TDS-11SA

Top Drive System

Top Drive System

Contents
LUBRICATION
Major Components .......................2
Maintenance Schedules ...............6
Lubricants ...................................12
Lubrication Points ......................13

MAINTENANCE AND SPARES

Consummables ...........................23
Wash Pipe Assembly .................24
Making Up the Drill Stem ...........28

GENERAL INFORMATION
Torque Values .............................30
Service Centers ..........................32
Specifications .............................34
 TDS-11SA Top Drive TDS-11SA Top Drive
Major Components Major Components
Counterbalance
Assembly

AC Motor
Blower
Assembly

AC Motor
S-Pipe
Brakes

Wash Pipe
AC Drilling Assembly
Motors Hydraulic
System

Gearbox
Gearbox Assembly
Lubrication
Pump
Assembly

Carriage

Pipehandler
Assembly Elevator
Links Guide Beam

LUBRICATION
LUBRICATION

Elevator

2 3
 PH-50 Pipehandler PH-75 Pipehandler
Major Components Major Components

Rotating
Rotating Link
Link Adapter
Adapter

IBOP
IBOP Actuator Yoke
Actuator Yoke and Cylinder
and Cylinder

Link Tilt
Link Tilt
Well Control
Well Control System
System
Stabilizer
Stabilizer

Clamp
Clamp Cylinder
Cylinder Body Stabbing
Body Stabbing Guide
Guide

LUBRICATION
LUBRICATION

Elevator Elevator
Elevator Elevator Links
Links

4 5
 TDS-11SA Maintenance TDS-11SA Maintenance
Round Trip Schedule Daily Schedule
No more than once daily, Or after 8 hrs drilling
no less than once weekly
∆ ∆
Item Points Lubrication Item Points Lubrication
Drill Pipe Elevator Various Grease Wash Pipe Assy* 1 Grease
Power Slips Various Grease IBOP Actuator Cranks 2 Grease
RBS Various Grease IBOP Actuator Yoke and 5 Grease
Cylinder Pins
Stabilizer Bushing 4 Grease
Item Inspect for Action Clamp Cylinder Gate 2 Grease
Pipe Handler Worn or Broken Brush Clean or
Dies Replace as Necessary Item Inspect for Action
RBS Worn or Broken Brush Clean or TDS Motor Loose Bolts, Repair or
Dies Replace as Necessary Assembly Fittings, Safety Wire Replace as
Wireline Worn or Broken Replace as Necessary Pins, and Cotter Pins Necessary
Adapter Sheaves Pipe Handler Loose Bolts, Repair or
Fittings, Safety Wire Replace as
These round trip activities should take Pins, and Cotter Pins Necessary
approximately 10 minutes to perform Upper/Lower Proper Repair or
IBOP Valves Operation Replace as
∆Unless otherwise specified, apply Necessary
two pumps of grease where noted TDS Leaking Hoses, Repair or
Connectors and Replace as
Wash Pipe Necessary
Alignment Directly Adjust as
Safety Considerations Over Well Center Necessary
Carriage and Missing, Loose or Replace as
Top Drive maintenance requires personnel Guide Beams Damaged Retainer, Necessary
Lynch and Detent Pins
working at height and there exists the potential
for injury or dropped objects. TDS Controls* Verify Operation Repair or
Replace as
Necessary
Complete all appropriate job safety analysis
Hydraulic and Indicator Replace as
(JSA), permits, and crew safety briefings Gear Oil Filters Pop-up Necessary
immediately prior to each maintenance activity
LUBRICATION

LUBRICATION
Gear Oil and Proper Fill as
or session. If, at any point during the Hydraulic Fluid Levels Necessary
maintenance session, the planned activities
change for any reason, review the job safety These daily activities should take
requirements again to ensure the crew involved approximately 20 minutes to perform.
is aware of the changes in activities. Ensure all ∆Unless otherwise specified, apply
appropriate personal safety equipment is in
two pumps of grease where noted.
good condition and used when necessary.
* High priority and must be completed daily.
6 7
 TDS-11SA Maintenance TDS-11SA Maintenance
Weekly Schedule Weekly Schedule
Or after 60 hrs drilling Or after 60 hrs drilling

∆
Item Points Lubrication Item Inspect for Action
Upper Bonnet Seal 1 Grease Service Loops Damage, Abrasions Repair or Replace
Bail Pins 2 Grease and Snag Points as Necessary
Rotating Link Adapter Gear - Grease AC Motor Louvers Damage and Repair or Replace
and Screens Contamination as Necessary
Rotating Link Adapter 2 Grease
† Link Tilt Clamps Position and Adjust
Upper IBOP Valve 1 Grease
Tightness as Necessary
Carriage Assembly 4 Grease
Stabbing Guide Damage and Repair or Replace
Wireline Adapter 2 Grease and Flippers Wear as Necessary
Elevator Link Eyes 4 Pipe Dope Stabilizers Wear Replace
Torque Arrestor (PH-50) 4 Grease as Necessary
at Clamp Cylinder IBOP Actuator Leaks and Repair or Replace
Cylinder Tight Fittings as Necessary
∆Unless otherwise specified, apply IBOP Actuator Wear and Replace or Adjust
two pumps of grease where noted Rollers Excessive Play as Necessary
Tool Joint Locks Loose Bolts Adjust
†Remove 1/4" NPT plug, install grease fitting as Necessary
and apply ten pumps of grease Upper and Damage Repair or Replace
Lower IBOPs as Necessary
Carriage, Guide Missing, Loose or Replace
Beams and Damaged Nuts, Joint as Necessary
Tiebacks and Cotter Pins
Damaged Welds Repair
as Necessary
Carriage Rollers Damage, Wear Replace
or Looseness as Necessary

These weekly activities should take

approximately 20 minutes to perform
LUBRICATION

LUBRICATION
8 9
 TDS-11SA Maintenance TDS-11SA Maintenance
Monthly Schedule Quarterly Schedule
Or after 250 hrs drilling Or after 750 hrs drilling

Item Inspect for Action Item Points Lubrication

Main Body Flow of Oil (with Clean or Replace Gearbox Oil Filter 1 Replace
Lube Pump Running) as Necessary Hydraulic System Filter 1 Replace
S-Pipe Pitting, Corrosion Repair or Replace AC Drilling Motor 4 Motor Grease
or Erosion as Necessary Blower Motor 4 Motor Grease
Upper Erosion Caused by Replace Hydraulic Pump Motor 2 Motor Grease
Mainshaft Liner Leaking Wash Pipe as Necessary
Upper Bearing Wear on O-Ring, Oil Replace
Retainer Seal, Bearing Isolator as Necessary
Blower Motor Loose or Adjust or Replace
Assemblies Missing Bolts as Necessary
Brake Pads Wear Replace Semi Annual Schedule
as Necessary
Or after 1500 hrs drilling
Elevator Wear Repair or Replace
Link Eyes as Necessary
Link Tilt Wear Replace Item Points Lubrication
Bushings as Necessary Gearbox Oil 1 Replace and
Link Tilt Actuator Wear Replace Perform Analysis
Cylinder Clevis Pins as Necessary Hydraulic System Fluid 1 Perform Analysis
IBOP Actuator Excessive Play Adjust or Replace
Yoke or Wear as Necessary
Shot Pin Wear or Repair or Replace
Assembly Damage as Necessary
Crown Padeye Damage or Repair
and Guide Cracks on Welds as Necessary
Beam Joints
Hang-Off Link, Missing Cotter Replace
Bolt and Shackle and Safety Pins as Necessary
Assemblies Wear on Replace
Shackle or Bolt as Necessary
Wear on Hang- Repair or Replace
LUBRICATION

LUBRICATION
Off Link Bores as Necessary

These monthly activities should take

approximately 45 minutes to perform
(plus daily and weekly activities)

10 11
 TDS-11SA Maintenance Lubricants
Annual Schedule Mfr. General Purpose Grease
Ambient
Or after 3000 hrs drilling Temperature
Range
Below -20 C
(Below -4 F) ˚
˚
Above -20 C
(Above -4 F)
˚ ˚
Item Points Lubrication Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Hydraulic System Fluid 1 Replace Annually
or Earlier Based on Exxon Lidok EP1 Lidok EP2
Analysis Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Item Inspect for Action Statoil Uniway EP1N Uniway EP2N
Magnetic Contamination Clean and Replace Texaco Multifak EP1 Multifak EP2
Drain Plug as Necessary Total Multis EP1 Multis EP2
Gear Teeth Pitting, Wear Replace as Union Unoba EP1 Unoba EP2
and Backlash Necessary
Gearbox Wear or Repair or Replace Viscosity Index
Lubrication Pump Damage as Necessary NGLI 1 2
Mainshaft Axial Adjust
Movement as Necessary Mfr. Gear Oil
Bail, Bail Pins Wear Replace Ambient
and Bushings as Necessary
Temperature
Range ˚˚
-6 to 16 C
˚
(20 to 60 F)˚ ˚˚
7 to 30 C
(45 to 85 F)˚˚ Above 21 C
(Above 70 F) ˚
˚
Mainshaft Stem Wear or Pitting on Replace
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
and Load Collar Radial Grooves as Necessary
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Motors Meggar
Rotating Link Pitting or Chipping Replace Exxon Spartan EP68 Spartan EP150 Spartan EP320
Adapter on Piston Ring as Necessary Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Pitting, Grooves or Replace Mobil MobilGear 626 MobilGear 629 MobilGear 632
Chipping on Stem as Necessary Shell Omala 68 Omala 150 Omala 320
GLYD Rings, Replace Statoil Loadway EP68 Loadway EP150 Loadway EP320
O-Rings and Bushings
Texaco Meropa 68 Meropa 150 Meropa 320
Hydraulic Wear or Replace
Total Carter EP 68 Carter EP 150 Carter EP 320
Reservoir Damage as Necessary
Bladder or Every 2 Years Union Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Viscosity Index
5 Year shop overhaul - contact
LUBRICATION

LUBRICATION
service center for details NGLI N/R N/R N/R
AGMA 2EP 4EP 6EP
ISO 68 150 320
Viscosity
Grade

Mfr. Motor Grease

Shell Cyprina RA (All Temperatures)
12 13
 Gearbox Lubrication Inspecting Internal
Lubrication Flow

Upper
Gearbox Compound
Oil Fill Gear
Drain Hole
Gearbox
Oil Drain

Spillway

Gear Oil
Sight
Gauge

LUBRICATION
Body Spray
Nozzle,
Gear Oil Cover
Filter Nozzles Not
Pipe Plug Shown
Magnetic
Drain Plug

14 15
 Hydraulic Lubrication Motor Lubrication
AC Blower
Motor

AC Drilling
Motor
Hydraulic
Oil Filter

Hydraulic
Oil Sight
Gauge

Hydraulic
LUBRICATION

LUBRICATION
Oil Fill

Hydraulic
Pump
Hydraulic AC Motor
Oil Drain

16 17
 TDS-11SA Grease Points PH-50 Pipehandler
Grease Points

Upper
Bonnet
Seal
IBOP
Actuator
Wash Cylinder Pins
Pipe
Assembly IBOP
Actuator Yoke

IBOP
Actuator Cranks

Torque
Arrestor Tubes

Rotating Stabilizer
Link Bushing
Adapter
LUBRICATION

Bail Pins

LUBRICATION
Gear
Upper Clamp
IBOP Valve Cylinder
Gate

Rotating
Link Adapter Elevator
Link Eyes
18 19
 PH-75 Pipehandler TDS-11SA Carriage
Grease Points Grease Points
Rollers

IBOP
Actuator Yoke

IBOP
Actuator Cranks

Stabilizer
Bushing

Stabilizer
Bushing

Clamp
Cylinder
Gate
LUBRICATION

LUBRICATION
Upper Elevator
IBOP Valve Link Eyes

Rollers

20 21
 Wireline Adapter Pipehandler
Grease Points Consummables
Typical for PH-50 and PH-75

IBOP Actuator
Cam Followers

Upper IBOP
Valve Seals

Lower IBOP
Valve Seals

MAINTENANCE / SPARES
Saver Sub

Tong Dies
LUBRICATION

Wireline Adapter Guide Flippers

See Technical
Drawing Book
for Varco
part numbers
22 23
 Wash Pipe Assembly Wash Pipe Assembly
Typical Assembly View Reassembly Procedure
1. With the packing box upside down, assemble the
! packing seals and spacers into the packing box using
care to line-up the upper spacer slot with the dowel
The wash pipe nut pin. Install socket head dog hose screw and grease
and the packing fitting.
box have
left-handed 2. Hand pack all seals with multipurpose lithium-based or
threads high temperature moly-based grease using care not to
get grease between the spacers.
3. Install the wash pipe into the packing box assembly
Dowel Slide the
wash pipe nut (slotted end up) until the wash pipe end is flush with
Pin the packing box. Install the wash pipe nut onto the
and the packing
Upper box together wash pipe.
Spacer for installation 4. Lightly grease the packing seal and install into the
holding ring using care not to grease the holding ring.
Middle Hand pack all
Spacer 5. Install the packing seal and holding ring over the
seals with slotted end of the wash pipe.
Lower multipurpose
6. Install the snap ring into the groove on the wash pipe.
Spacer lithium-based or
high temperature 7. Install the upper and lower o-rings using grease to
moly-based grease hold them in place.
completely filling
the void Installation Procedure
1. Apply pipe dope to the threads, then install the wash
Ensure that the nose of the pipe assembly on the Top Drive and hand tighten the
socket head dog nose screw wash pipe nut and packing box.
is fully engaged in the groove of 2. Manually rotate the mainshaft 1 or 2 revolutions to
the lower spacer (screw should seat and align the pipe in the packing box.
not push spacer off center)
3. Set the Top Drive brake.
4. Tighten the packing box first with the wash pipe
wrench, or by hammering a few blows, on every other
lug. Release the brake, turn the mainshaft and
MAINTENANCE / SPARES

MAINTENANCE / SPARES
reset the brake with each blow until the packing box
.010" Min no longer turns (the packing box should tighten at
approximately 3/4 turn or advance 1/4 inch from the
hand tightened position).
The wash pipe should be replaced when any 5. Tighten the wash pipe nut next with the wash pipe
measurable wear or grooving is present. wrench or by hammering gently on a lug (the wash
pipe nut should tighten at approximately 1/4 turn or
Replace upper and middle spacer if I.D. exceeds advance 1/10 inch from the hand tightened position).
spec. 6. Apply 6 to 8 pumps of multipurpose lithium-based or
Small Bore 3.650 high temp moly-based grease to the grease fitting.
Large Bore 4.910 7. Rotate the Top Drive at approximately 50 rpm for 1
minute without mud pumps.
If the packing box is properly tightened, and a 8. Turn on the mud pumps and check for leaks (if leaks
leak is still present, do not attempt to eliminate occur, disassemble and repeat all previous steps).
the leak with additional hammering (See 9. If leaks continue, see the Top Drive service manual
Installation Procedure). for inspection of alignment and runout of mating parts.

24 25
 Wash Pipe Assembly Wash Pipe Assembly
Special Tools
Wash Pipe Wrench Parts Breakdown

Small Bore Big Bore

Recommended for proper 30123290 & 30123440 &
tightening of the wash pipe 30123290-1000 30123440-750
nut and packing box
3" Small Bore O-Ring O-Ring
51300-348-F 51300-359-F
Wash Pipe Wrench
Snap Ring Snap Ring
30150084 30123562 123634
Holding Ring Holding Ring
3.8" Big Bore 30123288 30123437
Wash Pipe Wrench Packing Set Packing Set
141481 (5 per Set) (5 per Set)
123292-2 or 123584-2 or
123292-3 123584-3

Wash Pipe Wash Pipe

Nut Nut
Small Bore Seal Kits (3.0" Bore) 123284 30123431

Part #'s Contents Comments Wash Pipe Wash Pipe

30123290-PK (1) Packing Set 123292-2 Pressure rated at 30123289 30123438
(Standard) (2) O-Rings 51300-348-F 5,000 psi (Use with *30123289-TC *30123438-TC
(1) Grease Fitting 53219-1 Wash Pipe 123289) * High Pressure * High Pressure

30123290-PK-1 (1) Packing Set 123292-3 Pressure rated at

(High Pressure) (2) O-Rings 51300-348-F 10,000 psi (Use only with Packing Box Packing Box
(1) Grease Fitting 53219-1 Wash Pipe 123289-TC) 30123563 123626

Grease Grease
Fitting Fitting
53219-1 53219-1
Socket Head Socket Head
Dog Nose Screw Dog Nose Screw
Big Bore Seal Kits (3.8" Bore) 30123564 30123564

Part #'s Contents Comments

30123440-PK (1) Packing Set 123584-2 Pressure rated at Long-Arm Long-Arm
MAINTENANCE / SPARES

MAINTENANCE / SPARES
Allen Wrench Allen Wrench
(Standard) (2) O-Rings 51300-359-F 5,000 psi (Use with
53303-14 53303-14
(1) Grease Fitting 53219-1 Wash Pipe 123438)
Upper Spacer Upper Spacer
123285 30123434
30123440-PK-1 (1) Packing Set 123584-3 Pressure rated at
(High Pressure) (2) O-Rings 51300-359-F 7,500 psi (Use only with
(1) Grease Fitting 53219-1 Wash Pipe 123438-TC)
Middle Spacer Middle Spacer
30123286 30123435

Middle Spacer Middle Spacer

30123286 13023435

Lower Spacer Lower Spacer

123287 30123436

O-Ring O-Ring
51300-348-F 51300-359-F

26 27
 Drill Stem Drill Stem
Torque Values
Inside Outside Minimum Maximum
Diameter Diameter Torque Torque
(inches) Connection (inches) (ft-lb) (ft-lb)

Crossover Main Shaft to Upper IBOP Valve

Sub 3 6-5/8 API Reg. 7-3/8 42,000 46,000

Upper IBOP Valve to Lower IBOP Valve

3 6-5/8 API Reg. 7-3/8 42,000 46,000

Lower IBOP Valve to Saver Sub

3 6-5/8 API Reg. 7-3/8 42,000 46,000
Upper IBOP
Crossover Sub to Lower IBOP Valve
3 6-5/8 API Reg. 7-3/8 42,000 46,000

IBOP Valve
Actuator
MAINTENANCE / SPARES

MAINTENANCE / SPARES
Lower IBOP

Short Long
Saver Sub Saver Sub

28 29
 Torque Values Torque Values
Bolts Lubricated with Bolts Lubricated with
Light Machine Oil Anti-seize Compound
Grade 5 Grade 5
Min. Max. Clamp Min. Max. Clamp
Threads Torque Torque Force Threads Torque Torque Force
Diameter per inch (ft lb) (ft lb) (lb) Diameter per inch (ft lb) (ft lb) (lb)
Coarse Thread Series, UNC Coarse Thread Series, UNC
1/4 20 7.6 8.4 2020 1/4 20 5.7 6.3 2020
5/16 18 16 18 3340 5/16 18 12.1 13.4 3340
3/8 16 29 32 4940 3/8 16 21.4 23.6 4490
7/16 14 48 53 6800 7/16 14 36 39 6800
1/2 13 71 79 9050 1/2 13 53 59 9050
9/16 12 105 116 11600 9/16 12 78 87 11600
5/8 11 143 158 14400 5/8 11 107 118 14400
3/4 10 247 273 21300 3/4 10 185 205 21300
7/8 9 409 452 29400 7/8 9 306 339 29400
1 8 608 672 38600 1 8 456 504 38600
1-1/8 7 760 840 42300 1-1/8 7 570 630 42300
1-1/4 7 1064 1176 53800 1-1/4 7 798 882 53800
1-3/8 6 1387 1533 64100 1-3/8 6 1040 1150 64100
1-1/2 6 1843 2037 78000 1-1/2 6 1382 1528 78000

Fine Thread Series, UNF Fine Thread Series, UNF

1/4 28 9.5 10.5 2320 1/4 28 7.1 7.9 2320
5/16 24 18 20 3700 5/16 24 13.5 15.0 3700
3/8 24 33 37 5600 3/8 24 25 28 5600
GENERAL INFORMATION

GENERAL INFORMATION
7/16 20 52 58 7550 7/16 20 39 43 7550
1/2 20 86 95 10700 1/2 20 64 71 10700
9/16 18 114 126 12950 9/16 18 86 95 12950
5/8 18 162 179 16300 5/8 18 121 134 16300
3/4 16 285 315 23800 3/4 16 214 236 23800
7/8 14 447 494 32400 7/8 14 335 370 32400
1 14 665 735 42200 1 14 499 551 42200
1-1/8 12 836 924 47500 1-1/8 12 627 693 47500
1-1/4 12 1178 1302 59600 1-1/4 12 884 977 59600
1-3/8 12 1596 1764 73000 1-3/8 12 1197 1323 73000
1-1/2 12 2090 2310 87700 1-1/2 12 1568 1733 87700
T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi
T.S. = 105,000 psi 1-1/8" to 1-1/2" dia. Proof Strength = 74,000 psi T.S. = 105,000 psi 1-1/8" to 1-1/2" dia. Proof Strength = 74,000 psi
30 31
 Service Centers Service Centers
United States of America India
Varco Varco
12950 West Little York Road Contact: Support Help Desk Contact: Service Manager
Houston, TX 77041 Telephone: (713) 856-4128 Office: (91) 36-155-1621
Fax: (713) 849-6197
P.O. Box 1473 Australia
Houston, TX 77251 Contact: Service Manager Varco
USA Office: (713) 937-5500 1378 Sale Contact: Service Manager
Victoria, 3850 Office: (61) 893-363-988
Varco Australia Fax: (61) 893-363-987
8404 West Hwy. 90 Contact: Service Manager
New Iberia, LA 70560 Office: (337) 364-4583
USA Fax: (337) 365-2545 Singapore
Varco
Brazil No. 8, Sixth Lok Yang Road Contact: Regional Service Manager
Jurong Town Mobile: (65) 97313441
Varco do Brasil Ltda. Singapore 628106
Estrada São José Imboassica, Office: 55-24-27-730600 Contact: Offshore Supervisor
sn-Imboassica Fax: 55-24-27-730600 Office: (65) 265-5066
Macaé Fax: (65) 265-7485
Rio de Janeiro 27902-000 Mobile: (65) 98314736

United Kingdom Contact: Workshop Manager

Mobile: (65) 96320997
Varco (U.K.) Ltd. Systems
Forties Road Contact: Service Manager
Montrose, Angus DD109ET Office: (011) 44-1674-677-222 China
Scotland Fax: (011) 44-1674-677-379 Varco
Contact: Service Manager
United Arab Emirates Mobile: (86) 1393008965
GENERAL INFORMATION

GENERAL INFORMATION
Varco Al Mansoori Services Contact: Service Manager
P.O. Box 27011 Contact: Service Manager Office: (86) 106-495-3025
Abu Dhabi Office: 971-2-5552668 Mobile: (86) 1391224037
United Arab Emirates Fax: 971-2-5540012

32 33
 Specifications
Drilling Motor
Reliance AC-550 VAC (2 x 400 hp)

Hoisting Capacity
400 ton

Pipe Handler
PH-50 50,000 lb ft torque @ 2000 psi
PH-75 75,000 lb ft torque @ 2000 psi

Drill Pipe Sizes

3-1/2 in. to 6-5/8 in. (4 in. to 8-1/2 in. OD tool joint)

Stack Up Height
18 ft (5.4 M)

System Output
PH-50 PH-75
Torque (lb ft)
Continuous 20,000 37,500
Intermittent 36,500 55,000
Maximum RPM 182 228
GENERAL INFORMATION

@Full Power

34
 1 2 3 3 2 1

F F

E E

D D

C C

B B

A A