (PH-50)
The two way link-tilt cylinder assemblies consist of the cylinder
rods pinned to the rotating link adapter and the cylinder bodies
pinned to the links through a set of clamps. Pressurising the
cylinder assemblies by operating the switch on the driller's
console extends the drill pipe elevator to the mouse hole or the
drill down position. A float position allows the links to return to
well centre, the latch on the cylinder assembly limits the travel
of the elevator to the derrick man position. Releasing the larch
by pulling a cable allows the elevator to travel to the mousehole
position
TDS Training Manual
AC Electrical
TDS Training Manual
AC Electrical
Internal Blowout Prevention
The two Internal Blowout Prevention (IBOP) control valves contained in the
pipehandler are ball type, full size. internal opening safety valves. These two valves
a hex drive remotely operated upper valve, and a manually operated lower valve.
form the ;well control system. Both valves have 6-5/8" regular RH connections and
15.000 psi pressure ratings. The remotely controlled upper IBOP valve is opened
and closed by a yoke and a hydraulic cylinder that is controlled from the driller's
console using an electric solenoid valve. A clam shell housing rotates with the valve
body and moves up and down to drive a small crank arm on each side of the valve
stem. The housing is actuated by a cylinder through a non-rotating actuator ring.
The hydraulic cylinder is attached to the torque arrestor frame. The lower valve is
the same type as the upper except it must be manually opened and closed with a
wrench. Both valves remain in the string at all times and are readily available by
connecting the Top Drive to the drill string. The lower valve can be broken-out from
the upper valve using tongs after swinging the torque arrestor frame out of the way.
The torque arrestor frame can be pulled away from the drill string after opening the
front gate on the clamp cylinder body and removing the stabiliser half. After
breaking-out the lower valve, the Top Drive can be hoisted away, allowing room to
install the appropriate subs arid valves for well control operations. After removing
the lower valve from the upper valve on the Top Drive using conventional fig tongs,
the lower valve remains connected to the drill string for well control purposes. A
crossover sub is included with the system to allow connection of the drill stem to the
lower valve. A drill pipe elevator hangs from a pair of conventional links that attach
the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up
pipe.
TDS Training Manuak
AC Electrical
TORQUE BACK-UP CLAMP
The torque hack-up clamp is supported by a torque arrestor frame that hangs from
the rotating link adapter. The backup clamp is located below the lower shoulder of
the saver sub and consists of a pair of gripping jaws with die inserts and 10"
diameter clamping cylinder for gripping the box end of the tool joint when connected
to the saver sub. The backup clamp body is attached to the torque arrestor frame in
such a way that it can float up or down to allow for thread engagement and counter
backup torque while making and breaking connections.
When the clamp mode is activated, a shot pin mechanism automatically engages
the rotating ring to prevent the link adapter from rotating while breaking out the
connection.
TDS Training Manual
AC Electrical
COUNTERBALANCE SYSTEM
The counterbalance system includes two hydraulic cylinders connected between
the bail and the hook. When the system is activated, the two cylinders support
most of the weight of the Top Drive. This system protects root joint threads by
taking much of the weight off the drill pipe while making or breaking connections.
A new feature for the TDS-9S is called STAND JUMP. It consists of a switch at
the driller's console allowing you to change the mode of operation of the
counterbalance cylinders from DRILL, which is a standard counterbalance
condition, to STAND JUMP. The STAND JUMP feature allows the cylinders to lift
the weight of the top drive off the drill string while breaking out a connection, this
eases the stress on the threads and avoids damage. The cylinders lift the swivel
bail off its resting point on the hook. The two hydraulic cylinders are connected
to a hydro-pneumatic accumulator located on the main body. A manual valve
can extend the cylinders to assist during rig-up. The accumulator is charged with
hydraulic fluid and maintained at a predetermined pressure setting by the
counterbalance circuit in the hydraulic control manifold, located on the main
body. The hydraulic manifold controls all hydraulic power to the Top Drive.
TDS Training Manual
AC Electrical
Electrical Interface
The electrical interface shown above is the standard layout for the TDS – 9/11S,
there are main parts of this schematic, the Varco Top Drive, the Varco Driller’s
Console, the Control House or Skid and the Service Loops/Connecting cables.
The Top Drive consists of the two AC Drilling motors, Encoder Feedback, Solenoids
Valves and Pressure and Temperature Switches.
The Varco Driller’s Console consists of the switches and Potentiometers to Control
the Top Drive System as well as Alarm Indicators and Horn, to indicate a Fault
condition to the Driller.
The Control House or Skid consists the Variable Frequency Drive which powers the
AC Drilling Motors on the Top Drive, Varco control Panel which controls all the
functions and Alarms on the Top Drive.
The Service Loops are all electrical, these are the cabling system, which gives all
the power to the Top Drive, as well as giving Alarm condition status back to the
Control Panel.
Preface
Manual conventions
This Preface contains the conventions used throughout this manual. Avoid injury to personnel and/or equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
Notes, cautions, and warnings
The following examples explain the symbols for notes, cautions, and warnings. Please pay close attention to these important advisories.
Note
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Provides additional information on procedures involving little or no risk of injury to personnel or equipment damage.Caution
!
Alerts the reader to procedures involving a risk of equipment damage.Warning
Warns the reader of procedures involving a definite risk of injury to rig personnel.
Product Bulletins
The Product Bulletin tab, if included in your manual, defines a section of the manual in which you can store Product and Safety bulletins that may be issued by Varco.
Overall equipment safety requirements
Varco drilling equipment is installed and operated in a controlled drilling rig environment that involves hazardous operations and situations.
i
To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.Personnel training
All personnel installing, operating, repairing, or maintaining equipment, or those in the vicinity of this equipment, should be trained in rig safety, tool operation, and maintenance as applicable. This measure helps ensure the safety of everyone exposed to the equipment for whatever purpose.
i
During installation, operation, maintenance, or repair of this equipment, personnel should wear protective equipment.Contact the Varco Service Department to arrange for training for equipment operation and maintenance.
Systems safety practices
The equipment covered by this manual may require or contain one or more utilities such as electrical, hydraulic, pneumatic, and cooling water.
i
Before installing or performing maintenance or repairs on the equipment, read the following instructions to avoid endangering exposed persons or damaging equipment.❏ Isolate all energy sources before beginning work.
❏ Avoid performing maintenance and repairs while the equipment is in operation.
❏ Wear proper protective equipment during the installation, maintenance, or repair of this equipment.
Electrical systems and components
All electrical wiring, junction boxes, sensors, glands, and related equipment are designed for the specific application, environment and particular zone where the equipment is intended to be used.
❏ Before beginning work on this equipment, familiarize yourself with the electrical schematics, as well as the equipment power and voltage requirements.
❏ When performing installation, maintenance, or repairs on the equipment, isolate all power. Lock out switches and tag them to prevent injury.
❏ Prior to disconnecting wires, verify that all wires and terminals are properly labeled to ensure proper reconnection.
Hydraulic systems and components
Hydraulic systems and components are designed for specific use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi.
❏ Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics. ❏ Isolate, lock out, and tag the hydraulic and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques.
n
Hydraulic fluids can be extremely hot and under high pressure. ❏ Properly discharge all system accumulators.❏ Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination.
❏ Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components, such as junction boxes.
Pneumatic systems and components
Pneumatic systems and components are designed for specific use in the drilling industry. The pneumatic pressure for this equipment can be as high as 150 psi.
❏ Prior to beginning work on any portion of the pneumatic system, familiarize yourself with the pneumatic and electrical schematics. ❏ Isolate, lock out, and tag the pneumatic and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques.
❏ Properly discharge all system accumulators.
Water cooling systems and components
Water cooling systems and components are designed for specific use in the drilling industry. The water can reach temperatures high enough to cause scalding.
❏ Prior to beginning work on any portion of the cooling system familiarize yourself with the plumbing and electrical schematics. ❏ Isolate, lock out, and tag the cooling water and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques.
❏ Collect all residual cooling water in a container to prevent rig or environmental contamination if necessary.
❏ Take precautions to prevent cooling water from leaking into other open electrical or mechanical components such as junction boxes.
General safety
Equipment motion hazardsSome of the Varco equipment travels either horizontally, vertically on rails, or both.
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Avoid placing objects in or near the path of motion for this equipment. Such interference could cause personnel to be trapped or crushed by equipment.i
Keep the working envelope/zone of the equipment free from personnel.When replacing components
❏ During disassembly and reassembly of any equipment, verify all components such as cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly.
❏ Replace failed or damaged components with Varco certified parts. Failure to do so could result in a hazard, equipment damage, or personal injury.
During routine maintenance
Equipment must be maintained on a regular basis. See the body of the service manual for maintenance recommendations.
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Failure to conduct regular maintenance can result in a hazard, equipment damage, or injury to personnel.Visibility of equipment operation
Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not block or impair the equipment operator’s field of view. In cases where this is not possible, the customer must install video cameras to ensure adequate visibility.
Proper use of equipment
Varco equipment is designed for specific functions and applications and should be used only for the intended purpose.
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Do not hoist personnel using this equipment.Contact the Varco service center for questions regarding equipment operation, maintenance, hazards, and designed function.
TDS Training Manual
AC Electrical
Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Section 1
3
4
5
6
General Information
7
8
9
1
2
TDS-11SAHow to use this manual ... 1-2
Identification numbers ... 1-3
Lifting points ... 1-4
Safety wiring ... 1-5
Torque values ... 1-6
Basic useage ... 1-7
Drilling ahead with singles ... 1-7
Drilling ahead with triples... 1-8
Backreaming ... 1-9
TDS-9/11SA consumables ... 1-10
1
Varco Systems General Information
1-2
How to use this manual
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 the thumb index tabs for each section and the back cover. You can quickly find each section without looking through a full table of contents. Use the symbols printed at the top corner of each page as a quick reference system. Each section uses a different symbol.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this may manual contain warnings about proceedures which could damage equipment, make it unsafe, or 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
i
!
!
(Note) Gives helpful information.
(Caution) Indicates a possibility of personal injury or equipment damage if instructions are not followed.
(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.
Where applicable, each section includes:
1. A table of contents, or an illustrated view index showing: • Major assemblies, systems or operations
• Page references to descriptions in text 2. Disassembly / assembly information and tools 3. Inspection information
4. Testing / troubleshooting information 5. Repair information
6. Adjustment information 7. Torque values
1
TDS-11SA
General Information
1-3
Identification numbers
SALES ORDER NO.
ASSY NO. REV TRACE CODE
DATE OF MANUFACTURE
Encoder Instruction Label
Located on the side of the brake housing
Warning Label
Located on the side of the bonnet
Warning Labels
Located on the side of each AC motor
AC Motor Identification Label
Located on the side of each AC motor
Top Drive Identification Plate
Located on the front of the motor housing Trace code identifies the configuration of your equipment
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1
Varco Systems General Information1-4
Lifting points
!
!
!
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Bail Lock Must be installed beforelowering/hoisting the Top Drive to/from the skid
Lifting Point For lowering/hoisting the Top Drive to/from the skid
30,000 lb (13600 kg) TDS-11SA on the skid For information on
Center of gravity see pages 2-2 and 2-3 27,000 lb
(12300 kg) TDS-11SA
Lifting Points For the skid with Top Drive attached
Lifting Points For the skid with Top Drive attached
Locking pins Must be in place prior to moving the skid with Top Drive attached
Locking pins Must be in place prior to moving the skid with Top Drive attached
1
TDS-11SA General Information1-5
Safety wiring
3
4
5
2
1
1
Varco Systems General Information
1-6
Torque values
(Unless otherwise specified)
Diameter 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 20 18 16 14 13 12 11 10 9 8 7 7 6 6 Threads per inch 28 24 24 20 20 18 18 16 14 14 12 12 12 12
Bolts Lubricated with
Light Machine Oil
Grade 5 7.6 16 29 48 71 105 143 247 409 608 760 1064 1387 1843 Min. Torque (ft lb) 9.5 18 33 52 86 114 162 285 447 665 836 1178 1596 2090 8.4 18 32 53 79 116 158 273 452 672 840 1176 1533 2037 Max. Torque (ft lb) 10.5 20 37 58 95 126 179 315 494 735 924 1302 1764 2310 2020 3340 4940 6800 9050 11600 14400 21300 29400 38600 42300 53800 64100 78000 Clamp Force (lb) 2320 3700 5600 7550 10700 12950 16300 23800 32400 42200 47500 59600 73000 87700 5.7 12.1 21.4 36 53 78 107 185 306 456 570 798 1040 1382 Min. Torque (ft lb) 7.1 13.5 25 39 64 86 121 214 335 499 627 884 1197 1568 6.3 13.4 23.6 39 59 87 118 205 339 504 630 882 1150 1528 Max. Torque (ft lb) 7.9 15.0 28 43 71 95 134 236 370 551 693 977 1323 1733 2020 3340 4490 6800 9050 11600 14400 21300 29400 38600 42300 53800 64100 78000 Clamp Force (lb) 2320 3700 5600 7550 10700 12950 16300 23800 32400 42200 47500 59600 73000 87700
Bolts Lubricated with
Anti-seize Compound
Grade 5
Coarse Thread Series, UNC
Fine Thread Series, UNF
T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi
1
TDS-11SA
General Information
1-7
Basic useage
Drilling ahead with singles
Set slips on string Stop circulation Close IBOP
Breakout connection using pipehandler and drilling motor (in reverse)
Lower block to stab motor into top of single Spin in motor and single Makeup both connections with motor in torque mode Pull slips Open IBOP Start circulation Begin drilling Tilt links to mousehole
Latch drill pipe elevator around single
Pickup single with elevator
Release link tilt Stab bottom of single onto string
Stab Open IBOP Makeup Close IBOP Link Tilt Makeup
1
Varco Systems General Information
1-8
Basic useage
Drilling ahead with triples
Set slips on string Stop circulation Breakout connection
using pipehandler and drilling motor (in reverse)
Raise block Tilt link tilt to
derrickman
Pickup stand with elevator Stab bottom of
stand onto string
Lower block to stab motor into top of stand Spin in motor and stand Makeup both connections with motor Pull slips Start circulation Begin drilling Stab Stop Circulation Link Tilt Makeup Makeup Start Circulation
1
TDS-11SA General Information1-9
Basic useage
Backreaming
Hoist while circulating and rotating When 3-rd connection surfaces, stop rotation and circulation Setback standusing link tilt Lower block, stab motor into string Spin in motor
and makeup connection with motor
Start circulation, pull slips, hoist and rotate Hoist free stand
with elevator Set slips on string
Breakout connection using pipehandler and drilling motor (reverse) Breakout and spinout stand at floor Setback Breakout Breakout Hoist Hoist and Rotate
1
Varco Systems General Information1-10
TDS-9/11SA consumables
Tong Dies Stabilizer, Front Stabilizer, RearFlippers, Stabbing Guide Wash Pipe
Wash Pipe (Tungsten Coated) Wash Pipe Packing Kit, 3" Standard (Use with Wash Pipe 123289 or 123289-TC) Wash Pipe Packing Kit, 3" High Pressure (Use with Wash Pipe 123289-TC only) Hydraulic Oil Filter
Gear Oil Filter
Wash Pipe
Gear Oil Filter Hydraulic Oil Filter
Stabilizers Tong Dies Stabbing Guide
Consumables Quantity Part Number Page Ref.
16781 118368 118367 76442 123289 123289-TC 123290-PK 123290-PK-1 114416-1 111013-1 See page 7-14 See page 7-15 See page 7-15 See page 7-15 See page 6-11 See page 6-11 See page 6-11 See page 6-11 See page 4-30 See page 4-32 4 1 1 2 1 1 1 1 1 1
TDS Training Manual
AC Electrical
Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Section 2
2
TDS-11SA Specifications2-1
3
4
5
6
Specifications
7
8
9
1
2
TDS-11SASize specifications ... 2-2
General specifications ... 2-4
2
Varco Systems Specifications2-2
Size specifications
233.0 in. (5.82 m) 214.0 in. (5.43 m) = 30,000 lb = 13600 kg To Center of Gravity 112 in. (2.85 m) 72 in. (1.83 m) 62 in. (1.58 m) 56 in. (1.42 m) To Center of Gravity 28 in. (.71 m) To Center of Gravity 37 in. (.94 m) 18.5 in. (.47 m) Bail 120 in. (3.05 m) Bail 88 in. (2.24 m)2
TDS-11SA Specifications2-3
Size specifications
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 33.8 in. (859 mm) 21.1 in. (53 mm) 22.1 in. (561 mm) 30.0 in. (762 mm) Setback (Standard) C L Well C L Rear Front2
Varco Systems Specifications2-4
General specifications
Top Drive Drilling Motor Pipe Handler Drill PipeVariable Frequency Drive
Motor Braking
Motor Cooling System
Gearcase Gearcase Lubrication Hydraulic System Electrical House Weight Stack-up Height Power Requirements Horsepower
Output torque (continuous) Tool torque (intermittent @ stall) Maximum Speed @ full power Hoisting capacity Load Path Sizes Type Type Type Type Type Power Speed Type Gear ratio Type Reservoir capacity Full internal flow Oil Type Power Flow Reservoir capacity Oil Type Size Type Weight Input requirement Items 27,000 lb 17.8 ft 700 KVA @ 575-600 VAC, 50/60 Hz 800 hp 37,500 ft lb (800 hp) 55,000 ft lb 228 rpm 500 ton Single
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) or Siemens (800 hp, 600 VAC)
Hydraulic caliper disc brakes Local intake pressure blower (2) 5 hp AC motors
3,600 rpm
Single speed, double reduction helical gear system 10.5:1 (4.38:1 optional) Pressure feed 15 gal EP Grade 10 hp, AC motor (1) 6 gpm, (1) 4 gpm 25 gal
Mineral based hydraulic oil
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 lb
600 VAC(50/60 Hz), or 750 VDC, or 690 VDC(50/60 Hz)
Description Components
2
TDS-11SA
Specifications
2-5
Typical mast interface
*
**
Dimensions are Subject to Verification
Standard TDS Configuration-Two IBOP’s with 108 in. Elevator Links
AC Cables
Existing Traveling Equipment 500-ton Hook/Block Combo-Typ.
TDS-11SA Varco Portable Top Drive System
Crown Block Top Bail Rest Tool Joint Tool Joint Beam Service Loop Sectional Guide Beam
Mud Hose 75 ft. (22.9 m)* Connected to Standpipe at 73 ft. (22.3 m) Level Service Loop Derrick Termination at ~73 ft. (24.4 m) Level*
Portable Torque Reaction Beam “U”- Bolted to Spanners - (by Customer)
2 Custom Spanners
On A-Frames or Mast Side Panels (by Customer)
Varco Driller’s Control
Control Cable with Connectors 150 ft. (45.7 m)
Local Power Supply Diesel/Alternator Set/AC Buss
Unitized Variable Frequency Inverter & Varco Control Panel
Drill Floor AC Power and Control Cables Drill Stand Made-up at 4 ft. (1,2 m) Level 93 ft. (28.3 m) Clearance 13.5 ft. (4.1 m)** TDS Work Height 18.0 ft. (5.4 m)** Stroked-Typ. 13.5 ft. (4.1 m)* 4.0 ft. (1.2 m) 10.0 ft. (3 m)-Minim um* 7.0 ft. (2.1 m)-Minim um Clear Working Height 142 ft. (43.3 m) C L
TDS Training Manual
AC Electrical
Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Section 3
3
4
5
6
Lubrication and
Maintenance
7
8
9
1
2
TDS-11SATransmission ... 3-2
Selecting the proper gearbox oil ... 3-2
Lubrication schedule ... 3-2
Recommended gear oils ... 3-3
Gearbox lubrication ... 3-4
Hydraulic system ... 3-5
Precautions ... 3-5
Lubrication schedule ... 3-5
Recommended hydraulic fluid ... 3-6
Hydraulic lubrication ... 3-7
Motors ... 3-8
Lubrication schedule ... 3-8
Recommended motor grease ... 3-8
Motor lubrication ... 3-9
General purpose lubrication ... 3-10
Lubrication schedule ... 3-10
Recommended lubricants ... 3-11
General lubrication ... 3-12
3
Varco Systems
Lubrication
3-2
Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and shock loads. 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 an AGMA “extra pressure” rating (EP), and a minimum viscosity of 100 SUS at internal operating temperature. Varco Top Drives also operate under a wide variety of ambient temperatures. Select lubrication for the TDS based on the minimum ambient temperature (surrounding air) to be expected before the next oil change. Under all but the most severe operatingconditions, Varco recommends changing the oil every six months. Introducing an oil viscosity greater than required by the ambient temperature can:
❏ Damage the gearbox due to reduced oil flow ❏ Damage the oil pump because of excessive load
Lubrication schedule
Replace the Gearbox Oil Following Intial Break-in Replace the Gearbox Oil and Perform an Oil Analysis
Oil viscosity should be adjusted based on expected ambient conditions for next six months Replace the Gearbox Oil Filter (P/N 111013)
Remove, clean and replace the Magnetic Drain Plug
Following first month of operation 1 x every 6 Months 1 x every 3 Months
1 x every Year
Description Frequency
The first oil change should be performed after the first month of operation since new units often contain metal contaminates and contaminates caused by initial break-in.
3
TDS-11SA
Lubrication
3-3
Transmission
Recommended gear oils
Ambient Temperature Range
Manufacturer Viscosity Index Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union AGMA
ISO Viscosity Grade
Above 21˚ C (Above 70˚ F) Alpha LS-320 NL Gear 320 Spartan EP320 EP Lube HD320 MobilGear 632 Omala 320 Loadway EP320 Meropa 320 Carter EP 320 Extra Duty NL6EP
6EP 320 7˚ to 30˚ C (45˚ to 85˚ F) Alpha LS-150 NL Gear 150 Spartan EP150 EP Lube HD150 MobilGear 629 Omala 150 Loadway EP150 Meropa 150 Carter EP 150 Extra Duty NL4EP
4EP 150 -6˚ to 16˚ C (20˚ to 60˚ F) Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobilGear 626 Omala 68 Loadway EP68 Meropa 68 Carter EP 68 Extra Duty NL2EP
2EP 68
!
Oils of insufficient viscosity can damage gears by allowing metal to metal contact.i
For minimum temperatures below 20°F, the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. If drilling conditions dictate oil temperatures below 20°F, consult Varco service center.If the oil temperature rises above 200°F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F, consult Varco service center.
3
Varco Systems Lubrication3-4
Gearbox lubrication
Gear Oil Sight Gauge Check with Top Drive“OFF”
Gearbox Oil Fill Clean area before removing plug,
then use a 1 3/8 inch, 12 point socket to remove plug
Magnetic Drain Plug Remove and clean contamination
Gearbox Oil “Drain” Cork Ball (Level Indicator) Sight Glass “Pop-up” Dirt Alarm
Gear Oil Filter
i
i
Check oil level, prior to adding oil (do not mistake the tan colored foam for the dark brown oil) Ensure that the unit is turned OFF The area must be wiped clean
prior to adding gearbox oil Recheck oil level and replace the
plug after adding oil
Run the unit and recheck the oil level (not foam level), after the unit has been running and the
transmission oil is warm
Procedure
3
TDS-11SA Lubrication3-5
Hydraulic system
Precautions
Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.
!
Use care when handling components to prevent nicking close tolerance finishes.!
Use care to prevent contamination from entering the hydraulic system during 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 Months
1 x Year, or Earlier Based on Oil Analysis 1 x every 3 Months
3
Varco Systems
Lubrication
3-6
Hydraulic system
Recommended hydraulic fluid
Hyspin AWS-46 AW Hyd oil 46 Nuto H46 Harmony 46AW DTE 25 Tellus 46 Hydraway HMA 46 Rando oil HD46 Azolla ZS 46 Unax AW46 46 Hyspin AWS-32 AW Hyd oil 32 Nuto H32 Harmony 32AW DTE 24 Tellus 32 Hydraway HMA 32 Rando oil HD32 Azolla ZS 32 Unax AW32 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
3
TDS-11SA Lubrication3-7
Hydraulic system
Hydraulic lubrication
Hydraulic Lubrication Kit 55 gal Drum Varco P/N 92643 Red “Pop-up” Dirt Alarm Hydraulic Oil Filter Hydraulic Oil Fill Hydraulic Oil Sight Gauge Cork Ball (Level Indicator) Sight GlassHydraulic Oil Fill Male Quick Disconnect
Dust Plug Female Quick Disconnect Hydraulic Oil Drain The area must be clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill
Remove dust plug from the female quick disconnect on the lubrication kit and connect it to the male fitting Pump fluid until the level reaches the middle of the
sight glass as shown
After adding fluid, replace the dust plugs
3
Varco Systems
Lubrication
3-8
Motors
Varco recommends that lubrication of all AC motors should be done 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 Grease Motor Grease Motor Grease 1 x every 3 Months 1 x every 3 Months 1 x every 3 Months 4 4 2
Recommended motor grease
Black Pearl EP2 (Do Not Substitute) Motor Grease
Manufacturer
3
TDS-11SA Lubrication3-9
Motors
Motor lubrication
AC Blower Motor (2) 3 pumps (2 grease fittings each motor) AC Drilling Motor (2) 5 pumps (2 grease fittings each motor) Pipe Plug 1/8 inch (remove and reinstall after lubricating) Grease Fitting 1/8 inch Varco P/N 53201 3 Months 3 Months 3 MonthsHydraulic Pump AC Motor 3 pumps
(2 grease fittings) As Viewed From Below Apply motor grease
to designated grease fittings with hand grease gun
i
!
Remove the lubrication point plug Install a grease fitting
Grease with a hand pump only Re-install the plug
Procedure Grease Fittings
3
Varco Systems
Lubrication
3-10
General purpose lubrication
!
The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, etc., may require more frequent lubrication.!
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Be careful not to over lubricate parts. For example, too much grease forced into a fitting can pop out a bearing seal. Over lubrication can also affect safety since over lubricated parts can drip, creating a potential slipping hazard for personnel.Lubrication schedule
Washpipe Assembly Upper Bonnet Seal Bail Pins
Rotating Link Adapter Gear Rotating Link Adapter
IBOP Actuator Yoke, Cylinder Pins IBOP Actuator Cranks
Upper IBOP Valve Stabilizer Bushing Clamp Cylinder Gate Carriage Assembly
Torque Arrestor at Clamp Cylinder Wireline Adapter
Elevator Link Eyes
General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease General Purpose Grease
Pipe Dope 1 1 2 – 2 5 2 1 4 2 8 4 2 4 Daily Weekly Weekly Weekly Weekly Daily Daily Weekly Daily Daily Weekly Weekly Weekly Weekly
3
TDS-11SA
Lubrication
3-11
General purpose lubrication
Recommended lubricants
Above -20˚ C (Above -4˚ F) Below -20˚ C (Below -4˚ F) MP Grease Avi-Motive Lidok EP2 Gulf Crown EP32Mobilux EP2 Alvania EP2 Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 N/R Avi-Motive W Lidok EP1 Gulf Crown EP31
Mobilux EP1 Alvania EP1 Uniway EP1N Multifak EP1 Multis EP1 Unoba EP1 1
Ambient Temperature Range
Manufacturer Viscosity Index Castrol Chevron Exxon Gulf Mobil Shell Statoil Texaco Total Union NGLI
3
Varco Systems
Lubrication
3-12
General purpose lubrication
General lubrication
Wash Pipe Assembly Apply one pump at beginning of tour Apply general purpose
grease to designated grease fittings with grease gun. Use a brush when greasing other parts.
Daily
Upper Bonnet Seal One pump Use Hand Pump Only
Weekly
Bail Pins (2) Two pumps each side
Weekly
Rotating Link Adapter Gear
Weekly
Rotating Link Adapter Three pumps each
Weekly
3
TDS-11SA
Lubrication
3-13
General purpose lubrication
General lubrication
!
IBOP Actuator Yoke One pump (if equipped)
Daily IBOP Actuator Cylinder Pins One pump each (if equipped)
Daily
IBOP Actuator Yoke One pump each side
Daily
IBOP Actuator Cranks One pump each side
Daily
Stabilizer Bushing One pump each
Daily Clamp Cylinder Gate
One pump each side Daily
Stabilizer Bushing One pump each side
Daily Elevator Link Eyes
(4)
Weekly
Torque Arrestor Tubes
Weekly
Upper IBOP Valve Remove 1/4" NPT plug,
install grease fitting Apply ten pumps
Weekly
Pipe Dope
Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.
Replace plug before
operating
i
3
Varco Systems
Lubrication
3-14
General purpose lubrication
General lubrication
Rollers One pump each
(if equipped)
Weekly
Rollers One pump each
(if equipped)
Weekly
Apply general purpose grease to designated grease fittings
with grease gun
i
3
TDS-11SA
Lubrication
3-15
General purpose lubrication
General lubrication
Wireline Adapter One pump each
Weekly
Apply general purpose grease to designated grease fittings
with grease gun
i
TDS Training Manual
AC Electrical
Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Section 4
Installation, Commissioning and
Decommissioning
3
4
5
6
Installation, Commissioning
and Decommissioning
7
8
9
1
2
TDS-11SAIllustrated index ... 4-3
Preinstallation ... 4-4
Preparation ... 4-4
Installing the crown padeye and hang-off link ... 4-5
Locating the control house ... 4-6
Installing power cables ... 4-7
Earthing the control house (land rigs) ... 4-8
Checklist ... 4-9
Installation ... 4-10
Moving the TDS-11SA to the drill floor ... 4-10
Removing the TDS-11SA from the skid ... 4-11
Disengaging the lower carriage latch ... 4-12
Moving guide beam sections ... 4-13
Present and hook the first guide beam section ... 4-14
Hoist the first guide beam section ... 4-15
Stab and pin the first guide beam section ... 4-16
Completing guide beam installation ... 4-17
Hanging the guide beam ... 4-18
Installing the main tieback ... 4-19
Installing the intermediate restraints ... 4-20
Disengaging the upper carriage latch ... 4-21
Installing derrick termination ... 4-22
Installing the service loop to the derrick ... 4-23
Installing the driller’s console... 4-24
Installing the driller’s console cabling ... 4-25
Motor rotation checkout procedure ... 4-26
Installing the pipe elevator and links ... 4-27
Installing the counterbalance ... 4-28
Commissioning ... 4-29
Checkout procedure ... 4-29
Hydraulic system checkout procedure ... 4-30
Electrical system checkout procedure ... 4-31
Mechanical checkout procedure ... 4-32
Adjusting the link tilt ... 4-33
Removing and installing the saver sub ... 4-34
4
Varco Systems Installation, Commissioning and Decommissioning4-2
3
4
5
6
Installation, Commissioning
and Decommissioning
7
8
9
1
2
Varco SystemsDecommissioning ... 4-35
Securing the TDS-
9/
11SA for rig-down ... 4-35
Removing and storing the electrical cables
and service loops ... 4-36
Setting the latches and locking the bail ... 4-37
Disconnecting the guide beam ... 4-38
Unpinning each guide beam section ... 4-39
Lowering each guide beam section ... 4-40
Returning the TDS-
9/
11SA to the skid ... 4-41
Removing the TDS-
9/
11SA from the drill floor ... 4-42
4
TDS-11SA Installation, Commissioning and Decommissioning4-3
Illustrated index
AC Cables Page 4-7 Varco Driller’s Console (VDC) Page 4-24 Control Cable with Connectors Page 4-25Local Power Supply Diesel/Alternator Set/AC Bus
Unitized Variable Frequency Inverter and Varco Control Panel (House)
Page 4-6 AC Power and Control Cables Page 4-7 Derrick Termination Page 4-22 Main Tieback Page 4-19 Service Loop Page 4-23 Rotary Hose Crown Padeye and
Hang-off Link Page 4-5 Counterbalance Page 4-27 Intermediate Restraints Page 4-20 Guide Beam Page 4-13
4
Varco Systems Installation, Commissioning and Decommissioning4-4
Preinstallation
Preparation
The TDS-11SA interfaces with the rig’s hoisting system and
electrical power system. Derrick and electrical system modifications are required when installing the TDS-11SA on existing rigs.
For derricks that handle triples, the required top drive travel is about 100 ft. compared to about 75 ft. when using a Kelly. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. long) with a 75 ft. hose, and extend the standpipe height to approximately 73 ft.
Although many rig floor layouts are possible, installing the guide beam on the drawworks side of the derrick, or mast, and opposite the door is an ideal arrangement for handling tubulars from the V-door.
The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop and mud hose. Other important installation considerations include the location of:
❏ The casing stabbing board ❏ Floor and derrick accessories ❏ Drawworks fastline
❏ Guide beam hang-off bracket ❏ Torque reaction beam ❏ Mud stand pipe extension ❏ Varco drillers console location
❏ Variable frequency inverter/Varco control panel location Derrick height is a critical interface requirement. Handling a 93 ft. stand typically requires 97 ft., resulting in an overall height from the floor to the top of the traveling block of at least 126 ft.
152 ft. 147 ft. 142 ft. 136 ft.
Derrick Clear Working Height
25 ft. 20 ft. 15 ft. 9 ft.
Derrick Crown Clearance
Each rig has different crown clearance for efficient tripping. Installing the TDS-11SA with existing traveling equipment may require an adapter–further reducing crown clearance.
4
TDS-11SA Installation, Commissioning and Decommissioning4-5
Preinstallation
Installing the crown padeye and hang-off link
See Table Well C L Crown Padeye Weld according to table above Crown Shackle Hang-off Link 36.8 inches 33.8 inches 30.0 inches
Standard height configuration (adjustable) Varco’s IDS Top Drive requirements Original setback for TDS-9S/11S
Description Dimension
4
Varco Systems Installation, Commissioning and Decommissioning4-6
Preinstallation
Locating the control house
Varco Driller’s Console
Control House
Recommended Area for Control House Location
9,500 lb (4300 kg) Control House V-Door Ramp TDS-11SA Drawworks 91 in. (2310 mm) 90 in. (2290 mm) 140 in. (3560 mm) Recommendations
Position the control house off-driller’s side or behind the drawworks
Position as close to derrick plate as possible to minimize cable lengths
Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts)
Location of the control house must ensure accessibility from all sides
Do not expose the control house to H2S Well C L Well C L
4
TDS-11SA Installation, Commissioning and Decommissioning4-7
Preinstallation
Installing power cables
W IN CO MING 575VA C U O UTGOIN G 575VAC V OUTG OIN G 575VAC W OUTGOIN G 575VAC U INCO MING 575VAC V IN CO MING 575VA C COMPOSITE CONNECTOR
AUX. POWER CONNECTOR
SERIAL CONNECTOR Rain Cover Plug Panel Varco Control House Procedure
Clean all connector contacts
Connect the power cables with the isolation circuit breaker turned OFF
Connect cables in accordance with the electrical schematic provided in the Technical Drawings book
Lockwire all connector nuts
Earth the control house with the Varco Ground Rod Kit (See page 4-8) Incoming Power Cables
575VAC to main circuit breaker (3 Places)
Outgoing Power Cables to Top Drive (3 or 6 Places)
Plug Panel Ground Lug
4
Varco Systems Installation, Commissioning and Decommissioning4-8
Preinstallation
Earthing the control house (land rigs)
Procedure
Insert the grounding rod into the soil (the rod must be in contact with ground water)
Connect the rod to the control house (connection must be clean)
Grounding Points Located at opposite corners of the house floor Cable Lug
Cable Clamp Copper Plated
Steel Rod
Ground Rod Kit P/N 116004
Copper Wire 10 ft
The control house must be properly grounded to prevent injury to personnel
For offshore installations the control house must be grounded to the ground point on the rig structure
4
TDS-11SA Installation, Commissioning and Decommissioning4-9
Preinstallation
Checklist
The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and TDS-11SA. This includes:
❏ Make sure the derrick/mast is vertical, with the block over the center of the rotary table.
❏ Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed and inspected to conform to Varco specifications as detailed in FIP00003.
❏ The service loop bracket is installed in the derrick/mast. ❏ The control panel and frequency drive are installed.
❏ Rigging of tong lines, etc. is inspected to ensure that they will not foul with the TDS-11SA.
❏ The hook or adaptor becket is installed. The hook should open toward the drawworks.
4
Varco Systems Installation, Commissioning and Decommissioning4-10
Installation
Moving the TDS-9/11SA to the drill floor
!
!
V-Door Ramp Lifting Sling Backup Line TDS-11SA In position prior to lifting from skid2
The Bail Lock Assembly must be installed Tube (P/N 113498) U-Bolt (P/N 113497)
2x 3/4" nuts
Be sure that the Top Drive is pinned to the skid prior to hoisting it to the drill floor Lifting Sling Attached to bail for hoisting TDS-11SA on Skid
3
1
Drill Floor Lifting Block Hoist using the drawwork 30,000 lb (13600 kg) TDS-11SA on Skid ProcedureLocate the Top Drive at the bottom of the V-Door ramp
Ensure that the bail lock assembly is installed Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor
4
TDS-11SA Installation, Commissioning and Decommissioning4-11
Installation
Removing the TDS-9/11SA from the skid
!
Lock Pin Remove prior to hoisting from skid
3
2
1
Hoist the
TDS-11SA
from the skid using the drawwork
Drill Floor
The Bail Lock Assembly must be installed. Remove only
after installation is complete.
TDS-11SA View of Carriage from Rear 27,000 lb (12300 kg) TDS-11SA Pin Pin Latches Both sides engaged for hoisting Procedure
Ensure that both carriage latches are engaged for hoisting from the skid
Ensure that the bail lock assembly is installed Engage the hook with the bail
Remove the lock pin
Hoist the Top Drive from the skid Ensure the Top Drive
4
Varco Systems Installation, Commissioning and Decommissioning4-12
Installation
Disengaging the lower carriage latch
!
Ensure that the lower carriage latch is disengaged
Ensure that the upper carriage latch is engaged
Hoist the Top Drive
Remove the skid from the drill floor As viewed from
rear of Carriage
Pin
Ensure the Top Drive or the guide beam does not contact the rig
Pin Guide Beam Wings Guide Beam Top 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-11SA Lifted from the skid 27,000 lb (12300 kg) TDS-11SA In position to disengage lower latch Skid
Remove from drill floor after hoisting the TDS-11SA
3,000 lb (1360 kg)
