TOP DRIVE

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Introduction Major Components.

Sections Section 1 - General Information Section 2 – Specifications Section 3 - Lubrication and Maintenance Section 4 - Installation, Commissioning and Decommissioning Section 5 - Guide Beams and Carriage Section 6 - Motor Housing, Transmission Section 7 - PH-50 Pipehandler Section 8 - Hydraulic System Section 9 - Varco Driller's Console Section 10 - System Interconnect Section 11 - Siemens Step 7 PLC Section 12 - Basics of AC Motors Section 13 - Basics of AC Drives Section 14 - Seimens 70 Series Drive Chassis AC to AC Section 15 - Parameter Listing Section 16 - Encoder Troubleshooting Instructions Section 17 - Simovis Version 5

Motor Cooling System

Counterbalance System

Hydraulic Disc Brakes (2)

Gooseneck (S-Pipe)

AC Drilling Motors (2) Transmission/ Motor Housing

Electrical System

Hydraulic System

Rotating Link Adapter

Guide Beam and Carriage

PH-50 Pipehandler

Rear

Left Side

Right Side

Front

A brief history of Top Drives Since the advent rotary drilling in the early 1900s, drilling technology has made steady and, in some cases, spectacular progress. In a little over 100 years, well depths have gone from the 70-foot depth of Drake's Well to over 40,000 feet at the rig on Kola Peninsula east of Finland. To accomplish this, advances were necessary in rig design, equipment, bits, materials and drilling techniques. Varco International, Inc., is proud of its part in advancing the technology of drilling. In 1982 they introduced the industry's first top drive drilling system. By replacing the traditional rotary drive and kelly with an advanced system that rotates the drill string and handles entire 93-ft. stands of pipe, Varco was able to reduce drilling time by up to 25% while increasing the overall capability and efficiency of the drilling operation. As a result, Varco Top Drive Drilling Systems have now become the new performance standard for the drilling industry. And Varco continues to extend the threshold of Top drive technology with the introduction of a complete line of AC top drive systems.

A new threshold in AC technology For years the backbone of oil industry power has been the 1000 hp DC traction motor adapted from locomotives. They are used extensively to power a variety drilling operations including drawworks, rotary tables and mud pumps. DC traction motors area rugged, dependable, readily available source of high torque electric power. These characteristics made them the ideal choice for the conversion of drilling equipment from direct drive diesel to electric power. In developing its Top Drive systems, Varco first turned to these DC motors to power its new technology. And while they were appropriate for some applications, it became evident that smaller, more compact motors were needed for today's performance requirements. There was a need for an efficient, highperformance alternative to traditional DC systems. As part of Varco’s ongoing development effort, various AC motors and

drives were reviewed in an effort to satisfy the specific requirements of drilling applications. Varco design engineers determined that rapid developments in adjustable frequency technology made AC drives and motors a better solution for certain applications traditionally served by DC systems. These modern AC motor/control combinations are uniquely suited for the requirements of the drilling industry. By optimising various components, rugged, reliable AC drives and motors now can produce superior power density for a given frame size. The result - compact, efficient power plants that extend the performance envelope of drilling operations.

A performance paradigm By utilising highly efficient AC motors with the latest variable frequency drives, Varco has defined a new category of performance top drive systems. These new AC drives can stall at full torque for extended periods of time, provide significantly higher intermittent torque and offer more precise control at all speeds. An additional benefit of the advanced AC technology of Varco top drives is constant, useable horsepower over a greater range of speed and torque. This means that you can run faster with more torque - an ideal condition for maximising the potential of diamond and polycrystalline diamond compact (PDC) bits. In the competitive world of drilling and production, Varco has developed technology that is defining a new performance paradigm. Their AC top drive systems combine increased performance, reduced maintenance, lower power consumption, and flexible drive parameters into an unbeatable combination over a wide variety of applications.

Varco’s Top Drive Drilling Systems development

Portable Top Drive Comparison

Specifications Comparison

Working Height-Ft Weight-Lbs.

IDS-1

TDS-9S

(DC SHUNT)

(AC)

(AC)

(AC)

23.0

17.8

16.0

18.0

30,700

24,000

18,000

28,000

Cont. Torque. 34,900 Ft-Lbs. @155 RPM

TDS-10S TDS-11S

32,500 20,000 38,000 @114 RPM @89 RPM @114 RPM

Horse Pwr.

1,000

700

350

800

Rated Ton.

500

400

250

500

TDS-9SA TORQUE SPEED

TDS-10SA TORQUE/SPEED

TDS-11SA TORQUE SPEED

TDS Training Manual

TOP DRIVE COMPONENTS

Typical TDS-9/11SA

AC Electrical

TDS Training Manual

TDS-9SA/TDS-11SA PLAN VIEW

AC Electrical

TDS Training Manual

POWER TRAIN CUTAWAY

AC Electrical

TDS Training Manual

TRANSMISSION/MOTOR HOUSING AND SWIVEL ASSEMBLY

AC Electrical

TDS Training Manual

Transmission/Motor Housing (Main Body) and Swivel Assembly

The transmission/motor housing and swivel assembly transfers the power produced by AC drilling motors to the drill string. Inside the transmission/motor housing main body is a single-speed double-reduction spur gear system that provides a 10.5:1 ratio from the motors to the main shaft. The main thrust bearing located inside the motor housing supports drilling loads, while the load stem, which bypasses the thrust bearing and provides support for the rotating link adapter and pipe handler, carries the tripping loads. The main body of the motor housing provides a sealed oil lubrication reservoir for the transmission gears and bearings. Bearings and gears are force fed by an oil pump that is integral with the main body. A low speed hydraulic motor drives the oil pump. The filtered lubrication oil constantly circulates through the main thrust bearing, take-up bearing, lower radial and compound gear bearings and over the gear meshes. An industry standard wash pipe packing box assembly is located between the main shaft/swivel stem and the S-pipe weldment. The bonnet supports the S-pipe weldment. The forged alloy steel bail swings forward for attaching to standard rotary drilling hooks. The bail is fitted with bronze bushings that are grease lubricated.

AC Electrical

TDS Training Manual

MOTOR COOLING SYSTEM

The motor cooling system on the AC TDS is a local intake pressure blower type. It consists of two 5 HP AC motors integrally mounted on top of each AC drilling motor. Air is drawn in from the combination brake cover/air intake and delivered through rigid ducting to an opening in the top of each motor. The cooling air then passes through the inside of the open-frame type AC drilling motors and exits out of two louver openings near the bottom of the motors.

AC Electrical

TDS Training Manual

HYDRAULIC CONTROL SYSTEM

AC Electrical

TDS Training Manual

HYDRAULIC SYSTEM

AC Electrical

TDS Training Manual

The hydraulic control system is a completely self-contained, onboard system. A 10horsepower, 1800 RPM, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the Lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder link tilt and counterbalance system. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the two AC drilling motors and is equipped with strainers and oil level sight gauges. Three hydro-pneumatic accumulators are located on the main body. The counterbalance system uses the largest accumulator. The medium size accumulator unloads the variable displacement pump and the smallest accumulator activates the delay circuit on the IBOP actuator.

AC Electrical

TDS Training Manual

AC DRILLING MOTOR BRAKES

A modified U-face attaches the motors to the main body. This mounting method allows installation of the motors without shimming or special alignment. Each motor has double-ended shafts with a drive pinion mounted on the lower end and disc brake rotor mounted on the upper end. Two hydraulic calliper disc brakes mounted to the top end of each motor, hold torque in the drill string and assist in positioning during directional work. An electrical solenoid valve remotely operates the hydraulic calliper disc brakes. The AC drilling motors are an open-frame type, meaning that the cooling air passes through the inside of the motion The drilling motors, manufactured specifically for top drive applications, have internal temperature sensors, vacuum varnish impregnated windings, high capacity bearings, and tapered output shafts to improve serviceability of the pinion gear and brake hubs.

AC Electrical

TDS Training Manual

Powered Rotating link

The powered rotating link adapter located at the top of the pipe handler is a slip ring assembly. It allows the hydraulic lines to remain connected as the pipe handler rotates with the drill stem components while tripping out or positioning the link tilt. The rotating link adapter also provides an attachment for the link tilt, pipe backup clamp cylinder and remote IBOP actuator assembly. Grooves in the rotating link adapter align with radial holes in the load stem, allowing hydraulic fluid to flow between the rotating link adapter and the load stem as they rotate. The radial passages at the upper end of the load stem intersect with each hose attachment that runs to the hydraulic manifold. The radial passages in the lower end of the load stem intersect sealed grooves in the rotating link adapter that, in turn, connect with hose attachments that run to all the actuators on the pipe handler. The rotating link adapter can be powered in either direction by a hydraulic drive motor. A pinion gear on the hydraulic drive motor engages a ring gear attached to the top of the rotating link adapter. An electric solenoid valve operates the rotating link adapter hydraulic motor.

AC Electrical

TDS Training Manual

PH-50 PIPEHANDLER

AC Electrical

TDS Training Manual

TWO WAY LINK TILT (PH-50)

The two way link-tilt cylinder assemblies consist of the cylinder rods pinned to the rotating link adapter and the cylinder bodies pinned to the links through a set of clamps. Pressurising the cylinder assemblies by operating the switch on the driller's console extends the drill pipe elevator to the mouse hole or the drill down position. A float position allows the links to return to well centre, the latch on the cylinder assembly limits the travel of the elevator to the derrick man position. Releasing the larch by pulling a cable allows the elevator to travel to the mousehole position AC Electrical

TDS Training Manual

INTERNAL BLOWOUT PREVENTION

AC Electrical

TDS Training Manual

Internal Blowout Prevention The two Internal Blowout Prevention (IBOP) control valves contained in the pipehandler are ball type, full size. internal opening safety valves. These two valves a hex drive remotely operated upper valve, and a manually operated lower valve. form the ;well control system. Both valves have 6-5/8" regular RH connections and 15.000 psi pressure ratings. The remotely controlled upper IBOP valve is opened and closed by a yoke and a hydraulic cylinder that is controlled from the driller's console using an electric solenoid valve. A clam shell housing rotates with the valve body and moves up and down to drive a small crank arm on each side of the valve stem. The housing is actuated by a cylinder through a non-rotating actuator ring. The hydraulic cylinder is attached to the torque arrestor frame. The lower valve is the same type as the upper except it must be manually opened and closed with a wrench. Both valves remain in the string at all times and are readily available by connecting the Top Drive to the drill string. The lower valve can be broken-out from the upper valve using tongs after swinging the torque arrestor frame out of the way. The torque arrestor frame can be pulled away from the drill string after opening the front gate on the clamp cylinder body and removing the stabiliser half. After breaking-out the lower valve, the Top Drive can be hoisted away, allowing room to install the appropriate subs arid valves for well control operations. After removing the lower valve from the upper valve on the Top Drive using conventional fig tongs, the lower valve remains connected to the drill string for well control purposes. A crossover sub is included with the system to allow connection of the drill stem to the lower valve. A drill pipe elevator hangs from a pair of conventional links that attach the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up pipe.

AC Electrical

TDS Training Manuak

TORQUE BACK-UP CLAMP

The torque hack-up clamp is supported by a torque arrestor frame that hangs from the rotating link adapter. The backup clamp is located below the lower shoulder of the saver sub and consists of a pair of gripping jaws with die inserts and 10" diameter clamping cylinder for gripping the box end of the tool joint when connected to the saver sub. The backup clamp body is attached to the torque arrestor frame in such a way that it can float up or down to allow for thread engagement and counter backup torque while making and breaking connections. When the clamp mode is activated, a shot pin mechanism automatically engages the rotating ring to prevent the link adapter from rotating while breaking out the connection.

AC Electrical

TDS Training Manual

COUNTERBALANCE SYSTEM

The counterbalance system includes two hydraulic cylinders connected between the bail and the hook. When the system is activated, the two cylinders support most of the weight of the Top Drive. This system protects root joint threads by taking much of the weight off the drill pipe while making or breaking connections. A new feature for the TDS-9S is called STAND JUMP. It consists of a switch at the driller's console allowing you to change the mode of operation of the counterbalance cylinders from DRILL, which is a standard counterbalance condition, to STAND JUMP. The STAND JUMP feature allows the cylinders to lift the weight of the top drive off the drill string while breaking out a connection, this eases the stress on the threads and avoids damage. The cylinders lift the swivel bail off its resting point on the hook. The two hydraulic cylinders are connected to a hydro-pneumatic accumulator located on the main body. A manual valve can extend the cylinders to assist during rig-up. The accumulator is charged with hydraulic fluid and maintained at a predetermined pressure setting by the counterbalance circuit in the hydraulic control manifold, located on the main body. The hydraulic manifold controls all hydraulic power to the Top Drive.

AC Electrical

TDS Training Manual

Electrical Interface

The electrical interface shown above is the standard layout for the TDS – 9/11S, there are main parts of this schematic, the Varco Top Drive, the Varco Driller’s Console, the Control House or Skid and the Service Loops/Connecting cables. The Top Drive consists of the two AC Drilling motors, Encoder Feedback, Solenoids Valves and Pressure and Temperature Switches. The Varco Driller’s Console consists of the switches and Potentiometers to Control the Top Drive System as well as Alarm Indicators and Horn, to indicate a Fault condition to the Driller. The Control House or Skid consists the Variable Frequency Drive which powers the AC Drilling Motors on the Top Drive, Varco control Panel which controls all the functions and Alarms on the Top Drive. The Service Loops are all electrical, these are the cabling system, which gives all the power to the Top Drive, as well as giving Alarm condition status back to the Control Panel.

AC Electrical

Preface Manual conventions This Preface contains the conventions used throughout this manual. Avoid injury to personnel and/or equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment. Notes, cautions, and warnings The following examples explain the symbols for notes, cautions, and warnings. Please pay close attention to these important advisories.

Note

i

Provides additional information on procedures involving little or no risk of injury to personnel or equipment damage.

Caution

!

Alerts the reader to procedures involving a risk of equipment damage.

Warning

Warns the reader of procedures involving a definite risk of injury to rig personnel.

Product Bulletins The Product Bulletin tab, if included in your manual, defines a section of the manual in which you can store Product and Safety bulletins that may be issued by Varco.

Overall equipment safety requirements Varco drilling equipment is installed and operated in a controlled drilling rig environment that involves hazardous operations and situations.

i

To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.

Personnel training All personnel installing, operating, repairing, or maintaining equipment, or those in the vicinity of this equipment, should be trained in rig safety, tool operation, and maintenance as applicable. This measure helps ensure the safety of everyone exposed to the equipment for whatever purpose.

i

During installation, operation, maintenance, or repair of this equipment, personnel should wear protective equipment. Contact the Varco Service Department to arrange for training for equipment operation and maintenance.

Systems safety practices The equipment covered by this manual may require or contain one or more utilities such as electrical, hydraulic, pneumatic, and cooling water.

i

Before installing or performing maintenance or repairs on the equipment, read the following instructions to avoid endangering exposed persons or damaging equipment. ❏ Isolate all energy sources before beginning work. ❏ Avoid performing maintenance and repairs while the equipment is in operation. ❏ Wear proper protective equipment during the installation, maintenance, or repair of this equipment.

Electrical systems and components

All electrical wiring, junction boxes, sensors, glands, and related equipment are designed for the specific application, environment and particular zone where the equipment is intended to be used. ❏ Before beginning work on this equipment, familiarize yourself with the electrical schematics, as well as the equipment power and voltage requirements. ❏ When performing installation, maintenance, or repairs on the equipment, isolate all power. Lock out switches and tag them to prevent injury. ❏ Prior to disconnecting wires, verify that all wires and terminals are properly labeled to ensure proper reconnection. Hydraulic systems and components

Hydraulic systems and components are designed for specific use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi. ❏ Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics. ❏ Isolate, lock out, and tag the hydraulic and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques.

n

Hydraulic fluids can be extremely hot and under high pressure. ❏ Properly discharge all system accumulators. ❏ Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination. ❏ Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components, such as junction boxes.

Pneumatic systems and components

Pneumatic systems and components are designed for specific use in the drilling industry. The pneumatic pressure for this equipment can be as high as 150 psi. ❏ Prior to beginning work on any portion of the pneumatic system, familiarize yourself with the pneumatic and electrical schematics. ❏ Isolate, lock out, and tag the pneumatic and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. ❏ Properly discharge all system accumulators. Water cooling systems and components

Water cooling systems and components are designed for specific use in the drilling industry. The water can reach temperatures high enough to cause scalding. ❏ Prior to beginning work on any portion of the cooling system familiarize yourself with the plumbing and electrical schematics. ❏ Isolate, lock out, and tag the cooling water and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. ❏ Collect all residual cooling water in a container to prevent rig or environmental contamination if necessary. ❏ Take precautions to prevent cooling water from leaking into other open electrical or mechanical components such as junction boxes.

General safety Equipment motion hazards

Some of the Varco equipment travels either horizontally, vertically on rails, or both.

i

i

Avoid placing objects in or near the path of motion for this equipment. Such interference could cause personnel to be trapped or crushed by equipment.

Keep the working envelope/zone of the equipment free from personnel.

When replacing components

❏ During disassembly and reassembly of any equipment, verify all components such as cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly. ❏ Replace failed or damaged components with Varco certified parts. Failure to do so could result in a hazard, equipment damage, or personal injury. During routine maintenance

Equipment must be maintained on a regular basis. See the body of the service manual for maintenance recommendations.

i

Failure to conduct regular maintenance can result in a hazard, equipment damage, or injury to personnel.

Visibility of equipment operation

Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not block or impair the equipment operator’s field of view. In cases where this is not possible, the customer must install video cameras to ensure adequate visibility. Proper use of equipment

Varco equipment is designed for specific functions and applications and should be used only for the intended purpose.

i

Do not hoist personnel using this equipment. Contact the Varco service center for questions regarding equipment operation, maintenance, hazards, and designed function.

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 1

General Information

AC Electrical

General Information

How to use this manual ...................................... 1-2 Identification numbers ....................................... 1-3

1

Lifting points ....................................................... 1-4 Safety wiring ....................................................... 1-5 Torque values ..................................................... 1-6

2

Basic useage ...................................................... 1-7 Drilling ahead with singles ............................................. 1-7 Drilling ahead with triples............................................... 1-8 Backreaming ................................................................. 1-9

3

TDS-9/11SA consumables ..................................... 1-10

4

5

6

7

8

9

TDS-11SA

General Information

How to use this manual 1

This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with the thumb index tabs for each section and the back cover. You can quickly find each section without looking through a full table of contents. Use the symbols printed at the top corner of each page as a quick reference system. Each section uses a different symbol. Where applicable, each section includes: 1. A table of contents, or an illustrated view index showing: • Major assemblies, systems or operations • Page references to descriptions in text 2. Disassembly / assembly information and tools 3. Inspection information 4. Testing / troubleshooting information 5. Repair information 6. Adjustment information 7. Torque values

Notes, Cautions and Warnings

i !

(Note)

Gives helpful information.

(Caution)

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

Special Information

!

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this may manual contain warnings about proceedures which could damage equipment, make it unsafe, or cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized.

All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text, figures and tables.

1-2

Varco Systems

General Information

Identification numbers 1 Encoder Instruction Label Located on the side of the brake housing

AC Motor Identification Label Located on the side of each AC motor

Warning Labels Located on the side of each AC motor

i

Trace code identifies the configuration of your equipment

SALES ORDER NO. ASSY NO. TRACE CODE DATE OF MANUFACTURE

REV

Top Drive Identification Plate Located on the front of the motor housing

Warning Label Located on the side of the bonnet

TDS-11SA

1-3

General Information

Lifting points 27,000 lb (12300 kg) TDS-11SA

1

Lifting Point For lowering/hoisting the Top Drive to/from the skid

! Bail Lock Must be installed before lowering/hoisting the Top Drive to/from the skid Lifting Points For the skid with Top Drive attached

i For information on Center of gravity see pages 2-2 and 2-3

30,000 lb (13600 kg) TDS-11SA on the skid

Lifting Points For the skid with Top Drive attached

!

1-4

Locking pins Must be in place prior to moving the skid with Top Drive attached

!

Locking pins Must be in place prior to moving the skid with Top Drive attached

Varco Systems

General Information

Safety wiring 1

3

TDS-11SA

2

4

1

5

1-5

General Information

Torque values (Unless otherwise specified) 1

Diameter

Threads per inch

Bolts Lubricated with Light Machine Oil

Bolts Lubricated with Anti-seize Compound

Grade 5

Grade 5

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Coarse Thread Series, UNC 1/4

20

7.6

8.4

2020

5.7

6.3

2020

5/16

18

16

18

3340

12.1

13.4

3340

3/8

16

29

32

4940

21.4

23.6

4490

7/16

14

48

53

6800

36

39

6800

1/2

13

71

79

9050

53

59

9050

9/16

12

105

116

11600

78

87

11600

5/8

11

143

158

14400

107

118

14400

3/4

10

247

273

21300

185

205

21300

7/8

9

409

452

29400

306

339

29400

1

8

608

672

38600

456

504

38600

1 1/8

7

760

840

42300

570

630

42300

1 1/4

7

1064

1176

53800

798

882

53800

1 3/8

6

1387

1533

64100

1040

1150

64100

1 1/2

6

1843

2037

78000

1382

1528

78000

Fine Thread Series, UNF 1/4

28

9.5

10.5

2320

7.1

7.9

2320

5/16

24

18

20

3700

13.5

15.0

3700

3/8

24

33

37

5600

25

28

5600

7/16

20

52

58

7550

39

43

7550

1/2

20

86

95

10700

64

71

10700

9/16

18

114

126

12950

86

95

12950

5/8

18

162

179

16300

121

134

16300

3/4

16

285

315

23800

214

236

23800

7/8

14

447

494

32400

335

370

32400

1

14

665

735

42200

499

551

42200

1 1/8

12

836

924

47500

627

693

47500

1 1/4

12

1178

1302

59600

884

977

59600

1 3/8

12

1596

1764

73000

1197

1323

73000

1 1/2

12

2090

2310

87700

1568

1733

87700

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

1-6

Varco Systems

General Information

Basic useage Drilling ahead with singles 1 Step 1
Set slips on string
Stop circulation
Close IBOP
Breakout connection using pipehandler and drilling motor (in reverse)

Step 2

Step 3

Step 4


Tilt links to mousehole


Pickup single with elevator


Latch drill pipe elevator around single


Release link tilt
Stab bottom of single onto string

Step 5


Lower block to stab motor into top of single


Pull slips


Spin in motor and single


Start circulation


Makeup both connections with motor in torque mode


Open IBOP


Begin drilling

Makeup

Open IBOP Link Tilt Close IBOP Stab

TDS-11SA

Makeup

1-7

General Information

Basic useage Drilling ahead with triples 1

Step 1

Step 2


Set slips on string


Raise block


Stop circulation


Tilt link tilt to derrickman


Breakout connection using pipehandler and drilling motor (in reverse)

Step 3
Pickup stand with elevator
Stab bottom of stand onto string

Step 4

Step 5


Lower block to stab motor into top of stand


Pull slips


Spin in motor and stand


Begin drilling


Start circulation


Makeup both connections with motor

Makeup

Link Tilt

Start Circulation

Stop Circulation Stab

1-8

Makeup

Varco Systems

General Information

Basic useage Backreaming Step 1
Hoist while circulating and rotating
When 3-rd connection surfaces, stop rotation and circulation

Step 2
Set slips on string
Breakout connection using pipehandler and drilling motor (reverse)

Step 3
Hoist free stand with elevator

Step 4
Setback stand using link tilt

1


Lower block, stab motor into string
Spin in motor and makeup connection with motor


Breakout and spinout stand at floor

Breakout

Step 5


Start circulation, pull slips, hoist and rotate

Hoist

Setback

Hoist and Rotate Breakout

TDS-11SA

1-9

General Information

TDS-9/11SA consumables 1

Consumables

Quantity

Part Number

Page Ref.

Tong Dies

4

16781

See page 7-14

Stabilizer, Front

1

118368

See page 7-15

Stabilizer, Rear

1

118367

See page 7-15

Flippers, Stabbing Guide

2

76442

See page 7-15

Wash Pipe

1

123289

See page 6-11

Wash Pipe (Tungsten Coated)

1

123289-TC

See page 6-11

Wash Pipe Packing Kit, 3" Standard (Use with Wash Pipe 123289 or 123289-TC)

1

123290-PK

See page 6-11

Wash Pipe Packing Kit, 3" High Pressure (Use with Wash Pipe 123289-TC only)

1

123290-PK-1

See page 6-11

Hydraulic Oil Filter

1

114416-1

See page 4-30

Gear Oil Filter

1

111013-1

See page 4-32

Hydraulic Oil Filter

Wash Pipe

Gear Oil Filter

Stabilizers

Tong Dies

Stabbing Guide

1-10

Varco Systems

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 2

Specifications

AC Electrical

Specifications

Specifications

Size specifications ............................................. 2-2 1

General specifications ....................................... 2-4 Typical mast interface ....................................... 2-5

22

3

4

5

6

7

8

9

TDS-11SA TDS-11SA

2-1

Specifications

Size specifications Bail 120 in. (3.05 m)

18.5 in. (.47 m)

Bail 88 in. (2.24 m)

2

214.0 in. (5.43 m)

233.0 in. (5.82 m)

To Center of Gravity 112 in. (2.85 m)

To Center of Gravity 28 in. (.71 m)

56 in. (1.42 m) 62 in. (1.58 m)

2-2

To Center of Gravity 37 in. (.94 m)

72 in. (1.83 m)

= 30,000 lb = 13600 kg

Varco Systems

Specifications

Size specifications

Rear 33.7 in. (856 mm)

2

33.8 in. (859 mm) 30.0 in. (762 mm) Setback (Standard)

22.8 in. (579 mm)

C L Well 21.1 in. (53 mm) 22.1 in. (561 mm)

31.0 in. (787 mm) 32.6 in. (828 mm) 26.0 in. (660 mm)

36.9 in. (937 mm)

C L Well

Front

TDS-11SA

2-3

Specifications

General specifications Components

Items

Description

Top Drive

2

Weight Stack-up Height Power Requirements Horsepower Output torque (continuous) Tool torque (intermittent @ stall) Maximum Speed @ full power Hoisting capacity Load Path

27,000 lb 17.8 ft 700 KVA @ 575-600 VAC, 50/60 Hz 800 hp 37,500 ft lb (800 hp) 55,000 ft lb 228 rpm 500 ton Single

Sizes

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

Type

PH-50 (55,000 ft lb torque)

Type

Reliance AC-575 VAC (2 x 400 hp)

Type

IDM Yaskowa Drive (800 hp, 575 VAC) or Siemens (800 hp, 600 VAC)

Type

Hydraulic caliper disc brakes

Type Power Speed

Local intake pressure blower (2) 5 hp AC motors 3,600 rpm

Type

Single speed, double reduction helical gear system 10.5:1 (4.38:1 optional)

Drill Pipe Pipe Handler Drilling Motor Variable Frequency Drive

Motor Braking Motor Cooling System

Gearcase

Gear ratio Gearcase Lubrication Type Reservoir capacity Full internal flow Oil Type

Pressure feed 15 gal

Power Flow Reservoir capacity Oil Type

10 hp, AC motor (1) 6 gpm, (1) 4 gpm 25 gal Mineral based hydraulic oil

Size Type Weight Input requirement

125.4 in. x 84.0 in., 91.2 in. height (Siemens) 140.0 in. x 90.0 in., 91.0 in. height (IDM) 9,500 lb 600 VAC(50/60 Hz), or 750 VDC, or 690 VDC(50/60 Hz)

EP Grade

Hydraulic System

Electrical House

2-4

Varco Systems

Specifications

Typical mast interface Existing Traveling Equipment 500-ton Hook/Block Combo-Typ.

* Dimensions are Subject to Verification ** Standard TDS ConfigurationTwo IBOP’s with 108 in. Elevator Links

TDS-11SA Varco Portable Top Drive System

Crown Clearance 13.5 ft. (4.1 m)**

Block Top

Stroked-Typ. 13.5 ft. (4.1 m)*

2

Bail Rest Sectional Guide Beam

TDS Work Height 18.0 ft. (5.4 m)** Tool Joint

Derrick Termination at ~73 ft. (24.4 m) Level* Mud Hose 75 ft. (22.9 m)* Connected to Standpipe at 73 ft. (22.3 m) Level

Drill Stand Made-up at 4 ft. (1,2 m) Level 93 ft. (28.3 m)

Service Loop

Varco Driller’s Control

Control Cable with Connectors 150 ft. (45.7 m)

Unitized Variable Frequency Inverter & Varco Control Panel Local Power Supply Diesel/Alternator Set/AC Buss

AC Cables

TDS-11SA

7.0 ft. (2.1 m)-Minimum

2 Custom Spanners On A-Frames or Mast Side Panels (by Customer)

10.0 ft. (3 m)-Minimum*

Portable Torque Reaction Beam “U”- Bolted to Spanners - (by Customer)

Clear Working Height 142 ft. (43.3 m)

C L Beam Service Loop Tool Joint 4.0 ft. (1.2 m) Drill Floor

AC Power and Control Cables

2-5

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 3

Lubrication and Maintenance

AC Electrical

Lubrication and Maintenance

Transmission ...................................................... 3-2 Selecting the proper gearbox oil .................................... 3-2

1

Lubrication schedule ..................................................... 3-2 Recommended gear oils ............................................... 3-3 Gearbox lubrication ............................................ 3-4 Hydraulic system ................................................ 3-5 Precautions ................................................................... 3-5

2

Lubrication schedule ..................................................... 3-5 Recommended hydraulic fluid ....................................... 3-6 Hydraulic lubrication ...................................................... 3-7

3

Motors ................................................................. 3-8 Lubrication schedule ..................................................... 3-8 Recommended motor grease ........................................ 3-8 Motor lubrication ............................................................ 3-9

4

General purpose lubrication ............................... 3-10 Lubrication schedule ..................................................... 3-10 Recommended lubricants .............................................. 3-11

5

General lubrication ........................................................ 3-12

6

7

8

9

TDS-11SA

Lubrication

Transmission Selecting the proper gearbox oil TDS transmissions operate under a combination of heavy and shock loads. Under these conditions oil tends to extrude out of the gear mesh. Keeping an effective film of oil on the gear mesh requires oil with an AGMA “extra pressure” rating (EP), and a minimum viscosity of 100 SUS at internal operating temperature. Varco Top Drives also operate under a wide variety of ambient temperatures. Select lubrication for the TDS based on the minimum ambient temperature (surrounding air) to be expected before the next oil change. Under all but the most severe operating conditions, Varco recommends changing the oil every six months. Introducing an oil viscosity greater than required by the ambient temperature can:

3

❏ Damage the gearbox due to reduced oil flow ❏ Damage the oil pump because of excessive load

Lubrication schedule Description Replace the Gearbox Oil Following Intial Break-in

Frequency Following first month of operation

Replace the Gearbox Oil and Perform an Oil Analysis Oil viscosity should be adjusted based on expected ambient conditions for next six months

1 x every 6 Months

Replace the Gearbox Oil Filter (P/N 111013)

1 x every 3 Months

Remove, clean and replace the Magnetic Drain Plug

1 x every Year

The first oil change should be performed after the first month of operation since new units often contain metal contaminates and contaminates caused by initial break-in.

3-2

Varco Systems

Lubrication

Transmission Recommended gear oils Ambient Temperature Range -6˚ to 16˚ C

7˚ to 30˚ C

Above 21˚ C

(20˚ to 60˚ F)

(45˚ to 85˚ F)

(Above 70˚ F)

Alpha LS-68

Alpha LS-150

Alpha LS-320

Manufacturer Castrol

NL Gear 68

NL Gear 150

NL Gear 320

Exxon

Spartan EP68

Spartan EP150

Spartan EP320

Gulf

EP Lube HD68

EP Lube HD150

EP Lube HD320

Mobil

MobilGear 626

MobilGear 629

MobilGear 632

Chevron

Omala 68

Omala 150

Omala 320

Statoil

Loadway EP68

Loadway EP150

Loadway EP320

Texaco

Meropa 68

Meropa 150

Meropa 320

Total

Carter EP 68

Carter EP 150

Carter EP 320

Union

Extra Duty NL2EP

Extra Duty NL4EP

Extra Duty NL6EP

2EP

4EP

6EP

68

150

320

Shell

3

Viscosity Index AGMA ISO Viscosity Grade

!

i

Oils of insufficient viscosity can damage gears by allowing metal to metal contact.

For minimum temperatures below 20°F, the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. If drilling conditions dictate oil temperatures below 20°F, consult Varco service center. If the oil temperature rises above 200°F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F, consult Varco service center.

TDS-11SA

3-3

Lubrication

Gearbox lubrication

Gearbox Oil “Drain”

3 Cork Ball (Level Indicator)

Sight Glass

i Gear Oil Sight Gauge Check with Top Drive “OFF”

i Gearbox Oil Fill Clean area before removing plug, then use a 1 3/8 inch, 12 point socket to remove plug

“Pop-up” Dirt Alarm

Procedure

Gear Oil Filter

Yearly Magnetic Drain Plug Remove and clean contamination

3-4


Check oil level, prior to adding oil (do not mistake the tan colored foam for the dark brown oil)
Ensure that the unit is turned OFF
The area must be wiped clean prior to adding gearbox oil
Recheck oil level and replace the plug after adding oil
Run the unit and recheck the oil level (not foam level), after the unit has been running and the transmission oil is warm

Varco Systems

Lubrication

Hydraulic system Precautions Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

!

!

Use care when handling components to prevent nicking close tolerance finishes.

Use care to prevent contamination from entering the hydraulic system during maintenance activities.

Lubrication schedule Description Perform Hydraulic System Oil Analysis Replace the Hydraulic Fluid Replace the Hydraulic System Filter (P/N 114416-1)

TDS-11SA

Frequency 1 x every 6 Months 1 x Year, or Earlier Based on Oil Analysis 1 x every 3 Months

3-5

3

Lubrication

Hydraulic system Recommended hydraulic fluid Oil Temperature Range -15˚ to 75˚ C

-10˚ to 85˚ C

(5˚ to 167˚ F)

(14˚ to 185˚ F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Manufacturer Castrol Chevron Exxon

Harmony 32AW

Harmony 46AW

Mobil

DTE 24

DTE 25

Shell

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Gulf

3

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

32

46

Viscosity Index ISO Viscosity Grade

3-6

Varco Systems

Lubrication

Hydraulic system Hydraulic lubrication Procedure
The area must be clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill
Remove dust plug from the female quick disconnect on the lubrication kit and connect it to the male fitting
Pump fluid until the level reaches the middle of the sight glass as shown
After adding fluid, replace the dust plugs

Cork Ball (Level Indicator)

3 Red “Pop-up” Dirt Alarm

Sight Glass Hydraulic Oil Sight Gauge

Hydraulic Oil Filter

Hydraulic Oil Fill Male Quick Disconnect Dust Plug

Hydraulic Oil Fill

Female Quick Disconnect

Hydraulic Lubrication Kit 55 gal Drum Varco P/N 92643 Hydraulic Oil Drain

TDS-11SA

3-7

Lubrication

Motors Varco recommends that lubrication of all AC motors should be done by the rig electrician.

Lubrication schedule Description

3

No. of Points

Frequency

Type

Lubricate the AC Drilling Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Blower Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Hydraulic Pump Motor

2

1 x every 3 Months

Motor Grease

Recommended motor grease Motor Grease

Manufacturer Chevron

3-8

Black Pearl EP2 (Do Not Substitute)

Varco Systems

Lubrication

Motors Motor lubrication

i Apply motor grease to designated grease fittings with hand grease gun

3 Months AC Blower Motor (2) 3 pumps (2 grease fittings each motor)

Grease Fittings Grease Fitting 1/8 inch Varco P/N 53201

! Pipe Plug 1/8 inch (remove and reinstall after lubricating)

3

As Viewed From Below

3 Months AC Drilling Motor (2) 5 pumps (2 grease fittings each motor)

3 Months Hydraulic Pump AC Motor 3 pumps (2 grease fittings)

Procedure
Remove the lubrication point plug
Install a grease fitting
Grease with a hand pump only
Re-install the plug

TDS-11SA

3-9

Lubrication

General purpose lubrication

!

!

3

The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, etc., may require more frequent lubrication.

Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Be careful not to over lubricate parts. For example, too much grease forced into a fitting can pop out a bearing seal. Over lubrication can also affect safety since over lubricated parts can drip, creating a potential slipping hazard for personnel.

Lubrication schedule Description

No. of Points

Frequency

Type

Washpipe Assembly

1

Daily

General Purpose Grease

Upper Bonnet Seal

1

Weekly

General Purpose Grease

Bail Pins

2

Weekly

General Purpose Grease

Rotating Link Adapter Gear

–

Weekly

General Purpose Grease

Rotating Link Adapter

2

Weekly

General Purpose Grease

IBOP Actuator Yoke, Cylinder Pins

5

Daily

General Purpose Grease

IBOP Actuator Cranks

2

Daily

General Purpose Grease

Upper IBOP Valve

1

Weekly

General Purpose Grease

Stabilizer Bushing

4

Daily

General Purpose Grease

Clamp Cylinder Gate

2

Daily

General Purpose Grease

Carriage Assembly

8

Weekly

General Purpose Grease

Torque Arrestor at Clamp Cylinder

4

Weekly

General Purpose Grease

Wireline Adapter

2

Weekly

General Purpose Grease

Elevator Link Eyes

4

Weekly

Pipe Dope

3-10

Varco Systems

Lubrication

General purpose lubrication Recommended lubricants Ambient Temperature Range Below -20˚ C

Above -20˚ C

(Below -4˚ F)

(Above -4˚ F)

N/R

MP Grease

Avi-Motive W

Avi-Motive

Manufacturer Castrol Chevron

Lidok EP1

Lidok EP2

Gulf Crown EP31

Gulf Crown EP32

Mobil

Mobilux EP1

Mobilux EP2

Shell

Alvania EP1

Alvania EP2

Statoil

Uniway EP1N

Uniway EP2N

Texaco

Multifak EP1

Multifak EP2

Total

Multis EP1

Multis EP2

Union

Unoba EP1

Unoba EP2

1

2

Exxon Gulf

3

Viscosity Index NGLI

TDS-11SA

3-11

Lubrication

General purpose lubrication General lubrication

i Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

3

Daily Wash Pipe Assembly Apply one pump at beginning of tour

Weekly

Weekly

Bail Pins (2) Two pumps each side

Upper Bonnet Seal One pump Use Hand Pump Only

Weekly Rotating Link Adapter Gear

3-12

Weekly Rotating Link Adapter Three pumps each

Varco Systems

Lubrication

General purpose lubrication General lubrication

i Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

Daily

3

IBOP Actuator Cylinder Pins One pump each (if equipped)

Daily IBOP Actuator Yoke One pump (if equipped)

Daily IBOP Actuator Yoke One pump each side

Daily

Weekly

IBOP Actuator Cranks One pump each side

Upper IBOP Valve Remove 1/4" NPT plug, install grease fitting Apply ten pumps

Weekly Torque Arrestor Tubes

!

Replace plug before operating

Daily Clamp Cylinder Gate One pump each side

Daily Stabilizer Bushing One pump each

Weekly Elevator Link Eyes (4)

Pipe Dope

Daily Stabilizer Bushing One pump each side

TDS-11SA

3-13

Lubrication

General purpose lubrication General lubrication

i Apply general purpose grease to designated grease fittings with grease gun

3

Weekly Rollers One pump each (if equipped)

Weekly Rollers One pump each (if equipped)

3-14

Varco Systems

Lubrication

General purpose lubrication General lubrication

i Apply general purpose grease to designated grease fittings with grease gun

3

Weekly Wireline Adapter One pump each

TDS-11SA

3-15

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 4

Installation, Commissioning and Decommissioning

AC Electrical

Installation, Commissioning and Decommissioning Illustrated index ................................................. 4-3 Preinstallation .................................................... 4-4 Preparation .................................................................... 4-4

1

Installing the crown padeye and hang-off link ............... 4-5 Locating the control house ............................................ 4-6 Installing power cables .................................................. 4-7 Earthing the control house (land rigs) ............................ 4-8

2

Checklist ........................................................................ 4-9 Installation .......................................................... 4-10 Moving the TDS-11SA to the drill floor .......................... 4-10

3

Removing the TDS-11SA from the skid ......................... 4-11 Disengaging the lower carriage latch ............................ 4-12 Moving guide beam sections ......................................... 4-13 Present and hook the first guide beam section ............. 4-14

4

Hoist the first guide beam section ................................. 4-15 Stab and pin the first guide beam section ..................... 4-16 Completing guide beam installation............................... 4-17 Hanging the guide beam ............................................... 4-18

5

Installing the main tieback ............................................. 4-19 Installing the intermediate restraints .............................. 4-20 Disengaging the upper carriage latch ............................ 4-21 Installing derrick termination .......................................... 4-22

6

Installing the service loop to the derrick ........................ 4-23 Installing the driller’s console......................................... 4-24 Installing the driller’s console cabling ............................ 4-25 Motor rotation checkout procedure ................................ 4-26

7

Installing the pipe elevator and links.............................. 4-27 Installing the counterbalance ......................................... 4-28 Commissioning ................................................... 4-29 Checkout procedure ...................................................... 4-29

8

Hydraulic system checkout procedure........................... 4-30 Electrical system checkout procedure ........................... 4-31 Mechanical checkout procedure .................................... 4-32 Adjusting the link tilt ....................................................... 4-33 Removing and installing the saver sub .......................... 4-34 TDS-11SA

9

Installation, Commissioning and Decommissioning

Installation, Commissioning and Decommissioning

Decommissioning ............................................... 4-35 Securing the TDS-9/11SA for rig-down ............................ 4-35

1

Removing and storing the electrical cables and service loops .......................................................... 4-36 Setting the latches and locking the bail ......................... 4-37 Disconnecting the guide beam ...................................... 4-38

2

Unpinning each guide beam section ............................. 4-39 Lowering each guide beam section ............................... 4-40 Returning the TDS-9/11SA to the skid ............................. 4-41 Removing the TDS-9/11SA from the drill floor ................. 4-42

3

Long term storage procedures ...................................... 4-43

44

5

6

7

8

9

4-2

Varco Varco Systems Systems

Installation, Commissioning and Decommissioning

Illustrated index Crown Padeye and Hang-off Link Page 4-5

Counterbalance Page 4-27

Guide Beam Page 4-13

Rotary Hose

Derrick Termination Page 4-22

4

Intermediate Restraints Page 4-20

Service Loop Page 4-23

Varco Driller’s Console (VDC) Page 4-24 Control Cable with Connectors Page 4-25

Main Tieback Page 4-19

Unitized Variable Frequency Inverter and Varco Control Panel (House) Page 4-6 Local Power Supply Diesel/Alternator Set/AC Bus AC Cables Page 4-7 AC Power and Control Cables Page 4-7

TDS-11SA

4-3

Installation, Commissioning and Decommissioning

Preinstallation Preparation The TDS-11SA interfaces with the rig’s hoisting system and electrical power system. Derrick and electrical system modifications are required when installing the TDS-11SA on existing rigs. For derricks that handle triples, the required top drive travel is about 100 ft. compared to about 75 ft. when using a Kelly. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. long) with a 75 ft. hose, and extend the standpipe height to approximately 73 ft. Although many rig floor layouts are possible, installing the guide beam on the drawworks side of the derrick, or mast, and opposite the V-door is an ideal arrangement for handling tubulars from the Vdoor. The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop and mud hose. Other important installation considerations include the location of:

4

❏ The casing stabbing board ❏ Floor and derrick accessories ❏ Drawworks fastline ❏ Guide beam hang-off bracket ❏ Torque reaction beam ❏ Mud stand pipe extension ❏ Varco drillers console location ❏ Variable frequency inverter/Varco control panel location Derrick height is a critical interface requirement. Handling a 93 ft. stand typically requires 97 ft., resulting in an overall height from the floor to the top of the traveling block of at least 126 ft. Derrick Clear Working Height

Derrick Crown Clearance

152 ft.

25 ft.

147 ft.

20 ft.

142 ft.

15 ft.

136 ft.

9 ft.

Each rig has different crown clearance for efficient tripping. Installing the TDS-11SA with existing traveling equipment may require an adapter–further reducing crown clearance.

4-4

Varco Systems

Installation, Commissioning and Decommissioning

Preinstallation Installing the crown padeye and hang-off link Recommended installations Dimension

Description

36.8 inches

Standard height configuration (adjustable)

33.8 inches

Varco’s IDS Top Drive requirements

30.0 inches

Original setback for TDS-9S/11S

Crown

Crown Padeye Weld according to table above

4 Shackle

See Table

Hang-off Link

C L Well

TDS-11SA

4-5

Installation, Commissioning and Decommissioning

Preinstallation Locating the control house

Drawworks

Recommended Area for Control House Location

C L Well

4

V-Door Ramp TDS-11SA

Varco Driller’s Console

9,500 lb (4300 kg) Control House

C L Well

Control House

Recommendations 91 in. (2310 mm)


Position the control house off-driller’s side or behind the drawworks
Position as close to derrick plate as possible to minimize cable lengths
Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts)

140 in. (3560 mm)

90 in. (2290 mm)


Location of the control house must ensure accessibility from all sides
Do not expose the control house to H2S

4-6

Varco Systems

Installation, Commissioning and Decommissioning

Preinstallation Installing power cables COM POS ITE

CON NEC TOR

AUX . PO WE RC ON NEC TOR

Ground Lug to Top Drive

SER IAL CON NEC TOR

Plug Panel

UI NC OM ING 575 VA C V IN CO MIN G5 75V AC WI NC OM ING 575 VA C

Incoming Power Cables 575VAC to main circuit breaker (3 Places)

4

UO UT GO ING 575 VA C VO UT GO ING 575 VA C WO UT GO ING 575 VA C

Outgoing Power Cables to Top Drive (3 or 6 Places)

Varco Control House

Rain Cover Plug Panel

Procedure
Clean all connector contacts
Connect the power cables with the isolation circuit breaker turned OFF
Connect cables in accordance with the electrical schematic provided in the Technical Drawings book
Lockwire all connector nuts
Earth the control house with the Varco Ground Rod Kit (See page 4-8)

TDS-11SA

4-7

Installation, Commissioning and Decommissioning

Preinstallation Earthing the control house (land rigs)

Copper Plated Steel Rod Cable Clamp

Cable Lug Copper Wire 10 ft

4

The control house must be properly grounded to prevent injury to personnel

Procedure
Insert the grounding rod into the soil (the rod must be in contact with ground water)
Connect the rod to the control house (connection must be clean)

i

Ground Rod Kit P/N 116004

Grounding Points Located at opposite corners of the house floor

For offshore installations the control house must be grounded to the ground point on the rig structure

4-8

Varco Systems

Installation, Commissioning and Decommissioning

Preinstallation Checklist The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and TDS-11SA. This includes: ❏ Make sure the derrick/mast is vertical, with the block over the center of the rotary table. ❏ Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed and inspected to conform to Varco specifications as detailed in FIP00003. ❏ The service loop bracket is installed in the derrick/mast. ❏ The control panel and frequency drive are installed. ❏ Rigging of tong lines, etc. is inspected to ensure that they will not foul with the TDS-11SA.

4

❏ The hook or adaptor becket is installed. The hook should open toward the drawworks.

TDS-11SA

4-9

Installation, Commissioning and Decommissioning

Installation Moving the TDS-9/11SA to the drill floor Procedure Ensure the safety of all personnel
Locate the Top Drive at the bottom of the V-Door ramp
Ensure that the bail lock assembly is installed
Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor

! The Bail Lock Assembly must be installed Tube (P/N 113498) U-Bolt (P/N 113497) 2x 3/4" nuts

4 TDS-11SA on Skid

Lifting Block Hoist using the drawwork

Lifting Sling Attached to bail for hoisting

Lifting Sling

! Be sure that the Top Drive is pinned to the skid prior to hoisting it to the drill floor

3 TDS-11SA In position prior to lifting from skid

Drill Floor

2

30,000 lb (13600 kg) TDS-11SA on Skid Backup Line V-Door Ramp

1

4-10

Varco Systems

Installation, Commissioning and Decommissioning

Installation Removing the TDS-9/11SA from the skid

! The Bail Lock Assembly must be installed. Remove only after installation is complete.

27,000 lb (12300 kg) TDS-11SA

View of Carriage from Rear

4 Pin

1 Latches Both sides engaged for hoisting

TDS-11SA

Pin

3

2

Hoist the TDS-11SA from the skid using the drawwork

Drill Floor

Procedure Ensure the Top Drive does not contact the rig

TDS-11SA

Lock Pin Remove prior to hoisting from skid


Ensure that both carriage latches are engaged for hoisting from the skid
Ensure that the bail lock assembly is installed
Engage the hook with the bail
Remove the lock pin
Hoist the Top Drive from the skid

4-11

Installation, Commissioning and Decommissioning

Installation Disengaging the lower carriage latch

Guide Beam Top Section

Carriage

Guide Beam Wings

2

4

TDS-11SA Lifted from the skid 27,000 lb (12300 kg)

! After hoisting the TDS-11SA from the skid, disengage the Lower Carriage Latch and pin it as shown.

Pin

1 Upper Latch Engaged

Lower Latch Disengaged

As viewed from rear of Carriage

TDS-11SA In position to disengage lower latch

Pin

3 Drill Floor

Skid Remove from drill floor after hoisting the TDS-11SA 3,000 lb (1360 kg)

Procedure
Ensure that the lower carriage latch is disengaged
Ensure that the upper carriage latch is engaged
Hoist the Top Drive Ensure the Top Drive or the guide beam does not contact the rig
Remove the skid from the drill floor

4-12

Varco Systems

Installation, Commissioning and Decommissioning

Installation Moving guide beam sections

Procedure
Locate the guide beam sections near the V-Door
Attach lifting slings to the lifting eyes of the first guide beam section to be hoisted
Hoist the guide beam section to the drill floor

2,100 lb (950 kg) 20 ft. Guide Beam Section

4

Sling Ensure the Top Drive does not contact the rig

TDS-11SA

Guide Beam Section

3

2

Guide Beam Section Hoist to the drill floor

Lifting Eyes Attach slings for hoisting

Drill Floor

1 Guide Beam Sections Prior to Installation

TDS-11SA

4-13

Installation, Commissioning and Decommissioning

Installation Present and hook the first guide beam section Guide Beam Top Section

1

2

Present

Match

Grease the bores on both joint halves Guide Surface Radius locks joint from unhooking at 8° rotation Hook Pin

Grease the bores on both joint halves

4 3

4

Engage

Hook

Ensure the Top Drive does not contact the rig

Present and Hook the first guide beam section

Guide Beam Section Hooked Drill Floor

4-14

Hook Pin In fully engaged position

Hook Pin Saddle

Procedure
Locate the guide beam to be hooked under the top guide beam section
Grease the bores on both joint halves
Align the guide surface with the hook pin as shown
Lower the top guide beam to match and engage the hook pin to the hook pin saddle
Hoist the top guide beam to fully engage the hook pin
Manually stabilize the back end of the guide beam

Varco Systems

Installation, Commissioning and Decommissioning

Installation Hoist the first guide beam section

Guide Beam Top Section Hoist

Hook Pin

First Guide Beam Section Initially hoisted by the hook pin

4

Bar and Radius Locates pin bores for easy insertion of pins Hoist Using the drawwork

Ensure the Top Drive does not contact the rig Drill Floor

TDS-11SA

4-15

Installation, Commissioning and Decommissioning

Installation Stab and pin the first guide beam section

Guide Beam Top Section

1 Stab the guide beam joints together

Lynch Pin

2 Joint Pin Install after stabbing

4

4

3

Secure with the lynch pin

Retainer Pin Apply grease and insert

Stab and Pin the guide beam joint

Block as Required Drill Floor

4-16

Ensure the Top Drive does not contact the rig

Procedure
Lower the guide beam to drill floor and stab the guide beam joints together
Block the guide beam in a vertical position if required
Install the joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as shown

Varco Systems

Installation, Commissioning and Decommissioning

Installation Completing guide beam installation

Ensure the Top Drive does not contact the rig

4

Repeat previous steps until Guide Beam Installation is complete

Procedure

Drill Floor

TDS-11SA


Move the next guide beam section to the drill floor
Present the end of the guide beam to be hooked
Ensure that the bores on both joint halves have been greased
Engage the hook pin saddle around the hook pin
Hoist the guide beam with the drawwork
Lower the guide beam to the drill floor and stab the guide beam joints together
Install the joint pin
Install the retainer pin
Secure the pins with the lynch pin

4-17

Installation, Commissioning and Decommissioning

Installation Hanging the guide beam

i

Crown Pin the Guide Beam to the hang-off link Ensure the Top Drive does not contact the rig

Note: Use these pin positions if crown padeye installation is based on: 36.8 in. (935 mm) Standard adjustable height configuration

Crown Padeye

33.8 in. (859 mm) Varco’s IDS Top Drive requirements

! Ensure that the Shackle is pinned and the cotter pin is in place

30.0 in. (762 mm) Original TDS-9S/11S or if plate extension (36.8 in.) needs to be cut off due to interference.

Hang-off Link

4 Pin

Safety Pin

Guide Beam Top Section

C L

C L

Guide Beam Top Section

Well

Procedure Drill Floor

Floor Clearance

+.5 ft 7 ft. -0 ft +150 mm (2100 mm -0 mm )

4-18


Using the drawwork, hoist the top guide beam to the hang-off link
Ensure that the shackle is pinned and it’s cotter pin is in place
Pin the guide beam to the hang-off link in the appropriate position
Check for 7 ft clearance from bottom of guide beam to the drill floor
Secure the pin to the hang-off link with the nut and safety pin

Varco Systems

Installation, Commissioning and Decommissioning

Installation Installing the main tieback Procedure Guide Beam Bottom Section


Check for Top Drive mainshaft alignment over well center
Install the main spreader beam at the appropriate distance from well center
Install the tieback plate and tieback link
Check for Top Drive mainshaft alignment over well center
Torque and lock wire all bolts Tieback Link Guide Beam Assembled

Tieback Plate

4 Main Spreader Beam

Apply Anti-seize Compound Typical Auxiliary Spreader Beam

Main Tieback and Spreader Beam Install after guide beam is assembled Mast Leg Drill Floor

Recommended Installations See Table

TDS-11SA

Dimension

Description

36.8 inches

Standard height configuration (adjustable)

C L

33.8 inches

Varco’s IDS Top Drive requirements

Well

30.0 inches

Original setback for TDS-9S/11S

4-19

Installation, Commissioning and Decommissioning

Installation Installing the intermediate restraints Apply Anti-seize Compound Typical

Intermediate Tieback Plate 2 Places

Girt

Padeye 2 places if greater than 3 inches from girt

3 inches

4 105 Feet

i Padeye 1 place if less than 3 inches from girt

Double nut Space between girt and guide beam

Pin and Cotter Pin Guide Beam Assembled 55 Feet

Procedure

Drill Floor

4-20


Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor
Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches
Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches
Install intermediate tieback plates as required
Torque and lock wire all bolts
Secure all pins with cotter pins

Varco Systems

Installation, Commissioning and Decommissioning

Installation Disengaging the upper carriage latch Guide Beam Top Section

2

Carriage

Remove the Bail Lock Assembly Guide Beam Wings

3

!

Slowly lower the TDS-11SA

After hanging the guide beam, installing the tiebacks, and prior to lowering the Top Drive, disengage the Upper Carriage Latch and pin it as shown.

Pin

1 Upper Latch Disengaged

Lower Latch Disengaged

As viewed from rear of Carriage Pin

Procedure

Drill Floor

Bail Lock Assembly Remove

TDS-11SA


Ensure that the lower carriage latch is disengaged
Ensure that the upper carriage latch is disengaged
Remove the bail lock assembly
Ensure the mast is clear of all obstructions and slowly run the Top Drive down the guide beam

4-21

4

Installation, Commissioning and Decommissioning

Installation Installing derrick termination Hoist Line Attachment Point

Derrick/ Mast Leg

Derrick Leg Plate Hoist Line Attachment Points

Service Loop Brackets

4 Mount the Derrick Termination Plate as recommended

83 ft from drill floor

Recommendations
Mount on the side of the derrick adjacent to the service loop brackets on the TDS-11SA
Mount as far as practical from well center, to maintain a 36 inch minimum bend radius

Drill Floor

!

Maintaining a larger radius increases loop life and reduces damage due to “pinching”
Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc

4-22

Varco Systems

Installation, Commissioning and Decommissioning

Installation Installing the service loop to the derrick Hoist

Derrick Termination Plate

1,000 lb (450 kg) Each Service Loop

Sling

4

! Avoid damage to the service loops by using care when dragging it near sharp edges and allow room for passing under the V-door

TDS Service Loop

Lifting Eyes Do not remove Derrick Service Loop

!

Recommendations

Avoid damage to the service loops by maintaining a 36 inch minimum bend radius Service Loop and Storage Tub 3,600 lb (1600 kg)

TDS-11SA


Do not unpack the service loops until they are ready to hang
Use a sling attached to the lifting eyes to hoist each service loop
Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting

4-23

Installation, Commissioning and Decommissioning

Installation

Drawworks

Installing the driller’s console

TDS-11SA

V-Door Ramp

4

Recommended Area for Varco Driller’s Console Location

!

UE RQ TO

P IBO

Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system, as it is specifically made for use with the TDS-11SA.

E AK BR

Y NC GE ER OP EM ST

ER DL AN EH PIP

Recommendations

Pigtail Cable Connect to control house

4-24


Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated
Location must ensure that the gauges are easily seen by the driller during drilling operations
Location must be visible and readable at night

Varco Systems

Installation, Commissioning and Decommissioning

Installation Installing the driller’s console cabling COM POS ITE

CON NEC TOR

AUX . PO WE RC ON NEC TOR

SER IAL CON NEC TOR

Profibus Serial Link to Driller’s Console

UI NC OM ING 575 VA C V IN CO MIN G5 75V AC

Plug Panel WI NC OM ING 575 VA C

4

UO UT GO ING 575 VA C VO UT GO ING 575 VA C WO UT GO ING 575 VA C

Varco Control House

Rain Cover Plug Panel

Recommendations
Ensure that the Varco Driller’s Console is properly located
Connect the power cables with the isolation circuit breaker turned OFF
Connect cables in accordance with the electrical schematic provided in the Technical Drawings book
Tighten connector nuts
Lockwire connector nuts to prevent loosening

TDS-11SA

4-25

Installation, Commissioning and Decommissioning

Installation Motor rotation checkout procedure Direction of Rotation Counterclockwise

Procedure Direction of Rotation Clockwise


Assign the Top Drive and inverter by selecting FORWARD or REVERSE on the driller’s console
Check the rotation direction of the cooling and oil pump motors
Rotate the drill stem using the THROTTLE on the driller’s console and observe proper operation Cooling Motors 2 Places

4 TO

RQ

UE

RQ

TO X

MA

OP

IB P IBOSED O CL

Y NC GE ER OP M T E S

UE

RQ

0

ILL

TO

DR D

SE

P LO IBO C

F

OF

N PE

O

IVE DRULT FA

AR

RW

FO

X

MA

SE

R

VE

RE

0

Throttle

Direction of Rotation Counterclockwise

Forward/Reverse Control Varco Driller’s Console TO

IB

BR

PIP

EH

AN

DL

AK

E

RQ

UE

Oil Pump Motor

OP

Y NC

GE ER OP EM ST

ER

Drill Stem Direction of Rotation

Reverse

Forward

4-26

Varco Systems

Installation, Commissioning and Decommissioning

Installation Installing the pipe elevator and links Catch Link Bolt

Rear

Motor Guard

Catch Link Pin

600-2,400 lb (270-1100 kg) Elevator Link

AT

LO

ER T F DLK TIL ANLIN

EH PIAPTE IGHT

T RO

Catch Link

R

FT

LE

4

ILT KT LT LINOFF TI

H NC LL RELD DRI E WHO QUH & R TOPUS

Front Pipehandler Rotate Switch Link Tilt

Varco Driller’s Console

Link UE RQ TO

OP IB E AK BR

Y NC

GE ER OP EM ST

ER DL AN EH PIP

Clevis Pin

Procedure
Using the Varco Driller’s Console, rotate the pipehandler 90˚ (positioning the catch link under the front of the motor guard)
Lubricate the elevator link eyes with pipe dope
Hoist the elevator link onto the rotating link adapter (the small link eye at the bottom)
Secure the catch link with the pin and bolt
Secure the elevator link to the link tilt
Rotate the pipehandler 180˚ and install the other elevator link
Install the pipe elevator in accordance with the pipe elevator manual

TDS-11SA

4-27

Installation, Commissioning and Decommissioning

Installation Installing the counterbalance Procedure
Refer to Setting up the circuits in the Hydraulic section of this manual for initial system set up
Install the pear links to the ears on the hook
Turn on the Top Drive power
Rotate the counterbalance mode valve from the RUN position to the RIG-UP position
When the cylinders reach the end of stroke, slide the cylinder clevis over the pear link and install the cylinder clevis pin
After securing the counterbalance cylinder to the pear link, rotate the counterbalance mode valve to the RUN position
Adjust PCC clockwise to raise the pressure at test port CB until the bail just begins to lift off of the block
Reduce the pressure slowly (25 psi) to allow pressure to stabilize

4

Hook

Pear Link 2 Places

Cylinder Clevis 2 Places

Cylinder Clevis Pin 2 Places Counterbalance Cylinder 2 Places (8.5 inch stroke)

Rig-up/Run/ Shutdown Valve Shown in RIG-UP position (switch to RUN after the counterbalance is installed)

Bail

RIG-UP

SHUTDOWN

RUN

CO

UN

NC

EM

P

ALA

-U

RB

IG

TE

R

4-28

S

H

U

N

T

U

D

R

O

W

N

COUNTERBALANCE MODE

OD

E

Hydraulic Manifold

Varco Systems

Installation, Commissioning and Decommissioning

Commissioning Checkout procedure Initial Rig-Up
Pre-charge all accumulators (See the Hydraulics System section of this manual)
Adjust the hydraulic system
Bleed the air from the hydraulic system
Constantly monitor the hydraulic fluid level, and never allow the level to fall below the middle of the sight glass (system power OFF)

Cork Ball (Level Indicator)

Checkout Procedure
Lubricate all grease points (See Lubrication)
Check for loose or missing connectors
Lockwire all connector nuts
Check for interference along entire mast
Remove exhaust covers from AC drilling motors
Check blower inlets and outlets for blockage
Set the air conditioner to 75˚F (27˚C)
Turn on the main breaker

Sight Glass Hydraulic Oil Sight Gauge

4

Air Inlet Between motor and brake housing, 2 Places

TOP DRIVE

INS T WH ALL UN EN ST IT IS OR ED

VARCO

Exhaust Cover 4 Places

Exhaust Outlet Through louvers at bottom of AC drilling motors, 6 Places

TDS-11SA

4-29

Installation, Commissioning and Decommissioning

Commissioning Hydraulic system checkout procedure Checking hydraulic fluid level

Cork Ball (Level Indicator)

Red “Pop-up” Dirt Alarm Sight Glass

4

Hydraulic Oil Sight Gauge Hydraulic Oil Filter

Procedure
Ensure that the pipehandler clamp cylinder is unclamped, the counterbalance cylinders are connected to the hook, the bail is resting in the hook, and the system power is OFF
Check to see that the hydrulic fluid level is at the middle of the sight glass
If the fluid is low, add hydraulic fluid (see the Lubrication and Maintenance section of this manual
Check the red “pop-up” alarm on the hydraulic filter for contamination
Replace the filter (P/N 114416-1) if the indicator has popped up
Use care to prevent contamination from entering the hydraulic system during maintenance activities

4-30

Varco Systems

Installation, Commissioning and Decommissioning

Commissioning Electrical system checkout procedure

Emergency Stop

Latch 9 Places

M

RP

TO

RQ

UE

UE

RQ

TO MA

P IBOOP

Y NC GE ER OP EM ST

IB SED O CL

E AK BRRAKE

B N O

ER

DL

AN

H IPE

P RO

PR

S OILLOS S ES

P -U IT KE LIM MAENT RR CU OR OT P L M EM X RIL RT MA DOVE

LE

TE RIG

KT

ILT

FL

OA

T

P LO IBO C

E E AK AK BR TO BRON AU

FT

ILT

KT LINOFF

T

ILT

O

DR

SE OF

N PE IVE DRULT FA

RE

VE

RS

F

FO

RW

AR

ILL

TO

RQ

UE

4

Torque Meter

D MA

E

X

0

F OF

CH EN ILL WR LD DR UE HO RQ H & TOPUS

0

R YD MP H LA ECK U TO A M CH AR AL NCE ILE

AU

LIC

R WE PO N O

/

S

SP DR

TA

LIN HT

0

RPM Meter

X

IN

TO

RQ

BL UE

OW

E

O RL

SS

ILL

Procedure All personnel must stand clear
All personnel operating the Top Drive should be trained in rig safety and tool operation
Operate each control on the Varco driller’s console (See Varco FIP00003)
Check for alarm conditions and resolve any alarms at this time (See Varco FIP00003)
Check all connectors for tightness and lockwire
Check operation of meters
Check operation of emergency stop
Check the latches on the driller’s console for tightness

Pigtail Cable Connected to control house

TDS-11SA

4-31

Installation, Commissioning and Decommissioning

Commissioning Mechanical checkout procedure Checking gearbox oil level Procedure
With the drive motors and hydraulic system off, check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox
Always check the oil level, not foam level (oil is dark brown, foam is tan) after the unit has been running and the transmission oil is warm
If the oil level is low, add gear oil (see the Lubrication and Maintenance section of this manual
Check the red “pop-up” alarm on the gear oil filter for contamination
Replace the filter (P/N 111013-1) if the indicator has popped up

4 Cork Ball (Level Indicator)

Sight Glass

i

i

Gear Oil Sight Gauge Check with Top Drive “OFF”

Gearbox Oil Fill Clean area before removing plug, then use a 1 3/8 inch, 12 point socket to remove plug

“Pop-up” Dirt Alarm

Gear Oil Filter

4-32

Varco Systems

Installation, Commissioning and Decommissioning

Commissioning Adjusting the link tilt

i

See the PH-50 Pipehandler section of this manual for inspection and disassembly/ assembly details

Jam Nut Adjust the derrickman position with the adjusting screw and lock in position with the jam nut Link Tilt Crank Assembly

Pin

4 26 inches (660 mm) Typical

Clamp

i Mousehole Position Cable Pull “up” or “down” to set mousehole position

3-4 inches (76-102 mm)

i Link Mousehole Position Derrickman’s Position Link clamps should be adjusted so that the elevator does not hit the diving board in this position

TDS-11SA

Drill Down Position Bottom of elevator should be above the bottom of the stabbing guide

Elevator Well Center Float Position

4-33

Installation, Commissioning and Decommissioning

Commissioning Removing and installing the saver sub Torque values for drill stem components Component

I.D.

Connection

O. D.

Torque

Mainshaft to Upper IBOP Valve

3 in.

6 5/8 API Reg.

7 3/4 in.

52,000 ft-lb

Upper IBOP Valve to Lower IBOP Valve

3 in.

6 5/8 API Reg.

7 3/8 in.

48,000 ft-lb

Lower IBOP Valve to Saver Sub

3 in.

6 5/8 API Reg.

7 3/8 in.

46,000 ft-lb

Crossover Sub to Lower IBOP Valve

3 in.

6 5/8 API Reg.

7 3/8 in.

46,000 ft-lb

Crossover Sub

Tugger Line

Cylinder Pins Remove Torque Arrestor

4

V A R C O P H 5

Upper IBOP

i See the Technical Drawing Package for configuration details

0

IBOP Crank and Shell Remove CO

R VA

Lower IBOP

Swing Clear

Short Saver Sub For use with lower IBOP

4-34

Long Saver Sub For use without lower IBOP

Gate Pin Remove one

i Use Tongs for torquing the components together

Varco Systems

Installation, Commissioning and Decommissioning

Decommissioning Securing the TDS-9/11SA for rig-down Procedure
Lower the Top Drive to the drill floor
Remove the mud hose, drill pipe elevator and links
Power may be needed to turn rotating head into position for removing the links
Locate the RIG-UP/RUN/SHUTDOWN valve on the hydraulic manifold
With the hydraulic power ON select the “RIG-UP” position and remove the extended counterbalance cylinders from the hook ears
Select the “SHUTDOWN” position and turn off the Top Drive
Isolate and lock out ALL power to the Varco control house

4

O

W

N

Hydraulic Manifold

RU

S

H

U

T

D

N

-U

IG

R P

E C N LA BA R TE N U O C E D O M

TDS-11SA Lower to the drill floor

Rig-up/Run/ Shutdown Valve Rotate from RIG-UP to SHUTDOWN for Top Drive rig-down

RIG-UP

SHUTDOWN

RUN

Drill Floor

COUNTERBALANCE MODE

TDS-11SA

4-35

Installation, Commissioning and Decommissioning

Decommissioning Removing and storing the electrical cables and service loops Lower

Derrick Termination Plate

1,000 lb (450 kg) Each Service Loop

Sling

4

! Avoid damage to the service loops by using care when dragging it near sharp edges and allow room for passing under the V-door

Derrick Service Loop

TDS Service Loop Lifting Eyes Do not remove

Procedure

! Avoid damage to the service loops by maintaining a 36 inch minimum bend radius Service Loop and Storage Tub 3,600 lb (1600 kg)

4-36


Position the service loop tubs for convenient loading of the service loops
Disconnect the derrick service loop from the derrick termination plate and the control house
Disconnect jumper cables (if installed)
Cap all connectors and lower the derrick service loop into a service loop tub
Use a sling attached to the lifting eyes to lower each service loop and a swivel at the tugger line attachment to allow each service loop to coil without twisting
Disconnect the Top Drive service loop and repeat the above procedure
Remove the service loop tubs from the area
Remove the derrick termination plate if necessary

Varco Systems

Installation, Commissioning and Decommissioning

Decommissioning Setting the latches and locking the bail

TDS-11SA Hoist to the crown

View of Carriage from Rear

Counterbalance Cylinders Disconnect from the hook 2 Places

Exhaust Cover 4 Places

!

VARCO

TOP DRIVE

INS TA WH LL UN EN ST IT IS OR ED

The Bail Lock Assembly must be installed

Pin

Latches Both sides engaged

Pin

Procedure Drill Floor

TDS-11SA


Install the bail lock assembly
It is NOT necessary to drain gear oil or hydraulic fluid for rig down
Disconnect the counterbalance cylinders from the hook
Install exhaust covers
Hoist the Top Drive to the crown
Engage the upper and lower carriage latches as shown

4-37

4

Installation, Commissioning and Decommissioning

Decommissioning Disconnecting the guide beam Crown TDS-11SA Disconnect from the hang-off link Crown Padeye Do not remove Shackle Intermediate Tiebacks Disconnect from the guide beam

Hang-off Link

4 Bolt Pin

Safety Pin

Guide Beam Top Section

Procedure

Drill Floor

4-38

Main Tieback Disconnect from the guide beam


Ensure that the bail lock assembly is installed and that both carriage latches are engaged (See page 4-37, Setting the latches and locking the bail)
Disconnect the guide beam from the main tieback and intermediate tiebacks
Hoist the Top Drive and guide beam to take the load off the hang-off link
Remove the guide beam from the hang-off link
Replace the pin, bolt and safety pin on the guide beam top section as shown
Remove the hang-off link if necessary

Varco Systems

Installation, Commissioning and Decommissioning

Decommissioning Unpinning each guide beam section

Ensure the Top Drive does not contact the rig

3 Guide Beam Hoist Lynch Pin Remove

2 Hook Pin Retainer Pin Remove

Joint Pin Remove

1 Guide Beam Lower to the drill floor

Drill Floor

TDS-11SA

Block as Required

Procedure
Lower the guide beam to drill floor
Block the guide beam in a vertical position if required
Slightly compress the guide beam
Remove the retainer pin, lynch pin and joint pin at the joint between the two lower guide beam sections
Hoist the guide beam to open the joint

4-39

4

Installation, Commissioning and Decommissioning

Decommissioning Lowering each guide beam section Procedure Ensure the Top Drive does not contact the rig

2 Guide Beam Lower to the drill floor


Using a tugger or crane, pull the lower guide beam section to a horizontal position
Do not allow the angle at the guide beam joint to become less than 90 degrees
Lower the guide beam to the drill floor
Attach lifting slings to the lifting eyes of the lower guide beam section to be removed
Unhook the lower guide beam section and remove from the drill floor
Repeat the previous steps for each of the remaining guide beam sections until only the upper section remains

2,100 lb (950 kg) Guide Beam Section

Sling

4

Guide Beam Section

3 Lifting Eyes Attach slings, and unhook the guide beam section

Lower Guide Beam Section Horizontal position must remain greater than 90˚

1 Drill Floor Tugger

4-40

Varco Systems

Installation, Commissioning and Decommissioning

Decommissioning Returning the TDS-9/11SA to the skid Pin Hook onto the top of the skid

27,000 lb (12300 kg) TDS-11SA

2 TDS-11SA Lowered onto skid

4

Ensure the Top Drive does not contact the rig

3 Lock Pin Install after lowering TDS-11SA onto the skid

Skid

Procedure Drill Floor

1 3,000 lb (1360 kg) Skid

TDS-11SA


Ensure that the bail lock is installed
Hoist the storage skid to the drill floor
Using the drawwork, lower the TDS-11SA onto the skid
Ensure that all carriage latches remain engaged
Hook the TDS-11SA at the top of the skid and pin it at the bottom of the skid
Install pin retainers

4-41

Installation, Commissioning and Decommissioning

Decommissioning Removing the TDS-9/11SA from the drill floor Procedure
Ensure that the bail lock assembly is installed
Using the drawwork, lower the TDS-11SA and skid down the V-door ramp or from the drill floor using a crane

Sling

! The Bail Lock Assembly must be installed

4 Lifting Block Lower using the drawwork

Lifting Sling

Drill Floor

TDS-11SA with Skid 30,000 lb (13600 kg)

Lower the TDS-11SA on the Skid from the drill floor

Backup Line

4-42

Varco Systems

Installation, Commissioning and Decommissioning

Decommissioning Long term storage procedures TDS-11SA Long Term Storage Procedures
For indoor storage, cover the TDS-11SA in its shipping and handling skid. A cargo container is appropriate for outdoor storage.
Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60˚-80˚F ambient.
All exposed unpainted metal surfaces are coated with a rust preventive prior to shipment; however, check these surfaces periodically to be sure that no corrosion is taking place. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.
Cover all openings to prevent water or dust from entering. Leave enough space around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent.
During storage, rotate the motors and gear train periodically to distribute lubricant. Perform this at three month intervals if stored indoors, and at one month intervals if stored outdoors.
For long term storage recommendations dealing with the AC drilling motors, see the motor manufacturer’s manual.

Returning the TDS-11SA to Service After Storage

4


Remove all rust preventive and any corrosion that may have taken place, taking special care with load carrying components.
Repaint the tool if necessary.
Follow the return to service procedures in the AC drilling motor manufacturer’s manual.
Check for water and remove if any is found.
Change the hydraulic fluid and gearbox oil.
Lubricate the cooling and oil pump motors.
Lubricate the tool with general purpose grease.
Megger all connectors.

TDS-11SA

4-43

Guide Beams and Carriage

Inspecting the crown padeye and hang-off link 5-2 Inspecting the top section of the guide beam ... 5-3

1

Inspecting the guide beam joints....................... 5-4 Inspecting the main tieback .............................. 5-5 Inspecting the intermediate restraints .............. 5-6

2

Inspecting the carriage ...................................... 5-7

3

4

5

6

7

8

9

TDS-11SA

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 5

Guide Beams and Carriage

AC Electrical

Guide Beams and Carriage

Inspecting the crown padeye and hang-off link Crown

Yearly Crown Padeye

2.1" (52 mm) minimum

Monthly Crown Padeye Visually inspect weld for cracks

Monthly Cotter Pin Replace if missing

Shackle 2.0" (50 mm) minimum

Monthly

5

Shackle Inspect and replace if worn 1.5" (37 mm) minimum

Monthly Hang-off Link Bores Inspect and repair if worn Hang-off Link Bores

5-2

Varco Systems

Guide Beams and Carriage

Inspecting the top section of the guide beam Crown

2.1" (52 mm) minimum 1.5" (37 mm) minimum

Bolt Assembly

Hang-off Link Bores

Monthly Safety Pin Replace if missing

Monthly Hang-off Link Bores Inspect and repair if worn

Guide Beam Top Section

TDS-11SA

5-3

5

Guide Beams and Carriage

Inspecting the guide beam joints

! Verify that the joint pins, retainer pins and lynch pins are in place and secure. Replace any missing or damaged pins.

Secure

Daily Lynch Pin

5

Weekly Joint Pin

Yearly Typical Guide Beam Joint

Daily Retainer Pin

Monthly Inspect welds for cracks

5-4

Varco Systems

Guide Beams and Carriage

Inspecting the main tieback Guide Beam Bottom Section

Daily Check that the tool is aligned directly over well center Main Spreader Beam

Tieback Link

Tieback Plate

Yearly Typical all welds

5 Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks. Auxiliary Spreader Beam

Mast Leg

See General Information for torque values See Installation for assembly/disassembly

TDS-11SA

5-5

Guide Beams and Carriage

Inspecting the intermediate restraints Daily Check that the tool is aligned directly over well center

Weekly Check for tightness of cotter pins, and double nuts. If there are signs of shifting, verify alignment.

Weekly

5

Pin and Cotter Pin Verify that all pins are in place. Replace any missing or damaged pins.

Mast Girt

Yearly Typical all welds Guide Beam

See General Information for torque values See Installation for assembly/disassembly

5-6

Varco Systems

Guide Beams and Carriage

Inspecting the carriage

Weekly Typical all rollers Inspect for uneven wear, damage and looseness. Replace as required.

5

Daily Typical all detent pins Verify that pins are in place and secure

See General Information for torque values

TDS-11SA

5-7

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 6

Motor Housing, Transmission

AC Electrical

Motor Housing, Transmission

Illustrated index ................................................. 6-2 Inspection schedules ......................................... 6-3

1

Inspecting the internal lubrication flow (monthly) ............................................................. 6-4 Adjusting the encoder ........................................ 6-5

2

Gearbox lube pump assembly ............................ 6-7 Disassembly/assembly .................................................. 6-7 Inspection (yearly) ......................................................... 6-8 Gear backlash ..................................................... 6-9 Inspection (yearly) ......................................................... 6-9

3

Bail and main body ............................................. 6-10 S-pipe .................................................................. 6-11 Upper mainshaft liner ......................................... 6-12

4

Washpipe assembly ............................................ 6-13 Assembly ....................................................................... 6-13 Inspection ...................................................................... 6-14

5

Upper bonnet seals (yearly) ............................... 6-16 Mainshaft ............................................................ 6-17 Inspection ...................................................................... 6-17 Inspecting mainshaft end play (yearly) .......................... 6-18

6

Blower motor assemblies (monthly) .................. 6-19 Motor brakes (monthly) ...................................... 6-20 AC drilling motors (weekly) ................................ 6-21

7

Transmission disassembly/assembly ................. 6-22 Nondestructive Examination (NDE) ................... 6-23 Visual inspection ........................................................... 6-23 Magnetic Particle Inspection (MPI) ................................ 6-24

8

Ultrasonic Inspection ..................................................... 6-25 Safety valve inspection procedures (IBOP) ................... 6-25 9

TDS-11SA

Motor Housing and Transmission

Illustrated index

AC Motor Blower Assembly (2) Page 6-19

AC Motor Brakes (2) Page 6-20

6

Bail Page 6-10

S-Pipe Page 6-11

AC Drilling Motors (2) Page 6-21

Washpipe Assembly Page 6-13

Gearbox Lubrication Pump Assembly Page 6-7

Gearbox Assembly Page 6-4, 6-7

For AC motor and transmission lubrication see Page 3-2 thru 3-12

6-2

Varco Systems

Motor Housing and Transmission

Inspection schedules Daily

Page Number

Check for missing lockwire and cotter pins Check for loose or broken parts and leaks Check for damaged hoses and fittings Check the wash pipe assembly for leaks

See page 6-14

Check fluid levels and filter condition

See page 3-4

Weekly Check the AC motor louvers for damage

See page 6-19

Check the AC motor screens for contamination

See page 6-19

Monthly Check the flow of oil throughout the main body while the lube pump is running

See page 6-4

Check the S-pipe for pitting, corrosion, or erosion

See page 6-11

Check the upper mainshaft liner for erosion caused by leaking wash pipe packing

See page 6-18

Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear

See page 6-18

Check the blower motor assemblies for loose bolts

See page 6-19

Check brake pads for wear

See page 6-20

Yearly Check the gearbox lubrication pump assembly for wear or damage

See page 6-7

Check the gear teeth for pitting and corrosive wear

See page 6-8

Check for primary and secondary gear set backlash

See page 6-9

Check the mainshaft for axial movement

See page 6-18

Check bail, bushings and bail pins for wear

See page 6-10

Check the radial grooves on the stem and the load collar for wear

See page 6-17

6

Megger motors

5 Years Magnetic particle inspection (MPI)

TDS-11SA

See page 6-24

6-3

Motor Housing and Transmission

Inspecting the internal lubrication flow (monthly) Procedure
Remove the 3 in. pipe plugs from the main body and check the flow of oil coming from the four spray nozzles (two in the body, two in cover) while the lube pump is operating
Check that oil is running out of the upper gear drain holes in each compound gear set (indicates upper orifice is not blocked) and that oil is running through the spillway running from the thrust bearing (indicates orifice is not blocked)

Pipe Plug

Pipe Plugs

Monthly Upper Compound Gear Drain Hole Check flow

Monthly Body Spray Nozzles Cover spray nozzles not shown

6

Monthly Spillway Check flow

Pipe Plug Remove using a 2 inch, 12 point socket Main Body

6-4

Varco Systems

Motor Housing and Transmission

Adjusting the encoder Use the following procedure to adjust the encoder belt tension: 1. Remove the access covers 2. Disconnect all of the electrical connectors from the encoder. 3. Remove the lockwire and loosen the four sled hold-down screws. 4. Let the sled to move freely, allowing the belt tension spring to apply the proper tension to the belt.

!

Do not tension the belt by hand.

5. Carefully tighten the sled hold-down screws and torque them to 7 ft lb. 6. Lockwire the sled hold-down screws. 7. Reconnect the encoder electrical connections. 8. Replace both access covers and tighten the access cover screws to 15 ft lb and lockwire them.

6

TDS-11SA

6-5

Motor Housing and Transmission

Adjusting the encoder

Belt Tension Spring

Sled Hold-down Screws 4 Places

View from Side

Encoder Belt

Sled

View from Top (Blower Motor removed for clarity)

6

Electrical Connector Sled Encoder Belt

Encoder

Belt Tension Spring

6-6

Sled Hold-down Screws 4 Places

Varco Systems

Motor Housing and Transmission

Gearbox lube pump assembly Disassembly/assembly Disassemble the gearbox lubrication pump assembly and inspect the pump assembly components yearly for wear and damage as follows: 1. Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly 2. Remove the pump assembly by removing the eight lockwired capscrews that attach the pump adapter plate to the main body 3. Disassemble the spline adapter, pump, and housing using the pump vendor service instruction HS15 (located in the Vendor Documentation Package) 4. Inspect the pump assembly components, replacing any parts that are worn or damaged. Pay particular attention to the spline between the pump and motor, the gears, and the motor and pump sideplates. 5. Assemble the lubrication pump assembly in the reverse order of disassembly

i

Follow the pump vendor service instruction HS15 (located in the Vendor Documentation Package) when assembling the lubrication pump components, and torque all fasteners in accordance with DS00008, located in the Supplemental Materials book.

6

i

When reinstalling the pump assembly into the main body, inspect the O-ring for damage and replace the O-ring if any flat spots, nicks, or other damage is found.

6. Install the pump assembly into the main body. Torque the fasteners in accordance with DS00008, and reconnect the hydraulic and electrical connections.

TDS-11SA

6-7

Motor Housing and Transmission

Gearbox lube pump assembly Inspection (yearly) End Cover Thrust Plate 2 Places

Yearly Gearbox Lubrication Pump Assembly Check parts for wear or damage

Ring Seal

Body Seal 2 Places Gear Housing

Roller Bearing 4 Places

Gear Set

Pump Adapter Plate Capscrew 10 Places

6 Hydraulic Motor Low-Speed/High-Torque

O-ring

Main Body

Procedure
Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly
Remove the pump assembly by removing the ten lockwired capscrews that attach the pump adapter plate to the main body
Disassemble using the drawings in the Technical Drawing Package as well as the pump vender service instruction
Inspect and relace any parts that are worn or damaged

6-8

Varco Systems

Motor Housing and Transmission

Gear backlash Inspection (yearly)

A

6 Months Gear Teeth Check for wear, pitting, and gear set backlash

B

Solid Wire Solder

A

B

Dim. A + Dim. B = Backlash

Procedure

i

Inspect the pump adapter plate at the same time the gear backlash is checked

6
Drain the gearbox oil
Remove the access cover and the pump adapter plate to check primary and secondary gear set backlash
Run a piece of solid wire solder through the primary and secondary gear meshes and measure the thickness of the two flat spots made by the gear teeth surfaces with a micrometer. If the primary gear mesh backlash exceeds .030 in. or the secondary gear mesh backlash exceeds .040 in., excessive gear wear or bearing failure is indicated.

i

TDS-11SA

Check the gear teeth for pitting or corrosive wear at the same time the gear set backlash is checked

6-9

Motor Housing and Transmission

Bail and main body Inspection Wear allowances Component

Replace when

Bushing

Inner diameter is less than 4.450 in.

Bail Pin

Outer diameter is less than 4.125 in.

Bail

Yearly

Bushing 2 Places

Yearly

Main Body Cover

5 Years

6

Main Body

5 Years

Bail Pin 2 Places

Yearly

6-10

Varco Systems

Motor Housing and Transmission

S-pipe Inspection Procedure
Unscrew the two nuts that hold the S-pipe in place along with the six bolts that secure the clamp to remove and inspect the S-pipe
Clean the bore of the S-pipe and inspect for visible signs of pitting, corrosion, or erosion

i

Wing Nut

Seal Ring Plug

Use a flashlight and mirror to visually inspect the bore of the S-pipe. A Bore-o-Scope is best for inspection, if available.

Monthly Pressure test to rated working pressure


Remove and perform an ultrasonic inspection on the S-pipe if visual inspection indicates erosion or corrosion
Check condition of the seals
Apply pipe dope to the threads before re-installing

Monthly S-Pipe Check for visible signs of pitting, corrosion, or erosion (pitting or corrosion should be no deeper than 0.125 inch)

Clamp

Bolts

Seal Ring

Right-hand (inside of guard) configuration shown. Your S-pipe configuration may vary.

TDS-11SA

Wing Nut

6-11

6

Motor Housing and Transmission

Upper mainshaft liner Inspection Procedure
Remove the wash pipe assembly
Check the upper mainshaft liner for erosion caused by leaking wash pipe packing and replace the liner if erosion is found

i

The 3.875 in. OD polypack seal must also be replaced whenever the upper stem liner is replaced
Grease the polypack seal and clean the mainshaft bore before re-installing
Make sure the O-ring of the seal is facing down when the seal is installed on the liner

Wash Pipe Assembly

Monthly Upper Mainshaft Liner Replace if erosion is found during inspection

Polypack Seal

6 Polypack Seal Replace OD polypack seal when the upper mainshaft liner is replaced Main Shaft

Upper Mainshaft Liner

6-12

Varco Systems

Motor Housing and Transmission

Washpipe assembly Assembly 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 pin. 2. Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease using care not to grease the outside diameter of the spacers. 3. Install the socket head dog nose screw, ensuring that the screw nose is fully engaged in the groove of the lower spacer. 4. Install the grease fitting and turn the packing box upright. 5. Install the wash pipe into the packing box assembly (slotted end up). 6. Install the wash pipe nut onto the wash pipe. 7. Grease the packing seal and install into the holding ring using care not to grease the outside diameter of the holding ring. 8. Install the packing seal and holding ring over the slotted end of the wash pipe. 9. Install the snap ring. 10. Install the upper and lower o-rings using grease to hold them in place. 11. Compress the assembly to the length of the wash pipe.

6

Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the Washpipe Assembly Guide, P/N 128844.

TDS-11SA

6-13

Motor Housing and Transmission

Washpipe assembly Inspection

! The wash pipe nut and the packing box have left-handed threads

Slide the wash pipe nut and the packing box together for installation

Dowel Pin

Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease completely filling the void

6 Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer

Special Tools

3" Bore Wash Pipe Wrench 30150084

Recommended for proper tightening of the wash pipe nut and packing box

6-14

Varco Systems

Motor Housing and Transmission

Washpipe assembly Inspection O-Ring Snap Ring

Holding Ring

Daily

Packing Seal 5 per set

Wash Pipe Assembly Inspect for leaks

Wash Pipe Nut

Upper Spacer

Middle Spacer

Wash Pipe

Middle Spacer

Packing Assembly Box

6

Straight Ext. Grease Fitting

Lower Spacer

Socket Head Dog Nose Screw

O-Ring

Procedure
Visually inspect the wash pipe assembly for leaks
Replace any worn or damaged parts
Apply pipe dope to the threads before installing in the Top Drive

TDS-11SA

6-15

Motor Housing and Transmission

Upper bonnet seals (yearly) Inspection Procedure
Remove the bearing shield, the bearing retainer cap screws, and the bearing retainer
Inspect the bearing isolator, the oil seal, and the retainer o-ring for wear
Replace any worn or damaged parts

i

Align the shims so that the bearing lube tube bore is not blocked

Bearing Retainer Cap Screw 6 Places

Bearing Shield

Bearing Retainer

Lube Tube Oil Seal Bearing Shield

Bearing Isolator

Bearing Retainer Cap Screw 6 Places Bearing Retainer

Retainer O-Ring

Lube Tube O-Ring 2 Places

Yearly Retainer O-Ring

Yearly Bearing Isolator

6 Yearly Oil Seal

Lube Tube

Shims Hand pack the void with grease

6-16

Varco Systems

Motor Housing and Transmission

Mainshaft Inspection Wear allowances Component

Replace when

Stem Grooves

Groove width exceeds 0.650 in.

Load Collar Grooves

Groove width exceeds 0.620 in.

Stem

5 Years

Radial Grooves Inspect for groove wear and pitting 0.650 max

Yearly

Split Load Collar

5 Years

Radial Grooves Inspect for groove wear and pitting

Yearly

0.620 max

Retainer Ring

TDS-11SA

6-17

6

Motor Housing and Transmission

Mainshaft Inspecting mainshaft end play (yearly)

Dial Indicator Bearing Retainer Cap Screw 6 Places

Mainshaft Check for axial movement

Yearly Shims Bearing Retainer

Procedure

6


Remove the washpipe packing
Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator
If axial shaft movement is not .001 in. to .002 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .002 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to 250-270 ft lb

6-18

Varco Systems

Motor Housing and Transmission

Blower motor assemblies (monthly) Inspection Drip Shield

Bolts 4 Places, lock wire in pairs

Motor Fan Cover

Motor Fan

Bolts 4 Places, lock wire in pairs

Bolts 6 Places

Top Bearing Housing

Monthly Check for loose bolts

6 Procedure
Check bolts for tightness
Tighten as needed
Check motor cables for damage
Megger motors yearly

TDS-11SA

6-19

Motor Housing and Transmission

Motor brakes (monthly) Inspection Procedure
Remove the brake housing covers to access the drilling motor brakes
Inspect the brake pads for wear, and replace the pads if worn below the allowable lining wear limit given by the manufacturer
If the brake pads are wearing unevenly, adjust the pads by adjusting the bolts on the brake calipers
Inspect the brake hydraulic lines for leaks

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.

Caliper Mounting Bolts

6

Calipers and Pads Check pads for wear

Monthly

Brake Disc

Steel Plate 0.09 in. Min.

Adjust

Caliper Mounting Bracket

6-20

Brake Pads

Equal Gap

Varco Systems

Motor Housing and Transmission

AC drilling motors (weekly) Inspection Procedure
Check for missing or damaged louvers
Check screens for contamination
Check motor leads for damage
Check for missing lockwire
Megger motors yearly

Weekly Motor Leads Check for damage

6 Weekly Louvers Check for damage

Weekly Screen Check for contamination

TDS-11SA

6-21

Motor Housing and Transmission

Transmission disassembly/assembly Stem Sleeve Taper Roller Bearing

Main Body Cover Cap Screw Upper Spray Nozzles

Dowel Pin

Upper Compound Roller Bearing

Lock Washer

Dowel Pin

Bull Gear

Internal Retaining Ring Upper Stem Liner

Compound Gear Internal Retaining Ring Spacer Ring

Poly Pack Seal Oil Gallery O-Ring

Lower Compound Roller Bearing Bearing Lock Washer Main Shaft Stem

Internal Locknut Retainer Main Body O-Ring

Tapered Roller Thrust Bearing

6 Main Body

Main Shaft Sleeve

Lower Main Bearing

Main Lower Roller Bearing

Wear Sleeve Lube Plate Oil Assembly

Lock Washer

Bearing Retainer

Cap Screw

6-22

Varco Systems

Motor Housing and Transmission

Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.

NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, xray examination, and other methods of nondestructive testing for metallurgical integrity.

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

6

TDS-11SA

6-23

Motor Housing and Transmission

Nondestructive Examination (NDE) Magnetic Particle Inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components 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 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 carrying components over their 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 cause for replacing the suspect component. The load carrying components are:

6

❏

Mainshaft (lower portion)

❏

Bail

❏

Landing collar (yearly)

❏

Upper and lower IBOP

❏

Link adapter

❏

Saver, crossover, and spacer subs

❏

Power subs

❏

Power swivels

❏

Elevator links

Details on MPI procedures are in the following publications:

6-24

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 Inspection

Varco Systems

Motor Housing and Transmission

Nondestructive Examination (NDE) Ultrasonic Inspection In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.

Safety valve inspection procedures (IBOP) Upper and lower IBOP 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 IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).

6

TDS-11SA

6-25

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 7

PH50 Pipehandler

AC Electrical

PH-50 Pipehandler

PH-50 Pipehandler

PH-50 Pipehandler illustrated index .................. 7-2 Inspection schedule ........................................... 7-3

1

Precautions ......................................................... 7-4 Elevator links ...................................................... 7-5 Disassembly/assembly .................................................. 7-5 Inspection ...................................................................... 7-6

2

Link tilt ................................................................ 7-8 Disassembly/assembly .................................................. 7-8 Inspection ...................................................................... 7-9 3

Torque wrench assembly ................................... 7-10 Clamp cylinder body disassembly/assembly ................. 7-10 Inspecting the clamp cylinder body ............................... 7-14 Inspecting the stabilizer ................................................. 7-15

4

Inspecting the IBOP actuator cylinder and yoke ............ 7-17 Well control system ............................................ 7-19 Tool joint locks disassembly/assembly .......................... 7-19 Inspecting the tool joint locks......................................... 7-20

5

Inspecting the IBOP valves and saver subs .................. 7-21 Shot pin assembly .............................................. 7-22 Disassembly/assembly .................................................. 7-22 Inspection ...................................................................... 7-23

6

Rotating link adapter/load stem ......................... 7-24 Removing the pipehandler and link tilt from the top drive (while in mast) ............................................................... 7-24 Disassembling the link tilt assembly .............................. 7-24

77

Assembling the link adapter .......................................... 7-26 Assembling the link adapter to the top drive (while in mast) ............................................................... 7-27 Wireline adapter ................................................. 7-28 Inspection ...................................................................... 7-28

8

Nondestructive Examination (NDE) ................... 7-29 Visual inspection ........................................................... 7-29 Magnetic Particle Inspection (MPI) ................................ 7-30

9

Ultrasonic Inspection ..................................................... 7-31 Safety valve inspection procedures (IBOP) ................... 7-31 TDS-11SA TDS-11SA

7-1

PH-50 Pipehandler

PH-50 Pipehandler illustrated index

Rotating Link Adapter Page 7-25

Link Tilt Page 7-9

IBOP Actuator Yoke and Cylinder Page 7-19

Stabilizer Page 7-16 Well Control System Page 7-20 Clamp Cylinder Body Page 7-11

7 Stabbing Guide Page 7-14

For pipehandler lubrication see Page 3-13

7-2

Drill Pipe Elevator and Elevator Links Page 7-6

Varco Systems

PH-50 Pipehandler

Inspection schedule Each Use

Page Reference

Check wireline adapter sheaves for excessive wear or damage

See page 7-30

Daily Check for missing lockwire and cotter pins Check for loose or broken parts and leaks Check for damaged hoses and fittings Check clamp cylinder gate pins and retainer bolts

See page 7-11

Check tong dies for wear

See page 7-14

Check upper and lower IBOP valves for proper operation

See page 7-21

Weekly Check link tilt clamps for position and tightness

See page 7-9

Check stabbing guide and flippers for damage and wear

See page 7-11

Check front and rear stabilizers for wear

See page 7-16

Check IBOP actuator cylinder for leaks, tighten fittings

See page 7-17

Check IBOP actuator rollers for wear or excessive play

See page 7-19

Check tool joint locks for loose bolts

See page 7-20

Check upper and lower (if equipped) IBOPs for damage

See page 7-22

Monthly Check elevator link eyes for wear

See page 7-8

Check link tilt bushings for wear

See page 7-9

Check link tilt actuator cylinder clevis pins for wear

See page 7-19

Check IBOP actuator yoke for wear or excessive play

See page 7-19

Check shot pin assembly for wear or damage

See page 7-23

7 Yearly Check piston ring for pitting and chipping

See page 7-25

Check stem for pitting, grooves and chipping

See page 7-25

Replace GLYD rings, o-rings and bushings on rotating link adapter

See page 7-25

5 Years MPI Inspection

TDS-11SA

See page 7-31

7-3

PH-50 Pipehandler

Precautions To avoid serious injury or death, read and understand the following warnings before performing inspection and maintenance procedures:

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is moving.

Use caution when draining lubricant. It can be hot.

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.

Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system.

7 Do not attempt repairs you do not understand.

Read and understand all safety precautions and warnings before performing maintenance procedures.

7-4

Varco Systems

PH-50 Pipehandler

Elevator links Disassembly/assembly 1. Disconnect and remove the drill pipe elevator from the elevator links. 2. Using the Varco Driller’s Console (VDC), rotate the pipehandler 90° to position one of the elevator links directly below the front of the motor guard. 3. Remove the catch link bolt from the catch link. 4. Remove the clevis pin from the link, which connects the link tilt to the elevator link. 5. Using the sling, hoist the elevator link away from the pipehandler. 6. Rotate the pipehandler 180°, repeat the procedure to remove the other elevator link.

7

TDS-11SA

7-5

PH-50 Pipehandler

Elevator links Inspection Recess in Motor Guard

Rear 2 Lift and remove Link Tilt

Upper Catch Link

Catch Link Pin

950 lb (431 kg) Elevator Link

Front

26" (635mm) Typical

P

LE RO IPE FT T AT HA ND E

L

RIG LI ER HT NK TIL TF LO AT

Link

TO RQ PU UE SH WR & H EN OL CH D

DR LINK ILL O TI FF LT TIL T

Pipehandler Rotate Switch

Weekly

1

7

Link Clamps Inspect for position and tightness

Clevis Pin

Rotate PIP

EH

AN

DL

ER BR AK E IBO P

EM ER G ST EN OP CY

TO

Varco Driller’s Console

RQ

UE

Monthly

TO

RQ

UE

RP

M

7-6

Elevator Link Eyes Inspect for wear (see table)

Varco Systems

PH-50 Pipehandler

Elevator links Inspection (Varco links only) Wear Chart - Forged Links Upper Eye Dimension (C)

Lower Eye Dimension (A)

Capacity (per set) in Tons

5 inches

2 3/4 inches

350

4 13/16 inches

2 9/16 inches

300

4 5/8 inches

2 3/8 inches

225

7 7/16 inches

2 3/16 inches

175

C

Upper Eye (Hook)

C

B = 3 1/2 in., 350-Ton

B

B = 4 1/2 in., 500-Ton 6 inches

3 1/2 inches

500

5 3/4 inches

3 1/4 inches

420

5 1/2 inches

3 inches

325

5 1/4 inches

2 3/4 inches

250

7 1/2 inches

7 1/2 inches

350

7 1/4 inches

7 1/4 inches

300

7 inches

7 inches

225

6 3/4 inches

7 3/4 inches

175

B

B = 6 1/4 in., 750-Ton

To determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link.

A

Lower Eye (Elevator)

A

7

TDS-11SA

7-7

PH-50 Pipehandler

Link tilt Disassembly/assembly 1. Shutdown the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections. 3. Unpin and remove the link tilt cylinders. 4. Unpin and remove the link tilt crank.

i

Use the recommended spanner wrench to remove the rod gland seal.

7

7-8

Varco Systems

PH-50 Pipehandler

Link tilt Inspection

Pins Inspect for wear replace as needed

Monthly

Monthly Bushings Inspect for wear replace as needed

Monthly Link Tilt Actuator Cylinders Inspect the hydraulic connections for leaks

Link Tilt

Monthly Bushings Inspect for wear replace as needed

7

Wear allowances Component

Replace when

Pins

Wear exceeds .06 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

i

TDS-11SA

Bushings should be pressed in using the mating pin as an installation mandrel.

7-9

PH-50 Pipehandler

Torque wrench assembly Clamp cylinder body disassembly/assembly 1.

Shutdown power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections. 3. Support the clamp cylinder body. 4. Remove the two hex-head capscrews and lockwashers that hold the end cap in place. 5. Remove the end cap, spring spacer, spring sleeve, and spring. 6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a suitable work area. 7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on the clamp cylinder body. 8. Remove the four wear bushings, and replace the wear bushings as necessary. 9. Remove the two hinge pin retainer hex-head screws. 10. Swing out the two hinge pin retainers. 11. Remove the two hinge pins. 12. Remove the gate, front jaw, front stabilizer, and front stabbing guide. 13. Remove the two socket-head capscrews and hi-collar washers from the front jaw. 14. Remove the front jaw from the gate.

7

15. Repeat steps 11 and 12 for the rear jaw. 16. Push the cylinder head in enough to relieve the load on the cylinder head ring. Remove the cylinder head ring. Use care in this operation.

7-10

Varco Systems

PH-50 Pipehandler

Torque wrench assembly 17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the piston seal. 18. Carefully push the piston out of the body. Remove and discard the piston seal. 19. Remove the wiper rod and rod seal from the body. Discard the seals. 20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new seals and seal surfaces prior to reassembly.

i

Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

7

TDS-11SA

7-11

PH-50 Pipehandler

Torque wrench assembly

Hydraulic Manifold

RIG-UP

SHUTDOWN

RUN

COUNTERBALANCE MODE

Rig-up/Run/ Shutdown Valve Shown in SHUTDOWN position (Shown with link tilt removed)

Torque Arrestor

Spring

Spring Spacer Spring Shims Adjust to ensure the torque wrench clamps fully onto the saver sub

7

Support clamp cylinder body before removing end cap.

End Cap

Clamp Cylinder Body

7-12

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Manifold

Rear Stabilizer Front Stabilizer Hinge Pin Retainer

Spring Hex Head Screws

Cylinder Head Ring

Clamp Cylinder Body Body Seals

Cylinder Head

Jaw Assembly

Piston Seals

Tong Dies Piston Gate

Wear Bushing Socket Head Cap Screws Hinge Pin Front Stabbing Guide

Rear Stabbing Guide

7

Stabilizer

Spring

TDS-11SA

Retaining Plate

7-13

PH-50 Pipehandler

Torque wrench assembly Inspecting the clamp cylinder body

Tugger Line

V A R C O P H 5

0

Front and Rear Stabilizers Inspect for wear

Weekly

Tong Dies Inspect for excessive wear

CO

R VA

Daily Stabbing Guide Inspect for damage

Weekly

7 Clamp Cylinder Gate (Shown open)

Weekly Flippers Inspect for damage and excessive wear Swing Clear

Wear allowances Component

Replace when

Stabilizer

Wear exceeds 1/8 in.

Flippers

Wear exceeds 1/8 in.

7-14

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Inspecting the stabilizer Remove the two bolts (with slotted nuts and cotter pins) that hold the front stabilizer. Check the springs for damage and replace if needed. Pack spring cavities with grease and reassemble. Be sure all safety wire, cotter pins, and capscrews are tight, and tighten or replace as necessary.

7

TDS-11SA

7-15

PH-50 Pipehandler

Torque wrench assembly Inspecting the stabilizer

Stabilizer Springs Check for damage, replace as necessary.

Monthly

Monthly Stabilizers Inspect for wear. Replace if wear exceeds 1/8 in.

Cotter Pin

7

7-16

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Inspecting the IBOP actuator cylinder and yoke

Weekly IBOP Actuator Cylinder Check for leaks, tighten fittings

Daily Hoses Replace if worn or damaged

Monthly Pins and Bushings Check for wear or excessive play

Monthly Weekly

IBOP Actuator Yoke Check pins and bushings for wear or excessive play

IBOP Actuator Yoke Check cam followers for wear or excessive play

For IBOP Actuator Yoke lubrication see Page 3-13

Wear allowances Component

Replace when

Pins

Wear exceeds .03 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

i

Bushings should be pressed in using the mating pin as an installation mandrel.

TDS-11SA

7-17

7

PH-50 Pipehandler

Torque wrench assembly Inspecting the IBOP actuator cylinder and yoke Disassembling the IBOP actuator cylinder and yoke 1. Shutdown the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Remove one gate hinge pin, open the gate, and pull back the torque wrench assembly. 3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all connections. 4. Unpin and remove the IBOP actuator cylinder and yoke. 5. Replace the hydraulic lines as necessary. 6. Check for cylinder leaks.

7

7-18

Varco Systems

PH-50 Pipehandler

Well control system Tool joint locks disassembly/assembly

!

Do not reuse locking screws.

1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the inner rings with molybdenum disulfide grease, such as Molykote Gn paste. 2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as tong marks. If high spots exist, remove with file or light grinding. 3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub. 4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure these surfaces are smooth and free of grease, oil, and pipe dope. 5. Locate the tool joint lock symmetrically at each joint.

!

Never tighten locking screws before the tool joint lock is at the correct location, otherwise it will not slide freely.

6. Take any three or four locking screws equally spaced and tighten them to establish parallel or perpendicular position of the tool joint lock collars relative to the main shaft, IBOP valves, and saver sub respectively. This properly seats the collars on the taper of the inner ring and aligns the collars. 7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or counterclockwise sequence (not in a diametrically opposite sequence). Continue tightening all of the screws until they reach 185±5 ft lb.

7

8. Make sure no screw turns any more. The gap between the tool joint collars should be as equal as possible all the way around. 9. Safety wire all screws.

TDS-11SA

7-19

PH-50 Pipehandler

Well control system Inspecting the tool joint locks Tool Joint Lock to be Equally Spaced on Upper IBOP and Main Stem Joint Connection

1.4"

Tool Joint Shoulder

1.4"

Remove O-Ring and Look through this Space and Split on Inner Ring

Tapered Inner Ring Tool Joint Lock to be Offset on Upper and Lower IBOP Joint Connection Tool Joint 1.0" Shoulder

I.D. Groove First Line Up this Point with the Tool Joint Shoulder. Then Move Inner Ring Down 3/8" with the Outer Assembly. Replace O-Ring

Daily

7

1.4"

Tool Joint Shoulder

1.4"

Tool Joint Locks Inspect for loose bolts. Repair or replace if necessary. Torque to 185±5 ft lb.

Tool Joint Lock to be Equally Spaced on Lower IBOP and Saver Sub Joint Connection

Removing the Tool Joint Locks
Gradually release the locking screws all the way around. Initially release each screw about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the screws completely at this time, otherwise the collars may spring off.
Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.

7-20

Varco Systems

PH-50 Pipehandler

Well control system Inspecting the IBOP valves and saver subs Wear allowances Component

Replace when

Saver Sub

Threads have been recut to a minimum shoulder-to-shoulder length of 5 in.

i

See the IBOP Service Manual for IBOP disassembly/assembly and servicing information.

Weekly

Daily

Upper IBOP (Remote) Inspect for damage

Valve Check for proper operation and pressure test for leaks

Weekly IBOP Crank (Remote) Inspect for damage

Weekly

Daily

Lower IBOP (Manual) (Optional) Inspect for damage

Valve Check for proper operation and pressure test for leaks

7

5 Years Upper and Lower IBOP

TDS-11SA

7-21

PH-50 Pipehandler

Shot pin assembly Disassembly/assembly 1. Disconnect the hydraulic and electrical lines. 2. Remove the capscrews that attach the shot pin assembly to the main body. 3. Remove the capscrew and lockwasher holding the shot pin cover in place 4. Remove the shot pin components as shown in the illustration on Page 7-24 (end cap, o-rings, rod seal assembly, shot pin) 5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting bracket if the bearing is scored or damaged. 6. Remove the capscrew and lockwasher that hold the pinion gear in place, and remove the gear. 7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and remove the motor. Inspect the disassemble parts and replace any worn or damaged parts. Assemble the shot pin in the reverse order of disassembly.

7

7-22

Varco Systems

PH-50 Pipehandler

Shot pin assembly Inspection Shot Pin Assembly

Shot Pin Base

Dowel Pin

Shot Pin Remove burrs

Rod Seal Assembly

Hydraulic Motor

Rod Seal Assembly Dual Port Manifold

Shot Pin Sleeve O-ring

Shot Pin Bushing

Shot Pin Cap

7

Shot Pin Cover

Wear allowances Component

Replace when

Shot Pin

Outer diameter is less than 1.375 in.

Shot Pin Sleeve

Inner diameter is greater than 1.510 in.

Shot Pin Bushing

Inner diameter is greater than 1.475 in.

TDS-11SA

Pinion Gear

7-23

PH-50 Pipehandler

Rotating link adapter/load stem Removing the pipehandler and link tilt from the top drive (while in mast) 1. Drain the oil from the gearbox. 2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar. 3. Build a support over well center to support the weight of the link adapter. 4. Lower the top drive to the support built in Step 3. 5. Remove the bolts that attach the load stem to the main body. 6. Raise the top drive slowly to separate the link adapter from the main body. 7. Move the link adapter assembly to a clean, safe work area. 8. Orient the assembly with the stem flange up and block the entire assembly so that it is secure in this position.

Disassembling the link tilt assembly 1. Attach a 3-point sling to the stem and pull the stem out of the link adapter. 2. Turn the stem over and place it on its flange.

!

Protect the internal surfaces of the rotating link adapter and the surfaces of the drive stem when separating the two components. When removing the rotating link adapter from the stem, carefully tap with a mallet. There can be misalignment between the two bores when raising the drive stem and gear assembly.

7

i

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. 3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings from inside the rotating link adapter and gear inside dimension. 4. Remove and discard the stem flange O-rings and stem bore shaft seals.

7-24

Varco Systems

PH-50 Pipehandler

Rotating link adapter/load stem Inspecting the rotating link adapter Rotary GLYD Ring Remove, discard and replace

Yearly Rotary Link Adaptor O-Ring Remove, discard and replace

Yearly Thrust Ring Remove, discard and replace

Retainer Ring

Yearly

Turcite Bushing Remove, discard and replace

O-Ring

Yearly

Rotary GLYD Ring Wiper Seal

Yearly Piston Ring Inspect for pitting and chipped plating (Heat to 175-200° F to install)

Rotating Link Adapter Gear

Wear allowances Component

Replace when

Thrust Ring

Thickness is less than 0.105 in.

Turcite Bushing

Thickness is less than 0.112 in.

Yearly Stem Inspect for pitting, grooves and chipped plating

Stem O-Ring Remove, discard and replace

Index Mark Indicates front of stem

Yearly

Level Work Surface

TDS-11SA

7-25

7

PH-50 Pipehandler

Rotating link adapter/load stem Assembling the link adapter 1. Orient the stem so the drive stem flange is down on a suitably protected surface. 2. Install the gear with its rotating seal and wiper in place. 3. Install the O-ring for the piston ring. 4. Install the piston ring by tapping on it lightly with a mallet to press it into place (Heat to 220-250°) 5. Install the retainer ring. 6. Install all of the rotary seals on the rotating link adapter, 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. 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. Hammering with a large plastic mallet is an aid when assembing the stem to the link adapter.

i

Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts.

7

12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports. 13. Grease all lubrication points on the assembly. 14. Inspect the lower gearbox seal (located inside the stem flange), and replace as necessary.

7-26

Varco Systems

PH-50 Pipehandler

Rotating link adapter/load stem Assembling the link adapter to the top drive (while in mast) 1. Check the condition of the manshaft wear ring and replace if there is any evidence of grooving. 2. Place the rotating link adapter assembly back on the support built over well center, orienting the assembly so that the stem flange is up, and so that the idex mark faces forward. 3. Carefully lower the top drive to engage the mainshaft in the stem bore and then the stem flange pilot diameter is in the main body bore. 4. Install the flange bolts. 5. Install the link tilt cylinders, pin, and secure in place. 6. Install the link tilt crank and pin, and secure in place. 7

Install all hose assemblies.

8. Install tubing. 9. Install the shot pin assembly. 10. Fill the gearcase with gear oil (see Lubrication). 11. Check and fill the hydraulic oil as necessary. 12. Turn on the top drive and perform all pipehandler functions several times, checking for proper function and any leaks. 13. Re-check the hydraulic oil level and fill as necessary.

!

Always install a new mainshaft seal and use care not to damage the seal or the case.

i

!

TDS-11SA

A light coating of grease applied to the O-ring helps in installing the rotating link adapter assembly into the main body.

Always install a new drive stem O-ring and use care not to damage the O-ring or the case.

7-27

7

PH-50 Pipehandler

Wireline adapter Inspection

i Inspect the condition of the sheaves before and after each use.

7

Each Use Sheaves Replace or repair damaged parts as necessary

7-28

Varco Systems

PH-50 Pipehandler

Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.

NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, xray examination, and other methods of nondestructive testing for metallurgical integrity.

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

7

TDS-11SA

7-29

PH-50 Pipehandler

Nondestructive Examination (NDE) Magnetic Particle Inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components 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 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 carrying components over their 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 cause for replacing the suspect component. The load carrying components are:

7

❏

Mainshaft (lower portion)

❏

Bail

❏

Landing collar (yearly)

❏

Upper and lower IBOP

❏

Link adapter

❏

Saver, crossover, and spacer subs

❏

Power subs

❏

Power swivels

❏

Elevator links

Details on MPI procedures are in the following publications:

7-30

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 Inspection

Varco Systems

PH-50 Pipehandler

Nondestructive Examination (NDE) Ultrasonic Inspection In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.

Safety valve inspection procedures (IBOP) Upper and lower IBOP 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 IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).

7

TDS-11SA

7-31

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 8

Hydraulic System

AC Electrical

Hydraulic System

Hydraulic system ................................................ 8-2 Illustrated index ................................................. 8-3

1

Hydraulic system diagram.................................. 8-4 Inspection ........................................................... Precautions ................................................................... Maintenance schedule .................................................. Hydraulic fluid level and filter ......................................... Adding the hydraulic fluid .............................................. Draining the hydraulic fluid ............................................ Hydraulic reservoir bladder (yearly) ............................... Heat exchanger ............................................................. Using the hydraulic system test ports ............................ Precharging the accumulators ....................................... IBOP timing circuit ......................................................... IBOP and oil pressure switch ........................................

8-5 8-5 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16

Setting up the circuits ........................................ Hydraulic pumps and unloading circuit .......................... Fixed displacement (lube) and variable displacement pumps ............................................................................ Counterbalance circuit and stand-jump circuit ............... AC motor brake circuit ................................................... Shot pin circuit ............................................................... Link tilt cylinder circuit.................................................... Rotating link adapter hydraulic motor relief circuit .........

8-17 8-17

3

4

5 8-18 8-22 8-26 8-27 8-29 8-30

Troubleshooting .................................................. 8-31 HPU and reservoir bladder ............................................ 8-31 Counterbalance and stand jump.................................... 8-33 Stand jump testing ......................................................... 8-34 Counterbalance and stand jump schematic diagram .... 8-36 Troubleshooting the brakes ........................................... 8-37 Shot pin cylinder and clamp cylinder ............................. 8-39 Link tilt cylinders ............................................................ 8-41 Gearbox lubrication hydraulic system ............................ 8-43 Rotating link adapter motor schematic diagram ............ 8-46 IBOP actuator schematic diagram ................................. 8-47 Hydraulic schematic symbols ............................ 8-48 TDS-11SA

2

6

7

8

9

Hydraulic System

Hydraulic system The hydraulic control system is a completely self-contained, onboard system. A 10-horse power, 1800 rpm, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalance system. Three hydropneumatic accumulators are located on the main body. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the AC drilling motors and is equipped with strainers and an oil level sight gauge.

8

8-2

Varco Systems

Hydraulic System

Illustrated index Specifications

Hydraulic Oil Filter Page 8-8

Pump Motor

10 hp, 1,800 rpm, AC motor

Reservoir Capacity

25 gal

Counterbalance Manifold Page 8-22

Counterbalance Accumulator Page 8-14

Main Hydraulic Manifold Page 8-13

Upper IBOP TimeDelay Accumulator Page 8-15 Hydraulic Oil Fill Page 8-9

Link Tilt Manifold Page 8-29

Oil Pressure Switch Page 8-16

Link Tilt Cylinders Page 8-29

System Accumulator Page 8-14 IBOP Pressure Switch Page 8-16 Upper IBOP Actuator Cylinder Page 8-15

Front

Counterbalance Cylinders Page 8-22 Hydraulic Oil Reservoir Page 8-11 Rotating Head Motor and Shot Pin Assembly Page 8-27

Rear

Front

10 HP AC Motor and Pump Assembly Page 8-17

Rear

8

TDS-11SA

8-3

Hydraulic System

Hydraulic system diagram Drilling Motor Brake

Upper IBOP Actuator Cylinder

Link Tilt Cylinders

Pipehandler Clamp Cylinder

Link Tilt Manifold

Counterbalance Accumulator

Rotating Head (Elevator Positioner)

Shot Pin Cylinder

Counterbalance Cylinders

Rotating Link Adapter Lift

Rotating Head Motor

Gearbox Lube Oil Distribution

Counterbalance Manifold

Main Hydraulic Manifold

Low Speed Hydraulic Motor Upper IBOP Time-Delay Accumulator

System Accumulator

Lube Oil Pump

Gearbox Sump

M 10 HP A.C. Motor

8

8-4

Variable Displacement Pump

Fixed Displacement Pump (Mtr. Lube)

Hydraulic Reservoir

Varco Systems

Hydraulic System

Inspection Precautions To avoid serious injury or death, read and understand the following warnings before performing inspection and maintenance procedures:

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is moving.

Use caution when draining lubricant. It can be hot.

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.

Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system.

Do not attempt repairs you do not understand.

8 Read and understand all safety precautions and warnings before performing maintenance procedures.

TDS-11SA

8-5

Hydraulic System

Inspection Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

!

Use care when handling components to prevent nicking close tolerance finishes.

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 daily 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.

8 Replace worn or damaged hydraulic system components immediately. Inspect the hydraulic fluid level in the hydraulic reservoir located between the AC drilling motors daily. Inspect the hydraulic filter located on the upper left AC drilling motor daily.

8-6

Varco Systems

Hydraulic System

Inspection Maintenance schedule Hydraulic system oil lubrication schedule Description

Frequency

Replace hydraulic system filter (P/N 114416-1)

1 x every 3 months

Perform hydraulic system oil analysis

1 x every 6 months

Replace hydraulic fluid

1 x every year, or earlier based on oil analysis

Inspect hydraulic reservior bladder

1 x every year

Replace hydraulic reservior bladder

1 x every 2 years

Daily inspections Description Check the condition of the hydraulic filter indicator Check hydraulic fluid levels Check for hydraulic fluid leaks Check the condition of hydraulic hoses

Recommended hydraulic lubricants Oil Temperature Range -15˚ to 75˚ C

-10˚ to 85˚ C

(5˚ to 167˚ F)

(14˚ to 185˚ F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Harmony 32AW

Harmony 46AW

Manufacturer Castrol Chevron Exxon Gulf Mobil

DTE 24

DTE 25

Shell

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

8 Viscosity Index ISO Viscosity Grade

TDS-11SA

32

46

8-7

Hydraulic System

Inspection Hydraulic fluid level and filter

Cork Ball (Level Indicator)

Daily Red “Pop-up” Dirt Alarm

Sight Glass Hydraulic Oil Sight Gauge

Hydraulic Oil Filter

Procedure

8


Check the red “pop-up” alarm on the hydraulic filter daily
Replace the filter (Varco P/N 114416)if the indicator has popped up or as recommended
Use care to prevent contamination from entering the hydraulic system during maintenance activities

8-8

Varco Systems

Hydraulic System

Inspection Adding the hydraulic fluid Specifications Reservoir Capacity

25 gal

Procedure
Turn the TDS-11SA off
Ensure that the area is clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill
Remove dust plug from the female quick disconnect on the lubrication kit
Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm
See Lube Schedule for specifications
After adding fluid, replace the dust plugs

Cork Ball (Level Indicator)

Sight Glass Hydraulic Oil Sight Gauge

Hydraulic Oil Fill Male Quick Disconnect

Hydraulic Oil Fill

Female Quick Disconnect

Hydraulic Lubrication Kit 55 gal Drum Varco P/N 92643

TDS-11SA

8

8-9

Hydraulic System

Inspection Draining the hydraulic fluid

Precautions
Hydraulic fluid may be hot
Use care when opening the valve
Avoid spills
Holds 25 gallons

Valve Handle

Pump Inlet/Drain Adapter 10 HP AC Pump Motor

Procedure

8


Isolate power to the pump motor
Ensure that the valve is closed
Remove the plug and attach a hose
Open the valve and drain the fluid
Close the valve and remove the hose
Replace the plug

8-10

Fixed Displacement Pump Variable Displacement Pump

Varco Systems

Hydraulic System

Inspection Hydraulic reservoir bladder (yearly)

Reservoir Breather

Hydraulic Oil Reservoir Between AC Drilling Motors Reservoir Cover

Apply gasket sealing compound to prevent leaks

Yearly Reservoir Bladder Varco P/N 110191-501 Check for wear and damage Gasket Varco P/N 110132

Front Apply gasket sealing compound to prevent leaks

Rear

Hydraulic Oil Reservoir

Procedure
Drain hydraulic fluid and clean area before inspecting the reservoir bladder
Remove the 10 cap screws and lock washers from the cover
Remove cover with bladder attached
Check yearly for wear or damage
Replace the bladder every two years
Replace the bladder if fluid escapes the reservoir breather when the Top Drive is on its back

TDS-11SA

8-11

8

Hydraulic System

Inspection Heat exchanger

Blower and Brake Covers

Monthly Oil Heat Exchanger Remove any dirt and inspect for leaks, corrosion, and cleanliness

Drill Motor Assembly Left side

8

8-12

Varco Systems

Hydraulic System

Inspection Using the hydraulic system test ports

Stand Jump SV9 L4

PV

Brake SV1

Clamp/ Shot Pin SV5

P1 IBOP SV4

PF

Float Link SV8 Tilt SV6

* B8

G5

A4 CB

* SA * P

* T1

C4 SV2 Rotating Link Adapter Z1

B9 B1

A6 C5 B5

8

B6

* These test ports are on sides or bottom of manifold.

As Viewed From Below

TDS-11SA

8-13

Hydraulic System

Inspection Precharging the accumulators

i

Port

Accumulator

Setting

System Accumulator

(125-cubic inch displacement) 800 psi precharge

SA

Counterbalance Accumulator

(728-cubic inch displacement) 900 psi precharge

CB

Time-Delay Accumulator

(30-cubic inch displacement) 800 psi precharge

C4

Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above.

Procedure
Disconnect the hydraulic lines to the accumulators and drain them of all hydraulic fluid.
With the hydraulic system shut down, and the counterbalance mode valve in the “shut down” position, test the hydraulic pressure at CB, SA and C4 on the hydraulic manifold, mounted to the transmission housing. Verify that all three points measure 0 psi.

i

Note that there is a time delay in pressure decay on port C4.

Counterbalance Accumulator

Upper IBOP Time- Delay Accumulator


Test the precharge pressure on the following three nitrogen filled accumulators, using part number 114446-1.

Varco Part Number 114446-1

Hydraulic Manifold (Reference)

System Accumulator

Front

Rear

8

8-14

Varco Systems

Hydraulic System

Inspection IBOP timing circuit IBOP Actuator Cylinder 2.500" Dia. Bore X 4.00" Stroke 1.750" Dia. Rod Open

Test Point Typical

Close

Hydraulic Cylinder CR LODC

30 PSI CXCD

2

Time-Delay Accumulator

1

T-13A

1

Logic Cartridge

30 Cubic Inches 800 PSI Precharge

2

3 50 PSI CP

VR

T-11A

Gas Charged Accumulator

A4

B4

A4

B4

-6

-6

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055ø D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A

2

1

.010ø 2

8

3

PC4

System Pressure

TDS-11SA

Tank

8-15

Hydraulic System

Inspection IBOP and oil pressure switch Hoses Inspect for wear or damage. Replace yearly or as required.

Yearly

IBOP Pressure Switch Configuration

Oil Pressure Switch Configuration

Pressure Adjusting Screw

Yearly

Switch Pressure Settings Component

Setting

IBOP Pressure Switch

Factory preset at 102.0 BAR (1500 psi) rising +0 Factory preset at 18.0 -1.0 psi decreasing

Wires Inspect for wear or lose connections.

8 Oil Pressure Switch

8-16

Varco Systems

Hydraulic System

Setting up the circuits Hydraulic pumps and unloading circuit There are two pumps – a fixed displacement pump runs the transmission lubrication system and a variable displacement pump provides hydraulic flow to the hydraulic system.

Guide Beam

Pump/Motor

Pump Pressure Compensator Adjustment Point

8 Variable Displacement Pump

TDS-11SA

Fixed Displacement Pump

10 HP AC Pump Motor

8-17

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 1. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when looking into pump shaft/ electric motor fan). Correct as required. 2. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would indicate cavitation; check for leaks. 3. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end, cap the tube and plug the PF port using steel fittings. 4. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise, which allows the hydraulic system to operate without building up pressure. 5. Set the relief valve RV2 to minimum pressure, fully counterclockwise.

i

Make sure the variable displacement pump case is filled with clean hydraulic oil.

6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the pressure increases to 400 psi at test point PF. Set the jam nut on RV2. A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.

i

While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor.

8

8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate. 9. Restart the hydraulic system electric motor. 10. Set the counterbalance mode valve to the RUN position. 11. Adjust UV1, fully clockwise, to maximum pressure.

8-18

Varco Systems

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 12. Connect a gauge to test point PV. Note the ammeter reading while RV1 is at minimum setting. 13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a steady rate. During the pressure rise, observe the ammeter. The motor current should rise to a maximum value at 800 psi, then drop off and begin to rise again. The point where the current drops is the pump pressure compensator setpoint. 14. Adjust relief valve RV1 to its minimum setting. If maximum motor current does not occur at 800 psi, adjust the pump pressure compensator as required. 15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0 psi to verify maximum motor current at 800 psi. 16. Connect a gauge to test point SA, and leave the gauge on PV. 17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut. 18. Install steel cap over the adjustment screw to discourage unauthorized adjustment. 19. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off, then an additional two turns counterclockwise. The pressure cycles like a sawtooth wave. Pressure at PV

3000

Pressure at SA

2000 Pressure 1700 (psi)

1000 800

8

150 0

10

20

30

40

50

60

Approximate Time (seconds)

TDS-11SA

8-19

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 20. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2,000 psi. The pressure at SA decays until UV1 reloads. After reloading, the pressure rapidly rises to the unload pressure. 21. Observe several unload-reload cycles to determine the unload pressure. 22. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.

!

Perform the adjustment with reasonable speed. The process takes no longer than two minutes. Taking longer increases the temperature of the hydraulic fluid.

23. Observe the cycle of loading and unloading of the relief valve. To verify the setting of UV1, note the difference in pump noise level between the loaded and unloaded condition.

RV1

RV2 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold Bottom View

B6

A6

Z1

DR

TF B5

B5

B4

C5

B9 TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

P5 C4

B8

PF RIG-UP

MV SHUTDOWN

PV DF

P/N 0181

PF RUN

SV4

COUNTERB NCE MODE

G5

8

PF

8-20

Varco Systems

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps

Manifold Assembly UV1 2200 PSI

T-10A RV2

2

3

T-11A

1 Z1 1

400 PSI

2 RV1

PV

PF

800 PSIG

Pump-Motor Assembly B 1.00 IN^ 3/REV. L

1.10 IN^ 3/REV. MAX. .50 IN^ 3/REV. MIN.

S

L1

8

TDS-11SA

8-21

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit 1. For the counterbalance circuit there are three adjustments: ❏

Relief valve (on counterbalance cylinder)

❏

PCC – operator set

❏

SJR – operator set

2. To set the relief valve, make sure the pumps are operating. 3. Adjust pressure reducing valve PCC to the maximum setting, fully clockwise. 4. Connect a gauge to test port CB. 5. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting. 6. Increase the pressure clockwise using a 5/32 in. Allen wrench and 9/16 in. open-end wrench. 7. Observe the relationship of turning the relief valve adjustment clockwise to pressure increase. 8. When the relief valve reaches system pressure, turn the setting one full turn clockwise beyond the setting and set the jam nut. 9. Install a steel cover over the valve. 10. Adjust PCC to 1,200 psi. 11. Measure pressure at test port CB. 12. Prepare the hardware to attach the cylinder pear links to the hook. 13. Rotate the counterbalance mode valve from the RUN position to RIG-UP position. This causes the counterbalance cylinders to slowly extend.

8

!

Cylinders stroke to the end of stroke with the mode valve in the RUN position.

8-22

Varco Systems

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit 14. Once cylinders reach end of stroke, attach hardware to the pear links on the hook. 15. Rotate the counterbalance mode valve back to the RUN position. 16. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just begins to lift off of the hook. 17. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize. 18. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down counterbalance cylinders and system accumulator before shipping or performing maintenance. 19. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the hook. Note the pressure at CB. 20. Reduce PCC an additional 25 psi. The pressure at CB is about 1,600 psi. 21. Connect a gauge to test point B9. Activate the STAND JUMP mode on the drilling console. Adjust relief valve SJR until the bail lifts off the hook. The gauge at B9 should read about 190 psi. 22. Switch back to DRILL counterbalance mode and observe the pressure at test point CB. 23. Switch back to STAND JUMP mode and observe the pressure CB increase by 190 psi.

8

TDS-11SA

8-23

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit PCC CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

B6

A6

Z1

DR

P

Manifold Bottom View TF

B5

B5

B4

C5

Manifold End View

B9

SA

CTR

TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

C4 PF

UV1

RIG-UP

MV

1 XC

SHUTDOWN

PV

P/N 0181

PF COUNTERB NCE MODE

SV4

RUN

G5

DF

SA

CB

P5

B8

CB

8

8-24

Varco Systems

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit Pressure Relief Valve

2500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 .010ø

T

Counterbalance Accumulator

Normally-Open Logic Cartridge Metering

T

728 Cubic Inches 900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

System Accumulator

SA

TDS-11SA

2 2

TF

4

PCC T-21A

DF

126 Cubic Inches 800 PSI Precharge

1

1600 PSI

T-13A

T-5A 30 PSI

1

Pressure Relief Valve

1 SJR 2

190 PSI

3

8

System Pressure CTF

To Tank

8-25

Hydraulic System

Setting up the circuits AC motor brake circuit The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,400 psi. The pressure reducing valve regulates the pressure to 1,400 psi. The solenoid valve operates to apply pressure, setting the brakes, or stop pressure to release the brakes. 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 1,400 psi. If the reading is not 1,400 psi, adjust the pressure control reducing valve PC 1 to 1,400. Turn the auto brakes switch to the OFF position. The pressure reading should be very low. If the pressure is high, the solenoid valve might be sticking. RV2 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold Bottom View

B6

A6

Z1

DR

TF B5

B5

B4

C5

B9 TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

P5 C4

B8

PF RIG-UP

PV

MV SHUTDOWN

DF

P/N 0181

PF COUNTERB NCE MODE

SV4

RUN

G5

B1

8

8-26

Varco Systems

Hydraulic System

Setting up the circuits Shot pin circuit 1. Set the adjustable relief valve near the body of the cylinder. The shot pin often misses the hole in the rotating gear. The force the shot pin exerts is limited until the pin engages a hole.

i

The electrical system jogs the rotating head until the pin engages a hole.

2. To limit the amount of force, you set the valve by operating solenoid valve SV5 manually, forcing the pin to stop on the face of the gear. 3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to 200 psi. 4. Tighten the jam nut on the relief valve. 5. At rest, the SV5 valve is de-energized. 6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi. Hydraulic Drive Motor SV5

C5 Link Adapter Rotation Gear

Hydraulic Manifold

(As Viewed from Below)

Shot Pin

8

(Simplified for Clarity)

TDS-11SA

8-27

Hydraulic System

Setting up the circuits Rotating Link Adapter Drive Motor and Shot Pin Assembly

10 HP AC Motor and Pump Assembly

(Simplified for Clarity)

Hydraulic Drive Motor

Motor Relief Valve Rotating Link Adapter

B5

Shot Pin Relief Valve

A B Motor Relief Valve

C5 Link Adapter Rotation Gear

A5

Shot Pin

8

8-28

Varco Systems

Hydraulic System

Setting up the circuits Link tilt cylinder circuit 1. There is nothing to adjust on the manifold for the link tilt circuit. 2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all four counterbalance valves fully clockwise, then one turn counterclockwise.

i

If the valves are not adjusted correctly, link tilt operation is not synchronized.

3. The correct pressure setting is 1,500 psi. The procedure is the same for all four valves. Adjust the valves one at a time. 4. There is a test point on each loading manifold. 5. From the driller’s console, move the link tilt to go to the mousehole position. 6. The cylinder goes to full extension and the pressure at the test port TP is 2,000 psi. 7. Command the link tilt to the OFF position and observe the pressure delay at TP. This delayed pressure is the setpoint of the counterbalance valve. 8. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise. 9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

i

!

This is an iterative process. Continue to set the driller’s console control to the mousehole position and OFF, taking present and decayed pressure readings.

Turning the counterbalance valve counterclockwise increases the pressure.

8

10. Repeat the procedure above for the other cylinder at the mousehole position. 11. Command the link tilt to the DRILL position and repeat the procedure above to set both counterbalance valves on the DRILL side.

TDS-11SA

8-29

Hydraulic System

Setting up the circuits Rotating link adapter hydraulic motor relief circuit 1. Set the relief valves mounted on rotation motor. 2. Operate the clamp. The shot pin must go through the hole, which locks up the gear. 3. Turn the manual override on the SV2-rotation circuit to drive the head in the counterclockwise direction. Test the pressure at A and adjust the relief valve to 1,600 psi. 4. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the clockwise direction and test the pressure at B. Adjust the relief valve to 1,600 psi.

Hydraulic Drive Motor

Relief Valves

Manifold Link Adapter Rotation Gear Test Points

(Simplified for Clarity)

8

8-30

Varco Systems

Hydraulic System

Troubleshooting HPU and reservoir bladder Problem

Probable cause

Remedy

Hydraulic system overheating

Relief valves RV1 and RV2 out of adjustment.

Test pressures and adjust relief valves.

Unloading valve is not working.

Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down position too long and pressure bleeds down.

Check system pressure.

No precharge in system accumulator.

Charge system accumulator.

System pressure is down.

Test pumps and motors. Test relief valve pressures. Adjust as required. Check for leaks, loose fittings, loose cylinders, worn hoses, fluid levels and seals.

Piston pump is not working.

Replace the piston pump.

Flexible coupling is damaged.

Replace the flexible coupling.

Lubrication pump is not working.

Replace the lubrication pump.

Pressure at UV1 is too low.

Adjust pressure at UV1.

Pumps are rotating in the wrong direction.

Inspect hydraulic connections and correct rotation.

Suction valve closed.

Open suction valve.

Low oil level in reservoir.

Fill hydraulic reservoir.

Hydraulic components do not operate.

8

TDS-11SA

8-31

Hydraulic System

Troubleshooting HPU and reservoir bladder schematic diagram

PV

PF

TR

DR

Manifold Assembly Hydraulic Fill Disconnect

System Pressure 6µm

50 PSID

Prefill Valve -12

Pressure Compensator Control

T

Filter with Bypass Valve

T -16

800 PSIG -6 XC B 1.00 In^ 3/Rev. L 1.10 In^ 3/Rev. Max. .50 In^ 3/Rev. Min.

M 10 HP 1800 RPM S

Variable Displacement Pump

L1

Filter (Strainer)

4 PSI Vent

Fixed Displacement Pump

Reservoir Assembly

8

8-32

Varco Systems

Hydraulic System

Troubleshooting Counterbalance and stand jump The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a hydraulic pressure. Refer to the vendor documentation material located 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-11SA off the hook. The optional stand jump feature 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-11SA 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 1600 psi at CB. Perform the following steps to adjust the force: 1. Set the counterbalance mode valve on the bottom of the manifold 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.

TDS-11SA

8

8-33

Hydraulic System

Troubleshooting Stand jump testing For the optional stand jump feature, a lift of about 33,000 lb is achieved with a pressure of approximately 1800 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.

i

Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

8

8-34

Varco Systems

Hydraulic System

Troubleshooting Problem

Probable cause

Remedy

Counterbalance does not function.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and ajust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Stand jump does not function.

8

TDS-11SA

8-35

Hydraulic System

Troubleshooting Counterbalance and stand jump schematic diagram Pressure Relief Valve

2500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 T

.010ø

T

Counterbalance Accumulator

Normally-Open Logic Cartridge Metering

728 Cubic Inches 900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

8

System Accumulator

SA

8-36

2 2

TF

4

PCC T-21A

DF

126 Cubic Inches 800 PSI Precharge

1

1600 PSI

T-13A

T-5A 30 PSI

1

Pressure Relief Valve

1 SJR 2

190 PSI

3

System Pressure CTF

To Tank

Varco Systems

Hydraulic System

Troubleshooting Troubleshooting the brakes Problem

Probable cause

Remedy

Brake does not release.

Directional valve is stuck.

Test the valve and replace if necessary.

Brake releases but still drags.

Check valve is blocked or tube is pinched.

Replace the check valve or tube as required.

Mechanical problems with brakes.

Repair brake mechanism.

Hydraulic oil on brake pads.

Check for hydraulic leaks and repair.

Pressure is not 1,400 psi or does not rise crisply to 1,400 psi.

Reducing valve is plugged or needs to be adjusted or replaced.

Directional valve is stuck (check pressure at B1).

Replace valve or check electrical signal.

Hydraulic oil is contaminated.

Replace hydraulic oil.

Pressured reducing valve is faulty.

Replace valve.

Brakes do not engage or slip.

Delay in brakes actuating after console switch is turned on.

8

TDS-11SA

8-37

Hydraulic System

Brake circuit schematic diagram Brake Calipers

2 Position Solenoid Valve Brakes On

Cable ID Number

A

B

P

T

b

-4

C01

B1

SV1

.071ø

Manifold Assembly

D03

Non-Adjustable Orifice P1

Test Point

1400 PSI PC1

Reducing Valve

8

1

T-11A

2

System Pressure

8-38

3

Tank

Drain

Varco Systems

Hydraulic System

Troubleshooting Shot pin cylinder and clamp cylinder Problem

Probable cause

Remedy

Shot pin does not engage.

Solenoid valve is not operating or relief valve is not adjusted.

Check electrical actuation and test pressure. Adjust as required.

Abnormal pressure change at B5 and C5 indicates valve problem.

Replace directional control valve.

Normal pressure change indicates plumbing or shot pin cylinder are faulty.

Repair plumbing or shot pin cylinder.

Shot pin applies excessive force to rotating head gear.

Relief valve is not operating or out of adjustment.

Test pressures and adjust as required.

Clamp cylinder does not actuate.

No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.

i

Shot pin engages but clamp cylinder does not activate.

Cylinder is damaged.

Inspect cylinder and repair or replace.

To provide high pressure to the clamp circuit, pressure at C5 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 link adapter, and clamp cylinder.

Repair plumbing, rotating head, or clamp cylinder.

While clamping, pressure at CR 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.

Clean or repair CNEC valve.

Control valve not operating.

Check pressure at C5. Replace valve CV5 if required or the regenerate manifold.

8

TDS-11SA

8-39

Hydraulic System

Troubleshooting Shot pin cylinder and clamp cylinder schematic diagram Clamp Cylinder 10.000" Dia. Bore X 2.0" Stroke 8.000" Dia. Rod

Hydraulic Cylinder Cavity Plug

CP

CR

1

Pilot-to-Close Check Valve

2

3 T-2A

CKEB

30 PSID 2 1 CNEC

Shot-Pin Cylinder

3

2.000" Dia. Bore X 2.31" Stroke 1.500" Dia. Rod

Relief Valve

T-2A

1 T-5A

COFA .047ø

2

Shot Pin Cylinder

400 PSI

2

30 PSID

2

2x .094ø

VR

VP 1

2 Position Solenoid Valve 5 Clamp/Shot Pin

Non-Adjustable Flow Control

Cable ID Number

A

B

P

T

b

A5

.159ø

SV5 D03

E5

G5

E5

G5

-8

G5

.039ø

B5

.031ø

C5

AR5 2

3

Pressure Reducing Valve

2

1 LC5

1

T-11A

.031ø

50 PSI 3

Logic Cartridge

Rotating Link Adapter Assembly

-6

-6

C05

E5

-8

Clamp

-8

-8

T-10A B5 C5

.031ø

500 PSI

T-11A

3

2

T-21A CV5

Externally-Drained Pilot-to-Open Valve

1

4 75 PSI P5

Drain

1

8

3

T-11A

System Pressure

PC5

2

Tank

Drain System Pressure Tank T1

8-40

T1

D5

Manifold Assembly

Varco Systems

Hydraulic System

Troubleshooting Link tilt cylinders Problem

Probable cause

Remedy

Drill pipe elevator does not reach mouse hole/ derrickman position.

Link clamp incorrectly adjusted.

Readjust

Links drift when valve is released.

Pressure at B8 does not decay to less than 100 psi.

Replace the pilot to open check valve.

Pilot to open check valve is stuck open or contaminated.

Replace the pilot to open check valve.

Faulty cylinder seal.

Replace the seal.

Load holding relief valves are out of adjustment, stuck open, or contaminated.

Adjust or replace the load holding relief valve.

Drill pipe elevator does not float back to center position.

Use manual override. If the link tilts, the problem is electrical. If the links do not tilt, the problem is hydraulic.

Test the solenoid and connectors. Test the hydraulic system.

Link tilt does not tilt.

Solenoid valve is not shifting.

Check electrical continuity.

Links do not move together.

Load holding valves are out of adjustment.

Adjust the pressure for all four valves to 1,500 psi.

8

TDS-11SA

8-41

Hydraulic System

Troubleshooting Link tilt cylinders schematic diagram Link Tilt Cylinder 3.250" Dia. Bore X 10.3" Stroke 1.380" Dia. Rod

Mousehole Drill Down

C1

C1

1500 PSI

CV1 T-11A 1

X1

C2

CV2 T-11A 3

1

X2

3 2

2

2

C2

T-11A CB2

1

3

2

C2

1500 PSI

T-11A CB1

1

3

C1

V1

V2

H

J

Link Tilt "Tilt" Solenoid (Solenoid Valve 6)

Link Tilt "Drill Down" Solenoid (Solenoid Valve 6)

B

P

T

SV8

Logic Cartridge

D03

B8

LA6 T-11A 1 50 PSI 2

8

3 A6

A

B

C07 Drill Down P

T

b

-8

A

-6

b C08

Link Tilt

E6 .031ø

.071ø

1

SV6

D03 .031ø

75 PSI

.031ø B6

3

3

2

4

.031ø

Logic Cartridge

a C06 M'hole

-8

Link-Tilt Float

X -8

X -8

G6

-8 X

-8

J

Rotating Link Adapter Assembly

Link Tilt "Float" Solenoid (Solenoid Valve 8)

CA6 T-21A .031ø

G6

T-11A 1

50 PSI 2 LB6

.071ø 4

2

3

1 CB6 75 PSI T-21A

Pressure Tank

Manifold Assembly X

D1

X

A8

8-42

H

-8 X

E6

G6

-8

B8

-8

E6

Cable ID Number

-8

-8 G6

X

-8

-8

E6

X

-6 B8

X

-6 B8

V2

V1

FL

Varco Systems

Hydraulic System

Troubleshooting Gearbox lubrication hydraulic system Problem

Probable cause

Remedy

Oil leaking from lower seal. Worn oil seals.

Replace seals.

Oil leaking from upper bearing retainer.

Worn oil seals.

Replace seals.

Gearbox oil temperature (less than 230˚F).

Oil level too low or too high.

Adjust oil level to middle of sight glass.

Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Damaged gears or bearings.

Repair or replace as needed.

Oil level is too low. Oil overheated.

Add oil.

Oil pressure switch is out of adjustment.

Adjust per page 8-16.

Gear spray nozzle missing.

Replace spray nozzle.

Excessive oil viscosity.

Lower oil viscosity.

Faulty motor. Intermittent operation.

Replace motor.

Oil pump hydraulic motor failure.

Replace motor.

Broken lube pump adapter plate spline.

Replace adapter plate spline.

Faulty fixed displacement pump.

Check pressure at PF. Replace pump if pressure is low.

Low hydraulic fluid in reservoir.

Add hydraulic fluid.

Suction valve closed on fixed displacement pump.

Open suction valve.

Missing inspection plugs.

Replace inspection plugs.

Upper gearbox seals worn.

Replace seals.

Water in oil.

Replace oil.

Excessively viscous oil. Cold oil.

Lower oil viscosity.

Worn gears or damaged bearings.

Replace gears or bearings.

Damaged oil pump.

Replace oil pump.

Foreign particles blocking orifice or nozzle.

Clean orifice or nozzle.

Oil pump loss alarm is on.

Water/mud in oil.

Excessive foaming.

Metal in oil.

Restricted oil flow.

TDS-11SA

8

8-43

Hydraulic System

Troubleshooting Gearbox lubrication hydraulic system schematic diagram Pressure Switch S04

Spray Nozzles (4)

Orifices (6)

18 PSI Decreasing -16 1.0 GPM Ea.

1.5 GPM Ea.

Upper Compound Gear

Lower Compound Gear

.205ø

.062ø

Upper Mainshaft Bearing

.047ø .047ø

.059ø .059ø

Lower Radial/Main Thrust Bearings

Upper Compound Bearing

L4

Lower Compound Bearing

Lube-Oil Filter Lube Pump

60µm

5.10 In.^ 3/Rev. L1 -16

Lube-Oil Pump -10 A

-10

Tank

B

3.0 In.^ 3/Rev. Lube Pump Motor

Hydraulic Motor

Hydraulic Heat Exchanger

Tank

T-10A RV2

2

1

400 PSI

Manifold

PF

1.00 IN^ 3/REV.

8 Part of Pump Motor Assembly

8-44

Reservoir Assembly

Varco Systems

Hydraulic System

Troubleshooting Problem

Probable cause

Remedy

Tool does not rotate.

Direct control valve or relief valve is sticking.

Inspect, repair or replace the valve.

When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death.

Tool does not return to home position.

Links are not synchronized.

Solenoid valve is not electrically operating.

Check electrical connections and valve functions.

Motor is worn out or gear teeth are broken.

Replace the motor.

Shot pin is engaged.

Adjust the relief valve.

Mechanical interference.

Inspect and repair.

Directional valve does not shift.

Test pressure left and right. Replace the valve.

Fixed valve orifice is plugged.

Clear orifice or replace the valve.

Hydraulic lines are damaged.

Replace hydraulic lines.

Valve is sticking or relief valve is out of adjustment.

Test pressures and inspect valves. Adjust the relief valve as required.

Sensor is broken.

Replace sensor.

If the motor will drive normally, but not drive to the home position, the cause could be the control system.

Checkout control system.

Counterbalance valves are out of adjustment.

Adjust valves together-pressure is the same for all four valves.

8

TDS-11SA

8-45

Hydraulic System

Troubleshooting Rotating link adapter motor schematic diagram Rotating Head Motor

A

B

Fixed Displacement Motor 2

1

T-10A

Pressure Relief Valves

1600 PSI

1600 PSI

T-10A

2

1

A

B

Rotate Left Solenoid

Rotate Right Solenoid

Rotating Head

Cable ID Number

A

Cable ID Number

B

b

a

C03

C02 P

T

-6

Right

-6

Left

A2

8

SV2 .071ø

Non-Adjustable Orifice

8-46

B2

D03

Pressure

Tank

Manifold Assembly

3 Position Solenoid Valve

Varco Systems

Hydraulic System

Troubleshooting IBOP actuator schematic diagram IBOP Actuator Cylinder 2.500" Dia. Bore X 4.00" Stroke 1.750" Dia. Rod Open

Test Point Typical

Close

Hydraulic Cylinder CR LODC

30 PSI CXCD

2

Time-Delay Accumulator

1

T-13A

1

Logic Cartridge

30 Cubic Inches 800 PSI Precharge

2

3 50 PSI CP

VR

T-11A

Gas Charged Accumulator

A4

B4

A4

B4

-6

-6

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055ø D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A

2

1

.010ø 2

8

3

PC4

System Pressure

TDS-11SA

Tank

8-47

Hydraulic System

Hydraulic schematic symbols The following hydraulic troubleshooting section provides a schematic diagram and description for each TDS-11SA 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.

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.

8

8-48

Varco Systems

Hydraulic System

Hydraulic schematic symbols Description

Symbol

Schematic Reference

2 Position 4 Way Valves (Single Solenoid) Solenoid Operated Valves

SV1, SV4, SV5, SV8, SV9 33-1

3 Position 4 Way Valves (Double Solenoid)

SV2, SV6 33-2

Manual Valve (Rotary)

MV

3 Position 4 Way Valve 33-3

Fixed Displacement 33-4

Pumps Variable Displacement

33-5

RV2, A2R, B2R, SJR

Standard Valve 33-6

Pressure Relief Valves

Ventable Relief Valve

RV1 33-7

UV1

Differential Unloading Valve 33-8

Pressure Reducing Valve

PC1, PC4 33-9

PCC

Pressure Reducing/Relieving Valve

8

33-10

Chack Valve 33-11

TDS-11SA

CDF, CTF, CV2, CTR, CDR, CXCD Prefill valve assembly CV1, CV2

8-49

Hydraulic System

Hydraulic schematic symbols Description

Symbol

Schematic Reference CKCB (Link Tilt)

Pilot-To-Open Check Valves

33-12

CA6, CB6, CV3, CV4 (Clamp Body)

Pilot-To-Close 33-13

1 3

PC5

Cavity Plug 2 33-14

Internal Plug 33-15

CV1

Non Adjustable Flow Control Valves 33-16

Non Adjustable Orifice

Diameter in inches 33-17

CBCA (Link Tilt Circuit)

3 Port (Internal Drain) Counterbalance Valves

33-18

4 Port (External Drain)

CWCK (Link Tilt Circuit) 33-19

Standard Cartridge Logic Cartridge

LA6, LB6, LC5, LODC 33-20

With Metering

8

See Prefill Assembly 33-21

Quick Disconnect Coupling 33-22

8-50

Varco Systems

Hydraulic System

Hydraulic schematic symbols Description

Symbol

Schematic Reference See Lube Oil Circuit

Non Bypass Filter 33-23

Filter with Bypass

See Return Circuit 33-24

Manual Shutoff Valve 33-25

Lube Oil Circuit

Thermostat 33-26

Pressure Switch

Lube Oil Circuit 33-27

Hydraulic Circuit (Inside Brake Housing)

Heat Exchanger 33-28

Pressure Compensator Control

Part of the Pump 33-29

Hydro-Pneumatic Accumulator 33-30

Hydraulic Motor (Bi-Directional) 33-31

Hydraulic Cylinder 33-32

8

Tank (Reservoir) 33-33

Test Point 33-34

TDS-11SA

8-51

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 9

Varco Driller’s Console

AC Electrical

Varco Driller’s Console

VARCO DRILLERS CONSOLE (VDC)

The VDC is made from 300-series stainless steel, it uses full size oil tight switches and indicators and is designed for zone one hazardous areas with its EEx de (ia) rating without requiring to be purged. The Varco supplied Driller’s console is equipped with the following items to directly interface with the AC frequency drives: Throttle The throttle uses a design similar to a standard throttle control supplied with SCR Systems. The handle includes integral stops to prevent damage Torque Limit The torque limit it potentiometer is very similar to the designs used on SCR Systems. The maximum torque output of the drive is limited to the continuous torque rating of the drive and motors. Make-Up Limit Potentiometer The make-up potentiometer controls the makeup torque when the top drive is used to makeup connections using the drilling motor. This control allows the top drive to operate at the intermittent rating. AC TDS Training Manual

Varco Driller’s Console

VDC CONTROLS

1. DRIVE FAULT Red indicator light flashes and horn sounds when a drive (VFI) fault is detected. 2. BLOWER LOSS Red indicator light flashes and horn sounds if there is a failure in one or both of the air cooling motors. 3. BRAKE ON Red indicator illuminates when the brake solenoid valve is energised. The indicator flashes in case of a faulty make-up connection. 4. DRILL MOTOR OVER-TEMPERATURE Red indicator flashes and horn sounds if there is an over- temperature condition in one or both of the AC drilling motors. AC TDS Training Manual

Varco Driller’s Console

5. IBOP CLOSED Amber indicator light illuminates when there is hydraulic pressure to the cylinder that closes the IBOP valve. 6. OIL PRESSURE LOSS Red indicator flashes when there is an oil pressure loss in the gear case lubrication system. 7. ALARM SILENCE/LAMP CHECK When any alarm indicator light flashes and the horn sounds, press the switch to silence the horn, the alarm light stays on until the fault is rectified, if the fault is not rectified 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 is three brake switch positions, OFF, AUTO and ON, turning the switch to the ON position turns the brake on and lights the brake indicator. In the AUTO position, the brake automatically turns on when the throttle is turned off. Turning the brake to the OFF position turns the brake off. The brake will operate if there is a drive fault with the VFI. 9. DRILL CURRENT LIMIT POTENTIOMETER The potentiometer sets the current limit in the VFI during drilling operations, this sets the torque for normal drilling operations in the drill position. 10. DRILL PIPE ELEVATOR SWITCH There are three switch positions, OFF, LEFT and RIGHT, turning the spring operated switch to the left moves the drill pipe elevator to the left, and turning the switch to the right moves the drill pipe elevator to the right. NOTE: - This works only after the link tilt float switch is pressed. 11. DRILL/SPIN/TORQUE SWITCH There are three switch positions, DRILL, SPIN and TORQUE, the switch is in the DRILL mode during normal drilling, SPIN mode is a fixed speed and current signal to the AC motors and TORQUE mode is a fixed speed with gradual rise in torque up to the make-up value set by the makeup potentiometer when in Forward mode, when in Reverse the Torque value rises to maximum until the connection is broken. 12. EMERGENCY STOP CIRCUIT The Emergency Stop switch is hard wired to the VFI, pressing the button deselects the VFI and will cause the Top Drive rotation cost to a stop regardless of throttle position. NOTE: - All other auxiliary functions remain ON.

13. IBOP SWITCH The 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. AC TDS Training Manual

Varco Driller’s Console

14. LINK TILT FLOAT The elevator links “float” to the centre (NEURAL) position when the pushbutton is pushed, thus the drill pipe elevator can then be rotated. 15. LINK TILT SWITCH This activates the link tilt cylinders, the centre position is OFF, turning the switch to the left extends the cylinders, turning the switch to the right retracts the cylinders. This is a maintained switch that holds the position of the cylinder when returned to the OFF position. 16. MAKE UP CURRENT LIMIT POTENTIOMETER This potentiometer sets the current limit in the VFI when using the Top Drive to make connections, the Torque can be adjusted by turning the potentiometer to increase or decrease the Torque. 17. OFF/FORWARD/REVERSE SWITCH There are three switch positions, OFF, FORWRD and REVERSE, the OFF position is used to deselect the VFI, FORWARD and REVERSE are used when drilling or making/breaking connections. The switch acts as the drive assignment. 18. TORQUE WRENCH SWITCH Pushing this button engages the pipe clamp and shot pin lock. NOTE: - Wrench cannot clamp with the brake on or throttle open.

19. RPM METER Displays the RPM of the drill pipe. 20. TORQUE METER Displays the drill pipe Torque in Ft/Lbs. 21. STAND-JUMP SWITCH Energises the stand-jump solenoid, this causes drill pipe connection to separate from the saver-sub as it unscrews. 22. THROTTLE Controls the speed of the AC Drilling motors when in drill mode, by sending a reference signal to the VFI. 23. TORQUE RELEASE When the Top Drive is drilling ahead and stalled out, pressing the Torque Release switch will slowly unwind the Torque out of the drill string in a controlled manner. 24. HYDRAULIC POWER AUTO/ON When switched to ON, the Top Drive Hydraulics can still be operated with the Forward/Reverse switch in the OFF position. When in the AUTO position the hydraulics are operated by the assignment of the Top Drive Forward/Reverse. Thus when the Top Drive rotation of the main shaft is not required, the hydraulics can still be operated.

AC TDS Training Manual

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 10

System Interconnect

AC Electrical

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 11

Siemens Step 7 PLC

AC Electrical

PLC Introduction Programmable Logic Controllers (PLCs), also referred to as programmable controllers, are in the computer family. They are used in commercial and industrial applications. A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine. This course is meant to supply you with basic information on the functions and configurations of PLCs.

PLCs consist of input modules, a Central Processing Unit (CPU), and output modules. An input accepts a variety of digital or analogue signals from various field devices (sensors) and converts them into a logic signal that can be used by the CPU. The CPU makes decisions and executes control instructions based on program instructions in memory. Output modules convert control instructions from the CPU into a digital or analogue signal that can be used to control various field devices (actuators). A programming device is used to input the desired instructions. These instructions determine what the PLC will do for a specific input. An operator interface device allows process information to be displayed and new control parameters to be entered. Prior to PLCs, many of these control tasks were solved with contactor or relay controls. This is often referred to as hard-wired control. Circuit diagrams had to be designed, electrical components specified and installed, and wiring lists created. Electricians would then wire the components necessary to perform a specific task. If an error was made the wires had to be reconnected correctly. A change in function or system expansion required extensive component changes and rewiring. The same, as well as more complex tasks, can be done with a PLC. Wiring between devices and relay contacts is done in the PLC program. Hard-wiring, though still required to connect field devices, is less intensive. Modifying the application and correcting errors are easier to handle. It is easier to create and change a program in a PLC than it is to wire and rewire a circuit. PLC Advantages • Smaller physical size than hard-wire solutions • Easier and faster to make changes • PLCs have integrated diagnostics and override functions • Diagnostics are centrally available • Applications can be immediately documented

Siemens Step 7 PLC

Various Varco control systems uses the Siemens Step 7 300 series PLC (AR4000, TDS-4S, Electronic Driller). The complete system consists of the 315-DP CPU, with local Inputs and Outputs, and remote Inputs and Outputs through the PROFIBUS DP network. What is PROFIBUS ? PROFIBUS is a serial fieldbus used primarily as the communication system for exchange and information between automation systems and distributed field devices. Thousands of successful applications have provided impressive proof that use of fieldbus technology can save up to 40% in costs for cabling, commissioning and maintenance as opposed to conventional technology. Only two wires are used to transmit all relevant information (i.e. input and output data, parameters, diagnostic data, programs and operating power for field devices). In the past, incompatible vendorspecific fieldbuses were frequently used, virtually all systems in design today are open standard systems, the user is no longer tied to individual vendors and is able to select the best and most economical product from a wide variety of products. PROFIBUS specifies the technical and functional characteristics of a serial fieldbus system with which decentralised digital controllers can be networked together from the field level to the cell level, Profibus distinguishes between master and devices and slave devices.

Siemens Step 7 PLC Programming The Siemens Step 7 PLC has three main methods of programming, these are LAD (Ladder Logic), STL (Statement List) and FBD (Function Block Diagram). The software for the AC Top drive is written mainly in Ladder Logic with a small part written in Statement List (For the communication with the Siemens 70 Series Drive), none of the program was written in Function Block Diagram.

Ladder Logic Diagram The left vertical line of a Ladder Logic Diagram (above), represents the power or energised conductor. The output element or instruction represents the neutral or return path of the circuit. The right vertical line, which represents the return path on a hard-wired control line diagram, is omitted. Ladder logic diagrams are read from leftto-right, top-to-bottom. Rungs are sometimes referred to as networks. A network may have several control elements, but only one output coil.

Statement List A statement is an instruction for the PLC. A Statement List (STL) (above), provides another view of a set of instructions. A comparison between the statement list shown below, and the ladder logic shown above, reveals a similar structure. The operation, what is to be done, is shown on the left. The operand, the item to be operated on by the operation, is shown on the right.

Understanding Ladder Logic

Diagram 1

Diagram 2

Diagram 3

Diagram 4

Diagram 5

Central Processing Unit 315-2 DP

Varco P/N = 122627-03 Mode Selector RUN-P Run program mode The CPU scans the user program, the key cannot be taken out in this position. Programs can be read of out and loaded into the CPU with a programming device. RUN Run mode. The CPU scans the user program, the key can be removed in this position to prevent anyone changing the operating mode. Programs in the CPU can be read out with a programming device, but the program in the load memory cannot be changed. STOP Stop mode. The CPU does not scan the user program, the key can be removed to prevent anyone changing the operating mode. Programs can be read of out and loaded into the CPU with a programming device. MRES Reset CPU memory Momentary contact position of the mode selector switch for resetting the CPU memory when a special sequence is carried out.

Status and Fault LED’s SF (red) System error fault Lights up in the event of: - (a) Hardware faults, (b) Firmware errors, (c) Programming errors, (d) Parameter assignment errors, (e) Arithmetic errors, (f) Timer errors, (g) Defective memory card, (h) Battery failure or no back-up on POWER ON, (i) I/O fault error. Note:- You must use a programming device and read out the contents of the diagnostic buffer to determine the exact nature of the error/fault. BATF (red) Battery fault Lights up if the battery defective, not inserted or discharged. 5VDC (green) 5 VDC supply for CPU Lights up if the internal 5 VDC supply is OK. RUN (green) Run mode. Flashes at a CPU restart for at least three seconds, during the CPU re-start the STOP LED also lights up, when the STOP LED goes off and the RUN LED is on constant, the outputs are enabled. STOP (yellow) Stop mode. Lights up when the CPU is not scanning the user program. Flashes at one-second intervals when the CPU requests a memory re-set. Display Elements for PROFIBUS LED’S SF DP BUSF Description Off

Off

Configuration data OK, all configured slaves are addressable.

On

On

Bus Hardware fault, DP interface fault

Possible Remedies:- Check the bus cable for short or interruption, evaluate the diagnostic data, reconfigure or correct the configuring data. On

Flashes

Station failure or at least one of the configured slaves cannot be addressed.

Possible Remedies:- Check to make sure that the bus cable is connected correctly to the CPU or that the bus is not interrupted. Wait until the CPU has completed its power up, if the LED does not stop flashing, check the DP slaves or evaluate the diagnostic data for the DP slaves. On

Off

Missing or incorrect configuring data.

Possible Remedies:- Evaluate the diagnostic data, reconfigure or correct the configuring data.

Step 7 CPU315-DP Back-up battery

Varco P/N = 122627-26

The Back-up battery for the CPU315-DP should only be replaced with the Power On, to prevent the loss of data from the internal user memory, and to keep the clock of the CPU running. Siemens recommend that the Back-Up battery be replaced at yearly intervals. When not in use the Back-Up batteries should be stored in a cool dry place, and can be stored for five years.

Flash EPROM Memory Card

Installing the Memory card into the CPU. Varco P/N – 122627-24 The purpose of the Memory Card is to store the user program, this will then be retained when the CPU is powered down, even if a back-up battery has not been installed. With the 315 - 2DP CPU, the Memory Card can be written to directly when installed as above in the CPU. The following procedure should be used for writing to the Flash Card when inserted in the CPU :-

1. 2. 3. 4. 5.

Power down the CPU and insert the Flash card. Power up the CPU. Delete the CPU using the key switch. In the OFFLINE mode, download all the Blocks and System Data to the RAM. Once all Blocks and Data are loaded, do a compare ONLINE and OFFLINE, this should show that there are no differences (except for DB’s). 6. Still in the OFFLINE mode, do a Save RAM to ROM. This should then display the message that this has been carried out satisfactory.

CPU Memory Reset The CPU memory must be reset before a transfer of a complete user program to the CPU, or if the CPU requests a MRES with its STOP LED flashing at one second intervals, possible reasons for this are as follows:-

1. Wrong memory card has been plugged into the CPU. 2. RAM error in CPU. 3. Working memory too small, that is not all blocks of the user program on a memory card could be loaded. 4. Attempt to load blocks with errors, for example if a wrong command has been programmed. With the 315-2 DP CPU and 5V FEPROM plugged in, the CPU requests a memory reset.

Resetting the CPU Memory using the Mode Selector. To reset the CPU using the Mode selector the following procedure should be carried out:-

1. Turn the key to the STOP position 2. Turn the key to the MRES position and hold it in this position for about three seconds, until the STOP LED lights up again. 3. Within three seconds, you must turn the key back to the MRES position and hold it in this position until the STOP LED flashes, when the CPU has completed the reset, the STOP LED stops flashing and remains lit. The CPU has then performed the Reset.

PS 307 Power Supply Module (5A)

Varco P/N = 122627-01 The PS 307 power supply module has an output voltage of 24 VDC with an output current of 5 Amp, this is short circuit and open circuit proof.

Basic Circuit Diagram

Relay Output module SM 322

Module front view and block diagram of relay outputs

Varco P/N = 122627-18 The relay output module has 8 output points, isolated in groups of two. There are two Relay Outputs in the PLC rack (Slot 4 and 5), Slot 4 is used for all the 24 VDC solenoids on the Top Drive (Brakes On, IBOP Closed, Torque Wrench, etc.). Slot 5 is used for the Motor Starters for the Hydraulic Pump and the Right and Left Blower motors, it is also used for the Encoder By-Pass Indicator. If fitted to the Top Drive it would also control the Stand Jump and Elevator Open/Close solenoids.

Digital Input Module SM 321

Module front view and block diagram of digital inputs

Varco P/N = 122627-09

The digital inputs module has 16 input points, isolated in groups of 16. The rated input voltage is 24 VDC, they Inputs are used for the Over-temperatue and Pressure Switches on the Top Drive, the Encoder By-Pass switch is also inputted to this module.

Bartec Distributed I/O system

The Bartec Distributed I/O System

The field bus on which the Bartec Modex System is based on a version of PROFIBUS known as PROFIBUS DP (DP = Decentralised Periphery or Distributed I/0), this is designed for minimum reaction times in communication with the distributed inputs and outputs. The Modex System comes from MODular EXplosion and consists of an EEx d flameproof enclosure and EEx e connecting terminals. The analogue modules used with the Varco Driller’s Console also have intrinsically safe circuits EEx ia.

AC TDS Training Manual

Bartec Distributed I/O system

Bartec Profibus Analogue Output

Varco P/N = 140244-2 The Bartec Profibus Analogue output module has eight intrinsically safe direct analogue outputs of 4-20mA. Two of these outputs are used as 4-20mA signals to supply the Electro Flow RPM and Torque gauges on the Varco Driller’s Console, the other two can be used for the customer logging equipment. LED Indicators ON BF SF UB2 OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Outputs. Separate supply voltage to terminal U+/U-, glows green when voltage applied, will turn off when no voltage applied. 8 x Double LED (1-8). Yellow – Output satisfactory, Red – Open/Short Circuit.

AC TDS Training Manual

Bartec Distributed I/O system

Bartec Modex Potentiometer Input

Varco P/N = 140968-4 The Bartec Profibus Potentiometer Input module, has a supply voltage of 24 VDC with four analogue inputs, three of these inputs are used for the Throttle, Drill Torque Limit and Make Up Torque Limit potentiometers on the Varco Driller’s Console. The fourth input is an unused spare, which could be used if there was a problem with any of the other inputs, with software and cabling changes inside the VDC. LED Indicators ON BF SF OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Inputs. 4 x Double LED (1-4). Yellow – Input active, Red – Open/Short Circuit.

AC TDS Training Manual

Bartec Distributed I/O system

Bartec Modex Digital Input Modual

Varco P/N = 140968-2

There are two Bartec Profibus Digital Inputs modules in the Varco Driller’s Console, they have a supply voltage of 24 VDC, with 16 EEx e digital inputs. The Inputs are received from all the switch functions in the Varco Driller’s Console (Brake, IBOP, Forward/Reverse, etc.).

LED Indicators ON BF SF INPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. N/A 16 x Double LED (1-16). Yellow On – Input High (1) (+10V to +30V), Yellow Off – Input Low (0) (-30V to +5V).

AC TDS Training Manual

Bartec Distributed I/O system

Bartec Modex Digital Output Module

Varco P/N = 140244

The Bartec Profibus Digital Output module has a supply voltage of 24 VDC, it has 16 outputs of 24 V DC. The Outputs go to all the Indicators and the Horn in the Varco Driller’s console (Drive Fault, Brake On, IBOP Closed, Horn, etc.) LED Indicators

ON BF SF OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Outputs. 16 x Double LED (1-16). Yellow – Output active, Red – Open/Short Circuit.

AC TDS Training Manual

AC Top Drive Step 7 PLC Program Structure

The Step 7 program for the AC Top Drive is structured as above, the program is split into Functions (FC), which are initially called from the Organisation Block (OB). There are two Program Block types, they are User Blocks and System Blocks. User Blocks are the areas provided for managing the program code and the data for the program. Based on the requirement of the process, the program can be structured with the various options for user blocks, some of these blocks can be executed cyclically, while others can be executed only when needed. User blocks are also referred as Program blocks. System Blocks are pre-defined function or function blocks integrated in the operating system on the CPU, these blocks do not occupy any additional space in the user memory. System blocks are called from the user program level, these blocks have the same interface ,same design and the same number in the entire system. The User Blocks types that are used are Organisation block, Functions and Data blocks. Organisational Blocks (OB) form the interface between the S7 CPU and the user program, the program for the AC Top drive is stored in various blocks and uses OB1 to call these blocks when needed.

Functions (FC) are logic operation blocks to which no memory area is assigned, an FC does not need an instance data block, temporary variables are stored in the local stack until the Function is concluded, and are lost when the FC finishes executing. Data Blocks (DB) are permanently assigned areas in which data or information is stored that another function collected, they are read/write areas that can be loaded in the CPU as part of the program. The System Block that is used in the program is the System Functions (SFC). A System Function is a pre-programmed, debugged function that is integrated in the S7 CPU, some of these tasks supported by these blocks are setting parameters for modules, data communication, copying functions etc. SFC’s can be called from the program without being loaded as part of the program, and do not have to be assigned to a data block.

When the program is structured into Blocks, it must be accessed by calling one block from another. As seen in the diagram above, when the program calls the second block, the called block then executes all of its instructions, once the called block has completed execution of its instructions, the calling block resumes the execution of its program at the network following the Call instruction.

Choosing The Correct Operating mode Step 7 allows you to examine, modify and write to programs in three different ways, these ways are Direct, Offline and Online.

DIRECT This mode is ideal for maintenance, in this mode you can directly monitor programs without referencing to a project (no program loaded into Step 7). The project can be can be modified or simply monitored to gather information about the system.

OFFLINE Offline mode is best suited to offline programming, i.e. when the CPU is not present or when the programming unit is not connected to the CPU. In this mode, blocks can be written and then transferred (downloaded) to the CPU, downloading is obviously only possible if the MPI cable is connected to the system. The program can also be monitored, providing the program in the programming unit is the same as the one in the CPU.

ONLINE Online mode is the suited to programming with the programming unit connected to the CPU, if the MPI cable is not present, the link will be automatically aborted. Programming changes will however only take place when the appropriate ICON has been selected. To avoid differences between the program on the disk and the program in the CPU (time stamp conflict), it is essential to STORE TO DISK first and then DOWNLOAD to the CPU. Monitoring in this state is easier as you are looking at what is at present in the CPU.

When working with Step 7, it is essential that only one of these modes is selected at any one time, Step 7 will not allow to have blocks open in the Offline and online modes together, one of the modes will have to be closed down before continuing.

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 12

Basics of AC Motors

AC Electrical

Basics of AC Motors

AC MOTOR BENEFITS

AC TDS Training Manual

Basics of AC Motors

AC EXTRA PERFORMANCE

AC TDS Training Manual

Basics of AC Motors

AC MOTORS •

Operate on the principle of induced magnetic field from an alternating electric current.

•

Magnetic field induced in STATOR rotates around STATOR frame, which in turn induces current in stationary ROTOR.

•

ROTOR current induces a magnetic field on ROTOR, this field tries to align itself with rotating magnetic field on STATOR.

•

The result of this attempted alignment is TORQUE at the ROTOR shaft, the magnitude of this TORQUE depends how much SLIP occurs between the rotating magnetic field on the STATOR and the ROTOR magnetic field.

AC TDS Training Manual

Basics of AC Motors

AC MOTOR CONSTRUCTION •

•

Used in industrial applications

Three phase 550/575 VAC in TDS applications

AC TDS Training Manual

Basics of AC Motors

ROTOR CONSTRUCTION Squirrel Cage Most Common Rotor consists of Stack of Steel Laminations with evenly spaced conductor bars.

• Current flows through the Rotor bars and around the End ring. • Current flow produces Magnetic Fields around each Rotor bar. • Rotor becomes an Electromagnet with alternating North and South poles. • Magnetic Fields of Rotor interact with Magnetic Fields of Stator. • Current and Magnetic Fields of Stator and Rotor constantly changing. • As Stator Magnetic Field rotates, Rotor and Shaft follow. AC TDS Training Manual

Basics of AC Motors

STATOR CONSTRUCTION The stator of the induction motor is a hollow cylinder made up from silicon iron laminations with the winding housed in slots in the inner surface. Like the D.C. motor field, it can have any number of pole pairs and each pole can be produced by any number of concentric coils. The drawing below shows a motor with only two poles two coils per phase (i.e. 4 slots per pole per phase). Note that only one pole per phase is shown for clarity.

AC TDS Training Manual

Basics of AC Motors

ROTATING MAGNET FIELD •

•

• •

Rotating Magnetic Field produced in Motor Stator windings. Number of Poles is depending by how many times a phase winding appears. TDS-9, 10 and 11, 4 Pole (2 pole pairs). TDS-8, 6 Pole (3 pole pairs).

2- Pole Stator Windings.

AC TDS Training Manual

Basics of AC Motors

Rotating Magnet •

•

• •

•

No direct electrical connection between Stator and Rotor. To visualise how a Rotor works, substitute a Magnet for the Squirrel cage Rotor. Magnet Field interacts with rotating Stator Field. North Pole of Stator attracts South Pole of Magnet. Magnet follows rotating Magnetic fields.

AC TDS Training Manual

Basics of AC Motors

ROTATING MAGNETIC FIELD

• •

Evaluate the Field at 60° intervals After six intervals the field rotates 360°.

AC TDS Training Manual

Basics of AC Motors

Synchronous Speed • Speed of Rotating Magnet Field Refereed to as Synchronous Speed (Ns). • Equal to 120 Times the Frequency (F) Divided by the Number of Poles.

Slip • Relative Difference between Speed of Rotor and Rotating Magnetic Field. • Necessary to Produce Torque. • Dependent on Load.

AC TDS Training Manual

Basics of AC Motors

Electrical components of an AC Motor • • • • • • • • •

Vs = Line Voltage applied to Stator power leads. Rs = Stator Resistance. Ls = Stator leakage inductance. Is = Stator current. E = Air gap or magnetising voltage. Lm = Magnetising inductance. Im = Magnetising current. Rr = Rotor leakage inductance. Iw = Working or Torque producing current.

AC TDS Training Manual

Basics of AC Motors

Working Current • Current that Flows in the Rotor Circuit and produces Torque. • Function of the Load. • An Increase in Load Causes the Rotor Circuit to Work Harder, Increasing Working Current (Iw). • A Decrease in Load, Decreases the Work of the Rotor Circuit does Decreasing Working Current (Iw).

Stator Current • Full-Load Ampere rating on the Motor Nameplate. • Current that flows in the Stator Circuit. • Can be measured on the Supply Line and is also referred to as Line Current.

AC TDS Training Manual

Basics of AC Motors

HORSEPOWER AND KILOWATTS •

•

AC Drives and Motors manufactured in United States measured in HP (Horsepower). AC Drives and Motors manufactured in Europe, generally rated in KW (Kilowatts). KW = 0.746 * HP HP = 1.341 * KW

DRILLING MOTORS •

•

• • • •

Glass served installation on all new and reworked motors to increase voltage rating. Snubbers added to reduce voltage from Siemens and IDM IGBT drives. TDS-8 = 1 * 1150 HP motor. TDS-9 = 2 * 350 HP motors (700 HP). TDS-10 = 1 * 350 HP motor. TDS-11 = 2 * 400 HP motors (800 HP).

AC TDS Training Manual

Basics of AC Motors

MOTOR NAMEPLATE •

Installation Class

•

Established by NEMA. Ambient temperature is standardised at 40° C or 104° F. Combination of ambient temperature and allowed temperature rise equals maximum winding temperature.

• •

•

NEMA Design

•

National Electrical Manufacturers Association (NEMA) established standards for motor construction and performance.

•

Efficiency

•

Indication of how much input electrical energy is converted to output mechanical energy.

•

Voltage Connection and Amps

• •

The Reliance motor is specified for 550 Volts. Maximum full load current of 331 Amps.

•

Base Speed

• •

Nameplate speed, given in RPM, where motor develops rated Horsepower at rated Voltage and Frequency. Reliance motor is 1155 RPM.

•

Maximum Speed

•

Maximum rated speed of the motor, torque is reduced. Reliance motor is 2400 RPM.

•

Reliance motor used on TDS-9 + 10. (TDS-11, 575 V & 366 A) AC TDS Training Manual

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 13

Basics of AC Drives

AC Electrical

Basics of AC Drives

AC Drives u

Speed of an AC Motor can be Controlled Using Electronic Drive Equipment. – – – –

Variable or Adjustable Speed Drives. Commonly known as AC Drives Also referred to as Inverters. Although the Inverter is only one part of the AC Drive.

Vector Control u u u u u u

Control Torque and Speed Continuously through Zero Speed. Can hold motor stationary against an applied torque. Requires Tach feedback to work best. Speed control reaction time 40 ºC .

Check:

A023

r954 6

A024

r954 7

A025

r954 8

A029

r954 12

A033

r955 0

A034

r955 1

A035

r955

Motor temperature

•

Whether the fan -E1 is connected and is rotating in the correct direction.

•

The air intake and discharge openings for blockage.

•

The temperature sensor at -X30.

The parameterizable threshold for initiating an alarm has been exceeded.

Check the motor (load, ventilation, etc.). The current temperature can be read in r009 Motor Tmp. Check the KTY84 input at connector X103:29,30 for short-circuit.

Motor movement

Lock the motor

The motor has moved during motor data identification in first start-up.

I2t Inv. If the instantaneous load condition is maintained, then the inverter will be thermally overloaded.

I2t motor The parameterized limit value for the I2t monitoring of the motor has been exceeded.

Overspeed Bit 3 in r553 status word 2 of the setpoint channel. The speed actual value has exceeded the value of maximum speed plus the set hysteresis.

Motor load cycle exceeded! Check the parameters: P382 Motor Cooling P383 Mot Tmp T1 P384 Mot Load Limits Motor load cycle is exceeded! Check the parameters: P382 Motor Cooling P383 Mot Tmp T1 P384 Mot Load Limits P804 Overspeed Hyst plus P452 n/f(max, FWD Spd) or P453 n/f(max,REV Spd) has been exceeded. Increase the parameter for the maximum frequencies or reduce the regenerative load.

Setpoint/actual value deviation Check: Bit 8 in r552 status word 1 of setpoint • Whether an excessive torque channel. The difference between requirement is present. frequency setpoint/actual value is Whether the motor has been • greater than the parameterizable dimensioned too small. value and the control monitoring time has elapsed. Increase values P792 Perm Deviation Frq/ set/actual DevSpeed and P794 Deviation Time

Wire break

Check whether cable(s) to the

Alarm number

Param. No.

Cause

Counter-measure

Bit No. The clockwise and/or the counterclockwise rotating field is not enabled, or a wire breakage is present in the terminal wiring (both control word bits are zero)

corresponding digital input(s), P572 Src REV Speed/ P571 Src FWD Speed is (are) interrupted or released.

A036

Brake checkback "Brake still closed”

Check the brake checkback (see FD 470)

A037

Brake checkback "Brake still open"

Check brake checkback (see FP 470)

Vdmax controller inhibit

Check:

The line voltage is too high or the drive line voltage (P071) is incorrectly parameterized. The Vdmax controller is disabled despite parameter access (P515), as otherwise the motor would accelerate immediately in operation to the maximum frequency.

•

Line voltage

•

P071 Line Volts

Motor stall/lock

Check:

Motor is stalled or locked.

•

Whether the drive is locked.

The alarm cannot be influenced by P805 ” PullOut/BlckTime”, but by P794 ”Deviation Time”.

•

Whether the encoder cable is interrupted during speed control and whether the shield is connected.

•

Whether the drive has stalled.

•

For synchronous motors (P095=12): excitation current injection

2

A041

r955 8

A042

r955 9

A043

r955 10

n-act jump The permissible change value of the speed encoder signal (P215) has been exceeded. Additionally for synchronous motors (P095=12): The motor rotates with more than 2 % of the rated speed at the time of inverter release. The inverter status "Ready for operation" is not exited.

A044

r955 11

I too low Only for synchronous motors

Check the tachometer cables for interruptions. Check the earthing of the tachometer shield. •

The shield must be connected both on the motor and on the converter side.

•

The encoder cable must not be interrupted.

•

The encoder cable must not be laid with the power cables.

•

Only the recommended encoders should be used.

•

If there is a signal fault, use the DTI board if necessary.

•

If necessary, change P215

•

Additionally for synchronous motors (P095=12): Do not grant inverter release until the motor is at standstill.

Only for synchronous motors P095 = 12 Check:

Alarm number

Param. No.

Cause

Counter-measure

Bit No. (P095=12) in operation: The difference smoothed with P159 between excitation current setpoint and actual value (r160 - r156 ) deviates from zero by more than 25 % of the rated magnetizing current.

A045

r955 12

A049

r956 0

A050

r956 1

A051

r956 2

A052

r956 3

A053

r956 4

A057

r956 8

DC braking activated

•

Whether the current limitation of the excitation current control is too small.

•

Whether the dynamic performance of the excitation current injection is too low.

•

Whether the excitation current injection function is operating,

•

Whether the wiring of excitation current actual-value P155 is correct,

•

Whether the wiring of excitation current setpoint r160 is correct,

•

Whether there is a wire breakage between MASTERDRIVES and the excitation device.

•

Whether the voltage limitation is too low for dynamic excitation current control.

•

Whether the analog output for r160 takes place without isolating amplifiers (despite cable length > 4m).

•

Increase frequency at which DC braking begins.

The DC braking function has been activated and the motor frequency is still above the frequency at which DC braking begins (P398).

No slave

P690 SCI AnaIn Conf

At ser. I/O (SCB1 with SCI1/2) no slave is connected or fiber-optic cable is interrupted or slaves are without voltage.

•

Check slave.

•

Check cable.

Slave incorrect

Check P690 SCI AnaIn Conf

At ser. I/O the slaves required according to a parameterized configuration are not present (slave number or slave type).

Peer Bdrate In a peer-to-peer connection, a baud rate has been selected which is too high or too different.

Adjust the baud rate in conjunction with the SCB boards P701 SCom/SCB Baud Rate

Peer PcD L

Reduce number of words In a peer-to-peer connection, a PcD P703 SCom PcD #. length has been set which is too high (>5).

Peer Lng f. In a peer-to-peer connection, the PcD length of transmitter and receiver do not match.

TB Param Occurs when a TB is logged on and

Adjust the word length for transmitter and receiver P703 SCom/SCB PcD # Replace TB configuration (software).

Alarm number

Param. No.

Cause

Counter-measure

Bit No. present, but parameter tasks from the PMU, SCom1 or SCom2 are not answered by the TB within 6 seconds.

A061

Alarm 1 function blocks

Check cause of alarm (see FP 710)

A062

Alarm 2 function blocks

Check cause of alarm (see FP 710)

A063

Alarm 3 function blocks

Check cause of alarm (see FP 710)

A064

Alarm 4 function blocks

Check cause of alarm (see FP 710)

Auto restart active

Caution!

The auto restart option (P373) restarts the drive. A possibly parameterized power-up delay time (P374) expires if flying restart is not selected. During pre-charging of the DC link, there is no time monitoring i.e. with an external electronics power supply, it is also switched-in again.

Personnel could be in danger when the drive automatically restarts. Check whether the auto restart function is really required!

fsyn > fmax

Check:

The measured target frequency of the external converter (or supply) is greater than the parameterized maximum frequency of the synchronizing converter.

•

P452 n/f(max, FWD Spd)/ P453 n/f(max,REV Spd) are correct and

•

Correct motor data set P578 Src MotDSet Bit0 are selected.

fsyn < fmin

Check:

The measured target frequency of the external converter (or supply) is less than the minimum frequency required for synchronizing.

•

r533 Sync Target Freq

•

Synchronising cable

fsynfsoll

Adjust total setpoint (main and additional setpoints) to the target frequency displayed in visualization parameter r533.

A065

r957 0

A066

r957 1

A067

r957 2

A068

r957 3

A069

r957 4

A070

r957 5

The setpoint frequency of the synchronizing converter deviates too significantly from the measured target frequency of the external converter (or supply). The permissible deviation can be set in P529.

RGen active

Wait until acceleration has been completed. Synchronizing is not started as long Check whether: as the ramp-function generator in the • P462 Accel Time synchronizing converter setpoint channel is active. This alarm is only • P463 Accel Time Unit has been output if synchronizing is selected. correctly set.

Sync. Error This alarm is output if the phase difference goes outside the synchronizing window (P 391) after successful synchronization.

The alarm can only be deleted after synchronization has been exited.

Alarm number

Param. No.

Cause

Counter-measure

Bit No.

A071

r957 6

A076

r957 11

A077

r957 12

A078

r957 13

A079

r957 14

A080

r957 15

A081.. A096 A097.. A112 A113.. A128

r958 1...15 r959 1...15 r960 1...15

TSY missing

Insert the TSY board in the subrack.

An attempt was made to start synchronization with either the synchronizing board not inserted or not parameterized.

t-comp lim The determined compensation time was limited to the value range of 0.5µs - 1.5µs.

r-g limit The measured resistance was limited to the maximum value of 49 %.

The converter output and the motor output are too different. Check motor data entries P095 to P109. Converter output and motor output are too different. Check motor data entries P095 to P109.

Stands. Meas

If the standstill measurement can be The standstill measurement is executed without any danger: executed when the converter is • Power up the converter powered-up. With this measurement, the motor can align itself in any direction of rotation.

MId Inv Stop

P561 Src InvRelease – Release the inverter

The rotating measurement has been aborted or cannot commence because an inverter stop command is present.

or re-start the measurement by powering-up the converter.

MotId:Dr.M.

If the rotating measurement can be When the converter is powered-up, executed without any danger: the rotating measurement • Power-up the converter automatically accelerates the drive. The drive can then only be externally controlled in a very restricted fashion.

CB alarm See user manual for CB board

TB alarm 1 See user manual for TB board

TB alarm 2 See user manual for TB board

Fatal errors (FF)

Fatal errors are serious hardware or software errors which no longer permit normal operation of the unit. They only appear on the PMU in the form "FF". The software is re-booted by actuating any key on the PMU.

FFxx

Error message

FF01

Time slot overflow A non-removable time sector overflow was identified in the higher priority time sectors.

•

Increase sampling time (P357) or reduce pulse frequency (P340)

•

Replace CU

Access error, optional board Fatal errors occurred when accessing external optional boards (CB, TB, SCB, TSY ..)

•

Replace CU

•

Replace LBA

•

Replace optional board

Stack overflow Overflow of the stack.

•

Increase sampling time (P357) or reduce pulse frequency (P340)

•

Replace CU

Other fatal errors

•

Replace CU

E

Fatal hardware errors

•

Replace CU

EEEE

Fatal firmware errors

•

Replace CU

•

Re-load firmware

FF03

FF06

FFxx

Power-down the converter and power-up again. Call the service personnel if a fatal error message is displayed again

Maintenance and Repair WARNING

SIMOVERT MASTERDRIVES units are operated at high voltages. All work carried out on or with the equipment must conform to all the national electrical codes (VBG 4 in Germany). Maintenance and service work may only be executed by qualified personnel. Only spare parts authorized by the manufacturer may be used. The prescribed maintenance intervals and also the instructions for repair and replacement must be complied with. Hazardous voltages are still present in the drive units up to 5 minutes after the converter has been powered down due to the DC link capacitors. Thus, the unit or the DC link terminals must not be worked on until at least after this delay time. The power terminals and control terminals can still be at hazardous voltage levels even when the motor is stationary. If it is absolutely necessary that the drive converter be worked on when powered-up: ♦ Never touch any live parts. ♦ Only use the appropriate measuring and test equipment and protective clothing. ♦ Always stand on an ungrounded, isolated and ESD-compatible pad. If these warnings are not observed, this can result in death, severe bodily injury or significant material damage.

Replacing the Fan T he fan is des igned for an operating time of L 10 ³ 35 000 hours at an ambient temperature of T u = 40 °C . It s hould be replaced in good time to maintain the availability of the unit.

Torx M8x12

Torx M8x12

F an

F an hous ing

T he fan as s embly cons is ts of: ¨

the fan hous ing

¨

a fan.

T he fan as s embly is ins talled at the top of the chas s is . ¨

W ithdraw connector X 20.

¨

Undo the two M8 s crews of the fan as s embly.

¨

P ull out the fan as s embly towards the front (if neces s ary, tilt it s lightly downwards at the front) and lay it down s afely.

CAUTION

The fan assembly weighs up to 38 kg, depending on its design.

♦ Undo the cable fastenings and fan connections. ♦ Take the fan support plate out of the fan assembly and remove the fan from the support plate. ♦ Install the new fan assembly in the reverse sequence. Prior to start-up, check that the fan can run freely and check for correct direction of air flow. The air must be blown upwards out of the unit. The direction of rotation is counter-clockwise when seen from above.

Replacing the fan fuse The fuses are in a fuse holder which is mounted on a DIN rail in the bottom of the unit. The fuse holder has to be opened to replace the fuses.

Replacing the fan transformer fuse -F3, -F4 : Fuses -F3, -F4 The fuses are in a fuse holder which is arranged below the fan in front of the air baffle plate. To replace the fuses, the fuse holder has to be opened.

Replacing the fan transformer

♦ Mark the connecting cables on the transformer and disconnect them. ♦ Undo the screw connections at the bottom on the transformer plate and remove the transformer. Secure the transformer against falling down! ♦ Install the new transformer in the reverse sequence.

The starting capacitor is situated • inside the fan housing (, -C110). ♦ Withdraw the plug connections on the starting capacitor. ♦ Unscrew the starting capacitor. ♦ Install the new starting capacitor in reverse sequence (4.5 Nm).

Replacing the capacitor battery The unit is an assembly which consists of the DC link capacitors, the capacitor support and the DC link bus module.

The capacitor battery consists of three modules. Each module has a capacitor support and a DC link bus module. ♦ Withdraw the plug connections. ♦ Detach the mechanical fastening (four screws: two on the left, two on the right). Swing the capacitor battery out as far as it will go, slightly raise the unit and pull it forwards out of the converter. CAUTION

The capacitor battery weighs up to 15 kg, depending on the converter output!

Replacing the SML and the SMU SML: Snubber Module Lower SMU: Snubber Module Upper ♦ Remove the capacitor battery. ♦ Undo the fixing screws (4 x M8, 8 - 10 Nm or 4 x M6, 2.5 - 5 Nm, 1 x M4, max 1.8 Nm). ♦ Remove the modules. Install the new modules in the reverse sequence.

Removing and installing the module busbars Removal

♦ Remove the capacitor battery. ♦ Undo the screws of the module busbars. M8 power connections M6 fastening on spacers M4 circuit. ♦ Take out the insulation of the SMU / SML. ♦ Lift out the module busbars.

Installation NOTE

The spacing between the plus busbar and the minus busbar must be at least 4 mm. In order to install the module busbars, you must therefore use a template, e.g. a 4 mm thick piece of plastic. ♦ Place the module busbars and SMU/SML insulation on spacer bolts and fix in place (M6). ♦ Place the template instead of the DC link bus module in the module busbars. ♦ Locate the SMU and SML and tighten the modular connections (M8, 8 - 10 Nm, M6, 2.5 - 5 Nm). ♦ Screw the nuts tight on the spacer bolts (6 Nm). ♦ Connect the circuit resistors (M4, 1.8 Nm). ♦ Tighten the power connections (M8, 13 Nm). ♦ Remove the template from the module busbars. Template 4 mm

Module screw connection −

Module screw connection +

4

Replacing the balancing resistor The balancing resistor is situated in the rear installation level on the heat sink between the inverter modules, i.e. behind the capacitor battery and the module busbars. ♦ Remove the capacitor battery. ♦ Remove the module busbars and the IGD module. ♦ Undo the fixing screws and take out the balancing resistor. ♦ Install the new component in reverse sequence. ♦ The balancing resistor is tightened with 1.8 Nm. Coat the base plate evenly and thinly with a thermo-lubricant, paying attention to correct contact assignment.

Replacing the IVI Board ♦ Unscrew the two screws of the electronics slide-in unit and pull it out to its endstops. ♦ Disconnect the ground cable of the electronics slide-in unit. ♦ Remove all boards from the electronics box and place them on a suitable surface which cannot be statically charged. ♦ Unscrew the two fixing screws of the electronics box. ♦ Push the electronics box out of its interlock and take it out towards the front. ♦ Pull out the ABO Adaption Board. ♦ Disconnect the fiber-optic cables. ♦ Unscrew the IVI board and take it out. ♦ Install the new IVI in the reverse sequence.

Replacing the VDU and the VDU resistor VDU: Voltage-Dividing Unit The VDU and the VDU resistor are only found on converters with higher supply voltages. The VDU bracket is an integral component of the electronics slide-in unit. VDU

♦ Detach the plug-in connections. ♦ Undo the fixing screw ♦ Take out the VDU. ♦ Install the new VDU in the reverse sequence.

VDU resistor

♦ Unscrew the cable fasteners. ♦ Detach the plug-in connections. ♦ Take out the VDU resistor. ♦ Install the new VDU resistor in the reverse sequence.

Replacing the PSU2

¨

R emove the V DU and the V DU res is tor (if pres ent).

¨

R emove the V DU retainer plate.

¨

Detach the plug-in connections on the P S U.

¨

Undo the s crews (s ix T orx M4 s crews ) on the P S U.

¨

T ake out the P S U.

¨

Ins tall the new P S U in the revers e s equence.

R eplacing the IG D

NOT E

T he s pacing between the plus bus bar and the minus bus bar mus t be at leas t 4 mm. In order to ins tall the module bus bars , you mus t therefore us e a template, e.g. a 4 mm thick piece of plas tic. ¨

T he IG D board is s ituated behind the module bus bars .

¨

T ake out the capacitor battery.

¨

T ake out the S ML and S MU modules .

¨

R emove the module bus bars .

¨

R emove the nine fiber-optic cables at the top of the IG D.

¨

W ithdraw the P 15 feeder cable.

¨

Undo the fixing s crews and remove the IG D board.

¨

Ins tall the new IG D in the revers e s equence. Make s ure when doing s o that you pus h in the fiber-optic cables up to the ends top.

Replacing the TDB TDB: Thyristor Drive Board The TDB is arranged in front of the thyristor modules. These are situated in the rectifier section between the fan assembly and the inverter. ♦ Remove the cover (undo screws, then first of all detach the righthand snap hook, and then the left-hand snap hook) ♦ Withdraw connectors X246, X11, X12 and X13. ♦ Disconnect the PUD and NUD connections of the pre-charging resistors R1 and R2 (M4, Torx). ♦ Disconnect the connections to phases U, V, W . ♦ Disconnect the NUD1, NUD2, NUD3 connections. ♦ Remove the TDB board. ♦ Install the new TDB in the reverse sequence. See figure under section "Replacing the thyristor modules"

Replacing the IGBT module Replacement is carried out as in the case of the IGD board, with the following additions: ♦ Remove the fixing screws of the faulty IGBT module and take it out. ♦ Install a new IGBT module, paying attention to the following: • Coat the contact surfaces thinly and evenly with a thermolubricant. • Tighten the fixing screws of the IGBT module with 5 Nm, observing the sequence of tightening. ♦ Modules with the same type designation e.g. FZxxxxRYYKF4 must be installed in every phase 1

4

3

2

3

C

E

6

1

2

5

4

Screw on IGBT module: 1. Hand-tighten (~ 0.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6 2. Tighten with 5 Nm (Order No. 6SE7031-8EF60: 2.5 - 3.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6

Replacing the thyristor modules (V1 to V3, ) Replacement as in the case of the TDB, with the following additions: ♦ Disconnect the supply cables C+ D− of the option terminals ♦ Disconnect the connection of the C and D bars between the rectifier and the inverter. ♦ Disconnect the connections U, V, W of the modules. ♦ Disconnect the connections between modules and C(+) bar. ♦ Remove the connecting bar C(+). ♦ Disconnect the connections between modules and D(−) bar. ♦ Remove the connecting bar D(−). ♦ Undo the module fixing screws (M6, Torx). ♦ Remove the module (weight approx. 500 g). ♦ Clean the contact surface. ♦ Coat the new modules thinly and evenly with a thermo-lubricant and mount them. Tightening torque of the fixing screws: 6 Nm ± 15 %. ♦ Further installation is performed in the reverse sequence. Tightening torque of the electrical connections (C and D): 12 Nm (+ 5 %, − 10 %).

Replacing the PMU ♦ Remove the ground cable on the side panel. ♦ Carefully press the snap catches on the adapter section together, remove the PMU with adapter section from the electronics box. ♦ Withdraw connector X108 on the CUx board. ♦ Carefully lift forward the PMU out of the adapter section using a screwdriver. ♦ Install the new PMU in the reverse sequence.

Adapter section PMU

E-box

Snap catches

Replacing the pre-charging resistors (R1 - R4, ) These are situated on the right next to the TDB board in the rectifier section. ♦ Remove the cover (undo screws, then detach first the right-hand snap catch and then the left-hand snap catch). ♦ Disconnect the PUD and the NUD connections of the pre-charging resistors R1 - R4 (M4, Torx). ♦ Detach the pre-charging resistors and take them out. ♦ Install the new pre-charging resistor with torque of 20 Nm ± 10 %. CAUTION

Do NOT tilt the pre-charging resistor!

♦ Mount the fastenings and the connections in the reverse sequence. See figure under section "Replacing the thyristor modules"

Replacing the circuit resistor ♦ Take out the capacitor battery. ♦ Take out the SML and SMU modules. ♦ Remove the module busbars. ♦ Undo the fixing screws (2 x M5, torque: max. 1.8 Nm) and take out the circuit resistor. ♦ The new resistor must be thinly and uniformly rolled in a thermolubricant. ♦ Max. torque of the electrical connections: 1.8 Nm. ♦ Install the new circuit in the reverse sequence.

Forming If a unit has been non-operational for more than one year, the DC link capacitors have to be newly formed. If this is not carried out, the unit can be damaged when the line voltage is powered up. If the unit was started-up within one year after having been manufactured, the DC link capacitors do not have to be re-formed. The date of manufacture of the unit can be read from the serial number. How the serial number is made up

(Example: A-J60147512345) Digit

Example

Significance

1 and 2

A-

Place of manufacture

3

H

1996

J

1997

K

1998

4

1 to 9

January to September

O

October

N

November

D

December

5 to 14

Not relevant for forming

The following applies for the above example: Manufacture took place in June 1997. During forming, the DC link of the unit is connected up via a rectifier, a smoothing capacitor and a resistor. As a result, the DC link capacitors receive a defined voltage and a limited current, and the internal conditions necessary for the function of the DC link capacitors are restored.

3AC

A

C

R

C / L+

D / L-

Forming

Disconnect

Motorconnection

Pre-charging

U1/L1

U2/T1

V1/L2

V2/T2

W1/L3

W2/T3

DC link PE1

Rectifier

Inverter PE2

Components for the forming circuit (suggestion)

Types E to G: Vrated

A

R

C

3AC 380 V to 480 V

SKD 62 / 16

330 Ω / 150 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

470 Ω / 200 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

470 Ω / 100 W

22 nF / 1600 V

A

R

C

3AC 380 V to 480 V

SKD 62 / 16

100 Ω / 500 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

150 Ω / 500 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

150 Ω / 500 W

22 nF / 1600 V

Type K: Vrated

Procedure

♦ Before you form the unit, all mains connections must be disconnected. ♦ Connect the required components in accordance with the circuit example. ♦ Energize the forming circuit. The duration of forming depends on the idle time of the converter. 6

Forming time in hours

5 4 3 2

Off-circuit idle time in years

1

1

2

3

4

5

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 15

Parameter Listings

AC Electrical

TDS-9S

SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL) LISTING OF INVERTER PARAMETERS

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

YES P050 YES P053 YES P060 2 P068 P070 P071 P072 P073 P075 P075 P076 P076 P095 P095 P100 P100 P101 P101 YES P102 YES P102 P103 P103 P104 P104 YES P105 YES P105 P106 P106 P107 P107 P108 P108 P109 P109 YES P113 YES P113 YES P115 3 P116 P116 P120 P120 P121 P121 P122 P122 P127 P127 YES P128 YES P128 P130 P130

0 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

Language Parameter Access Menu Select Output Filter Order No. 6SE70 Line Volts Rated Drive Amps Rated Drive Power X (magnet,d)tot X (magnet,d)tot X (magnet,q)tot X (magnet,q)tot Type of Motor Type of Motor Control Mode Control Mode Motor Rated Volts Motor Rated Volts Motor Rated Current Motor Rated Current Motor Magn Current Motor Magn Current Motor Power Factor Motor Power Factor Motor Rated Power Motor Rated Power Motor Rated Efficiency Motor Rated Efficiency Motor Rated Frequency Motor Rated Frequency Motor Rated Speed Motor Rated Speed Motor #Pole Pairs Motor #Pole Pairs Motor Rated Torque Motor Rated Torque Calc Motor Model Start-Up Time Start-Up Time Main Reactance Main Reactance Stator Resistance Stator Resistance Total Leakage React Total Leakage React RotResistTmpFact RotResistTmpFact Imax Imax Select Motor Encoder Select Motor Encoder

1 6 0 0 38-6U.6. 780V 860.0A 630.0 kW 150.0% 150.0% 150.0% 150.0% 11 11 4 3 550V 550V 662.0A 662.0A 0 0 0.87 0.87 700.0 Hp 700.0 Hp 92.0% 92.0% 39.2 Hz 39.2 Hz 1155 1/min 1155 1/min 2 2 4203.0 Nm 4203.0 Nm 0 0.18 s typ 0.20 s typ 380.5 typ 391.0 typ 3.24% typ 3.35% typ 25.61% typ 25.80% typ 82.8% typ 84.4% typ 1169.5 A 1169.5 A 11 10

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Language (1=English) Access for Parameters Parameter Menu (7 = Free Access) No Output filter MLFB: Drive Size 128 Rated Drive Voltage Rated Drive Current Rated Drive Power (Default) (Default) (Default) (Default) NEMA Induction Motor NEMA Induction Motor Speed Regulation Frequency Regulation Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Typ = 22.1% Typ = 22.5% Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Calculated From Motor Nameplate Calculated From Motor Nameplate Auto Tune (P115=2, 4, 5) Auto Tuned Auto Tuned (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) Resistance Temp Factor (Auto tuned) Resistance Temp Factor (Auto tuned) Maximum current setpoint (1.5 x P102) Maximum current setpoint (1.5 x P102) 11 = Encoder 10 = No encoder

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126743 REV.SHEET 2 OF 14

VIEW PAR. NO.

P151 P151 YES P215 YES P215 P216 P216 P221 P221 P222 P222 P223 P223 P233 P233 P234 P234 P235 P235 P236 P236 P240 P240 YES P259 YES P259 P273 P273 P274 P274 P283 P283 P284 P284 P287 P287 P291 P291 YES P295 YES P295 P303 P303 P305 P305 P313 P313 P314 P314 P315 P315 P316 P316 P338 P338 P338 P338

IND.

PARAMETER DESC.

VALUE(Units)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4

Encoder Pulse # Encoder Pulse # Max dn/dt Max dn/dt Smooth n/f (FWD) Smooth n/f (FWD) Smooth n/f (Set) Smooth n/f (Set) Source of n/f (act) Source of n/f (act) Smooth n/f (act) Smooth n/f (act) n/f Reg. Adapt.1 n/f Reg. Adapt.1 n/f Reg. Adapt.2 n/f Reg. Adapt.2 n/f-reg. Gain 1 n/f-reg. Gain 1 n/f-reg. Gain 2 n/f-reg. Gain 2 n/f Reg. Time n/f Reg. Time Max Regen Power Max Regen Power Smooth Isq (set) Smooth Isq (set) Isq (set) grad. Isq (set) grad. Current Reg Gain Current Reg Gain Current Reg Time Current Reg Time SmoothDCBusVolts SmoothDCBusVolts Fsetp Flux (set) Fsetp Flux (set) Efficiency Optim Efficiency Optim Smooth Flux (Set) Smooth Flux (Set) FieldWeakRegTime FieldWeakRegTime f(cEMF Mod) f(cEMF Mod) f(cEMF->AMP-mod) f(cEMF->AMP-mod) cEMF Reg Gain cEMF Reg Gain cEMF Reg Time cEMF Reg Time Common Mode Comp Common Mode Comp Common Mode Comp Common Mode Comp

1024 1024 8.10 Hz 8.10 Hz 0.0 ms typ 4.8 ms typ 4 ms 4 ms 0 0 4 ms typ 0 ms typ 0.0% 0.0% 100.0% 100.0% 2.6 typ 1.7 typ 2.6 typ 1.7 typ 134 ms typ 230 ms typ -30.0% -30.0% 7 ms typ 7 ms typ 2648.0 A typ 2648.0 A typ 0.324 typ 0.327 typ 6.4 ms typ 6.4 ms typ 9 9 100.0% 100.0% 50.0% 50.0% 20 ms typ 15 ms typ 150 ms 150 ms 3.92 Hz typ 3.92 Hz typ 50.0% 50.0% 0.162 typ 0.324 typ 50.0 ms typ 50.0 ms typ 3.00 us 3.00 us 3.00 us 3.00 us

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Number of encoder pulses Number of encoder pulses Speed Error Allowed Speed Error Allowed Smoothing Value for Speed Reg (Auto tuned) Smoothing Value for Speed Reg (Auto tuned) (Default) (Default) (Default) (Default) (Auto tuned) (Auto tuned) (Default) (Default) (Default) (Default) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Integral time of speed controller (Auto tuned) Integral time of speed controller (Auto tuned) Maximum allowed regenerative power. Maximum allowed regenerative power. Torque smoothing time constant (Auto tuned) Torque smoothing time constant (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Gain of the PI current controller (Auto tuned) Gain of the PI current controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) DC link bus V smoothing time const (Default) DC link bus V smoothing time const (Default) Flux setpoint from rated rotor flux (Default) Flux setpoint from rated rotor flux (Default) Better Control at Reduced Load Better Control at Reduced Load Flux setpt smoothing time const (Auto tuned) Flux setpt smoothing time const (Auto tuned) Field weakening time for PI contoller (Default) Field weakening time for PI contoller (Default) Frequency of switch for models (Auto tuned) Frequency of switch for models (Auto tuned) Frequency of switch for models (Default) Frequency of switch for models (Default) PI for counter EMF model (Auto tuned) PI for counter EMF model (Auto tuned) Integral time for counter EMF (Auto tuned) Integral time for counter EMF (Auto tuned) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default)

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126743 REV.SHEET 3 OF 14

VIEW PAR. NO.

P338 P338 P339 P339 P340 P340 P342 P342 P344 P344 P347 P347 P348 P349 YES P350 P351 P352 P353 YES P354 P357 YES P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360

IND.

PARAMETER DESC.

VALUE(Units)

5 6 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Common Mode Comp Common Mode Comp ModSystemRelease ModSystemRelease Pulse Frequency Pulse Frequency Max ModulatDepth Max ModulatDepth ModDepth Headroom ModDepth Headroom ON VoltsCompens. ON VoltsCompens. Dead Time Comp T(DeadtimeComp.) Ref Amps Ref Volts Ref Frequency Ref Speed Ref torque Sampling time Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter

3.00 us 3.00 us 0 0 2.5 kHz 2.5 kHz 96.0% 96.0% 0.0% 0.0% 1.1 V typ 1.1 V typ 0 2.50us 662.0 A 550 V 81.50 Hz 2400 1/min 4203.00Nm 1.2 ms P060 P053 P358 r001 r002 r003 r004 r005 r006 r007 r008 r011 r012 r013 r014 r015 P050 P102 P105 P113 P115 P128 P215 P259 P295 P350 P354 P401 r419 P492 r496 r497 P498 r502

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Freq system type to release P338 (Default) Freq system type to release P338 (Default) Drive Carrier Frequency (Default) Drive Carrier Frequency (Default) Max modulation depth of modulator (Default) Max modulation depth of modulator (Default) Modulator headroom depth (Default) Modulator headroom depth (Default) IGBT voltage diff compensation (Auto tuned) IGBT voltage diff compensation (Auto tuned) Select deadtime Comp,0=off (Auto tuned) Gate unit intrlock compens time (Auto tuned) Set to P102 (Motor Rated Current) Set to P101 (Motor Rated Voltage) Motor Nameplate Motor Nameplate Set to P113 (Motor Rated Torque) Base Sampling Time Always select P060 (Menu Access) Always select P053 (Parameter access) Always select P358 (Key unlock parameter) Select Drive Status. Select Rotational Frequency Select Output Volts Select Output Amps Select Output Power Select DC Bus Volts Select Motor Torque Select Motor Utilization Select Active Motor Data Set Select Active BICO Data Set Select Active Function Data Set Select Set Point Speed Select Speed Actual Input Select Language Select Motor Rated Amps Select Motor Rated Power Select Motor Rated Torque Select Motor Calculation (Auto Tune) Select Imax Select max. dn/dt Select Max Regen Power Select Efficiency Optim Select Reference Amps Select Reference Torque Select Fixed Setpoint 1 Select # of Active Fault Setpoints Select FixTorque 1 Set Select Fix Torque 1 Select Actual Upper Torque Limit Select FixTorq 2 Set Select Fix Torque 2

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126743 REV.SHEET 4 OF 14

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P361 P366 P368 P370 P375 P382 P382 P383 P383 P401 P401 P401 P421 P422 P423 P425 P426 P427 P428 P429 P430 P433 P433 P434 P434 P434 P443 P443 P444 P444 P444 P445 P445 P445

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3

Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter OP1s Backlight Select FactSet Select Setp Src Quick Param Ground Flt Test Motor Cooling Motor Cooling Mot ThermT-Const Mot ThermT-Const Fixed Setpoint 1 Fixed Setpoint 1 Fixed Setpoint 1 MOP (max) MOP (min) Src MOP inv. Conf MOP StartValue MOP Src Set MOP Src SetV MOP Src Auto SetP Src Manual/Auto Src AddSetpoint1 Src AddSetpoint1 Scale Add Setpoint Scale Add Setpoint Scale Add Setpoint Src MainSetpoint Src MainSetpoint Scale Main Setp Scale Main Setp Scale Main Setp Base Setpoint Base Setpoint Base Setpoint

r550 r551 r552 r553 P590 P602 P640 P643 P644 r782 r783 r784 r785 r786 r787 r825 r947 r949 P971 U002 0 1 1 0 0 1 1 1800 s 1800 s 0.00% 10.00% 5.00% 100.0% 0.0% 2111 0110 0.0% 0 0 0 0 41 0 100.00% 100.00% 100.00% 3002 58 100.00% 100.00% 100.00% 0.0% 0.0% 0.0%

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Select Control Word 1 Select Control Word 2 Select Status Word 1 Select Status Word 2 Select Src BICO Dset Select Excitation time Select Src Analog Out Select CU AnalogOutGain Select CU- AnalogOutOff Select Last 8 Fault Trip Times Select n/f actual (r218) at time of last trip Select n/f actual/second at time of last trip Select actual torque current at time of trip Select actual converter out V at time of trip Select Control Status at time of trip Select Operating Hours (Inverter Pulsing) Select Last 8 Faults Select Last 8 Fault Values Select EEPROM Saving Select Fixed Setpt 18 (Meter Torque Scaling) 0= Always On Select Factory Setting (Default) Analog Input & Terminal Strip (Default) P370=1 Will Factory DEFAULT Parameters!!!! Blocked (Default) 1 = Forced Vent 1 = Forced Vent Max Time Allowed in Stall = 30 min. Max Time Allowed in Stall = 30 min. Additional Drill Speed Spin Speed Set to 10% of Rated Speed Torque Speed Set to 5% of Rated Speed Upper Limit of OP1S (Default) Lower Limit of OP1S (Default) BICO for Direction Change on OP1S Configuration of MOP MOP Starting Value BICO Source for MOP Use (Default) BICO Source for MOP Set Value (Default) BICO Source for MOP Auto Setpt (Default) BICO Source for Manual/Auto Switching BICO to Set Spin, Torque, and Speed BICO to Set Spin, Torque, and Speed Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) BICO for Main Setpoint BICO for Main Setpoint Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def)

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126743 REV.SHEET 5 OF 14

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P448 P449 P452 P452 P452 P453 P453 P453 P457 P457 P457 P462 P462 P462 P463 P463 P463 P464 P464 P464 P465 P465 P465 P466 P466 P467 P467 P467 P468 P469 P469 P469 P470 P470 P470 P471 P471 P475 P476 P492 P492 P492 P493 P493 P494 P494 P494 P498 P498 P498 P499 P499 P500 P500

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3 1 2 1 2

Jog Setp 1 Jog Setp 2 n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max,REV Spd) n/f(max,REV Spd) n/f(max,REV Spd) Min setp Min setp Min setp Accel. Time Accel. Time Accel. Time Accel. Time Unit Accel. Time Unit Accel. Time Unit Decel. Time Decel. Time Decel. Time Decel. Time Unit Decel. Time Unit Decel. Time Unit Decel. Time OFF3 Decel. Time OFF3 ProtRampGen Gain ProtRampGen Gain ProtRampGen Gain Rgen Round Type Ramp StartSmooth Ramp StartSmooth Ramp StartSmooth Ramp End Smooth Ramp End Smooth Ramp End Smooth Scale Torq (PRE) Scale Torq (PRE) Ramp Limitation RampGen Act Hyst FixTorque 1 Set FixTorque 1 Set FixTorque 1 Set Src Fixtorque 1 Src Fixtorque 1 FixTorque 1 Gain FixTorque 1 Gain FixTorque 1 Gain FixTorque 2 Set FixTorque 2 Set FixTorque 2 Set Src FixTorque 2 Src FixTorque 2 Scale TorqLim2 Scale TorqLim2

10.00% 20.00% 100.0% 100.0% 100.0% -50.00% -50.00% -50.00% 0.0% 0.0% 0.0% 5.0 5.0 5.0 0 0 0 2 2 2 0 0 0 2.0 s 0.0 s 2.9 typ 1.0 typ 1.0 typ 0 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 100.0% 100.0% 0.0% 1.0% 100.0% 10.0% 150.0% 3003 170 100.00% 100.00% 100.00% -100.00% -10.00% -200.00% 3005 171 100.00% 100.00%

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Jogging Setpoint 1 (Default) Jogging Setpoint 2 (Default) Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% 0 = Seconds 0 = Seconds 0 = Seconds Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% 0 = Seconds 0 = Seconds 0 = Seconds Keypad "quickstop" from 100% to standstill Keypad "quickstop" from 100% to standstill Acceleration Time (P462) Gain Factor(Auto Tn) Acceleration Time (P462) Gain Factor Acceleration Time (P462) Gain Factor Mode for Ramp Function Rounding (Default) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Gain of the n/f controller precontrol (Default) Gain of the n/f controller precontrol (Default) "0.0" Deactivates Ramp-Func Tracking (Def) Hysteresis for "Rmp-Func Gen Active" msg. Forward Maximum Drill Torque Forward Spin Torque Maximum Make-up Torque (Forward) BICO Source for Upper Torque Limitation BICO Source for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Reverse Maximum Drill Torque Reverse Spin Torque Maximum Breakout Torque (Reverse) BICO Source for Lower Torque Limit BICO Source for Lower Torque Limit Scaling Factor for Lower Torque Limit (Def) Scaling Factor for Lower Torque Limit (Def)

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126743 REV.SHEET 6 OF 14

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P500 P535 P535 P536 P536 P537 P537 P554 P554 P555 P555 P556 P556 P557 P557 P558 P558 P559 P559 P560 P560 P561 P561 P562 P562 P563 P563 P564 P564 P565 P565 P566 P566 P567 P567 P568 P568 P569 P569 P571 P571 P572 P572 P573 P573 P574 P574 P575 P575 P576 P576 P577 P577 P578

3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1

Scale TorqLim2 SIMO Sound SIMO Sound n/f RegDyn (set) n/f RegDyn (set) n/f RegDyn (act) n/f RegDyn (act) Src ON/OFF1 Src ON/OFF1 Src1 OFF2 (Coast) Src1 OFF2 (Coast) Src2 OFF2 (Coast) Src2 OFF2 (Coast) Src3 OFF2 (Coast) Src3 OFF2 (Coast) Src1 OFF3 (Qstop) Src1 OFF3 (Qstop) Src2 OFF3 (Qstop) Src2 OFF3 (Qstop) Src3 OFF3 (Qstop) Src3 OFF3 (Qstop) Src InvRelease Src InvRelease Src RampGen Rel Src RampGen Rel Src RampGen Stop Src RampGen Stop Src Setp Release Src Setp Release Src1 Fault Reset Src1 Fault Reset Src2 Fault Reset Src2 Fault Reset Src3 Fault Reset Src3 Fault Reset Src Jog Bit0 Src Jog Bit0 Src Jog Bit1 Src Jog Bit1 Src FWD Speed Src FWD Speed Src REV Speed Src REV Speed Src MOP UP Src MOP UP Src MOP Down Src MOP Down Src No ExtFault1 Src No ExtFault1 Src FuncDSet Bit0 Src FuncDSet Bit0 Src FuncDSet Bit1 Src FuncDSet Bit1 Src MotSSet Bit0

100.00% 1 1 50% 50% 50% typ 49% typ 3100 2100 22 22 1 1 1 1 2102 2102 1 1 1 1 1 1 1 1 1 1 1 1 18 18 3107 0 2107 2107 3108 2108 0 0 3111 2111 3112 2112 2113 2113 2114 2114 20 20 3400 0 3401 0 3402

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Scaling Factor for Lower Torque Limit (Def) Adjusts Noise Spectrum of Machine Adjusts Noise Spectrum of Machine Dynamic Response of n Control Circuit (Def) Dynamic Response of n Control Circuit (Def) P536 Adjustment After P115=5 (Auto Tuned) P536 Adjustment After P115=5 (Auto Tuned) Drive ON/OFF Command,P590=0 (PLC Cntrl) Drive ON/OFF Command,P590=1 (OP1S Ctrl) Drive OFF Command From E-STOP (Coast) Drive OFF Command From E-STOP (Coast) 2nd BICO Source for OFF (Coast Stop)(Def) 2nd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) Drive OFF Command From OP1S (Qck Stop) Drive OFF Command From OP1S (Qck Stop) 2nd BICO Source for OFF (Quick Stop)(Def) 2nd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) Digital In 5 (Not used) Digital In 5 (Not used) AutoReset Drive From PLC Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Jog from Bit 8, Control Word 1 Jog from OP1S Keypad BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Source to Command Fwd Rotation(PLC) BICO Source to Command Fwd Rot (Keypad) BICO Source to Command Rev Rotation (PLC) BICO Source to Command Rev Rot (Keypad) BICO Source to Increase MOP (Not Used) BICO Source to Increase MOP (Keypad) BICO Source to Decrease MOP (Not Used) BICO Source to Decrease MOP (Keypad) BICO Source for External Fault 1 BICO Source for External Fault 1 BICO Src for Func Data Set (cw2,bit16) BICO Src for Func Data Set (cw2,bit16)(Def) BICO Src for Func Data Set (cw2,bit17) BICO Src for Func Data Set (cw2,bit17)(Def) BICO Src for Motor Data Set (cw2,bit 18)

23/03/2001 10:56

126743 REV.SHEET 7 OF 14

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P578 P579 P579 P590 P602 P602 P603 P603 P640 P640 P643 P643 P644 P644 P652 P652 P722 P722 P734 P734 P734 P734 P734 P734 P952 P970 P971 U001 U001 U001 U002 U002 U002 U107 U107 U108 U108 U117 U118 U119 U120 U121 U122 U950 U950 U950 U951 U951 U952

2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 1 2 3 1 2 3 1 2 1 2 031 032 075 004 059 047

Src MotSSet Bit0 Src MotSSet Bit1 Src MotSSet Bit1 Src BICO Dset Excitation Time Excitation Time De-MagnetizeTime De-MagnetizeTime Src AnaOut Src AnaOut CU AnalogOutGain CU AnalogOutGain CU--AnalogOutOFF CU--AnalogOutOFF Src DigOut2 Src DigOut2 CB/TB TlgOFF CB/TB TlgOFF SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData # of Faults Factory Setting EEPROM Saving FixSetp 17 FixSetp 17 FixSetp 17 fixSetp 18 fixSetp 18 fixSetp 18 Src Conn Mult1 Src Conn Mult1 Src Conn Mult2 Src Conn Mult2 Src ConnAbsV1 Mode ConnAbsV1 SmoothConAbsV1 Src ConnAbsV2 Mode ConnAbsV2 SmoothConAbsV2 Sampling Times1 Sampling Times1 Sampling Times1 Sampling Times2 Sampling Times2 Sampling Times3

3402 0 0 0 0.20 s 0.20 s 3.00 s 3.00 s 148 24 10.00 V 10.00 V 0.00 V 0.00 V 122 122 10 ms 10 ms 32 467 33 468 170 250 7 1 0 95.00% 95.00% 95.00% 54.50% 54.50% 54.50% 491 401 492 402 148 1 0 ms 24 1 0 ms 2 2 2 2 2 2

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

BICO Src for Motor Data Set (cw2,bit 18) BICO Src for Motor Data Set (cw2,bit 19)(Def) BICO Src for Motor Data Set (cw2,bit 19)(Def) Set PLC or OP1S Control (0=PLC) Wait Time Before Releasing Frequency Wait Time Before Releasing Frequency Time to DE-excite Motor (Auto Tuned) Time to DE-excite Motor (Auto Tuned) BICO for Analog 1 Out (Speed) BICO for Analog 1 Out (Torque) Porportional Gain for Analog Outputs (Def) Porportional Gain for Analog Outputs (Def) Offset Voltage for P643 Analog Outs (Def) Offset Voltage for P643 Analog Outs (Def) Undervoltage Fault (Status Word 1, Bit 11) Undervoltage Fault (Status Word 1, Bit 11) Fault if No Communication for 10 ms (Def) Fault if No Communication for 10 ms (Def) Status Word 1(To PLC) Speed to Meter (To PLC) Status Word 2 (To PLC) Torque to Meter (To PLC) Spin Torque (To PLC) Fault Number (To PLC) Number of Stored Fault Trips P970=0 Will Factory DEFAULT Parameters!!!! Save Parameters(Ram To EEPROM)(P971=1) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Multipliers for RPM Meter Multipliers for RPM Meter Multipliers for Torque Meter Multipliers for Torque Meter BICO Source for 1st Abs Value Generator Mode Sel for Ist Abs Value Gen (1=| Signal |) Smoothing Time Const for 1st Abs Val Gen BICO Source for 2nd Abs Value Generator Mode Sel for 2nd Abs Value Gen (1=| Signal |) Smoothing Time Const for 2nd Abs Val Gen Sampling time Sampling time Sampling time Sampling time Sampling time Sampling time

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126743 REV.SHEET 8 OF 14

TDS-9S

PAR. NO.

P050 P051 P052 P053 P054 P071 P074 P075 P076 P077 P090 P091 P140 P141 P144 P160 P310 P311 P312 P313 P314 P315 P316 P317 P318 P319 P320 P329 P353 P354 P366 P368 P408 P409 P486 P517 P518 P554 P555 P556 P557 P561 P565 P566 P567 P568 P569 P571 P575 P578

SIEMENS SERIES 70 DRIVE LISTING OF RECTIFIER PARAMETERS IND.

0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PARAMETER DESC.

Language Access Level Function Select Parameter Access Display Light Line Volts Limit LowVoltage Rtd Amps Config. Pcircuit Factory Set type Board Position 2 Board Position 3 Rectifier Resistance Rectifier Inductance DC Bus Capacitance Motor Current Limit DC Current Reg Gain DC Current Reg Time DC Cur Reg CWord DC Volts Reg Gain DC Volts Reg Time DC Volts Reg CWord DC V-Reg +Limit DC V-Reg -Limit DC V(Set,red) DC V(Set,red)Hys Smooth Load Amps Pre Charge Time Thyristor Test Ground Flt Test Auto Restart Time DC Bus Volts Caps Forming Time Contactor Delay Src Current Setup DC Volts Dev Limit Deviation Time Src ON/OFF1 Src1 OFF2(coast) Src2 OFF2(coast) Src3 OFF2(coast) Src InvRelease Src1 Fault Reset Src2 Fault Reset Src3 Fault Reset Src Jog1 ON Src Jog2 ON Src Reduce DC V Src No ExtFault1 Src RDataSet Bit0

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

1 3 0 6 0 575.0 V 61 1023 1 0 0 0 0.007 0.21 32.22 150 0.15 0.015 2111 8.8 3 0010 0.01 -1.00 95.00 6.00 5.00 500 0 2 2 6.1 10 0 0 2 0.1 1001 0001 0001 0001 1003 1004 0000H 2001 0000H 0000H 0001 0001 0000H

COMMENTS

Set DC Bus to 780V

Restart After Power Recovery

Used To Reduce DC Bus Via P318

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126743 REV.SHEET 10 OF 14

PAR. NO.

P579 P586 P587 P588 P589 P590 P591 P600 P601 P602 P603 P604 P606 P607 P608 P610 P611 P612 P613 P618 P619 P620 P621 P622 P623 P624 P631 P655 P656 P657 P658 P660 P661 P662 P664 P665 P666 P680 P681 P682 P683 P684 P685 P686 P687 P688 P689 P690 P694 P695 P696 P697 P698 P699

IND.

1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1 0 1 1 1 1 1 0 1 1 1 0 0 0 0 0

PARAMETER DESC.

Src RDataSet Bit1 Src No ExtFault2 Src Master/Slave Src No Ext Warn1 Src No Ext Warn2 Src Base/Reserve Src ContactorMsg Trg Bit Ready ON Trg Bit Ready Operator Trg Bit Oper Trg Bit Fault Trg Bit No OFF2 Trg Bit On blocked Trg Bit Warning Trg Regen Ready Trg Low Voltage Trg Low Voltage Trg Bit Contact Trg DC V reduced Trg Current Lim. Trg Bit Ext Flt1 Trg Bit Ext Flt2 Trg Bit Ext Warn Trg Bit i2tInv Trg Bit Flt Tmp Inv TrgBitWarTmpInv Trig Bit Charging CUR AnaOutActVal CUR AnaOut Gain CUR AnaOut Offset AnaOut Conf Curr SCI AnaLogInConf SCI AnaInSmooth SCI AnaLogInOffs SCI AnaOutActVal SCI AnaOut Gain SCI AnaOut Offs SCom1 Act Value SCom2 Act Value SCB Protocol SCom/SCB BusAddr SCom/SCB Baud SCom/SCB PCV SCOM/SCB # PrDat SCom/SCB TlgOFF SCom2 Protocol SCB Peer2PeerExt SCB Act Values CB/TB Act Values CB/TB Tlg Off Time CB Parameter 1 CB Parameter 2 CB Parameter 3 CB Parameter 4

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

COMMENTS

0000H 0001H 0000H 0001H 0001H 0000H 0001H 0000H 0000H 0000H 1001 0 0 1002 0 0 0 0 0 0 0 0 0000H 0000H 0000H 0000H 0000H 37 10.00 0.00 0 0 2 0 0 10 0 968 968 0 0 6 127 2 0 ms 1 0 0 968 20ms 0 0 0 0

23/03/2001 10:56

126743 REV.SHEET 11 OF 14

PAR. NO.

P700 P701 P702 P703 P704 P705 P772 P773 P775 P776 P777 P778 P779 P780 P785 P788 P793 P799 P917 P918 P928 P971

IND.

0 0 0 0 0 0 1 1 1 1 1 1 0 1 0 1 0 0 0 0 0 0

PARAMETER DESC.

CB Parameter 5 CB Parameter 6 CB Parameter 7 CB Parameter 8 CB Parameter 9 CB Parameter 10 Thyr Voltg Corr Deadband Convert Min Gating Angle Max Gating Angle Max Gat Ang Ramp Line FrquFiltTime Phase Shift Corr Fault Masking I2T Control Word RAM Access Addr Line Voltg Delay Special Access Change Reports CB Bus Address Src Base/Reserve EEPROM Storing

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

COMMENTS

0 0 0 0 0 0 0 0.01 0 150 20 200 0.8 0 1 0 0.03 4 0 3 0000H 0

23/03/2001 10:56

126743 REV.SHEET 12 OF 14

TDS-11S

SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL) LISTING OF INVERTER PARAMETERS

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

YES P050 YES P053 YES P060 2 P068 P070 P071 P072 P073 P075 P075 P076 P076 P095 P095 P100 P100 P101 P101 YES P102 YES P102 P103 P103 P104 P104 YES P105 YES P105 P106 P106 P107 P107 P108 P108 P109 P109 YES P113 YES P113 YES P115 3 P116 P116 P120 P120 P121 P121 P122 P122 P127 P127 YES P128 YES P128 P130 P130

0 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

Language Parameter Access Menu Select Output Filter Order No. 6SE70 Line Volts Rated Drive Amps Rated Drive Power X (magnet,d)tot X (magnet,d)tot X (magnet,q)tot X (magnet,q)tot Type of Motor Type of Motor Control Mode Control Mode Motor Rated Volts Motor Rated Volts Motor Rated Current Motor Rated Current Motor Magn Current Motor Magn Current Motor Power Factor Motor Power Factor Motor Rated Power Motor Rated Power Motor Rated Efficiency Motor Rated Efficiency Motor Rated Frequency Motor Rated Frequency Motor Rated Speed Motor Rated Speed Motor #Pole Pairs Motor #Pole Pairs Motor Rated Torque Motor Rated Torque Calc Motor Model Start-Up Time Start-Up Time Main Reactance Main Reactance Stator Resistance Stator Resistance Total Leakage React Total Leakage React RotResistTmpFact RotResistTmpFact Imax Imax Select Motor Encoder Select Motor Encoder

1 6 0 0 38-6U.6. 780V 860.0A 630.0 kW 150.0% 150.0% 150.0% 150.0% 11 11 4 3 575V 575V 732.0A 732.0A 0 0 0.87 0.87 800.0 Hp 800.0 Hp 92% 92% 39.2 Hz 39.2 Hz 1155 1/min 1155 1/min 2 2 4934.0 Nm 4934.0 Nm 0 0.20 s typ 0.21 s typ 380.9 typ 388.3 typ 3.43% typ 3.38% typ 31.15% typ 31.21% typ 80.7% typ 78.6% typ 1169.5 A 1169.5 A 11 10

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Language (1=English) Access for Parameters Parameter Menu (7 = Free Access) No Output filter MLFB: Drive Size 128 Rated Drive Voltage Rated Drive Current Rated Drive Power (Default) (Default) (Default) (Default) NEMA Induction Motor NEMA Induction Motor Speed Regulation Frequency Regulation Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Typ = 22.3% Typ = 22.3% Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Calculated From Motor Nameplate Calculated From Motor Nameplate Auto Tune (P115=2, 4, 5) Auto Tuned Auto Tuned (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) Resistance Temp Factor (Auto tuned) Resistance Temp Factor (Auto tuned) Maximum current setpoint (1.5 x P102) Maximum current setpoint (1.5 x P102) 11 = Encoder 10 = No encoder

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124965 REV.B SHEET 2 OF 13

VIEW PAR. NO.

P151 P151 YES P215 YES P215 P216 P216 P221 P221 P222 P222 P223 P223 P233 P233 P234 P234 P235 P235 P236 P236 P240 P240 YES P259 YES P259 P273 P273 P274 P274 P283 P283 P284 P284 P287 P287 P291 P291 YES P295 YES P295 P303 P303 P305 P305 P313 P313 P314 P314 P315 P315 P316 P316 P338 P338 P338 P338

IND.

PARAMETER DESC.

VALUE(Units)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4

Encoder Pulse # Encoder Pulse # Max dn/dt Max dn/dt Smooth n/f (FWD) Smooth n/f (FWD) Smooth n/f (Set) Smooth n/f (Set) Source of n/f (act) Source of n/f (act) Smooth n/f (act) Smooth n/f (act) n/f Reg. Adapt.1 n/f Reg. Adapt.1 n/f Reg. Adapt.2 n/f Reg. Adapt.2 n/f-reg. Gain 1 n/f-reg. Gain 1 n/f-reg. Gain 2 n/f-reg. Gain 2 n/f Reg. Time n/f Reg. Time Max Regen Power Max Regen Power Smooth Isq (set) Smooth Isq (set) Isq (set) grad. Isq (set) grad. Current Reg Gain Current Reg Gain Current Reg Time Current Reg Time SmoothDCBusVolts SmoothDCBusVolts Fsetp Flux (set) Fsetp Flux (set) Efficiency Optim Efficiency Optim Smooth Flux (Set) Smooth Flux (Set) FieldWeakRegTime FieldWeakRegTime f(cEMF Mod) f(cEMF Mod) f(cEMF->AMP-mod) f(cEMF->AMP-mod) cEMF Reg Gain cEMF Reg Gain cEMF Reg Time cEMF Reg Time Common Mode Comp Common Mode Comp Common Mode Comp Common Mode Comp

1024 1024 8.10 Hz 8.10 Hz 0.0 ms typ 4.8 ms typ 4 ms 4 ms 0 0 4 ms typ 0 ms typ 0.0% 0.0% 100.0% 100.0% 2.9 typ 1.6 typ 2.9 typ 1.6 typ 134 ms typ 258 ms typ -30.0% -30.0% 7 ms typ 7 ms typ 2928.0 A typ 2928.0 A typ 0.395 typ 0.395 typ 6.4 ms typ 6.4 ms typ 9 9 100.0% 100.0% 50.0% 50.0% 20 ms typ 20 ms typ 150 ms 150 ms 3.93 Hz typ 3.93 Hz typ 50.0% 50.0% 0.156 typ 0.300 typ 52.0 ms typ 54.0 ms typ 3.00 us 3.00 us 3.00 us 3.00 us

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Number of encoder pulses Number of encoder pulses Speed Error Allowed Speed Error Allowed Smoothing Value for Speed Reg (Auto tuned) Smoothing Value for Speed Reg (Auto tuned) (Default) (Default) (Default) (Default) (Auto tuned) (Auto tuned) (Default) (Default) (Default) (Default) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Integral time of speed controller (Auto tuned) Integral time of speed controller (Auto tuned) Maximum allowed regenerative power. Maximum allowed regenerative power. Torque smoothing time constant (Auto tuned) Torque smoothing time constant (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Gain of the PI current controller (Auto tuned) Gain of the PI current controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) DC link bus V smoothing time const (Default) DC link bus V smoothing time const (Default) Flux setpoint from rated rotor flux (Default) Flux setpoint from rated rotor flux (Default) Better Control at Reduced Load Better Control at Reduced Load Flux setpt smoothing time const (Auto tuned) Flux setpt smoothing time const (Auto tuned) Field weakening time for PI contoller (Default) Field weakening time for PI contoller (Default) Frequency of switch for models (Auto tuned) Frequency of switch for models (Auto tuned) Frequency of switch for models (Default) Frequency of switch for models (Default) PI for counter EMF model (Auto tuned) PI for counter EMF model (Auto tuned) Integral time for counter EMF (Auto tuned) Integral time for counter EMF (Auto tuned) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default)

14/02/2001 16:29

124965 REV.B SHEET 3 OF 13

VIEW PAR. NO.

P338 P338 P339 P339 P340 P340 P342 P342 P344 P344 P347 P347 P348 P349 YES P350 P351 P352 P353 YES P354 P357 YES P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360

IND.

PARAMETER DESC.

VALUE(Units)

5 6 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Common Mode Comp Common Mode Comp ModSystemRelease ModSystemRelease Pulse Frequency Pulse Frequency Max ModulatDepth Max ModulatDepth ModDepth Headroom ModDepth Headroom ON VoltsCompens. ON VoltsCompens. Dead Time Comp T(DeadtimeComp.) Ref Amps Ref Volts Ref Frequency Ref Speed Ref torque Sampling time Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter

3.00 us 3.00 us 0 0 2.5 kHz 2.5 kHz 96.0% 96.0% 0.0% 0.0% 1.1 V typ 1.1 V typ 0 2.55us 732.0 A 575 V 81.50 Hz 2400 1/min 4934.00Nm 1.2 ms P060 P053 P358 r001 r002 r003 r004 r005 r006 r007 r008 r011 r012 r013 r014 r015 P050 P102 P105 P113 P115 P128 P215 P259 P295 P350 P354 P401 r419 P492 r496 r497 P498 r502

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Freq system type to release P338 (Default) Freq system type to release P338 (Default) Drive Carrier Frequency (Default) Drive Carrier Frequency (Default) Max modulation depth of modulator (Default) Max modulation depth of modulator (Default) Modulator headroom depth (Default) Modulator headroom depth (Default) IGBT voltage diff compensation (Auto tuned) IGBT voltage diff compensation (Auto tuned) Select deadtime Comp,0=off (Auto tuned) Gate unit intrlock compens time (Auto tuned) Set to P102 (Motor Rated Current) Set to P101 (Motor Rated Voltage) Motor Nameplate Motor Nameplate Set to P113 (Motor Rated Torque) Base Sampling Time Always select P060 (Menu Access) Always select P053 (Parameter access) Always select P358 (Key unlock parameter) Select Drive Status. Select Rotational Frequency Select Output Volts Select Output Amps Select Output Power Select DC Bus Volts Select Motor Torque Select Motor Utilization Select Active Motor Data Set Select Active BICO Data Set Select Active Function Data Set Select Set Point Speed Select Speed Actual Input Select Language Select Motor Rated Amps Select Motor Rated Power Select Motor Rated Torque Select Motor Calculation (Auto Tune) Select Imax Select max. dn/dt Select Max Regen Power Select Efficiency Optim Select Reference Amps Select Reference Torque Select Fixed Setpoint 1 Select # of Active Fault Setpoints Select FixTorque 1 Set Select Fix Torque 1 Select Actual Upper Torque Limit Select FixTorq 2 Set Select Fix Torque 2

14/02/2001 16:29

124965 REV.B SHEET 4 OF 13

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P361 P366 P368 P370 P375 P382 P382 P383 P383 P401 P401 P401 P421 P422 P423 P425 P426 P427 P428 P429 P430 P433 P433 P434 P434 P434 P443 P443 P444 P444 P444 P445 P445 P445

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3

Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter OP1s Backlight Select FactSet Select Setp Src Quick Param Ground Flt Test Motor Cooling Motor Cooling Mot ThermT-Const Mot ThermT-Const Fixed Setpoint 1 Fixed Setpoint 1 Fixed Setpoint 1 MOP (max) MOP (min) Src MOP inv. Conf MOP StartValue MOP Src Set MOP Src SetV MOP Src Auto SetP Src Manual/Auto Src AddSetpoint1 Src AddSetpoint1 Scale Add Setpoint Scale Add Setpoint Scale Add Setpoint Src MainSetpoint Src MainSetpoint Scale Main Setp Scale Main Setp Scale Main Setp Base Setpoint Base Setpoint Base Setpoint

r550 r551 r552 r553 P590 P602 P640 P643 P644 r782 r783 r784 r785 r786 r787 r825 r947 r949 P971 U002 0 1 1 0 0 1 1 1800 s 1800 s 0.00% 10.00% 5.00% 100.0% 0.0% 2111 0110 0.0% 0 0 0 0 41 0 100.00% 100.00% 100.00% 3002 58 100.00% 100.00% 100.00% 0.0% 0.0% 0.0%

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Select Control Word 1 Select Control Word 2 Select Status Word 1 Select Status Word 2 Select Src BICO Dset Select Excitation time Select Src Analog Out Select CU AnalogOutGain Select CU- AnalogOutOff Select Last 8 Fault Trip Times Select n/f actual (r218) at time of last trip Select n/f actual/second at time of last trip Select actual torque current at time of trip Select actual converter out V at time of trip Select Control Status at time of trip Select Operating Hours (Inverter Pulsing) Select Last 8 Faults Select Last 8 Fault Values Select EEPROM Saving Select Fixed Setpt 18 (Meter Torque Scaling) 0= Always On Select Factory Setting (Default) Analog Input & Terminal Strip (Default) P370=1 Will Factory DEFAULT Parameters!!!! Blocked (Default) 1 = Forced Vent 1 = Forced Vent Max Time Allowed in Stall = 30 min. Max Time Allowed in Stall = 30 min. Additional Drill Speed Spin Speed Set to 10% of Rated Speed Torque Speed Set to 5% of Rated Speed Upper Limit of OP1S (Default) Lower Limit of OP1S (Default) BICO for Direction Change on OP1S Configuration of MOP MOP Starting Value BICO Source for MOP Use (Default) BICO Source for MOP Set Value (Default) BICO Source for MOP Auto Setpt (Default) BICO Source for Manual/Auto Switching BICO to Set Spin, Torque, and Speed BICO to Set Spin, Torque, and Speed Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) BICO for Main Setpoint BICO for Main Setpoint Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def)

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124965 REV.B SHEET 5 OF 13

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P448 P449 P452 P452 P452 P453 P453 P453 P457 P457 P457 P462 P462 P462 P463 P463 P463 P464 P464 P464 P465 P465 P465 P466 P466 P467 P467 P467 P468 P469 P469 P469 P470 P470 P470 P471 P471 P475 P476 P492 P492 P492 P493 P493 P494 P494 P494 P498 P498 P498 P499 P499 P500 P500

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3 1 2 1 2

Jog Setp 1 Jog Setp 2 n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max,REV Spd) n/f(max,REV Spd) n/f(max,REV Spd) Min setp Min setp Min setp Accel. Time Accel. Time Accel. Time Accel. Time Unit Accel. Time Unit Accel. Time Unit Decel. Time Decel. Time Decel. Time Decel. Time Unit Decel. Time Unit Decel. Time Unit Decel. Time OFF3 Decel. Time OFF3 ProtRampGen Gain ProtRampGen Gain ProtRampGen Gain Rgen Round Type Ramp StartSmooth Ramp StartSmooth Ramp StartSmooth Ramp End Smooth Ramp End Smooth Ramp End Smooth Scale Torq (PRE) Scale Torq (PRE) Ramp Limitation RampGen Act Hyst FixTorque 1 Set FixTorque 1 Set FixTorque 1 Set Src Fixtorque 1 Src Fixtorque 1 FixTorque 1 Gain FixTorque 1 Gain FixTorque 1 Gain FixTorque 2 Set FixTorque 2 Set FixTorque 2 Set Src FixTorque 2 Src FixTorque 2 Scale TorqLim2 Scale TorqLim2

10.00% 20.00% 100.0% 100.0% 100.0% -50.00% -50.00% -50.00% 0.0% 0.0% 0.0% 5.0 5.0 5.0 0 0 0 2 2 2 0 0 0 2.0 s 0.0 s 2.9 typ 1.0 1.0 0 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 100.0% 100.0% 0.0% 1.0% 100.0% 10.0% 133.0% 3003 170 100.00% 100.00% 100.00% -100.00% -10.00% -200.00% 3005 171 100.00% 100.00%

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Jogging Setpoint 1 (Default) Jogging Setpoint 2 (Default) Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% 0 = Seconds 0 = Seconds 0 = Seconds Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% 0 = Seconds 0 = Seconds 0 = Seconds Keypad "quickstop" from 100% to standstill Keypad "quickstop" from 100% to standstill Acceleration Time (P462) Gain Factor(AutoTn) Acceleration Time (P462) Gain Factor (Def) Acceleration Time (P462) Gain Factor (Def) Mode for Ramp Function Rounding (Default) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Gain of the n/f controller precontrol (Default) Gain of the n/f controller precontrol (Default) "0.0" Deactivates Ramp-Func Tracking (Def) Hysteresis for "Rmp-Func Gen Active" msg. Forward Maximum Drill Torque Forward Spin Torque Maximum Make-up Torque (Forward) BICO Source for Upper Torque Limitation BICO Source for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Reverse Maximum Drill Torque Reverse Spin Torque Maximum Breakout Torque (Reverse) BICO Source for Lower Torque Limit BICO Source for Lower Torque Limit Scaling Factor for Lower Torque Limit (Def) Scaling Factor for Lower Torque Limit (Def)

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VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P500 P535 P535 P536 P536 P537 P537 P554 P554 P555 P555 P556 P556 P557 P557 P558 P558 P559 P559 P560 P560 P561 P561 P562 P562 P563 P563 P564 P564 P565 P565 P566 P566 P567 P567 P568 P568 P569 P569 P571 P571 P572 P572 P573 P573 P574 P574 P575 P575 P576 P576 P577 P577 P578

3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1

Scale TorqLim2 SIMO Sound SIMO Sound n/f RegDyn (set) n/f RegDyn (set) n/f RegDyn (act) n/f RegDyn (act) Src ON/OFF1 Src ON/OFF1 Src1 OFF2 (Coast) Src1 OFF2 (Coast) Src2 OFF2 (Coast) Src2 OFF2 (Coast) Src3 OFF2 (Coast) Src3 OFF2 (Coast) Src1 OFF3 (Qstop) Src1 OFF3 (Qstop) Src2 OFF3 (Qstop) Src2 OFF3 (Qstop) Src3 OFF3 (Qstop) Src3 OFF3 (Qstop) Src InvRelease Src InvRelease Src RampGen Rel Src RampGen Rel Src RampGen Stop Src RampGen Stop Src Setp Release Src Setp Release Src1 Fault Reset Src1 Fault Reset Src2 Fault Reset Src2 Fault Reset Src3 Fault Reset Src3 Fault Reset Src Jog Bit0 Src Jog Bit0 Src Jog Bit1 Src Jog Bit1 Src FWD Speed Src FWD Speed Src REV Speed Src REV Speed Src MOP UP Src MOP UP Src MOP Down Src MOP Down Src No ExtFault1 Src No ExtFault1 Src FuncDSet Bit0 Src FuncDSet Bit0 Src FuncDSet Bit1 Src FuncDSet Bit1 Src MotSSet Bit0

100.00% 1 1 50% 50% 50% typ 49% typ 3100 2100 22 22 1 1 1 1 2102 2102 1 1 1 1 1 1 1 1 1 1 1 1 18 18 3107 0 2107 2107 3108 2108 0 0 3111 2111 3112 2112 2113 2113 2114 2114 20 20 3400 0 3401 0 3402

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Scaling Factor for Lower Torque Limit (Def) Adjusts Noise Spectrum of Machine Adjusts Noise Spectrum of Machine Dynamic Response of n Control Circuit (Def) Dynamic Response of n Control Circuit (Def) P536 Adjustment After P115=5 (Auto Tuned) P536 Adjustment After P115=5 (Auto Tuned) Drive ON/OFF Command,P590=0 (PLC Cntrl) Drive ON/OFF Command,P590=1 (OP1S Ctrl) Drive OFF Command From E-STOP (Coast) Drive OFF Command From E-STOP (Coast) 2nd BICO Source for OFF (Coast Stop)(Def) 2nd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) Drive OFF Command From OP1S (Qck Stop) Drive OFF Command From OP1S (Qck Stop) 2nd BICO Source for OFF (Quick Stop)(Def) 2nd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) Digital In 5 (Not used) Digital In 5 (Not used) AutoReset Drive From PLC Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Jog from Bit 8, Control Word 1 Jog from OP1S Keypad BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Source to Command Fwd Rotation(PLC) BICO Source to Command Fwd Rot (Keypad) BICO Source to Command Rev Rotation (PLC) BICO Source to Command Rev Rot (Keypad) BICO Source to Increase MOP (Not Used) BICO Source to Increase MOP (Keypad) BICO Source to Decrease MOP (Not Used) BICO Source to Decrease MOP (Keypad) BICO Source for External Fault 1 BICO Source for External Fault 1 BICO Src for Func Data Set (cw2,bit16) BICO Src for Func Data Set (cw2,bit16)(Def) BICO Src for Func Data Set (cw2,bit17) BICO Src for Func Data Set (cw2,bit17)(Def) BICO Src for Motor Data Set (cw2,bit 18)

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VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P578 P579 P579 P590 P602 P602 P603 P603 P640 P640 P643 P643 P644 P644 P652 P652 P722 P722 P734 P734 P734 P734 P734 P734 P952 P970 P971 U001 U001 U001 U002 U002 U002 U107 U107 U108 U108 U117 U118 U119 U120 U121 U122 U950 U950 U950 U951 U951 U952

2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 1 2 3 1 2 3 1 2 1 2 031 032 075 004 059 047

Src MotSSet Bit0 Src MotSSet Bit1 Src MotSSet Bit1 Src BICO Dset Excitation Time Excitation Time De-MagnetizeTime De-MagnetizeTime Src AnaOut Src AnaOut CU AnalogOutGain CU AnalogOutGain CU--AnalogOutOFF CU--AnalogOutOFF Src DigOut2 Src DigOut2 CB/TB TlgOFF CB/TB TlgOFF SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData # of Faults Factory Setting EEPROM Saving FixSetp 17 FixSetp 17 FixSetp 17 fixSetp 18 fixSetp 18 fixSetp 18 Src Conn Mult1 Src Conn Mult1 Src Conn Mult2 Src Conn Mult2 Src ConnAbsV1 Mode ConnAbsV1 SmoothConAbsV1 Src ConnAbsV2 Mode ConnAbsV2 SmoothConAbsV2 Sampling Times1 Sampling Times1 Sampling Times1 Sampling Times2 Sampling Times2 Sampling Times3

3402 0 0 0 0.20 s 0.20 s 3.00 s 3.00 s 148 24 10.00 V 10.00 V 0.00 V 0.00 V 122 122 10 ms 10 ms 32 467 33 468 170 250 7 1 0 95.00% 95.00% 95.00% 62.58% 62.58% 62.58% 491 401 492 402 148 1 0 ms 24 1 0 ms 2 2 2 2 2 2

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

BICO Src for Motor Data Set (cw2,bit 18) BICO Src for Motor Data Set (cw2,bit 19)(Def) BICO Src for Motor Data Set (cw2,bit 19)(Def) Set PLC or OP1S Control (0=PLC) Wait Time Before Releasing Frequency Wait Time Before Releasing Frequency Time to DE-excite Motor (Auto Tuned) Time to DE-excite Motor (Auto Tuned) BICO for Analog 1 Out (Speed) BICO for Analog 1 Out (Torque) Porportional Gain for Analog Outputs (Def) Porportional Gain for Analog Outputs (Def) Offset Voltage for P643 Analog Outs (Def) Offset Voltage for P643 Analog Outs (Def) Undervoltage Fault (Status Word 1, Bit 11) Undervoltage Fault (Status Word 1, Bit 11) Fault if No Communication for 10 ms (Def) Fault if No Communication for 10 ms (Def) Status Word 1(To PLC) Speed to Meter (To PLC) Status Word 2 (To PLC) Torque to Meter (To PLC) Spin Torque (To PLC) Fault Number (To PLC) Number of Stored Fault Trips P970=0 Will Factory DEFAULT Parameters!!!! Save Parameters(Ram To EEPROM)(P971=1) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Multipliers for RPM Meter Multipliers for RPM Meter Multipliers for Torque Meter Multipliers for Torque Meter BICO Source for 1st Abs Value Generator Mode Sel for Ist Abs Value Gen (1=| Signal |) Smoothing Time Const for 1st Abs Val Gen BICO Source for 2nd Abs Value Generator Mode Sel for 2nd Abs Value Gen (1=| Signal |) Smoothing Time Const for 2nd Abs Val Gen Sampling time Sampling time Sampling time Sampling time Sampling time Sampling time

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TDS-11S

PAR. NO.

P050 P051 P052 P053 P054 P071 P074 P075 P076 P077 P090 P091 P140 P141 P144 P160 P310 P311 P312 P313 P314 P315 P316 P317 P318 P319 P320 P329 P353 P354 P366 P368 P408 P409 P486 P517 P518 P554 P555 P556 P557 P561 P565 P566 P567 P568 P569 P571 P575 P578

SIEMENS SERIES 70 DRIVE LISTING OF RECTIFIER PARAMETERS IND.

0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PARAMETER DESC.

Language Access Level Function Select Parameter Access Display Light Line Volts Limit LowVoltage Rtd Amps Config. Pcircuit Factory Set type Board Position 2 Board Position 3 Rectifier Resistance Rectifier Inductance DC Bus Capacitance Motor Current Limit DC Current Reg Gain DC Current Reg Time DC Cur Reg CWord DC Volts Reg Gain DC Volts Reg Time DC Volts Reg CWord DC V-Reg +Limit DC V-Reg -Limit DC V(Set,red) DC V(Set,red)Hys Smooth Load Amps Pre Charge Time Thyristor Test Ground Flt Test Auto Restart Time DC Bus Volts Caps Forming Time Contactor Delay Src Current Setup DC Volts Dev Limit Deviation Time Src ON/OFF1 Src1 OFF2(coast) Src2 OFF2(coast) Src3 OFF2(coast) Src InvRelease Src1 Fault Reset Src2 Fault Reset Src3 Fault Reset Src Jog1 ON Src Jog2 ON Src Reduce DC V Src No ExtFault1 Src RDataSet Bit0

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

1 3 0 6 0 575.0 V 61 1023 1 0 0 0 0.007 0.21 32.22 150 0.15 0.015 2111 8.8 3 0010 0.01 -1.00 95.00 6.00 5.00 500 0 2 2 6.1 10 0 0 2 0.1 1001 0001 0001 0001 1003 1004 0000H 2001 0000H 0000H 0001 0001 0000H

COMMENTS

Set DC Bus to 780V

Restart After Power Recovery

Used To Reduce DC Bus Via P318

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PAR. NO.

P579 P586 P587 P588 P589 P590 P591 P600 P601 P602 P603 P604 P606 P607 P608 P610 P611 P612 P613 P618 P619 P620 P621 P622 P623 P624 P631 P655 P656 P657 P658 P660 P661 P662 P664 P665 P666 P680 P681 P682 P683 P684 P685 P686 P687 P688 P689 P690 P694 P695 P696 P697 P698 P699

IND.

1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1 0 1 1 1 1 1 0 1 1 1 0 0 0 0 0

PARAMETER DESC.

Src RDataSet Bit1 Src No ExtFault2 Src Master/Slave Src No Ext Warn1 Src No Ext Warn2 Src Base/Reserve Src ContactorMsg Trg Bit Ready ON Trg Bit Ready Operator Trg Bit Oper Trg Bit Fault Trg Bit No OFF2 Trg Bit On blocked Trg Bit Warning Trg Regen Ready Trg Low Voltage Trg Low Voltage Trg Bit Contact Trg DC V reduced Trg Current Lim. Trg Bit Ext Flt1 Trg Bit Ext Flt2 Trg Bit Ext Warn Trg Bit i2tInv Trg Bit Flt Tmp Inv TrgBitWarTmpInv Trig Bit Charging CUR AnaOutActVal CUR AnaOut Gain CUR AnaOut Offset AnaOut Conf Curr SCI AnaLogInConf SCI AnaInSmooth SCI AnaLogInOffs SCI AnaOutActVal SCI AnaOut Gain SCI AnaOut Offs SCom1 Act Value SCom2 Act Value SCB Protocol SCom/SCB BusAddr SCom/SCB Baud SCom/SCB PCV SCOM/SCB # PrDat SCom/SCB TlgOFF SCom2 Protocol SCB Peer2PeerExt SCB Act Values CB/TB Act Values CB/TB Tlg Off Time CB Parameter 1 CB Parameter 2 CB Parameter 3 CB Parameter 4

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

COMMENTS

0000H 0001H 0000H 0001H 0001H 0000H 0001H 0000H 0000H 0000H 1001 0 0 1002 0 0 0 0 0 0 0 0 0000H 0000H 0000H 0000H 0000H 37 10.00 0.00 0 0 2 0 0 10 0 968 968 0 0 6 127 2 0 ms 1 0 0 968 20ms 0 0 0 0

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PAR. NO.

P700 P701 P702 P703 P704 P705 P772 P773 P775 P776 P777 P778 P779 P780 P785 P788 P793 P799 P917 P918 P928 P971

IND.

0 0 0 0 0 0 1 1 1 1 1 1 0 1 0 1 0 0 0 0 0 0

PARAMETER DESC.

CB Parameter 5 CB Parameter 6 CB Parameter 7 CB Parameter 8 CB Parameter 9 CB Parameter 10 Thyr Voltg Corr Deadband Convert Min Gating Angle Max Gating Angle Max Gat Ang Ramp Line FrquFiltTime Phase Shift Corr Fault Masking I2T Control Word RAM Access Addr Line Voltg Delay Special Access Change Reports CB Bus Address Src Base/Reserve EEPROM Storing

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

VALUE(Units)

COMMENTS

0 0 0 0 0 0 0 0.01 0 150 20 200 0.8 0 1 0 0.03 4 0 3 0000H 0

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TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 16

Encoder Troubleshooting

AC Electrical

Encoder Troubleshooting Instructions CUVC Card Version

The encoder is used to provide rotational position information to the Variable Frequency Drive (VFD). On the AC TDS systems, the encoder signal comes into the Varco Interface Terminal Strip (TB1 Drive on drawing) in the drive. The +I5VDC for the encoder is provided from the CUVC card and goes out on terminal 31 (Common) and terminal 32 (+15VDC). The AC Top Drives use a differential input signal and on the Siemens drive an optional Digital Tach. Interface board to convert this differential signal (A+,A- and B+,B-) to a single ended signal (A+ and B+). The (A+) signal comes into terminal 34, the (A-) signal is 35, the (B+) signal is 37 and the (B-) signal is 38. This can be verified on the schematics. The waveforms for the respective signals are shown above. The symptom of encoder failure is that the drive when assigned and throttle given will refuse to rotate or rotate very slowly, with high Torque showing on the Torque meter. You probably will not see a failure indication on the drive, or it may trip out due to over-current. If you suspect the encoder change the drive from speed control (n) to frequency control (f) by using the encoder bypass switch. If the AC TDS starts rotating you have an encoder problem. If it does not verify that you have performed the changeover from speed control to frequency control correctly by viewing the motor data set in the VFD (parameter r011, 1=n speed control, 2 =f frequency control) and then try again. If it still does not turn you should look at the inputs to the drive and not the encoder. The first check of the encoder should be measurement of the signals with a voltmeter this should be done with the drive stopped. There should be approximately 15V between

terminals 31 and 32 (+15DCV and Common) if there is not disconnect the encoder cable, to see if it is being shortened out. There should be approximately 15V between pins 34 and 35 (A+ and A-) and between terminals 37 and 38 (B+ and B-) if there is not and you have a scope check the individual signals to see which one or ones are missing this will require you to run the AC TDS in the frequency mode. If you are missing a signal remember that on the Siemens drive you can rewire the signals so that they do not pass through the DTI card to keep running. If (A+) and (B+) are both good disconnect the (A+) and (B+) signals from the DTI card at terminals X403 and X402. You can then connect (A+) to (A+) and (B+) to the (B+) wire straight across, be sure to do the same with both the (+15VDC) and both the (Common) signals as well. If you still can not get the top drive to turn and you have signals that are 90 degrees from each other (See A+ and B+ above) try reversing the (A+) and (B+) wires. Encoder Fuse There is a "fuse" in line with the (+15VDC), if too much current is drawn the fuse opens. This thermal fuse is self resetting after it cools. With a short on one of the outputs, the driver sources too much current “opening” the fuse. When power is removed the fuse will reset after a short period of time, and upon application of power the signals will come back. If it appears that you have no output from the encoder disconnect the encoder cable then reconnect after a few minutes. Cable Testing A common fault with the encoder is a broken or a shorted cable in the encoder loop, this can be checked by disconnecting the encoder cable at the Top Drive end and also at the Varco control house end, the cables should then be checked for continuity and also tested between cores for possible shorts. A common problem is that the Top drive will fault at the same place in the derrick this is good way of telling there is a problem with the service loop.

Waveforms

The above picture shows a scoped waveform from a rotating Top Drive, this is what would be expected to see when looking at both the (A+) and (B+) signals together with an oscilloscope. If the Top drive was drilling ahead when checking the signals you could expect to see the widths of the waveforms constantly changing, this would be because when the Top Drive experiences “down-hole Torque”, it would momentarily slow down (remember that the encoder sends out 1024 pulses per revolution of both the motor and encoder). What should be noted from these waveforms is that the small “spikes” at the edges of the waves are not a problem because the signal is a digital signal, only when the “spike” was in the middle of the waveform would there be a possibility that this would be a problem, but it would be expected that the DTI card would rectify that problem.

DTI Schematic

EEx Digital Encoder

Varco P/N = 122725 The Eex Digital Encoder used on the AC Top Drive, has a four channel output (A+,A-,B+,B-) with 90° Displacement at 1024 pulses per Revolution.

TDS Training Manual

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Section 17

Simovis Version 5

AC Electrical

Table of Contents Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 -

Introduction (page 3) Configuration of Control Card (page 4) UPREAD from the AC DRIVE to a PC (page 6) Viewing the UPREAD parameters (page 8) DOWNLOADING from a PC to the AC DRIVE (page 10) Examination (page 12) Examination Answers(page 13)

2

Section 1 - Introduction SIMOVIS Version – 5, is for use with the Siemens 70 Series Drive, by using the SIMOVIS PC program, you can UPREAD parameter sets from the units, store them on the hard disk or on floppy disks and transfer them back to the units by DOWNLOAD. You have the additional possibility of editing the parameters off-line and of creating parameter files especially for your application. These files do not have to contain the complete parameter scope. They can be limited to parameters, which are relevant for the particular application. This module is mainly aimed at the newer Vector Control Card the CUVC, but the same method is used for Upreading and Downloading parameters to a CU2 card, the communication differences are explained in Section 2. This section is split into four parts, they are Configuration of Control Card, UPREAD, View an UPREAD set and DOWNLOAD. Section 2 – Configuration of Control Card This part shows how to configure the type of control card that is inserted in the Siemens 70 Series drive. For this section we are using a CUVC card, but if the card that was to be configured the Section 3 – UPREAD a parameter set This part shows how to UPREAD a complete parameter set from the AC Drive to a PC. Section 4 – View an UPREAD parameter set. The second part of this section shows how to view an upread set of parameters once it has been upread from the AC Drive and stored to disk. Section 5 – DOWNLOAD a parameter set The third part of this section shows how to DOWNLOAD a complete parameter set into the AC Drive from a PC and how to check for errors.

3

Section 2 - Configuration of Control Card To get ONLINE with SIMOVIS, firstly ensure that the cable (RS 232) is inserted into the PMU and “Com Port 1” on the PC. Details on this cable can be found in the SIMOVIS “Readme” file. The Siemens Part Number for the cable is:- 6SX7005-0AB00

Above is the first window that is viewed when SIMOVIS is opened from the Desktop of your PC. To configure a Drive you click on the “Blue Cross”.

This brings up the “Add a drive” screen, to set up for the CUVC card with software version 3.1, click on the down arrows at “Drive type” and “SW-version”, and select the type and version as above, then click on “OK”. For this section we are using a CUVC card, but if the card that was to be configured was a CU2 card, this would be selected from the list and would be “MASTERDRIVES VC(CU2).

4

The Drive Type, Software, etc. is then displayed under Bus Address 0, other Drive types could be configured to different Bus Addresses, this would be done in “Add a Drive”. To communicate with the Drive, double click on the blue highlighted bar for the CUVC card.

This then communicates with the Drive and all the present value of the parameters are displayed down the right hand side of the screen, the top of the screen displaying “Online (EEPROM) identifies this. The Drive status is also displayed in the bottom left of the screen, in this case the drive shows a green “OK” which means there is no faults or alarms on the drive at present, but if there was a fault, it would then display a red “F” here. If you cannot get ONLINE, check the cable connection or the “Drive type” and then try again.

5

Section 3 - UPREAD from the AC DRIVE to a PC

To UPREAD all the parameters from the Drive, Select “Upread” then “Base unit all” from “File”, as shown above.

The program then automatically defaults to save the parameter set to the “Masterdives VC(CUVC)” folder in SIMOVIS, this can be changed to another folder on the hard drive (c) or to a floppy disk (a), by clicking on the down arrow next to “Masterdives VC(CUVC)” and then selecting the required option. It is best when saving to the hard drive (c), to save to the SIMOVIS default, as it will also automatically default to this when “DOWNLOAD” is selected. At this stage the parameter set that is to be Upread from the AC Drive requires a name, for this example “Test” is to be used, this should be written into the “File name” box. Once the folder has been chosen and the parameter set has been given a name, click on “Save” to start Upreading the parameter set.

6

When the “UPREAD” has started, the above dialog box will be displayed, this shows that SIMOVIS is Upreading the parameters and saving them as “TEST” (top of box), it also displays the amount of parameters to be upread (in this case 1030), how many have been upread (in this case 37), how many have been upread successfully (OK) and how many have not been upread successfully (E). This function can be aborted by clicking on “Cancel”.

If the upread has been completed successfully, this will be displayed by a dialog box as above, if there has been a problem, it will show a dialog box with the details of the problem parameters (this will be shown later in the DOWNLOAD section). To proceed, click on “OK”.

7

Section 4 - Viewing the UPREAD parameters

To view the Upread parameters, you have to change to the “OFFLINE” mode. To do this, select “Offline” from the “View”, as shown above.

This will then display either “File New” (factory parameter set), or “File Open” (Open a previously saved parameter set). Choose and click on “File Open” as above, because you want to open your previously saved parameter set (TEST).

8

The “Open parameter set” dialog box then appears; this is asking you what parameter set you require to open. The above dialog box shows three options, TDS11S(CUVC), Test or Train CUVC. To open the “Test” parameter set, click on “Test” as shown above, this is then shown in the “File name” box, finally click on “Open”, thus opening “Test”.

The parameter set “Test” is then viewed in the Offline mode as shown at the top of the screen as “offline (Test)” with all the parameters shown down the right hand side of the screen. The “Drive status” in the bottom left of the screen is now shown as a blue “O”, to signify that the drive is Offline. Note you do not have to be connected to the drive to view parameter sets in the Offline mode.

9

Section 5 - DOWNLOADING from PC to the AC DRIVE

To Download a parameter set from a PC to the Siemens 70 Series Drive, you have to be Online with the drive, and in the Online Status, this was previously shown in the Upread part. Once SIMOVIS is successfully Online with the Drive, select “Download” and then “Save (EEPROM)”, from “File” as shown above. It is best to save to EEPROM, as the parameters are permanently stored into the Drive.

The “Open parameter set” dialog box appears which again automatically defaults to “Masterdrives VC (CUVC)”, from this the previously saved program to be downloaded can be selected. Shown above is “Test” set to be Downloaded, to do this click on “Test”, this is then shown in the “File name” box, then click on “Open”, this opens the parameter set to be downloaded, and starts the downloading process.

10

The dialog box “Download” appears as above, this shows at the top of the box, the parameter set that is being downloaded, in this case “Test”. Also shown is the number of parameters that are to be Downloaded in this case 829, the number of parameters that have been downloaded in this case 15 and the number of parameters that have been successfully Downloaded (OK) or not successfully downloaded (E). This process can be aborted by clicking on “Cancel”. When the Download is in process the drive will automatically default to download status 21, this should be viewed on the PMU.

A dialog box will then be displayed explaining how many parameters have been written and refused, in the case above from 829 parameters, 828 were written successfully and 1 was refused, the parameters that were refused can be looked at by clicking on “Details”. If no parameters were refused only the “OK” box would be available.

If the “Details” box was selected in the previous dialog box, the “Error” dialog box will be displayed as above, with the parameters that SIMOVIS was not able to Write to the drive. In this case only one parameter was refused 368, this would have to be checked and then manually changed by either the PMU, OP1S or SIMOVIS. Clicking on “OK” returns you to the Online screen where all the parameters that have been downloaded can now be viewed.

11

Section 6 – Examination 1. What type of cable is used to communicate a PC to a Siemens 70 Series drive? ___________________________________________________________________ ___________________________________________________________________ 2. What two type of Siemens 70 Series Drive control cards has Varco used to control its AC Top Drives and Pipe Racking Systems? ___________________________________________________________________ ___________________________________________________________________ 3. What is the difference between UPREAD and DOWNLOAD when using SIMOVIS version 5? ___________________________________________________________________ ___________________________________________________________________

4. What type of files are used to store the parameter sets in SIMOVIS version 5? ___________________________________________________________________ ___________________________________________________________________ 5. If the Drive Status is shown as a Blue “O”, what does this mean? ___________________________________________________________________ ___________________________________________________________________ 6. If the Drive Status is shown as a Red “F”, what does this mean? ___________________________________________________________________ ___________________________________________________________________ 7. What is the difference between a “P” type parameter and an “r” type parameter? ___________________________________________________________________ ___________________________________________________________________ 8. Can Parameters be changed in the AC Drive through SIMOVIS when the PC is connected to the AC Drive? ___________________________________________________________________ ___________________________________________________________________

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Section 7 – Examination Answers 1) What type of cable is used to communicate a PC to a Siemens 70 Series drive? An RS232 cable is used to communicate a PC to a Siemens 70 Series Drive. 2) What two type of Siemens 70 Series Drive control cards has Varco used to control its AC Top Drives and Pipe Racking Systems? Varco use either a CU2 or a CUVC card to control the Siemens 70 Series drives in their equipment. 3) What is the difference between UPREAD and DOWNLOAD when using SIMOVIS version 5? UPREAD is used to transfer parameters from the AC drive to a PC, DOWNLOAD is used to transfer parameters from a PC to the AC drive. 4) What type of files are used to store the parameter sets in SIMOVIS version 5? The File type that is used to store parameters in SIMOVIS version 5 is Download files (*.DNL). 5) If the Drive Status is shown as a Blue “O”, what does this mean? This signifies that the AC drive is OFFLINE from the PC and the parameter set displayed is from an internal file in the PC and not from the AC drive. 6) If the Drive Status is shown as a Red “F”, what does this mean? This signifies that the AC drive is ONLINE and communicating with the PC satisfactory, but there is a fault at present with the AC drive. 7) What is the difference between a “P” type parameter and an “r” type parameter? A “P” type parameter is an operator changeable parameter that can be changed to alter the control of the AC drive. An “r” type parameter is a read only parameter, this can only be viewed to gain information about the AC drive. 8) Can Parameters be changed in the AC Drive through SIMOVIS when the PC is connected to the AC Drive? Yes, parameters can be changed in the AC drive when the PC is connected and ONLINE, care should be taken NOT to change parameters unnecessarily.

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