Top Drive Drilling System PDF

TDS-10S
Top Drive
Drilling
System
Service Manual
SM00400
March 2, 1998
Manual conventions
This manual uses conventions that make it easy for the reader to
locate key information and detailed descriptions. Graphics
illustrate descriptions of equipment and assemblies to provide a
better understanding of the equipment and its components.
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention. Note the examples below
and pay close attention to these important advisories.
z Note: Indicates advisories for operational or servicing procedures

involving no risk of personal injury or equipment damage.
e Caution: Indicates advisories involving a risk of equipment damage.
n Warning: Indicates advisories involving a definite risk of injury

to rig personnel.
Avoid personal injury and equipment damage by reading this

manual and related documents prior to operating or maintaining
the equipment.
ii TDS-10S
About thisContents
manual
Contents
Book 1 – Description, Installation and Operation
Preface
Manual conventions............................................................ 5
Safety information .............................................................. 5
Directional references ......................................................... 6
Illustrations ......................................................................... 6
Manual layout..................................................................... 6
Varco service centers ........................................................... 6
Chapter 1 Introduction
Introduction to the TDS-10S ............................................. 7
Chapter 2 Description
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
TDS-10S Contents iii

March 2, 1998
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
Chapter 4 Operation
Driller’s interface and driller’s console ............................... 33
Throttle control .......................................................... 33
Torque control............................................................ 34
Switches ...................................................................... 34
Indicators .................................................................... 36
Varco control system ................................................... 37
Variable frequency inverter ............................................... 38
Rectifier and DC link filter ......................................... 38
Power modules ........................................................... 38
Control section ........................................................... 38
Service loop ...................................................................... 39
Drilling ahead ................................................................... 40
Drilling ahead with triples .......................................... 40
Drilling ahead with singles .......................................... 42
Tripping in and tripping out ....................................... 44
Back reaming .............................................................. 44
Well control procedures .............................................. 46
Running casing ........................................................... 48
Chapter 5 Specifications
General ............................................................................. 49
Drilling parameters ..................................................... 50
Rated capacities..................................................... 50
Drilling motor ...................................................... 50
Pipehandler (PH-55) ............................................ 50
Chapter 6 Appendix............................... 51
iv TDS-10S Contents
Book 2 – Maintenance and Troubleshooting
Preface
Illustrations ......................................................................... 8
Manual layout..................................................................... 8
Precautions ......................................................................... 9
Chapter 2 Maintenance schedules

Inspection schedules ......................................................... 11
Lubrication schedule ......................................................... 13
Lubricant specifications .................................................... 14
Selecting a lubricating/hydraulic oil ............................ 14
Selecting a lubricant .................................................... 15
Chapter 3 Inspection
Inspecting hardware and fittings ....................................... 17
Inspecting the AC drilling motor brakes ........................... 18
Inspecting the AC drilling motor louvers .......................... 18
Inspecting the wash pipe assembly .................................... 18
Inspecting the upper stem liner ......................................... 19
Inspecting main shaft end play .......................................... 21
Inspecting the gearbox oil level ......................................... 22
Inspecting the guide beam ................................................ 22
Inspecting the IBOPs ........................................................ 22
Inspecting the pipehandler ................................................ 23
Nondestructive Examination (NDE) ................................ 24
Inspecting the elevator link eyes .................................. 24
Inspecting the drive stem ............................................ 26
Magnetic particle inspection (MPI) ............................ 27
Ultrasonic inspection .................................................. 28
Inspecting the hydraulic system ........................................ 29
Inspecting the electrical system ......................................... 29
TDS-10S Contents v
March 2, 1998
Chapter 4 Lubrication
Introduction ..................................................................... 31
Lubricating the AC blower motor bearings ....................... 32
Lubricating the hydraulic pump AC motor ....................... 32
Lubricating the AC drilling motor bearings ...................... 32
Lubricating the wash pipe assembly .................................. 34
Lubricating the upper main body oil seals ......................... 35
Replacing the gearbox oil .................................................. 35
Initial oil change ......................................................... 35
Oil capacity................................................................. 35
Replacing the gearbox oil filter .......................................... 36
Lubricating the carriage and guide beam ........................... 36
Lubricating the rotating link adapter ................................. 36
Lubricating the link tilt and PH-55 stabilizer bushing ...... 38
Lubricating the elevator support and
master bushing wear guide ................................................ 38
Lubricating the wireline adapter ........................................ 38
Lubricating the IBOP actuator yoke ................................. 39
Lubricating the IBOP actuator crank ................................ 40
Lubricating the torque arrestor tubes and
clamp cylinder gate ........................................................... 41
Chapter 5 Maintenance
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................ 45
Troubleshooting the AC blower motor ............................. 46
Troubleshooting the hydraulic system ............................... 47
Troubleshooting the AC
drilling motor brakes ......................................................... 51
Troubleshooting the rotating link adapter
(rotating head) motor ....................................................... 52
Operation ................................................................... 52
System test .................................................................. 52
Troubleshooting the IBOP actuator cylinder .................... 54
Operation ................................................................... 54
System test .................................................................. 55
vi TDS-10S Contents
Troubleshooting the shot pin cylinder
and clamp cylinder ............................................................ 57
Operation ................................................................... 57
System test .................................................................. 58
Troubleshooting the counterbalance system ...................... 60
Counterbalance testing ............................................... 61
Stand jump testing ...................................................... 62
Troubleshooting the hydraulic power unit (HPU)
and reservoir ..................................................................... 64
Operation ................................................................... 64
System test .................................................................. 64
Chapter 7 Disassembly and assembly

Precautions ....................................................................... 67
PH-55 Pipehandler ........................................................... 69
Disassembling the PH-55 Pipehandler ........................ 69
Assembling the PH-55 Pipehandler ............................ 71
Rotating link adapter ........................................................ 72
Disassembling the rotating link adapter assembly ........ 72
Assembling the rotating link adapter assembly ............ 73
Transmission/motor housing ............................................ 75
Removing the transmission/motor housing ................. 75
Installing the transmission/motor housing .................. 75
Disassembling the transmission/motor housing .......... 76
Removing the bonnet and wash pipe .................... 76
Removing the upper bearing retainer plate .................. 77
Removing the AC drilling motor .......................... 77
Removing transmission components ..................... 78
Assembling the transmission/
motor housing ............................................................ 81
Assembling the main body .................................... 81
Assembling the main shaft .................................... 82
Assembling the gears to the main body ................. 84
Installing the AC drilling motor ............................ 87
Installing the upper bearing retainer plate ............. 89
Installing the wash pipe......................................... 91
Checking the gear train backlash ........................... 91
AC drilling motor disassembly/assembly ........................... 92
AC drilling motor disassembly .................................... 92
AC drilling motor assembly ........................................ 94
Replacing the safety wiring ............................................... 96
Safety wiring tips ........................................................ 98
TDS-10S Contents vii

March 2, 1998
Book 3 – Control System
General description ............................................................. 5
Major component descriptions ........................................... 7
Varco Driller’s Console (VDC) ..................................... 7
Programmable logic controller (PLC) ..................... 9
Variable Frequency Drive (VFD) .......................... 10
Electrical service loops................................................. 12
Chapter 2 Operation
Preoperational checklists ................................................... 13
VDC controls ................................................................... 17
Correcting a drive fault ..................................................... 20
Drive fault while drilling ............................................. 20
Drive fault while making up ....................................... 21
Maintaining the control system ......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
Book 4 – Supplemental Material
viii TDS-10S Contents

TDS-10S
Top Drive
Drilling
System
Description,
Installation and
Operation
March 10, 1998
2 TDS-10S Service Manual

Contents
Preface
Illustrations ......................................................................... 6
Manual layout..................................................................... 6
Introduction to the TDS-10S ............................................. 7
TDS-10S major components .............................................. 9
Motor housing and swivel assembly ............................ 10
Transmission and swivel housing .......................... 10
Integrated swivel assembly .................................... 11
Drilling motor and brakes ..................................... 11
Motor cooling system ................................................. 12
Carriage and guide beam............................................. 14
PH-55 pipehandler ..................................................... 14
Powered rotating link adapter ............................... 14
Torque backup clamp cylinder .............................. 15
Bidirectional link tilt ............................................. 16
Internal blowout prevention ................................. 18
Hydraulic control system ............................................ 20
Counterbalance system ......................................... 22
STAND JUMP feature (optional) ................... 23
AC motor and control system ..................................... 24
Chapter 3 Installation
Installing the TDS-10S ..................................................... 27
TDS-10S Service Manual 3

March 10, 1998
Chapter 4 Operation
Driller’s interface and driller’s console ............................... 33
Throttle control .......................................................... 33
Torque control............................................................ 34
Switches ...................................................................... 34
Indicators .................................................................... 36
Varco control system ................................................... 37
Variable frequency inverter ............................................... 38
Rectifier and DC link filter ......................................... 38
Power modules ........................................................... 38
Control section ........................................................... 38
Service loop ...................................................................... 39
Drilling ahead ................................................................... 40
Drilling ahead with triples .......................................... 40
Drilling ahead with singles .......................................... 42
Tripping in and tripping out ....................................... 44
Back reaming .............................................................. 44
Well control procedures .............................................. 46
Running casing ........................................................... 48
Chapter 5 Specifications
General ............................................................................. 49
Drilling parameters ..................................................... 50
Rated capacities..................................................... 50
Drilling motor ...................................................... 50
Pipehandler (PH-55) ............................................ 50
Chapter 6 Appendix ............................... 51

Preface
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
better understanding of the equipment and assemblies to provide
a better understanding of the equipment’s functionality.
Safety information
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
z Indicates advisories for operational or servicing procedures

involving little or no risk of personal injury and equipment
damage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rig

personnel.

March 10, 1998

manual and related documents before operating, inspecting, or
servicing the equipment.
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assembly–standing behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Varco service centers

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

Chapter 1
Introduction
Introduction to the TDS-10S

Varco Drilling Systems developed the TDS-10S Top Drive
Drilling System primarily for smaller land rigs.
Varco made use of the recent advancements in AC technology,
designing the TDS-10S to use one 350-hp AC drilling motor.
This 350-hp system produces 20,000 ft lb of continuous drilling
torque and 36,500 ft lb of makeup/break out torque. The TDS-
10S is compact enough to be safely operated in a standard 136 ft.
mast while providing 250 tons of hoisting capacity. Its highly
portable design allows for simple rig-up and rig-down in just a
few hours. It easily integrates into existing rigs at minimal
installation cost and rig modification.

March 10, 1998

Chapter 2
Description
TDS-10S major components

The TDS-10S drilling system includes the following assemblies
and subassemblies:
❏ Motor housing and swivel assembly

❏ Motor cooling system
❏ Guide beam
❏ PH-55 pipehandler
❏ Hydraulic control system
❏ Counterbalance system
❏ AC drilling motor
❏ Electrical control system

March 10, 1998
Motor housing and swivel assembly

This assembly is comprised of the following subassemblies:
❏ Transmission and swivel housing

❏ Integrated swivel assembly
❏ Drilling motor and brakes
Transmission and swivel housing

The assembly consists of the following components:
❏ Bonnet/cover
❏ Main body
❏ Motor pinion
❏ Compound gear
❏ Bull gear
❏ Main shaft
❏ Lubrication system
The single-speed helical gear transmission with double reduction
provides a 13.1:1 ratio from the motor to the main shaft. The
main body and gear case cover house the transmission, the main
thrust and radial bearings. The gear case cover houses the upper
take-up bearing and supports the AC motor. The bull gear
attaches to the load shoulder on the main shaft. All lubrication of
the gears and bearing is via a pressurized system integrated into
the main body and cover.

Integrated swivel assembly
An industry-standard washpipe packing assembly is located
between the main shaft and gooseneck, and allows for the
rotation of the drill string. The bonnet/gear case cover supports
the assembly and attaches to the gear case to provide lateral
support.
An alloy steel swivel bail attaches to the main body. The swivel
bail can stroke vertically relative to the swivel housing to provide
an integral counterbalance system. An extended length is available
to allow operator clearance between the gooseneck and hook for
wireline packing assemblies.
Drilling motor and brakes

A 350 hp AC drilling motor supplies power to the TDS-10S.
The motor mounts vertically on top of the transmission gear case
cover with a modified “D-face” to avoid shimming or special
alignment during installation.
The motor has a double-ended shaft with a drive hub mounted
on the lower end and a disc brake rotor mounted on the upper
end. Two hydraulic caliper disc brakes mount to the top end of
the motor, where they can be easily inspected and serviced via the
access covers around the brake covers. The caliper disc brakes also
assist in drill string positioning when performing directional
work. They are remotely operated from the driller’s console.

March 10, 1998
Motor cooling system

The motor cooling system (Figure 1) on the TDS-10S is a local
intake centrifugal blower consisting of a cooling fan motor
mounted on top of the AC drilling motor. The system draws air
across the brake and delivers it through rigid ducting to an
opening at the top of the motor. The cooling air then passes
through the inside of the open-frame type AC drilling motor and
exits through the louvered openings near the bottom of the
motor. This rugged, simple design provides highly reliable service
with positive ventilation.

Duct
Blower Motor
Centrifugal Blower
Air Flow
Disk Brake Housing
AC Drilling Motor
Intake Air Flow

(Between Motor and
Brake Housing)
Louvers
Exhaust Air Flow
Figure 1. TDS-10S motor cooling system

March 10, 1998
Carriage and guide beam

The TDS-10S drilling system travels on a hanging guide beam by
means of a carriage attached to the gear case. The guide beam
hangs from the crown and extends to within seven feet of the drill
floor. There, it attaches to either a lower mast girt or a torque
reaction beam mounted across the lower section of the mast or
derrick.
The drilling torque is reacted through the carriage and into the
guide beam. The guide beam is available in 18-ft. sections
(63 lb/ft) and hangs from a pad eye at the crown. The guide beam
sections are pinned together making installation easy. Guide beam
sections can be assembled one section at a time, at the drill floor,
while raising the guide beam to the crown attachment using the
drawworks.
The carriage consists of an angle structure and low friction guide
pads. This arrangement maintains alignment of the main shaft
with the drill string while moving up and down on the guide
beam.
PH-55 pipehandler
The PH-55 pipehandler consists of the following major
components:
❏ Powered rotating link adapter

❏ Torque backup clamp cylinder
❏ Bidirectional link tilt
❏ Remote upper IBOP actuator
❏ Elevator links and drill pipe elevator
Powered rotating link adapter

The powered rotating link adapter hangs from the stem.
Hydraulic pressure applied to an annulus between the stem and
the rotating link adapter supports the weight of the pipe handler
with links and drill pipe elevator during drilling. During tripping,
when the drill pipe elevator supports the weight of the drill string,
the rotating link adapter strokes down to the landing collar seat
and, in turn, transfers the load to the main shaft.

The powered rotating link adapter allows the hydraulic lines to
remain connected as the pipehandler rotates with the drill stem
components while tripping or when positioning the link tilt.
During this operation, the pressurized annulus acts as a hydraulic
thrust bearing.
The powered rotating link adapter has a hydraulic drive motor to
rotate it in either direction. An electric solenoid valve operates the
hydraulic motor. A pinion gear on the hydraulic drive motor
rotates the positioning gear that is attached to the top of the
rotating link adapter.
During make or brake operations the rotating link adapter can be
locked into any of 24 index positions by selecting the pipehandler
clamp mode which actuates a hydraulically operated shot pin.
When the hydraulic drive motor is not powered the link adapter
can rotate freely.
The link tilt mechanism is integrated into the rotating link adapter.
The torque arrestor frame hangs from the rotating link adapter.
Two bushings located toward the top and bottom ends of the
rotating link adapter and sandwiched radially against the stem,
support the radial loads. The internal hydraulic fluid passages in
the stem connect to the respective fluid passages in the rotating
link adapter.
Fluid is fed from the main manifold into the stem through the radial
passages at the upper end. This fluid is routed from the vertical
passages in the stem to grooves in the rotating link adapter, and out
to all actuators on the pipe handler. While rotating or in any
stationary position, fluid flows between the two components.
Torque backup clamp cylinder

The torque backup clamp cylinder assembly is located below the
lower shoulder of the saver sub. It includes two gripping jaws
with die inserts and a clamping cylinder for gripping the box end
of the drill string when connecting to a saver sub. A torque
arrestor frame hanging from the rotating link adapter supports
the torque backup clamp cylinder and allows the clamp cylinder
to float up or down to allow for thread engagement and
disengagement. With the torque backup clamp cylinder
pressurized to clamp on a tool joint, torque is reacted through the
torque arrestor frame while making and breaking connections.
The torque backup clamp cylinder position is adjustable. Its
position is adjusted so that the top of the dies are 3/8 to 1/2 in.
below the top of the box end of the tool joint.

March 10, 1998
Bidirectional link tilt

The link tilt mechanism consists of two hydraulic cylinders and a
crank mounted with a pivot arrangement on the rotating link
adapter (Figure 2). The top end of the crank is connected to the
rod end clevises of the two hydraulic cylinders. The bottom end
of the crank is connected to the elevator links through two levers,
attached to the links with U-bolts and link clamps.
The stop mechanism limits the travel of the elevator to the
derrickman position which is adjustable. Releasing the stop (by
pulling a cable) allows the elevator to travel to the mousehole
position.
The elevator is fully extended in the opposite direction by
extending the two hydraulic cylinders. This gives the tool overdrill
capability.
The link tilt operates from a three-position switch located on the
driller’s console. The TILT position moves the links toward the
mousehole or derrickman by retracting the two hydraulic
cylinders. The DRILL position tilts the links back to clear the
drill pipe and raise the elevator to allow drilling down to the floor.
The spring centered position holds the link at any intermediate
position. There is a separate float switch which is used to allow
the links to hang free. The DRILL position changes the tilt
direction, which also keeps the elevator off the drill pipe when
drilling or moves it away from the well center to clear the drill
floor when drilling down to the floor. The links may be stopped
at any intermediate position. The links float back to the well
center when the FLOAT position button on the driller’s console is
operated.

Link Tilt Cylinder (2)
All dimensions are true for

108" long Elevator Links and
FOR REFERENCE ONLY
* At Monkey Board level (80')

and placed into view
FOR CLARITY ONLY
Ov
er
dr
ill
ole
eh
108"
us
an *
Mo
ickm
Derr
Drill
34"
14"
4"
28" 36"
Typ.
56" 76"
CL Well Drill Floor
Figure 2. Bidirectional link tilt positions

March 10, 1998
Internal blowout prevention

The two ball-type internal blowout prevention (IBOP) valves are
full size, internal opening safety valves (Figure 3). The remotely
operated upper valve and the manually operated lower valve form
the well control system. Both valves have 6 5/8 in. regular RH
connections and 15,000 psi pressure ratings.
A two-position switch at the driller’s console operates the OPEN
and CLOSE functions of the upper IBOP valve. When the switch
is operated, a hydraulic cylinder through a non-rotating lever
arrangement attached to the torque arrestor slides an actuator
shell up and down. This lever arrangement drives a small crank
arm on each side of the valve which opens and closes the upper
IBOP valve.
Both upper and lower IBOP valves can be broken out and sent
down hole.

Main Shaft
Tool Joint Lock
Upper IBOP Actuator Cylinder

Upper IBOP and Actuator
(Remote)
Tool Joint Lock
Manual Lower IBOP Torque Arrestor Frame

(Optional)
Tool Joint Lock
Saver Sub
Back-up Clamp Cylinder Assembly Stabbing Guide
Figure 3. TDS-10S drill stem assembly

March 10, 1998
Hydraulic control system

The hydraulic control system (Figure 4) is completely self-
contained (on board) and supplies all hydraulic power. It
eliminates the need for an additional service loop. The system
consists of components that operate the following assemblies:
❏ Counterbalance system
❏ AC motor brakes
❏ Gear/main bearings lubrication system
❏ Powered rotating head
❏ Remotely actuated IBOP
❏ Torque backup clamp cylinder
❏ Link tilt
The hydraulic control system is powered by a 10 hp, 1,200 rpm
AC motor that is direct coupled to drive a hydraulic pump.
An integral hydraulic manifold mounts to the carriage and
contains all solenoid, pressure, and flow control valves.
There is also a manifold mounted to the shot pin housing for
controlling the hydraulic rotating link adapter motor.
Hydro-pneumatic accumulators operate the IBOP, pressure
control valves, and counterbalance system.

Upper IBOP
Actuator Link Tilt Torque Backup
Cylinder Cylinders Clamp
Cylinder
Counterbalance
Accumulator
Drilling
Motor Brake
Pipehandler Rotating Link Adapter

(D.P. Elevator Positioner)
Counterbalance Shot Pin

Cylinders Cylinder
Lube Oil
Distribution
Rotating Link
Adapter Motor
System Control Manifold
10 HP A.C.
Motor
Hydraulic
Upper IBOP
M Pump
Time Delay
Accumulator
Reservoir
System
Accumulator
Figure 4. TDS-10S hydraulic system

March 10, 1998
Counterbalance system
The integral counterbalance system prevents damage to tool joint
threads while making or breaking connections with the TDS-10S.
It replaces the function of the hook compensator spring.
The system consists of two hydraulic cylinders attached between
the transmission cover and bail, a hydraulic accumulator, and a
hydraulic manifold. The system is integral to the TDS-10S and
therefore does not require any external attachment to the hook.
The cylinders are connected to a hydraulic accumulator. The
accumulator is charged with hydraulic fluid and maintained at a
predetermined pressure setting by the counterbalance circuit in
the main hydraulic control system manifold.

STAND JUMP feature (optional)
The stand jump feature developed for the TDS-9S is available as
an option for the TDS-10S. It consists of a switch at the driller’s
console allowing the operator to change the mode of operation of
the counterbalance cylinders from DRILL, which is a standard
counterbalance condition, to STAND JUMP. The STAND
JUMP feature allows the cylinders to lift the weight of the top
drive off the drill string while breaking out a connection. This
eases the stress on the threads and avoids damage.

March 10, 1998
AC motor and control system

The TDS-10S uses one 350 hp AC motor (Figure 5). It is located
on top of the gear case, which minimizes the distance from the
well centerline to the rear of the guide beam.
Varco selected an AC drilling motor for use on the TDS-10S
because it provides the following benefits:
❏ Reliability
❏ Low maintenance
❏ Nonpolluting
❏ Wide operational range
❏ May be stalled indefinitely at full torque
❏ 180% overload capability for up to one minute
❏ Brushless
❏ Nonsparking
One AC induction motor powers the TDS-10S at 550 VAC
maximum, 3-phase. The TDS-10S includes an air cooling system.
The motor is fed from a PWM inverter that provides variable
voltage at variable frequency for speed and torque control.
The motor is rated at 350 hp with a maximum constant output
torque of 1,550 ft lb. Maximum constant torque is available from
0 to 1,200 motor rpm, with constant power of 350-hp from
1,200 rpm up to the maximum rated motor speed of 2,400 rpm.
(See the TDS-10S output curve figures in the Appendix chapter.)

Hydraulic Motor Brake (Ref)
Upper Grease Fitting
Thrust Ball Bearing
Air Inlet
(1100 CFM)
End Coil
Rotor Assembly
(Laminated)
Motor Frame
(Laminated) Stator Assembly
(Laminated)
Air Exhaust
Motor Shaft
(Vertical Type)
End Coil
Mounting Base
Lower Grease Fitting
Hub (Ref)
Guide Roller Bearing
Figure 5. AC drilling motor

March 10, 1998
The AC motor (350 hp) and the gear ratios (13.1:1 high torque,
standard speed, or optional 4.8:1 low torque, high speed) provide
20,000 ft lb of torque at a drill stem operating speed range of 0 to
87 rpm. Maintaining constant 350-hp output, the top drive
provides 8,081 ft lb of torque at a maximum drill stem speed of
182 rpm.
The open-frame design of the AC drilling motor allows the
cooling air to pass through the inside of the motor, which
provides more efficient transfer of rotor and winding heat to the
cooling air. The motor is manufactured specifically for top drive
applications. They include:
❏ Internal temperature sensors

❏ Double varnish impregnated glass-served windings
❏ Upgraded bearing/shaft seals
❏ High-capacity bearings
❏ Tapered output shafts
❏ High strength tie bolts
❏ Improved material castings

Chapter 3
Installation
Installing the TDS-10S

Electrical, mechanical and structural modifications are necessary
to install a TDS-10S on an existing rig. Dependent upon the
specific rig characteristics, possible modifications can include:
❏ Extending the standpipe to 73 ft.

❏ Replacing the rotary hose (75 ft.)
❏ Installing an AC drive electrical generator (new or upgrade)
❏ Tie-back for the guide beam
❏ Crown pad eye for the guide beam
❏ Attachment pad eye for service loop/bundle saddle
installation at the 80 ft. level
❏ Location of tongs, pipe spinner, mud bucket and trigger lines
❏ Guide beam clearance to girts and fastline
❏ Location of the casing stabbing board

March 10, 1998
All of the above modifications may not be necessary, but all must
be considered as well as the overall rig floor layout in order to
ensure that proper installation, time utilization and accurate cost
information is made.
The functional operation of a TDS-10S has many considerations;
a primary consideration is the mast/derrick height. The working
height and crown clearance are two primary factors to finalize
prior to ordering and installing your TDS-10S. Working height
and Crown clearance can both vary dependent upon hook, block,
bail, elevator links, and coupling chosen. Figure 6 shows a typical
TDS-10S mast interface. A mast/derrick interface requirements
and worksheet is provided in the Appendix chapter.

Existing Traveling Equipment Crown
(250 ton Hook/Block Combo-Typ.) 12.6 ft(3,8 m)-Std.
11.6 ft(3,5 m)-Opt.
Block Top Clearance**
Varco Portable Top

Drive System TDS-10S 11.4 ft(3,5 m)*
Stroked-Typ.
Bail Rest
Sectional Guide Beam 15.0 ft(4,6 m)-Std.

10 X 10" Square Tube 16.0 ft(4,9 m)-Opt.
TDS Work Height**
Tool Joint
Service Loop Saddle
at ~80 Ft(24,4 M) Level*
75 ft(22,9 m) Mud Hose* Connected
136 ft(41,5 m) - Clear Working Height

to Standpipe at 73 ft (22,3 m) Level
200 ft(61 m)* Unitized Service Loop

93 ft(28,4 m)
Drill Stand
Made-up at
Portable Torque Reaction Beam 4 ft(1,2 m)
(Varco Universal Clamp on System, or Custormer Supplied) Level
10.0 ft(3,0 m)-Min*
7.0 ft(2,1 m)-Min

Varco Driller's Control
150 ft (45,7 m) Control

Cable with Connectors
CL
Beam
Unitized Variable Frequency Service Loop
Inverter & Varco Control Panel Tool Joint
4.0 ft(1,2 m)
"Local Power Supply" Drill Floor
(Diesel/Alternator Set)
* Dimensions are Subject for
Verification
** Standard TDS Configuration-
One IBOP with 96" elev.Links
3X50 ft(3X15,2 m) Optional TDS Configuration-
Two IBOP’s with 108" elev. Links
A.C. Cables
Figure 6. Typical TDS-10S mast interface

March 10, 1998
Another key consideration in selecting and successfully operating

a top drive is how well the top drive fits inside of the mast/
derrick. Given the specific dimensions within the mast/derrick
legs, the top drive and its guidance system need to utilize the
complete working height. Figure 7 shows a detailed top view of
the TDS-10S.
The TDS-10S is shipped on a transportation skid with the PH-55
pipehandler connected. In the skid, the top drive is attached to
the upper section of the guide beam. Using the hook or a crane,
the TDS-10S and skid is moved to the rig floor.
Following the directions provided will allow for easy connection
and locking-in of the remainder of the guide beam section and
the attachment to the upper support brackets.
Once the guide beam is secured at the top, the lower end of the
guide beam is attached to the spreader beam and tied back to the
mast/derrick. Proper attachment and tieback is vital to the
transmission of the system torque to the rig structure.
Additional unit subsystem checkouts and precautions are
provided, all of which must be followed to ensure proper
functionality of the TDS-10S unit.

Guide Beam
10 X 10 (250 X 250)
Square Tube
CL
Well
Reliance Electric CL
AC Induction
350 HP Drilling Motor Carriage Assembly
with Guide Pads
24.0 (610) 20.5 (521)
CL
25.6 26.0
(650) (660)
Ref. 19.5
(495)
44.0
(1118)
Ref.
CL
18.0
(457)
28.0 (711)
Dimensions
are in inches
48.0 (1219) Ref. (millimeters)
Motor Housing Gooseneck Service Loop Bracket
Figure 7. TDS-10S envelope/plan view

March 10, 1998

Chapter 4
Operation
Driller’s interface and driller’s console

The driller’s console is manufactured from 300-series stainless
steel and it uses full-size, oil-tight switches and indicators. It is
designed for purging to meet hazardous area requirements. By
request, Varco can supply the console with Pyle-National
connectors.
Throttle control
The throttle uses a design similar to the standard throttle control
used with SCR systems. The handle is robust and includes
integral stops to prevent damage.

March 10, 1998
Torque control
Two torque limit potentiometers are provided for setting drill and
makeup torque limits.
The drill limit control allows the driller to set the maximum
torque output of the top drive to match the drill pipe size being
used.
The makeup control sets the torque when making up connections
using the TDS-10S drilling motor.
Switches
Various switches control the following functions:
❏ Drill/Spin/Torque mode select

❏ Link tilt
❏ Brake
❏ Backup clamp cylinder
❏ Powered rotating link adapter
❏ IBOP valve
❏ Forward and reverse selection for the drill pipe rotation
❏ Emergency stop
❏ Stand jump (optional)

Skid Top Drive
DC Generator
Encoder
(Alternate) Motor
* Mast 1
Saddle
- +
-
* Variable
System
Frequency Electrical
Drive / Electrical Panel
Service
* Varco Loop Solenoids
Driller's J-Box
Interface
Sensors
AC Power
Highline
or
Diesel/Alternator
Set
Varco
* Jumper Cable Assemblies
Driller's
Console could be used between
Mast Termination Plate
and Skid (Control House).
Figure 8. Electrical interface

March 10, 1998
Indicators
Various indicators report status/faults to the driller:
❏ Oil pressure loss

❏ Drill motor over temp
❏ Blower loss
❏ Rotating link adapter
❏ IBOP closed
❏ Brake
❏ Drive fault
PIPEHANDLER BRAKE IBOP

MAKE-UP OIL BRAKE IBOP
CURRENT LIMIT PRESS LOSS ROTATE LINK TILT FLOAT ON CLOSED THROTTLE
LEFT RIGHT
R R A
0 MAX
DRILL MOTOR TORQUE WRENCH LINK TILT BRAKE EMERGENCY
OVERTEMP PUSH & HOLD OFF AUTO IBOP
DRILL TILT OPEN CLOSE
STOP
OFF BRAKE
ON
R
0 MAX
OFF DRILL TORQUE

ALARM LAMP DRIVE
SPIN BLOWER LOSS SILENCE CHECK HYDRAULIC POWER FAULT REVERSE FORWARD
DRILL TORQUE
AUTO ON
TORQUE RPM
R R
0 MAX
Figure 9. Typical TDS-10S Varco driller’s console (VDC)

Varco control system
The driller’s interface is integrated with the Variable Frequency
Drive (VFD). The VFD is located in an environmentally
controlled house.
The driller’s interface integrated with the VFD includes the
following components:
❏ Control logic for system interlocks

❏ Blower and oil pump motor starters
❏ Control circuitry for pipehandler functions
❏ Power supply for TDS-10S solenoids and VDC indicators
❏ AC inverter
❏ Programmable Logic Controller (PLC)
The driller’s interface to the VFD is via a common data bus.
Function changes are implemented with programming tools
standard for Varco top drive systems.
The driller’s interface receives input from the operator controls on
the driller’s console and processes this information through the
programmable logic controller (PLC). It controls the responses of
the cooling system motor, the solenoid valves, the brakes, IBOP
functions, and sensors. The PLC reads the status of the sensors
and acts as an interlock to prevent inadvertent tool operations. It
notifies the driller of the operational status of the TDS-10S and
provides a diagnosis of any inadvertent operational conditions.

March 10, 1998
Variable frequency inverter

The frequency inverter consists of the following three major
sections:
Rectifier and DC link filter

In this section, the incoming 3-phase AC voltage is converted to
DC voltage and filtered by the DC link capacitors. This provides
a ripple-free 740 VDC voltage as input for the inverter.
Alternately, by bypassing the rectifier section, the inverter can be
powered from a 740 VDC source.
Power modules
AC motor speed control requires variable frequency voltage. To
do this, the DC voltage is converted to an output waveform that
consists of a series of pulses. The duration of each pulse is
controlled so that the fundamental voltage applied to the AC
motor has the desired frequency and amplitude. The technique of
using pulses to develop a waveform that appears to the motor as a
sine wave is called pulse width modulation or PWM.
Control section
The control section monitors the performance of the drilling
motor, accepts throttle and torque limit signals from the
TDS-10S control system, and controls the firing circuits of the
power modules.
To vary motor speed, the driller uses a hand throttle. The throttle
varies the frequency and voltage to the motor. Because the drilling
motor is frequency synchronous, the motor speed is proportional
to the frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1,200
motor rpm).
One of the greatest advantages of an AC variable frequency drive
is the quality of the speed and torque control. It allows precise
control of the drill pipe speed over the full operational range.

Variable Frequency Drive
600 VAC, 42 to 62 Hz
810 VDC
Resultant Pulse DC 20 Hz=600 RPM @ Mtr.
3-Phase (350 AMPS) 0
0 0
0-575VAC, 0 to 80 Hz, 3-Phase

0
Insulated gate Bi-polar
Transistors (IGBT)
TDS-10S AC Motors
+
AC
Power
Source
-
AC Inverter
(AC Frequency Drive) Inverter Controller
0
40 Hz=1200 RPM @ Mtr.
PLC
Data Bus
Figure 9. AC power conversion to variable frequency
Service loop
The TDS-10S has an on board hydraulic system and, therefore,
does not need a fluids service loop. This adds to the cost-
effectiveness of the TDS-10S drilling system and provides a safer
work area.
The TDS-10S has three electrical service loops. One loop consists
of four 313 MCM cables (three for drilling motor power, one for
ground). One loop is a composite cable that contains conductors
for the sensors and actuator (solenoid) control. The third loop
contains power for the smaller AC motors and space heater for
the drive motor.

March 10, 1998
Drilling ahead
Drilling ahead with triples

This is the common drilling mode for the TDS-10S. There are
various sources for triples to drill with. On skidding rigs drilling
multiple wells, or rigs that can move with racked pipe, the drill
pipe can be left racked and used to drill the next well. If triples do
not currently exist to drill with, there are two recommended
methods of obtaining them. One is to leave some triples racked in
the derrick when tripping back in the hole and finish the trip
with singles. Enough triples should be left racked to handle
anticipated bit life. The second is to make up triples in the
mousehole while drilling ahead or during rig idle time. For safety
reasons it is best to have a pivoting mousehole so it can be put in
a vertical plane to simplify making connections. Note that the
connections just need to be spun up as they will be torqued when
the Top drive motor applies the makeup torque.
Use the following procedure for drilling ahead with triples
(Figure 11):
1. Drill down the existing stand and set slips.
2. Break out the saver sub from the drill pipe using the top drive
motor and backup clamp in the pipehandler.
3 Spin out the connection using the drilling motor.
4. Lift the top drive.
5. The derrickman latches the triple in the elevator and the floor
crew stabs it in the box.
6. Lower the top drive stabbing the pipe into the stabbing guide
until the pin of the saver sub enters the box.
7. Spin-up and torque the connection using the drilling motor
(makeup torque must be preset). Use a backup tong to react
the torque.
8. Pull the slips, start the mud pumps and drill ahead.

Set slips on Raise block Pickup stand with Lower block to Pull slips
string elevator stab motor into
Tilt link tilt top of stand Start circulation
Stop circulation to derrickman Stab bottom of
stand onto string Spin in motor Open IBOP
Close IBOP and stand
Begin drilling
Breakout Makeup both
connection connections with
using pipehandler motor
and drilling motor
(in reverse)
1 2 3 4 5
Link
Makeup
Tilt
Open
IBOP
Close
IBOP
Stab Makeup
Figure 11. Drilling ahead with triples

March 10, 1998
Drilling ahead with singles

Typically there are two situations when it is desirable to drill
ahead with singles. One is beginning operations on a new well
and there are no triples made-up and racked back. The other is
when surveys must be made every 30 feet (kicking off using a
downhole mud motor). The link tilt feature makes drilling with
singles safe and efficient by moving the elevators to the
mousehole to pick up the singles.
Use the following procedure for drilling ahead with singles
(Figure 12):
1. Drill down existing joint and set the slips.
2. Break out the saver sub from the using the top drive motor
and the backup clamp in the pipehandler.
3. Spin out the connection using the drilling motor.
4. Lift the top drive until elevators clear box.
5. Actuate the link tilt to bring the elevator over to the single in
the mousehole, lower the top drive and latch the elevator
around the single in the mousehole.
6. Pull the single out of the mousehole and as the pin clears the
floor, release the link tilt to allow the single to come to well
center.
7. Stab the connection at the floor and lower the top drive
allowing the added single to enter the stabbing guide.
8. Spin-up and torque the connection using the drilling motor
(torque mode). Set a backup tong to react the torque.
9. Pull the slips, start the mud pumps and drill ahead.

Set slips on Tilt links to Pickup single with Lower block to Pull slips
string mousehole elevator stab motor into
top of single Open IBOP
Stop circulation Latch drill pipe Release link tilt
elevator around Spin in motor Start circulation
Close IBOP single Stab bottom of and single
single onto string Begin drilling
Breakout Makeup both
connection connections with
using pipehandler motor in
and drilling motor torque mode
(in reverse)
1 2 3 4 5
Makeup
Open
IBOP
Close Link
IBOP Tilt
Stab Makeup
Figure 12. Drilling ahead with singles

March 10, 1998
Tripping in and tripping out

Tripping is handled in the conventional manner. The link tilt feature
can be used to tilt the elevator to the derrickman, enhancing his
ability to latch it around the pipe thus improving trip times.
The link tilt has an intermediate stop which is adjustable to set
the elevator at a convenient working distance from the monkey
board. The intermediate stop is tilted out of the way to allow the
elevator to reach the mousehole.
If a tight spot or key seat is encountered while tripping out of the
hole, the drilling motor may be spun into the stand at any height
in the derrick and circulation and rotation established
immediately to work the pipe through the tight spot.
Back reaming
The TDS-10S permits reaming out of open hole to prevent pipe
sticking and reducing keyseat formation, without affecting
racking functions associated with normal tripping; i.e., no singles
to contend with. This is provided by the ability of the top drive
and backup clamp to break out 93 ft. stands in the derrick/mast.
Use the following procedures for reaming out of the hole
(Figure 13):
1. Hoist the block while circulating and rotating the drill motor
until the third connection appears.
2. Stop circulation and rotation, and set the slips.
3. Break out the stand at floor level, and spin out using the
drilling motor.
4. Break out the drilling motor from the top of the stand using
the top drive motor and backup clamp, then spin out with
the drilling motor.
5. Pick up the stand with the drill pipe elevator.
6. Rack stand back.
7. Lower the top drive to the floor.
8. Stab drilling motor into box, spin-up and torque with the
drilling motor and backup clamp.
9. Resume circulation and continue reaming out of the hole.

Hoist while Set slips on Hoist free stand Setback stand Lower block,
circulating and string with elevator using link tilt stab motor into
rotating string
Breakout connec-
When 3-rd tion using pipehandler Spin in motor
connection and drilling motor and makeup
surfaces, stop (reverse) connection with
rotation and motor
circulation Breakout and
spinout stand Start circulation,
at floor pull slips,
hoist and rotate
1 2 3 4 5
Breakout Hoist Setback
Hoist and
Rotate
Breakout
Figure 13. Back reaming

March 10, 1998
Well control procedures

The TDS-10S can stab into the string at any point in the derrick.
While drilling, the remotely controlled upper IBOP valve is
always in the string for immediate use as needed.
The lower IBOP valve is the same type as the upper IBOP valve
except it must be operated manually with a wrench. Both valves
always remain in the string and are therefore always readily
available by connecting the TDS-10S to the drill string.
To attach well control equipment to the drill string the torque
arrestor frame assembly can be pulled away from the drill string
by opening the clamp cylinder.
After removing the lower valve from the upper valve, the lower
valve remains connected to the drill string for well control
purposes. The TDS-10S includes crossover subs for connecting
the drill stem to the lower valve.
Use the following procedure for well control during tripping
operations (Figure 14):
1. On indication of a kick, set the slips and stab the top drive
into the string.
2. Spin-up and torque the connection.
3. Close the remote upper IBOP.
Internal pipe pressure of up to 15,000 psi is now held by the
upper IBOP valve. If it becomes necessary to continue
tripping in with a dart valve, or another well control
accessory, the lower IBOP valve can be used to assist the
operation. In this case, the following steps may be followed:
4. Lower string to the floor and reset the slips.
5. Manually close the lower IBOP valve.
6. With the tugger line attached to the back of the unit, swing
out the torque arrestor clamp cylinder assembly.
7. Remove the lower and intermediate tool joint locks.
8. Break out lower IBOP and saver sub from upper IBOP using
tongs.
9. Install appropriate crossover sub, check valve or circulation
sub on top of lower IBOP valve.
10. Proceed with normal well control procedures.

Add X-Over Sub
(Check Valve etc.)
Remote IBOP
Actuator Cylinder
Upper IBOP Valve
Lower IBOP
Valve
Saver Sub
Insert New
Saver Sub
Drill Pipe
Figure 14. PH-55 pipehandler well control procedures

March 10, 1998
Running casing
Use longer elevator links (180 in.) to allow clearance for
cementing head under the backup clamp in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.

Chapter 5
Specifications
General
Transmission 13.1:1 high torque/low
speed, or optional 4.8:1
low torque/high speed
double reduction helical
gear
Transmission lube Pressure fed, filtered
Powered rotating head Infinitely positionable
System weight 18,000 lb

March 10, 1998
Drilling parameters
Drilling speed range 0 to 182 rpm continuous
Drilling torque 20,000 ft lb maximum
continuous (27115 Nm)
Breakout torque 36,500 ft lb max. int.
Drilling horsepower 350 maximum continuous
Static locking brake 35,000 ft lb (47455 Nm)
Rated capacities
Hoisting 250 Tons, API-8C, PSL-1
Drilling (rotating) 250 Tons
Water course (main shaft bore) 5,000 psi CWP (3 in.)
Drilling motor
Type AC induction, forced air
cooled.
Rating 350 hp
Rated speed 1,200 rpm
Maximum speed 2,400 rpm
Maximum continuous torque 1,550 ft lb
Maximum intermittent torque 2,790 ft lb
Pipehandler (PH-55)
Torque capacity 50,000 ft lb @ 2,000 psi
Drill pipe range (OD) 2 7/8 in. through 5 in.
(4 in. through 6 5/8 in.
OD tool joint)
Upper IBOP (remote) 6 5/8 in. API Reg. RH,
Box
Lower IBOP (manual) 6 5/8 in. API Reg . RH,
Box and Pin (optional)
IBOP pressure rating 15,000 psi CWP
Elevator links 175 tons, 250 tons, or 350
tons, API, 96 in. long
(108 in. links optional)
Chapter 6
Appendix

March 10, 1998
TDS-4S IDS-1 TDS-10S

650 Ton System 500 Ton System 250 Ton System
1,100 HP DC Motor 1,000 HP DC Motor 350 HP AC Motor
Output Torque Output Torque Output Torque
29,100(HI)/45,000(LO) ft-lbs 34,000 ft-lbs 20,000 ft-lbs
Bail Rest
Bail Rest
Bail Rest
23.0 ft
20.8 ft (7,0 m)
(6,3 m) IDS-1
TDS-4S Working
Working Height
Height 15.0 ft
(4,6 m)
TDS-10S
Working
Height
Tool Joint Tool Joint Tool Joint
Drill Floor
Varco’s Top Drive Drilling Systems comparison

350 HP AC Motor - 13.1:1 Tranmission (Standard)
40,000
Max. Stall @
36,500 ft lb
35,000
30,000
Drill Pipe Torque (Ft-Lbs)
25,000
20,000
15,000
10,000
5,000
0
0 50 100 150 200
Drill Pipe RPM
TDS-10S output curve (13.1:1)

March 10, 1998
350 HP AC Motor - 4.8:1 Tranmission (Optional)

15,000
Max. Stall @
13,390 ft lb
12,500
10,000
Drill Pipe Torque (Ft-Lbs)
7,500
5,000
2,500
0
0 100 200 300 400 500
Drill Pipe RPM
TDS-10S output curve (4.8:1)

Block Top TRAVELING WORKING HEIGHT WEIGHT (EST)
MAKE MODEL
EQUIPMENT 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
Block
NATIONAL 660H500 109 9.0 2756 18750 8509
760H650 112 9.3 2832 21800 9888
H350 77 6.4 1956 9380 4255
B500 100 8.3 2543 17900 8119
OILWELL
Hook-Block 650 104 8.6 2629 20240 9181
Saddle Combination TRAVELING A750 120 10.4 3210 34016 15429
BLOCKS TB525-6-60 105 8.8 2670 18200 8255
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
Hook Integrated RA60-7-750 110 9.2 2794 22871 10374
(If Used) 500 91 7.6 2315 21500 9752
Drilling System McKISSICK
650 109 9.1 2769 22590 10246
(IDS) 500-1195 92 7.7 2340 21546 10000
MH
(Integrated Block 650-1090 105 8.7 2664 26932 12500
and Swivel) PYRAMID
500 104 8.7 2648 22000 9979
650/750 103 8.5 2604 27000 12247
Saddle Saddle 540G250 137 11.4 3480 11600 5262
545G350 152 12.6 3861 15260 6922
HOOK-BLOCK NATIONAL 650G500 169 14.1 4293 21250 9639
COMBOS 660G500 184 15.3 4674 26500 12020
(stroked 8") 760G650 192 16.0 4883 31780 14415
IDECO UTB 525-6-60 181 15.1 4607 9000 4082
Swivel 5250 104 8.7 2642 5050 2291
5350 106 8.8 2692 6340 2876
VARCO BJ 5500 117 9.8 2981 9950 4513
S-Type 5750 138 11.5 3493 18090 8205
Stem Drilling 51000 158 13.2 4035 32076 14550
System HOOKS 500 97 8.1 2457 6920 3138
Shoulder (stroked 8")
(Integrated NATIONAL 650 103 8.6 2623 8550 3872
Swivel) 750 113 9.4 2873 9750 4423
WEB WILS. 500 120 10.0 3048 8500 3856
500 112 9.3 2845 11850 5500
MH
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
Drilling OILWELL
PC500 94 7.8 2388 5708 2589
System PC650 96 8.0 2438 7350 3334
TL-500 91 7.6 2311 5200 2359
IDECO TL-650 101 8.4 2562 6900 3130
SWIVELS TL-750 114 9.5 2899 8200 3719
LB500 91 7.6 2311 5947 2698
CECO
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
Tool Joint 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
To short-couple a Swivel Bail/Top Drive TDS-4S 250 20.8 6350 38750 17593
to a Traveling Block VARCO offers special VARCO TDS-5H 214 17.8 5436 35200 15981
Adapters with a 3 to 4 ft working height. TDS-6S* 276 23.0 7010 43750 19826
TOP DRIVES TDS-7S 250 20.8 6350 49000 22742
TDS-9S 214 17.8 5425 24000 10886
* Includes 750 Ton Hook Adapter
TDS-10S 192 16.0 4877 18000 8164
** With 500 Ton 60-in Sheave IDS-11S 216 18.0 5486 26500 12020
Varco Integrated Taveling Block IDS-1** 346 28.8 8788 49000 22742
Top drive worksheet

March 10, 1998
Crown
Customer: ..................
Clearance
Block Top
..........................................
.......................................... ..................
(Stroked)
Bail Rest
Existing
Traveling Equipment:
15.0 or 16.0 ft
TDS Working Height
...........................................
Tool Joint
...........................................
Service
Traveling Equipment Loop/Mast
Short-Coupling using Bundle
............ft Mast Operating Height

Saddle
Varco Adapter/Becket @..........ft
(if applicable):
.............ft
............................................
Mud Hose,
............................................ Standpipe
@..........ft
93 ft Drill Stand
............................................
Sectional
Guide Beam
.............ft
Mast
Bundle
.............ft
CL
Beam
Tool Joint
VFD / Varco Driller's Interface
4 ft
Drill Floor
TDS-10S Mast interface worksheet (generic)

TDS-10S
Top Drive
Drilling
System
Maintenance
and
Troubleshooting
March 2, 1998
2 TDS-10S Maintenance and Troubleshooting

Contents
Preface
Illustrations ......................................................................... 8
Manual layout ..................................................................... 8
Precautions ......................................................................... 9
Chapter 2 Maintenance schedules

Inspection schedules ......................................................... 11
Lubrication schedule ......................................................... 13
Lubricant specifications .................................................... 14
Selecting a lubricating/hydraulic oil ............................ 14
Selecting a lubricant .................................................... 15
Chapter 3 Inspection
Inspecting hardware and fittings ....................................... 17
Inspecting the AC drilling motor brakes ........................... 18
Inspecting the AC drilling motor louvers .......................... 18
Inspecting the wash pipe assembly .................................... 18
Inspecting the upper stem liner ......................................... 19
Inspecting main shaft end play .......................................... 21
Inspecting the gearbox oil level ......................................... 22
Inspecting the guide beam ................................................ 22
Inspecting the IBOPs ........................................................ 22
Inspecting the pipehandler ................................................ 23
Nondestructive Examination (NDE) ................................ 24
Inspecting the elevator link eyes .................................. 24
Inspecting the drive stem ............................................ 26
Magnetic particle inspection (MPI) ............................ 27
Ultrasonic inspection .................................................. 28
Inspecting the hydraulic system ........................................ 29
Inspecting the electrical system ......................................... 29
TDS-10S Maintenance and Troubleshooting 3

March 2, 1998
Chapter 4 Lubrication
Introduction ..................................................................... 31
Lubricating the AC blower motor bearings ....................... 32
Lubricating the hydraulic pump AC motor ....................... 32
Lubricating the AC drilling motor bearings ...................... 32
Lubricating the wash pipe assembly .................................. 34
Lubricating the upper main body oil seals ......................... 35
Replacing the gearbox oil .................................................. 35
Initial oil change ......................................................... 35
Oil capacity................................................................. 35
Replacing the gearbox oil filter .......................................... 36
Lubricating the carriage and guide beam ........................... 36
Lubricating the rotating link adapter ................................. 36
Lubricating the link tilt and PH-55 stabilizer bushing ...... 38
Lubricating the elevator support and
master bushing wear guide ................................................ 38
Lubricating the wireline adapter ........................................ 38
Lubricating the IBOP actuator yoke ................................. 39
Lubricating the IBOP actuator crank ................................ 40
clamp cylinder gate ........................................................... 41
General hydraulic system maintenance.............................. 43
Start-up procedure ...................................................... 44
Accumulator maintenance ................................................ 44
Chapter 6 Troubleshooting
Troubleshooting the AC drilling motor ............................ 45
Troubleshooting the AC blower motor ............................. 46
Troubleshooting the hydraulic system ............................... 47
drilling motor brakes......................................................... 51
(rotating head) motor ....................................................... 52
Operation ................................................................... 52
System test .................................................................. 52
Troubleshooting the IBOP actuator cylinder .................... 54
Operation ................................................................... 54
System test .................................................................. 55

and clamp cylinder ............................................................ 57
Operation ................................................................... 57
System test .................................................................. 58
Troubleshooting the counterbalance system ...................... 60
Counterbalance testing ............................................... 61
Stand jump testing ...................................................... 62
Troubleshooting the hydraulic power unit (HPU)
and reservoir ..................................................................... 64
Operation ................................................................... 64
System test .................................................................. 64
Chapter 7 Disassembly and assembly

Precautions ....................................................................... 67
PH-55 Pipehandler ........................................................... 69
Disassembling the PH-55 Pipehandler ........................ 69
Assembling the PH-55 Pipehandler ............................ 71
Rotating link adapter ........................................................ 72
Disassembling the rotating link adapter assembly ........ 72
Assembling the rotating link adapter assembly ............ 73
Transmission/motor housing ............................................ 75
Removing the transmission/motor housing ................. 75
Installing the transmission/motor housing .................. 75
Disassembling the transmission/motor housing .......... 76
Removing the bonnet and wash pipe .................... 76
Removing the upper bearing retainer plate .................. 77
Removing the AC drilling motor .......................... 77
Removing transmission components ..................... 78
motor housing ............................................................ 81
Assembling the main body .................................... 81
Assembling the main shaft .................................... 82
Assembling the gears to the main body ................. 84
Installing the AC drilling motor ............................ 87
Installing the upper bearing retainer plate ............. 89
Installing the wash pipe......................................... 91
Checking the gear train backlash ........................... 91
AC drilling motor disassembly/assembly ........................... 92
AC drilling motor disassembly .................................... 92
AC drilling motor assembly ........................................ 94
Replacing the safety wiring ............................................... 96
Safety wiring tips ........................................................ 98

March 2, 1998

Preface
Manual conventions
This manual contains conventions that make it easy for the reader
to locate key information and detailed descriptions. Graphics
better understanding of the equipment and assemblies to provide
a better understanding of the equipment’s functionality.
Safety information
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the symbols below
and pay close attention to these important advisories throughout
the text.
z Indicates advisories for operational or servicing procedures

involving little or no risk of personal injury and equipment
damage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rig

personnel.

March 2, 1998

manual and related documents before operating, inspecting, or
servicing the equipment.
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the tool
assembly–standing behind the tool as it faces well center.
Illustrations
Figures present a graphical representation of tool components for
use in identifying parts or establishing nomenclature.
Illustrations show measurements with inches (in.), followed by
millimeters (mm).
For more specific component information pertinent to your rig
configuration, see the drawing index in the Drawings chapter to
obtain the engineering drawing number.
Manual layout
This binder contains several separate chapters that you can
remove individually for convenience.
Varco service centers

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

Chapter 1
Introduction
Precautions
To avoid serious injury or death, read and understand the
following warnings before performing maintenance procedures:
n Properly lockout the main power source before performing

lubrication, inspection, or replacement procedures, unless
specifically noted in this manual.
n Wear protective glasses to prevent eye injuries from fluids under

pressure, as well as other hazards.
n Do not attempt any adjustments while the machine is moving.

March 2, 1998
n Use caution when draining lubricant. It can be hot.
n Never check for hydraulic leaks with your hands. Oil under
pressure escaping from a hole can be nearly invisible and can
penetrate skin causing serious injury. Always check for leaks with
a piece of wood or cardboard and always wear protective eyewear
when working on hydraulic components.
n Always discharge the three hydro pneumatic accumulators before

performing repairs on the hydraulic system.
n Do not attempt repairs you do not understand.
n Read and understand all safety precautions and warnings before

performing maintenance procedures.

Chapter 2
Maintenance
schedules
Inspection schedules
z The service intervals listed in Table 1 on the following page are

based on average operating conditions. Use the schedule as a
guide. Some conditions (excessive loadings, dusty or corrosive
atmosphere, temperature extremes, etc.) may warrant more
frequent service intervals.

March 2, 1998
Table 1. Inspection schedule
Component Check for Frequency

Gearbox/Hydraulic reservoir Oil level Daily
Hardware and fittings Looseness Daily
Wash pipe assembly Leaks Daily
Main body Lubrication oil spray/flow Weekly
AC drilling motor Louvers/screens Weekly
Guide beam Hinge pin retainers Weekly
Guide beam wear
Upper stem liner Corrosion Monthly, or whenever the
wash pipe packing is serviced
Elevator link Eye diameter Monthly
AC drilling motor brakes Wear and hydraulic leaks Monthly
Main shaft Axial movement (end play) Every three months
Accumulators (3) Charge Every three months
Gooseneck Wear Every six months
IBOPs Damage Whenever connections
are broken
Load bearing components Magnetic Particle Inspection At three months or 1,500
(MPI) hours on exposed surfaces
At five years over
entire surface
Ultrasonic Inspection to be
performed along with MPI

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 fittings 3 General purpose grease Weekly
Clamp 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 Weekly
AC drilling motor bearings 2 Chevron Black Pearl EP2 Three months
AC blower motor 2 Chevron Black Pearl EP2 Three months
Hydraulic pump motor 2 Chevron Black Pearl EP2 Three months
Replace oil Gear oil Three months
Replace oil filter Three months

March 2, 1998
Lubricant specifications
Selecting a lubricating/hydraulic oil

Varco Top Drives operate under a wide variety of temperatures
and conditions. The oil viscosity varies from quite thick at start-
up in cold climates to very thin in hot climates during difficult
drilling conditions.
Select gearbox lubrication based on the minimum ambient
temperature to be expected before the next oil change.
Introducing an oil viscosity greater than required by the ambient
temperature could damage the gearbox due to reduced oil flow, or
damage the oil pump with an excessive load.
Use the following table to select the proper lubricant:
e The TDS-10S uses the same lubricant for both the transmission and
hydraulic reservoir.
Table 3. Selecting a lubricating/hydraulic oil
Minimum ambient temp Oil type required Varco P/N

Below -15°F (-26°C) See note below See note below
-15 to 35°F (-26 to 2°C) ISO 32 56008-1
20 to 65°F (-7 to 18°C) ISO 68 56008-2
40 to 85°F (4 to 29°C) ISO 100 56008-3
65 to 100° (18 to 38°C) ISO 150 56008-4
z For minimum temperatures below -15°F, warm the TDS-10S up

by rotating at a very light load and very slow speeds until the oil
temperature is above -15°F. Contact your local Varco Service
Center for specific instructions.

Selecting a lubricant
Use Table 4 to select the appropriate lubricant for your specific
application.
Table 4. Recommended lubricants
Lube Code and Description
1
General Purpose Grease
Ambient
temperature Above -20˚ Below -20˚C
range
Castrol MP grease -
Chevron Avi-Motive Avi-Motive W
Exxon Lidok EP2 Lidok EP1
Gulf Gulf Crown EP32 Gulf Crown EP31
Mobil Mobilux EP2 Mobilux EP1
Shell Alvania EP2 Alvania EP1
Statoil Uniway EP2N Uniway EP1N
Texaco Multifak EP2 Multifak EP1
Total Multis EP2 Multis EP1
Union Unoba EP2 Unoba EP1
NGL1 2 1
AGMA - -
ISO Viscosity - -
Grade
Use Chevron Black Pearl EP2 grease for all temperatures where
applicable.

March 2, 1998

Chapter 3
Inspection
Inspecting hardware and fittings

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

March 2, 1998
Inspecting the AC drilling motor brakes

Remove the brake housing covers to access the drilling motor
brakes.
Inspect the brake shoes for wear, and replace the shoes if worn
below the allowable lining wear limit given by the manufacturer
(approximately 3/32 in.). See the brake manual included in the
Vendor Documentation Package for additional information. If the
brake shoes are wearing unevenly, adjust the brake pads by
adjusting the bolts on the brake calipers.
Inspect the brake hydraulic lines for leaks.
n Never check for hydraulic leaks with your hands. Oil under pressure
escaping from a hole can be nearly invisible and can penetrate skin
causing serious injury. Always check for leaks with a piece of wood or
cardboard.
Inspecting the AC drilling motor louvers

Make sure that no AC drill motor louvers are missing or
damaged.
Make sure that the screens inside the louvers are clean and free of
contaminates and allow for adequate ventilation.
Inspecting the wash pipe assembly

Visually inspect the wash pipe assembly daily for leaks.

Inspecting the upper stem liner
Use the following procedure to inspect the upper stem liner when
replacing the washpipe assembly.
1. Remove the wash pipe packing (Figure 1).
2. Check the upper stem liner for erosion cause by leaking wash
pipe packing and replace the liner if erosion is found.
z The 3.875 in. OD polypack seal must also be replaced whenever

the upper stem liner is replaced. Make sure the O-ring of the seal
is facing down when the seal is installed on the liner.

March 2, 1998
Wash Pipe Assembly
Polypack Seal
Upper Stem Liner
Upper Stem Polypack Seal

Liner
Main Shaft
Figure 1. Inspecting the upper stem liner

Inspecting main shaft end play
Use the following procedure to check for main shaft end play:
1. Remove the wash pipe packing.
2. Check the main shaft axial movement by applying an upward
force to the main shaft and measuring the amount of axial
movement with a dial indicator.
3. If axial shaft movement is not .001 to .002 in., remove the
upper bearing retainer plate and adjust the number of shims
under the bearing retainer plate as required to allow .001 to
.002 in. of axial shaft movement (end play) with the retainer
plate cap screws tightened to 250-270 ft lb.
z Align the shims so that the upper bearing lube tube bore is not
blocked.
z Refer to Installing the upper bearing retainer plate in the

Disassembly and assembly section of this book for further details
on this adjustment.

March 2, 1998
Inspecting the gearbox oil level

With the drive motor and hydraulic system off, check to see that
the oil level is at the middle of the sight glass located on the lube
pump adapter plate mounted on the side of the gearbox.
z Oil level is identified by three sight glasses. Oil level should be at

the top of the upper sight glass.
z Always check the oil level after the unit has been running and the
transmission oil is warm. Look for oil level (oil is dark brown);
not foam level (foam is tan).
Inspecting the guide beam

Inspect the guide beam components weekly. Verify that the hinge
pins and retainer pins are in place. Re-torque tieback clamp nuts.
Inspecting the IBOPs
z Upper and lower safety valves, because of their internal grooves

and shoulders, are particularly susceptible to corrosion fatigue
cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly
inspect the safety valves on a frequent basis. Read and use the
safety valve inspection procedures described in the IBOP Service
Manual included in this manual.

Inspecting the pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings
daily. If any safety wire or cotter pins were removed during
repairs, replace them immediately.
Inspect the hinge pins and retainer bolts daily to make sure they
are not separating from the pipehandler. Make sure the hinge pins
are not loose because of excessive wear in either the bore of the
gate or clamp body.

March 2, 1998
Nondestructive Examination (NDE)

Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path
items.
z NDE inspection includes visual examination, dye penetrant

examination, magnetic particle inspection (MPI), ultrasonic
inspection, x-ray examination, and other methods of
nondestructive testing for metallurgical integrity.
Inspecting the elevator link eyes

Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart (Figure 2) to determine the current strength of the elevator
links. The capacity of the links equals the capacity of the weakest
link.

Upper
Eye
,
C
(Hook)
C
Wear Chart - Forged Links

Upper Lower Capacity
Eye Eye (Per Set)
Dimen- Dimen- In
sion C sion A Tons
,
B = 2-7/8 in., 250 Ton
5 2-1/4 250
4-7/8 2-1/8 210
4-5/8 2-1/16 188
4-3/8 1-3/4 137 B
B
B = 3-1/2 in., 350 Ton
5 2-3/4 350
4-13/16 2-9/16 300
,
4-5/8 2-3/8 225
4-7/16 2-3/16 175
To Determine the strength of worn links,

measure (with calipers) the amount of eye
wear and compare the measurements A
with the above Wear Chart to find the Lower
current capacity. The capacity of the set of Eye
links is determined by the weakest link. (Elevator)
Figure 2. Visual inspection of elevator links

March 2, 1998
Inspecting the drive stem

Regularly inspect and measure the drive stem/main shaft for wear.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B as
guidelines for interpreting and performing inspections.
Measurement techniques are specified in API RP 7G, Section 10.
Use API Bulletin 5T1 to identify and define imperfections found
during inspections.

Magnetic particle inspection (MPI)
Once a year, or every 3,000 operating hours, Varco recommends
performing a MPI of the exposed surfaces of all load bearing
components and load collar grooves to reveal any fatigue or crack
indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are a cause for replacing
the suspect component.
After approximately five years or 15,000 operating hours,
depending on the severity of operating conditions, Varco
recommends performing a MPI of all load bearing components
over the entire surface (including internal bores) to reveal any
fatigue or crack indications. Any indications found are a
potential cause for replacing the suspect component. Round
bottom pits and erosion are acceptable as long as the defect is less
than 1/16 in. deep. Larger defects or any crack indications are a
cause for replacing the suspect component. The load bearing
components are:
❏ Bail
❏ Main body casting
❏ Landing collar
❏ Main shaft
❏ Upper and lower IBOPs
❏ Saver sub
❏ Elevator
❏ Elevator links
Details on MPI Inspection procedures are in the following

publications:
❏ ASTM A-275, Standard Method for Magnetic Particle

Inspection of Steel Forgings
❏ ASTM E-709, Standard Recommended Practice for Magnetic
Particle Inspection
❏ I.A.D.C., Drilling Manual, 9th Edition

March 2, 1998
Ultrasonic inspection
In addition to MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capacity of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the following
publications:
❏ I.A.D.C., Drilling Manual, 9th Edition

❏ ASTM A-388, Standard Practice for Ultrasonic Examination of
Heavy Steel Forgings
z Upper and lower safety valves, because of their internal grooves

and shoulders, are particularly susceptible to corrosion fatigue
cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly
inspect the safety valves on a frequent basis. Read and use the
safety valve inspection procedures described in the IBOP Service
Manual included in this manual.

Inspecting the hydraulic system
n Hydraulic fluid escaping under pressure can penetrate the skin

causing serious injury. Avoid injury by discharging the three
accumulators and relieving pressure before disconnecting
hydraulic lines. Always search for hydraulic leaks with a piece of
cardboard or wood-not with your bare hands. Get immediate
medical attention for hydraulic fluid injuries. Fluid injected into
the skin must be surgically removed within a few hours or
gangrene may result. Do not tighten hydraulic fittings while they
are under pressure.
Inspect the hydraulic system weekly for leaks at fittings, damaged

hose covers, kinked or crushed hoses, hard or stiff hoses, and
damaged or corroded fittings. In addition, during the inspection,
tighten or replace any leaking port connections, and clean any
dirt buildup from hydraulic components.
e Keep in mind that a loss of hydraulic oil is also a loss of gear

lubrication
Inspecting the electrical system

Periodically, depending on severity of service, check all electrical
lines, connectors, and related electrical hardware for loose
connections and damage, and replace components and tighten
connections as necessary.
Also, inspect electrical sensors for exterior damage and replace
components as required.

March 2, 1998

Chapter 4
Lubrication
Introduction
The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.

March 2, 1998
Lubricating the AC blower motor bearings

Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings.
Apply grease every three months to the grease fittings for the
bearings in the AC blower motor located on top of the AC
drilling motor, and to the grease fittings for the bearings in the
AC motor that powers the hydraulic system. All fittings are
located on the ends of the motor. After greasing, remove the
fittings and reinstall the plugs.
Lubricating the hydraulic pump AC motor

Remove the 1/8 in. pipe plugs and install 1/8 in. grease fittings.
Apply grease every three months to the grease fittings for the
bearings in the hydraulic pump AC motor located on top of the
AC drilling motor, and to the grease fittings for the bearings in
the AC motor that powers the hydraulic system. All fittings are
located on the ends of the motor. After greasing, remove the
fittings and reinstall the plugs.
Lubricating the AC drilling motor bearings

Use the following procedure to lubricate the AC drilling motor
bearings at the locations indicated every three months with the
shaft stationary and the motor warm.
1. Locate the grease inlet at the top of the motor frame
(Figure 3).
2. Clean the area and replace the 1/8 in. pipe plug with a grease
fitting and remove the grease drain plug located opposite the
grease inlet.
3. Repeat steps 1 and 2 for the bottom of the motor frame

4. Add grease to the bearing with a manual grease gun. The
motor manufacturer’s manual located in the Vendor
Documentation Package, contains information on the proper
amount and type of grease to use.
5. Clean any excess grease from the grease drain and replace the
pipe plugs at the inlet and the drain.
0.375" Drain Hole
Grease Inlet For

.125-27 NPT Grease Fitting
AC Drilling Motor
Grease Inlet For

0.375" Drain Hole
.125-27 NPT Grease Fitting
Figure 3. Lubricating the AC drilling motor

March 2, 1998
Lubricating the wash pipe assembly

Apply grease daily to the wash pipe assembly grease fitting with
the mud pump shut off (Figure 4).
Grease Fitting
Washpipe Assembly
Upper Main Body Oil Seal

Grease Fittings
Figure 4. Lubricating the wash pipe assembly

Lubricating the upper main body oil seals
Apply grease daily to the two grease fittings for the main body
upper oil seals located inside the bonnet.
z Grease the main body oil seals daily to prevent abrasive drilling
mud from leaking into the main body.
Replacing the gearbox oil
Initial oil change

Drain and refill the gearbox after the first four weeks, or 500
hours of operation, whichever comes first. Replace the oil filter
when changing the oil.
z After every oil change, check for proper lubrication oil flow.
Oil capacity
The TDS-10S main body holds approximately 17-19 gallons of
oil. Always fill the transmission to the middle of the upper sight
glass. Use the following procedure to fill the transmission for the
first time:
1. Use a hand pump to fill the gearbox to the top of the sight
glass (approximately 17-19 gallons).
2. Operate the TDS and hydraulic systems 10-15 minutes and
then check the sight glass.
3. If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass.

March 2, 1998
Replacing the gearbox oil filter

Replace the gearbox oil filter at the same time the oil is changed. The
filter is located on a bracket attached to the carriage.
Lubricating the carriage and guide beam

Apply a thin film of grease to the running surfaces of the guide
beam once a week.
Lubricating the rotating link adapter

Apply grease weekly to the three grease fittings on the rotating
link adapter (Figure 5).

Rotating Link Adapter
250 TON
Grease Grease
Fitting Fitting
Front
L H J A4 B4 E5 Rotating Link Adapter
J
E6
E6
G6
B8 G6
A4 G5
B4
E5
Grease Fittings H
Back
Figure 5. Lubricating the rotating link adapter

March 2, 1998
Lubricating the link tilt and PH-55 stabilizer

bushing
Apply grease to the four link tilt grease fittings weekly. Lubricate
the stabilizer bushing daily.
Lubricating the elevator support and master

bushing wear guide
Apply grease to the seven fittings on the elevator support weekly.
The master bushing wear guide has four fittings. Lubricate
weekly. Inspect the guide ring periodically for wear or damage
and replace it as necessary.
Lubricating the wireline adapter

Apply grease to the wireline adapter weekly. The wireline adapter
has one fitting. Inspect the sheaves periodically for wear or
damage and replace as necessary.

Lubricating the IBOP actuator yoke
Apply grease to the five grease fittings on the IBOP actuator daily
(Figure 6).
IBOP Actuator Cylinder
Grease Fitting (2)
IBOP Actuator
Yoke
Upper IBOP
Actuator Shell
Figure 6. Lubricating the IBOP actuator yoke

March 2, 1998
Lubricating the IBOP actuator crank

Apply grease daily to the two IBOP actuator crank grease fittings
(Figure 7).
Closed
Position
Open
Position
Actuator Arm Groove
Actuator Shell
Crank Arm
Grease Fitting
Upper IBOP
Valve
Figure 7. Lubricating the IBOP actuator crank

clamp cylinder gate
Apply grease with a brush to the torque arrestor tubes and apply
grease to the four clamp cylinder gate fittings weekly (Figure 8).
Torque Arrestor
Grease Fitting (2)
Grease Locations
(Each side)
Clamp Cylinder Gate
Grease Fittings
(Each side)
Figure 8. Lubricating the torque arrestor tubes and clamp cylinder gate

March 2, 1998

Chapter 5
Maintenance
General hydraulic system maintenance
n Release all hydraulic oil pressure by bleeding accumulators before

disconnecting hydraulic lines. Allow several minutes after the
hydraulic system is turned off prior to attempting any service
which would involve opening hydraulic lines. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
n Before opening hydraulic system, thoroughly clean work area, and

maintain system cleanliness by promptly capping all disconnected
lines. Dirt is extremely harmful to hydraulic system components
and can cause equipment failure and subsequent injury to
personnel.
e Use care when handling components to prevent nicking close tolerance

finishes.

March 2, 1998
Start-up procedure
e Only operate the hydraulic system when the TDS-10S is in the

vertical position.
Perform the following start-up procedure whenever restarting a

hydraulic system in which a motor or pump has been removed
and reinstalled:
1. Inspect all hydraulic system components (reservoir, hoses,
valves, fittings, etc.) to make sure they are clean prior to filling
with fluid.
2. Fill the gear case oil reservoir with the recommended
lubricating oil passed through a 10 micron (nominal, no
bypass) filter.
3. Check the oil level and add filtered fluid if necessary.
4. Jog start the AC drilling motor to verify correct rotation
direction.
Accumulator maintenance
The Vendor Documentation Package contains the accumulator
manufacturer’s instructions for the TDS-10S hydraulic
accumulators (Bulletin SB1630-M1). This bulletin contains all
necessary maintenance, removal and replacement, and pre-
charging instructions for the TDS-10S accumulators.

Chapter 6
Troubleshooting
Troubleshooting the AC drilling motor

Refer to the AC motor manufacturer service manual in the Vendor
Documentation Package.

March 2, 1998
Troubleshooting the AC blower motor

The AC blower motor is located on top of the AC drilling motor.
The Table 5 describes problems, probable causes and remedies.
Table 5. Troubleshooting the AC blower motor
Problem Probable cause Remedy

Mechanical noise in blower. Loose impeller. Reinstall impeller and hub
with threadlocking
compound on screws.
Faulty motor bearings. Repair or replace as needed.
Blower runs intermittently. Faulty or loose wiring. Locate and repair as needed.
Faulty motor starter. Check for dirt or trash
between starter coil. Repair
or replace as needed.
Broken service loop Use spare service loop
conductor. conductor.
Motor overheating, overtemp Incorrect blower rotation. Verify blower rotation
alarm stays on with blower correct.
running.
Broken service loop Use spare service loop
conductor. conductor.

Troubleshooting the hydraulic system
The following hydraulic troubleshooting section provides a
schematic diagram and description for each TDS-10S hydraulic
circuit. Following each schematic is a group of troubleshooting
charts to help you quickly locate and correct hydraulic system
problems.
When performing hydraulic troubleshooting, be aware that:
❏ The electrical control system can be bypassed for

troubleshooting by manually overriding the solenoid valve for
each operational system.
n Alert all personnel near the top drive before overriding a solenoid
valve. When you override a solenoid valve, you bypass the safety
interlock and top drive components will move possibly causing
serious injury or death.
❏ Test points shown in the hydraulic schematic with a box

(e.g., A4) can be found on the manifold under the main body.
There are also test points on the rotating link adapter motor.
❏ The system is preadjusted. Hydraulic problems are usually
related to faulty valves, contamination, or other damage to
the system rather than misadjustments. Changes to
adjustments should be made only after all other possible
causes have been eliminated.
❏ Table 6 identifies the schematic symbols used in this section.

March 2, 1998
Table 6. Hydraulic schematic symbols
Description Symbol Schematic Reference

A B
Solenoid
Operated
2 Position 4 way Valves (Single Solenoid) SV1, SV4, SV5, SV8, SV9
Valves
P T
A B
3 Position 4 way Valves (Double Solenoid) SV2, SV6

P T
Manual A B
Valve 3 Position 4 way Valve MV
(Rotary) P T
Pump
Fixed Displacement
1
Pressure
Relief
Valves Standard Valve RV2, A2R, B2R, SJR
2
3
Ventable Relief Valve 1 2 RV1
Differential Unloading Valve UV1
Pressure
Reducing
Valve PC1, PC4
Pressure
Reducing/Relieving
Vavle PCC
Check CDF, CTF, CV2, CTR,

Valve CDR, CXCD
Prefill valve assembly
CV1, CV2

Table 6. Hydraulic schematic symbols (continued)
Pilot-To-Open Check Valve CKCB (Link Tilt)
Pilot-To-Close Check Valve CA6, CB6, CV3, CV4

(Clamp Body)
1
3
Cavity Plug PC5
2
Internal Plug
Non Adjustable Flow Control Valves CV1
Non Adjustable Orifice Diameter in Inches
3 Port (Internal Drain) CBCA (Link Tilt Circuit)
Counterbalance
Valves
4 Port (Internal Drain) CWCK (Link Tilt Circuit)
Logic Cartridges LA6, LB6, LC5, LODC
Logic Cartridge With Metering See Prefill Assembly
Quick Disconnect Coupling

March 2, 1998
Table 6. Hydraulic schematic symbols (continued)
Non Bypass Filter See Lube Oil Circuit
Filter With Bypass See Return Circuit
Manual Shutoff Valve
Thermostat Lube Oil Circuit
Pressure Switch Lube Oil Circuit
Hydraulic Circuit
Heat Exchanger
(Inside Brake Housing)
Pressure Compensator Control Part of the Pump
Hydro-Pneumatic Accumulator
Hydraulic Motor (Bi-Directional)
Hydraulic Cylinder
Tank (Reservoir)
Test Point

drilling motor brakes
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 2,000 psi. The solenoid valve operates to apply
pressure, setting the brakes, or stop pressure to release the brakes.
Table 7. Troubleshooting the AC drilling motor brakes

Brake does not release. Directional valve is stuck. Test the valve and replace if
necessary.
Brakes release but still drags. Check valve is blocked or the Replace the check valve or
tube is pinched. tube as required.
Mechanical problems with Repair the brake mechanism.
brakes.
Brakes do not engage or slip. There is hydraulic oil on the Check for hydraulic leaks
brake pads. and repair.
Delay in the brakes actuating The hydraulic oil is Replace the hydraulic oil.
after the console switch is contaminated.
turned on.
The pressure reducing valve Replace the valve.
is faulty.
To test the system, turn the AUTO BRAKES switch on the

driller’s console to the ON position. Attach a pressure gauge to
B1 in the manifold. The pressure reading should be 2,000 psi.
Turn the AUTO BRAKES switch to the OFF position. The
pressure reading should be very low. If the pressure is high, the
solenoid valve could be sticking.

March 2, 1998

(rotating head) motor
Operation
The three position directional valve controls the direction of the
rotating head to the left or right. The pressure is applied to the A
or B port of the hydraulic motor, depending on the selected
direction. The auto return function is controlled by the processor
and returns the tool to the home position.
System test
To test the system, operate the rotating head switch on the
control panel. Verify both directions of rotation. The rotation
speed is limited by the nonadjustable orifice. The torque is
limited by the two relief valves.
z The 1,600 psi test pressure at ports A and B is maximum load

pressure. If the rotating link adapter is free to rotate, the load
pressure will be less than maximum. The shot pin must be
engaged to achieve full load pressure.

Table 8. Troubleshooting the rotating link adapter (rotating head) motor

Tool does not rotate. Direct control valve or Inspect, repair or replace the valve.
relief valve is sticking. Look for pressure changes when
solenoid is energized. If there is no
pressure change, try the manual
overide on the valve.
n When you overide a directional

valve, you bypass the safety
interlock and top drive
components move, possibly
causing serious injury or death.
Solenoid valve is not Check the electrical connections and
electrically operating. valve functions.
Motor is worn out or gear Replace the motor.
teeth are broken.
Shot pin is engaged. Adjust the relief valve.
Mechanical interference. Inspect and repair.
Directional valve does not Test pressure the left and right.
shift. Replace the valve.
Fixed valve orifice is Clear the orifice or replace the valve.
plugged.
Hydraulic lines are Replace the hydraulic lines.
damaged.

March 2, 1998
Troubleshooting the IBOP actuator cylinder
Operation
The IBOP is in the open position under low hydraulic pressure,
A4 = 500 psi, B4 and C4 = less than 100 psi. When you close
the IBOP, high pressure is applied to the cylinder. A4 is less than
100 psi; B4 and C4 are 2000 psi. When the solenoid is de-
energized, for opening the IBOP, A4 goes to 500 psi after a small
time delay. B4 is less than 100 psi and C4 reaches 2,000 psi after
a small time delay. The time delay is operated by the time delay
accumulator.
Table 9. Troubleshooting the IBOP actuator cylinder

Safety valve leaks. Internal parts are worn out. Check for washouts or
defective parts and repair or
replace as needed.
Actuator is not functioning Check the mechanical
properly. operation of actuator.
Check the reducing valves.
Excessive vibration or wobble Yoke bushings or actuator Replace the bushings.
while rotating. bushings are worn out.
Worn cam rollers. Repair or replace the rollers
and roller brackets.
Cylinder does not actuate. Pressure reducing valve Test pressures and adjust or
plugged orifice. replace the pressure reducing
valve.
Accumulator is not charged. Test the accumulator
pressure and charge as
required.
No system pressure. Check the hydraulic system
operation.

System test
Refer to the hydraulic circuit schematic in the Technical Drawing
book for the IBOP actuator cylinder. The IBOP is normally
open.
n Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
To test the system, engage the IBOP and measure the pressure at
B4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open the
IBOP and test the pressure at A4, which increases to 2,000 psi.
The pressure at B4 and C4 drops to 500 psi.

March 2, 1998
11.5 IN^ 3
500 PSI
PRECHARGE
N07
IBOP CLOSE
A B
b
N12
P T
A4 SV4 D03 B4 C4
.055Ø FC4
500 PSI 2 T-13A
T-11A 1 PC4
.016Ø
3
1 30 PSI
2
2 3
4 1
T-21A 400 PSI
A4 SQ4 B4
A4 B4
A4 B4
OPEN
CLOSE Hydraulic Cylinder
IBOP ACTUATOR CYLINDER

2.500 DIA. BORE X 2.00 STROKE
1.375 DIA. DOUBLE ROD
Figure 9. Hydraulic circuit for the IBOP actuator cylinder

and clamp cylinder
Operation
The shot pin cylinder and clamp cylinder operation are
interrelated and complex. The shot pin cylinder is different in
that it has an extra port called the barrel port. The barrel port is
back from the end of stroke which creates a valving effect. When
the shot pin and clamp cylinders are not activated, the shot pin is
fully retracted with full pressure and the clamp cylinder is
retracted with 500 psi.
When you energize the clamp cylinder, the shot pin cylinder is
actuated against the rotating gear and it may miss one of the 24
holes. The control system starts pulsing the rotating head to move
slowly until the shot pin engages a hole on the rotating gear. The
shot pin cylinder pressure is limited by the relief valve until the
cylinder passes through one of the holes. Once the pin engages
the hole, full system pressure is applied to C5 which opens valve
CV5, applying full pressure to the clamp cylinder to close.
When the clamp cylinder is de-energized, the clamp releases and
the shot pin pulls out.

March 2, 1998
System test
At rest, the pressure at C5 is 2,000 psi, B5 is less than 100 psi,
CP is less than 100 psi, and CR is 500 psi.
n Alert all personnel near the shot pin, clamp, and rotating head
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.
When you energize solenoid valve SV5, using the manual

override, pressure increases to the barrel of the shot pin cylinder.
The pressure is controlled by a .031 pressure reducing valve that
prevents the shot pin from putting full force on the rotating head
surface until the pin engages in one of the holes.
Pressure at B5 is 200 psi (limited by the relief valve), C5 is less
than 100 psi, G5 is less than 100 psi, CP is less than 100 psi, and
CR is less than 100 psi.
Once the shot pin engages the hole, full pressure is applied in C5
to control valve CV5 open for clamp. Pressure at B5 is 2000 psi,
C5 is 2000 psi (forces valve CV5 open for clamp), G5 is less than
100 psi, CP is 2,000 psi, and CR is less than 100 psi.
When solenoid valve SV5 is de-energized, the shot pin cylinder
withdraws the shot pin, and the clamp disengages at the same
time. The circuit returns to rest conditions.

Table 10. Troubleshooting the shot pin cylinder and clamp cylinder

Shot pin does not engage. Solenoid valve is not operating or Check the electrical actuation
relief valve is not adjusted. and test pressure. Adjust as
required.
Abnormal pressure change at B5 Replace the directional control
and C5 indicates valve problem. valve.
Normal pressure change Repair the plumbing or shot pin
indicates plumbing or shot pin cylinder.
cylinder are faulty.
Shot pin applies excessive Relief valve is not operating or Test pressures and adjust as
force to rotating head out of adjustment. required.
gear.
Clamp cylinder does not No pressure or reduced pressure Test pressures and adjust and
actuate. at the cylinder. repair as required.
Cylinder is damaged. Inspect the cylinder and repair or
replace.
z To provide high pressure to the

clamp circuit, pressure at C5
Repair plumbing, rotating head,
or clamp cylinder.
must be 2,000 psi and G5 must
be less than 100 psi. If this
condition is met, pressure at CP
should increase from less than
100 psi to higher than 2,000 psi.
If not, check the plumbing,
rotating head, and clamp
cylinder.
While clamping, pressure at CR Clean or repair the CNEC valve.
should be 2.7 times the pressure
at CP. When the dies contact the
pipe, pressure at CR should be
less than 100 psi. If the pressure
does not fade, check valve
CNEC for contamination.
Shot pin engages but Control valve not operating. Check the pressure at C5.
clamp cylinder does not Replace valve CV5 if required or
activate. the regenerate manifold.

March 2, 1998
Troubleshooting the counterbalance system

The accumulator, with precharge pressure of 900 psi, along with
check valve CV3, maintains a hydraulic pressure. Refer to the
manufacturer's documentation in the Vendor Documentation
Package for the gas charging procedure for the accumulator.
A three-position manually operated valve controls counterbalance
operation for rig-up, run, and shut down modes. In the rig-up
mode, system pressure is applied to XC and the prefill valve,
causing both cylinders to extend. When the cylinders extend, you
make up the mechanical connection to the bail. In the run mode,
for counterbalance operation, approximately 1,600 psi is needed
at the counterbalance cylinders to lift the TDS-10S off the hook.
Stand jump operation is controlled by solenoid valve SV9. With
the counterbalance in the run mode and the stand jump switch
on, additional pressure of approximately 300 psi is applied to over
the normal counterbalance pressure to lift the TDS-10S and drill
string off the hook.
In the shutdown mode, the hydraulic system bleeds down the
system accumulator and the counterbalance accumulator pressure.

Counterbalance testing
For the counterbalance operation, a lift of approximately
30,000 lb is achieved with a pressure of 1,600 psi at CB.
Perform the following steps to adjust the force:
1. Set the COUNTERBALANCE MODE switch to the RUN
mode. Set the pressure control valve PCC to the minimum
setting (fully counterclockwise).
2. Test the pressure at port B9. There should be a 0 psi reading.
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
4. Adjust the pressure at pressure control valve PCC clockwise,
observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on
the hook.

March 2, 1998
Stand jump testing

For the stand jump operation, a lift of about 33,000 lb is achieved
with a pressure of approximately 1,800 psi at CB. The additional
300 psi pressure over the normal counterbalance pressure is
provided by energizing the stand jump solenoid valve SV9.
Perform the following steps to adjust the pressure:
1. Set the counterbalance mode switch to Run and engage the
stand jump switch. Test the pressure at port CB and B9.
Adjust relief valve SJR fully counterclockwise to the
minimum setting.
2. Slowly increase the pressure at CB by adjusting relief valve
SJR clockwise until the bail lifts off the hook with a stand of
pipe in the elevator.
z Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

Table 11. Troubleshooting the counterbalance system

Counterbalance does Cylinder damaged. Seal leaks. Inspect the cylinder and repair or
not function. replace the seal.
No hydraulic pressure. Test the pressure and adjust the
pressure reducing valve.
Solenoid valve SV9 is Test the electrical and hydraulic
not operating. operation. Replace or repair as
applicable.
PCC is not operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on accumulator Charge the accumulator.
is low.
Stand jump does not Cylinder damaged. Seal leaks. Inspect the cylinder and repair or
function. replace the seal.
No hydraulic pressure. Test the pressure and adjust the
pressure reducing valve.
Solenoid valve SV9 is Test the electrical and hydraulic
not operating. operation. Replace or repair as
applicable.
PCC is not operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on accumulator Charge the accumulator.
is low.

March 2, 1998
Troubleshooting the hydraulic power unit

(HPU) and reservoir
Operation
Figure 10 shows the onboard HPU schematic. A 10 hp electric
motor drives the fixed displacement pump.
The fixed displacement pump provides hydraulic power to
operate the lubrication pump motor. Pressure can be tested at
port PF. Relief valve RV2 limits the driving pressure of the lube
oil circuit.
System test
Test the circuit pressure at port PV. Relief valves RV1 and UV1
are a part of the circuit. UV1 is a differential unloading valve,
which can be pressure checked at port Z1.
RV2 is set at 400 psi and can be tested at PF. Test the pressure at
PV to confirm the relief valve RV1 is set at 800 psi. The
differential unloading valve UV1 is tested at Z1 to confirm the
pressure is 2,000 psi.

IN
10 Micron
No Bypass Out
30 PSI
N08
PF Y1 D .062Ø .205Ø .059Ø .047Ø

1.0 1.5
GPM GPM
Upper Compound
M Gear
10 HP 1.40 in3/rev
1200 RPM Lower Compound Gear
Upper Mainshaft Bearing
Lower Radial/Main Thrust Bearings
Upper Compound Bearing
Lower Compound Bearing
Figure 10. Hydraulic circuit for the HPU and reservoir

March 2, 1998
Table 12. Troubleshooting the hydraulic power unit (HPU) and reservoir

Hydraulic system Relief valves out of Test the pressures and adjust
overheating. adjustment. the relief valves.
Unloading valve is not Test and adjust the UV1 or
working. replace the unloading valve.
Counterbalance mode Check the system pressure.
valve left in shut down
position too long and
pressure bleeds down.
No precharge in system Charge the system
accumulator. accumulator.
Hydraulic components System pressure is down. Test the pump and motor.
do not operate. Test the relief valve pressures.
Adjust as required. Check for
leaks, loose fittings, loose
cylinders, worn hoses, fluid
levels and seals.
Flexible coupling is Replace the flexible coupling.
damaged.
Pressure at UV1 is too low. Adjust the pressure at UV1.
Pump is rotating in the Inspect the hydraulic
wrong direction. connections and correct
rotation.
Low oil level in reservoir. Fill the hydraulic reservoir.

Chapter 7
Disassembly and
assembly
Precautions
e Only authorized Varco repair technicians should perform the

following major disassembly and assembly procedures.
e Transport hydraulic components to a clean, dust-free service area

before disassembling for service.

March 2, 1998
z Disassembly procedures are usually performed when replacing

damaged components that are causing a tool function to fail.
Whenever performing a disassembly, practice preventive
maintenance by:
❏ Cleaning and inspecting all disassembled parts.

❏ Replacing all worn and damaged parts before they can cause
another failure.
❏ Installing thread protectors on exposed threads.
e Torque all fasteners to the limits given in DS00008 (Design

Specification Design Torque Standard), located in the Supplemental
Materials book, unless an alternative torque value is given in the
procedure.

PH-55 Pipehandler
Disassembling the PH-55

Pipehandler
Remove the PH-55 Pipehandler to service the following
components:
❏ Stem
❏ Stem seals
❏ Rotating link adapter upper and lower wear bushings
❏ Rotating link adapter rotary seals
n Release all hydraulic oil pressure before disconnecting hydraulic

lines. Hydraulic oil under pressure can penetrate skin and cause
serious injury.
n Before opening the hydraulic system, thoroughly clean the work

area, and maintain system cleanliness by promptly capping all
disconnected lines. Dirt is extremely harmful to hydraulic system
components and can cause equipment failure and subsequent
injury to personnel.
z To protect the rotating link adapter seals and inner surfaces,

remove the stem along with the rotating link adapter.
z Contact the nearest Varco Service Center for details about

building an appropriate stand for removing the rotating link
adapter.

March 2, 1998
Use the following procedures to disassemble the pipehandler:

1. Remove the elevator links and the elevator.
2. Disengage and remove the shot pin.
3. Disconnect the hydraulic lines and cap all connections.
4. Remove one of the backup clamp cylinder gate hinge pins and
open the gate.
z The link tilt brackets remain attached to the links.

5. Remove the two pins that attach the link tilt crank to the link
tilt lever.
6. Remove the pin attaching the torque arrestor to the rotating
link adapter and remove the torque arrestor with the clamp
cylinder assembly.
7. Remove the upper IBOP crank assembly.
8. Remove the lower tool joint lock.
9. Remove the intermediate joint lock.
10. Remove the IBOP actuator shell.
11. Remove the upper tool joint lock.
12. Remove the saver sub, lower IBOP, and upper IBOP.
13. Remove the pipe plug from the stem flange and drain the
transmission oil from the housing.
14. Lower the top drive until the bottom of the rotating link
adapter just rests on a stand or blocks.
15. Remove the landing collar assembly from the main shaft.
16. Remove the screws holding the rotating link adapter to the
main housing.
17. Raise the top drive slowly, leaving the rotating link adapter on
the stand or blocks.

Assembling the PH-55 Pipehandler
Use the following procedures to assemble the pipehandler:
1. Install the new main shaft seals inside the stem bore.
e Always install new main shaft seals and use care not to damage seal
lips or case.
2. Install the new O-rings on the stem flange.

3. Grease the walls of the bore in the main body, the stem main
shaft seals, and the O-rings on the rotating link adapter
assembly.
4. Position the rotating link adapter assembly, supporting it with
the same stand or block used in the disassembly procedure.
5. Using three 5/8-11 UNC bolts, pull the rotating link adapter
to the main body and completely seat the rotating link
adapter into the bore.
6. Install screws to secure the rotating link adapter to the main
body.
7. Replace the drain plug.
8. Install the upper IBOP, lower IBOP, and saver sub.
9. Install the upper tool joint lock and tighten the bolts to
180 to 190 ft lb.
10. Install the IBOP actuator shell.
11. Install the intermediate tool joint lock and tighten the bolts to
180 to 190 ft lb.
12. Install the lower tool joint lock.
13. Install the upper IBOP crank assembly.
14. Pin the torque arrestor to the rotating link adapter.
z The link clamp assembly remains attached to the torque arrestor.

15. Position the drill pipe elevator and links, and pin the link tilt
levers to the link clamp assemblies.
16. Close and pin the torque backup clamp cylinder gate.
17. Connect all hydraulic lines.

March 2, 1998
Rotating link adapter
Disassembling the rotating link

adapter assembly
Use the following procedures to disassemble the rotating link
adapter assembly:
1. Remove the pipehandler as described above and transport the
rotating link adapter assembly to a suitable work area.
2. Support the rotating link adapter assembly on a work table so
that the link tilt crank hangs down.
3. Remove the hose assemblies, link tilt crank and the two
cylinders.
4. Remove the lock wire and screws that hold the gear and stem
assembly to the rotating link adapter body.
5. Attach three lifting slings symmetrically to the top of the stem
flange and slowly raise the stem and gear assembly to separate
it from the rotating link adapter body.
6. Set the stem and gear assembly on a suitably protected
surface.
e Protect the internal surfaces of the rotating link adapter body and the
surfaces of the stem when separating the two components. When
removing the rotating link adapter from the stem, carefully tap with a
mallet to remove the rotating link adapter from the stem. There can
be resistance from misalignment between the two bores when rasing
the stem and gear assembly.
7. Prepare a work area to stand up the stem and gear assembly

on the bottom surface of the stem.
8. Remove the retainer ring under the piston ring from the stem
and gear assembly.
9. Remove the piston ring and the gear. This may require light
tapping on top of the gear with the gear sitting on the piston
ring.

e The piston ring is assembled with a light press fit. Provide a support
under the gear so that it does not drop when it breaks loose.
10. Remove and discard all rotary seals, o-rings, the thrust ring,
and two wear bushings from inside the rotating link adapter
and gear inside dimension.
11. Remove and discard the stem flange O-rings and stem bore
shaft seals.
Assembling the rotating link adapter

assembly
Use the following procedures to assemble the rotating link
adapter assembly:
1. Orient the stem so the stem flange (top of the stem) is down
on a suitably protected surface.
2. Install the gear with it's rotating seal and wiper in place. Note
the orientation.
3. Install the o-ring for the piston ring.
4. Install the piston ring. It requires light tapping to press it into
place.
5. Install the retainer ring.
6. Install all of the rotary seals on the rotating link adapter (nine
of one size and one larger), and an o-ring on the top surface.
7. Install the two wear bushings and the thrust ring in the
rotating link adapter.
8. Rest the rotating link adapter on its bottom surface.
9. Clean and then lubricate (with hydraulic oil) the sealing
surface of the stem and the inside diameter of the rotating
link adapter.

March 2, 1998
10. Attach three lifting slings symmetrically through the holes on

the top of the stem flange and slowly lower the assembly into
the rotating link adapter body.
e Make sure the seals do not twist in the grooves.
11. Line up the dowel pin holes and replace all of the screws and
safety wire.
12. Install the link tilt cylinders; pin and secure in place.
13. Install the link tilt crank; pin and secure in place.
14. Install all hose assemblies.
15. Invert the rotating link adapter assembly so that the stem
flange is up.
19. Install a new main shaft seal inside the stem bore with the seal
lip facing up.
e Always install a new mainshaft seal and use care not to damage the
seal or the case.
20. Install new stem flange O-ring.
z A light coating of grease applied to the O-ring helps in installing

the rotating link adapter assembly into the TDS main body.
e Always install new stem O-ring and use care not to damage the
O-ring or the case.

Transmission/motor housing
Removing the transmission/motor

housing
Remove the transmission/motor housing to service the following
components:
❏ Compound gear and bearings

❏ Main shaft
❏ Main thrust bearing
❏ Bull gear
The AC drive motor can be removed with the TDS-10S left in

place. To remove this component, skip to the applicable removal
section below.
To remove the transmission/motor housing:
1. Remove the PH-55 pipehandler components as described
above.
2. Remove the saver sub and the lower and upper IBOPs. See
the IBOP Service Manual, included in the Supplemental
Materials book for the procedure.
3. Disconnect the service loop, rig down the tool, and transport
the transmission/motor housing to a suitable work area.
Installing the transmission/motor

housing
Perform the rig up procedures in the Installation chapter.

March 2, 1998
Disassembling the transmission/

motor housing
z Drain the oil from the transmission/motor housing before

disassembling components.
Removing the bonnet and wash pipe

Use the following procedures to disassemble the transmission/
motor housing assembly upper component:
1. Remove the bail (see steps a through g).
e An installation tool is required to safely remove the bail from the

TDS-10S.
a. Remove the bail retainers from the main body.

b. Disconnect the counterbalance cylinders from the bail
and main body cover.
c. Attach two swivel lifting eyes (rated for 10,000 lb
minimum), one on each side, 2 in. up from the bottom of
the bail.
d. Using shackles rated for 10,000 lb minimum, attach the
swivel eyes to the installation tool.
e. Tighten the nut on the turnbuckle shaft until the distance
between the tips of the bail have increased by
approximately 3.5 in. over the beginning position.
f. The bail can be removed by leaving one end engaged in
the pocket and rocking the other end around the pocket
in the main body until it is fully clear.
g. Move the bail until it is clear of the main body and then
remove the installation tool.
2. Remove the wash pipe packing box assembly.
3. Remove the upper stem liner on top of the main shaft using
the two pry points, and remove and discard the liner seal.
4. Remove the bearing shield from the top of the main shaft.

Removing the upper bearing
retainer plate
Use the following procedures to remove the upper bearing
retainer plate:
1. Remove the six cap screws and lockwashers that attach the
bearing retainer plate to the main body cover and remove the
plate.
z Use the two jacking holes in the upper bearing retainer plate as
required to help remove the plate.
2. Remove the lube tube from the lube tube bore of the cover,
and remove the lube tube O-rings.
3. Remove and discard the two lip seals in the bearing retainer
plate.
4. Remove the bearing retainer plate shims.
5. Remove the taper roller bearing outer race from the cover
bore.
Removing the AC drilling motor

Use the following procedures to remove the AC drilling motor:
1. Remove the four nuts and tie rods between the brake adapter
plate at the top of the motor, and the top of the main body
cover.
2. Remove the four cap screws and lockwashers that attach the
AC drilling motor to the main body cover. Attach handling
gear to the brake end of the motor and lift the motor off the
main body cover. The pinion hub separates from the pinion
shaft as the motor rises.
3. Remove the O-ring that seals the AC drilling motor to the
main body cover.

March 2, 1998
Removing transmission components
e Heat the bearings with an induction heater to facilitate bearing

removal. Because this method heats quickly and could possibly
damage bearings, always use a Tempilstik or pyrometer to monitor
bearing temperature.
Use the following procedures to disassemble the transmission/

motor housing:
1. Remove the oil reservoir by removing all but four attachment
screws. Leave four screws (one on each edge) loosened
approximately 1/8 in. Using screws to jack the reservoir apart,
thread the screws into the threaded holes located around the
reservoir flange. Tighten the screws until the sealant separates.
Remove the last four screws after providing suitable support
for the weight of the reservoir.
2. Mark, disconnect and plug all hoses attached to the hydraulic
pump/motor assembly. Remove the hydraulic pump/motor
assembly. Disconnect the electrical cable attached to the
electric motor.
3. Remove the screws that attach the pump assembly to the
main body cover. Use jack screws around the perimeter of the
flange to remove the pump assembly.
4. Remove the cap screws that attach the cover to the main
body. Use jack screws around the perimeter of the main body
cover to separate the cover from the main body and remove
the cover.
5. Remove the oil gallery O-rings.
6. Carefully lift the main shaft/bull gear assembly straight up.
e When raising the main shaft, the main thrust bearing separates.
Lift the main shaft slowly.
7. Use the lifting eye on the end of the compound shaft to lift
out the compound gear.

8. Install a lifting eye in the bottom of the internal splined area
and apply tension to remove the pinion gear. Remove all
hoses that attach to the pinion shaft retainer. Remove the
attachment screws and use jack screws, if necessary, to remove
the pinion shaft retainer from the bottom side of the main
body. Lower the pinion and bearing assembly out of the
bottom of the main body.
9. Remove and inspect the main body orifices and the pipe
plugs.
e Do not use a steel hammer when removing the gears. It can damage
components.
10. Remove the mainshaft upper wear sleeve by heating the sleeve
to 250°F (121°C). Check the sleeve for wear after removing
it.
11. Remove and discard the upper taper bearing inner race by
heating the race to 250°F (121°C).
z If replacing the bull gear, perform steps 12, 13, and 14. If not,
proceed to step 15 and remove the bull gear along with the main
shaft.
12. Remove the 10 lockwired cap screws that hold the bull gear in
place.
13. Install two 5/8-11 UNC forged eyebolts in the bull gear
pickup holes and heat the bull gear to between 150°F (66°C)
and 200°F (93°C), then remove the bull gear by lifting the
gear straight up off the alignment pin.
14. Inspect the bull gear alignment dowel pin, and remove and
discard the pin if damaged.
15. Remove the main shaft wear sleeve by heating the sleeve to
250°F (121°C), then pulling the sleeve off shaft. Check the
sleeve for wear grooves after it is removed.
16. Remove the lower radial bearing inner race by heating the
race to 250°F (121°C), then pulling the race off the main
shaft.

March 2, 1998
17. Remove the main shaft sleeve by heating the sleeve to between
200°F (93°C) and 250°F (121°C) and pulling the sleeve off
the shaft.
18. Remove half of the thrust bearing race, the bearings, and the
cage of the thrust bearing.
19. Remove the other half of the thrust bearing race by heating
the race to 200°F (93°C) and pulling the race off the main
shaft.
20. Remove the four lockwired cap screws that hold the lower
radial bearing ring retainers in place and remove the retainers.
21. Remove the outer race of the lower radial bearing from the
bore in the housing with a bearing puller.
22. Remove the retainer nut and washer from the pinion shaft to
separate the bearing from the pinion gear. Heat the bearing to
200°F (93°C) and pull the bearing from the shaft.
23. Heat the inner bearing races to 200°F (93°C) and pull it off
the journals to remove the inner bearing races (cones) from
the compound gear journals.
24. When replacing the thrust bearing or radial bearing inner
race, turn the main shaft assembly upside down with the
6 5/8 in. pin connection pointed up. In order to turn the
assembly upside down, raise the lower race of the thrust
bearing until the rollers contact the upper race. Use two large
C-clamps and clamp the lower race and rollers to the main
shaft shoulder. Once the shaft is inverted, remove the clamps.
e Do not drop the races or rollers during this tipping over process.

motor housing
e Keep the transmission bearings, shafts, and housing free of chips,

burrs, and dirt during the following assembly process to prevent
damage to transmission parts.
z Varco strongly recommends replacing any bearing or gear where

even the slightest wear is indicated. It is usually less expensive to
replace any questionable parts found during disassembly than risk
having to rebuilt the gearbox later.
Assembling the main body

Use the following procedures to assemble the main body:
1. Steam clean the main body, blowing out all passages (make
sure all the plugs and spray nozzles are removed). Apply a
protective coating, such as WD-40, to all unpainted internal
surfaces.
z Do not apply any thread sealant to the orifice.

2. Chill the outer race of the lower radial bearing to at least 0°F
(-18°C), but no lower than -60°F (-51°C), then install the
bearing into the bore of the main body. Immediately after
installing the bearing, spray the bearing with WD-40 to
prevent corrosion.
e Do not use liquid nitrogen to cool parts. Temperatures below -60°F

(-51°C) can affect the composition of certain metals and lead to the
weakening of parts.
3. Install the two lower radial bearing ring retainers.

4. Apply an anti-seize compound to the threads of the four
1/2 in. hex-head cap screws that hold the bearing ring
retainers in place, and install the cap screws and lockwashers
in place. Tighten the cap screws in a star pattern to 71-79
ft lb.
5. Safety wire the cap screws with .047 in. diameter lockwire.
6. Turn the main body over.

March 2, 1998
Assembling the main shaft

1. Remove any burrs, steam clean, and coat the main shaft with
a protective coating such as WD-40.
e C-clamps must be used when the main shaft assembly is inverted.
2. Restrain the main shaft in a vertical position with the bottom

facing up (Figure 11).
3. Heat the upper race of the main thrust bearing to 200°F
(93°C) and install the race on top of the 18 in. diameter load
plate machined into the shaft. Rotate the race until it seats flat
on the plate.
4. Install the thrust bearing’s roller bearings and cage and
liberally apply oil to the bearing rollers.
5. Install the other half of the thrust bearing race.
6. Heat the lower radial bearing inner race to between 225°F
(107°C) and 250°F (121°C) and install the race onto the
main shaft sleeve by rotating the race until it seats.
7. Inspect the lower wear sleeve. If the sleeve shows signs of wear
or damage, replace it.
8. Heat the wear sleeve to 250°F (121°C) and install the sleeve.

Lower Race
Rollers and Cage

Tapered Roller Upper Race
Thrust Bearing Heat to 200°F (93°C)
Bottom End of Shaft
Main Shaft
Stem
Shaft Shoulder
18" Diameter
Load Plate
Rest
Top End of Shaft
Figure 11. Assembling transmission/motor housing

March 2, 1998
Assembling the gears to the main body

1. Reinstall the pipe plugs, orifices, and nozzles. Apply thread
sealant (not Teflon tape) to the plugs and Loctite 232
Threadlocker (blue) to orifices and nozzles.
2. Ensure that the lower radial bearings and bearing ring
retainers are installed before proceeding (see Assembling the
main body).
3. Heat the inner races of compound (cones) bearings to 200°F
(93°C) and install on each end of the compound gear.
4. Heat the pinion shaft bearing to 200°F (93°C) and install on
the pinion shaft until the inner race shoulders against the
pinion shaft.
5. Install the lockwasher and nut. Tighten the nut to 200 ft lb
and continue tightening until the tab from the washer aligns
with the slot. Bend the tab up into the slot.
6. Using a lifting eye installed in the bottom of the internal
splined area, raise the pinion/bearing assembly from the
bottom into the main housing.
7. Install the pinion shaft retainer using the six bolts.
e Support the pinion shaft in a vertical attitude–do not allow it to tilt.

Otherwise the bearing will bind when attempting to return the
pinion shaft to vertical.
8. Loosely install the compound bearing retainer into the main

body, leaving 3/16 in. gap between the mating surfaces of the
retainer and the main body.
9. Install cups of compound bearings in the bores of the main
body and main body cover. Chill 30°F if needed.
10. Position the compound gear in the main body using the
lifting hole in the end of the compound gear to aid in
handling.

11. Liberally apply oil to the lower radial bearing and inner race
of same bearing. Before lowering the main shaft, slowly loosen
the C-clamps until the lower race of the thrust bearing rests
on the inner race of the main radial bearing. Remove the C-
clamps.
e Loosen the C-clamps slowly to prevent the rollers from fallong out.
Lower the main shaft assembly through the main bore of the
main body until both the main thrust bearing races contact
the rollers and the main shaft rotates easily.
12. Heat the bull gear to between 150°F (66°C) and 200°F
(93°C). Install two 5/8-11 UNC forged eyebolts in the gear
pickup holes, making sure the stamping “TOP SIDE” is up.
13. Carefully lower the bull gear into position until it seats. If the
old dowel pin has been removed, rotate the gear until the
1 in. dowel pin hole is aligned.
z If the bull gear dowel pin has been removed, chill the new dowel
pin to at least 0°F (-18°C), but no lower than -60°F
(-51°C) as the bull gear is being placed into position. Then drive
the dowel pin into the alignment hole using a bronze hammer.
The pin will sit flush to 1/4 in. high.
14. Apply an anti-seize compound to the threads of the ten 1 in.

hex-head cap screws that hold the bull gear in place, and
install the cap screws and lockwashers in place. Tighten the
cap screws in a star pattern to 610-670 ft lb.
15. Safety wire the cap screws with .051 in. diameter lockwire.
16. Heat the upper taper bearing inner race to between 225°F
(107°C) and 250°F (121°C). Install the bearing rotating the
race until it seats.
17. Inspect the upper wear sleeve. If the sleeve shows signs of wear
or damage, replace it.
18. Heat the upper wear sleeve to between 200°F (93°C) and
250°F (121°C). Install the sleeve and rotate the sleeve until it
seats.

March 2, 1998
19. Install dowel pins in the main body cover and keys in the
main body.
20. Apply a thin layer of sealant to the mating surfaces of the
main body and main body cover.
21. Install O-rings around the oil galleys in the back wall of the
main body.
22. Liberally apply oil to the upper cone of compound gear and
cup in cover. Lower the cover onto the main body, making
certain the compound gear bearing halves are aligned.
23. Install and tighten the cover bolts.
24. Lightly tighten the screws to the compound retainer and
measure the gap between the retainer and the main body.
25. Install a stack of shims between the retainer and the main
body that exceeds the gap by approximately .002 in.
26. Tighten the screws to 75 ft lb. Check the end play by
inserting a dial indicator through the hole in the bearing
retainer and moving the compound up and down using a pry
bar.
27. Disassemble the retainer and remove or add shims to obtain
an end play of .001 to .002 in.
28. Clean the mating faces, then apply a thin layer of sealant to
the mating faces. Install the reservoir.
29. Place the O-ring in the groove on the top face of the main
body cover where the hydraulic pump assembly attaches.
30. Install the hydraulic pump assembly.
e Take care to not damage the inlet filter when lowering the pump
into place.

Installing the AC drilling motor
z This procedure assumes the brake and cooling system is

installed on the AC drilling motor as well as the pinion hub.
See AC drilling motor assembly for instructions on installing the
brake hub and pinion hub to the AC motor shaft.
Use the following procedures to assemble the transmission/motor
housing upper component:
1. Inspect the O-ring that seals the AC drilling motor to the
main body joint and replace any O-ring that has flat spots,
nicks, or other damage. Place the O-ring on the pilot bore
diameters and apply grease (Figure 12).
2. Pick up the AC motor by the brake end (using lifting straps
placed under the brake adapter) and lower it into position on
the pilot bore being careful not to move or crush the O-ring.
z Make sure the brake end with mounting feet faces the rear, and
the blower duct faces the hydraulic pump when installing the AC
drilling motor.
3. Install the four cap screws and lockwashers that hold the AC
drilling motor to the main body.
4. Apply an anti-seize compound to the threads of the four main
body cover bolts for the motor. Tighten the four main body
cover bolts to 250-270 ft lb.
5. Install the tie rods by first inserting the end of the rod with
the greatest length of thread into the holes in the brake
adapter plate.
a. Raise the tie rod until the lower end clears the top of the
main body cover.
b. Install the tie rod into the threaded holes.
c. Tighten the tie rods until the lower end shoulders against
the main body cover.
d. Install the flat washer and locknut onto the remaining end
of the tie rod and torque to 325 ft lb.

March 2, 1998
AC Motor
Pilot Bore
O-Ring
Figure 12. Installing the AC drilling motor

Installing the upper bearing retainer plate
1. Oil the taper roller bearing on top of the main shaft. Chill the
taper roller bearing outer race to at least 0°F (-18°C), then
install the race into the cover bore.
2. Clean the retainer plate pipe plugs, apply thread sealer (not
Teflon tape) to the pipe plug threads, and install the plugs
into the retainer plate.
3. Determine the proper number of shims required under the
bearing retainer plate by installing shims, installing the
retainer plate, and checking the main shaft axial movement.
Check main shaft axial movement by applying a force to the
end of the main shaft and measuring the amount of axial
movement at the other end with a dial indicator. Add or
delete shims as necessary to obtain .001 to .002 in. of axial
shaft movement (end play) with the retainer plate cap screws
tightened to 250-270 ft lb.
z Align the shims so that the upper bearing lube tube bore is not
blocked.
4. Remove the bearing retainer plate cap screws and the bearing
retainer plate.
5. Install the two new upper bonnet oil seals in the bearing
retainer plate with the lips facing up.
e Use care not to damage the seals. Be careful to install the seals with
the lips facing up since these seals function to keep mud from entering
the main body.
6. Using a center punch, stake the last seal in place on eight

points.
7. Install the O-ring on the bearing retainer plate and coat the
O-ring with grease.
8. Install two O-rings on the upper bearing lube tube and coat
the O-rings with grease.
9. Install the lube tube into the lube tube bore in the cover with
the .060 in. diameter hole facing up.

March 2, 1998
10. Install the bearing retainer plate, being careful to align the
lube tube bore in the retainer with the lube tube protruding
from the cover.
11. Carefully tap the bearing retainer plate to seat the plate on
top of the cover.
12. Apply an anti-seize compound to the threads of the six
bearing retainer plate cap screws, install the six cap screws and
lockwashers, and tighten to 250-270 ft lb. Safety wire the cap
screws.
13. Recheck the main shaft axial movement by applying a force to
the main shaft and measuring the amount of axial movement
with a dial indicator. The main shaft movement must be
between .001 and .002 in. If the movement falls outside of
this specification, readjust the number of shims under the
bearing retainer plate.
14. Install two new grease fittings into the bearing retainer plate.

Installing the wash pipe
1. Install the new bearing shield on top of the main shaft. Hold
the shield in place with the worm clamp.
2. Install the 3.875 in. OD polypack seal onto the upper stem
liner with the O-ring facing away from the flange of the stem
liner.
3. Lubricate the upper stem liner with grease and tap the liner in
place on top of the main shaft.
4. Using a dial indicator, measure the main shaft to adapter
wash pipe pilot on the gooseneck. The TIR should not exceed
.006 in.
5. Install the wash pipe packing and tighten.
6. Grease the wash pipe packing and the bearing retainer plate
seals.
Checking the gear train backlash

Using feeler gauges, check the backlash of the primary and
secondary gears through the access covers on the right side and
left side of the main body (you can also use 3 in. NPT ports for
access).
z Backlash for the primary gears should be .010 to .020 in.

(.024 in. maximum). Backlash for the secondary gears should be
.010 to .024 in. (.030 in. maximum).

March 2, 1998
AC drilling motor disassembly/assembly
AC drilling motor disassembly

Each AC drilling motor has a brake hub on the top of the motor
shaft, and a pinion hub at the bottom of the motor shaft as
shown in Figure 13. When disassembling the brake hub and
pinion hub from the motor shaft:
1. Obtain special tool 110026, a hydraulic hand pump with a
gauge and high pressure hose, and connect as shown in
Figure 13.
2. Increase the pressure to 35,000 psi and remove the brake hub.
3. Use the same procedure described in steps one and two, to
remove the pinion hub.

Brake Hub
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
AC Motor
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Pressure Gauge ,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
Hub
Hydraulic Hand Pump
Tool # 110026
High Pressure Hose
Figure 13. AC drilling motor disassembly

March 2, 1998
AC drilling motor assembly

Each AC drilling motor has a brake hub installed on the top of
the motor shaft, and a pinion hub installed at the bottom of the
motor shaft as shown in Figure 14. When assembling the brake
hub and pinion hub to the motor shaft:
1. Lap the brake hub and pinion hub to their respective ends of
the motor shaft until the contact area between them is at least
85%.
2. Lightly install the brake hub and pinion hub onto the motor
shaft and measure the gap to the motor (dimension A).
3. Remove the brake hub and pinion hub and heat them in an
oven to between 400°F and 425°F.
4. Reinstall the brake hub and pinion hub onto the motor shaft
advancing the pinion hub .068 ± .005 in. and the brake hub
.054 ± .005 in. past the original dimension A. This ensures
they remain securely fastened to the motor shaft.

Lap to 85% Contact
,,,,,,,,,,
,,,,,,,,,,
5.029 ,,,,,,,,,,
,,,,,,,,,,
Brake Hub
Ref ,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,
AC Motor
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,
5.975 ,,,,,,,,,,,
,,,,,,,,,,,
Ref ,,,,,,,,,,,
,,,,,,,,,,, Lap to 85% Contact
,,,,,,,,,,,
,,,,,,,,,,,
Pinion Hub
Figure 14. AC drilling motor assembly

March 2, 1998
Replacing the safety wiring

Use the following procedures to safety wire screws, nuts, bolts, or
other fasteners where applicable.
n Torque fasteners before safety wiring any screw, nut, plug, or

other fastener. Never overtorque or loosen a torqued fastener to
align safety wire holes.
Use the size and type of safety wire required in the applicable
specifications and drawings. Whenever possible, use double-twist
safety wiring.
n Limit single-twist wiring to the following: small screws located in

closely spaced, closed geometrical patterns (e.g., triangle, square,
rectangle, circle), parts in electrical systems, or parts that are
difficult to reach.
n Do not reuse safety wire.
To install safety wire:

1. Open the jaws of the safety twist pliers:
2. Squeeze the handles of the pliers together and unlock the
round, perforated slider in the center of the pliers from the
hook lock.
3. Grip both safety wires in the jaw. Squeeze the handles
together with one hand and pull the slider toward the rear of
the pliers with the other hand to lock the pliers.
4. Twist the safety wire by pulling the aluminum knob and twist
the rod out from the pliers. Let the pliers spin free.
5. Return the knob and twist the rod by holding the pliers
steady with one hand and pushing against the end of the
knob the with other hand (step 4 in Figure 15).
6. Repeat the previous twisting cycle.

7. After threading the safety wire through the hole in the
fastener, pull the wire straight through without nicking the
wire. Twist four to five complete revolutions per inch of wire.
8. Make a pigtail of approximately 1 in. (25 mm) length (four
twists minimum) at the end of the wiring and bend back or
under to prevent it from becoming a snag.
1
2
3 4
Figure 15. Safety wiring procedures

March 2, 1998
Safety wiring tips

❏ Pull the safety wire firmly, but do not stretch it or let kinks
develop. Make twists tight, even, and as taut as possible
without weakening the wire by overtwisting (Figure 16).
n Do not nick the wire with the edge of the hole in the fastener.
Position the safety wire so the pull exerted by the wire tightens the
nut. For best results, let the wire leave the fastener in a clockwise
direction
❏ Twist the safety wire so the loop around the bolt or head has
sufficient tension to keep it from slipping up and over the
bolt head, with resulting slack in the safety wiring.
n When securing castellated nuts with safety wire, tighten the nut to
the low side of the selected torque range, unless otherwise specified.
If necessary, continue tightening within specified torque limits
until a slot aligns with the hole.
❏ The number of nuts, bolts or screws that can be safety-wired

together depends on the application. As a guide, when safety-
wiring widely spaced bolts by the double-twist method, a
group of three, or a 24 in. (610 mm) length of safety wire is
usually the maximum.
Figure 16. Safety wiring examples

TDS-10S
Top Drive
Drilling
System
Control System
March 2, 1998
2 TDS-10S Control System

Contents
General description ............................................................. 5
Major component descriptions ........................................... 7
Varco Driller’s Console (VDC)..................................... 7
Programmable logic controller (PLC) ..................... 9
Variable Frequency Drive (VFD) .......................... 10
Electrical service loops................................................. 12
Chapter 2 Operation
Preoperational checklists ................................................... 13
VDC controls ................................................................... 17
Correcting a drive fault ..................................................... 20
Drive fault while drilling ............................................. 20
Drive fault while making up ....................................... 21
Maintaining the control system......................................... 23
Troubleshooting ............................................................... 25
VFD ........................................................................... 28
TDS-10S Control System 3

March 2, 1998

Chapter 1
Description
The following chapter describes the TDS-10S Control System in

general and its major components in detail.
General description
The TDS-10S control system consists of the following three
major components:
❏ Varco Driller’s Console (VDC)

❏ Varco Electrical House (VEH)
❏ Electrical Service Loops
These components directly interface to control and provide safety
interlocks for the TDS-10S (Figure 1).

March 2, 1998
Variable
Frequency Drive 3-Phase Power
(VFD)
Control
Varco Signals
Driller's Console Data Control
(VDC) PLC TDS-10S
Bus Signals
Remote I/O
Varco Electrical House (VEH)
Figure 1. TDS-10S control system interface

Major component descriptions
Varco Driller’s Console (VDC)

The VDC, made from 300-series stainless steel, uses full size oil
tight switches and indicators, and is designed for purging to meet
hazardous area requirements (Figure 2).
PIPEHANDLER IBOP BRAKE

MAKE-UP OIL ROTATE IBOP BRAKE
CURRENT LIMIT PRESS LOSS LINK TILT FLOAT CLOSED ON THROTTLE
LEFT RIGHT
R G A R
0 MAX
VDC
PRESS LOSS
DRILL MOTOR
OVERTEMP
TORQUE WRENCH
PUSH & HOLD
LINK TILT
OFF IBOP
BRAKE
AUTO
EMERGENCY
DRILL TILT OPEN CLOSE OFF BRAKE STOP
ON
R R 0 MAX
OFF DRILL TORQUE

ALARM LAMP HYDRAULIC POWER DRIVE
SPIN BLOWER LOSS SILENCE CHECK FAULT REVERSE FORWARD
DRILL TORQUE AUTO ON
TORQUE RPM
R R
0 MAX
Figure 2. Varco Driller’s Console (VDC)

March 2, 1998
It is equipped with the following items to directly interface with

the programmable logic controller (PLC):
❏ Throttle
❏ Torque limit potentiometer
❏ Makeup limit potentiometer
❏ Switches and buttons
❏ Indicator lights
The throttle uses a design similar to a standard throttle control
supplied with Silicone Controlled Rectifier (SCR) systems. The
handle includes integral stops to prevent damage.
The torque limit potentiometer is also similar to the design used
on SCR systems. The maximum torque output of the drive is
limited to the continuous torque rating of the drive and motors.
The makeup limit potentiometer controls the makeup torque
when using the drilling motor to makeup connections.
Switches and buttons control the following:
❏ Drill, Spin, Torque mode select
❏ Link tilt
❏ AC drilling motor brakes
❏ Backup clamp
❏ Remote IBOP valve
❏ Drill pipe forward/reverse select
❏ Emergency stop
Indicator lights show the following conditions:
❏ Oil pressure loss
❏ Drill motor overtemperature
❏ Blower loss
❏ IBOP closed
❏ Brake
❏ Drive fault

Programmable logic controller (PLC)
The Variable Frequency Drive (VFD) cabinet encloses the
following electrical components:
❏ Master programmable logic controller (PLC)

❏ Circuit breakers
❏ 24 Volt DC power supply for solenoids and VDC
❏ Motor starters for blower and oil pump
With the PLC functioning as the central control unit for the
TDS-10S, interface to the variable frequency drive (VFD) is
limited to a digital communication buss. Input signals from the
PLC to the drive include the following:
❏ Control word 1 (On/Off, fwd/rev)

❏ Control word 2 (set point data set selection)
❏ Speed
❏ Torque forward
❏ Torque reverse
Communication from the drive to the PLC includes rpm, torque
and status word (fault).
Any changes to alarm or interlock functions have no effect on the
VFD.
The remote I/O receives input from the operator controls on the
VDC and processes this information through the PLC. The PLC
controls the responses of the cooling system motor, solenoid
valves, brakes, IBOP functions, and sensors. It reads the status of
the sensors and creates interlock conditions to prevent inadvertent
tool operations. The PLC also notifies the operator of the
operational status of the TDS-10S using alarm indicators which
provide diagnosis of inadvertent operational conditions.

March 2, 1998
Variable Frequency Drive (VFD)

The VFD, used to operate the TDS-10S AC drilling motors,
consists of three major parts:
❏ Rectifier section
❏ Control section
❏ Power inverter section
The rectifier section converts incoming 3-phase AC power to DC
for use by the power devices.
The control section monitors the performance of the drilling
motor, accepts throttle and torque limit signals from the driller,
and controls the firing circuits of the power modules.
The power inverter section converts DC power into a simulated
AC signal using pulse-width-modulation (PWM) field vector
control techniques.
The driller controls the speed of the AC drilling motors with a
hand throttle. The throttle varies the frequency and voltage to the
motor. The speed of the drilling motor is proportional to the
frequency (i.e., 20 Hz is 600 motor rpm, 40 Hz is 1200 motor
rpm).

600 VAC, 42 to 62 Hz
810 VDC
Resultant Pulse DC 20 Hz=600 RPM @ Mtr.
3-Phase (350 AMPS) 0
0 0
0-575VAC, 0 to 80 Hz, 3-Phase

0
Insulated gate Bi-polar
Transistors (IGBT)
TDS-10S AC Motors
+
AC
Power
Source
-
AC Inverter
(AC Frequency Drive) Inverter Controller
0
40 Hz=1200 RPM @ Mtr.
PLC
Data Bus
VFD
Figure 3. Variable Frequency Drive (VFD)

March 2, 1998
Electrical service loops

The TDS-10S requires three electrical service loops. The main
loop consists of four 313 MCM power conductors (three for
drilling motor power, one for ground); and a composite cable that
contains all of the conductors for sensors and actuator (solenoid)
control. This encoder signal is contained in three of four twisted
pair shielded wire in the composit cable. An auxiliary power loop
provides power for the auxiliary AC motors and heater.

Chapter 2
Operation
The following chapter contains the TDS-10S Control System

preoperational checklists and detailed descriptions of the VDC
controls.
Preoperational checklists
The tables on the subsequent pages provide the following
preoperational checklists:
❏ Drive control system function checks (Table 1)

❏ Top Drive control system function checks (Table 2)
❏ Top Drive control system interlock checks (Table 3)
❏ Top Drive control system alarm checks (Table 4)

March 2, 1998
Table 1. Drive control system function checks
Switch Indicator Physical

Function Position Display Lamp Check Check OK
Blowers Forward N/A Blower on
Reverse N/A Blower on
Off N/A Blower off
Oil pump Forward N/A Oil pump on
Reverse N/A Oil pump on
Off N/A Oil pump off
IBOP Closed On Actuator shell up
Open Off Actuator shell
down
Link tilt Drill N/A Links to drill
down position
Off N/A No movement
Tilt N/A Links extended
to mousehole
Link tilt float Push N/A Links float to
w/c
Rotating head Left N/A Rotates left
(manual) Right N/A Rotates right
Counterbalance Drill N/A Balance TDS
weight
Stand Jump N/A Lifts TDS
(opt.) weight

Table 2. Top Drive control system function checks
Switch Indicator Physical

Function Position Display Lamp Check Check OK
Brake Off Off Brake released
On On Brake set
Auto/throttle on Off Brake released
Auto/throttle off On Brake set
Torque wrench Off N/A Jaws unclamped
Clamp N/A Jaws clamped
Alarm silence Push On Horn silenced
Lamp check Push On All lamps on
(after 2 seconds) (after 2 seconds)
Table 3. Top Drive control system interlock checks
Control
Function Sequence Action Check OK
Rotating head With links in tilt or No rotation
drill position,
actuate rotate
left/right.
With links in tilt or Links float toward
drill position, wrench clamp.
actuate float push
button.
After 5 seconds After 5 seconds,
actuate rotate rotating head
left/right. rotates.
Torque wrench With No torque wrench
clamp drill/spin/torque clamp
switch in drill mode
and throttle on,
actuate torque
wrench clamp.

March 2, 1998
Table 4. Top Drive control system alarm checks
Alarm Function Action to Initiate Display Indication Check OK

Oil pressure loss Remove/cap oil “Oil Pressure Alarm”
Press line to oil flashes and horn
Press switch sounds
Disconnect aux. “Oil Pressure Alarm”
power loop flashes and horn
sounds
Blower differential Remove line to left “Blower Press
press differential press Alarm” flashes and
switch horn sounds
Disconnect aux. “Blower Press
power loop Alarm” flashes and
horn sounds

VDC controls
Table 5 describes each of the VDC controls in detail (Figure 4).
24 1 6 4 2 20
21
OIL DRILL MOTOR

PRESS LOSS OVERTEMP BLOWER LOSS
12
DRIVE PURGE
FAULT LOSS
13
3
TORQUE RPM
IBOP BRAKE 8
IBOP
BRAKE ON BRAKE
CLOSED IBOP AUTO
10 OPEN CLOSE OFF BRAKE
ON
EMERGENCY
STOP
16
THROTTLE
PIPE HANDLER
MAKE-UP
CURRENT LMIT ROTATE LINK TILT FLOAT
LEFT RIGHT
0 MAX
0 MAX
HYDRAULIC LINK TILT TORQUE WRENCH DRILL TORQUE
POWER OFF PUSH & HOLD COUNTERBALANCE
OFF ON DRILL TILT
DRILL STAND 23
JUMP
0 MAX
ALARM/LAMP TEST
OFF
SPIN (PRESS TO SILENCE)
DRILL TORQUE REVERSE FORWARD
19
9
11 15 7 14 18 17 22
Figure 4. VDC controls

March 2, 1998
Table 5. VDC controls
Control/Indicator
Name Description and Function
1 DRIVE FAULT Red indicator light flashes and horn sounds when a VFD fault
is detected. Pressing the alarm silence button stops the horn.
The alarm indicator light stays on while the switch is timed
for 5 minutes. The alarm returns if the fault is not fixed,
otherwise, the alarm light turns off.
2 BLOWER LOSS Red indicator light illuminates in case of a failure in air
cooling motor.
3 BRAKE ON Red indicator light illuminates when the brake solenoid valve
is energized.
4 DRILL MOTOR Red indicator light illuminates in case of an overtemperature
OVERTEMP condition in the 350 hp AC drilling motor.
5 IBOP CLOSED Amber indicator light illuminates when there is hydraulic
pressure to the cylinder that closes the IBOP valve.
6 OIL PRESS LOSS Red indicator light illuminates when there is an oil pressure
loss in the gearcase lubrication system.
7 ALARM /LAMP TEST When the alarm indicator light illuminates and the horn
switch sounds, press the switch to silence the horn. The alarm light
stays on until the fault is corrected. If it is not corrected in 5
minutes, the alarm repeats. The switch is also a lamp check for
all lights on the VDC. The switch must be pushed and held
for two seconds to obtain a lamp check.
8 BRAKE switch There are three brake switch positions: OFF, AUTO, and
ON. Turning the switch to the ON position turns the brake
on and lights the indicator light above the switch. In the
AUTO position, the brake automatically turns on when the
throttle is turned off. Turning the switch to the OFF position
turns the brake off. After a DRIVE FAULT or emergency
stop, the BRAKE SWITCH must be turned ON and then
OFF to reset the brake.
9 DRILL TORQUE A potentiometer sets the current limit in the VFD during
Limit Potentiometer drilling operations. This sets the torque for normal drilling
operations in the drill position. Torque and rpm are displayed
and can be adjusted. Adjust the torque by setting the brake
and turning the potentiometer to increase or decrease the
torque.
10 ROTATE There are three switch positions: OFF, LEFT, and RIGHT.
Turn the spring-loaded switch to the left to rotate the head to
the left, and turn the switch to the right to rotate the head to
the right.
NOTE: Works only after the link tilt float switch is pressed.

Table 5. VDC controls (continued)
Control/Indicator
Name Description and Function
11 DRILL/SPIN,/ There are three switch positions: DRILL, SPIN, and
TORQUE switch TORQUE. The switch is in the DRILL mode during normal
drilling. SPIN mode is a fixed speed of the AC drilling
motors. TORQUE mode is a slower fixed speed of the AC
drilling motors. It generates a gradual increase in torque to the
make-up limit.
12 EMERGENCY STOP Emergency stop shuts down all operations. Emergency stop
switch switch is hardwired to the VFD. Pressing the stop button
deselects the drive and sets the brake, causing the top drive
rotation to stop regardless of throttle position. Auxiliary
cooling motors remain on.
13 IBOP switch Activates the upper IBOP valve. Turning the switch to the left
retracts the IBOP actuator cylinder to close the valve. Turning
the switch to the right extends the cylinder to open the valve.
14 LINK TILT FLOAT The links “float” to the center (NEUTRAL) position when the
pushbutton is depressed.
15 LINK TILT switch Activates the link tilt cylinder. The center position is OFF;
turning the switch to the left extends the cylinder to the
mousehole; and turning the switch to the right retracts the
cylinder for drill down. This is a maintained switch that holds
the position of the cylinder when returned to OFF.
16 MAKE-UP CURRENT A potentiometer sets the torque limit in the VFD when using
LIMIT Potentiometer the top drive to makeup connections. Torque is displayed on
the torque meter. Adjust the torque by setting the brake and
turning the potentiometer to increase or decrease the torque.
17 REVERSE /OFF/ There are three switch positions: OFF, FORWARD, and
FORWARD switch REVERSE. In the OFF position, the top drive cannot
operate. FORWARD and REVERSE are used when drilling
or making/breaking connections. This switch acts as the drive
assignment.
18 TORQUE WRENCH Pushing this button engages the pipe clamp and shot pin lock.
PUSH & HOLD The rotating head rotates until the shop pin engages. The pipe
switch clamp operates after the shot pin is engaged.
19 HYDRAULIC POWER Turns the tool hydraulics on or off.
20 PURGE LOSS Indicates that the VDC has lost purge pressure.
21 RPM meter Displays the rpm of drill pipe.
23 THROTTLE Controls the speed of the AC drilling motors. Motor rpm is

displayed on the rpm meter.
24 TORQUE meter Displays the drill pipe torque in ft lb.

March 2, 1998
Correcting a drive fault

When a drive fault occurs, the brake automatically sets regardless
of the brake switch position. The brake sets at less than 5 rpm.
Use the following procedure to release the brakes and unwind the
drill string torque in a controlled operation.
Drive fault while drilling

1. Turn the brake switch on, if it is not already there. This sets
the top drive brakes and keeps the drill string from rotating.
2. Rest the drive. If there is torque build up on the string, open
the throttle. The torque meter indicates the preset drill torque
limit. If the torque meter reading is different from the drill
torque limit prior to the drive fault, readjust the drill torque
limit before releasing the brake.
3. Turn the brake control switch off to release the brakes.
4. Rotate the drill torque limit control slowly to unwind the drill
string torque.
5. If the drive does not reset and there is torque build up in the
drill string, toggle the brake switch from on to off repeatedly.
This releases a little torque each time, until it is safe to
completely release the brakes.
e The top drive must not be deassigned (hydraulic pump and blower
motors running) for more than 10 minutes to maintain maximum
braking. Brakes are applied by hydraulic caliper pressure actuated by
accumulator pressure. When the hydraulic pump is off, the
accumulator pressure drops due to normal system leakage, resulting in
a decrease in braking. The decrease in braking is gradual until the
accumulator precharge pressure is reached. If the drill string torque is
low, there may be noticeable rotation due to a gradual decrease in
braking since the required brake holding pressure is low. In this
situation, the brakes release once hydraulic pressure reaches the
accumulator precharge pressure.

Drive fault while making up
1. Turn the brake switch on, if it not already there. This sets the
top drive brakes and keeps the drive stem from rotating.
2. Toggle the brake switch from on to off repeatedly. This
releases a little torque in the drive stem each time until there
is slack in the back-up tong line and it is safe to completely
release the brakes.
n Floor hands should stay clear of back-up tong and long line
during this operation due to the possibility that a sudden release
of torque might cause the tong to recoil and fall to the floor.

March 2, 1998

Chapter 3
Maintenance
The following chapter contains the TDS-10S Control System

maintenance guide.
Maintaining the control system

Refer to the following documentation for maintenance
information:
❏ Periodic control system maintenance schedule (Table 6)

❏ Preoperational checklists (Chapter 2)
❏ PLC manufacturer’s manual
❏ VFD manufacturer’s manual

March 2, 1998
Table 6. Periodic control system maintenance schedule
Location Procedure Interval

Indicator lamps Test using the lamp test switch on the Daily
VDC.
Heater Check operation with an ohmmeter. Monthly
High voltage Check for discolored or brittle Monthly
connections insulation. Monthly
Check retaining bolt torque (25 ft lb).
Component Check fastener tightness, especially in Monthly
mounting vibration-prone areas.
Seals and gaskets Check for integrity. Monthly

Troubleshooting
The figures in the subsequent pages show the following PLC
modules during normal operations:
❏ S7-300 CPU (Figure 5)

❏ Input module (Figure 6)
❏ Output module (Figure 7)
❏ Remote I/O (Figure 8)
CPU315-2 DP
SF
BATF BUSF
DC5V
Status and fault LEDs FRCE
RUN
STOP Memory card

receptacle
RUN-P
RUN
Mode Selector
STOP
MRES
Battery Compartment
MPI port
Jumper (removable) M PROFIBUS-DP

L+
DC
interface
Terminals for M 24V
power supply and
functional ground
X1 MPI X2 DP
(Cover removed for clarity)
Figure 5. S7-300 CPU during normal operations

March 2, 1998
RUN
BF
DIA
ET 200B -4AI
0 1
RUN STOP
Figure 6. Input module during normal operations
RUN
BF
DIA
ET 200B -4AO
0 4
RUN STOP
Figure 7. Output modules during normal operations

RUN
BF
DIA
0 5
RUN STOP
Figure 8. Remote I/O during normal operations

March 2, 1998
VFD
The VFD has an LCD panel that can be used for troubleshooting
(Figure 9).
Output current 15,2A 120V Output voltage

Actual value # 14.00Hz
Setpoint * 14.00Hz
Mode number °014=Operation Mode name
Fault
Run
Jog 7 8 9
4 5 6
1 2 3
0 +/- Reset
Figure 9. LCD panel

TDS-10S
Top Drive
Drilling
System
Supplemental
Material
March 2, 1998
2 TDS-10S Supplemental Material

Contents
Supplemental Material
Supplement list ................................................................ 8-5
TDS-10S Supplemental Material 3

March 2, 1998

Supplemental
Material
Supplement list
This chapter contains the following supplements:
❏ Design Specification, Design Torque Standard (DS00008)

❏ IBOP Service Manual
TDS-10S Supplemental Material 5

March 2, 1998

Safety Valve
(IBOP)
Service Manual
® ™
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
i
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the driller’s console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
1
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Splined Adapter
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
2
Feb. 2, 1994
Link Rotating
Tilt Head (Ref.)
Link
Adapter
Torque
Arrestor
V
Link a
r
Splined Adapter c
o
Support
Upper Plate
Safety
Valve
Safety Valve
Actuator Torque
350 Ton Wrench
108" Links
(Ref.)
Plain Lower
Safety Valve
Saver
350 Ton
Sub
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
N
OPE
Back-up
CL SD
Rings
O-Ring
O-Ring
Ball
Sleeve
Seal Ring Stabilizer

Ring
Crank
Grease/
Mud Seal
Seat
Wave Thread
Spring Protector
Back-up Ring
O-Ring
Figure 3. Typical Upper Safety Valve (IBOP)
4
Feb. 2, 1994
PH-60 IBOP/Actuator Upgrade Kit
Introduction
Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing
PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both
as a primary safety valve and as a mud saver while drilling ahead.
Maintenance and operating costs will be greatly reduced, allowing a minimum planned
maintenance interval of six months for the upper IBOP.
PRINCIPLE FEATURES
❏ The upper IBOP valves (2 ea.) are equipped with:

• PH-85 style dual-path operating systems
• New low-stress inside body contours
• Completely redesigned long-life internals
❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides.
❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
❏ The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, grease-
packed, and completely isolated from mud caking and corrosion to ensure full bore opening.
5
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Aug. 9, 1993. A.N.
Figure 4. PH-60 Upgrade Kit
6
Feb. 2, 1994
Remote IBOP Actuator Improvements
(Refer to Drawing 99261 in the Appendix)
1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%
larger piston area ensures positive, complete ball rotation under the most arduous conditions.
A 60% increase in available cylinder stroke eliminates the need for sensitive position
adjustments, both at initial rig-up as well as over the life of the system.
2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current
multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable)
guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides
directly on the IBOP outer diameter. The new design is very robust, requires no adjustments,
and is able to withstand punishing environments without damage.
3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This
change reduces the operating and environmental forces on the internal and external components
by 50%. It also provides a balanced reaction force to the actuating levers. This force balance
allows elimination of the bolt-on guide roller assemblies.
Each of the two external crank housings is anchored to the IBOP body with 1/2" screws
instead of the 3/8" screws used in the previous design. The crank housings are also secured
to react the ball stop torque using a close-tolerance fit between the base of the housing and
the machined recess in the IBOP valve body. When required, jacking screws make removing
the housings easier.
7
Feb. 2, 1994
Internal Valve Mechanism Improvements
1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They are
replaced with a smooth bore through the ball and seat region. This significantly lowers the
maximum stress in the valve body and effectively eliminates the possibility of leaks caused
by cracking at the crank bores under corrosive mud conditions.
2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball
rotation stop in the previous design. The crank was easily replaced, but the body was not
repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over
extended use could eventually allow the ball to over-travel, leading to washouts.
In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal
cranks (2) and external crank housings (2) need replacement should they ever become worn.
The external crank housings in the new design serve as the ball rotation stops. Each external
crank housing has two struts which contact the internal crank to stop the ball precisely at the
open or closed position. The torque required to stop the ball is then shared by four surfaces
rather than the previous design’s single surface.
The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated
regions beneath the external cranks. This eliminates the presence of caked drilling fluid
around the stop mechanism and is more reliable.
3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,
the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and
locating components, decreasing wear and eliminating mechanical failure.
8
Feb. 2, 1994
INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
5. Screw the stem/main shaft and upper IBOP together.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
a. Torque up to the recommended torque value (Table 1).

b. Back off the connection and inspect the threads and face.
c. Torque up to the recommended torque value (Table 1).
9
Feb. 2, 1994
Table 1. Make-Up Torque Values
Torque (ft-lb)
Components I.D. Connection O.D. (min.) (max.)
Mainshaft to Upper 3" 6-5/8 API Reg. 7-3/4 60,000 70,000

IBOP Safety Valve*
Upper IBOP Safety 3" 6-5/8 API Reg. 7-3/4 50,000 70,000
Valve to Lower
IBOP Valve
Lower IBOP Valve 3" 6-5/8 API Reg. 7-3/8 46,000 64,000
to Saver Sub
Crossover Sub to 3" 6-5/8 API Reg. 7-3/8 46,000 60,000

Lower IBOP Safety
Valve
Mainshaft to Upper 3" 7-5/8 API Reg. 9 83,000 91,000

IBOP Safety
Valve**
Upper IBOP Safety 3" 7-5/8 API Reg. 9 75,000 91,000

Valve to Lower
IBOP
Lower IBOP Valve 3" 7-5/8 API Reg. 8-5/8 66,000 85,000
to Saver Sub
Crossover Sub to 3" 7-5/8 API Reg. 9 75,000 91,000

Lower IBOP Valve
* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a. Carefully grind off any raised tong marks on the O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of the actuator).
c. Orient the levers on the crank assemblies horizontally as shown.
d. Slide the shell up onto the valve with the actuator arm groove on the bottom.
e. Hold the shell in position relative to the valve operating sockets.
f. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90° of crank travel.
10
Feb. 2, 1994
Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90° of crank travel.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Lock Tabs Groove
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
7/8" Allen Crank
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Crank
Crank Assembly Assembly
Roller Retaining Screw
Assembly (3)
Slot
Roller
Assembly
Actuator (3)
Shell
Crank*
Roller
Assembly (3) Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Open Closed
Position Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the driller’s console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
16
Feb. 2, 1994
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
1. Breakout and remove the lower IBOP.
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
4. Re-assemble the valves.
5. Reinstall and torque the lower valve.
Figure 9. Lower IBOP Seal Removal
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
1. To verify the integrity of the grease seal.
2. To lubricate the floating seat.
3. To flush mud and debris from the spring cavity.
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly —
the valve should be serviced.
2. Install a suitable grease fitting.
3. Open the valve.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT BALL

C C
Figure 10. Lubricating a Typical Upper IBOP
L L
FLOATING
SEAT
19
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
WAVE SPRING
FIXED SEAT BALL
Figure 11. Lubricating a Typical Lower IBOP

C C
L L
FLOATING
SEAT
20
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
PRESSURE PLUG
Feb. 2, 1994
GREASE PORT
Feb. 2, 1994
INSPECTION
Magnetic Particle Inspection

After approximately three to six months (depending on the severity of operating conditions)
Varco recommends performing a Magnetic Particle Inspection of all load bearing components
– including IBOPs – over their entire surface and internal bores to reveal any fatigue or crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic Particle
Safety Valve Inspection Procedures

Upper and lower safety valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack
may begin at the root of the pit.
Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH
levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse
cracks every three to six months, depending on the severity of the exposure.
Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be
hidden under corrosion products. Use the magnetic particle inspection procedure.
Concentrate attention on (Figure 12):

❏ The area inside the operating crank window
❏ The fillet radii of internal grooves and shoulders
❏ The last engaged threads of box connections
❏ The IBOP actuator shell
21
Feb. 2, 1994
Recommended
Inspection Areas
Figure 12. IBOP Inspection Points
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.
VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of the
mechanism and to minimize mechanical component wear. The actuator shell installs over the
upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the
safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13)
adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator
shell as follows:
1. After removing the crank assemblies, make sure the actuator shell easily moves up and down
over the upper IBOP.
NOTE
There is only one crank on upper IBOPs for the PH-60 pipehandler.
There are also three roller assemblies.
2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.

3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab.
4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check
for signs of binding. Make sure the shell travels freely throughout its full range of travel. If
binding exists, troubleshoot to eliminate any problems before returning to service.
5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders
should retract and the actuator ring should be down.
6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the
cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance
is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch.
7. Actuate the valve to make sure it opens and closes fully.
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Cylinder Adapter
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2) Upper IBOP Valve
Actuator Shell
Upper IBOP Valve
Actuator Air Cylinders (2) Crank Assy(Shown with
Valve OPEN. Note Crank
Assy Position
CLOSE
OPEN
*1 Inch Actuator
Arm
Cylinder
Gland Upper IBOP
Cylinder Rod
in OPEN End
Position Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &
Single Crank PH-60
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13 19
2 17 6 1 10 18 5 14 15
20 7 16
8
2X 4
9
12
11
12 7/8" Hex
Note: Dual Crank Remote IBOP Shown
Single Crank Remote and Lower IBOP
have similar construction.
Figure 14. IBOP Safety Valve Illustrated Parts List
25
Feb. 2, 1994
Parts List
ITEM DESCRIPTION PART NUMBERS QYT. / KIT
1 BALL, DUAL CRANK (SET) 90939-5 1 1 - 1
2 RETAINING RING 89141-1 1 1 -
3 O'RING 90441-9 1 1 1
4 BACK-UP RING 90441-10 1 1 1
5 LOWER SEAT (SET) 90939-5 1 1 - 1
6 UPPER SEAT (SET) 90939-5 1 1 - 1
7 POLYSEAL 96439 1 1 1
8 BACK-UP RING 89141-13 2 2 2
9 CROWN SEAL 89141-8 1 2 2
10 SLEEVE 90441-7 (93806-12 for Dual Crank) 1 2 -
11 O'RING 89141-11 1 2 2
12 BACKING RING 89141-12 2 4 4
13 CRANK, RIGHT HAND 89141-7 (93806-10 for Dual Crank) 1 1 -
14 WAVE SPRING 89141-9 1 1 -
15 BODY - - -
16 O'RING 89141-3 1 1 1
17 NYLON PLUG 2 2 2 2
18 CRANK, LEFT HAND 93806-11 - 1 -
19 PLUG 1 1 -
20 SEAL RING STABILIZER 96438 1 1 1
REPAIR KIT - SINGLE CRANK

Refer to the Appendix for Part Numbers
REPAIR KIT - DUAL CRANK

REPAIR KIT - SOFT SEAL ONLY

(For either Single or Dual Crank)
BALL/SEAT SET
Figure 14. IBOP Illustrated Parts List (Cont.)
26
Feb. 2, 1994
Shop Assembly and Disassembly
The following tools are required (Figure 15):

Crank wrench Varco Part No. 77408
Seat puller Varco Part No. 79489-14
Nut wrench (for internal nut) Varco Part No. 89141-18
Bushing installation tool
Open end or adjustable wrenches
Two large flat screwdrivers or light pry bars
1/4" and 3/4" allen wrenches
Pipe vise or suitable holding device to hold valve secure
Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or
mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,
but also serves to loosen internal components. Follow these general rules while working on the
valve:
1. Take proper precautions while working with the components of the valve to make sure
precision matched surfaces and seal contact surfaces are not damaged.
2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts
as they are removed.
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Seat Puller For All Models Nut Wrench for DSV Models
Varco Part No. 79489-14 Varco Part No. 89141-18
7/8" Hex Wrench For All Models

Varco Part No. 89141-18
Figure 15. IBOP Tools
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or

clamp to hold the valve
securely (Figure 16).
Figure 16
2. Engage the seat puller in

the inside groove of the
lower seat (Figure 17).
3. Using the load bar across

the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).
Figure 17
28
Feb. 2, 1994
4. At the other end of the

valve, insert the upper seat
wrench, P/N 89141-18, into
the upper seat engaging the
wrench lugs into the mating
slots (Figure 18).
5. Using the crank wrench,

P/N 77408, as a lever in the
hole provided in the upper
seat wrench, rotate the
upper seat clockwise until Figure 18
it stops (Figure 18).
6. Remove the wrench.
7. Remove the retainer ring

from the groove in the valve
body by using a screwdriver
to pry one end of the retainer
ring out of the groove. The
ring can then be removed
by hand (Figure 19).
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat

counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the

upper seat (Figure 20).
Figure 20
29
Feb. 2, 1994
11. Remove the ball valve

(Figure 21).
Figure 21
12. From the outside of the

valve, push the crank into
the valve body and remove
them (Figure 22).
Figure 22
13. Remove the pulling tool

from the lower seat.
14. Insert the pulling tool from

the opposite end of the
valve and engage the
groove on the I.D. of the
Figure 23
30
Feb. 2, 1994
15. Using the load bar across

tighten the nut against it to
remove the lower seat and
the wave spring (Figures
24 and 25).
16. Remove and discard the

seals from all IBOP
components.
17. Thoroughly clean and

inspect each item.
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
1. Inspect the lower seat.

Look carefully for signs of
corrosion, pitting and
gaulling – especially in the
sealing areas (Figure 26).
2. Make sure the wave spring

is not broken or damaged
(Figure 26).
3. Inspect the steel stabilizer

ring, making sure it is not
worn, pitted or damaged
(Figure 26).
Figure 26
4. Replace all O-rings, backup
rings and seals (Figure 26).
5. Install the steel stabilizer

and seal on the lower seat
(floating seat), by placing
the steel stabilizer in the
groove of the U-cup seal
and, starting on one side of
the seat, work the stabilizer
and seal around the seat
using a screw driver (Figure
27).
NOTE
The steel stabilizer ring
should be inside the seal
when properly installed.
Figure 27
32
Feb. 2, 1994
6. Install the wave spring on

the lower seat (Figure 28).
Figure 28
7. Inspect the ball valve for

corrosion, pitting and
gaulling (Figure 29).
Figure 29
33
Feb. 2, 1994
8. Install new nylon plugs on

the upper stationary seat
(Figure 30).
Figure 30
9. Make sure the snap ring is

not broken or damaged
(Figure 31).
Figure 31
34
Feb. 2, 1994
10. Make sure the crank

assembly notches are not
worn and there is no pitting
on the outside (Figure 32).
Check for a sliding fit with
the slots in the ball.
11. Install the seals on the crank

assembly.
12. Inspect the crank sleeve for

wear and washouts.
Replace as necessary.
Figure 32
13. Thoroughly lubricate the

valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the Figure 33
pulling tool until it seats on
the spring surface of the
17. Insert the threaded rod of
the pulling tool first into
the box opposite the splined
end of the upper valve,
pulling the lower seat into
place in the valve body
(Figure 33).
35
Feb. 2, 1994
18. Using the load bar against

tighten the nut to firmly
seat the lower seat in the
valve body (Figure 34).
Figure 34

grease to the outside of the
sleeve and crank.
20. From the inside of the valve

body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).
Figure 35
21. Make sure the crank moves

90° to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the

Closed position.

grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).
Figure 36
36
Feb. 2, 1994
24. Slide the ball onto the crank

inside the valve body. The
keyway must be in the
Closed position, or parallel
to the key of the crank.

grease to the outside threads
and seal of the upper seat.
26. Insert the upper seat into

the valve body, engaging
the threads (Figure 37). Figure 37
27. Insert the upper seat wrench

into the mating slots of the
upper seat.
28. Rotate the wrench

clockwise until the upper
seat sets firmly against the
ball.
29. Remove the upper seat

wrench and install the
retainer ring firmly into the
groove of the body (Figure
Figure 38
38).
30. Insert the upper seat wrench
into the mating slots of the
upper seat.
31. Rotate the upper seat

counterclockwise until the
seat is firmly against the
retainer ring.
32. Remove the puller and use

an allen wrench to make
sure the valve functions
properly.
33. Leave the valve in the Open

position.
34. Remove the wrench.
37
Feb. 2, 1994
35. Grease the valve through

the pressure plug until
grease extrudes from inside
the valve (Figure 39).
NOTE
The grease pressure should not exceed
300 psi. Excess pressure can cause the
mud/grease seal to extrude.
Figure 39
36. Install the 1/4" N.P.T. plug

into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.
38
Feb. 2, 1994
IBOP VALVE TESTING IN THE SHOP
Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test
pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the
following procedure to test IBOPs:
1. Rotate the valve crank to the Open position.
2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug
in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve
to the plug in the opposite end.
3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for
lower IBOP) with the ball and the bleed valve in the Open position.
4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,
but using water increases the liklihood of corrosion in the valve body—especially when the
valve is not in use for a prolonged period of time.
NOTE
Open and close the valve five times to release trapped air and
overflow through the bleed valve for approximately 30 seconds to
assure complete filling of the valve cavity.
5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed
position.
6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus
1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.
7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic
test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper
IBOP, box end up for lower IBOP).
8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP
(pin end of the lower IBOP).
9. Fill the valve cavity with water while rotating the ball full open to closed five times to release
trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working
pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the
duration of the test.
10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to
insure smooth operation.
11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is
acceptable.
12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to
release trapped fluid. When testing with water, coat the valve internals with a preservative
to prevent oxidation and install thread protectors.
39
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP TYPE OF REPAIR KIT SOFT SEALS BALL/SEAT

PART NO. SERVICE DESCRIPTION PART NO. PART NO. PART NO.
94769-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5

94769-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94769-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94770-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5

94770-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94099-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5

94099-501 NAM Landing Collar Design 90939-2 90939-1 90939-5
94100-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5

94100-501 NAM Landing Collar Design 90939-2 90939-1 90939-5
90815 STD Upper Valve - PH85 93806 93806-1 90939-5
- H2S 6 5/8 Box X 6 5/8 Box (Spl End) - - -
- NAM Land Collar Design - - -

- NAM Load Collar Design - - -

94206-500 STD Upper Valve - PH85 93806 93806-1 90939-5

94206-502 NAM Landing Collar Design 93806 93806-1 90939-5

40
Feb. 2, 1994
IBOP Part Numbers (Cont.)

IBOP TYPE OF REPAIR KIT SOFT SEALS BALL/SEAT
PART NO. SERVICE DESCRIPTION PART NO. PART NO. PART NO.
91138 STD Upper Valve - PH85 - Big Bore 95384 91137-SP 91137-1
89451-501 STD Lower Valve 90939-2 90939-1 90939-5

89491-503 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15
86434 NAM
89452-501 STD Lower Valve-Stepped 90939-2 90939-1 90939-5
89492-502 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15
- NAM 90939-2 90939-1 90939-5
90811 STD Lower Valve 93807 93807-1 90939-5
- H2S 7 5/8 Pin X 7 5/8 Box - - -
- NAM - - -
91138 STD Lower Valve - Big Bore 94385 91137-SP 91137-1

- H2S 7 5/8 Pin X 7 5/8 Box - - -
- NAM - - -
105629 STD Upper Valve - Type "E" - - 90939-5
- H2S 6 5/8 Pin X 6 5/8 Box - - - -
- NAM For Ids Only - - -
103220 STD Upper Valve - Type "E" 90939-2 90939-1 90939-5
- H2S 6 5/8 Pin X 6 5/8 Box - - -
- NAM For TDS and SDS - - -
98977-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
98977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
98977-501 NAM Landing Collar Design 99468-2 99468-1 65170014
99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
NAM Landing Collar Design 99468-2 99468-1 65170014
41
Feb. 2, 1994
Identifying Varco Safety Valves
42
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46
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TDS-10S

z Note: Indicates advisories for operational or servicing procedures

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

n Warning: Indicates advisories involving a definite risk of injury

Avoid personal injury and equipment damage by reading this

Book 1 – Description, Installation and Operation

TDS-10S Contents iii

Chapter 2 Maintenance schedules

Chapter 7 Disassembly and assembly

TDS-10S Contents vii

Book 3 – Control System

Book 4 – Supplemental Material

viii TDS-10S Contents

2 TDS-10S Service Manual

TDS-10S Service Manual 3

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

4 TDS-10S Service Manual

z Indicates advisories for operational or servicing procedures

e Indicates advisories involving a risk of equipment damage.

n Indicates advisories involving a definite risk of injury to rig

TDS-10S Service Manual 5

Avoid personal injury and equipment damage by reading this

Varco service centers

6 TDS-10S Service Manual

Introduction to the TDS-10S

TDS-10S Service Manual 7

8 TDS-10S Service Manual

TDS-10S major components

❏ Motor housing and swivel assembly

TDS-10S Service Manual 9

Motor housing and swivel assembly

❏ Transmission and swivel housing

Transmission and swivel housing

10 TDS-10S Service Manual

Drilling motor and brakes

TDS-10S Service Manual 11

Motor cooling system

12 TDS-10S Service Manual

Disk Brake Housing

Intake Air Flow

Exhaust Air Flow

Figure 1. TDS-10S motor cooling system

TDS-10S Service Manual 13

Carriage and guide beam

❏ Powered rotating link adapter

❏ Elevator links and drill pipe elevator

Powered rotating link adapter

14 TDS-10S Service Manual

Torque backup clamp cylinder

TDS-10S Service Manual 15

Bidirectional link tilt

16 TDS-10S Service Manual

All dimensions are true for

* At Monkey Board level (80')

CL Well Drill Floor

Figure 2. Bidirectional link tilt positions

TDS-10S Service Manual 17

Internal blowout prevention

18 TDS-10S Service Manual

Tool Joint Lock

Upper IBOP Actuator Cylinder

Tool Joint Lock

Manual Lower IBOP Torque Arrestor Frame