User Manual
TDS-11SA – Top Drive Drilling System
Customer References
Customer: Galena Park
Rig / Hull: Rig 135
Tag Number: N/A
National Oilwell Varco References:
SO Number / Project Number: 134718/TX8912
Document Number: D811002283-MAN-002
Revision: 01
Volume: 1
www.nov.com
Document number
Revision
Page
D811002283-MAN-002
01
2
REVISION HISTORY
01
09.10.2012
Rev
Date (dd.mm.yyyy)
For Information
CHANGE DESCRIPTION
Revision
01
Change Description
For Initial Release
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Reason for issue
I. Vargas
L. Krajenbrink
H. Lim
Prepared
Checked
Approved
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Part Number
Description
SM00856
SM01053
50000870
D811002283-DOS-001
M614003010-SPL-001
10620488-SPL
127425
D392001271-MKT-001
D25TDS11-MAN-001
VDR00029
VDR00030
ASP00020
3ASP00073
ASP00019
DS00008
D811000719-PRO-001
SM00081
D811001337-DAS-001
Service Manual, TDS-11SA
Service Manual, Washpipe Assembly
Links User Manual
Technical Drawing Package
Mechanical Spares List
Control Spares List
Electrical Trouble Shooting Guide
TDS-11SA, Pocket Guide
TDS-11SA VFD Operation Manual
Reliance Installation, Operating Manual (180-449)
Reliance Installation, Operating Manual (L210-400)
Motor Housing Assembly Procedure (TDS-9SA/TDS-11SA)
Installation Procedure for TDS Motor Hub & Pinion Gear
Safety Wiring Procedure
Design Torque Standard
Recommended Lubricants and Fluids
Hydraulic Fluid Cleanliness
Service Center Directory
NEXT ASSY
PRODUCT
M611005667-GEN-001
TDS-11SA
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco
CURRENT
DRAWN
INITIAL
T. Harmon
CHECKED
H. Lim
APPVD
H. Lim
DATE
User Manual
NOV Galena Park, AC Ideal Rig 135
TDS-11SA
01/13/2012
SCALE:
WT LBS:
SIZE:
SHT:
AV
DWG NO.:
D811002283-MAN-001
1 OF 1
REV:
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D811000457-GEN-001/04
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 1.0
Service Manual, TDS-11SA
www.nov.com
Service Manual
TDS-11SA Top Drive
Reference
Reference Description
This document contains proprietary and confidential
information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only
National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
11000 Corporate Centre Drive
others is not permitted without the express written consent of
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
www.nov.com
Form D811001123-GEN-001/06
Document Number
Rev.
SM00856
D
SM00856
Revision D
Revision History
D
15.08.2012
Engineering Update
J. Roman
H. Lim
M. Clark
C
11.11.2011
Engineering Update
T. Drake
H. Lim
M. Clark
B
2006
Teamcenter migration version.
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A
2003
Teamcenter migration version.
–
–
–
–
2000
First Issue: Original Instructions
–
–
–
Rev
Date (dd.mm.yyyy)
Reason for issue
Prepared
Checked
Approved
Change Description
Revision
Change Description
–
First Issue: Original Instructions. No relevant issue history.
A
Revision migrated in Teamcenter. No relevant revision history.
B
Revision migrated in Teamcenter. No relevant revision history.
C
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D
• Corrected Guide Beam Joint illustration (page 5-6).
• Corrected Plan View dimensions; added 30.0” setback illustration (page 2-7 and page 2-8).
www.nov.com
Updated cover illustration, applied latest FrameMaker template, and reorganized material.
Removed outdated VFD references and added ABB ASC800 reference and specs (page 2-3).
Added Noise Data (page 2-5).
Updated upper main body seals lubrication interval and procedure (page 5-59 and page 5-60).
Added optional NOV Mechanical Washpipe information (various locations throughout manual).
Added new control house illustration, dimensions and weight (various pages, starting with page 3-6).
Added new guide beam warning information (page 3-9, page 3-12, page 3-16, page 3-23).
Changed procedure so it was not specific to option 2 (page 3-26).
Added auxiliary cable jacket installation procedure (page 3-29).
Added secondary retention to counterbalance illustration (page 3-34).
Added bail lock components to decommissioning illustration (page 3-42).
Added additional long-term storage and return-to-service instructions (CE fix) (page 3-43).
Added new console illustrations and operation information (starting on page 3-30 and page 4-1).
Moved Making and Breaking Tool Joint Connections to Operation (page 4-19).
Added Well Control Procedure (page 4-28)
Added Joint Pin and Bushing wear limits to Guide Beam Joint Inspection (page 5-6).
Removed Blower Motor Inspection illustration from red lined instructions.
Updated Non-Destructive Examination section (page 5-56).
Replaced Link Tilt in illustrations where maintenance procedure are affected (various pages).
Added driller’s control console maintenance information (page 5-97)
Moved hydraulic setup to Maintenance and troubleshooting to the new troubleshooting chapter.
Moved hydraulic symbol description to Appendix A.
Moved PH-50 Pipe Handler service manual information to Appendix B.
SM00856
Revision D
Page i of viii
Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chapter 2: Description
Introduction to the TDS-11SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Noise Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Top Drive Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
30.0" Setback Top View Dimensions (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
39.5" Setback Top View Dimensions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Identification Labels and Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Typical Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Chapter 3: Installation
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
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SM00856
Revision D
Page ii of viii
Table of Contents
Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Grounding the Control House (Land Rigs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Identifying Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Raising the Top Guide Beam Section to the Drill Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Attaching the Carriage Sling to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Stabbing and Pinning the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Completing Guide Beam Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Removing the Hoist Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Bottom Intermediate Section Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Installing Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Installing Service Loop Jackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Initial Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Hydraulic System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Electrical System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Mechanical Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Adjusting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Setting the Latches and Locking the Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Long Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Storage Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Pre-Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
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SM00856
Revision D
Page iii of viii
Table of Contents
Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Returning the Top Drive to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Chapter 4: Operation
Stateless Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
IBOP and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
E-Stop, BX Elevator, Counterbalance, and Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Amphion™ Touchscreen Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Basic Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Drilling Ahead with Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Drilling Ahead with Triples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Making and Breaking Tool Joint Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Breaking out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Making up the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Making up the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Making up the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Chapter 5: Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Pre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Regulatory Standards You Will Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Secondary Retention Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
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Inspecting Rig Interface Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Inspecting the Guide Beam and Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Inspecting the Motor Housing and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Belt-Driven Encoder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Bail and Main Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
S-Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Upper Main Shaft Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Standard Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Drilling Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Inspecting the PH-75 Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Recommended Lubricants and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
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Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Every Three Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Every Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Yearly and As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Gearbox Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
General Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Location of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Using the Hydraulic System Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Precharging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Draining Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Setting Up Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Counterbalance Circuit and Stand-Jump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
AC Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Shot Pin Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Link Tilt Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Control Console Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Chapter 6: Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Determining the Nature of Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Identifying Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Electrical System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lubrication and Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
HPU and Reservoir Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Counterbalance and Stand Jump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Counterbalance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Stand Jump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Shot Pin Cylinder and Clamp Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Gearbox Lubrication Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Tool Rotation and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Appendix A: Hydraulic Symbols
Appendix B: PH-50 Pipe Handler
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Clamp Cylinder Body Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Disassembling the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
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Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Inspecting the Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Disassembling the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15
Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
IBOP Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Tool Joint Locks Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Rotating Link Adapter/Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Removing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . B-22
Disassembling the Link Tilt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Inspecting the Rotating Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Assembling the Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Installing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . . B-25
Wireline Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
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Figure 2-1. TDS-11SA Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2. Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-3. Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-4. Top Drive Plan View (30.0" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-5. Top Drive Plan View (39.5" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-6. Identification Labels and Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-7. Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-8. Typical Installed Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 3-1. Illustrated Installation Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2. Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-3. Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-4. Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-5. Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-6. Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-7. Grounding the Control House (Land Rigs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-8. Raising the Top Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-9. Attaching the Carriage Sling to the Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-10. Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-11. Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-12. Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-13. Stabbing and Pinning the First Guide Beam Section. . . . . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3-14. Completing Guide Beam Section Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-15. Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-16. Removing the Hoist Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-17. Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Figure 3-18. Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Figure 3-19. Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Figure 3-20. Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Figure 3-21. Bottom Intermediate Guide Beam Section Warning Label . . . . . . . . . . . . . . . . . . . 3-23
Figure 3-22. Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Figure 3-23. Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Figure 3-24. Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Figure 3-25. Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Figure 3-26. Installing Derrick Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Figure 3-27. Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Figure 3-28. Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Figure 3-29. Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Figure 3-30. Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Figure 3-31. Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Figure 3-32. Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Figure 3-33. Hydraulic System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Figure 3-34. Electrical System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Figure 3-35. Mechanical Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Figure 3-36. Adjusting the Link Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Figure 3-37. Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Figure 3-38. Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Figure 3-39. Setting the Latches and Locking the Bail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
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Figure 4-1. NOV Stateless Driller’s Control Console (Front Panel Closed) . . . . . . . . . . . . . . . . . 4-2
Figure 4-2. NOV Stateless Driller’s Control Console (Front Panel Opened) . . . . . . . . . . . . . . . . 4-3
Figure 4-3. Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-4. Top Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-5. IBOP and Brake Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-6. Pipe Handler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-8. Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-9. Default Top Drive Amphion Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-10. Drilling Ahead With Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-11. Drilling Ahead With Triples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-12. Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-13. Breaking Out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-14. Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Figure 4-15. Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Figure 4-16. Well Control Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Figure 5-1. Inspecting the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-2. Inspecting the Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-3. Inspecting the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-4. Inspecting the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Figure 5-5. Inspecting the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-6. Motor Housing and Transmission Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-7. Inspecting Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-8. Adjusting the Belt-Driven Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Figure 5-9. Inspecting the Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 5-10. Inspecting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Figure 5-11. Inspecting the Bail and Main Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Figure 5-12. Inspecting the S-Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Figure 5-13. Inspecting the Upper Main Shaft Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Figure 5-14. Inspecting the Washpipe (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-15. Inspecting the Washpipe (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Figure 5-16. Inspecting the Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Figure 5-17. Inspecting the Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Figure 5-18. Inspecting Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Figure 5-19. Inspecting the Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Figure 5-20. Inspecting the Drilling Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Figure 5-21. Disassembling/Assembling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Figure 5-22. PH-75 PIpe Handler Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Figure 5-23. Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Figure 5-24. Inspecting the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Figure 5-25. Inspecting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Figure 5-26. Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Figure 5-27. Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Figure 5-28. Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Figure 5-29. Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Figure 5-30. Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Figure 5-31. Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
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List of Figures
Figure 5-32. Inspecting the IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Figure 5-33. Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Figure 5-34. Inspecting the Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . 5-53
Figure 5-35. General Lubrication (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Figure 5-36. General Lubrication (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Figure 5-37. General Lubrication (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Figure 5-38. Gearbox Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Figure 5-39. Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Figure 5-40. Hydraulic System Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Figure 5-41. Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Figure 5-42. Inspecting the Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Figure 5-43. Inspecting the Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Figure 5-44. Inspecting the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Figure 5-45. Using the Hydraulic System Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Figure 5-46. Precharging the Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Figure 5-47. Inspecting the IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Figure 5-48. Inspecting the IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Figure 5-49. Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Figure 5-50. Draining Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Figure 5-51. Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Figure 5-52. Pressure Cycle Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Figure 5-53. Pump Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Figure 5-54. Pump Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Figure 5-55. Counterbalance Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
Figure 5-56. Counterbalance Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Figure 5-57. Motor Brake Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Figure 5-58. Setting up the Shot Pin Circuit (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Figure 5-59. Setting up the Shot Pin Circuit (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Figure 5-60. Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . 5-96
Figure 6-1. HPU and Reservoir Bladder Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-2. Counterbalance and Stand Jump Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-3. Brake Circuit Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-4. Shot Pin Cylinder and Clamp Cylinder Schematic Diagram . . . . . . . . . . . . . . . . . . 6-15
Figure 6-5. Link Tilt Cylinders Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Figure 6-6. Gearbox Lubrication Hydraulic System Schematic Diagram . . . . . . . . . . . . . . . . . . 6-19
Figure 6-7. Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Figure 6-8. IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Figure A-1. Hydraulic Symbols (1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Figure A-2. Hydraulic Symbols (2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Figure A-3. Hydraulic Symbols (3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Figure B-1. PH-50 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Figure B-2. PH-50: Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Figure B-3. PH-50: Elevator Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Figure B-4. PH-50: Link Tilt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Figure B-5. PH-50: Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Figure B-6. PH-50: Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Figure B-7. PH-50: Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
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List of Figures
Figure B-8. PH-50: Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
Figure B-9. PH-50: Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . B-16
Figure B-10. PH-50: Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Figure B-11. PH-50: Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Figure B-12. PH-50: Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Figure B-13. PH-50: Inspecting the Rotating Link Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Figure B-14. PH-50: Inspecting the Wireline Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
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General Information
1
Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every reasonable effort has been made to ensure the accuracy of the information contained
herein. National Oilwell Varco® (NOV) will not be held liable for errors in this material, or for
consequences arising from misuse of this material.
Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information
provides additional details and may advise the reader to take a specific action to protect personnel
from potential injury or lethal conditions. Advisories may also describe actions necessary to
prevent equipment damage.
Note
The note symbol indicates that additional information is
provided about the current topic.
Caution
!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning
The warning symbol indicates a definite risk of
equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.
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General Information
Conventions
Advisories
Hot Surfaces
The hot surface symbol indicates the presence of a
hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.
Electrostatic Discharge
The Electrostatic Discharge (ESD) symbol indicates the
potential for static electrical discharge is present. ESD can
damage or destroy sensitive electronic components. ESD
can also set off explosions or fires in flammable environments. Always discharge static electricity prior to working
on sensitive components or in flammable environments.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.
Safety Requirements
The NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in the equipment manuals are the recommended methods of performing operations and
maintenance.
!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.
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General Information
1
Safety Requirements
Proper Use of Equipment
NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.
Safe Lifting
When lifting and handling NOV equipment, use approved lifting procedures and safe methods.
Lifting equipment improperly creates a hazardous
working environment. To avoid lifting hazards, only lift
equipment with material handling equipment rated for
the expected load and only from the designated lift
points. Failure to follow safe lifting guidelines may
result in serious or fatal injury to personnel,
significant equipment damage, and extended rig down
time.
!
Individuals working with rig equipment must never lift
anything over 55 lb (25 kg) without assistance. Always get
help from additional rig personnel or use lifting equipment.
Always follow all federal, state and local rules, codes, and
rig-specific safety guidelines when lifting and handling
NOV equipment. Operators and maintenance personnel
should be properly trained in safe lifting procedures and
the inspection of material handling equipment and lifting
components. Safe lifting recommendations provided in this
manual do not take precedence over local safety rules and
regulations, OSHA regulations, or instructions issued by
the manufacturers of rig hoisting equipment and other tools
on the rig.
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General Information
Safety Requirements
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation,
and maintenance to ensure their safety.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
Contact the NOV training department for more information about equipment operation and
maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
The equipment manufacturer recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures and that personnel are not using tools that were not specifically recommended by the
manufacturer.
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities such as
electrical, hydraulic, pneumatic, or cooling water.
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.

Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.

Wear proper protective equipment during equipment installation, maintenance, or
repair.
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General Information
1
Safety Requirements
Replacing Components

Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installation.

Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals for
maintenance recommendations.
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
Equipment Documentation Location
The User Manual provided with the equipment order contains this service manual, the engineering
installation and commissioning procedures, the Technical Drawing Package (TDP), along with
specifications, parts lists, and other instructions. These documents must be used by the
installation and commissioning crew, equipment operators, and maintenance personnel. Make
sure an equipment User Manual is available in the location where the equipment is being installed,
commissioned, operated, and maintained.
Equipment Disposal
The equipment owner is responsible for removing and dismantling the equipment at the end of the
equipment’s useful operating life. It is also the equipment owner’s responsibility to conform to all
applicable regulatory policies, standards, and recycling guidelines when removing the equipment,
dismantling equipment components, disposing of fluids, and disposing of consumable spare parts
after scheduled and unscheduled equipment maintenance.
Service Centers
For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled
“Service Center Directory.” This document is located in the User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
www.nov.com/ContactUs/24HrEmergencyContacts.aspx
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Revision D
Description
2
Introduction to the TDS-11SA
Overview
The TDS-11SA Top Drive is an AC-motor top drive developed for use as a portable or permanent
unit on a wide variety of land and offshore applications. Its compact size also allows for installation
on small workover and portable rigs. The top drive is driven by a Variable Frequency Drive (VFD)
control system.
The TDS-11SA generates 800 HP with a hoisting capacity of 500 tons and a continuous drilling
torque rating of 37,500 foot-pounds (ft-lb) (50,843 [N-m]). The top drive has a maximum speed of
228 rpm and a make-up / break-out torque capacity of 50,000 ft-lb / 60,000 ft-lb (65,791 N-m /
81,349 N-m). Speed can be maintained from 114 rpm to 180 rpm without downgrading the 800 HP
rating of the motors.
The following are components of the TDS-11SA Top Drive:

Integrated swivel

Single-speed gear box

Bi-directional link tilt system

Remote and manual internal blowout preventers (IBOPs)

PH-75 Pipe Handler (75,000 ft-lb backup capacity [101,686 N-m])

A dual guide-rail assembly to react torque
Figure 2-1 shows the TDS-11SA Top Drive and the location of major components.
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Description
Introduction to the TDS-11SA
Major Components
Counterbalance
System
Motor Cooling
System
Hydraulic Disc
Brakes (2)
Gooseneck
(S-Pipe)
AC Drilling
Motors (2)
Transmission/
Motor Housing
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
Rear
Right Side
Pipehandler
Left Side
Front
Figure 2-1. TDS-11SA Top Drive
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Description
2
Specifications
General Specifications
Component
Item
Description
Weight
• 35,000 lb (15,876 kg) – Top Drive/Shipping Skid
• 31,000 lb (14,061 kg) – Top Drive only
Stack-up height
19 ft (5.8 m)
Power requirements
700 KVA @ 575-600 VAC, 50/60 Hz
Horsepower
800 hp
Output torque (continuous)
37,500 ft-lb (50,843 N-m) (800 hp)
Tool torque (intermittent and stall)
55,000 ft-lb (74,570 N-m)
Maximum speed (at full power)
228 rpm
Hoisting capacity
500 ton (453.6 mt)
Load path
Single
Gooseneck entry
3 in. 1002 female union
S-Pipe mud hose connection
4 in. API line pipe or 4 in. 1002 female union
Drill Pipe
Sizes
3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
Pipe Handler
Type
PH-75 (75,000 ft-lb [101,686 N-m] backup torque)
Drilling Motor
Type
Reliance AC-575 VAC (2 x 400 hp)
Variable
Frequency Drive
Type
ABB ASC800 2 (800 hp, 600/690 VAC input)
Motor Braking
Type
Hydraulic caliper disc brakes
Type
Local intake pressure blower
Power
(2) 5 hp AC motors
Speed
3,600 rpm
Type
Single speed, double reduction helical gear system
Gear ratio
10.5:1 (4.38:1 optional)
Top Drive
Motor Cooling
System
Gearcase
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Description
Specifications
General Specifications
Component
Gearcase
Lubrication
Hydraulic System
Electrical and
Control House
(Drive House)
Item
Description
Type
Pressure feed
Reservoir capacity
15 gallons (56.8 liters)
Full internal flow
10 gpm (37.9 lpm)
Oil type
EP grade
(see Recommended Lubricants and Hydraulic Fluids,
D81100719-PRO-001)
Oil pressure
10 psi (minimum), 30 psi (maximum)
Power
10 hp, AC motor
Flow
8.0 gpm/3.5 gpm (30.3 lpm/13.2 lpm) (high/low)
Reservoir capacity
25 gallons (95 liters)
Oil type
Mineral-based hydraulic oil
(see Recommended Lubricants and Hydraulic Fluids,
D81100719-PRO-001)
Size
14’6" L x 7’0" W x 7’8" H
Weight
8,000 lb (3630 kg) (with single A/C unit)
Input requirement
600 VAC (50/60 Hz), or 750 VDC, or 690 VAC (50 Hz)
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Description
2
Specifications
Performance Curve
55,000
50,000
45,000
Drill Pipe Torque (ft-lbs)
800 HP
40,000
35,000
Dual AC Motor Top Drive TDS-11SA
2 x 400 = 800 HP, 500 Ton System
10.5:1 Transmission
30,000
25,000
20,000
15,000
10,000
5,000
0
0
25
50
75
100
125 150
175 200
225 250
Drill Pipe RPM
Figure 2-2. Performance Curve
Noise Data
The following data was taken one meter (39.4 in) radially outward from the outer diameter of the
gearbox and at a height of 1.6 meters (63 in) above the drill floor, with the top drive in its lowest
position. Noise data was recorded at eight equal angles around the top drive.
The highest noise level is at the rear (91.3 dB(A)).
Front
86.2 dB(A)
Front+45°
86.6 dB(A)
Right
90.4 dB(A)
Right+45°
87.7 dB(A)
Rear
91.3 dB(A)
Rear+45°
88.3 dB(A)
Left
89.0 dB(A)
Left+45°
89.9 dB(A)
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Description
Specifications
Top Drive Height
Bail
120 in
(304.8 cm)
31.0 in (78.7 cm)
Bail
88 in
(223.5 cm)
260.0 in
(660.4 cm)
230.0 in (584.2 cm)
To Center
of Gravity
160.0 in
(406.4 cm)
To Center
of Gravity
25.0 in (63.5 cm)
50.0 in
(127 cm)
67.0 in
(170.2 cm)
= 35,000 lb
(15876 kg)
65.0 in
(165.1 cm)
To Center
of Gravity
41.5 in
(105.4 cm)
Figure 2-3. Top Drive Height
2-6
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SM00856
Revision D
Page 2-7 of 12
2
Description
Specifications
Top Drive Plan View
30.0" Setback Top View Dimensions (Standard)
Rear
35.9 in
(91.2 cm)
2.5 in (Shipping Skid Only)
(6.35 cm)
Guide
C
L
Beam
30.0 in
Setback
(76.2 cm)
34 in
(86.4 cm)
56.1 in O.A.
(142.5 cm)
C Well
L
15.8 in
(40.1 cm)
22.1 in
(56.1 cm)
21 in
(53.3 cm)
31.0 in
(78.7 cm)
26.0 in
(66.0 cm)
32.6 in
(82.8 cm)
Service Loop Bracket
(Left-Hand Option)
C
L
Well
65.2 in
(165.6 cm)
Front
S-Pipe (Outside Guard)
(Left-Hand Option)
Figure 2-4. Top Drive Plan View (30.0" Setback)
2-7
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2
SM00856
Revision D
Page 2-8 of 12
Description
Specifications
Top Drive Plan View
39.5" Setback Top View Dimensions (Optional)
Rear
35.9 in
(91.2 cm)
2.5 in (Shipping Skid Only)
(6.35 cm)
Guide
C
L
Beam
39.5 in
Setback
(76.2 cm)
65.6 in O.A.
(166.6 cm)
43.5 in
(110.5 cm)
C Well
L
15.8 in
(40.1 cm)
22.0 in
(55.8 cm)
21 in
(53.3 cm)
31.0 in
(78.7 cm)
26.0 in
(66.0 cm)
32.6 in
(82.8 cm)
Service Loop Bracket
(Left-Hand Option)
C
L
Well
65.2 in
(165.6 cm)
Front
S-Pipe (Outside Guard)
(Left-Hand Option)
Figure 2-5. Top Drive Plan View (39.5" Setback)
2-8
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SM00856
Revision D
Page 2-9 of 12
Description
2
Identification Labels and Numbers
Trace code identifies the
configuration of your equipment.
Encoder
Instruction Label
Located on the righthand
brake cover
AC Motor
Identification Label
Located on the side
of each AC motor
TOP DRIVE DRILLING SYSTEM
MODEL: TDS-11SA
SERIAL NO:
GROSS WT (LBS):
PART No & REV:
(KG):
SALES ORDER:
MFG DATE:
SAFE WORKING LOAD: 500 TONS
MAX RPM: 228
RATED VOLTAGE: 550V/3 PHASE
FULL LOAD CURRENT: 732A
MAX MUD PRESSURE (PSI):
Top Drive
Identification Plate
Located on the front
of the motor housing
Warning Labels
Located on the side
of each AC motor
Warning Label
Located on the
side of the bonnet
If an equipment label is worn, dirty,
or otherwise illegible, clean it or
order a new label. Failure to adhere
to this warning could result in
severe injury to rig personnel.
Figure 2-6. Identification Labels and Numbers
2-9
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2
SM00856
Revision D
Page 2-10 of 12
Description
Lifting Points
Lifting Point
For lowering/hoisting the
Top Drive and
Guide Beam/Skid
Tag Line
Attachment Points
For the Guide
Beam/Skid with
Top Drive attached
Optional
Lifting Point
For the Guide
Beam/Skid with
Top Drive attached
Crane
Lifting Points
For the Guide
Beam/Skid with
Top Drive attached
Crane
Lifting Points
For the Guide
Beam/Skid with
Top Drive attached
(1 each side)
Figure 2-7. Lifting Points
2-10
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SM00856
Revision D
Page 2-11 of 12
2
Description
Typical Equipment Arrangement
Existing
Traveling Equipment
500-ton Hook/Block Combo-Typ.
Crown
Clearance
12.5 ft. (3.8 m)**
Block Top
* Dimensions are subject
to verification.
Stroked-Typ.
13.5 ft. (4.1 m)*
TDS-11SA Top Drive
** Standard configuration
with two IBOPs and
120 in. elevator links.
Bail Rest
TDS Work Height
19.0 ft. (5.8 m)**
Sectional Guide Beam
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
Two (2) Custom Spanners
On A-Frames or Mast Side Panels (by Customer)
Driller’s Control Console
Control Cable with Connectors
150 ft. (45.7 m)
NOV Drive House
Local Power Supply
Diesel/Alternator Set/AC Buss
AC Cables
7.0 ft. (2.1 m)-Minimum
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
Figure 2-8. Typical Installed Equipment Arrangement
2-11
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2
Description
SM00856
Revision D
Page 2-12 of 12
2-12
www.nov.com
SM00856
Revision D
Installation
3
!
The User Manual provided with the equipment order
contains this service manual, the engineering installation
and commissioning procedures, the Technical Drawing
Package (TDP), along with specifications, parts lists, and
other instructions. These documents must be used by the
installation and commissioning crew. Make sure an
equipment User Manual is available in the location where
the equipment is being installed and commissioned.
Preparation
The top drive interfaces with the rig’s hoisting system and electrical power system. Derrick and
electrical system modifications are required when installing the top drive on existing rigs.
For derricks that handle triples, the required top drive travel is about 100 ft. (30.5 m) compared to
about 75 ft. (23 m) when using a Kelly. It is generally necessary to replace the regular rotary hose
(which is normally 60 ft. [18 m] long) with a 75 ft. (23 m) hose, and extend the standpipe height to
approximately 73 ft. (22 m).
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
V-door. The location of the electrical loop and mud hose is an important installation consideration
for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop
and mud hose. Other important installation considerations include the location of the following:

The casing stabbing board

Floor and derrick accessories

Drawworks fastline

Guide beam hang-off bracket and torque reaction beam

Mud stand pipe extension

Driller’s control console location

Variable frequency drive/electrical house location
To successfully install the TDS-11SA, it is critical to know
the precise height and length of the travelling equipment,
as well as the location of the tie backs. Refer to the rig GA
drawing for these critical dimensions. The GA drawing is
located in the Technical Drawing Package (TDP).
3-1
www.nov.com
Form D811001123-GEN-001/06
3
SM00856
Revision D
Page 3-2 of 48
Installation
Illustrated Index
Crown Padeye and
Hang-off Link
Page 3-3
Counterbalance
Page 3-34
Guide Beam
Page 3-9
Intermediate
Tieback
Page 3-4
Rotary Hose
Derrick
Termination
Page 3-27
Service Loops
Page 3-28
Driller’s Control
Console
Page 3-30
Control Cable
with Connectors
Page 3-31
Main Tieback
Page 3-5
Variable Frequency Drive (VFD)
Electrical House (Drive House)
Page 3-6
Local Power Supply
Diesel/Alternator Set/AC Bus
Power Cables
Page 3-7
AC Power and
Control Cables
Figure 3-1. Illustrated Installation Index
3-2
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SM00856
Revision D
Page 3-3 of 48
3
Installation
Pre-Installation
Installing the Crown Padeye and Hang-Off Link
Crown Padeye
Weld at 30 inches
from well center
Padeye to be suitable
for 25 ton load
Crown
30 inches
25 Ton
Shackle
For land rig applications,
when possible, install crown
padeye, hang-off link and
tieback with mast layed down.
Hang-off Link
Adjust length per
General Arrangement
Drawing
Hang-off
Tieback
Drill
Floor
Typical
Cross Girt
Below Crown
C
L
Well
Figure 3-2. Installing the Crown Padeye and Hang-Off Link
3-3
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3
SM00856
Revision D
Page 3-4 of 48
Installation
Pre-Installation
Installing the Intermediate Tieback
To rotate intermediate tieback
loosen locking bolt and rotate
out of the way. To secure after
rotating tighten locking bolt.
Intermediate
Tieback
(Shown in Locked
Position)
Rotate
Locking
Bolt
Pivot
Point
Drill
Floor
30.0 inches
Refer to General Arrangement
Drawing for installation height.
C
L
Well
Figure 3-3. Installing the Intermediate Tieback
3-4
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SM00856
Revision D
Page 3-5 of 48
3
Installation
Pre-Installation
Installing the Main Tieback
Procedure
Install the main spreader beam at the
appropriate distance from well center
Install the tieback plate and tieback link
Torque and lock wire all bolts
Typical (depending
on block and hook
configuration.
Tieback Link
Tieback
Plate
Main
Spreader
Beam
Apply Anti-seize
Compound
Typical
Auxiliary
Spreader Beam
Optional
Main Tieback and
Spreader Beam
Adjust after
installation
of TDS and
guide beams
Mast Leg
Drill
Floor
30.0 inches
C
L
Well
Figure 3-4. Installing the Main Tieback
3-5
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3
SM00856
Revision D
Page 3-6 of 48
Installation
Pre-Installation
Locating the Control House
Drawworks
Recommended Area for
VFD House Location
C
L
Well
V-Door
Ramp
TDS
Driller’s
Control
Console
8,000 lb
(3630 kg)
VFD House w/
single AC unit
C
L
Well
Typical installation
VFD
House
Recommendations
Position the VFD house off-driller’s side or
behind the drawworks
Position as close to derrick plate as possible
to minimize cable lengths
92 in.
(2337 mm)
174 in.
(4420 mm)
84 in.
(2134 mm)
Ensure a safe distance from direct sources of
heat (i.e. diesel engines, general exhausts)
Location of the VFD house must ensure
accessibility from all sides
Do not expose the control house to H2S
Figure 3-5. Locating the Control House
3-6
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SM00856
Revision D
Page 3-7 of 48
3
Installation
Pre-Installation
Installing Power Cables
Plug Panel
C1
COM
P
P
AUX 5
PW
R
P6
VDC
P7
HM
I
C2
VDC
Typical installation
C3
HM
I
Blanking Plates
Spare incoming power connections
(3 Places)
P10
-A
P11
-B
VFD
Grounding
Lug
P12
-C
P10
BLK
Incoming Power Cables
600/690VAC to main circuit breaker
(3 Places)
Outgoing Power Cables
to Top Drive
(3 Places)
P11
WH
T
P12
RED
P10
BLK
P11
WH
T
P12
RED
Procedure
Clean all connector contacts
Plug Panel
Connect the power cables with the isolation circuit
breaker turned OFF
Connect cables in accordance with the electrical
schematic provided in the Technical Drawing
Package (TDP)
Rain Cover
VFD House
Typical
Lockwire all connector nuts
Earth the control house with the Ground Rod Kit
Figure 3-6. Installing Power Cables
3-7
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3
SM00856
Revision D
Page 3-8 of 48
Installation
Pre-Installation
Grounding the Control House (Land Rigs)
Copper Plated
Steel Rod
Cable Clamp
Cable Lug
Copper Wire
10 ft
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)
Ground Rod Kit
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
Figure 3-7. Grounding the Control House (Land Rigs)
3-8
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SM00856
Revision D
Page 3-9 of 48
Installation
3
Installation
Checklist
The following assumes that all pre-installation planning and rig-up is complete prior to installation
of the guide beam assembly and top drive. 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 per recommendations on the general
arrangement drawing.

The service loop bracket is installed in the derrick/mast.

The control panel and the variable frequency drive (VFD) are installed.

All rigging is inspected to ensure there is no interference with the top drive.

The hook or adaptor becket is installed. The hook should open toward the
drawworks when possible.
Identifying Guide Beam Sections
Thoroughly review the Guide Beam Kit engineering drawing in the TDP prior to beginning the
guide beam installation procedure. The guide beam sections must be installed in the correct order.
Failure to install them in the correct order may result in a guide beam section falling to the rig floor.
The bottom hinge joint on the bottom intermediate guide beam section is specifically designed
to be connected to the upper hinge joint on the top drive shipping skid/guide beam section.The
bottom intermediate guide beam section has a warning label identifying where it connects to the
top drive shipping skid/guide beam section (see the section titled "Bottom Intermediate Section
Warning Label" on page 3-23).
Always make sure to identify the bottom intermediate
guide beam section and the location where the top
drive skid/guide beam section connects to it. If these
are installed improperly, a guide beam section could
fall to the rig floor. A falling guide beam section will
damage equipment and could result in severe injury or
death.
If the warning label on the bottom intermediate guide
beam section is worn, dirty, or otherwise illegible,
clean it or order a new warning label to affix to the
same place on the bottom-intermediate guide beam.
Failure to adhere to this warning could result in severe
injury or death.
3-9
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3
SM00856
Revision D
Page 3-10 of 48
Installation
Installation
Raising the Top Guide Beam Section to the Drill Floor
Procedure
Locate the top guide beam section near the
V-Door
Ensure the hoist carriage is free to slide the
entire length of the guide beam
Ensure the latch moves freely
Attach lifting slings to the lifting eyes of the
hoist carriage
Eusure the transport shipping pins are in
place and secure
Hoist the guide beam section to the drill floor
using a tugger line with a backup line to tail
Remove tugger line after top guide beam is in
position on drill floor
Hoist
Carriage
30,000 lb
Tugger Pull
Tugger Line
Attachment
Points
(Rig DOWN)
RIG DOWN UP
Tugger Line
Attachment
Points
(Rig UP)
Top Guide
Beam
Latch
Shipping
Pins
2 places
Drill
Floor
Backup
Line
Figure 3-8. Raising the Top Guide Beam Section
3-10
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SM00856
Revision D
Page 3-11 of 48
3
Installation
Installation
Attaching the Carriage Sling to the Hook
Hoist
Carriage
Cable Sling
Attachment
Points
(RIG DOWN)
RIG DOWN UP
Cable Sling
Attachment
Points
(RIG UP)
Top Guide
Beam
Disengage
Shipping Pins
Hoist
Procedure
Cable Sling
Attach a short cable sling from the hook/block
to the hoist carriage at the RIG UP
attachment points
Disengage the shipping pins
Hoist the top guide beam using the
drawworks
Figure 3-9. Attaching the Carriage Sling to the Hook
3-11
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3
SM00856
Revision D
Page 3-12 of 48
Installation
Installation
Moving Guide Beam Sections
Procedure
Do not move the bottom intermediate guide
beam section until all other sections are moved
to the rig floor. The bottom intermediate guide
beam section is designed to be hooked to the
top drive shipping skid/guide beam section
only. Connecting the bottom intermediate
section out of order may result in a guide beam
section falling to the rig floor.
Locate the remaining guide beam sections
near the V-Door
Attach tugger lines to the lifting eyes of the
first guide beam section to be hoisted
Hoist the guide beam section to the drill floor
using the rear tugger line or tailing line to
stabilize and balance the guide beam
Tugger
Line
3,200 lb
(1450 kg)
24 ft. Guide Beam Section
Tugger
Line
3
Guide Beam Section
Hoist to the drill floor
Guide Beam
Section
Tugger
Line
Tugger
Line
2
Lifting Eyes
Attach tugger lines
for hoisting
Drill
Floor
1
Guide Beam Sections
Prior to Installation
Figure 3-10. Moving Guide Beam Sections
3-12
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SM00856
Revision D
Page 3-13 of 48
3
Installation
Installation
Hooking 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
3
4
Engage
Hook
Hook Pin
In fully engaged
position
Present
and Hook
the first guide
beam section
Guide Beam
Section
Hooked
Hook Pin
Saddle
Tugger Line
Leave attached
to stabilize the
back end of
the guide beam
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
Figure 3-11. Hooking the First Guide Beam Section
3-13
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3
SM00856
Revision D
Page 3-14 of 48
Installation
Installation
Hoisting the First Guide Beam Section
Guide Beam
Top Section
Hoist
Hook Pin
First Guide
Beam Section
Initially hoisted
by the hook pin
Bar and Radius
Locates pin bores for
easy insertion of pins
Hoist
Using the
drawworks
Figure 3-12. Hoisting the First Guide Beam Section
3-14
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SM00856
Revision D
Page 3-15 of 48
3
Installation
Installation
Stabbing and Pinning 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
3
Secure
with the
lynch pin
Retainer Pin
Apply grease
and insert
Stab
and Pin
the guide
beam joint
Block as
Required
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 cleaned and greased joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Figure 3-13. Stabbing and Pinning the First Guide Beam Section
3-15
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3
SM00856
Revision D
Page 3-16 of 48
Installation
Installation
Completing Guide Beam Section Installation
Do not move the bottom intermediate guide
beam section until all other sections are moved
to the rig floor. The bottom intermediate guide
beam section is designed to be hooked to the
top drive shipping skid/guide beam section
only. Connecting the bottom intermediate
section out of order may result in a guide beam
section falling to the rig floor.
Repeat the previous steps until
guide beam sections are installed
Tugger
Line
Tugger
Line
Procedure
Drill
Floor
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 drawworks
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
Figure 3-14. Completing Guide Beam Section Installation
3-16
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SM00856
Revision D
Page 3-17 of 48
Installation
3
Installation
Hoisting and Attaching the Guide Beam
Latch is held in
unlock position
when carriage is
at top position
Latch locks beam
to hang-off link when
carriage is lowered
Diverter To Protect
Against Accidental
Unlatching
Procedure
Hoist Carriage
Extension
Attach guide beam
assembly to hangoff link
Procedure
Rotate intermediate
tieback handle UP 90
degrees
Insert the intermediate
tieback into the slot
located on the lower
guide beam
Rotate intermediate
tieback handle DOWN 90
degrees to lock the guide
beam in place
Adjust the tieback bracket
so the center of the guide
beam is 30 inches from
well center
Intermediate
Tieback
Tieback
Handle
Guide
Beam
Slot
Attach Intermediate
Tieback into Lower
Guide Beam Slot
Figure 3-15. Hoisting and Attaching the Guide Beam
3-17
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3
SM00856
Revision D
Page 3-18 of 48
Installation
Installation
Removing the Hoist Carriage
Hoist
Carriage
Drill
Floor
Procedure
Lower hoist carriage to drill floor
Remove hoist carriage from drill floor and
store (to be used again for rig down and
transport)
Figure 3-16. Removing the Hoist Carriage
3-18
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SM00856
Revision D
Page 3-19 of 48
3
Installation
Installation
Moving the Top Drive to the Rig Floor
Procedure
Ensure the safety of all personnel
Locate the Top Drive at the bottom of the
V-Door ramp
Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor
35,000 lb Crane Lift
35,000 lb
(15,876 kg)
TDS-11SA
on the skid
Lifting
Block
Hoist using
the drawwork
Optional Crane Placement
Side Bracket
2
TDS
hoisted up
V-Door Ramp
Bail
Drill
Floor
Lifting Detail
60 ft Slings
1
TDS
on skid
Backup
Line
Figure 3-17. Moving the Top Drive to the Rig Floor
3-19
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3
SM00856
Revision D
Page 3-20 of 48
Installation
Installation
Attaching the Top Drive to the Hook
There are two basic methods for installing the TDS-11SA top drive, depending on
the travelling equipment configuration. Follow the installation procedures for option 1
or option 2 as appropriate for the rig.
Bail
Bail Lock
TDS-11SA
V-Door
Post
Attach Sling
or Tugger Lines
to Secure Skid
V-Door
Ramp
Procedure
Remove hoist cable slings
Attach bail to block or hook
Secure lower end of skid to prevent
movement toward or down V-door
ramp
Hoist using drawworks
Figure 3-18. Attaching the Top Drive to the Hook
3-20
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SM00856
Revision D
Page 3-21 of 48
3
Installation
Installation
Lifting the Top Drive into the Rig
Option 1 Procedure
Option 2 Procedure
Set TDS on the rig floor
Secure the bottom end of the
skid to the floor or the v-door
posts to prevent the TDS
from moving back down the
v-dor ramp
If the traveling equipment
and the TDS bail length
allows, the bail can be
connected directly to the
hook/block (refer to the
general arrangement
drawing)
Hoist the TDS from the v-door
to a vertical position using
slings
Connect the TDS skid to the
guide beam
Hook open
towards
drawworks
Hook open
towards
v-door
Depending on the
traveling equipment and
bail length, variations of
this procedure may be
required
Figure 3-19. Lifting the Top Drive into the Rig
3-21
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3
SM00856
Revision D
Page 3-22 of 48
Installation
Installation
Connecting the Top Drive to the Guide Beam
1
Bottom
Intermediate
Section
Present
Hook
Insert hook pin
into hook pin saddle
Lower TDS/Skid
until it makes
contact with Lower
Tieback
Hook Pin
Grease
the bores on
both joint
halves
2
Grease
the bores on
both joint
halves
Hook Pin
In fully engaged
position
Hook Pin
Saddle
Guide Beam
/Skid Section
Skid not shown
3
Attach
Lower
Tieback
OPTION
2
Lower
Tieback
Present
and Hook
TDS to the guide
beam section
Guide Beam
/Skid Section
Skid not shown
Hook
Joint
OPTION
1
Lower
Tieback
Procedure
Backup
Line
Locate the TDS skid to be hooked under the
bottom intermediate guide beam section
Grease the bores on both joint halves
Align the guide surface with the hook pin as shown
Lower the TDS skid to match and engage the hook
pin to the hook pin saddle
The bottom intermediate guide beam section and
skid will contact the lower tieback
Figure 3-20. Connecting the Top Drive to the Guide Beam
3-22
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SM00856
Revision D
Page 3-23 of 48
Installation
3
Installation
Bottom Intermediate Section Warning Label
Bottom Intermediate
Guide Beam Section
Warning Plaque
(P/N P614000138)
If an equipment warning plaque
is worn, dirty, or otherwise
illegible, clean it or order a new
warning label. Failure to adhere
to this warning could result in
severe injury or death.
Top Drive
Shipping Skid/
Guide Beam
Section
Figure 3-21. Bottom Intermediate Guide Beam Section Warning Label
3-23
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3
SM00856
Revision D
Page 3-24 of 48
Installation
Installation
Attaching the Torque Tieback
Tieback
Retainer
Pins
Tieback
Pivot Pin
Tieback
Hook
OPTION
2
Tieback
Pivot Pin
OPTION
1
Tieback
Hook
Procedure
Engage tieback hooks to secure the
lower guide beam/skid
Insert retainer pins
Figure 3-22. Attaching the Torque Tieback
3-24
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SM00856
Revision D
Page 3-25 of 48
3
Installation
Installation
Pinning the Top Drive to the Guide Beam
Guide Beam
Bottom Section
4
Secure
with the
lynch pin
Lynch
Pin
2
Lower
Tieback
Joint Pin
Install
Seating
Surfaces
3
Retainer Pin
Apply grease
and insert
OPTION
2
1
Guide Beam
/Skid Section
Hoist until it seats
Skid not shown
Hoist
Using the
drawworks
OPTION
1
Drill
Floor
The bottom end of guide
beam/skid should be
approximately 7 ft plus
or minus 6 inches above
the drill floor
Procedure
Hoist guide beam/skid section until it seats
Install the joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Figure 3-23. Pinning the Top Drive to the Guide Beam
3-25
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3
SM00856
Revision D
Page 3-26 of 48
Installation
Installation
Releasing the Top Drive from the Skid
After hoisting the TDS
disengage the Lower
Carriage Latch and pin it
as shown.
Pin
1
View of
Carriage
from Rear
Upper
Latch
Engaged
Lower
Latch
Disengaged
Pin
Pin
OPTION
2
Latches
Both sides
engaged
Pin
2
Pin
Upper
Latch
Disengaged
OPTION
1
Lower the TDS, disengage the
Upper Carriage Latch
and pin it as shown.
Lower
Latch
Disengaged
Pin
Procedure
Lower the blocks (option 2 only)
Remove the slings (option 2 only)
Connect the hook/block to the bail (option 2 only)
Disengage the carriage latches
Remove the Bail Lock and store it for future use
Figure 3-24. Releasing the Top Drive from the Skid
3-26
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SM00856
Revision D
Page 3-27 of 48
3
Installation
Installation
Installing Derrick Termination
Hoist Line
Attachment Point
Derrick/
Mast Leg
Derrick
Leg Plate
Hoist Line
Attachment
Points
Service Loop
Brackets
Mount
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 Top Drive
Drill
Floor
!
Mount as far as practical from well center, to
maintain a 36 inch minimum bend radius
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
Figure 3-25. Installing Derrick Termination
3-27
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3
SM00856
Revision D
Page 3-28 of 48
Installation
Installation
Installing Service Loops at the Derrick
Hoist
Derrick
Termination Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
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
!!
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
Avoid damage to the
service loops by maintaining a
40 inch minimum
bend radius
Service Loop
and Storage Tub
3,600 lb
(1600 kg)
!
Take care so the service loop pigtails are not
damaged during installation.
Figure 3-26. Installing Derrick Service Loops at the Derrick
3-28
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SM00856
Revision D
Page 3-29 of 48
Installation
3
Installation
Installing Service Loop Jackets
There are service loop jackets that are assembled around the service loops. Install the jackets
after the service loops have been attached at the derrick termination plate.
!
The double Velcro construction is hard to disassemble.
Make sure the orientation of the jacket is correct before
you close the strap.
Refer to Installation Instructions, Service Loop Jackets (D614000166-PRO-001) for annotated
photographs showing how to install a service loop jacket. This engineering procedure is located in
the equipment user manual.
To install each jacket:
1. Velcro the inner straps around the biggest cable/hose.
2. Close the flaps around the whole bundle and close the double Velcro edge. Leave a
little room so the cables/hoses can move up and down the jacket.
3. Secure the double Velcro edge with the two lock straps.
3-29
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3
SM00856
Revision D
Page 3-30 of 48
Installation
Installation
Drawworks
Installing the Driller’s Control Console
V-Door
Ramp
TDS
Recommended Area
for Driller’s Control
Console Location
INC
Y
NC
GE
ER OP
EM ST
UE
RQ
T
KE
SE MA
UP
INC
DR
EN
AT OP
L
RA
NE
GE
D
VF T
UL
FA
MS
AR TOR
AL ILL MOMP
ES
PR
OIL SS
LO
E
PM
SR
TD
AS
RE
E
UP
KE
MA
E
DECREAS
ILL
DR
OR
AT
EV
EL ED
BX CLOS
HO
U
HP / ON
TO
AU
OD
SM
TD SPIN
E
TO
RQ
UE
TE CW
TA
PH
CC
RO
W
T TILT
K TIL
/
LIN
ILL
DR
ILL
DR
E
AK
BR
AU
N
IO
TO
TD
P
IBO
OS
CL
TWAND
SH
PU
E
T
S
ER
OW
BL SS
LO
Profibus Cable
ER
DL CLAMP LD
AN
EH
PIP
TIL
K T
LIN OA
FL
TE
DR ER
OV
CE
EN
SILECK
M
AR CH
AL MP
LA
EL
INC
BX
D
ME
AR
CE
AN P
AL UM
RB DJ
TE AN
UN ST
CO /
ILL
DR
AS
RE
E
DECREAS
BX OR
EV
24 VDC Power
hard-wired E-Stop
AS
RE
E
DECREAS
S TO
TD ILL
LE
AB
EN
ED
FO
RW
AR
CT
IREF
SD
RS
E
VE
RE
OF
D
E
AK
BR OFF
/
ON
P
IBO
OS
CL
E
EN
OP
!
Customers who choose to use
control systems not manufactured
by NOV should be aware that NOV
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 NOV requirements.
NOV highly recommends the use
of its system, as it is specifically
made for use with the Top Drive.
Recommendations
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
Figure 3-27. Installing the Driller’s Control Console
3-30
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SM00856
Revision D
Page 3-31 of 48
3
Installation
Installation
Installing the Console Cabling
24VDC Power /
Hard-Wired E-Stop
to Driller’s Console
Profibus Serial Link
to Driller’s Console
C1
COM
P
P
AUX 5
PW
R
P6
VDC
P7
HM
I
C2
VDC
Typical installation
C3
HM
I
P10
-A
P11
-B
P12
-C
P10
BLK
Plug Panel
P11
WH
T
P12
RED
P10
BLK
P11
WH
T
P12
RED
Recommendations
Ensure that the Driller’s Control Console is
properly located
Connect the power cables with the isolation
circuit breaker turned OFF
Plug Panel
Rain Cover
VFD House
Typical
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawing Package
Tighten connector nuts
Lockwire connector nuts to prevent loosening
Figure 3-28. Installing the Console Cabling
3-31
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3
SM00856
Revision D
Page 3-32 of 48
Installation
Installation
Motor Rotation Checkout Procedure
Direction
of Rotation
Counterclockwise
Procedure
Assign the Top Drive and inverter by selecting
FORWARD or REVERSE TDS DIRECTION on the
driller’s console
Check the rotation direction of the cooling and oil
pump motors
Rotate the drill stem using the TDS RPM knob on the
driller’s console and observe proper operation
S
ES
PR
OIL OSS
L
Direction
of Rotation
Clockwise
UE
RQ
TO
E
D
MO
Cooling Motors
2 Places
S
TD SPIN
LI
ILL
DR
ILL
DR
E
AK
BR
E
RS
VE
N
RE
IO
TO
AU
T
EC
IR F
SD
TD
OF
D
AR
RW
FO
Driller’s
Control
Console
I NC
CY
GEN
ER OP
EM ST
EUP
S TOR
QUE
I NC
L
DRIL
BLE
OR N
VAT OPE
ELE
I NC
BX
ED
ARM
CE
LAN
UMP
RBA
NDJ
NTESTA
COUL /
DRIL
L
ERA
GEN
HA
PIPE
TD
MP D
CLA HOL
TWAND
H
PUS
S MO
ILL
DR
HPU/ ON
O
AUT
QUE
TOR
DE
PM
SR
TD
P
KEU
MA
OR
VAT
ELESED
BX CLO
TILT
LINK AT
FLO
DRIL RTE
OVE
A SE
RE
E
DECR EAS
R
LE
ND
VFD
LT
FAU
MS
AR
AL L MOTMPOR
SS
PRE
OIL S
LOS
A SE
RE
E
DE CR EAS
BX
ENA
WER
BLO S
LOS
A SE
RE
E
DE CR EAS
SET MAK
TD
ATE CW
PH
ROT
CCW
SPIN
TILT TILT
/
LINK
NCE
SILECK
RM CHE
ALA P
LAM
L
DRIL
L
DRIL
E
AK
N
IO
BR
O
AUT
TD
IBOP
SED
CLO
E
ERS
REV
CT
RE
S DI OFF
D
WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
INC
OPE
ASE
RE
INC
E
DECREAS
PM
SR
TD
ASE
RE
E
DECREAS
INC
P
R
E
EAS
EU
K
MA
E
DECREAS
ILL
DR
Direction
of Rotation
Counterclockwise
Oil Pump
Motor
Drill Stem
Direction
of Rotation
Forward
Reverse
Figure 3-29. Motor Rotation Checkout Procedure
3-32
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SM00856
Revision D
Page 3-33 of 48
3
Installation
Installation
Installing the Elevator Links
Procedure
Rotate the pipehandler 90˚
(positioning the link catch under
the front of the motor guard)
Lubricate the elevator link eyes
with pipe dope
Hoist the elevator link onto the
rotating link adapter (small eye
at bottom)
Secure the link catch with the pin
and fasteners
Secure the elevator link to the
link tilt
Rotate the pipehandler 180˚ and
install the other elevator link
Install the elevator (refer to the
elevator manual)
Link Catch Pin
Link Tilt
Link
Catch
Clevis Pin
Rear
Pipehandler
Rotate Switch
UN ST
CO L /
IL
DR
L
RA
NE
GE
ER
DL CLAMPOLD
N
HA
E
PIP
TWAND
SH
PU
H
T
IL
K TT
LIN OA
FL
U
HP / ON
TO
Link
AU
UE
E
AT CW
RQ
TO
PH
CC
T
RO
W
T
ILT TIL
Front
KT
LIN
ILL
DR
E
RS
VE
RE
Driller’s
Control
Console
600-2,400 lb
(270-1100 kg)
Elevator Link
I NC
CY
GEN
ER OP
EM ST
EUP
S TOR
QUE
I NC
L
DRIL
VAT OPE
L
ERA
I NC
ELE
A SE
RE
R
LE
D
ND CLAMP
HOL
HA TWH AND
PUS
PIPE
TILT
LINK AT
FLO
MA
TD
KEU
PM
SR
P
E
DECR EAS
DR
DRIL
GEN
VFD
LT
FAU
DRIL RTE
OVE
A SE
RE
E
DE CR EAS
BX OR N
BX
ED
ARM
CE
LAN
UMP
RBA
NDJ
NTESTA
COUL /
MS
AR
AL L MOTMPOR
A SE
RE
E
DE CR EAS
SET MAK
TD
BLE
ENA
ILL
OR
VAT
ELESED
BX CLO
HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE
TD
ATE CW
TOR
DE
WER
BLO S
LOS
PH
S MO
ROT
CCW
SPIN
TILT TILT
/
LINK
NCE
SILECK
RM CHE
ALA P
LAM
L
DRIL
L
DRIL
BR
AK
E
N
IO
O
AUT
TD
OP
IB
SED
E
ERS
REV
CT
RE
S DI OFF
D
CLO
WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
OPE
Take care when installing
elevator links. Links weigh
up to 2,400 lb (11,00 kg) and
can fall if handled improperly.
Figure 3-30. Installing the Elevator Links
3-33
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3
SM00856
Revision D
Page 3-34 of 48
Installation
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
Cylinder
Clevis Pin
2 Places
Rig-up/Run/
Shutdown Valve
Shown in RIG-UP
position (switch to RUN
after the counterbalance
is installed)
Hook
Pear Link
2 Places
Cylinder
Clevis
2 Places
Counterbalance
Cylinder
2 Places
(8.5 inch stroke)
Bail
RIG-UP
SHUTDOWN
RUN
S
H
N
U
T
D
U
R
O
W
N
COUNTERBALANCE MODE
E
C
N
LA
-U
P
BA
R
TE
R
IG
N
U
O
C
E
D
O
M
Hydraulic
Manifold
Figure 3-31. Installing the Counterbalance
3-34
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SM00856
Revision D
Page 3-35 of 48
Installation
3
Commissioning
Initial 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 (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
TOP DRIVE
Exhaust Cover
4 Places
INS
T
WH ALL
UN EN
ST IT IS
OR
ED
VARCO
Air Inlet
Between motor
and brake housing,
2 Places
Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places
Figure 3-32. Initial Checkout
3-35
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3
Installation
SM00856
Revision D
Page 3-36 of 48
Commissioning
Hydraulic System Checkout Procedure
Cork Ball
(Level Indicator)
Red
“Pop-up”
Dirt Alarm
Sight
Glass
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 if the indicator has
popped up
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Figure 3-33. Hydraulic System Checkout
3-36
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SM00856
Revision D
Page 3-37 of 48
3
Installation
Commissioning
Electrical System Checkout Procedure
Emergency Stop
INC
Y
NC
GE
ER OP
EM ST
S TOR
TD L
QU
P
T AKEU
E SE M
IL
INC
DR
ATOOPE
EV
EL
INC
BX
ASE
RE
MED
E
NC P
ALA M
RB DJU
TE AN
UN ST
CO L /
IL
DR
24 VDC Power
hard-wired E-Stop
D
VF LT
U
FA
MS
AR R
AL MOTOP
RQ
UE
L
RIL
D
R
HPU/ ON
TO
TE CW
TA
PH
O
SM
TD SPIN
RO
K
MA
E
DECREAS
EV
EL SE
BX CLO
AU
DE
TO
AR
PM
SR
P
EU
ATO
D
H
S
WER
BLO SS
LO
RPM Meter
W
CC
LT TILT
K TI
LIN
E/
NC
K
SILE
EC
RM CH
ALA MP
LA
ILL
DR
ILL
DR
E
AK
N
BR
IO
CT
SD
TD
IB
D
REV
SE
ER
Torque Meter
IRE
TO
AU
OP
SE
CLO
TWAND
SH
PU
LT
K TIT
LIN OA
FL
ILL TEM
DRVER
O
ES
PR
OIL SS
LO
ER
DL CLAMPOLD
AN
EH
PIP
TD
E
DECREAS
BX R N
LE
AB
EN
AL
ER
GEN
ASE
RE
E
DECREAS
ASE
RE
OFF
D
AR
RW
FO
E
AK
BR OFF
/
ON
P
IBO
OPE
Profibus Cable
SE
CLO
N
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 driller’s control console
(See the Operations chapter)
Check for alarm conditions and resolve any alarms
at this time (See the Operations chapter)
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
Figure 3-34. Electrical System Checkout
3-37
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3
SM00856
Revision D
Page 3-38 of 48
Installation
Commissioning
Mechanical Checkout Procedure
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 if the indicator has
popped up
Cork Ball
(Level
Indicator)
Sight
Glass
i
Gearbox Oil Fill
Clean area before removing
plug,then use a 1 3/8 inch,
12 point socket to remove plug
Gear Oil
Sight Gauge
Check with Top Drive
“OFF”
“Pop-up”
Dirt Alarm
Gear Oil Filter
Figure 3-35. Mechanical Checkout
3-38
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SM00856
Revision D
Page 3-39 of 48
Installation
3
Commissioning
Adjusting the Link Tilt
Jam Nut
Adjust the derrickman position
with the adjusting screw and
lock in position with the jam nut
Link Tilt
Crank
Assembly
Pin
26 inches
(660 mm)
Typical
Clamp
Mousehole
Position Cable
Pull “up” or “down”
to set mousehole
position
3-4 inches
(76-102 mm)
Link
Mousehole
Position
Derrickman’s Position
Link clamps should be adjusted
so that the elevator does not
hit the diving board in this position
Well Center
Float Position
Drill Down
Position
Bottom of elevator
should be above
the bottom of the
stabbing guide
Elevator
Figure 3-36. Adjusting the Link Tilt
3-39
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3
SM00856
Revision D
Page 3-40 of 48
Installation
Decommissioning
Securing the Top Drive 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
N
Hydraulic
Manifold
O
W
RU
H
U
T
D
N
S
CO
UN
TE
RB
-U
ALA
IG
R
NC
P
Lower
TDS to
drill floor
EM
OD
E
Rig-up/Run/
Shutdown Valve
Rotate from RIG-UP to
SHUTDOWN for Top Drive rig-down
RIG-UP
Drill
Floor
SHUTDOWN
RUN
COUNTERBALANCE MODE
Figure 3-37. Securing the Top Drive for Rig-Down
3-40
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SM00856
Revision D
Page 3-41 of 48
3
Installation
Decommissioning
Removing and Storing Cables and Service Loops
Derrick
Termination
Plate
Lower
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
!
Avoid damage
to the service
loops. Use care
when dragging
them near
sharp edges
and allow room
for passing
under the
V-door
Derrick
Service
Loop
TDS
Service
Loop
!!
Avoid damage to
the service loops by
maintaining a
36 inch minimum
bend radius
!
An electrical short can occur if quick
connectors are not kept clean and dry.
Whenever separating quick
connector(s), immediately install
the weather plugs to prevent
connectors from becoming
contaminated with water or debris.
When the connector is not in use
secure/locate the connector so that is
does not lie on the ground and make
sure to minimize any exposure to water,
mud, etc. Prior to re-connecting, inspect
the inside of the connectors to make
sure they are clean and dry.
Service
Loop and
Storage Tub
3,600 lb
(1600 kg)
Lifting Eyes
Do not remove
Procedure
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
Figure 3-38. Removing and Storing Cables and Service Loops
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Installation
Decommissioning
Setting the Latches and Locking the Bail
Counterbalance
Cylinders
Disconnect
from the hook
TOP DRIVE
Exhaust
Cover
4 Places
INST
WH ALL
UN EN
ST IT IS
OR
ED
Bail
Lock
VARCO
View of
Carriage
from Rear
Pin
Lower
TDS to
drill floor
Latches
Both sides
engaged
Pin
Procedure
Drill
Floor
Lower the top drive to the drill floor
It is NOT necessary to drain gear oil or
hydraulic fluid for rig down
Attach the bail lock by placing u-bolt behind
the gooseneck and attaching it to the tube as
shown
Disconnect the counterbalance cylinders from
the hook
Install exhaust covers
Engage the upper and lower carriage latches
as shown
Figure 3-39. Setting the Latches and Locking the Bail
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Installation
3
Long Term Storage
When the top drive will be idle for six months or more, use the following long-term storage
recommendations in order to preserve the top drive and to properly store equipment associated
with its care and maintenance.
General Guidelines
Before leaving the factory, top drives are protected only for shipment to the destination. The
following guidelines and procedures should be followed for storage after arrival or extended
storage (six months or longer) on the rig.
Safety
Safety must be a prime consideration during application of any rust inhibitors, since they are
combustible and generate explosive vapors. Follow the manufacturer’s recommended safety
precautions. All personnel must understand these precautions and be properly protected.
Before using combustible products on the rig, make
sure to read and understand the manufacturer’s safety
precautions.
Storage Location and Position
Store the top drive and accessories under cover, or indoors, if possible. Top drives should be
stored away from blowing dust, salt spray, sources of vibration, etc. Also, avoid storage areas
where rapid temperature changes occur as this type of environment produces condensation.
Store the top drive in a vertical position if possible. If the top drive cannot be stored in a vertical
position, store the top drive on its shipping skid. Racks or pallets should be used for all other parts
of the top drive to make sure they are stored off the ground, concrete, etc. Care must be given to
positioning of stored components to allow periodic reapplication of rust inhibitors, rotating of
machinery, and so forth.
Cleaning
Steam cleaning is acceptable, but should be limited to painted surfaces. Unpainted surfaces must
be thoroughly dried and protected with rust inhibitors. Care must be used to avoid getting steam or
water into gearboxes, hydraulic system, bearing housings, and bushings. No diesel-based
cleaners should be used in cleaning junction boxes, hoses and electrical items.
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Long Term Storage
Pre-Storage Procedure
In addition to the items indicated in the section titled "Storage Procedure" on page 3-45, perform
the following procedures at initial long-term storage of the top drive.
1. If the top drive is to be stored in vertical position, drain oil from gearbox. Refill to the
full level in the sight glass full with an AGMA mild EP gear oil with rust inhibitor, or
equivalent (see the Recommended Lubricants and Fluids document located in the
User Manual). Rotate gears and bearings to distribute lubrication.
2. Relieve all hydraulic pressure, including accumulators. If the top drive is stored in a
horizontal position, drain hydraulic lines to prevent hydraulic fluid leaking out into the
immediate storage area.
3. Seal or plug exposed ends of air, hydraulic, water and lube/oil lines.
4. Remove washpipe packing assembly, disassemble and remove O-rings and packing
rings. Clean and coat washpipe assembly with rust preventative and store
separately. Protect all exposed threads on washpipe, gooseneck and stem (grease
all threads before installing threaded protectors).
5. Cover all electrical control boxes (junction boxes, etc.) with paper impregnated with
a volatile-type inhibitor followed by thick black plastic sheeting (at least .006" thick).
All sharp corners should be protected with wood blocking. Add desiccant packs to
keep dry.
The instrument junction box will stay on the top drive. Seal all openings with plastic NPT caps, and
add desiccant packs inside each box.
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3
Installation
Long Term Storage
Storage Procedure
Complete the following steps at the monthly intervals indicated.
Step
Procedure Description
0.0
mo
1.5
mo
1
2
Rotate all rolling elements, and raceways (gearbox, handling ring
etc) to prevent etching or staining.
X
X
• Coat all exposed bare metal and moving parts with rust
preventative (dry-film type rust inhibitors can also be used).
• Remove all covers/guards to gain access to all moving parts
when necessary.
• Rotate parts involved while applying rust preventative to ensure
parts are fully coated. Make sure that covers/guards are
replaced after coating.
X
X
• Grease all pins and dowels.
• Rotate parts while applying grease to ensure parts are fully
coated.
X
X
4
Add/replace desiccant packs inside each electrical box.
X
X
5
If the top drive is to be stored in a horizontal position:
• drain gear box and bearing cavities, then
• coat the inside of gear box (all gears, pinions, etc.) and bearing
cavities with grease type rust inhibitor and then drain.
• Rotate gears and bearings while applying rust inhibitor to ensure
parts are fully coated.
X
X
6
Perform recommended Lubrication and Maintenance procedures
as indicated in this service manual.
X
X
7
• Thoroughly grease all fittings with rust inhibiting grease. Use
enough to completely coat all rotating surfaces.
• Rotate/actuate all parts involved while applying grease to ensure
full distribution.
X
X
8
Make sure all openings and covers are tightly sealed.
X
X
9
• Clean exterior of the top drive to remove all mud, dirt or other
foreign material.
• Remove any rust and then coat area with red oxide or zinc rich
primer.
X
X
3
3.0
mo
6.0
mo
For long-term storage procedures of original equipment
manufacturer (OEM) parts and components, see the
manufacturer’s documentation located in the User Manual
supplied with the equipment.
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Long Term Storage
Returning the Top Drive to Service
For bringing OEM parts and components out of storage for
use, see the manufacturer’s documentation located in the
User Manual supplied with the equipment.
1. Remove all protective covers, wrappings and desiccant packs. Inspect for corrosion
or damage. Repair as required.
2. Remove all storage plugs.
3. Drain and flush all oil, preservatives, and inhibitors.
4. Change all filters and clean all strainers.
5. Check and replace (as needed) all rubber/elastomer parts. For example: air hoses,
water hoses, hydraulic hoses, seals, and counterbalance bags.
6. Replace all parts removed for separate storage, such as the washpipe assembly.
7. Fill all lubrication systems to correct levels with specified lubricants (see the
Recommended Lubricants and Fluids document located in the User Manual).
8. Perform recommended lubrication and maintenance procedures (see Revision
DMaintenance).
9. A qualified electrician must test motor windings and service loops.
Accumulated moisture in motor windings and service loops
should be driven out by several hours of low amperage
use.
10. Prior to starting and operating the top drive:

perform a thorough inspection and checkout to verify that all of the top drive's
systems are fully functional and operational before returning the top drive to
service. Refer to the mechanical and electrical inspections in the appropriate
installation documents or mechanical and electrical checkout procedures.

lubricate the rotating head or link adapter with 25ml of hydraulic fluid. Manually
rotate the component clockwise and then counter-clockwise for two rotations.
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
Installation
3
make sure the top drive is oriented vertically for two hours prior to energizing the
top drive hydraulic system.
!
Allow adequate run-in time. Start slowly with no load for
two hours to assess the top drive for wear or damage.
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SM00856
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Operation
4
!
All procedures and methods provided in this manual are
superseded by the procedures and methods approved for
use at the location where the equipment is installed and
commissioned.
Stateless Driller’s Control Console
Overview
A stateless NOV Driller’s Control Console is typically used to operate the TDS-11SA Top Drive.
Some top drive installations may also include an Amphion™ Human-Machine Interface (HMI)
system, in addition to the stateless driller’s control console. In this chapter, the controls on the
stateless driller’s control console are provided to explain top drive operations. All the operator
controls described are replicated in the Amphion HMI.
The control console provides the control circuitry for all top drive and pipe handler functions. The
console enclosure also contains Intrinsically Safe (I.S.) barrier components that support Zone 2
certification.
The control console is integrated with the Variable Frequency Drive (VFD). The VFD is located in
an environmentally-controlled drive house. The communication path from the driller’s control
console to the VFD is via a common data bus. Functional changes can be implemented by NOV
using utilities that are common for NOV top drive systems.
Control commands from the console are processed through a single-board computer (SBC). The
SBC controls the actions of the cooling system, the solenoid valves, the brakes, IBOP functions,
switches and sensors. The SBC also monitors all component sensors and switches, and acts as a
safety interlock to prevent inadvertent tool operation. Additionally, the SBC notifies the driller of the
operational status of the top drive and diagnoses abnormal operating conditions.
Refer to the section titled "Installing the Driller’s Control Console" on page 3-30 for installation
information.
The illustrations in this chapter show a typical control
console panel layout. Depending on the top drive system
options, the layout of the console controls may vary. Refer
to the engineering drawings in the Technical Drawing
Package (TDP) for the rig-specific console layout for the
equipment order.
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Operation
Stateless Driller’s Control Console
Front Panel
Figure 4-1 shows the front panel for a typical stateless NOV Driller’s Control Console. Figure 4-2
shows the internal components with the front panel opened.
Refer to later sections of this chapter for
console button, switch, and gauge descriptions.
Front Panel (Door Closed)
For Reference Only. The illustrations in this supplement
show a typical control console panel layout. Depending
on the top drive system options, the layout of the console
controls may vary. Refer to the engineering drawings in the
Technical Drawing Package (TDP) for the rig-specific console
layout for the equipment order.
Figure 4-1. NOV Stateless Driller’s Control Console (Front Panel Closed)
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4
Operation
Stateless Driller’s Control Console
Internal Components
Figure 4-2 shows the internal components with the front panel opened.
Low Voltage
Wiring Only
I. S. Wiring Only
1.5 x 3
Field Cabling
1.5 x 3
I. S.
1.5 x 3
1.5 x 3
N. I. S.
N. I. S.
I. S.
2x3
AC Voltage
Front Panel (Door Opened)
Segregated
I.S. Wiring
For Reference Only. Refer to the engineering drawings
in the Technical Drawing Package (TDP) for the rig-specific
console wiring diagrams and other details.
Figure 4-2. NOV Stateless Driller’s Control Console (Front Panel Opened)
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Operation
Stateless Driller’s Control Console
Specifications
Enclosure
ATEX, Zone 2
Weight
120 lb (54 kg)
Power Input Range
(non I.S. terminals)
• 0-24 V DC, 0-9.5 A
• 120 V AC, 1.1 A
Power Input Range
(I.S. terminals)
28 V DC, 4-20 mA, 0.65 W
Operating Temperature Range
- 40°C to 45°C (-40°F to 113°F)
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Operation
4
Stateless Driller’s Control Console
Alarms
Alarms
Figure 4-3. Alarms

Alarm Silence / Lamp Check

When any alarm indicator light flashes and the horn sounds, press this button to
silence the alarm. The indicator will remain lit until the fault is cleared. If the fault
is not cleared in five minutes, the alarm horn sounds and the indicator flashes.

When the button is pressed and held for two seconds, the console indicators are
tested. When the button is pressed and held for four seconds, the TORQUE and
RPM meters go to full scale for a meter test.

Hyd Press Loss – Indicator flashes and horn sounds when hydraulic system
pressure loss is detected.

Oil Press Loss – Indicator flashes and horn sounds when oil pressure loss is
detected.

Drill Motor Overtemp – Indicator flashes and horn sounds when high temperature
is detected for the drilling motor.

Cooling Water Flow – Indicator flashes and horn sounds when a loss of pressure
in the cooling system flow is detected.

VFD Fault – Indicator flashes and horn sounds when a fault in the VFD is detected.

General – Indicator flashes when any of the alarms activate. For example, this
indicator flashes and the horn sounds when IBOP Close pressure loss is detected.
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Operation
Stateless Driller’s Control Console
Controls
Top Drive
TDS
TDS Mode
TDS Direction
Figure 4-4. Top Drive Controls

TDS – There is a green button and a three-position momentary switch in this
console area.

Enable – Pushing this illuminated button enables top drive operation from the
Driller’s Control Console. When the green indicator is illuminated, the operator
has control of the top drive from the console, the lubrication pump and cooling
system are turned on, and the hydraulic supply is ready for top drive operation.

Torque Set – This three-position momentary switch allows the operator to set
maximum drill and makeup torque setpoints. Turning the switch to DRILL and
then turning the DRILL encoder knob sets the maximum drill torque for DRILL
mode. Turning the switch to MAKEUP and then turning the MAKEUP encoder
knob sets the maximum makeup torque for TORQE mode, in the FORWARD
direction. This switch automatically returns to the center position (off) when
released.
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Operation
4
Stateless Driller’s Control Console
Controls
Top Drive


TDS Mode – There are three illuminated buttons in this console area.

Drill mode – When pushed, the green indicator illuminates to show that the top
drive is in DRILL mode. This mode is used for normal drilling operations. When
in this mode, the driller uses the DRILL and TDS RPM incremental encoder
knobs to set drilling operation limits.

Spin mode – When pushed, the green indicator illuminates to show that the top
drive is in SPIN mode. This mode is used for shouldering up pipe while making
up connections. When in this mode, the RPM and torque settings are fixed at
standard SPIN mode rotational speed and torque values.

Torque mode – When pushed and held, the green indicator illuminates to show
that the top drive is in TORQUE mode. This mode is used for making up and
breaking out connections. When this mode is selected in the FORWARD
direction, RPM is fixed and torque gradually ramps up to the makeup torque
setpoint. When this mode is selected in the REVERSE direction, RPM is fixed
and torque gradually ramps up to the maximum torque of the top drive, or until
the connection is broken, whichever happens first.
TDS Direction – There are three buttons in this console area.

Forward – When pushed, the rotational direction of the top drive is set to
forward (clockwise), the lubrication pump starts, and rotation ramps up to the
RPM setpoint. The green indicator illuminates when the top drive is assigned to
rotate clockwise (forward).

Off – When pushed, the top drive is de-assigned and rotation will stop.

Reverse – When pushed, the rotational direction of the top drive is set to
reverse (counterclockwise), the lubrication pump starts, and rotation ramps up
to the RPM setpoint. The green indicator illuminates when the top drive is
assigned to rotate counter-clockwise (reverse).
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Stateless Driller’s Control Console
Controls
IBOP and Brake
IBOP
Brake
Figure 4-5. IBOP and Brake Controls

IBOP – The IBOP area has a yellow indicator and a switch. The yellow indicator is
illuminated when the IBOP is closed. Turning the switch will open or close the IBOP.

Brake – There are two controls in this console area:

Auto – When pressed, the green indicator on this button illuminates to show
that the motor brakes are in AUTO mode. In this mode, the brakes are
automatically released when a speed command is sent to the VFD (in FWD or
REV mode). The brakes are automatically set when the speed command is
removed (OFF mode).

On / Off – The red indicator on this button lights whenever the motor brakes
have been applied and are engaged (ON). This indicator lights any time the
brake is set, regardless of whether or not the button has been pressed. When
this button is pressed once, the brakes are set and the light comes on. When
pressed again, the light goes out to show the brakes have been released.
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Operation
4
Stateless Driller’s Control Console
Controls
Pipe Handler
Pipe Handler
Figure 4-6. Pipe Handler Controls

Link Tilt Float – When pressed, the elevator links float to the center position. When
the elevator links are in float position, the green indicator illuminates. When the
elevator links are in float position, the pipe handler can be rotated.

Link Tilt Drill / Tilt – This is a three-position momentary switch.

When switched to DRILL, the elevator links tilt to the Drilldown position. This
position allows the top drive to continue operating close to the drill floor.

When switched to TILT, the elevator links extend the elevator to the Derrickman
position. If the switch is released at Derrickman position, then reapplied, the
links will tilt out to Mousehole position.

When the switch is in the center position, the elevator links are held in the
current position.
Any time the switch is released, tilt motion stops immediately.
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Stateless Driller’s Control Console
Controls
Pipe Handler

TW Clamp Push and Hold – When this button is pressed and held:

the pipe handler rotates counter-clockwise into position

the pipe handler locking mechanism locks the pipe handler in place

the torque wrench clamp engages
Once engaged, the clamp is used to make up and break out connections.

The clamp is used to make up connections when the top drive is in TORQUE
mode and when the FORWARD direction is selected. The torque will gradually
ramp up to the MAKEUP torque limit setpoint.

The clamp is used to break out connections when the top drive is in TORQUE
mode and when the REVERSE direction is selected. The torque will gradually
ramp up to 125% of the preset make-up torque limit. If break-out torque is
insufficient to break out the connection, exit TORQUE mode and increase the
MAKEUP torque limit setpoint.
The clamp disengages when the TW Clamp Push and Hold button is released.
The pipe handler clamp will not engage if the top drive
motor brakes are applied.
The pipe handler clamp will not engage if the elevator links
are not in float position
Refer to the section titled "Torque Wrench Auto Mode" on page 4-11 for information
about the Torque Wrench Auto Mode button.

PH Rotate CCW / CW – Turning this three-position momentary switch to the right
rotates the pipe handler clockwise. Turning the switch to the left rotates the pipe
handler counterclockwise. When released, the spring-centered switch returns to the
off position (center) and the pipe handler stops.
The pipe handler will not rotate if the elevator links are
tilted to any off-center position.
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Operation
4
Stateless Driller’s Control Console
Controls
Pipe Handler
Torque Wrench Auto Mode
When this button is pressed, the light turns green and the torque wrench will operate automatically.
When the torque wrench is in Auto Mode, the operator can move directly from Drill mode to
Torque mode and initiate automatic make-up or break-out operations, depending on the direction
of rotation.
Auto Mode Sequence: FORWARD Rotation
1. Operator switches from Drill mode to Torque mode.
2. Rotating Link Adapter jogs and the shot pin locks rotation.
3. The torque wrench clamp closes.
4. The top drive spins in the connection. The VFD provides feedback that the
connection is shouldered.
5. The top drive ramps up torque to the make-up torque setpoint.
If the pipe slips or the operator releases the Torque mode
button before the sequence reaches the make-up torque
setpoint, the sequence is aborted, the top drive is turned
off, and the brake is set.
6. The operator releases the Torque mode button.
7. Torque ramps down and the clamp releases.
Auto Mode Sequence: REVERSE Rotation
1. Operator switches from Drill mode to Torque mode.
2. Rotating Link Adapter jogs and the shot pin locks rotation.
3. The torque wrench clamp closes.
4. The top drive gradually ramps up torque to the maximum torque of the top drive, or
until the VFD provides feedback indicating the connection is broken.
When the connection breaks, the torque drops back to the spin torque setpoint.
5. The top drive spins out the connection.
6. The operator releases the Torque mode button.
7. Rotation stops and the clamp releases.
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Operation
Stateless Driller’s Control Console
Controls
E-Stop, BX Elevator, Counterbalance, and Dolly
E-Stop
Counterbalance
Dolly
BX Elevator
Figure 4-7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls

Emergency Stop – The Emergency Stop button is hard-wired to the Variable
Frequency Drive (VFD).
When pressed, the:

VFD slows down the shaft speed and then shuts off

power to the top drive shuts off

hydraulic supply shuts off

motor brakes are applied
To reset the system, reset the VFD and physically pull this switch back to its original
position.
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Operation
4
Stateless Driller’s Control Console
Controls
E-Stop, BX Elevator, Counterbalance, and Dolly


BX – There are two controls in this console area:

BX Elevator – This is a three-position switch. (The center position is neutral.)
Open opens the elevator and releases the pipe. Armed arms the elevator. This
readies the hydraulic cylinders in the elevator. In Armed mode, the elevator will
automatically close and hold a pipe that enters the elevator. The yellow indicator
illuminates when the elevator has closed on a pipe.

BX Rotate – This is a three-position switch. (The center position is neutral.)
Down tilts the elevator down. Up tilts the elevator up. This allows the elevator to
be better positioned for pipe handling from multiple locations.
Counterbalance – The counterbalance area has a green button indicator. When
pressed once, the light illuminates to indicate the counterbalance system is in Stand
Jump mode, retracting the counterbalance cylinders. When pressed again, the light
goes out to indicate that the counterbalance system has returned to DRILL mode.
Stand Jump mode is typically used immediately before breaking out a connection.
When the button is pressed, the top drive is lifted slightly off the connection by
elevated pressure to the cylinders. Normally, the counterbalance pressure is set to
about 1100 psi. During Stand Jump, 300 psi is added.

Dolly – The dolly area has a three-position momentary switch. The switch is used to
extend the dolly or retract the dolly to the guide beam.
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Operation
Stateless Driller’s Control Console
Meters and Limit Adjustment Knobs
Torque Meter
RPM Meter
Limit Knobs
Figure 4-8. Meters and Limit Adjustment Knobs

TORQUE meter – Shows the drill pipe torque in ft-lb (x 1000) increments from 0 to
80,000 ft-lb. In DRILL mode, the torque limit is set by the DRILL torque encoder
knob below the meter. In TORQUE mode and in the FORWARD direction, the
torque limit is set by the MAKEUP torque encoder knob below the meter.

RPM meter – Shows the rotational speed of the top drive from 0 to 250 RPM.
Rotational speed is controlled using the TDS RPM knob below the meter.

Drill knob – Sets the maximum allowable drill pipe torque when in DRILL mode. The
drilling torque limit is adjusted by turning the knob and observing the ft-lb of torque
displayed in the TORQUE meter.

Makeup knob – Sets the maximum allowable makeup torque in TORQUE mode, in
the FORWARD direction. The makeup torque limit is adjusted by turning the knob
and observing the ft-lb of torque displayed in the TORQUE meter.

TDS RPM knob – This is the top drive throttle. It controls the speed of the drilling
motor when in DRILL mode. The drilling speed is adjusted by turning the knob and
observing the RPM displayed in the RPM meter.
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Operation
4
Amphion™ Touchscreen Controls
The equipment and rig configuration may include one or more Amphion™ Control System
Touchscreen units in place of, or in addition to, the NOV Driller’s Control Console. This control
system interface allows the driller to control top drive operations using a touchscreen display.
Refer to the Amphion Operator’s Guide included with the
complete NOV rig equipment documentation package for
detailed Amphion control system information.
Figure 4-9 shows an example of an Amphion touchscreen display. This is a typical display and may
not represent your configuration.
Figure 4-9. Default Top Drive Amphion Touchscreen
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Operation
Basic Usage
Drilling Ahead with Singles
Step 1
Step 2
Step 3
Step 4
Step 5
Set slips on string
Tilt links to
mousehole
Pickup single
with elevator
Lower block to
stab motor into
top of single
Pull slips
Latch drill pipe
elevator around
single
Release link tilt
Spin in motor
and single
Start circulation
Stop circulation
Close IBOP
Breakout connection
using pipehandler
and drilling motor
(in reverse)
Stab bottom of
single onto string
Open IBOP
Begin drilling
Makeup both
connections
with motor in
torque mode
Makeup
Open
IBOP
Link Tilt
Close IBOP
Stab
Makeup
Figure 4-10. Drilling Ahead With Singles
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4
Operation
Basic Usage
Drilling Ahead with Triples
Step 1
Step 2
Step 3
Step 4
Step 5
Set slips on string
Raise block
Pickup stand
with elevator
Pull slips
Stop circulation
Tilt link tilt to
derrickman
Lower block to
stab motor into
top of stand
Spin in motor
and stand
Begin drilling
Breakout connection
using pipehandler
and drilling motor
(in reverse)
Stab bottom of
stand onto string
Start circulation
Makeup both
connections
with motor
Makeup
Link Tilt
Start
Circulation
Stop
Circulation
Stab
Makeup
Figure 4-11. Drilling Ahead With Triples
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Operation
Basic Usage
Back Reaming
Step 1
Step 2
Step 3
Step 4
Step 5
Hoist while
circulating and
rotating
Set slips on string
Hoist free stand
with elevator
Setback stand
using link tilt
Lower block, stab
motor into string
When 3rd
connection
surfaces, stop
rotation and
circulation
Break out
connection using
pipehandler and
drilling motor
(reverse)
Spin in motor
and make up
connection with
motor
Break out and
spin out stand
at floor
Start circulation,
pull slips, hoist
and rotate
Breakout
Hoist
Setback
Hoist and
Rotate
Breakout
Figure 4-12. Back Reaming
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Revision D
Page 4-19 of 30
Operation
4
Making and Breaking Tool Joint Connections
Tool joint locks become a pinching hazard once they
are loosened. Make sure to support them as they are
loosened. The tool joint locks can fall and injure rig
personnel.
Breaking out the Saver Sub
During normal operation, the torque backup clamp cylinder is sitting on the springs, which are
supported by the spring plate of the torque arrestor. Refer to Figure 4-13 for the following steps.
1. Loosen the tool joint lock between the saver sub and the lower IBOP valve by
unscrewing all the bolts. Refer to the tool joint lock assembly and disassembly
procedures in the Maintenance chapter. Slide the tool joint lock down until it rests on
the clamp cylinder body.
2. Raise the clamp cylinder until the clamp cylinder positioning slot lines up with the
first hole on the torque arrestor. Insert the safety pin through the clamp cylinder and
torque arrestor.
3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by
pressing and holding the TW CLAMP PUSH AND HOLD button.
4. Switch the drilling motor to REVERSE to break out the connection.
5. Once the connection is broken out, switch to SPIN and allow the motor to spin until
the saver sub and lower IBOP valve separate. Remove the safety pin. Lower the
clamp cylinder with the saver sub. The saver sub is ready for removal.
6. Unclamp the saver sub by releasing the TW CLAMP PUSH AND HOLD button.
Stand clear. The saver sub must be supported before
unclamping it. It will fall through the bottom of the
stabbing guide if not supported.
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4
SM00856
Revision D
Page 4-20 of 30
Operation
Making and Breaking Tool Joint Connections
Breaking Out the Saver Sub
CB1
CB2
V1
CB1
CB2
V2
V1
V2
Upper IBOP
Valve
Clamp
Body
Positioning
Holes
Lower IBOP
Valve
1
Tool Joint Lock
Loosen Screws
Torque
Arrestor
Clamp
Cylinder
Safety
Pin
2
Tool Joint Lock
Rest on Clamp
Cylinder
Positioning
Slot
Saver Sub
3
Clamp Cylinder
4
Select TORQUE mode.
5
TW CLAMP PUSH AND HOLD.
6
Drilling Motor REVERSE.
7
Drilling Motor SPIN.
Raise to Next Hole
In Torque Arrestor
8
Support Saver Sub and release
from Torque Back-up Clamp Cylinder.
Figure 4-13. Breaking Out the Saver Sub
4-20
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SM00856
Revision D
Page 4-21 of 30
Operation
4
Making and Breaking Tool Joint Connections
Making up the Saver Sub
1. Manually screw in the replacement saver sub into the lower IBOP valve.
To manually screw in the replacement saver sub into the lower IBOP valve:
a. Raise the clamp cylinder until the lower IBOP valve is exposed below the
stabbing guide (a pup joint may be used).
b.
Lower the clamp cylinder until the hole and the correct clamp position lines up.
c.
Insert the clamp positioning safety pin.
2. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by
pressing and holding the TW CLAMP PUSH AND HOLD button.
3. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling
motor until the saver sub shoulders against the lower IBOP valve. Select TORQUE
mode and apply the correct torque.
4. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp
cylinder all the way to its lowest position.
5. Position the tool joint lock correctly and follow the proper assembly procedure
described in the Tool Joint Locks section.
Breaking out the Lower IBOP
Remove the saver sub first, as described in the previous section. Refer to Figure 4-14 for the
following steps.
1. Loosen the tool joint lock between the lower IBOP valve and the upper IBOP valve
by unscrewing the bolts. Slide the tool joint lock down until it rests on the tool joint
lock sitting on the clamp cylinder body.
2. Raise the clamp cylinder (along with the two tool joint locks) until the clamp cylinder
positioning slot lines up with the second hole on the torque arrestor. Insert the pin.
3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the lower IBOP
by pressing and holding the TW CLAMP PUSH AND HOLD button.
4. Switch the drilling motor to REVERSE to break out the connection.
5. Once the connection is broken out, switch to SPIN and allow the motor to spin until
the lower IBOP valve and upper IBOP valve separate.
6. Remove the safety pin. Lower the clamp cylinder with the lower IBOP. The lower
IBOP is ready for removal.
7. Unclamp the IBOP valve by releasing the TW CLAMP PUSH AND HOLD button.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
4-21
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4
SM00856
Revision D
Page 4-22 of 30
Operation
Making and Breaking Tool Joint Connections
Breaking out the Lower IBOP
CB1
CB2
V1
CB1
CB2
V2
V1
V2
Torque
Arrestor
Upper IBOP
Valve
Lower IBOP
Valve
7
Clamp
Cylinder
Safety
Pin
Loosen Screws
8
1
Rest on
Clamp Cylinder
Tool Joint Lock
Loosen Screws
9
Raise
Clamp
Cylinder
to Next Hole
2
Tool Joint Lock
Rest on Clamp
Cylinder
Clamp
Cylinder
3
Raise to Next Hole
In Torque Arrestor
4
Select TORQUE mode.
10 Select TORQUE mode.
5
TW CLAMP PUSH AND HOLD.
11 TW CLAMP PUSH AND HOLD.
6
Drilling Motor REVERSE.
12 Drilling Motor REVERSE.
13 Drilling Motor SPIN.
14 Support IBOP Valve and Release From
Torque Back-up Clamp Cylinder
Figure 4-14. Breaking out the Lower IBOP
4-22
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SM00856
Revision D
Page 4-23 of 30
Operation
4
Making and Breaking Tool Joint Connections
Making up the Lower IBOP
1. Screw in the replacement saver sub and the lower IBOP valve together manually
and stand them under the clamp cylinder (a pup joint may be used to support it).
Position the clamp cylinder by stabbing over the lower IBOP valve. Make sure the
lower IBOP valve comes up through both tool joint locks sitting on the clamp cylinder
body.
2. Tighten four alternate screws on the top tool joint lock to secure it to the lower IBOP
valve to provide a temporary shoulder to support the weight of the lower IBOP valve
and the saver sub.
Make sure all four screws are tightened sufficiently so
that the tool joint will not slide through when the clamp
cylinder is raised.
3. Select SPIN and FORWARD modes.
4. Raise the clamp cylinder with the lower IBOP valve and saver sub while rotating the
upper IBOP to engage the threads. Once the upper IBOP valve and the lower IBOP
valve start to spin together, stop the drilling motor.
5. Lower the clamp cylinder and line up the first slot and hole on the clamp cylinder
and the torque arrestor. The clamp cylinder jaws line up with the saver sub.
6. Select TORQUE mode. Pressurize the torque backup clamp cylinder to clamp on
the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button.
7. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling
motor. Select TORQUE mode, apply desired torque and make up both connections.
8. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp
cylinder all the way down.
9. Loosen the temporarily made-up tool joint lock. Position both tool joint locks
correctly and assemble. (See the Tool Joint Locks section.)
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4
Operation
SM00856
Revision D
Page 4-24 of 30
Making and Breaking Tool Joint Connections
Breaking out the Upper IBOP
Refer to Figure 4-15 for the following steps.
1. Remove the saver sub and the lower IBOP first, as described previously.
The saver sub and lower IBOP can be removed as one unit
by breaking out the connection between the upper and
lower IBOPs.
2. Lower the clamp cylinder with the broken out lower IBOP valve and the saver sub.
3. Unclamp the lower IBOP valve/saver sub assembly by releasing the TW CLAMP
PUSH AND HOLD button.
4. Remove the two tool joint locks sitting on the clamp cylinder.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
5. Remove the IBOP actuator yoke by unpinning it.
6. Remove the two upper IBOP cranks by unscrewing the two sets of screws.
7. Loosen the top tool joint lock and let it sit on the actuator shell.
8. Raise the clamp cylinder with the actuator shell and the tool joint lock until the third
slot and hole line up. Insert the safety pin.
9. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the upper IBOP
valve by pressing and holding the TW CLAMP PUSH AND HOLD button.
10. Switch the drilling motor to REVERSE to break the connection.
11. Once the connection is broken out, switch to SPIN and allow the motor to spin until
the upper IBOP valve and drive stem separate.
12. Remove the safety pin. Lower the clamp cylinder with the upper IBOP. The upper
IBOP is ready for removal from the clamp cylinder.
13. Unclamp the upper IBOP valve by releasing the TW CLAMP PUSH AND HOLD
button.
14. Remove the tool joint lock and actuator shell.
4-24
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SM00856
Revision D
Page 4-25 of 30
4
Operation
Making and Breaking Tool Joint Connections
Breaking out the Upper IBOP
CB1
CB2
V1
CB1
CB2
V2
V1
V2
10
9
Upper IBOP
Valve
Tool Joint
Lock
Loosen
Screws
Clamp
Cylinder
Safety
Pin
Remove
Actuator
Yoke
1
Tool Joint
Lock
Loosen
Screws
2
Tool Joint
Lock
Rest on
Clamp
Cylinder
11
Clamp
Cylinder
8
3
Raise to Next Hole
In Torque Arrestor
Raise to Next Hole
In Torque Arrestor
Support Saver Sub/
Lower IBOP Valve
and release from
Clamp Cylinder.
Remove Lower
Tool Joint Locks.
4
Select TORQUE mode.
11 Select TORQUE mode.
5
TW CLAMP PUSH AND HOLD.
12 TW CLAMP PUSH AND HOLD.
6
Drilling Motor REVERSE.
13 Drilling Motor REVERSE.
7
Drilling Motor SPIN.
14 Drilling Motor SPIN.
Figure 4-15. Breaking out the Upper IBOP
4-25
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4
Operation
SM00856
Revision D
Page 4-26 of 30
Making and Breaking Tool Joint Connections
Making up the Upper IBOP
1. Place the upper IBOP valve on the floor under the clamp cylinder so that the clamp
cylinder can be stabbed over it (a pup joint may be used to support it). Lower the
clamp cylinder so that the upper IBOP comes up through the clamp cylinder.
2. Place the actuator shell and tool joint lock over the upper IBOP and tighten four
alternate locking screws to secure it to the upper IBOP, providing a temporary
shoulder to support its weight.
3. Install the actuator shell and cranks. (Refer to the engineering drawing the Technical
Drawing Package for details about actuator and crank installation.)
4. Raise the clamp cylinder with the upper IBOP valve while rotating the drive stem
clockwise to engage the threads. Once the drive stem and upper IBOP valve start to
spin together, stop the motor, switch to FORWARD and SPIN and press and hold
the TW CLAMP PUSH AND HOLD button to spin in.
5. Spin the lower IBOP and saver sub into position (refer to the appropriate procedures
in the previous sections). Make sure that the two tool joint locks are properly
installed on the clamp cylinder and in the correct sequence.
6. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp
cylinder until it lines up with the first hole, which is lined up with the saver sub.
7. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by
pressing and holding the TW CLAMP PUSH AND HOLD button and apply desired
torque to makeup all three connections.
8. Place the three tool joint locks at their respective joints. Install the three tool joint
locks. (See the section titled Tool Joint Locks.)
9. Install the IBOP actuator yoke and secure it.
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Revision D
Page 4-27 of 30
Operation
4
This page is intentionally blank.
4-27
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4
Operation
SM00856
Revision D
Page 4-28 of 30
Well Control
The TDS-11SA can stab into the string at any point in the derrick. While drilling, the remotely
controlled upper IBOP valve is available for immediate use as needed. On indication of a kick, use
the following well control procedure in conjunction with standard well control procedures.
Refer to section titled "Making and Breaking Tool Joint Connections" on page 4-19 for information
about breaking out and making up connections.
Procedure
1. On indication of a kick, set the slips and stab the top drive into the drill string
connection.
2. Make up the connection.
3. Remotely close the upper IBOP.
4. Lower the string to the drill floor and reset the slips.
5. Manually close the lower IBOP.
6. Loosen the intermediate and bottom tool joint locks. Let them both slide down until
they rest on top of the clamp cylinder body.
7. Raise the clamp cylinder and clamp onto the lower IBOP.
8. Break out the lower IBOP.
9. Remove the two joint locks loosened earlier.
10. Lower the clamp cylinder to Drill position and hoist the top drive clear of the
connection.
11. Install the crossover sub and a well control check valve (provided by others) onto the
lower IBOP. Make up both connections using the floor tongs or iron roughneck.
12. Slide the intermediate joint lock over the crossover sub and check valve and let it
rest on top of the clamp cylinder body.
13. Place the spacer sub onto the check valve, lower the top drive and stab into the
spacer sub.
14. Energize the clamp cylinder and make up the spacer sub to upper IBOP connection.
15. Lift the intermediate joint clamp and secure the connection between the upper IBOP
and spacer sub.
16. Spin out the spacer sub to check valve connection while hoisting the top drive.
17. Proceed with standard well control procedures.
Figure 4-16 shows the component configuration for normal drilling operations and for well control.
4-28
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SM00856
Revision D
Page 4-29 of 30
4
Operation
Well Control
Component Configuration
Normal Drilling
Well Control
main shaft
upper joint lock
main shaft
upper joint lock
NC50 connection
NC50 connection
upper ibop
intermediate joint lock
NC50 connection
upper ibop
intermediate joint lock
spacer sub
drill pipe connection
NC50 connection
lower ibop
bottom joint lock
drill pipe
NC50 connection
saver sub
drill pipe connection
drill pipe
drill pipe
drill pipe connection
check valve
(supplied by others)
drill pipe connection
crossover sub
NC50 connection
The intermediate and bottom joint
locks are removed when changing
over to well control operations. The
upper lock is not removed.
lower ibop
NC50 connection
saver sub
drill pipe connection
The bottom joint lock is not used
during well control operations. Reinstall
this lock when the stack is reconfigured
for normal drilling operations.
drill pipe
TDS11156
Figure 4-16. Well Control Component Configuration
4-29
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4
Operation
SM00856
Revision D
Page 4-30 of 30
4-30
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SM00856
Revision D
Maintenance
5
Introduction
The following sections describe periodic inspections and routine maintenance required to keep the
TDS-11SA Top Drive functioning properly.
In general, inspect all hoses and connections weekly.
Inspect pins, bushings, and bearings monthly.
Pre-Maintenance Checklist
Documentation You Will Need

Electrical Interconnects and Hydraulic Schematics

TDS-11SA Technical Drawing Package

TDS-11SA User Manual

Recommended Lubricants and Hydraulic Fluids (D811000719)

Links Service Manual (D6350000870)

Design Specification, Design Torque Standard (DS00008)

Safety Wiring Procedure (ASP00019)
Regulatory Standards You Will Use

ASTM A 275, Standard Practice for Magnetic Particle Examination of Steel Forgings

ASTM E 709, Standard Guide for Magnetic Particle Testing

ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings

API RP 8B, Recommended Practice for Procedures for Inspections, Maintenance,
Repair, and Remanufacture of Hoisting Equipment

API SPEC 8C, Specification for Drilling and Production Hoisting Equipment
(PSL 1 and PSL 2)
Spare Parts You May Need
Refer to the documents that list spare parts in your User Manual and contact your NOV
representative or an NOV Service Center.
Spare Parts and Fluids Disposal
The equipment owner is responsible for conforming to applicable regulatory policies, standards,
and recycling guidelines when removing the equipment, dismantling equipment components,
disposing of fluids, and disposing of consumable spare parts during and after maintenance.
5-1
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Form D811001123-GEN-001/06
5
Maintenance
SM00856
Revision D
Page 5-2 of 98
Safety Precautions
Warnings
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.
Complete all appropriate job safety analysis (JSA),
permits, and crew safety briefings immediately prior to
each maintenance activity or session. If, at any point
during the maintenance session, the planned activities
change for any reason, review the job safety
requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all
appropriate personal safety equipment is in good
condition and used when necessary.
Unless specifically noted in this manual, properly lock
out the main power source before performing
lubrication, inspection, or replacement procedures.
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.
Read and understand all safety precautions and
warnings before performing maintenance procedures.
Do not attempt repairs you do not understand.
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 all accumulators before servicing
the hydraulic system.
5-2
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SM00856
Revision D
Page 5-3 of 98
Maintenance
5
Safety Precautions
Top drive maintenance requires personnel working at
height and there exists the potential for injury or
dropped objects.
Equipment Records
Keep a record book of all maintenance procedures performed. Date each procedure, followed by a
description and the technician who performed it. This data is valuable for fault finding and problem
solving, should technical problems arise.
Procedures in this chapter relate to NOV-only components.
See the appropriate vendor-supplied OEM manuals for
inspection schedules and maintenance procedures for
non-NOV equipment and components.
Torque Values
Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque
standards to follow when tightening component fasteners.
Install bolts with anti-seize compound and tighten based
on the Design Torque Standard (DS00008). This document
is included in the equipment User Manual.
Safety Wire (Lockwire) Procedures
Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the
procedures required for installing safety wire (lockwire) on component fasteners.
Secondary Retention Guidelines
Refer to Design Guideline, Secondary Retention and Prevention of Dropped Objects
(D411000342-SPC-001) in the equipment User Manual for information related to secondary
retention of equipment components. Adhering to the recommendations and guidelines in this
specification will greatly reduce any risk of components falling from installed equipment.
5-3
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5
SM00856
Revision D
Page 5-4 of 98
Maintenance
Equipment Inspection
The following service intervals are based on average
operating conditions. More frequent service intervals are
required if you operate the equipment in conditions where
excessive load, dusty or corrosive operating atmosphere,
or extreme temperatures occur.
Inspecting Rig Interface Components
Inspection Schedule
Daily Inspection
Page Number

Check guide beam lynch pins and retainer pins
page 5-6

Make sure the top drive is aligned over well center
page 5-7

Check all detent pins in the carriage
page 5-9
Weekly Inspection
Page Number

Check crown padeye and hang-off link welds and fasteners
page 5-5

Check guide beam joint pin bushing
page 5-6

Check main and intermediate tieback welds and fasteners
page 5-7, page 5-8

Check all carriage rollers
page 5-9
Monthly Inspection
Page Number

Check crown padeye, cotter pin, shackle, and hang-off bores
page 5-5

Check guide beam joint pin
page 5-6
Yearly Inspection
Page Number

Check crown padeye
page 5-5

Check guide beam joints
page 5-6

Check main tieback link
page 5-7

Check all carriage bogeys
page 5-9
5-4
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SM00856
Revision D
Page 5-5 of 98
5
Maintenance
Equipment Inspection
Inspecting the Guide Beam and Carriage
Crown Padeye and Hang-Off Link
Crown
Cotter Pin
Replace if missing
2.1"
(52 mm)
minimum
Yearly
Monthly
Crown Padeye
Monthly
Crown Padeye
Visually inspect
weld for cracks
Shackle
2.0"
(50 mm)
minimum
Monthly
Shackle
Inspect and
replace if worn
Monthly
Hang-off Link Bores
Inspect and
repair if worn
1.5"
(37 mm)
minimum
Hang-off Link Bores
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Figure 5-1. Inspecting the Crown Padeye and Hang-Off Link
5-5
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5
SM00856
Revision D
Page 5-6 of 98
Maintenance
Equipment Inspection
Inspecting the Guide Beam and Carriage
Guide Beam Joints
!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Inspect joint pins and
bushings for wear. Replace any worn
or damaged components.
Component Replace when
Secure
Bushings
Inside diameter is more
than 2.050 in (52.07 mm).
Joint Pins
Outside diameter is less
than 1.963 in (49.86 mm).
Daily
Lynch Pin
Weekly
Bushing
Inspect for
wear replace
as needed
Yearly
Typical Guide
Beam Joint
Monthly
Joint Pin
Inspect for
wear replace
as needed
Daily
Retainer Pin
Monthly
Inspect welds
for cracks
Figure 5-2. Inspecting the Guide Beam Joints
5-6
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SM00856
Revision D
Page 5-7 of 98
Maintenance
5
Equipment Inspection
Inspecting the Guide Beam and Carriage
Main Tieback
Guide Beam
Bottom Section
Daily
Check that the tool is aligned
directly over well center
Main
Spreader Beam
Tieback Plate
Yearly
Tieback Link
Inspect retainer pins,
tieback hooks, and
pivot pins for wear.
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Auxiliary Spreader Beam
Mast Leg
Figure 5-3. Inspecting the Main Tieback
5-7
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5
SM00856
Revision D
Page 5-8 of 98
Maintenance
Equipment Inspection
Inspecting the Guide Beam and Carriage
Intermediate Tieback
Intermediate
Tieback
(Shown in Locked
Position)
Locking
Bolt
Pivot
Point
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Figure 5-4. Inspecting the Intermediate Tieback
5-8
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SM00856
Revision D
Page 5-9 of 98
5
Maintenance
Equipment Inspection
Inspecting the Guide Beam and Carriage
Carriage
Weekly
Typical
all rollers
Inspect for uneven
wear, damage and
looseness, replace
as required
Yearly
Bogey (16)
Disassemble,
inspect for wear,
and relubricate
Daily
Typical all
detent pins
Verify that pins
are in place
and secure
Figure 5-5. Inspecting the Carriage
5-9
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5
SM00856
Revision D
Page 5-10 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Illustrated Index
Bail
Page 5-19
S-Pipe
Page 5-20
AC Motor
Brakes (2)
Page 5-28
AC Drilling
Motors (2)
Page 5-29
Washpipe
Assembly
Page 5-22
Gearbox
Lubrication
Pump Assembly
Page 5-16
Gearbox
Assembly
Page 5-13
Gear Oil Filter
Page 5-66
For AC motor and
transmission lubrication
see Page 5-66, 5-67
Figure 5-6. Motor Housing and Transmission Illustrated Index
5-10
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SM00856
Revision D
Page 5-11 of 98
Maintenance
5
Equipment Inspection
Inspecting the Motor Housing and Transmission
Inspection Schedule
Daily Inspection
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
page 5-22

Check fluid levels and filter condition
page 5-65
Weekly Inspection
Page Number

Check the AC motor louvers for damage
page 5-29

Check the AC motor screens for contamination
page 5-29
Monthly Inspection

Check the flow of oil throughout the main body while the lube
pump is running

Check the blower motor assemblies for loose bolts

Check brake pads for wear
6 Month Inspection
Page Number
page 5-13
page 5-28
Page Number

Check the gear teeth for pitting and corrosive wear
page 5-18

Check for primary and secondary gear set backlash
page 5-18

Check the S-pipe for pitting, corrosion, or erosion
page 5-20

Check the upper main shaft liner for erosion caused by
leaking wash pip packing
page 5-21
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5
SM00856
Revision D
Page 5-12 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Inspection Schedule
Yearly Inspection
Page Number

Check the gearbox lubrication pump assembly for wear or
damage
page 5-17

Check bail, bushings and bail pins for wear
page 5-19

Check the upper bearing retainer o-ring, bearing isolator, and
oil seal for wear
page 5-25

Check the radial grooves on the main shaft and the load
collar for wear
page 5-26

Perform a Magnetic Particle Inspection (MPI) on the main
shaft, landing collar, and split load collar
page 5-26

Check the main shaft for axial movement
page 5-27

Meggar motors
5 Year Inspection

Perform a Magnetic Particle Inspection (MPI)
Page Number
page 5-56
5-12
www.nov.com
SM00856
Revision D
Page 5-13 of 98
5
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Internal Lubrication Flow
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
Monthly
Spillway
Check flow
Pipe Plug
Remove using a
2 inch, 12 point socket
Main Body
Figure 5-7. Inspecting Internal Lubrication Flow
5-13
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5
SM00856
Revision D
Page 5-14 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Belt-Driven Encoder Adjustment
Certain top drive models are equipped with non belt-driven
encoders. Refer to the detailed engineering drawings in the
Technical Drawing Package for information about non beltdriven encoders.
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. Allow the sled to move freely, allowing the belt tension spring to apply the proper
tension to the belt.
!
Do not tighten 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.
5-14
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SM00856
Revision D
Page 5-15 of 98
5
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Belt-Driven Encoder Adjustment
Belt Tension
Spring
Sled
Hold-down
Screws
4 Places
View from Side
Encoder Belt
Sled
View from Top
(Blower Motor
removed for clarity)
Sled
Electrical
Connector
Encoder Belt
Encoder
Belt Tension
Spring
Sled Hold-down
Screws
(Allow the sled to move
freely before tightening)
4 Places
Figure 5-8. Adjusting the Belt-Driven Encoder
5-15
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5
SM00856
Revision D
Page 5-16 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Gearbox Lube Pump 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 User Manual).
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 side plates.
5. Assemble the lubrication pump assembly in the reverse order of disassembly.
!
Follow the pump vendor service instruction HS15 (located
in the User Manual) when assembling the lubrication pump
components, and torque all fasteners in accordance with
DS00008.
!
When reinstalling the pump assembly into the main body,
inspect the O-ring for damage. 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.
5-16
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SM00856
Revision D
Page 5-17 of 98
Maintenance
5
Equipment Inspection
Inspecting the Motor Housing and Transmission
Gearbox Lube Pump Assembly
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
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
Figure 5-9. Inspecting the Gearbox Lube Pump Assembly
5-17
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5
SM00856
Revision D
Page 5-18 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Gear Backlash
A
6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash
B
A
Solid Wire Solder
B
Dim. A + Dim. B = Backlash
Procedure
Inspect the pump adapter plate at the same
time the gear backlash is checked
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 may be indicated
Check the gear teeth for pitting or corrosive
wear at the same time the gear set backlash
is checked
Record backlash data for future reference
Figure 5-10. Inspecting Gear Backlash
5-18
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SM00856
Revision D
Page 5-19 of 98
Maintenance
5
Equipment Inspection
Inspecting the Motor Housing and Transmission
Bail and Main Body
Component
Replace when
Bushing
Inner diameter is more 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
Main Body
5 Years
Bail Pin
2 Places
Yearly
Figure 5-11. Inspecting the Bail and Main Body
5-19
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5
SM00856
Revision D
Page 5-20 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
S-Pipe
Procedure
Wing Nut
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
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.
6 Months
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
6 Months
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.
Wing Nut
Figure 5-12. Inspecting the S-Pipe
5-20
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SM00856
Revision D
Page 5-21 of 98
5
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Upper Main Shaft Liner
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. The
upper surface of the mainshaft liner must be
flat and smooth
The 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
6 Months
Upper
Mainshaft Liner
Replace ONLY if
erosion is found
during inspection
Polypack
Seal
Polypack Seal
Replace the Polypack
Seal when the upper
mainshaft liner is replaced
Main Shaft
Remove any
corrosion found on
bore of mainshaft
Upper
Mainshaft Liner
Figure 5-13. Inspecting the Upper Main Shaft Liner
5-21
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5
Maintenance
SM00856
Revision D
Page 5-22 of 98
Equipment Inspection
Inspecting the Motor Housing and Transmission
Standard Washpipe
If the optional NOV mechanical washpipe is installed in the
unit, refer to the NOV Mechanical Washpipe Service
Manual (D811000200-PRO-001) for detailed maintenance
information. This manual is provided in the equipment User
Manual.
Assembly and Disassembly
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 molybased 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.
Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the
Standard Washpipe Manual, SM01053, for additional information.
Figure 5-14 shows disassembly and Figure 5-15 shows components that need to be inspected
after disassembly.
5-22
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SM00856
Revision D
Page 5-23 of 98
5
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Standard Washpipe
!
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
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
Recommended for proper
tightening of the wash pipe
nut and packing box
Figure 5-14. Inspecting the Washpipe (1 of 2)
5-23
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5
SM00856
Revision D
Page 5-24 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Standard Washpipe
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
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
Figure 5-15. Inspecting the Washpipe (2 of 2)
5-24
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SM00856
Revision D
Page 5-25 of 98
Maintenance
5
Equipment Inspection
Inspecting the Motor Housing and Transmission
Upper Bonnet Seals
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
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
Yearly
Oil Seal
Lube Tube
Shims
Hand pack the
void with grease
Figure 5-16. Inspecting the Upper Bonnet Seals
5-25
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5
SM00856
Revision D
Page 5-26 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Main Shaft and Load Collar
Component
Replace when
Stem Grooves
Groove width (female) is greater
than 0.650 in.
Load Collar
Grooves
Groove width (male) is less
than 0.579 in.
Stem
5 Years
Split Load Collar
Yearly
Radial Grooves
Inspect for groove
wear and pitting
0.650
max
Radial Grooves
Inspect for groove
wear and pitting
Yearly
Yearly
0.579
min
Retainer Ring
Figure 5-17. Inspecting the Main Shaft and Load Collar
5-26
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SM00856
Revision D
Page 5-27 of 98
5
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Main Shaft End Play
Dial
Indicator
Bearing Retainer
Cap Screw
6 Places
Mainshaft
Check for
axial movement
Yearly
Shims
Bearing
Retainer
Procedure
Check mainshaft endplay with every washpipe
changeout
Remove the washpipe assembly
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
Figure 5-18. Inspecting Main Shaft End Play
5-27
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5
SM00856
Revision D
Page 5-28 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Motor Brakes
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
If the brake pads are wearing unevenly, adjust
the pads by adjusting the bolts on the brake
calipers to acheive an equal gap as descibed
below
Calipers and Pads
Check pads for wear
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
Monthly
Brake Rotor
Steel
Plate
0.09 in.
Min.
Adjust
Caliper
Mounting
Bracket
Brake
Pads
Equal
Gap
Figure 5-19. Inspecting the Motor Brakes
5-28
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SM00856
Revision D
Page 5-29 of 98
Maintenance
5
Equipment Inspection
Inspecting the Motor Housing and Transmission
Drilling Motors
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
Weekly
Louvers
Check for damage
Weekly
Screen
Check for contamination
Figure 5-20. Inspecting the Drilling Motors
5-29
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5
SM00856
Revision D
Page 5-30 of 98
Maintenance
Equipment Inspection
Inspecting the Motor Housing and Transmission
Transmission
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
Compound Gear
Upper Stem
Liner
Internal
Retaining Ring
Spacer Ring
Lower Compound
Roller Bearing
Poly Pack
Seal
Oil
Gallery
O-Ring
Bearing Lock
Washer
Main Shaft
Stem
Internal
Locknut Retainer
Main Body O-Ring
Tapered Roller
Thrust Bearing
Main Body
Main Shaft
Sleeve
Lower Main
Bearing
Lube Plate
Oil Assembly
Lock Washer
Bearing
Retainer
Main Lower
Roller Bearing
Wear Sleeve
Cap Screw
Figure 5-21. Disassembling/Assembling the Transmission
5-30
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SM00856
Revision D
Page 5-31 of 98
Maintenance
5
This page is intentionally blank.
5-31
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5
SM00856
Revision D
Page 5-32 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Illustrated Index
Rotating Link
Adapter
Page 5-52
Link Tilt
Page 5-38
IBOP Actuator
Yoke and Cylinder
Page 5-46
Stabilizer
Page 5-44
IBOP Stack
Page 5-49
Clamp Cylinder
Body
Page 5-40 to 5-43
Stabbing Guide
Page 5-42
For pipehandler lubrication
see Page 5-64
Drill Pipe Elevator
and Elevator Links
Page 5-36
Figure 5-22. PH-75 PIpe Handler Illustrated Index
5-32
www.nov.com
SM00856
Revision D
Page 5-33 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Before beginning any inspection procedures, make
sure to read and understand the warnings in the
section titled "Safety Precautions" on page 5-2. Failure
to adhere to these warnings could result in severe
injury or death.
Inspection Schedule
Daily Inspection
Page Number

Check for missing lockwire and cotter pins

Check for loose or broken parts and leaks

Check for damaged hoses and fittings

Check tong dies for wear
page 5-42

Check clamp cylinder for leaks
page 5-42

Check hoses for wear or damage
page 5-46

Check tool joint locks for tightness
page 5-48

Check upper and lower IBOP valves for proper operation
page 5-49
Weekly Inspection
Page Number

Check link tilt clamps for position and tightness
page 5-37

Check stabbing guide and flippers for damage and wear
page 5-42

Check clamp cylinder gate hinge pin for wear
page 5-42

Check IBOP actuator cylinder for leaks
page 5-46

Check IBOP actuator cam followers for wear or excessive
play
page 5-46

Check upper and lower IBOPs and IBOP crank for damage (if
equipped)
page 5-49

Check shot pin assembly for leaks
page 5-51
5-33
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5
SM00856
Revision D
Page 5-34 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Inspection Schedule
Monthly Inspection
Page Number

Check elevator link eyes for wear
page 5-36

Check link tilt bushings for wear
page 5-39

Check link tilt actuator cylinders for leaks
page 5-39

Check link tilt actuator cylinder pins for wear
page 5-39

Check clamp cylinder body wear bushings for wear
page 5-42

Check stabilizer springs for damage
page 5-44

Check front and rear stabilizers for wear
page 5-44

Check pins and bushing on IBOP actuator cylinder and yoke
for wear
page 5-46

Check shot pin assembly for wear
page 5-51
Yearly Inspection
Page Number

Check piston ring for pitting and chipping
page 5-53

Check stem for pitting, grooves and chipping
page 5-53

Replace GLYD rings, o-rings, and bushings on rotating link
adapter
page 5-53
5 Year Inspection

Perform a Magnetic Particle Inspection (MPI)
Page Number
page 5-56
5-34
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SM00856
Revision D
Page 5-35 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Stopping and Starting the Top Drive
Shutting Down the Top Drive
Starting Up the Top Drive
Use the following procedure before
performing any work on the top drive.
Before turning the main power back on,
be sure that all rig personnel are well
clear of the top drive, pipehandler and
all link tilt system components.
Operate the Link Tilt control on the console
to the FLOAT position prior to shutting down
the top drive.
Make sure that the elevator links are hanging
vertically.
Turn the IBOP valve control to the OPEN
position on the console.
Turn the main power OFF at the main power
breaker in the VFD house.
Turn the hydraulic control switch on the top
drive hydraulic manifold from RUN to
SHUTDOWN mode.
Attempt to function test the LINK TILT
(Derrickman and Drilldown), the IBOP, and
pipehandler left and right rotation. If none of
these functions operate, all hydraulic
pressure is off.
Rig-up/Run/
Shutdown Valve
Shown in RIG-UP
position (switch to RUN
after the counterbalance
is installed)
Typical location for
Rig-up/Run/
Shutdown Valve.
This valve may be in
a different location
on your top drive.
RUN
RIG-UP
SHUTDOWN
Turn the hydraulic control switch on the top
drive from SHUTDOWN to RUN mode.
Turn the main power ON at the main power
breaker in the VFD house. Reset brake. You
may then function test the top drive after
repairs have been made.
S
H
N
U
T
U
R
D
O
W
N
COUNTERBALANCE MODE
E
C
N
P
LA
-U
BA
R
IG
TE
R
N
U
O
C
E
D
O
M
Hydraulic
Manifold
Figure 5-23. Stopping and Starting the Top Drive
5-35
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5
Maintenance
SM00856
Revision D
Page 5-36 of 98
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Elevator Links
Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the
measurement with the link wear charts in the Links User Manual (D6350000870). This manual is
included in the equipment User Manual.
Complete the following steps to remove the elevator links for inspection:
1. Disconnect and remove the drill pipe elevator from the elevator links.
2. Using the driller’s control console, rotate the pipe handler 90° to position one of the
elevator links directly below the front of the motor guard. (There is a recess at the
front of the motor guard that allows the elevator link to be hoisted away from the pipe
handler.)
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 pipe handler.
6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator
link.
5-36
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SM00856
Revision D
Page 5-37 of 98
5
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Elevator Links
Recess in
Motor Guard
Catch Link Pin
Elevator Link
2
Lift and
remove
Link Tilt
Link
Catch
Monthly
26"
(635mm)
Typical
Clevis Pin
Elevator
Link Eyes
Inspect for wear
(see table)
Rear
Pipehandler
Rotate Switch
Weekly
EH
Link Tilt Clamps
Inspect for position
and tightness
T AN
SH
PU
PIP
T
IL
K TT
LIN OA
FL
U
HP / ON
TO
AU
QU
E
Front
E
AT CW
OT
R
PH
CC
W
T
ILT TIL
T
INK
L
1
ILL
DR
Rotate
Driller’s
Control
Console
E
RS
VE
I NC
CY
GEN
ER OP
EM ST
EUP
QUE
L
DRIL
I NC
TD
BX OR N
VAT OPE
ELE
I NC
BX
ED
A SE
RE
ARM
CE
LAN
UMP
RBA
NDJ
NTESTA
COUL /
DRIL
L
ERA
GEN
R
LE
D
ND CLAMP
HOL
HA TWH AND
PUS
PIPE
VFD
LT
FAU
TILT
LINK AT
FLO
DRIL RTE
OVE
A SE
RE
TD
MA
KEU
P
E
DECR EAS
DR
ILL
OR
VAT
ELESED
BX CLO
HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE
TD
ATE CW
TOR
DE
WER
BLO S
LOS
PH
S MO
ROT
CCW
SPIN
TILT TILT
/
LINK
NCE
SILECK
RM CHE
ALA P
LAM
L
DRIL
L
DRIL
BR
AK
E
N
IO
O
AUT
TD
IBOP
SED
D
CLO
WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
OPE
Monthly
PM
SR
ECREASE
D
BLE
ENA
MS
AR
AL L MOTMPOR
A SE
RE
E
DE CR EAS
SET MAK
S TOR
E
ERS
REV
CT
RE
S DI OFF
Take care when inspecting
elevator links. Links weigh
up to 2,400 lb (11,00 kg) and
can fall if handled improperly.
Elevator
Link Eyes
Inspect for wear
(see table)
Figure 5-24. Inspecting the Elevator Links
5-37
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5
Maintenance
SM00856
Revision D
Page 5-38 of 98
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Link Tilt
1. Shut down 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.
Use the recommended spanner wrench to remove the rod
gland seal.
5-38
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SM00856
Revision D
Page 5-39 of 98
5
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Link Tilt
Pins
Inspect for wear
replace as needed
Monthly
Bushings should be
pressed in using the
mating pin as an
installation mandrel.
Monthly
Bushings
Inspect for
wear replace
as needed
Monthly
Link Tilt
Actuator
Cylinders
Inspect the
hydraulic
connections
for leaks
Yearly
Pipehandler
Dissassemble and
inspect per illustration
Link Tilt
Monthly
Component
Replace when
Pins
Wear exceeds .06 in. on diameter as measured by
comparing worn surfaces to un-worn surfaces
Bushings
Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear
Bushings
Inspect for wear
replace as needed
Monthly
Moving Components
Observe operation and
look for excessive wear
and replace as needed
Figure 5-25. Inspecting the Link Tilt
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Maintenance
SM00856
Revision D
Page 5-40 of 98
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Torque Wrench Assembly
Disassembling/Assembling the Clamp Cylinder Body
1. Shut down 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 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.
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.
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.
Use recommended spanner wrench to remove the rod
gland seal.
Assembly is performed in reverse order of disassembly.
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SM00856
Revision D
Page 5-41 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Torque Wrench Assembly
Clamp Cylinder
Safety Pin
Store Position
Torque
Arrestor
Clamp Cylinder
Safety Pin
Clamp Cylinder
Hanger
Clamp
Cylinder
Assembly
Spring
Spring
Post
Bottom
Plate
Support clamp
cylinder body
before removing
Bottom Plate.
Figure 5-26. Removing the Clamp Cylinder Body
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SM00856
Revision D
Page 5-42 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Torque Wrench Assembly
Socket-head
Capscrews
Stabilizer
Liner
Jaw
Retainer
Hex-head
Screw
Hinge Pin
Retainer
Hi-collar
Washers
Rod
Seal
Wiper
Rod
Stabilizer
Liner
Rear
Jaw
Screw
Front
Stabilizer
Washer
Hinge
Pin
Front
Jaw
Gate
Nut
Spring
Front
Stabbing
Guide
Retainer
Cylinder
Head
Ring
Front
Stabbing
Guide
Arm Guide
Cylinder
Head
Spring
Piston
Seal Piston
Seal
Piston
Figure 5-27. Disassembling the Clamp Cylinder Body
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SM00856
Revision D
Page 5-43 of 98
5
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Torque Wrench Assembly
CB1
CB2
Component
Replace when
Stabilizer
Wear exceeds 1/8 in. (radius >3.625")
Flippers
Wear exceeds 1/8 in. (radius >3.625")
Gate Hinge Pins
Wear exceeds .06 in.
V1
V2
Front and
Rear Stabilizers
Inspect for wear
Clamp Cylinder
Gate Hinge Pin
Check for pin wear,
replace as necessary
Weekly
6 Months
Tong Dies
Inspect for
excessive wear
Daily
Clamp Cylinder
Check for leaks,
replace seals
as necessary
Daily
Swing Clear
Weekly
Clamp
Cylinder Gate
Shown open
Weekly
Flippers
Inspect for damage
and excessive wear
Stabbing Guide
Inspect for damage
Figure 5-28. Inspecting the Clamp Cylinder Body
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SM00856
Revision D
Page 5-44 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Stabilizer
Procedure
Remove the two screws (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 screws are tight, and tighten or
replace as necessary.
Screw
Washer
Nut
6 Month
Stabilizer Springs
Check for damage,
replace as necessary
Cotter
Pin
Figure 5-29. Inspecting the Stabilizer
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SM00856
Revision D
Page 5-45 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
IBOP Actuator Cylinder and Yoke
Disassembling the IBOP Actuator Cylinder and Yoke
1. Shut down 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.
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SM00856
Revision D
Page 5-46 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
IBOP Actuator Cylinder and Yoke
Daily
Weekly
6 Months
Hoses
Replace if worn
or damaged
Actuator Cylinder
and Yoke
Check for looseness, etc.
Actuator Cylinder
and Yoke
Dissassemble and
inspect per illustration
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
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
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
Bushings should be pressed in using the mating pin
as an installation mandrel
Figure 5-30. Inspecting the IBOP Actuator Cylinder and Yoke
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SM00856
Revision D
Page 5-47 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Tool Joint Locks
Assembling/Disassembling the Tool Joint Locks
!
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.
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.
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SM00856
Revision D
Page 5-48 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
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
1.4"
1.4"
Tool Joint
Shoulder
Tool Joint
Locks
Inspect for loose bolts.
Repair or replace if necessary.
Torque to 1855 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.
Figure 5-31. Inspecting the Tool Joint Locks
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SM00856
Revision D
Page 5-49 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
IBOP Valves and Saver Sub
Close
Component
Replace when
Saver Sub
Threads have been recut to a minimum
shoulder-to-shoulder length of 5 in.
Weekly
Daily
Upper IBOP
(Remote)
Inspect for damage
Valve
Check for
proper operation
and pressure test
for leaks
Weekly
Open
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
5 Years
Upper and Lower IBOP
Figure 5-32. Inspecting the IBOP Valves and Saver Sub
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Maintenance
SM00856
Revision D
Page 5-50 of 98
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Shot Pin Assembly
Disassembling the Shot Pin 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 Figure 5-33 (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.
8. Inspect the disassemble parts and replace any worn or damaged parts.
Assemble the shot pin in the reverse order of disassembly.
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SM00856
Revision D
Page 5-51 of 98
5
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Shot Pin Assembly
Component
Replace when
Shot Pin
Outer diameter is
less than 1.375 in.
Shot Pin Sleeve
Inner diameter is
greater than 1.510 in.
Gear
Shaft
Flanged
Bearing
Hydraulic
Motor
Compound
Gear
Hydraulic
Manifold
Dowel
Pin
Flanged
Bearing
Bearing
Weekly
Drive
Gear
Shot Pin Assembly
Check for leaks,
tighten fittings
Bearing
Shot Pin
Housing
Assembly
Rod Seal
Assembly
Monthly
Shot Pin
Check for wear,
remove burrs
Bearing
Retainer
Rod Seal
Assembly
Monthly
Shot Pin Sleeve
Check for wear
O-ring
Retaining
Ring
Shot Pin
Flange Bushing
Figure 5-33. Inspecting the Shot Pin Assembly
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SM00856
Revision D
Page 5-52 of 98
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Rotating Link Adapter and Load Stem
Removing the Rotating Link Adapter (while the top drive is in the 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 Rotating Link Adapter
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.
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.
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SM00856
Revision D
Page 5-53 of 98
5
Maintenance
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Rotating Link Adapter and Load Stem
Eye Bolts
Rotary GLYD Ring
(10 Places)
Remove, discard and replace
Yearly
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
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
Figure 5-34. Inspecting the Rotating Link Adapter and Load Stem
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Maintenance
SM00856
Revision D
Page 5-54 of 98
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Rotating Link Adapter and Load Stem
Assembling the Rotating 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 assembling the stem to the link adapter.
Make sure the seals do not twist in the grooves.
11. Install the gear onto the link adapter and install the bolts.
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.
Installing the Rotating Link Adapter (while the top drive is in the mast)
1. Check the condition of the main shaft 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 index mark
faces forward.
3. Carefully lower the top drive to engage the main shaft 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.
This procedure continues on the next page.
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SM00856
Revision D
Page 5-55 of 98
Maintenance
5
Equipment Inspection
Inspecting the PH-75 Pipe Handler
Rotating Link Adapter and Load Stem
Installing the Rotating Link Adapter (while the top drive is in the mast), continued
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 the Lubrication section of this chapter).
11. Check and fill the hydraulic oil as necessary.
12. Turn on the top drive and perform all pipe handler 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 main shaft seal and use care not to
damage the seal or the case.
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.
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Maintenance
SM00856
Revision D
Page 5-56 of 98
Equipment Inspection
Nondestructive Examination
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, x-ray examination, and other
methods of nondestructive testing for metallurgical integrity.
Making Visual Inspections
Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare
the measurements with the information provided in the Links User Manual (D635000870) to
determine the current strength of the elevator links. The capacity of the links equals the capacity of
the weakest link.
Magnetic Particle Inspection (MPI)
Every five years, NOV recommends that customers inspect all top drive hoisting equipment using
the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation
listed in the following section before beginning the MPI for any equipment component.
Refer to the following standards that define the use of the wet fluorescent method of MPI when
examining machined surfaces for any equipment component.

ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings

ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection

I.A.D.C., Drilling Manual

API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance,
Repair and Remanufacture of Hoisting Equipment

API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI
inspection acceptance criteria)
Any indications found are a potential cause for replacing one or more of the following:

Main shaft (lower portion)

Bail

Split Load Collar

Upper and lower IBOP

Link adapter

Saver, crossover, and spacer subs

Power subs

Power swivels

Elevator links
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SM00856
Revision D
Page 5-57 of 98
Maintenance
5
Equipment Inspection
Nondestructive Examination
The drilling operator may determine that the MPI schedule should occur more frequently, based on
one or more of the following factors:

environment

load cycles

regulatory requirements

operating time

testing

repairs
Please contact your NOV Service Center if you have any questions.
Ultrasonic Inspection
In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the
previously listed components to detect any erosion of the inside diameter. Any erosion reduces the
load carrying 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
IBOP Inspection
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.
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SM00856
Revision D
Page 5-58 of 98
Maintenance
Recommended Lubricants and Fluids
Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for
recommended lubricants and hydraulic fluids for NOV drilling equipment.
The lubrication intervals described in this manual are based on lubricant supplier
recommendations. Severe conditions such as extreme loads or temperature, corrosive
atmosphere, and so on, may require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more
frequent lubrication is necessary.
Lubrication Schedules
!
Replace the gearbox oil in new units after initial break-in
(the first month of operation). New units can contain metal
contaminants and contaminants caused by initial break-in.
!
Do not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip, creating a slipping hazard.
The following service intervals are based on average
operating conditions. More frequent service intervals are
required if you operate the equipment in conditions where
excessive load, dusty or corrosive operating atmosphere,
or extreme temperatures occur.
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SM00856
Revision D
Page 5-59 of 98
Maintenance
5
Lubrication Schedules
Unless otherwise specified, use general purpose grease to
lubricate top drive components. Refer to Recommended
Lubricants and Fluids (D811000719) in the User Manual.
Daily
Lubrication

Standard washpipe (twice daily) (one place)
Note: If installed, the optional NOV mechanical washpipe does
not require daily lubrication. Refer to the NOV Mechanical
Washpipe Service Manual for maintenance information
(D811000200-PRO-001 in the User Manual).

Page Number
Upper bonnet (main body) seal: If a grease fitting is installed
in the location shown in Figure 5-35, lubricate the upper
bonnet seal daily.
page 5-62
page 5-62
Note: If a pipe plug is installed in this location, do not
lubricate daily (refer to the six-month lubrication schedule).

IBOP actuator yoke and cylinder pins
page 5-63

IBOP actuator cranks
page 5-63

Stabilizer liner
page 5-63

Clamp cylinder gate
page 5-63
Weekly
Lubrication
Page Number

Bail pins (2 places)
page 5-62

Rotating link adapter gear
page 5-62

Rotating link adapter (2 places)
page 5-62

Shot pin assembly
page 5-51

Upper IBOP valve (1 place)
page 5-63

Torque arrestor at clamp cylinder
page 5-41

Elevator link eyes (4 places)
page 5-63
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SM00856
Revision D
Page 5-60 of 98
Maintenance
Lubrication Schedules
Monthly
Lubrication


After the first month of initial break-in: Replace the gearbox
oil. New top drives can contain metal contaminants and other
contaminants caused by initial break-in.
Page Number
page 5-65
Traveling Block Sheaves (3 places)
Refer to the Traveling Block Supplement (10668162-MAN)
for additional block maintenance information. This manual is
included in the equipment User Manual.
Every Three Months
Lubrication
Page Number
Replace the top drive lubrication system filter, the top drive
hydraulic filter, and any hydraulic filters supplying hydraulic
system pressure to the equipment (optional NOV HPU or
other hydraulic system).
page 5-65

Lubricate the AC drilling motors (4 places)
page 5-66

Lubricate the AC blower motors (4 places)
page 5-66

Lubricate the hydraulic pump AC motor (2 places)
page 5-66

Use Chevron Black Pearl® EP2 motor grease (do not substitute) to lubricate AC
motors. NOV recommends that the rig electrician lubricate all AC motors.
Every Six Months
Lubrication

Upper bonnet (main body) oil seal: If a pipe plug is installed
in the location identified in Figure 5-35, lubricate the upper
bonnet seal every six months. Remove the pipe plugs (front
and rear) and install a grease fitting and relief fitting. Replace
plugs after lubricating the seals.
Page Number
page 5-62
Note: If a grease fitting is installed in this location, lubricate
daily (see daily lubrication schedule).

Landing collar (1 place). Use Jet Lube™ Arctic™ extreme
service grease.

Guide beam (grease running surfaces) (12 places)

Replace the lubrication system oil (and filter element).
page 5-26
page 5-65
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SM00856
Revision D
Page 5-61 of 98
Maintenance
5
Lubrication Schedules
Every Six Months
Lubrication
Page Number

Perform an oil analysis. Oil viscosity should be adjusted based on the expected
ambient conditions for the next six months.

Perform a hydraulic system oil analysis. (If oil analysis recommends it, replace the
hydraulic fluid; otherwise, change hydraulic fluid once a year.)
Yearly and As Required
Lubrication
Page Number

Replace the hydraulic fluid used by the top drive equipment.
page 5-80

Remove, clean, and replace the magnetic drain plug.
page 5-65

Every Two Years – Replace the hydraulic reservoir bladder.
page 5-74
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Maintenance
SM00856
Revision D
Page 5-62 of 98
Lubrication Procedures
General Lubrication
Apply general purpose
grease to designated
grease fittings with
grease gun. Use a brush
when greasing other parts.
The NOV Mechanical
washpipe (if installed)
does not require daily
lubrication.
Daily
Standard
Wash Pipe
Assembly
Apply one pump
twice daily
Upper Bonnet Seal
One pump
Use Hand Pump Only
Weekly
Upper Bonnet Seal
lubrication frequency
can vary based on
component design.
See lubrication
schedule for details.
Bail Pins (2)
Two pumps each side
Weekly
Rotating Link
Adapter Gear
Brush with grease
Weekly
Rotating Link Adapter
Three pumps each
Figure 5-35. General Lubrication (1 of 3)
5-62
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SM00856
Revision D
Page 5-63 of 98
5
Maintenance
Lubrication Procedures
General Lubrication
Apply general purpose grease to
designated grease fittings with
grease gun. Use a brush when
greasing other parts.
Daily
IBOP Actuator Yoke
One pump each side
Daily
IBOP Actuator Cranks
One pump each side
Daily
Weekly
Stabilizer Liner
One pump each side
Upper IBOP Valve
Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps
!
Weekly
Replace
plug before
operating
Clamp Cylinder Gate
One pump each side
Daily
Weekly
Stabilizer Liner
One pump each side
Elevator Link Eyes
(4)
Pipe Dope
Figure 5-36. General Lubrication (2 of 3)
5-63
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SM00856
Revision D
Page 5-64 of 98
Maintenance
Lubrication Procedures
General Lubrication
Apply general purpose grease
to designated grease fittings
with grease gun
Weekly
Guide Rollers
4 Places
One pump each
(if equipped)
Weekly
Guide Rollers
16 Places
One pump each
(if equipped)
Weekly
Bogies
4 Places
One pump each
(if equipped)
Figure 5-37. General Lubrication (3 of 3)
5-64
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SM00856
Revision D
Page 5-65 of 98
5
Maintenance
Lubrication Procedures
Gearbox Lubrication
Cork Ball
(Level
Indicator)
Sight
Glass
Gearbox
Oil Drain
Gear Oil
Sight Gauge
Check with Top Drive
“OFF”
Replace gear oil every
6 Months
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
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
Make sure 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
Gear Oil Filter
Replace every
3 Months
Yearly
Magnetic Drain Plug
Remove and clean contamination
Figure 5-38. Gearbox Lubrication
5-65
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5
SM00856
Revision D
Page 5-66 of 98
Maintenance
Lubrication Procedures
Motor Lubrication
!
Grease Fittings
NOV recommends that
the rig electrician
lubricate all AC motors.
Grease
Fitting
1/8 inch
!
Pipe Plug
1/8 inch
(remove and
reinstall after
lubricating)
3 Months
AC Blower
Motor (2)
3 pumps
(2 grease fittings
each motor)
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
Apply motor grease
to designated
grease fittings
with hand grease gun
Figure 5-39. Motor Lubrication
5-66
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SM00856
Revision D
Page 5-67 of 98
Maintenance
5
Hydraulic System Maintenance
Overview
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 hydro-pneumatic 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.
The hydraulic system diagrams provided in this section are
for reference only. Refer to the engineering hydraulic
schematics provided in the Technical Drawing Package
(TDP) for rig-specific schematics.
Refer to Appendix A, titled "Hydraulic Symbols" for a
description of the hydraulic symbols used in the schematic
diagrams shown in this section.
General Inspection Schedule
Daily Inspection
Page Number

Check the condition of the hydraulic filter indicator.
page 5-73

Check hydraulic fluid levels.
page 5-73

Check for hydraulic fluid leaks.

Check the condition of hydraulic hoses.
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5
SM00856
Revision D
Page 5-68 of 98
Maintenance
Hydraulic System Maintenance
Location of Hydraulic Components
Specifications
Pump Motor
10 hp, 1,800 rpm, AC motor
Reservoir Capacity
25 gal
Hydraulic Oil Filter
Page 5-73
Counterbalance
Manifold
Page 5-88
Counterbalance
Accumulator
Page 5-77
Main Hydraulic
Manifold
Page 5-76
Upper IBOP TimeDelay Accumulator
Page 5-77, -78
Hydraulic Oil Fill
Page 5-81
Link Tilt
Manifold
Page 5-95
Oil Pressure
Switch
Page 5-79
Link Tilt
Cylinders
Page 5-95
System
Accumulator
Page 5-77
Counterbalance
Cylinders
Page 5-88
IBOP Pressure
Switch
Page 5-79
Hydraulic Oil
Reservoir
Page 5-74
Upper IBOP
Actuator Cylinder
Page 5-77, -78
Front
Rear
Front
Rotating Head
Motor and
Shot Pin
Assembly
Page 5-93
10 HP AC
Motor and
Pump Assembly
Page 5-83
Rear
Figure 5-40. Hydraulic System Major Components
5-68
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SM00856
Revision D
Page 5-69 of 98
5
Maintenance
Hydraulic System Maintenance
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
Pre-Fill Valve
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
Variable
Displacement
Pump
Fixed
Displacement
Pump (Mtr. Lube)
Hydraulic
Reservoir
Figure 5-41. Hydraulic System Diagram
5-69
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Maintenance
SM00856
Revision D
Page 5-70 of 98
Hydraulic System Maintenance
Precautions
To avoid serious injury or death, read and understand the following precautions 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.
5-70
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SM00856
Revision D
Page 5-71 of 98
Maintenance
5
Hydraulic System Maintenance
Precautions
Always discharge the three
accumulators before performing
hydraulic system.
hydro-pneumatic
repairs on the
Do not attempt repairs you do not understand.
Read and understand all safety precautions and
warnings before performing maintenance procedures.
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.
5-71
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5
SM00856
Revision D
Page 5-72 of 98
Maintenance
Hydraulic System Maintenance
Precautions
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 build-up from hydraulic
components. Use care when handling components to
prevent nicking close tolerance finishes.
Replace worn or damaged
components immediately.
hydraulic
system
!
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.
5-72
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SM00856
Revision D
Page 5-73 of 98
Maintenance
5
Hydraulic System Maintenance
Inspection
Hydraulic Fluid Level and Indicator
Cork Ball
(Level Indicator)
Daily
Red
“Pop-up”
Dirt Alarm
Sight
Glass
Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
See the Lubrication
section for fluid
replacement
instructions
Procedure
Check the red “pop-up” alarm on the hydraulic
filter daily
Replace the filter if the indicator has popped
up or as recommended
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Figure 5-42. Inspecting the Hydraulic Fluid Level and Indicator
5-73
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5
SM00856
Revision D
Page 5-74 of 98
Maintenance
Hydraulic System Maintenance
Inspection
Hydraulic Reservoir Bladder (Yearly)
Reservoir
Breather
Reservoir
Cover
!
Hydraulic Oil
Reservoir
Between AC
Drilling Motors
Never put oil in the reservoir
bladder. Add oil at the
hydraulic oil fill only.
Apply gasket
sealing compound
to prevent leaks
Yearly
Reservoir Bladder
Check for wear and damage
Gasket
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 the bladder yearly for wear or damage
Replace the bladder every two years
Replace the bladder if fluid is found inside or
if fluid escapes the reservoir breather when
the top drive is on its back
Figure 5-43. Inspecting the Hydraulic Reservoir Bladder (Yearly)
5-74
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SM00856
Revision D
Page 5-75 of 98
Maintenance
5
Hydraulic System Maintenance
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
Figure 5-44. Inspecting the Heat Exchanger
5-75
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5
SM00856
Revision D
Page 5-76 of 98
Maintenance
Hydraulic System Maintenance
Inspection
Using the Hydraulic System 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
B6
* These test ports are on sides
or bottom of manifold.
As Viewed From Below
Figure 5-45. Using the Hydraulic System Test Ports
5-76
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SM00856
Revision D
Page 5-77 of 98
5
Maintenance
Hydraulic System Maintenance
Inspection
Precharging the Accumulators
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
Port
Bleed the accumulator if the pressure is higher, or add
nitrogen if the pressure is lower than specified above
Accumulator
Charging Assembly
Counterbalance
Accumulator
Upper IBOP
Time- Delay
Accumulator
Hydraulic
Manifold
(Reference)
System
Accumulator
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
Front
Rear
Note that there is a time delay in pressure decay
on port C4
Test the precharge pressure on the three
nitrogen-filled accumulators
Figure 5-46. Precharging the Accumulators
5-77
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5
SM00856
Revision D
Page 5-78 of 98
Maintenance
Hydraulic System Maintenance
Inspection
IBOP Timing Circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod
Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
-6
A4
B4
A4
B4
IBOP Close Solenoid
(Solenoid Valve 4)
Double Solenoid Valve
-6
-6
Rotating
Link Adapter
-6
(Small)
IBOP Close
Cable ID
Number
A
B
P
T
b
SV4
A4
B4
-6
-6
-6
C04
C4
Manifold Assembly
D03
500 PSI
CV4
Flow Control
Valve
D4
1
T-11A
3
T-11A
2
2
1
3
PC4
System
Pressure
Tank
Figure 5-47. Inspecting the IBOP Timing Circuit
5-78
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SM00856
Revision D
Page 5-79 of 98
5
Maintenance
Hydraulic System Maintenance
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
Wires
Inspect for wear
or lose connections.
Component
Setting
IBOP Pressure Switch
Factory preset at 1500 psi (102.0 BAR) rising
+0
Factory preset at 10.0 -1.0 psi decreasing
Oil Pressure Switch
Figure 5-48. Inspecting the IBOP and Oil Pressure Switch
5-79
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5
SM00856
Revision D
Page 5-80 of 98
Maintenance
Hydraulic System Maintenance
Lubrication
Before disconnecting hydraulic lines, release all
hydraulic oil pressure by bleeding accumulators. 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
the work area. 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.
5-80
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SM00856
Revision D
Page 5-81 of 98
5
Maintenance
Hydraulic System Maintenance
Lubrication
Adding Hydraulic Fluid
Procedure
The area must be clean prior to adding
hydraulic fluid
Remove dust plug from the male quick
disconnect at the TDS 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
Reservoir
capacity is
25 gallons
Cork Ball
(Level Indicator)
Red
"Pop-up"
Dirt Alarm
Sight
Glass
Replace every
Hydraulic
Oil Sight
Gauge
3 Months
Hydraulic
Oil Filter
Hydraulic Oil Fill
Male Quick Disconnect
Replace
hydraulic fluid
Yearly
or earlier based
on oil analysis
Dust Plug
Female
Quick
Disconnect
Hydraulic
Lubrication Kit
55 gal Drum
Hydraulic
Oil Drain
Figure 5-49. Adding Hydraulic Fluid
5-81
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5
Maintenance
SM00856
Revision D
Page 5-82 of 98
Hydraulic System Maintenance
Lubrication
Draining 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
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
Fixed
Displacement
Pump
Variable
Displacement
Pump
Figure 5-50. Draining Hydraulic Fluid
5-82
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SM00856
Revision D
Page 5-83 of 98
5
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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.
Pump Pressure
Compensator
Adjustment Point
Guide Beam
Pump/Motor
Variable
Displacement
Pump
Fixed
Displacement
Pump
10 HP AC
Pump Motor
Figure 5-51. Hydraulic Pumps and Unloading Circuit
5-83
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5
SM00856
Revision D
Page 5-84 of 98
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
Fixed Displacement (lube) and Variable Displacement Pumps
!
Make sure the top drive is properly filled with hydraulic fluid
and lube oil before performing this procedure. Also make
sure the Rig-Up/Shutdown valve is in the SHUTDOWN
position.
1. 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.
2. 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, and turn the motor off.
3. Set the relief valve RV2 to minimum pressure, fully counterclockwise.
4. 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.
5. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for
unusual noises that would indicate cavitation; check for leaks.
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.
!
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. 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.
5-84
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SM00856
Revision D
Page 5-85 of 98
5
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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
150
0
10
20
30
40
50
60
Approximate Time
(seconds)
Figure 5-52. Pressure Cycle Graph
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SM00856
Revision D
Page 5-86 of 98
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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
End View
Manifold
Bottom View
B6
A6
Z1
DR
P
TF
B5
B5
B4
C5
B9
TR
T1
CTR
SA
CB
SA
SV5
SV2
B4
E6
G6
E5
SV1
B1
SV9
SA
CV2
PV
P5
C4
B8
PF
RIG-UP
MV
1
P/N 0181
XC
PV
SHUTDOWN
DF
COUNTERB NCE MODE
PF
RUN
SV4
UV1
G5
UV1
PF
Figure 5-53. Pump Setup Manifold Ports
5-86
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SM00856
Revision D
Page 5-87 of 98
Maintenance
5
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
Fixed Displacement (lube) and Variable Displacement Pumps
Manifold Assembly
T-21A
4
UV1
2200 PSI
T-10A
RV2
2
2
3
T-11A
1
2000 PSI
3
1
Z1
1
400 PSI
2
RV1
PV
PF
800 PSIG
Variable Displacement
Pump-Motor Assembly
B
1.00 IN^ 3/REV.
L
Fixed
Displacement
Pump
1.10 IN^ 3/REV. MAX.
.50 IN^ 3/REV. MIN.
S
L1
Figure 5-54. Pump Setup Circuit Diagram
5-87
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SM00856
Revision D
Page 5-88 of 98
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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.
!
Cylinders stroke to the end of stroke with the mode valve in
the RUN position.
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.
This procedure continues on the next page.
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Maintenance
5
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
Counterbalance Circuit and Stand-Jump Circuit
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 200
psi.
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Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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
Manifold
End View
RIG-UP/SHUTDOWN
Valve
B6
A6
Z1
DR
P
Manifold
Bottom View
TF
B5
B5
B4
C5
B9
CTR
SA
CB
SA
TR
T1
SV5
SV2
B4
E6
G6
E5
SV1
B1
SV9
CV2
PV
P5
C4
B8
PF
UV1
RIG-UP
SV4
PV
MV
SHUTDOWN
DF
1
P/N 0181
XC
RUN
PF
COUNTERB NCE MODE
G5
CB
Manifold
Side View
SJR
A4
D4
PC5
AR5
D1
PC4
CV3
SJR
PF
P1
A8
PV
A4
A5
D5
C4
CB
G5
DF
2
Figure 5-55. Counterbalance Setup Manifold Ports
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5
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
Counterbalance Circuit and Stand-Jump Circuit
Pressure
Relief Valve
1500 PSI
T-3A
-4
OR1
ZC
2
CP
OR2
.075ø
.075ø
75 PSI
1
2
75 PSI
1
2
T-13A
T-13A
CV1
1
CP
-12
CP
-12
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
1
1
SJR
System
Accumulator
2
DF
126 Cubic Inches
800 PSI Precharge
2
TF
SA
4
PCC
T-21A
T-13A
T-5A
30 PSI
1
2
Pressure
Relief
Valve
200 PSI
3
System Pressure
CTF
To Tank
Figure 5-56. Counterbalance Setup Circuit Diagram
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Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
AC Motor Brake Circuit
The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,500 psi. The
pressure reducing valve regulates the pressure to 1,500 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 1,500 psi. If the reading is
not 1,500 psi, adjust the pressure control reducing valve PC 1 to 1,500. Turn the auto brakes
switch to the OFF position. The pressure reading should be very low.
PC1
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
Figure 5-57. Motor Brake Setup Manifold Ports
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5
Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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.
!
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
400 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 1,000 psi.
Hydraulic
Drive Motor
SV5
C5
Link Adapter
Rotation Gear
Hydraulic Manifold
View from Below
Shot Pin
Simplified for Clarity
Figure 5-58. Setting up the Shot Pin Circuit (1 of 2)
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Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic Circuits
Shot Pin Circuit
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
A
Shot Pin
Relief Valve
B
Motor
Relief Valve
C5
Link Adapter
Rotation Gear
A5
Shot Pin
Figure 5-59. Setting up the Shot Pin Circuit (2 of 2)
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Maintenance
5
Hydraulic System Maintenance
Setting Up Hydraulic 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.
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 both valves.
Adjust the valves one at a time.
4. There are two test points on the link tilt cylinder manifold.
5. From the driller’s console, move the link tilt to go to the mousehole position.
6. The cylinders go to full extension and the pressure at the test port C1 is 2,000 psi.
7. Command the link tilt to the OFF position and observe the pressure decay at C1.
This decayed 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.
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
increases the pressure.
valve
counterclockwise
10. Command the link tilt to the DRILL position and repeat the procedure above, using
test port C2 to set the counterbalance valve on the DRILL side.
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Maintenance
Hydraulic System Maintenance
Setting Up Hydraulic 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
1,700 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 1,700 psi.
Hydraulic
Drive Motor
Test Points
(3)
Motor
Relief
Valve
(2)
Link Adapter
Rotation Gear
Figure 5-60. Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit
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Maintenance
5
Control Console Maintenance
Inspect the console on a routine basis. Failure to
conduct routine inspections and maintenance may
result in equipment damage or injury to personnel.
The following is a general maintenance checklist.
Maintenance Checklist
Location
Procedure
Frequency
Console Indicator Lamps
Test using the Alarm Silence / Lamp
Check button on the console.
Each time the top drive is assigned.
Heater
Check operation with an Ohm meter.
Monthly
Console mounting fasteners
Check fastener tightness, especially
in vibration-prone areas.
Monthly
Check for integrity.
Monthly
Apply a light film of silicone lubricant.
Every Three Months
Enclosure seals and gaskets

If the console enclosure is damaged or faulty, the enclosure should be returned to
an NOV Service Center or other authorized service facility for repair.

If there is a faulty terminal or communication module, contact your NOV
representative, NOV Service Center, or authorized service facility for a replacement.
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Revision D
Troubleshooting
6
Introduction
This chapter provides guidelines to inspect and troubleshoot the components and circuits for the
TDS-11SA Top Drive.
!
All procedures and methods provided in this manual are
superseded by the procedures and methods approved for
use at the location where the equipment is installed and
commissioned.
There is no way to anticipate every issue that may be encountered. If the issue cannot be resolved
using the troubleshooting instructions, contact an NOV Service Center. A list of NOV Service
Centers is provided in the equipment User Manual.
For top drives using an Amphion™ control system, make
sure that all data cables are properly connected to the
single-board computer (SBC). Many issues can be
resolved by making sure these connections are working
properly.
Refer to the Maintenance chapter in this service manual for
specific maintenance procedures and other information
that may help you identify the cause of the issue.
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Troubleshooting
Introduction
Personnel Qualifications
Personnel conducting the troubleshooting procedures should be experienced and thoroughly
familiar with this NOV top drive. The personnel conducting troubleshooting procedures must read
and understand the information in all equipment documentation as well as understand all the
functions of the top drive.
!
Follow the general system safety practices included in this
manual before troubleshooting or performing maintenance
on the top drive system.
!
Personnel troubleshooting the top drive must be
experienced and thoroughly familiar with its function,
operation and maintenance requirements.
Failure to follow safe work procedures could result in
serious or fatal injury to personnel, significant
equipment damage, and/or extended rig down time.
Troubleshooting Guidelines
NOV top drive hydraulic and electrical systems use standard components and follow industrystandard design practices. For the hydraulic or electrical systems to function (produce flow at all
times and pressure when a load is present), the following basic operating conditions must be
present at all times:

The hydraulic and lubrication pump(s) must be running and rotating in the correct
direction.

There must be clean fluid and adequate fluid flow to the top drive.

The temperature of the hydraulic and lubrication fluids must be in the correct range
to ensure the viscosity is not too high (low temp) or low (high temp). Refer to
Recommended Lubricants and Fluids (D811000719) in the equipment User Manual
for recommended lubricants and hydraulic fluids for NOV drilling equipment.
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Troubleshooting
6
Introduction
Troubleshooting Guidelines

The hydraulic and electric circuits must be correctly connected and operable.

The piping, hoses, and service loops must positioned properly and unobstructed.
Make sure all electrical and hydraulic lines and valves
are isolated before any work is started on top drive
hydraulics. Failure to follow safe work procedures
could result in serious or fatal injury to personnel,
significant equipment damage, and rig downtime.
Determining the Nature of Problem
When troubleshooting the top drive, determine the nature of the problem using the troubleshooting
tables, detailed theory of operation information for components, and diagnostic procedures.
Potential component failure for most top drives falls into the following three categories:

Mechanical System components

Hydraulic System components

Electrical System components

Lubrication and Cooling System components
Identifying Troubleshooting Categories
Potential top drive system failure typically falls into one or more of the following categories.
Mechanical Components
Mechanical problems are usually related to damaged or worn out parts. Another factor that can
contribute to mechanical failures is a lack of periodic preventive maintenance. Periodic inspections
and equipment maintenance must be completed to ensure proper mechanical operation.
Hydraulic System and Components
Hydraulic circuit and component problems are usually related to faulty valves, hydraulic actuators,
contamination, fluid leakage, or damage not related to maladjusted hydraulic circuit components.
Changes to adjustments should only be made after eliminating all other possible causes.
Electrical System and Components
Electrical system and component problems are usually related to faulty discrete control switches,
electrical supply voltage, and or improper interconnection wiring.
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Troubleshooting
Introduction
Identifying Troubleshooting Categories
Lubrication and Cooling System Components
Lubrication and cooling system problems are usually related to contamination, faulty discrete
control switches, faulty valves and dirty filters. Making changes to the flow rate, system pressure,
or other adjustments should only be completed after eliminating all other possible causes.
Make sure to have the hydraulic, electrical, and lubrication
engineering schematics available before troubleshooting
system problems. These schematics are located in the
Technical Drawing Package (TDP).
Pre-Troubleshooting Inspection
Complete the following steps before troubleshooting the top drive system:
1. Make sure the top drive is properly installed and positioned in the rig structure. If
troubleshooting the top drive prior to rig installation, make sure the top drive is
secure and the drill shaft is lifted clear from the floor.
2. Check that all hoses and quick disconnects are properly connected.
3. Check lubrication system pressure output (the unit must be upright).
!
Lubrication oil pressure is critical to the performance and
proper operation of the top drive. Oil pressure must be
carefully monitored and maintained. Failure to adhere to
this advisory may result in damage to the top drive.
4. Check the flow and maximum pressure of the NOV hydraulic power unit (HPU) or
customer-supplied hydraulic power supply.
5. Check the lubrication system and hydraulic system filters for dirt pop-up indicators.
6. Check whether hydraulic fluid leaks are visible at hydraulic components, hoses, and
quick-disconnect couplings.
7. Review the lubrication system maintenance information in the Maintenance chapter
in this manual.
8. Determine the nature of the problem using standard diagnostic methods, the
troubleshooting tables, maintenance information, and operating information for the
equipment.
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Troubleshooting
6
Introduction
Service Centers
When problems cannot be solved, contact an authorized NOV Service Center. For a directory of
NOV Service Centers, see NOV document number D811001337-DAS-001, titled “Service Center
Directory.” This document is located in the equipment User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
www.nov.com/ContactUs/24HrEmergencyContacts.aspx
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Troubleshooting
Troubleshooting
HPU and Reservoir Bladder
Troubleshooting Table
Problem
Probable Cause
Remedy
Hydraulic system is overheating.
Relief valves RV1 and RV2 are out
of adjustment.
Test pressure 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.
First make sure the RIG-UP
SHUTDOWN valve is in the correct
position. 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 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.
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6
Troubleshooting
Troubleshooting
HPU and Reservoir Bladder
Schematic Diagram
PV
PF
TR
DR
Manifold Assembly
Hydraulic Fill
Disconnect
System
Pressure
6m
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
Figure 6-1. HPU and Reservoir Bladder Schematic Diagram
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Revision D
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Troubleshooting
Counterbalance and Stand Jump
The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a
hydraulic pressure.
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.
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.
Adjust relief valve SJR slowly to allow pressure at CB to
stabilize.
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Page 6-9 of 22
Troubleshooting
6
Troubleshooting
Counterbalance and Stand Jump
Troubleshooting Table
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 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.
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 no
operating.
Test electrical and hydraulic
operation. Replace or repair as
applicable.
PCC is no 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.
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Troubleshooting
Troubleshooting
Counterbalance and Stand Jump
Schematic Diagram
Pressure
Relief Valve
1500 PSI
T-3A
-4
OR1
ZC
2
CP
OR2
.075ø
.075ø
75 PSI
1
2
75 PSI
1
2
T-13A
T-13A
CV1
1
CP
-12
CP
-12
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
1
1
SJR
System
Accumulator
2
DF
126 Cubic Inches
800 PSI Precharge
2
TF
SA
4
PCC
T-21A
T-13A
T-5A
30 PSI
1
2
Pressure
Relief
Valve
200 PSI
3
System Pressure
CTF
To Tank
Figure 6-2. Counterbalance and Stand Jump Schematic Diagram
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6
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Troubleshooting
Troubleshooting
Motor Brakes
Troubleshooting Table
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 problem with brakes.
Repair brake mechanism.
Hydraulic oil on brake pads.
Check for hydraulic leaks and
repair.
Pressure is not 1,500 psi or does
not rise crisply to 1,500 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.
Pressure reducing valve is faulty.
Replace valve.
Brakes do not engage or slip.
Delay in brakes actuating after
console switch is turned on.
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Troubleshooting
6
Troubleshooting
Motor Brakes
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
1500 PSI
PC1
Reducing
Valve
1
T-11A
2
System
Pressure
3
Tank
Drain
Figure 6-3. Brake Circuit Schematic Diagram
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SM00856
Revision D
Page 6-14 of 22
Troubleshooting
Troubleshooting
Shot Pin Cylinder and Clamp Cylinder
Troubleshooting Table
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 a 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 is
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.
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.
Shot pin engages but clamp
cylinder does not activate.
6-14
www.nov.com
SM00856
Revision D
Page 6-15 of 22
6
Troubleshooting
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
3
T-2A
CKEB
2
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
400 PSI
Shot Pin
Cylinder
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
E5
G5
E5
G5
-8
G5
SV5
D03
B5
C5
50 PSI
.031ø
.159ø
AR5
2
3
Pressure
Reducing
Valve
2
1
LC5
1
T-11A
3
Logic
Cartridge
Rotating Link
Adapter Assembly
-6
-6
C05
E5
-8
Clamp
-8
-8
T-10A
B5 C5
.031ø
1000 PSI
T-11A
3
2
T-21A
CV5
Externally-Drained
Pilot-to-Open
Valve
1
4 75 PSI
P5
Drain
1
3
T-11A
System Pressure
PC5
2
Tank
Drain
System Pressure
Tank
T1
T1
D5
Manifold Assembly
Figure 6-4. Shot Pin Cylinder and Clamp Cylinder Schematic Diagram
6-15
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6
SM00856
Revision D
Page 6-16 of 22
Troubleshooting
Troubleshooting
Link Tilt Cylinders
Troubleshooting Table
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.
6-16
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SM00856
Revision D
Page 6-17 of 22
6
Troubleshooting
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
3
2
C2
C2
1
T-11A
CB2
1500 PSI
T-11A
CB1
1
3
C1
1
2
2
2
X2
3
V1
V2
G6
H
J
Rotating Link
Adapter Assembly
Link Tilt
"Float" Solenoid
(Solenoid Valve 8)
Link Tilt
"Tilt" Solenoid
(Solenoid Valve 6)
Link Tilt
"Drill Down" Solenoid
(Solenoid Valve 6)
Link-Tilt Float
P
T
SV8
Logic
Cartridge
D03
B8
LA6 T-11A
1
50 PSI 2
3
A6
A
B
C07
Drill Down P
b
E6 .031ø
.071ø
1
T
SV6
D03 .031ø
G6
75 PSI
.031ø
B6
3
3
2
4
.031ø
Logic
Cartridge
a
C06
M'hole
-8
B
-8
A
Link Tilt
-6
b
C08
X -8
X -8
J
-8 X
-8
H
-8 X
E6
G6
-8
B8
-8
E6
Cable ID
Number
-8
-8
G6
X
E6
X
-8
-8
-6
B8
X
-6
B8
V2
V1
FL
CA6
T-21A
.031ø
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
Figure 6-5. Link Tilt Cylinders Schematic Diagram
6-17
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6
SM00856
Revision D
Page 6-18 of 22
Troubleshooting
Troubleshooting
Gearbox Lubrication Hydraulic System
Troubleshooting Table
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 and replace as needed.
Oil level is too low. Oil overheated.
Add oil.
Oil pressure switch is out of
adjustment.
Adjust the switch (see the section
titled "IBOP and Oil Pressure
Switch" on page 5-79).
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.
6-18
www.nov.com
SM00856
Revision D
Page 6-19 of 22
6
Troubleshooting
Troubleshooting
Gearbox Lubrication Hydraulic System
Schematic Diagram
Pressure
Switch
S04
Spray
Nozzles (4)
Orifices (6)
10 PSI
Decreasing
-16
1.0
GPM
Ea.
1.5
GPM
Ea.
Upper
Compound
Gear
Lower
Compound
Gear
.062ø
.205ø
.059ø .059ø
Upper
Mainshaft
Bearing
Lower
Radial/Main
Thrust
Bearings
.047ø .047ø
Upper
Compound
Bearing
L4
Lower
Compound
Bearing
Lube-Oil
Filter
Lube Pump
60m
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
2
RV2
1
400 PSI
Manifold
PF
1.00 IN^ 3/REV.
Part of
Pump Motor
Assembly
Reservoir
Assembly
Figure 6-6. Gearbox Lubrication Hydraulic System Schematic Diagram
6-19
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6
SM00856
Revision D
Page 6-20 of 22
Troubleshooting
Troubleshooting
Tool Rotation and Movement
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. Top drive components
can then move, possibly causing
serious injury or death.
Tool does not return to the 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 pressure and inspect valves.
Adjust 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.
Check out the control system.
Counterbalance valves are out of
adjustment.
Adjust valves together. Make sure
pressure is the same for all four
valves.
6-20
www.nov.com
SM00856
Revision D
Page 6-21 of 22
6
Troubleshooting
Troubleshooting
Rotating Link Adapter Motor Schematic Diagram
Rotating Head Motor
A
B
Fixed
Displacement
Motor
2
1
T-10A
Pressure
Relief Valves
1700 PSI
1700 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
SV2
.071ø
Non-Adjustable
Orifice
B2
D03
Pressure
Tank
Manifold
Assembly
3 Position
Solenoid Valve
Figure 6-7. Rotating Link Adapter Motor Schematic Diagram
6-21
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6
SM00856
Revision D
Page 6-22 of 22
Troubleshooting
Troubleshooting
IBOP Actuator Schematic Diagram
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod
Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
-6
A4
B4
A4
B4
IBOP Close Solenoid
(Solenoid Valve 4)
Double Solenoid Valve
-6
-6
Rotating
Link Adapter
-6
(Small)
IBOP Close
Cable ID
Number
A
B
P
T
b
-6
-6
SV4
A4
-6
C04
B4
C4
Manifold Assembly
D03
500 PSI
CV4
Flow Control
Valve
D4
1
T-11A
3
T-11A
2
2
1
3
PC4
System
Pressure
Tank
Figure 6-8. IBOP Actuator Schematic Diagram
6-22
www.nov.com
SM00856
Revision D
Hydraulic Symbols
A
The following pages provide descriptions for hydraulic symbols used in the hydraulic schematic
diagrams.
A-1
www.nov.com
Form D811001123-GEN-001/06
A
SM00856
Revision D
Page A-2 of 4
Hydraulic 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
33-10
Chack Valve
33-11
CDF, CTF, CV2, CTR,
CDR, CXCD
Prefill valve assembly
CV1, CV2
Figure A-1. Hydraulic Symbols (1 of 3)
A-2
www.nov.com
SM00856
Revision D
Page A-3 of 4
Hydraulic Symbols
Description
Symbol
A
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
See Prefill Assembly
33-21
Quick Disconnect Coupling
33-22
Figure A-2. Hydraulic Symbols (2 of 3)
A-3
www.nov.com
A
SM00856
Revision D
Page A-4 of 4
Hydraulic Symbols
Description
Description
Symbol
Symbol
Schematic Reference
Reference
Schematic
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
Tank (Reservoir)
33-33
Test Point
33-34
Figure A-3. Hydraulic Symbols (3 of 3)
A-4
www.nov.com
SM00856
Revision D
PH-50 Pipe Handler
B
Appendix B provides information about the PH-50 Pipe Handler. Refer to section titled "Inspecting
the PH-75 Pipe Handler" on page 5-32 for information about the PH-75 Pipe Handler.
Rotating Link Adapter
Link Tilt
Remote IBOP
Actuator
Manual IBOP
Torque Back-up Clamp
Assembly
Elevator Links
Drive Pipe
Elevator Assembly
Figure B-1. PH-50 Major Components
B-1
www.nov.com
Form D811001123-GEN-001/06
B
SM00856
Revision D
Page B-2 of 28
PH-50 Pipe Handler
Inspection Schedule
Each Use
Page Reference
Check wireline adapter sheaves for excessive wear or damage
See page B-26
Daily
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check tong dies for wear
See page B-12
Check clamp cylinder for leaks
See page B-12
Check hoses for wear or damage
See page B-16
Check tool joint locks for tightness
See page B-18
Check upper and lower IBOP valves for proper operation
See page B-19
Weekly
Check link tilt clamps for position and tightness
See page B-6
Check stabbing guide and flippers for damage and wear
See page B-7
Check clamp cylinder gate hinge pin for wear
See page B-12
Check IBOP actuator cylinder for leaks
See page B-16
Check IBOP actuator cam followers for wear or excessive play
See page B-16
Check upper and lower IBOPs and IBOP crank for damage (if equipped)
See page B-19
Check shot pin assembly for leaks
See page B-21
Monthly
Check elevator link eyes for wear
See page B-6
Check link tilt bushings for wear
See page B-8
Check link tilt actuator cylinders for leaks
See page B-8
Check link tilt actuator cylinder pins for wear
See page B-8
Check clamp cylinder body wear bushings for wear
See page B-12
Check stabilizer springs for damage
See page B-14
Check front and rear stabilizers for wear
See page B-12, B-14
Check pins and bushings on IBOP actuator cylinder and yoke for wear
See page B-16
Check shot pin assembly for wear or damage
See page B-21
Yearly
Check piston ring for pitting and chipping
See page B-23
Check stem for pitting, grooves and chipping
See page B-23
Replace GLYD rings, o-rings and bushings on rotating link adapter
See page B-23
5 Years
MPI Inspection
See page B-27
Figure B-2. PH-50: Inspection Schedule
B-2
www.nov.com
SM00856
Revision D
Page B-3 of 28
PH-50 Pipe Handler
B
Safety Precautions
Warnings
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.
Complete all appropriate job safety analysis (JSA),
permits, and crew safety briefings immediately prior to
each maintenance activity or session. If, at any point
during the maintenance session, the planned activities
change for any reason, review the job safety
requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all
appropriate personal safety equipment is in good
condition and used when necessary.
Unless specifically noted in this manual, properly lock
out the main power source before performing
lubrication, inspection, or replacement procedures.
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.
Read and understand all safety precautions and
warnings before performing maintenance procedures.
Do not attempt repairs you do not understand.
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 all accumulators before servicing
the hydraulic system.
B-3
www.nov.com
B
PH-50 Pipe Handler
SM00856
Revision D
Page B-4 of 28
Safety Precautions
Top drive maintenance requires personnel working at
height and there exists the potential for injury or
dropped objects.
Equipment Records
Keep a record book of all maintenance procedures performed. Date each procedure, followed by a
description and the technician who performed it. This data is valuable for fault finding and problem
solving, should technical problems arise.
Procedures in this chapter relate to NOV-only components.
See the appropriate vendor-supplied OEM manuals for
inspection schedules and maintenance procedures for
non-NOV equipment and components.
Torque Values
Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque
standards to follow when tightening component fasteners.
Install bolts with anti-seize compound and tighten based
on the Design Torque Standard (DS00008). This document
is included in the equipment User Manual.
Safety Wire (Lockwire) Procedures
Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the
procedures required for installing safety wire (lockwire) on component fasteners.
B-4
www.nov.com
SM00856
Revision D
Page B-5 of 28
PH-50 Pipe Handler
B
Elevator Links
Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the
measurement with the link wear charts in the Links User Manual (D6350000870). This manual is
included in the equipment User Manual.
Disassembly/Assembly
1. Disconnect and remove the drill pipe elevator from the elevator links.
2. Using the Driller’s Control Console, rotate the pipe handler 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 pipe handler.
6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator
link.
B-5
www.nov.com
B
SM00856
Revision D
Page B-6 of 28
PH-50 Pipe Handler
Elevator Links
Inspection
Recess in
Motor Guard
950 lb
(431 kg)
Elevator Link
2
Lift and
remove
Link Tilt
Catch Link Pin
Upper
Catch
Link
26"
(635mm)
Typical
Monthly
Elevator
Link Eyes
Inspect for wear
(see table)
Rear
Clevis Pin
Link
Pipehandler
Rotate Switch
EH
T AN
SH
PU
PIP
Weekly
T
IL
K TT
LIN OA
FL
U
HP / ON
TO
Front
AU
QU
E
TE CW
TA
PH
C
RO
Link Tilt Clamps
Inspect for position
and tightness
CW
T
ILT TIL
KT
1
LIN
ILL
DR
Rotate
E
RS
VE
Driller’s
Control
Console
I NC
CY
GEN
ER OP
EM ST
EUP
S TOR
QUE
I NC
L
DRIL
BX
OR N
VAT OPE
ELE
I NC
BX
ED
A SE
RE
ARM
CE
LAN
UMP
GEN
R
LE
D
ND CLAMP
HOL
HA TWH AND
PUS
PIPE
VFD
LT
FAU
TILT
LINK AT
FLO
DRIL RTE
OVE
MA
TD
KEU
PM
SR
Monthly
P
E
DECR EAS
RBA
NDJ
NTESTA
COUL /
DRIL
MS
AR
AL L MOTMPOR
A SE
RE
ECREASE
D
BLE
ENA
L
ERA
A SE
RE
E
DE CR EAS
SET MAK
TD
DR
ILL
OR
VAT
ELESED
BX CLO
Elevator
Link Eyes
Inspect for wear
(see table)
HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE
DE
WER
BLO S
LOS
TD
ATE CW
TOR
PH
S MO
ROT
CCW
SPIN
TILT TILT
/
LINK
NCE
SILECK
RM CHE
ALA P
LAM
L
DRIL
L
DRIL
BR
AK
E
N
IO
O
AUT
TD
OP
IB
SED
E
ERS
REV
CT
RE
S DI OFF
D
CLO
WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
OPE
Figure B-3. PH-50: Elevator Link Inspection
B-6
www.nov.com
SM00856
Revision D
Page B-7 of 28
PH-50 Pipe Handler
B
Link Tilt
Disassembly/Assembly
1. Shut down 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.
Use the recommended spanner wrench to remove the rod
gland seal.
B-7
www.nov.com
B
SM00856
Revision D
Page B-8 of 28
PH-50 Pipe Handler
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
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
Bushings should be pressed in using the mating pin
as an installation mandrel.
Figure B-4. PH-50: Link Tilt Inspection
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PH-50 Pipe Handler
B
Torque Wrench Assembly
Clamp Cylinder Body Disassembly/Assembly
Procedure
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.
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.
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.
Use recommended spanner wrench to remove the rod
gland seal.
Assembly is performed in reverse order of disassembly.
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B
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Revision D
Page B-10 of 28
PH-50 Pipe Handler
Torque Wrench Assembly
Clamp Cylinder Body Disassembly/Assembly
Removing the Clamp Cylinder Body
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
Support clamp
cylinder body
before removing
end cap.
End Cap
Clamp Cylinder
Body
Figure B-5. PH-50: Removing the Clamp Cylinder Body
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B
PH-50 Pipe Handler
Torque Wrench Assembly
Clamp Cylinder Body Disassembly/Assembly
Disassembling the Clamp Cylinder Body
Manifold
Rear
Stabilizer
Front
Stabilizer
Hinge Pin
Retainer
Spring
Hex Head
Screws
Cylinder
Head Ring
Clamp
Cylinder
Body
Cylinder
Head
Body
Seals
Piston
Seals
Jaw
Assembly
Piston
Tong
Dies
Gate
Wear
Bushing
Socket
Head Cap
Screws
Hinge
Pin
Front
Stabbing
Guide
Rear
Stabbing
Guide
Flippers
Spring
Retaining
Plate
Figure B-6. PH-50: Disassembling the Clamp Cylinder Body
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Revision D
Page B-12 of 28
PH-50 Pipe Handler
Torque Wrench Assembly
Inspecting the Clamp Cylinder Body
Component
Replace when
Stabilizer
Wear exceeds 1/8 in.
Flippers
Wear exceeds 1/8 in.
Tugger
Line
V
A
R
C
O
P
H
5
0
Front and
Rear Stabilizers
Inspect for wear
Wear Bushings
Check for wear,
replace as necessary
Weekly
Monthly
Tong Dies
Inspect for
excessive wear
CO
R
VA
Daily
Daily
Clamp Cylinder
Check for leaks,
replace seals
as necessary
Swing Clear
Weekly
Clamp
Cylinder Gate
Shown open
Stabbing Guide
Inspect for damage
Weekly
Weekly
Flippers
Inspect for damage
and excessive wear
Clamp Cylinder
Gate Hinge Pin
Check for pin wear,
replace as necessary
Figure B-7. PH-50: Inspecting the Clamp Cylinder Body
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PH-50 Pipe Handler
B
Torque Wrench Assembly
Inspecting the Stabilizers
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.
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PH-50 Pipe Handler
SM00856
Revision D
Page B-14 of 28
Torque Wrench Assembly
Inspecting the Stabilizers
Stabilizer Springs
Check for damage,
replace as necessary
Monthly
Monthly
Stabilizers
Inspect for wear, replace
if wear exceeds 1/8 in.
Cotter Pin
Figure B-8. PH-50: Inspecting the Stabilizer
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Page B-15 of 28
B
PH-50 Pipe Handler
Torque Wrench Assembly
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.
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Revision D
Page B-16 of 28
PH-50 Pipe Handler
Torque Wrench Assembly
Inspecting the IBOP Actuator Cylinder and Yoke
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
Daily
Monthly
Hoses
Replace if worn
or damaged
Pins and Bushings
Check for wear
or excessive play
Monthly
IBOP
Actuator Yoke
Check pins and
bushings for wear
or excessive play
Component
Replace when
Pins
Wear exceeds .03 in. on diameter
Bushings
Metal backing is visible through the lining
Weekly
IBOP
Actuator Yoke
Check cam followers for wear
or excessive play
End cap of the metal backing exceeds .04 in. wear
i
Bushings should be pressed in using the mating pin
as an installation mandrel
Figure B-9. PH-50: Inspecting the IBOP Actuator Cylinder and Yoke
B-16
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Page B-17 of 28
PH-50 Pipe Handler
B
IBOP Stack
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.
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.
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PH-50 Pipe Handler
IBOP Stack
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
1.4"
Tool Joint
Shoulder
1.4"
Tool Joint
Locks
Inspect for loose bolts.
Repair or replace if necessary.
Torque to 1855 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.
Figure B-10. PH-50: Inspecting the Tool Joint Locks
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PH-50 Pipe Handler
B
IBOP Stack
Inspecting IBOP Valves and Saver Subs
Close
Component
Replace when
Saver Sub
Threads have been recut to a minimum
shoulder-to-shoulder length of 5 in.
Weekly
Daily
Upper IBOP
(Remote)
Inspect for damage
Valve
Check for
proper operation
and pressure test
for leaks
Weekly
Open
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
5 Years
Upper and Lower IBOP
Figure B-11. PH-50: Inspecting IBOP Valves and Saver Subs
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PH-50 Pipe Handler
SM00856
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Page B-20 of 28
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 Figure B-12 (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.
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Page B-21 of 28
B
PH-50 Pipe Handler
Shot Pin Assembly
Inspection
Weekly
Shot Pin Assembly
Check for leaks,
tighten fittings
Shot Pin
Base
Dowel Pin
Rod Seal
Assembly
Monthly
Shot Pin
Check for wear,
remove buurrs
Dual Port
Manifold
Rod Seal
Assembly
Monthly
Shot Pin Sleeve
Check for wear
Hydraulic
Motor
O-ring
Monthly
Shot Pin Bushing
Check for wear
Shot Pin
Cap
Pinion Gear
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.
Shot Pin
Cover
Figure B-12. PH-50: Inspecting the Shot Pin Assembly
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Revision D
Page B-22 of 28
PH-50 Pipe Handler
Rotating Link Adapter/Load Stem
Removing the Rotating Link Adapter (while the top
drive is in the 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 three-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.
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.
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B
PH-50 Pipe Handler
Rotating Link Adapter/Load Stem
Inspecting the Rotating Link Adapter
Eye Bolts
Rotary GLYD Ring
(10 Places)
Remove, discard and replace
Yearly
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
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
Figure B-13. PH-50: Inspecting the Rotating Link Adapter
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PH-50 Pipe Handler
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 assembling the stem to the link adapter.
!
Make sure the seals do not twist in the grooves.
11. Install the gear onto the link adapter and install the bolts.
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.
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Page B-25 of 28
PH-50 Pipe Handler
B
Rotating Link Adapter/Load Stem
Installing the Rotating Link Adapter (while the top drive
is in the mast)
1. Check the condition of the main shaft 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 index mark
faces forward.
3. Carefully lower the top drive to engage the main shaft 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 pipe handler 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 main shaft seal and use care not to
damage the seal or the case.
A light coating of grease applied to the O-ring helps in
installing the rotating link adapter assembly into the main
body.
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SM00856
Revision D
Page B-26 of 28
PH-50 Pipe Handler
Wireline Adapter
Inspection
i
Inspect the condition of the
sheaves before and after each use
Each Use
Sheaves
Replace or repair damaged
parts as necessary
Figure B-14. PH-50: Inspecting the Wireline Adapter
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Page B-27 of 28
B
PH-50 Pipe Handler
Nondestructive Examination
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, x-ray examination, and other
methods of nondestructive testing for metallurgical integrity.
Making Visual Inspections
Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare
the measurements with the information provided in the Links User Manual (D635000870) to
determine the current strength of the elevator links. The capacity of the links equals the capacity of
the weakest link.
Magnetic Particle Inspection (MPI)
Every five years, NOV recommends that customers inspect all top drive hoisting equipment using
the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation
listed in the following section before beginning the MPI for any equipment component.
Refer to the following standards that define the use of the wet fluorescent method of MPI when
examining machined surfaces for any equipment component.

ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings

ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection

I.A.D.C., Drilling Manual

API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance,
Repair and Remanufacture of Hoisting Equipment

API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI
inspection acceptance criteria)
Any indications found are a potential cause for replacing one or more of the following:

Main shaft (lower portion)

Bail

Split Load Collar

Upper and lower IBOP

Link adapter

Saver, crossover, and spacer subs

Power subs

Power swivels

Elevator links
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PH-50 Pipe Handler
SM00856
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Nondestructive Examination
Magnetic Particle Inspection (MPI)
The drilling operator may determine that the MPI schedule should occur more frequently, based on
one or more of the following factors:

environment

load cycles

regulatory requirements

operating time

testing

repairs
Please contact your NOV Service Center if you have any questions.
Ultrasonic Inspection
In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the
previously listed components to detect any erosion of the inside diameter. Any erosion reduces the
load carrying 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
IBOP Inspection
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.
Lubrication
Refer to the section titled "Lubrication Schedules" on page 5-58 for pipe handler component
lubrication schedules. Refer to Figure 5-36 on page 5-63 for general pipe handler lubrication
procedures.
B-28
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FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 2.0
Service Manual, Washpipe
Assembly
www.nov.com
WASHPIPE ASSEMBLY
Service Manual
SM01053
Revision A
© Copyright 2004 Varco® LP. All rights reserved.
Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This
publication is the property of, and contains information proprietary to, Varco International, Inc. No
part of this publication may be reproduced or copied in any form, or by any means, including
electronic, mechanical, photocopying, recording, or otherwise without the prior written permission
of Varco International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners. Information in this manual is subject to change without
notice.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended Audience and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Washpipe Assembly Pressure Ratings . . . . . . . . . . . . . . . . . . . . . 10
General Maintenance Practices . . . . . . . . . . . . . . . . . . . . 11
Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hammerless Washpipe Assembly . . . . . . . . . . . . . . . . . . 36
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removing the Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . 49
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Washpipe
3
4
Varco
General Information
Intended Audience and Use
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco International, Inc., will not be held liable for errors in this
material, or for consequences arising from misuse of this material.
This manual is intended as a supplement to the service manuals supplied with the Varco
Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with
additional information, and to advise the reader to take specific action to protect
personnel from potential injury or lethal conditions. They may also inform the reader of
actions necessary to prevent equipment damage.
Please pay close attention to these advisories.
Note:
i
The note symbol indicates that additional information is
provided about the current topics.
Caution:
!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning:
The warning symbol indicates a definite risk of
equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant
property loss, or significant equipment damage.
Illustrations
Figures provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not
be drawn to scale.
For more specific component information pertinent to your rig configuration, see the
technical drawings included with your Varco documentation.
Washpipe
5
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment
involving hazardous operations and situations. Proper service and repair is important for
safe and reliable operation. Operation and service procedures provided by Varco
manuals are the recommended methods of performing those operations.
!
To avoid injury to personnel or equipment damage,
carefully observe the following safety requirements.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on
the equipment, or those in the vicinity of the equipment, should be trained on rig safety,
tool operation, and maintenance to ensure their safety.
!
During installation, maintenance, or repair of equipment,
personnel should wear protective gear. Protective gear
must be worn during certain operation.
Contact the Varco training department for more information about equipment operation
and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
being described. Varco recommends that only those tools specified be used when
stated. Ensure that personnel and equipment safety are not jeopardized when using
service procedures or tools not specifically recommended by Varco.
6
Varco
Safety Requirements
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities,
such as electrical, hydraulic, pneumatic, or cooling water.
!
Before installing or performing maintenance or repairs on
equipment, read the following instructions to avoid
endangering exposed persons or damaging equipment.
‰
Isolate all energy sources before beginning work.
‰
Avoid performing maintenance or repairs while the equipment is in operation.
‰
Wear proper protective equipment during equipment installation, maintenance, or
repair.
Replacing Components
‰
Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during disassembly and reassembly of equipment to ensure correct installment.
‰
Replace failed or damaged components with Varco certified parts. Failure to do so
could result in equipment damage, or personal injury.
Routine Maintenance
Equipment must be maintained on a regular and routine basis. See the service manual
for maintenance recommendations.
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
Proper Use of Equipment
Varco equipment is designed for specific functions and applications, and should be used
only for their intended purpose.
Washpipe
7
General Description
Washpipe Assembly
The washpipe assembly is located between the main shaft and the gooseneck (S-pipe)
on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation
of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard
and hammerless.
8
Varco
General Description
Special Tools
The standard washpipe assembly has hammer nuts on its washpipe nut and packing
box. The hammer nuts are provided so that a special wrench and a hammer can be
used to tighten to washpipe nut and packing box during installation.
The hammerless washpipe assembly uses gear nuts which are tightened more precisely
without a hammer but with a special torque wrench kit. This feature makes the unit
easier to install by allowing the unit to swing in and out of its support bonnet before being
torqued and does not require the use of a hammer.
Standard Washpipe
Standard Washpipe Wrench
Strike here
Hammerless Washpipe
Torque Wrench
30-250 ft lb
Hammerless Washpipe
Torque Multiplier
3200 ft lb
Removable extension
not shown
Socket Adapter
Washpipe
9
Specifications
Washpipe Assembly Pressure Ratings
i
Assembly descriptions are repeated for similar units. Use
the assembly part number when referencing pressure
ratings.
Standard Washpipe Assembly
Description
Part No.
Pressure Rating
(psi)
Small Bore (3-inch)
30123290
7,500
Large Bore (4-inch)
30123440
7,500
Large-to-Small Bore
30153491-50
7,500
Hammerless Washpipe Assembly
10
Description
Part No.
Pressure Rating
(psi)
Large Bore (4-inch)
30156883
7,500
Large-to-Small Bore
30173058-50
7,500
Varco
General Maintenance Practices
Equipment Maintenance Records
Keep a record book of all maintenance procedures performed. Date each procedure,
followed by a description and the technician who performed it. This data is valuable for
fault finding and problem solving, should technical problems arise.
i
Procedures in this chapter relate to Varco only
components. See the vendor manuals for maintenance
procedures and schedules for the vendor equipment.
Maintenance Schedules
Maintenance schedules list preventive maintenance tasks.
Inspection schedules assume normal operating conditions. Some conditions (excessive
loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more
frequent inspection intervals. Perform the procedures indicated, as warranted by the
inspection.
Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the
important safety notes highlighted as Notes, Cautions, and Warnings used throughout
this manual.
To avoid serious injury or death, read and understand the following Warnings before
performing maintenance or troubleshooting procedures:
Unless instructed otherwise, properly lock out the
main power source before performing any
maintenance procedure.
Wear protective glasses to prevent eye injuries.
Do not attempt any adjustments while the machine is
moving.
Read and understand all safety precautions and
warnings before performing maintenance procedures.
Washpipe
11
Standard Washpipe Assembly
Initial Installation
Procedure
1. Install the washpipe assembly on the TDS/IDS and hand-tighten
the washpipe nut and packing box, then back off the packing box
and washpipe nut by 1/4 turn.
the packing box.
securely tighten.)
i
Nut
12
Varco
Standard Washpipe Assembly
Initial Installation
Washpipe
13
Standard Washpipe Assembly
Initial Installation
Procedure
11. Check washpipe alignment. Install dial indicator base on packing
box. Adjust dial indicator to contact the washpipe approximately
one inch above the packing box.
12. Rotate main shaft through one revolution, noting the minimum
and maximum readings on the dial indicator. Subtract the
minimum reading from the maximum reading to obtain the Total
Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.
Washpipe
Dial
Indicator
Packing
Box
14
Varco
Standard Washpipe Assembly
Maintenance Schedules
Inspection Schedule
Item
Inspect for
Interval
Mating surface of stem liner(s) while
it is installed in the TDS/IDS main
shaft or gooseneck
• Surface should be
TDS/IDS main shaft bearing endplay
Endplay is within
specification (refer to
TDS/IDS Service
Manual)
Once every six months
and immediately after
jarring
Washpipe Assembly grease fitting
Proper operation
Replace every six
months
Washpipe pilot on the gooseneck
and the washpipe pilot on the TDS/
IDS main shaft
Proper alignment
between pilots
After TDS/IDS main
shaft bearing endplay
has been checked and
is within specification
All parts
Refer to Disassembly
Procedure
Upon disassembly of
washpipe assembly
smooth and free of flaws
or burrs
• ID of stem liners
When washpipe
assembly is to be
removed from TDS/
IDS
Cleaning Schedule
Item
TDS/IDS bonnet (inside)
Procedure
Remove residual mud
Interval
Weekly
Lubrication Schedule
Washpipe
Item
Procedure
Interval
Washpipe Assembly grease fitting
Apply 3 to 4 pumps of
grease (refer to
Lubrication Procedure)
Twice daily or every 10
rotating hours
15
Standard Washpipe Assembly
Inspection Procedures
When Washpipe is to be Removed from TDS/IDS
Service Limit
(inches)
3.090
3.840
3.120
16
Varco
Standard Washpipe Assembly
Inspection Procedures
Every Six Months
Procedure
1. Remove the washpipe assembly and replace
the grease fitting.
2. Check the main shaft axial movement by
applying an upward force to the main shaft and
measuring the amount of axial movement with a
dial indicator.
3. If axial shaft movement is not .001 in. to .003
in., remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .003 in. of axial
shaft movement (end play) with the bearing
retainer capscrews tightened to the required
torque depending on the size of the capscrew
(refer to the Initial Installation Procedure for
proper torque requirements).
Washpipe
Grease Fitting
Replace
Dial
Indicator
Washpipe
17
Standard Washpipe Assembly
Inspection Procedures
Every Six Months
Gooseneck
Pilot
Dial
Indicator
0.002 TIR between
these two surfaces
Bonnet removed
for clarity.
Main Shaft
Pilot
18
Varco
Standard Washpipe Assembly
Lubrication Procedures
Daily Lubrication
Description
grease fitting.
Cyprina
2.
Washpipe
19
Standard Washpipe Assembly
Troubleshooting
i
The troubleshooting table does not necessarily cover all
possible symptoms. The table provides an insight to typical
symptoms, their possible causes, and what components to
check.
Symptom
Leakage at threads
between packing box and
TDS/IDS main shaft
Leakage at grease fitting
access hole
20
Probable cause
Remedy
Poly Pak seal failure in main
shaft stem liner
Replace seal by removing the stem liner
and installing the new seal. Be sure to
deburr the edges of the main shaft as
sharp edges will cut the seal on
installation. Reinstall the stem liner.
Lower O-ring failure
1. Remove washpipe assembly.
2. Inspect the main shaft and stem liner
for any burrs that can damage the O-ring
and deburr as required. The surface of
the stem liner should be smooth and flat.
If it is not, replace stem liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Stem liner not smooth and
does not allow O-ring to seal
properly
Follow instructions outlined in the
Inspection Procedures, When Washpipe
Is To Be Removed From TDS/IDS.
Stem liner not flat and does
not allow O-ring to seal
properly
Follow instructions outlined in the
Inspection Procedures, When Washpipe
Is To Be Removed From TDS/IDS.
Spacers not flat and prevents
packing seals from sealing
between spacers proper
Follow inspection procedures as outlined
in step 8 of the Disassembly Procedure.
Poly Pak seal failure in main
shaft stem liner
Replace seal by removing the stem liner
and installing the new seal. Be sure to
deburr the edges of the main shaft as
sharp edges will cut the seal on
installation. Reinstall the stem liner.
Lower O-ring failure
1. Remove washpipe assembly.
2. Inspect the main shaft and stem liner
for any burrs that can damage the O-ring
and deburr as required. The surface of
the stem liner should be smooth and flat.
If it is not, replace stem liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Varco
Standard Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Remedy
Leakage through grease
fitting access hole (cont)
Spacers not flat and prevents
packing seals from sealing
between spacers proper
Follow inspection procedures as outlined
the Inspection Procedure.
Leakage at grease fitting
Grease fitting failure
Follow inspection procedures as outlined
in step 12 of the Disassembly Procedure.
Leakage between the
washpipe and the packing
box
Packing failure
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Leakage between the
washpipe and the
washpipe nut
Packing failure or packing is
improperly seated
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Upper O-ring failure
1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
bore units with lined goosenecks, the
stem liner for any burrs that can damage
the O-ring and deburr as required. The
surface of the stem liner should be
smooth and flat. If it is not, replace stem
liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Upper O-ring failure
Leakage at threads
between washpipe nut and
gooseneck
1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
bore units with lined goosenecks, the
stem liner for any burrs that can damage
the O-ring and deburr as required. The
surface of the stem liner should be
smooth and flat. If it is not, replace stem
liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Premature failure after
greasing
Washpipe
Packing failure or packing
is improperly seated
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Improper greasing
procedure
Greasing can cause the seal to unseat
from the washpipe and cause premature
failure of the assembly. Running the TDS/
IDS without standpipe pressure allows
the seals to reseat. Follow greasing
procedure as outlined in the Lubrication
Procedures.
21
Standard Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Remedy
Premature failure
accompanied by
occasional spurts of mud
from packing box
Washpipe alignment caused
by improper installation, or
misalignment of the
gooseneck, or excessive
bearing endplay
If necessary, reinstall washpipe or realign
the gooseneck. Check washpipe
alignment as follows (see illustration on
following page):
1. Install dial indicator base on packing
box. Adjust dial indicator to contact the
washpipe approximately one inch above
the packing box.
2. Rotate main shaft through one
revolution, noting the minimum and
maximum readings on the dial indicator.
Subtract the minimum reading from the
maximum reading to obtain the Total
Indicated Runout (TIR). Maximum
allowable TIR is 0.007 inch.
3. If out of specification, check
gooseneck alignment.
Premature failure
accompanied by
occasional spurts of mud
from packing box
Misalignment of gooseneckto-washpipe pilot
Inspect main shaft and mainshaft-togooseneck alignment as described in the
Every Six Months Inspection procedure.
Installation problems
The proper installation sequence allows
the packing and washpipe to align to each
other, and ensures that both the
washpipe nut and the packing box
engage their pilots. Follow proper
installation procedures (refer to the Initial
Installation Procedure).
Nut not torqued
Improper torque prevents metal-to-metal
contact between the flat surfaces of the
spacers. When pressure is applied, it will
extrude the packing between the spacers.
Follow proper torquing procedures as
described in the Initial Installation
Procedure.
Too mush grease during
assembly of the unit
Too much grease prevents metal-to-metal
contact between the flat surfaces of the
spacers during operation. The grease can
sustain a hydrostatic pressure that resists
torque during the installation.
Premature failure due to
flanged packing
During operation the grease gradually
leaks out resulting in loosening of the
packing box. Follow proper greasing
procedure during reassembly and check
for proper spacer contact during
installation (refer to the Initial Installation
Procedure).
22
Varco
Standard Washpipe Assembly
Troubleshooting
Washpipe
Dial
Indicator
Packing
Box
Washpipe
23
Standard Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Packing is worn out
Poor greasing schedule or
improper grease.
Follow proper lubrication procedures.
RPM, pressure and mud
temperature too high
Friction between the seals and the
washpipe create heat. TDS/IDS rpm and
standpipe pressure contribute equally to
the amount of heat generated. If
pressure of rpm is increased, so is the
amount of heat generated. Heat
generation goes up with the square of the
bore size. Mud is what cools the system.
The hotter the mud, the less cooling it
provides. The greater the amount of heat
generated is relative to the amount of
cooling the mud will provide, the hotter
the seals run. As the seals run hotter, the
wear resistance of the rubber drops. If
using a large-bore washpipe, convert to a
small-bore washpipe.
Spacers too flat
If the spaces are not flat, then metal-tometal contact cannot be maintained even
when they are bottomed out against each
other. The resulting small gaps will allow
the packing to extrude into these areas.
Follow instructions outlined in the
Inspection Procedures.
Nut not torqued
Improper torque prevents metal-to-metal
contact between the flat surfaces of the
spacers. When pressure is applied, it will
extrude the packing between the spacers.
Follow proper torquing procedures as
described in the Initial Installation
Procedure.
Blue spacers
Improper torque or grease
on the OD of the spacers
Improper torque on the nut can lead to
situations where the lower and middle
spacers spin the packing box. The
resulting heat achieves temperatures
high enough to turn the spacers blue.
Unable to maintain torque
on packing box
Improper assembly or
installation
1. Remove washpipe assembly from
TDS/IDS.
2. Disassemble the washpipe assembly,
setting aside the packing seals for the
lower, middle, and upper spacers.
3. Reassemble the washpipe assembly
without the packing seals for the lower,
middle, and upper spacers.
Packing extruding
between spacers
24
Remedy
Varco
Standard Washpipe Assembly
Troubleshooting
Symptom
Unable to maintain torque
on packing box (cont)
Probable cause
Remedy
4. Reinstall the washpipe assembly on
the TDS/IDS as follows:
a. Install the packing box onto the TDS/
IDS main shaft. Tighten until spacers are
firmly held.
b. Install the holding ring into the
washpipe nut and install washpipe nut
onto the TDS/IDS goosneck until the
holding ring is firmly in place.
c. Using a dial indicator, measure and
record the distance between the flat
surfaces on the washpipe nut and the
packing box. Also for future use, mark the
location where the measurement is taken.
NOTE
To ensure that the washpipe assembly
has been sufficient tightened, measure
the distance with each subsequent
installation of the washpipe assembly.
Washpipe
25
Standard Washpipe Assembly
Disassembly
Procedure
Snap Ring
1. Remove washpipe assembly from the TDS/IDS.
2. Completely disassemble the washpipe assembly.
Take care to prevent damage to the sharp edge
of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings.
These parts are not serviceable and must be
replaced.
Holding Ring
Washpipe Nut
O-Ring
Packing Box
Grease
Fitting
i
Washpipe
Discard and replace
these non-serviceable
parts from the
washpipe assembly.
Upper Spacer
Packing Set
(5 per Set)
Socket Head
Dog Nose
Screw
Middle Spacer
Middle Spacer
O-Ring
26
Varco
Standard Washpipe Assembly
Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts.
5. Check that the ID of each spacer is within specification.
6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be
lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of
cuts, nicks, and burrs. If edge is damaged replace spacer.
This surface to be
smooth and flat
ID
This surface to be
smooth and flat
This edge to be
sharp
Spacer
Varco
Part
No.
Proper
ID
(inches)
Service
Limit ID
(inches)
Small Bore
Upper
Middle
Lower
123585
30123286
123287
3.635 to 3.640
3.635 to 3.640
3.635 to 3.640
3.645
3.645
3.645
Large Bore
Upper
Middle
Lower
30123434
30123435
30123436
4.895 to 4.900
4.895 to 4.900
4.895 to 4.900
4.905
4.905
4.905
Middle Spacer
Upper
Middle
Lower
123585
30123286
123287
3.635 to 3.640
3.635 to 3.640
3.635 to 3.640
3.645
3.645
3.645
Middle Spacer
Washpipe
Assembly
Large to Small Bore
Washpipe
Upper Spacer
27
Standard Washpipe Assembly
Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe
passes through.
9. Check that the ID of the packing box where the washpipe passes
through.
Washpipe
Nut
ID
Packing
Box
Washpipe
Assembly
Washpipe Nut
Part No.
Proper ID
(inches)
Service Limit ID
(inches)
Small Bore
123284
3.655 to 3.660
3.665
Large Bore
30123431
4.905 to 4.910
4.915
Large to
Small Bore
30153493
3.655 to 3.660
3.665
Washpipe
Assembly
Packing Box
Part No.
Proper ID
(inches)
Service Limit ID
(inches)
Small Bore
30123563
3.637 to 3.644
Large Bore
30123626
4.900 to 4.905
Large to
Small Bore
30153494
3.637 to 3.644
28
Varco
Standard Washpipe Assembly
Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight
undercut. If the undercut is no longer visible, replace the holding
ring.
Holding
Ring
This surface to be
smooth and flat
Undercut
rease
i
This surface to be
smooth and flat
11. Check that the flat portions of the holding ring are free of burrs
that could prevent the ring from seating properly. Burrs should
be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the
ball is not properly tensioned, replace the grease fitting. If in
doubt, replace the grease fitting. Replace the grease fitting every
six months or every other rebuild of the washpipe assembly,
whichever period is longer, even if the grease fitting is working
properly.
13. Reassemble the washpipe assembly as described in the
Reassembly Procedure.
Washpipe
29
Standard Washpipe Assembly
Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and
fill the plunge with grease, flush with the packing.
Packing
Seal
Fill with grease
to level shown
Spacer
2. Install one packing seal into each of the four spacers (one upper,
two middle, one lower) that go into the packing box. Wipe all
excess grease from the top edge of the packing and all excess
grease from the spacers. Take care to prevent damage to the
sharp edges of the spacers.
Upper Spacer
Sharp edge
of spacer
Sharp edge
of spacer
Sharp edge
of spacer
30
Wipe grease
from area shown,
all the way around
on each spacer.
Middle Spacer
Middle Spacer
Varco
Standard Washpipe Assembly
Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in
the packing box. Handle each spacer from the ID to ensure that
no grease gets between the metal portions of the spacer, or on
the outside diameter of the spacer. When installing the upper
spacer, line up the slot in the upper spacer with the dowel pin in
the packing box.
Dowel
Pin
Grease
Fitting
Socket Head
Dog Nose
Screw
Packing
Box
Ensure that the nose of the
socket head dog nose screw
is fully engaged in the groove of
the lower spacer (screw should
not push spacer off center)
.010" Min
i
In the following step, an Arbor press may be required
to compress the packing enough to in stall the screws.
4. Install the socket head cap screws. The heads of the screws
should bottom out in the nut casing. The dog head should not
bottom out on the space
er. The screw prevents the spacers from
not otherwise constrain them.
5.
packing box.
6.
NOT OVER GREASE.
Washpipe
31
Standard Washpipe Assembly
Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the
packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Washpipe
Nut
Washpipe
Packing
Box
32
Varco
Standard Washpipe Assembly
Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and
install in the holding ring, taking care to not damage the seal on
the splines of the washpipe. Wipe all excess grease from the top
edge of the packing and wipe all grease from the holding ring.
Holding
Ring
Wipe grease
from area shown,
all the way around
the holding ring.
Packing
Seal
Fill with grease
to level shown.
Holding
Ring
10. Insert the holding ring and packing, seal side down, over the
slotted end of the washpipe.
11. Install the snap ring.
12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
Packing
Seal
Snap
Ring
O-ring
13.
approximately the length of the washpip
pe.
14.
Initial Installation Procedure.
Washpipe
33
Standard Washpipe Assembly
Illustrated Parts List
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Set
5 per set
Washpipe
Nut
Middle Spacer
Middle Spacer
Washpipe
Lower Spacer
Packing Box
O-Ring
Grease Fitting
Socket Head
Dog Nose Screw
Long-Arm
Allen Wrench
34
Varco
Standard Washpipe Assembly
Illustrated Parts List
Washpipe
Description
Small Bore
(3-inch)
Large Bore
(4-inch)
Large-to-Small
Bore
Washpipe Assembly
30123290
30123440
30153491
O-Ring
51300-348-F
51300-359-F
51300-348-F
Snap Ring
30123562
123634
30123562
Holding Ring
30123288
30123437
30123288
Washpipe Nut
123284
30123431
30153493
Washpipe
30123289
(7,500 psi)
30123438
(7,500 psi)
30123289
(7,500 psi)
Packing Box
30123563
30123626
30153494
Grease Fitting
53219-1
53219-1
53219-1
Socket Head Screw
30123564
30123564
30123564
Upper Spacer
123585
30123434
123585
Middle Spacer
30123286
30123435
30123286
Lower Spacer
123287
30123436
123287
Pressure Seal Kit
(Packing Set)
30123290-PK
30123440-PK
30123290-PK
Stem Liners
98290
112871
30153492
Poly Pak Seal
98291
112895
112895
Grease
56005-1
56005-1
56005-1
35
Hammerless Washpipe Assembly
Initial Installation
Procedure
i
During installation the washpipe assembly is brought into
place as one unit and handled by a tugger line. Ensure that
the washpipe assembly is strapped together securely
before lifting.
1. Unlock the TDS/IDS handling yoke from its stored position
and swing it out to accept the washpipe assembly.
Makes the washpipe assembly
easier to install by allowing it to
swing in and out of the motorsupport bonnet.
i
Nut
Yoke
36
2 places
Varco
Hammerless Washpipe Assembly
Initial Installation
Procedure
the TDS/IDS main shaft.
4.
it until it makes contact with the top of the main shaft.
5.
packing box and the washpipe nuts.
6. Apply pipe dope to the threads and hand-tighten the
washpipe nut and packing box.
7.
align the pipe in the packing box.
8. Set the TDS/IDS brake.
Torque Multiplier
Ratio – 18.5 to 1
Removable extension
Torque Wrench
9. Loosen the thumb screw on the pinion gear and raise the
pinion gear from its stored position and lock the thumb
screw in place when it aligns with the gear on the packing
box. It may be necessary to rotate the square drive shaft
to engage the gears.
10. Install the torque kit assembly over the square shaft. Set
the torque wrench to 100 ft-lb and begin applying torque to
the packing box gradually until the torque wrench clicks.
Torque Wrench
Setting-ft.-lbf.
75
100
125
150
Applied Torque to
Nut-ft.-lbf.
4,500
6,000
7,500
9,000
11. Disengage the pinion gear from the packing box gear and
engage it with the washpipe nut gear and secure it in
place. Similarly, apply torque to the washpipe nut,
completing the installation of the washpipe assembly.
12. Apply 6 to 8 pumps of grease to the grease fittings.
13. Return the pinion gear to its stored position and secure it
with the thumb screw. Secure the handling yoke to its
stored position by pinning it with the two pins.
14. Release the TDS/IDS brake and rotate the TDS/IDS at
approximately 50 rpm for one minute.
Washpipe
37
Hammerless Washpipe Assembly
Maintenance Schedules
Inspection Schedule
Inspect for
Item
Interval
Mating surface of stem liner(s) while
it is installed in the TDS/IDS main
shaft or gooseneck
• Surface should be
TDS/IDS main shaft bearing endplay
Endplay is within
specification (refer to
TDS/IDS Service
Manual)
Once every six months
and immediately after
jarring
Washpipe Assembly grease fitting
Proper operation
Replace every six
months
Washpipe pilot on the gooseneck
and the washpipe pilot on the TDS/
IDS main shaft
Proper alignment
between pilots
After TDS/IDS main
shaft bearing endplay
has been checked and
is within specification
All parts
Refer to Disassembly
Procedure
Upon disassembly of
washpipe assembly
smooth and free of flaws
or burrs
• ID of stem liners
When washpipe
assembly is to be
removed from TDS/
IDS
Cleaning Schedule
Procedure
Item
TDS bonnet (inside)
Remove residual mud
Interval
Weekly
Lubrication Schedule
Item
Procedure
Interval
Washpipe Assembly grease fitting
Apply 3 to 4 pumps of
grease
Twice daily or every 10
rotating hours
!
To prevent rust from damaging parts, properly clean and
grease the following parts before storage:
1. Jacking nut and shaft threads
2. Square shaft from top to bottom
3. Gear teeth on all three gears
38
Varco
Hammerless Washpipe Assembly
Inspection Procedures
Every Six Months
Washpipe Assembly Alignment
Satisfactory packing life depends on good washpipe alignment. Use the following
procedure to check sleeve-to-gooseneck support alignment:
1. Attach an indicator base to the gooseneck support and place the indicator at the
top of the sleeve.
2. Raise and lower the sleeve and record the total indicator reading.
3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or
packing box.
4. Rotate the sleeve 360° and record the TIR.
Washpipe Assembly Tolerances
Use the following procedure to check washpipe assembly tolerances:
1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to
0.003 inch.
2. Check the clearance by raising and lowering the sleeve. The maximum allowable
misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum
allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum
allowable misalignment after complete assembly of the washpipe assembly is
0.010 inch TIR.
i
Inspection may indicate misalignment exceeding
recommended limits. The packing box assemblies are
designed to accommodate misalignment of the sleeve to
the gooseneck and can operate with some excessive
misalignment. However, to achieve maximum packing life,
maintain the misalignment at the washpipe within the
recommended limits.
Washpipe
39
Hammerless Washpipe Assembly
Inspection Procedures
Every Six Months
Procedure
1. Remove the washpipe assembly and replace
the grease fitting.
2. Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator.
3. If axial shaft movement is not .001 in. to .003
in., remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .003 in. of axial
shaft movement (end play) with the bearing
retainer capscrews tightened to the required
torque depending on the size of the capscrew
(refer to the Initial Installation Procedure for
proper torque requirements).
Washpipe
Grease Fitting
Replace
Dial
Indicator
40
Varco
Hammerless Washpipe Assembly
Inspection Procedures
Every Six Months
Gooseneck
Pilot
Dial
Indicator
0.002 TIR between
these two surfaces
Bonnet removed
for clarity.
Main Shaft
Pilot
Washpipe
41
Hammerless Washpipe Assembly
Lubrication Procedures
Daily Lubrication
Recommended Grease
Procedure
Manufacturer
Description
Shell
Cyprina
1. Twice daily or once every 10 hours of rotation,
apply 3 to 4 pumps of grease to the washpipe
grease fitting.
2. Rotate the TDS/IDS at 50 rpm for one minute
with 0 psi standpipe pressure.
3. Turn on the mud pumps and check for leaks.
42
Varco
Hammerless Washpipe Assembly
Troubleshooting
i
The troubleshooting table does not necessarily cover all
possible symptoms. The table provides an insight to typical
symptoms, their possible causes, and what components to
check.
Symptom
Leakage at threads
between packing box and
TDS/IDS main shaft
Leakage at grease fitting
access hole
Washpipe
Probable cause
Remedy
Poly Pak seal failure in main
shaft stem liner
Replace seal by removing the stem liner
and installing the new seal. Be sure to
deburr the edges of the main shaft as
sharp edges will cut the seal on
installation. Reinstall the stem liner.
Lower O-ring failure
1. Remove washpipe assembly.
2. Inspect the main shaft and stem liner
for any burrs that can damage the O-ring
and deburr as required. The surface of
the stem liner should be smooth and flat.
If it is not, replace stem liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Stem liner not smooth and
does not allow O-ring to seal
properly
Follow instructions outlined in the
Inspection Procedures, When Washpipe
Is To Be Removed From TDS/IDS.
Stem liner not flat and does
not allow O-ring to seal
properly
Follow instructions outlined in the
Inspection Procedures, When Washpipe
Is To Be Removed From TDS/IDS.
Spacers not flat and prevents
packing seals from sealing
between spacers proper
Follow inspection procedures as outlined
in step 8 of the Disassembly Procedure.
Poly Pak seal failure in main
shaft stem liner
Replace seal by removing the stem liner
and installing the new seal. Be sure to
deburr the edges of the main shaft as
sharp edges will cut the seal on
installation. Reinstall the stem liner.
Lower O-ring failure
1. Remove washpipe assembly.
2. Inspect the main shaft and stem liner
for any burrs that can damage the O-ring
and deburr as required. The surface of
the stem liner should be smooth and flat.
If it is not, replace stem liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
43
Hammerless Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Remedy
Leakage through grease
fitting access hole (cont)
Spacers not flat and prevents
packing seals from sealing
between spacers proper
Follow inspection procedures as outlined
the Inspection Procedure.
Leakage at grease fitting
Grease fitting failure
Follow inspection procedures as outlined
in step 12 of the Disassembly Procedure.
Leakage between the
washpipe and the packing
box
Packing failure
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Leakage between the
washpipe and the
washpipe nut
Packing failure or packing is
improperly seated
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Upper O-ring failure
1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
bore units with lined goosenecks, the
stem liner for any burrs that can damage
the O-ring and deburr as required. The
surface of the stem liner should be
smooth and flat. If it is not, replace stem
liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Upper O-ring failure
Leakage at threads
between washpipe nut and
gooseneck
1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
bore units with lined goosenecks, the
stem liner for any burrs that can damage
the O-ring and deburr as required. The
surface of the stem liner should be
smooth and flat. If it is not, replace stem
liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Premature failure after
greasing
44
Packing failure or packing
is improperly seated
Disassemble and inspect components.
Replace worn or damaged components
on reassembly of the washpipe.
Improper greasing
procedure
Greasing can cause the seal to unseat
from the washpipe and cause premature
failure of the assembly. Running the TDS/
IDS without standpipe pressure allows
the seals to reseat. Follow greasing
procedure as outlined in the Lubrication
Procedures.
Varco
Hammerless Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Remedy
Premature failure
accompanied by
occasional spurts of mud
from packing box
Washpipe alignment caused
by improper installation, or
misalignment of the
gooseneck, or excessive
bearing endplay
If necessary, reinstall washpipe or realign
the gooseneck. Check washpipe
alignment as follows (see illustration on
following page):
1. Install dial indicator base on packing
box. Adjust dial indicator to contact the
washpipe approximately one inch above
the packing box.
2. Rotate main shaft through one
revolution, noting the minimum and
maximum readings on the dial indicator.
Subtract the minimum reading from the
maximum reading to obtain the Total
Indicated Runout (TIR). Maximum
allowable TIR is 0.007 inch.
3. If out of specification, check
gooseneck alignment.
Premature failure
accompanied by
occasional spurts of mud
from packing box
Misalignment of gooseneckto-washpipe pilot
Inspect main shaft and mainshaft-togooseneck alignment as described in the
Every Six Months Inspection procedure.
Installation problems
The proper installation sequence allows
the packing and washpipe to align to each
other, and ensures that both the
washpipe nut and the packing box
engage their pilots. Follow proper
installation procedures (refer to the Initial
Installation Procedure).
Nut not torqued
Improper torque prevents metal-to-metal
contact between the flat surfaces of the
spacers. When pressure is applied, it will
extrude the packing between the spacers.
Follow proper torquing procedures as
described in the Initial Installation
Procedure.
Too mush grease during
assembly of the unit
Too much grease prevents metal-to-metal
contact between the flat surfaces of the
spacers during operation. The grease can
sustain a hydrostatic pressure that resists
torque during the installation.
Premature failure due to
flanged packing
During operation the grease gradually
leaks out resulting in loosening of the
packing box. Follow proper greasing
procedure during reassembly and check
for proper spacer contact during
installation (refer to the Initial Installation
Procedure).
Washpipe
45
Hammerless Washpipe Assembly
Troubleshooting
Washpipe
Dial
Indicator
Packing
Box
46
Varco
Hammerless Washpipe Assembly
Troubleshooting
Symptom
Probable cause
Packing is worn out
Poor greasing schedule or
improper grease.
Follow proper lubrication procedures.
RPM, pressure and mud
temperature too high
Friction between the seals and the
washpipe create heat. TDS/IDS rpm and
standpipe pressure contribute equally to
the amount of heat generated. If
pressure of rpm is increased, so is the
amount of heat generated. Heat
generation goes up with the square of the
bore size. Mud is what cools the system.
The hotter the mud, the less cooling it
provides. The greater the amount of heat
generated is relative to the amount of
cooling the mud will provide, the hotter
the seals run. As the seals run hotter, the
wear resistance of the rubber drops. If
using a large-bore washpipe, convert to a
small-bore washpipe.
Spacers too flat
If the spaces are not flat, then metal-tometal contact cannot be maintained even
when they are bottomed out against each
other. The resulting small gaps will allow
the packing to extrude into these areas.
Follow instructions outlined in the
Inspection Procedures.
Nut not torqued
Improper torque prevents metal-to-metal
contact between the flat surfaces of the
spacers. When pressure is applied, it will
extrude the packing between the spacers.
Follow proper torquing procedures as
described in the Initial Installation
Procedure.
Blue spacers
Improper torque or grease
on the OD of the spacers
Improper torque on the nut can lead to
situations where the lower and middle
spacers spin the packing box. The
resulting heat achieves temperatures
high enough to turn the spacers blue.
Unable to maintain torque
on packing box
Improper assembly or
installation
1. Remove washpipe assembly from
TDS/IDS.
2. Disassemble the washpipe assembly,
setting aside the packing seals for the
lower, middle, and upper spacers.
3. Reassemble the washpipe assembly
without the packing seals for the lower,
middle, and upper spacers.
Packing extruding
between spacers
Washpipe
Remedy
47
Hammerless Washpipe Assembly
Troubleshooting
Symptom
Unable to maintain torque
on packing box (cont)
Probable cause
Remedy
4. Reinstall the washpipe assembly on
the TDS/IDS as follows:
a. Install the packing box onto the TDS/
IDS main shaft. Tighten until spacers are
firmly held.
b. Install the holding ring into the
washpipe nut and install washpipe nut
onto the TDS/IDS goosneck until the
holding ring is firmly in place.
c. Using a dial indicator, measure and
record the distance between the flat
surfaces on the washpipe nut and the
packing box. Also for future use, mark the
location where the measurement is taken.
NOTE
To ensure that the washpipe assembly
has been sufficient tightened, measure
the distance with each subsequent
installation of the washpipe assembly.
48
Varco
Hammerless Washpipe Assembly
Removing the Washpipe Assembly
Remove the washpipe assembly by reversing the Installation Procedure.
!
Once the packing box and washpipe nuts are unscrewed,
the assembly must be strapped together as one unit before
it is picked up by the handling yoke.
i
The hammerless washpipe assembly must always be
handled as one unit. Avoid disassembly unless you
suspect faulty parts (refer to Troubleshooting).
Washpipe
49
Hammerless Washpipe Assembly
Disassembly
Procedure
Snap Ring
1. Remove washpipe assembly from the TDS/IDS.
2. Completely disassemble the washpipe assembly.
Take care to prevent damage to the sharp edge
of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings.
These parts are not serviceable and must be
replaced.
Holding Ring
Washpipe
Nut
O-Ring
Packing
Box
i
Washpipe
Discard and replace
these non-serviceable
parts from the
washpipe assembly.
Grease
Fitting
Socket Head
Dog Nose Screw
Upper Spacer
Packing Set
(5 per Set)
Middle Spacer
Middle Spacer
O-Ring
50
Varco
Hammerless Washpipe Assembly
Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts.
5. Check that the ID of each spacer is within specification.
6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be
lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of
cuts, nicks, and burrs. If edge is damaged replace spacer.
This surface to be
smooth and flat
ID
This surface to be
smooth and flat
This edge to be
sharp
Spacer
Varco
Part
No.
Proper
ID
(inches)
Service
Limit ID
(inches)
Large Bore
Upper
Middle
Lower
30123434
30123435
30123436
4.895 to 4.900
4.895 to 4.900
4.895 to 4.900
4.905
4.905
4.905
Large to Small Bore
Upper
Middle
Lower
123585
30123286
123287
3.635 to 3.640
3.635 to 3.640
3.635 to 3.640
3.645
3.645
3.645
Washpipe
Assembly
Washpipe
Upper Spacer
Middle Spacer
51
Hammerless Washpipe Assembly
Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe
passes through.
9. Check that the ID of the packing box where the washpipe passes
through.
hpipe
ut
ID
Packing
Box
Washpipe
Assembly
Washpipe Nut
Part No.
Proper ID
(inches)
Service Limit ID
(inches)
Large Bore
30123431
4.905 to 4.910
4.915
Large to
Small Bore
30153493
3.655 to 3.660
3.665
Washpipe
Assembly
Packing Box
Part No.
Proper ID
(inches)
Service Limit ID
(inches)
Large Bore
30123626
4.900 to 4.905
Large to
Small Bore
30153494
3.637 to 3.644
52
3 650
Varco
Hammerless Washpipe Assembly
Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight
undercut. If the undercut is no longer visible, replace the holding
ring.
Holding
Ring
This surface to be
smooth and flat
Undercut
Grea
Fitti
This surface to be
smooth and flat
11. Check that the flat portions of the holding ring are free of burrs
that could prevent the ring from seating properly. Burrs should
be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the
ball is not properly tensioned, replace the grease fitting. If in
doubt, replace the grease fitting. Replace the grease fitting every
six months or every other rebuild of the washpipe assembly,
whichever period is longer, even if the grease fitting is working
properly.
13. Reassemble the washpipe assembly as described in the
Reassembly Procedure.
Washpipe
53
Hammerless Washpipe Assembly
Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and
fill the plunge with grease, flush with the packing.
Packing
Seal
Fill with grease
to level shown
Spacer
2. Install one packing seal into each of the four spacers (one upper,
two middle, one lower) that go into the packing box. Wipe all
excess grease from the top edge of the packing and all excess
grease from the spacers. Take care to prevent damage to the
sharp edges of the spacers.
Upper Spacer
Sharp edge
of spacer
Sharp edge
of spacer
Wipe grease
from area shown,
all the way around
on each spacer.
Middle Spacer
Sharp edge
of spacer
54
Varco
Hammerless Washpipe Assembly
Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in
the packing box. Handle each spacer from the ID to ensure that
no grease gets between the metal portions of the spacer, or on
the outside diameter of the spacer. When installing the upper
spacer, line up the slot in the upper spacer with the dowel pin in
the packing box.
Dowel
Pin
Grease
Fitting
Socket Head
Dog Nose
Screw
Packing
Box
Ensure that the nose of the
socket head dog nose screw
is fully engaged in the groove of
the lower spacer (screw should
not push spacer off center)
.010" Min
i
In the following step, an Arbor press may be required
to compress the packing enough to in stall the screws.
4. Install the socket head cap screws. The heads of the screws
should bottom out in the nut casing. The dog head should not
bottom out on the space
er. The screw prevents the spacers from
not otherwise constrain them.
5.
packing box.
6.
NOT OVER GREASE.
Washpipe
55
Hammerless Washpipe Assembly
Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the
packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Washpipe
Nut
Washpipe
Packing
Box
56
Varco
Hammerless Washpipe Assembly
Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and
install in the holding ring, taking care to not damage the seal on
the splines of the washpipe. Wipe all excess grease from the top
edge of the packing and wipe all grease from the holding ring.
Holding
Ring
Wipe grease
from area shown,
all the way around
the holding ring.
Packing
Seal
Fill with grease
to level shown.
Holding
Ring
10. Insert the holding ring and packing, seal side down, over the
slotted end of the washpipe.
11. Install the snap ring.
12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
Packing
Seal
Snap
Ring
O-ring
13.
approximately the length of the washpip
pe.
14.
Initial Installation Procedure.
Washpipe
57
Hammerless Washpipe Assembly
Illustrated Parts List
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Set
5 per set
Washpipe
Nut
Middle Spacer
Middle Spacer
Washpipe
Lower Spacer
Packing Box
O-Ring
Grease Fitting
Socket Head
Dog Nose Screw
Long-Arm
Allen Wrench
58
Varco
Hammerless Washpipe Assembly
Illustrated Parts List
Description
Washpipe
Large Bore
(4-inch)
Large-to-Small Bore
Washpipe Assembly
30156883 & 30156883-750
30173058-50 & 30173058-100
O-Ring
51300-359-F
51300-348-F
Snap Ring
123634
30123562
Holding Ring
30123437
30123288
Washpipe Nut
30152547
30173057
Washpipe - Low Pressure
30123438 (7,500 psi)
30123289 (7,500 psi)
Washpipe - High Pressure
30123438-TC (7,500 psi)
30123289-TC (10,000 psi)
Packing Box
30156884
30173056
Grease Fitting
53219-1
53219-1
Socket Head Screw
30123564
30123564
Upper Spacer
30123434
123585
Middle Spacer
30123435
30123286
Lower Spacer
30123436
30123287
Pressure Seal Kit (Packing
Set)
30123584-2 (7,500 psi)
123292-2 (7,500 psi)
Stem Liner
112871
30153492
Poly Pak Seal
112895
112895
Grease
56005-1
56005-1
59
Glossary
ID - Inner Diameter
IDS - Integrated Drilling System
OD - Outer Diamaeter
TDS - Top Drive System
TIR - Total Indicator Reading
60
Varco
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 3.0
Links User Manual
www.nov.com
LINKS
USER’S MANUAL
Weldless Links
Perfection Links
Original Instructions
REFERENCE
Links
REFERENCE DESCRIPTION
Weldless Links and Perfection Links
This document contains proprietary and confidential
information which is the property of National Oilwell
Varco, L.p, its affiliates or subsidiaries (all collectively referred
to hereinafter as "NOV"). It is loaned for limited purposes
only and remains the property of NOV. Reproduction, in
whole or in part, or use of this design or distribution of this
information to others is not permitted without the express
written consent of NOV. This document is to be returned to
NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained
and represented herein is the copyrighted property of NOV.
DOCUMENT NUMBER
50000870-MAN-001
www.nov.com
VarcoBJ BV
Nijverheidsweg 45
4879 AP Etten-Leur
P.O. Box 17
4870 AA Etten-Leur
The Netherlands
Tel + 31-76-5083000
Fax + 31-76-5046000
www.nov.com
REV
E
Nov 2011
User’s Manual
Weldless Links
Perfection Links
REFERENCE
Link
REFERENCE DESCRIPTION
Links
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.p., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is
the copyrighted property of NOV.
DOCUMENT NUMBER
50000870-MAN-001
www.nov.com
VarcoBJ B.V.
Nijverheidsweg 45
4879AP Etten-Leur
Tel: +31-76-5083000
Fax: +31-76-5046000
REV
E
Document number
Revision
Page
50000870-MAN-001
E
2 of 20
Revision History
Revision
Change Description
-
First Issue
A
New style
B
Corrections
C
Corrections
D
Info added
E
Corrections
This document is PDM-link controlled
Change Description
E
21.11.2011
Corrected link compatibility
E
21.11.2011
Added information about allowable twist & wear data
D
01.06.2009
Added Link connectors info
C
18.05.2009
Added wear size Perfection links
B
28.10.2008
Added Link connector info
B
30.06.2008
Page 14: The SLX 5.1/2” - 24.1/2” link DOES fit in 500 tons 3.1/2” links, pn 25469
A
26.03.2007
Data updated; part numbers, inspection,handle
-
12.03.2007
Issued for Implementation
Rev
Date
Reason for issue
© Copyright 2011 NOV®. All rights reserved.
Varco is a registered trademark of Varco I/P reg. U.S. Patent & Trademark Office. This publication is the property of, and
contains information proprietary to NOV. No part of this publication may be reproduced or copied in any form, or by any means,
including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of NOV®.
All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective
owners. Information in this manual is subject to change without notice.
Patents Pending US & Worldwide (D) Varco I/P, Inc. No US. D533,432.
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Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Link restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Design safety factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safe Working Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Weldless Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Perfection Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reference Numbers* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Perfection links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Link handle kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Elevator link compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Link connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection & wear data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear chart shaft (shank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear chart forged links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear data Perfection links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MPI and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Qualifications and certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Evaluation of indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Acceptance criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Equipment covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Table of Contents
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1: General Information
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General Information
This manual contains installation, operation, maintenance and parts information. Information in
this manual should enable qualified personnel to install, operate and troubleshoot this system.
Every effort has been made to ensure the accuracy of the information contained herein. National
Oilwell Varco (NOV) will not be held liable for errors in this material, or for consequences arising
from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information and advise the reader
to take specific action to protect personnel from potential injury or lethal conditions. They may
also inform the reader of actions necessary to prevent equipment damage. Please pay close
attention to these advisories
Note:
The note symbol indicates that additional information is provided about the
current topics.
Caution:
The caution symbol indicates that potential damage to equipment or injury
to personnel exists. Follow instructions explicitly. Extreme care should be
taken when performing operations or procedures preceded by this caution
symbol.
Warning:
The warning symbol indicates a definite risk of equipment damage or
danger to personnel. Failure to observe and follow proper procedures
could result in serious or fatal injury to personnel, significant property
loss, or significant equipment damage.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not be
drawn to scale.
For component information specific to your application, see the technical drawings included with
your NOV documentation.
Safety Requirements
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in NOV manuals are the recommended methods of performing operations
and maintenance.
Caution: To avoid injury to personnel or equipment damage, carefully observe
requirements outlined in this section.
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1: General Information
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Caution: Personnel should wear protective gear during installation, maintenance, and
certain operations.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
NOV recommends that only those tools specified be used when stated. Ensure that personnel
and equipment safety are not jeopardized when following service procedures or using tools not
specifically recommended by NOV.
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.
Caution: Read and follow the guidelines below before installing equipment or performing
maintenance to avoid endangering exposed persons or damaging equipment.

Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.

Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installment.

Replace failed or damaged components with genuine NOV parts. Failure to do so could
result in equipment damage or injury to personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
Caution: Failure to conduct routine maintenance could result in equipment damage or
injury to personnel.
Proper Use of Equipment
NOV equipment is designed for specific functions and applications, and should be used only for
its intended purpose.
Lifting
The lifting procedures should carefully be observed and carried out according to the manual.
Link restrictions
The Link is designed to be used as an connecting element between Top Drive Systems and
elevators, or between Hooks and elevators, and must not be used for any other purpose.
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1: General Information
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Design safety factor
The design-safety factor and design verification of the links is in accordance with requirements
of API specification 8A, 8C PSL 1 or 8C PSL2.
During manufacturing the link is proof load tested to 1.5 times the rated load.
Safe Working Load
Per API Specification 8C – The operator of the equipment shall be responsible for determination
of the safe working load for any hoisting operation. The Safe working load is equal to the design
load minus the dynamic load.
Limited warranty
The warranty will be void if the Link were either:

unauthorized modified, repaired or serviced

replacement parts not manufactured by NOV were utilized

not properly stored or maintained

any welding is carried out
Identification numbers
You will find the serial number of the tool stamped into the shank near the small eye.
CE marking
The link complies with the Machinery Directive 98/37/EC and 2006/42/EC
The marking is as follows:
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1: General Information
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2: Specifications
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General specifications
Description
Weldless Links
Weldless links are forged from a single billet of high strength alloy steal and heat treated to
provide maximum strength and toughness. Additional material is added in critical wear areas for
extended life. NOV Weldless Links are available in 250, 350, 500, 750, and 1000 ton ratings.
Perfection Links
Dependable, efficient perfection links are designed for light loads. They are made by forging,
bending and electric welding of high quality steel bar stock, which is then heat-treated and
magnafluxed. For loads which exceed capacity ratings of perfection links Varco BJ Weldless
links are recommended.
Intended usage
The links are designed to hang elevators from Top Drive Systems, Hooks, Beckets and Link
Adapters.
Fig. 1
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Part No.
Nominal link Size, in (mm)
size (inch)
Rated Capacity /Set, Weight/Set,
tons (tonnes)
lb (Kg)
16363-1060
16363-1072
16363-1084
16363-1096
16363-1108
16363-1132
16363-1168
26940-1060
26940-1072
26940-1084
26940-1096
26940-1108
26940-1120
26940-1132
26940-1144
26940-1150
26940-1168
26940-1180
26940-1192
26940-1200
26940-1216
26940-1240
26940-1264
26940-1290
26940-1350
26940-1360
26940-1480
26940-1540
26940-1600
25469-1072
25469-1096
25469-1108
25469-1120
25469-1132
25469-1144
25469-1160
25469-1168
25469-1180
25469-1190
25469-1192
25469-1216
25469-1226
25469-1264
25469-1360
25469-1480
25469-1540
2.1/4 x 60
2.1/4 x 72
2.1/4 x 84
2.1/4 x 96
2.1/4 x 108
2.1/4 x 132
2.1/4 x 168
2.3/4 x 60
2.3/4 x 72
2.3/4 x 84
2.3/4 x 96
2.3/4 x 108
2.3/4 x 120
2.3/4 x 132
2.3/4 x 144
2.3/4 x 150
2.3/4 x 168
2.3/4 x 180
2.3/4 x 192
2.3/4 x 200
2.3/4 x 216
2.3/4 x 240
2.3/4 x 264
2.3/4 x 290
2.3/4 x 350
2.3/4 x 360
2.3/4 x 480
2.3/4 x 540
2.3/4 x 600
3.1/2 x 72
3.1/2 x 96
3.1/2 x 108
3.1/2 x 120
3.1/2 x 132
3.1/2 x 144
3.1/2 x 160
3.1/2 x 168
3.1/2 x 180
3.1/2 x 190
3.1/2 x 192
3.1/2 x 216
3.1/2 x 226
3.1/2 x 264
3.1/2 x 360
3.1/2 x 480
3.1/2 x 540
250 (226.8)
250 (226.8)
250 (226.8)
250 (226.8)
250 (226.8)
250 (226.8)
250 (226.8)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
350 (317.5)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
500 (453.6)
60” (1524)
72” (1828.8)
84” (2133.6)
96” (2438.4)
108” (2743.2)
132” (3353)
168” (4267)
60” (1524)
72” (1828.8)
84” (2133.6)
96” (2438.4)
108” (2743.2)
120” (3048)
132” (3353)
144” (3657)
150” (3810)
168” (4267.2)
180” (4572)
192” (4876.8)
200” (5080)
216” (5486.4)
240” (6096)
264” (6705)
290” (7366)
350” (8890)
360” (9144)
480” (12192)
540” (13716)
600” (15240)
72” (1829)
96” (2438)
108” (2743.2)
120” (3048)
132” (3353)
144” (3688)
160” (4064)
168” (4267.2)
180” (4572)
190” (4826)
192” (4826)
216” (5486)
226” (5740)
264” (6705.6)
360” (9144)
480” (12192)
540” (13716)
2: Specifications
480 (218)
530 (241)
580 (264)
630 (286)
680 (309)
780 (355)
880 (399)
620 (282)
685 (311)
740 (336)
805 (366)
870 (395)
935 (425)
1,000 (454)
1,064 (483)
1,095 (498)
1,190 (541)
1,255 (571)
1,320 (600)
1,363 (618)
1,450 (659)
1,580 (718)
1,770 (800)
1,944 (882)
2,180 (988)
2,235 (1014)
2,885 (1306)
3,187 (1446)
3,408 (1546)
705 (320)
1058 (480)
1,450 (659)
1,622 (736)
1,670 (759)
1,780 (809)
1,927 (876)
2,000 (909)
2,110 (959)
2,202 (998)
2,220 (1007)
2,422 (1098)
2,596 (1177)
2,882 (1307)
3,174 (1440)
3,968 (1800)
4,519 (2050)
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Document number
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Part No.
50000870-MAN-001
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Nominal link Size, in (mm) Rated Capacity /Set, Appr. weight/
size (inch)
tons (tonnes)
Set, lb (Kg)
16143-1132
4.3/4 x 132
16143-1144
4.3/4 x 144
16143-1160
4.3/4 x 160
16143-1180
4.3/4 x 180
16143-1200
4.3/4 x 200
16143-1216
4.3/4 x 216
16143-1240
4.3/4 x 240
16143-1264
4.3/4 x 264
16143-1300
4.3/4 x 300
70101-1200*
5.1/2 x 200
M614000320Y1180 5.1/2 x 180
M614000320Y1200 5.1/2 x 200
M614000320Y1240 5.1/2 x 240
For TDS-4 and TDS-5
15386-1108
2.3/4 x 108
132” (3352)
144” (3688)
160” (3688)
180” (4572)
200” (5080)
216” (5486)
240” (6096)
264” (6705)
300” (7620)
200” (5080)
200” (5080)
200” (5080)
200” (5080)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
750 (680.4)
1000 (907.2)
1,250 (1133)
1,250 (1133)
1,250 (1133)
1,741 (790)
2,312 (1051)
3,178 (1445)
3,900 (1769)
4,550 (2063)
5,200 (2364)
5,864 (2660)
7,275 (3300)
8,800 (3991)
5,100 (2315)
4,550 (2063)
5,100 (2315)
7,275 (3300)
108” (2743.2)
350 (317.5)
920 (418)
* other lengths on request
Reference Numbers*
Link P/N
Nominal Dim.
250 Ton
16363
2.1/4”
“
“
350 Ton
26940
2.3/4
"
“
500 Ton
25469
3.1/2
"
“
750 Ton
16143
4.3/4
"
“
1000 Ton
70101
5.1/2
"
“
1250 Ton
M614000320 5.1/2
"
“
A
B
C
D
E
F
G
H
in
(mm)
2.5/16"
58.7
5.1/2"
139.7
7.1/2"
190.5
2.7/8"
73
9.1/2"
241.3
12"
304.8
5"
127
15"
381
in
(mm)
2.13/16" 5.5/8"
71.4
142.9
8.3/8"
212.7
3.1/2"
88.9
9.1/2"
241.3
12"
304.8
5"
127
15"
381
in
(mm)
3.5/8"
92.1
6.1/2"
165.1
10.1/8"
257.2
4.1/2"
114.3
9.1/2"
241.3
12"
304.8
6"
152.4
17"
431.8
in
(mm)
7.1/2"
190.5
10"
254
14.5/8"
371.5
6"
152.4
10"
254
14.5/8"
371.5
7.1/2"
190.5
23"
584.2
in
(mm)
8.1/4"
209.6
12.3/4"
323.9
17.1/2"
444.5
6"
152.4
12.3/4" 17.1/2"
323.9 444.5
8.1/4"
209.6
29.1/4"
743
in
(mm)
8.1/4"
209.6
12.3/4"
323.9
17.1/2"
444.5
6"
152.4
12.3/4" 17.1/2"
323.9 444.5
8.1/4"
209.6
29.1/4"
743
* The dimensions are nominal and actual dimensions will vary slightly due to manufacturing
tolerances. All API contact radius dimensions are manufactured to API specifications, see Fig. 1
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2: Specifications
Perfection links
9.00
5.00
X
Fig. 2
2.00
3.12
Part No.
Size, in (mm)
Rated Cap/Set, Weight/Set, lb Dimension X inch
tons (tonnes)
(Kg)
(mm))
200450-130
200450-136
200450-142
200450-148
200450-160
2” x 30” (50.8 x 762)
2” x 36” (50.8 x 914)
2” x 42” (50.8 x 1,067)
2” x 48” (50.8 x 1,219)
2” x 60” (50.8 x 1,524)
100 (89.3)
100 (89.3)
100 (89.3)
100 (89.3)
100 (89.3)
49 (108)
58 (128)
67 (148)
76 (168)
95 (208)
30 (762)
36 (914)
42 (1,067)
48 (1,219)
60 (1,524)
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Link handle kit
The Link handle kit can be used in combination with any Manual Operated Elevator. It is
developed for easier handling of links and functions as a safe gripping point when closing and
opening elevators. It suitable for 250 (2.1/4”) and 350 (2.3/4”)ton links.
Part number 50006435.
Fitting
The handle(s) must be mounted to the eye of the link, and not to the shank.
Ensure no interference occurs between handle and elevator when rotating the elevator.
Fitted
handle
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2: Specifications
Elevator link compatibility
WARNING: Never use links which have a capacity too low
for carrying the load intended (dynamic + static), even if the
links may fit on the elevator.
Elevator links
Top Drive Solid Body Elevator Rating
250T
400T
500T
650T
250 Ton 2.1/4" pn 16363
yes
no
no
no
350 Ton 2.3/4" pn 26940
yes
yes
yes
yes
500 Ton 3.1/2" pn 25469
no
yes
yes
yes
750 Ton 4.3/4" pn 16143
no
no
no
yes
1000 Ton 5.1/2" pn 70101
no
no
no
no
1250 Ton 5.1/2" pn M14000320Y no
no
no
no
Elevator links
Elevator Y series
250 Ton 2.1/4" pn 16363
350 Ton 2.3/4" pn 26940
500 Ton 3.1/2" pn 25469
750 Ton 4.3/4" pn 16143
1000 Ton 5.1/2" pn 70101
YC
yes
yes
no
no
no
1250 Ton 5.1/2" pn M14000320Y no
750T
no
yes
yes
yes
no
no
MYC
yes
yes
no
no
no
HYC
yes
yes
yes
no
no
YT
yes
yes
no
no
no
HYT
yes
yes
yes
no
no
LYT*
no
no
no
no
no
MYT
yes
yes
no
no
no
no
no
no
no
no
no
*Requires link 7/8” - 1.3/4
Elevator links
Elevator T(M)A series
TA 1.050 - 2.7/8 TMA 2.3/8 - 5
250 Ton 2.1/4" pn 16363
350 Ton 2.3/4" pn 26940
500 Ton 3.1/2" pn 25469
750 Ton 4.3/4" pn 16143
1000 Ton 5.1/2" pn 70101
1250 Ton 5.1/2" pn M14000320Y
no
no
no
no
no
no
yes
yes
no
no
no
no
Elevator links
Elevator G series
250 Ton 2.1/4" pn 16363
350 Ton 2.3/4" pn 26940
500 Ton 3.1/2" pn 25469
750 Ton 4.3/4" pn 16143
1000 Ton 5.1/2" pn 70101
1250 Ton 5.1/2" pn M14000320Y
MG
yes
yes
no
no
no
no
RGG
yes
yes
no
no
no
no
MGG
yes
yes
yes
no
no
no
GG
yes
yes
yes
no
no
no
HGG
no
yes
yes
yes
no
no
TA 4.3/4 - 8.5/8
up to 100 ton
yes
yes
no
no
no
no
RGA
yes
yes
no
no
no
no
GA
yes
yes
yes
no
no
no
TA 4.3/4 - 11.1/4
150 ton only
yes
yes
yes
no
no
no
GGA
yes
yes
yes
no
no
no
www.nov.com
Document number
Revision
Page
2: Specifications
Elevator links
50000870-MAN-001
E
15 of 20
Elevator X series
SX
SSD
SLX
SLX
SSD
8.5/8-10.3/4 except
1.66-5.1/2 5.1/2-24.1/2 1.66-7.5/8
+ 11.3/4-14 350 ton
250 Ton 2.1/4" pn 16363 yes
yes
yes
yes
no
350 Ton 2.3/4" pn 26940 yes
yes
yes
yes
yes
500 Ton 3.1/2" pn 25469 no
yes
no
yes
yes
750 Ton 4.3/4" pn 16143 no
no
no
no
no
1000 Ton 5.1/2" pn 70101 no
no
no
no
no
1250 Ton 5.1/2"
no
no
no
no
no
pn M14000320Y
Elevator X series
SMX
SMX
150 Ton
250 + 350 Ton
250 Ton 2.1/4" pn 16363 yes
yes
350 Ton 2.3/4" pn 26940 yes
yes
500 Ton 3.1/2" pn 25469 no
yes* (rotation limited)
750 Ton 4.3/4" pn 16143 no
no
1000 Ton 5.1/2" pn 70101 no
no
1250 Ton 5.1/2"
no
no
pn M14000320Y
yes
yes
yes
no
no
no
elevators in
combination with 500
ton links gives reduced
rotation possibility. Be
advised to use 350 ton
links.
Casing Elevators /
Spiders BJ Type
Elevator links
750T 1000T
250T 350T 500T 1000T
24.1/2” 24.1/2”
no
no
yes no
no
no
no
no
yes yes no
no
yes
no
yes yes yes yes
yes
yes
no
yes yes yes
no
yes
no
no
no
no
no
yes
no
Riser handling solid body elevator rating
250 T
400 T
500 T
650T
750 T
250 Ton 2.1/4" pn 16363 yes
no
no
no
no
350 Ton 2.3/4" pn 26940 yes
yes
yes
yes
yes
500 Ton 3.1/2" pn 25469 no
yes
yes
yes
yes
750 Ton 4.3/4" pn 16143 no
no
no
yes
yes
1000 Ton 5.1/2" pn 70101 no
no
no
no
yes
1250 Ton 5.1/2"
no
no
no
no
yes
pn M14000320Y
no
no
Elevator links
www.nov.com
no
SLX
SD
*250 and 350 ton SMX
Elevator links
Casing Elevators /
Spiders Varco Type
750T
200T 350T 500T
14”
250 Ton 2.1/4" pn 16363 yes yes no
no
350 Ton 2.3/4" pn 26940 yes yes yes no
500 Ton 3.1/2" pn 25469 yes yes yes yes
750 Ton 4.3/4" pn 16143 no
no
no
yes
1000 Ton 5.1/2" pn 70101 no
no
no
no
1250 Ton 5.1/2"
no
no
no
no
pn M14000320Y
SX
350
ton
yes
yes
yes
no
no
1000T
no
no
no
yes
yes
yes
no
Document number
Revision
Page
50000870-MAN-001
E
16 of 20
Elevator links
2: Specifications
BX1
450 T
250 Ton 2.1/4" pn 16363 yes
350 Ton 2.3/4" pn 26940 yes
500 Ton 3.1/2" pn 25469 yes
750 Ton 4.3/4" pn 16143 no
1000 Ton 5.1/2" pn 70101 no
1250 Ton 5.1/2"
no
pn M14000320Y
BX2
500 T
no
yes
yes
no
no
BX3
350 T
no
yes
yes
yes
no
BX4-35
350 T
no
yes
yes
yes
no
no
no
no
Elevator links
BX4-75
750 T
no
no
yes
yes
no
BX5
1000 T
no
no
no
yes
yes
BX7
1250 T
no
no
no
no
yes
BXS, Slip type
350 T
yes
yes
yes
no
no
no
yes
yes
no
BX4-50
500 T
250 Ton 2.1/4" pn 16363 yes
350 Ton 2.3/4" pn 26940 yes
500 Ton 3.1/2" pn 25469 yes
750 Ton 4.3/4" pn 16143 no
1000 Ton 5.1/2" pn 70101 no
1250 Ton 5.1/2"
no
pn M14000320Y
NOTES:
1. Compatibility is based on API 8C radii unless specific link part No's are listed.
2. If a link part No. is not listed, suitable fit with the SBE is to be confirmed
3. In some cases special links are required for use on Top Drive SBE's to permit proper
operation of link tilt.
4. In general, an elevator will fit one size larger and one size smaller noted link. However, fit
should always be confirmed when combining sizes of links and elevators.
Link connectors
The link connector can be used to make a link assembly up to 50/60 Feet long.
Part number 350 ton: 250167.
Part number 500 ton: not available yet.
Partnumber 750: 250341
www.nov.com
Document number
Revision
Page
3: Inspection and wear data
50000870-MAN-001
E
17 of 20
Inspection & wear data
Safety
WARNING: NOV does not allow welding of links and bails. Links and
bails cannot be repaired or reconditioned by welding.
WARNING: Ensure daily if the secondary retention (wire, cotter pins) is
in good condition. Replace or repair if needed.
NOTE: Capacity of set is that of the weakest link.
Wear chart shaft (shank)
Wear/damage may result in a reduced section of the material, hence this will lead to a derating
of the link according to below table.
250 Ton Link 350 Ton Link 500 ton link
750 Ton Link 1000 Ton Link
1250 Ton Link
Diameter Rating Diameter Rating Diameter Rating Diameter Rating
Diameter
Rating
Diameter
Rating
2.75"
2.688"
2.625"
2.5"
5.25"
5.125"
5"
4.875"
1000
962
915
870
5.25"
5.125"
5"
4.875"
1250
1202
1143
1087
250
215
200
185
3.25"
3.188"
3.125"
3"
350
325
312
288
3.688"
3.625"
3.5"
3.375"
500
480
450
415
4.55"
4.438"
4.375"
4.25"
750
725
700
662
Wear chart forged links
Fig. 3
Upper eye
Lower eye
NOTE: In general, an allowable twist between the upper and lower eye is 2
degrees
Link
1.3/4" - 150 TON
www.nov.com
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
3.38"
3.25"
3.13"
Height less than 3.13
(greater or equal to)
1.625"
1.50"
1.44"
Height less than 1.44
(Short Ton)
150
125
112.5
Scrap
Document number
Revision
Page
50000870-MAN-001
E
18 of 20
Link
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
4.75"
4.63"
4.5"
Height less than 4.5"
(greater or equal to)
2.06"
1.88"
1.75"
Height less than 1.75"
(Short Ton)
250
200
180
Scrap
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
4.75"
4.63"
4.5"
Height less than 4.50"
(greater or equal to)
2.56"
2.38"
2.25"
Height less than 2.25"
(Short Ton)
350
290
260
Scrap
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
5.625"
5.25"
5."
Height less than 5"
(greater or equal to)
3.25"
3"
2.75"
Height less than 2.75"
(Short Ton)
500
440
375
Scrap
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
7"
6.75"
6.5"
Height less than 6.5"
(greater or equal to)
7"
6.75"
6.5"
Height less than 6.5"
(Short Ton)
750
700
600
Scrap
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
7.875"
7.5"
7.125"
Height less than 7.125"
(greater or equal to)
7.875"
7.5"
7.125"
Height less than 7.125"
(Short Ton)
1000
900
800
Scrap
Upper Eye (A)
Lower Eye (B)
Rating
(greater or equal to)
7.875"
7.5"
7.125"
Height less than 7.125"
(greater or equal to)
7.875"
7.5"
7.125"
Height less than 7.125"
(Short Ton)
1250
1125
1000
Scrap
2.1/4" - 250 TON
Link
2.3/4" - 350 TON
Link
3.1/2" - 500 TON
Link
750 TON
Link
1000 TON
Link
1250 TON
3: Inspection and wear data
Wear data Perfection links.
Standard diameter of a Perfection link is 2.00”.
Minimum allowable diameter is 1.75”
www.nov.com
3: Inspection and wear data
Document number
Revision
Page
50000870-MAN-001
E
19 of 20
MPI and inspection
References
1. ASTM E 709 (latest edition)
Standard Practice for Magnetic Particle Examination
2. ASTM A 275 (latest edition)
Standard Test Method for Magnetic Particle Examination of Steel Forgings.
3. API Specification 8A & 8C (latest edition)
4. API Recommended Practice RP 8B (latest edition)
Qualifications and certification
All personnel performing and interpreting examinations shall be qualified in accordance with the
guidelines of ASNT-TC-1A (latest edition) or an equivalent standard recognized by ASNT. All
personnel performing NDE shall also be trained in the NDE of forgings as well as trained in the
interpretation of the MPI with regard to the acceptance criteria.
Evaluation of indications
Relevant indications:
Only those indications with major dimensions greater than 1/16 inch (1.6mm) and associated
with a surface rupture shall be considered relevant. Relevant indications are indications that
results from discontinuities within the test part. Non relevant indications are indications that
results from excessive magnetizing current, structural design or permeability variances within
the test parts. Any indication believed to be non relevant shall be regarded as relevant and shall
be re-examined to determine whether an actual defect exists. Linear indications shall be
considered as those having a length of more than three times the width. Rounded indications
shall be considered as those having a length less than three times the width. Aligned indication
should be considered as a group of three or more indications which touch an imaginary straight
line connecting any two of the group.
Acceptance criteria
The link is considered critical in all area’s.
Equipment covered
Wrought material: In all cases as specified in the following table.
Relevant Indications
No relevant indications with a major dimension equal to or greater than
3/16 inch (4.8 mm)
No more than ten indications of 1/16 inch (1.6 mm) long or greater in
any continuous 6-square-inch (40 cm2) area
No more than three 1/16 inch (1.6 mm) long or greater indications in a
line separated by less than 1/16 inch (1.6 mm) edge to edge
www.nov.com
Document number
Revision
Page
50000870-MAN-001
E
20 of 20
3: Inspection and wear data
www.nov.com
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 4.0
Technical Drawing Package
www.nov.com
Technical Drawing Package
TDS-11SA
NOV Galena Park
AC Ideal Rig 135
RIG/PLANT
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
REMARKS
MAIN TAG NUMBER
DISCIPLINE
CLIENT PO NUMBER
CLIENT DOCUMENT NUMBER
Client Document Number
www.nov.com
D811000461-GEN-001/04
REFERENCE
REFERENCE DESCRIPTION
M611005667-GEN-001
Customer Configuration
This document contains proprietary and confidential information
which is the property of National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV.
Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to
NOV upon request or upon completion of the use for which it was
loaned. This document and the information contained and
represented herein is the copyrighted property of NOV.
© National Oilwell Varco
National Oilwell Varco
RIG SOLUTIONS
11000 Corporate Centre Drive
Houston, TX 77041
DOCUMENT NUMBER
REV
D811002283-DOS-001
01
Document number
Revision
Page
D811002283-DOS-001
01
2
REVISION HISTORY
01
13/01/2012
Rev
Date (dd.mm.yyyy)
First Issue
Reason for issue
T. Harmon
H. Lim
H. Lim
Prepared
Checked
Approved
CHANGE DESCRIPTION
Revision
01
Change Description
First Issue
www.nov.com
D811000461-GEN-001/04
Document number
Revision
Page
D811002283-DOS-001
01
3
TECHNICAL DRAWING PACKAGE
This document provides a list of drawings for the TDS-11SA. The actual drawings are arranged
in the binder by assembly order.
Drawings by Assembly
General
Customer Configuration ................................................................................ M611005667-GEN-001
General Arrangement, TDS-11SA ......................................................................................30170471
Hydraulic Schematic, TDS-11SA...................................................................D614000075-GAD-001
Block Diagram…………….. ........................................................................................ 10620480-DIA
Electrical Interconnect Diagram, TDS-11SA ............................................................. 10620482-DIA
Cable Schedule, TDS-11SA ....................................................................................... 10620483-IDX
Network Topology, TDS-11SA………………………… ............................................... 10620486-DIA
I/O Map…………......................................................................................................... 10620484-IDX
Hazardous Equipment Index………………….. ........................................................... 10620485-IDX
Top Drive Assembly
Motor Housing, TDS-11SA ............................................................................................... 120900-UL
Drilling Motor Assembly .......................................................................... 118217-40R60 & 40L60
Lube Pump Assembly .................................................................................................... 117603-1
Rotating Link Adapter Assembly ...................................................................................30173277
Hydraulic Drive/Shot Pin Assembly ....................................................................... 30151875-504
Hydraulic Oil Reservoir Assembly ................................................................................. 110068-2
Electrical Package ................................................................................................... 30188268-A60R
Motor/Pump Assembly................................................................................................... 114113-2
Manifold Assembly.............................................................................................................114174
Hydraulic Plumbing Package..................................................................................................121403
Carriage Package…………………………. .................................................................. 30124540-502
Carriage Assembly (Left)……… ................................................................................ 124538-502
Carriage Assembly (Right)…….. ........................................................................... 30124539-502
Counterbalance Package………………………… ........................................................... 112190-120
Cylinder Assembly………………………………..................................................................110703
Cylinder Assembly………………………………..................................................................110704
Motor Guard Package………….. ............................................................................................120917
S-Pipe Package……………….. .............................................................................. 30156835-R75-2
Washpipe Assembly.....................................................................................................30123290
www.nov.com
D811000461-GEN-001/04
Document number
Revision
Page
D811002283-DOS-001
01
4
Bail Package………………. ............................................................................................ 121442-120
Shipping Package……………… ................................................................................. 30179070-501
Lubrication Kit…………………............................................................................................ 92643-15
Counterbalance Attachment Kit…………………. ..................................................... 118244-BLOCK
BX Elevator Control Kit.. ............................................................................................ 30151452-CRT
Manifold Assembly, BX Elevator ............................................................................ 30156900-UL
Manifold Assembly, Rectifier ........................................................................................30116378
Pipe Handler and Adapter Kits
Pipe Handler Package, PH-75…………………………………….. .............................. 30157366-35-B
Hydraulic Cylinder Assembly………………. ..................................................................30119592
Torque Arrestor Assembly………………………. ...........................................................30157288
Cylinder Assembly, IBOP Actuator ............................................................................125594
Cylinder Assembly, Clamp…………………………………………………................30157287
Stabbing Guide Assembly……………….. ............................................................125158
Jaw Assembly……………………………. .........................................................30125052
Upper IBOP………………… ...................................................................................... 110103-500
Lower IBOP……………… .......................................................................................... 114706-500
IBOP (External) Crank Assembly…………………………. ...................................................98898
PH-75 Tool Kit………………………………………………. .................................. 30157616-NC50
Service Loops and Derrick Kits
Service Loop Kit, Electrical ...................................................................................... 30183283-75-75
Derrick Leg Kit………………………….. .......................................................................... 124977-100
Derrick Termination Kit .......................................................................................................30183678
Rigging
Guide Beam Kit………………………………………………………………………………..M614003021
Lower Tieback Kit………………………………………………………………………...………30178883
Accessories
Tool Joint Adapter Kit, NC38…………………………………………………...……….30157622-NC38
www.nov.com
D811000461-GEN-001/04
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.1
General
www.nov.com
This document contains proprietary information, and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from Varco International, Inc.
LTR
01
02
REVISIONS
PREPARED / DATE
DESCRIPTION
INITIAL RELEASE
See ECN
H. Lim
C. George
STANDARD ORDER INFORMATION
SHIPMENT DATE:
27-Jan-12
PRE-SHIP DATA:
N/A
RIG TYPE:
Land
INSTALLATION LOC:
US
OPERATING LOC:
US
RELATED CONFIGS:
N/A
SALES ORDER #:
25957
PO #:
GPK1000406
QUOTE #:
142603
SPARES QUOTE #:
N/A
TURNKEY QUOTE #:
N/A
UNIT #:
TBD
SERIAL (TDS)#:
TBD
CHECKED/ DATE
7/5/11 M. Clark
03-May-12 H. Lim
Rev. 0
APVD / DATE
7/5/11 H. Lim
03-May-12 H. Lim
QUALITY REQUIREMENTS
CERT AUTHORITY / RULES:
NATIONAL REGULATIONS:
INDEPENDENT BODY:
DATA BOOK:
3rd PARTY SERVICES:
NONE
NONE
NONE
NONE
NONE
CONTACT NOTES
CUSTOMER:
Tel:
Fax:
E-mail:
CONTRACTS:
SALES:
RESPONSIBLE ELEC. ENG.:
RESPONSIBLE MECH. ENG.:
Joyce Guilford
Michael Martin
Michael Maslyar
Hyoung Lim
7/5/11
03-May-12
APPLICATION NOTES:
1. Customer Configuration document to be inserted into the front of the Technical Drawing Package in the Owner’s Manual by the end user. The Customer
Configuration lists the rig specific part numbers used to identify the drawings.
2. Configured with IDEAL Rig Guide Beam Design and PH-75 Pipehandler.
3. Unit is CRT-Ready.
4. Configured with four section guide beam kit.
Sheet 1 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
PART NUMBER
QTY
-1* BSC
DESCRIPTION
*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.
QTE PO
REF REF
INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.
REFERENCE DRAWINGS / TEST SPECIFICATIONS
30170471
REF DRAWING, GENERAL ARRANGEMENT, TDS-11SA
D614000075-GAD-001
REF SCHEMATIC, HYDRAULIC, TDS-9/11SA, AC IDEAL RIG
M614003010-SPL-001
REF SPARES LIST, MECHANICAL, AC IDEAL RIG, TDS-11SA
ASP00020
REF TDS-9SA/11SA Motor Housing Assembly Procedure
3ASP00073
REF TDS-9SA/11SA Motor Installation Procedure, Brake Hub & Pinion Gear
3ASP00030
REF TDS Inspection Form
TS00259
REF Test Specification, Motor Housing Assembly, TDS-9SA/11SA
TS00271
REF TDS-9SA/11SA Final Function Test Procedure
TS00286
REF TDS-9SA/11SA Factory System Test
TS00162
REF Test Specification, Hydrostatic Pressure & Post MPI Test (Gooseneck / S-Pipe)
TS00168
REF Test Specification, Mag Particle Inspection
TS00419
REF Post Function Test, Hydraulic Fluid Cleanliness
TS00465
REF Hydrostatic Pressure Test, Rotating Link Adapter Assembly, PH-75
TS00167
REF Test Spec. Link Pull Test, All
TS00465
REF Hydrostatic Pressure Test, Clamp Cylinder Body
10620480-DIA
REF BLOCK DIAGRAM, TDS-11SA
10620482-DIA
REF ELECTRICAL INTERCONNECT DIAGRAM, TDS-11SA
10620483-IDX
REF CABLE SCHEDULE, TDS-11SA
10620484-IDX
REF I/O MAP, TDS-11SA
10620485-IDX
REF HAZARDOUS EQUIPMENT INDEX, TDS-11SA
10620486-DIA
REF NETWORK DIAGRAM, TDS-11SA
10620488-SPL
REF CONTROL SPARE LIST, TDS-11SA
D744000275
REF TRACEABILITY WORK SHEEET, TDS-9/10/11
Sheet 2 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
PART NUMBER
QTY
-1* BSC
DESCRIPTION
*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.
TOP DRIVE ASSEMBLY
M611005667-1
1
OID(10388308-001)
120900-UL
1
30188268-A-60-R
1
30151452-CRT
121403
1
1
30124540-502
30157366-35-B
1
1
112190-120
120917
1
1
30156835-R75-2
1
121442-120
30179070-501
92643-15
30157616-NC50
118244-BLOCK
QTE PO
REF REF
INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.
MOTOR/CARRIAGE ASSY, TDS-11SA
5000-7500 psi
1
MOTOR HOUSING, TDS-11SA
Pressure Rating:
ELECTRIC PACKAGE, TDS-11SA
System Electrical: UL
Installation Type:
Service Loop Location: Right
BX ELEVATOR CONTROL KIT
HYDRAULIC PLUMBING PACKAGE, TDS-11SA
System Electrical: UL
CARRIAGE PACKAGE, TDS-9/11SA
Setback:
PIPE HANDLER PACKAGE, PH-75, TDS-11SA
Drill String Connection: NC50
IBOP Trim:
Link Option: 350 Ton
COUNTERBALANCE PACKAGE, TDS-9/11SA
MOTOR GUARD PACKAGE, TDS-9/11SA
System Electrical: UL
S-PIPE PACKAGE, TDS-9/11SA
Mud Hose Connection: 4", Female Fig. 1002 S-Pipe Location:
Pressure Rating: 7500 psi
BAIL PACKAGE, TDS-9/11SA
Bail Length:
SHIPPING PACKAGE, GUIDE BEAM: W/SKID
Setback:
LUBRICATION KIT, TDS-9/11SA Lubricant Temperature Class:
1
1
PIPE HANDLER KIT, PH-75
Drill String Connection: NC50
COUNTERBALANCE ATTACHMENT KIT
Attachment: To Block
1
1
Sheet 3 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
Portable
39.5"
Standard
Right
120"
39.5", PH-75
High
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
PART NUMBER
QTY
-1* BSC
DESCRIPTION
*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.
RIGGING
M614003021
1
30178883
1
QTE PO
REF REF
INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.
GUIDE BEAM KIT: IDEAL RIG: FOUR SECTION IDEAL RIG
Mast Height: 142A ft
Guide Beam Section Length: TBD
KIT, TIEBACK LOWER
CONTROL SYSTEM (TDCS)
MJOB-7127-00
REF AC DRIVE HOUSE, Supplied By NOV-Ross-Hill
TDCS Connectors: Power & Control Cables
VFD Option: Ross Hill
TDCS Incoming Freq.: 60 Hz
CABLE REQUIREMENTS
30183283-75-75
1
124977-100
120591-100
30183287-100
30183678
30178585-50-H
84514-96-0
1
1
1
1
1
5
SERVICE LOOP KIT, 777 MCM (TDS to mid Derrick)
System Electrical: UL
Installation Type: Portable
Service Loop Length: 75 ft
Aux. Loop Length: 75 ft
DERRICK LEG KIT, 777 MCM, QD Installation Type: Portable
CRT DERRICK LEG CABLE – 24/C
CRT DERRICK LEG CABLE – 7 TSP
DERRICK TERMINATION KIT, 646 MCM/777 MCM, QD Installation Type: Portable
CABLE ASSEMBLY, 5 TSP
HEAT SHRINK TUBING
Sheet 4 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
PART NUMBER
QTY
-1* BSC
DESCRIPTION
*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.
QTE PO
REF REF
INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.
ACCESSORIES/SPECIAL ITEMS
30157622-NC38
1 TOOL JOINT ADAPTER KIT, NC38
26940Y1120
1 WELDLESS LINK, 350 TON X 120” LENGTH
Sheet 5 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
PART NUMBER
QTY
-1* BSC
DESCRIPTION
*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.
QTE PO
REF REF
INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.
SPARES
SERVICE MANUALS AND SUPPLEMENTS
10482378-001
4 OWNER’S MANUAL: TDS-11SA
D811002283-DOS-001
REF
TECHNICAL DRAWING PACKAGE
M611005667-GEN-001
4 CUSTOMER CONFIG DOCUMENT: See Note 1 on sheet 1.
LEGACY D811002283-MAN-001
CLASSIFICATION SOCIETY/STATUTORY/INDUSTRIAL STD
Designed, Built & Tested to API-8C, PSL-1
REF
REF CRITICAL LOAD PATH ITEMS - See later page(s) of this configuration
TDS SUMMARY (W/ACCESSORIES)
TDS Motor Type (2)
Elect. Type:
Space Htr per motor
Solenoids
Blower motor:
HydSystemMotor:
X
X
1
9
5
10
AC
UL
QTY
QTY
HP
HP
Encoder
EEx
115 VAC
24 VDC
575 VOLTS
575 VOLTS
X
60
Div 2
Hz
250 WATTS
60
60
Hz
Hz
3
3
Sheet 6 of 7
CUSTOMER
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
02
PHASE
PHASE
2
1
QTY
QTY
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
CLP: Critical Load Path (CLP) Component Index
ESS = ESSENTIAL COMPONENT
PRI = PRIMARY
ESS PRI
Motor/Carriage Assy: TDS-11SA (M611005667-1)
Motor Housing Assy (120900-UL)
Main Body (121227)
Main Shaft w/ Landing Collar (121131)
Collar, Landing (Set) (118377)
Retainer, Landing Collar (118378)
Rotating Link Adapter, 500 ton (121341)
Body, Rotating Link Adapter (121340)
S-Pipe Package (30156835-R75-2)
Weldment, S-Pipe (117063-7500)
Supply Pipe, Bent (117062-7500)
Sub, Female (81156)
Male Sub (110038)
Nut, 4” (81161)
Sub, Female, 3” (91922)
Casting, Adapter (110037)
Blind Plug, 3” (91921)
Nut, 3” Hammer Union (91924)
Wing Nut, 4” (81158)
Elbow, S-Pipe, 4” Female Fig. 1002 (84617)
Bail Package, 500 Ton (121442-120)
Bail (109505-3)
Bail Pin (109506)
Pipe Handler Package (30157366-35-B)
Saver Sub, NC50 (76666-2)
Upper IBOP (110103-500)
Lower IBOP (114706-500)
X
X
X
X
X
X
X
X
SEC = SECONDARY
SEC
PPC
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CONFIGURATION
FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012
ESS
PRI
X
X
X
X
X
X
X
X
X
X
X
X
Adapter Kit, PH-75, NC38 (30157622-NC38)
Crossover Sub (110852)
Saver Sub, NC50 (118954-1)
X
X
X
X
X
X
X
Weldless Link, 350 Ton X 120” (26940Y1120)
X
X
X
X
REVISION
DOCUMENT NUMBER
M611005667-GEN-001
SEC PPC
Pipe Handler Kit, PH-75 (30157616-NC50B)
Crossover Sub (79410-3)
Saver Sub, NC50 (76666-2)
Spacer Sub (80098)
X
X
X
Sheet 7 of 7
CUSTOMER
PPC = PRIMARY PRESSURE-RETAINING COMPONENT
02
CUSTOMER / OWNER
Cust:
Rig:
GALENA PARK
AC IDEAL RIG 135
TDS-11SA
MJOB-8375
TDS-11SA
NEXT ASSY
USED ON
APPLICATION
This document contains proprietary and confidential information which belongs to National-Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned
for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use
of this design or distribution of this information to others is not permitted without the express written
consent of NOV. This document is to be returned to NOV upon request and in any event upon
completion of the use for which it was loaned. This document and the information contained and
represented herein is the copyrighted property of NOV. © National Oilwell Varco
CURRENT
TITLE
CABLE SCHEDULE, TDS-11SA
AC IDEAL RIG 135
INITIAL
DRAWN
B. BOEPPLE
CHECKED
R. MOENCH
SIZE
APPVD
R. MOENCH
B
DATE
11/1/2011
SCALE
DWG NO
REV
10620483-IDX 01
NONE
WT LBS
SHEET
1 OF 3
D74DCF0049-TPL-001 (REV B)
FROM
TO
CABLE ID
CABLE
NOV
GLAND
GLAND
CABLE
TAG NO.
CONSTRUCTION
PART NO.
SIZE
P/N
TYPE
TAG NO.
30175017-75-4-3-B
-
-
-
POWER
POWER
POWER
POWER
POWER
POWER
POWER
POWER
POWER
POWER
POWER
POWER
PE
POWER
POWER
POWER
PE
POWER
POWER
POWER
PE
N.I.S.
TD-MOT-01
TD-MOT-01
TD-MOT-01
TD-MOT-01
TD-MOT-02
TD-MOT-02
TD-MOT-02
TD-MOT-02
TD-P01
TD-P02
TD-P03
TD-P04
TD-ENC-01
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
DRILL MOTOR ASSEMBLY
TOP DRIVE PLUG PANEL
MAST PLUG PANEL
MAST PLUG PANEL
MAST PLUG PANEL
MAST PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
DRILL MOTOR INCREMENTAL ENCODER
TD-P01-U
TD-P01-V
TD-P01-W
TD-P01-G
VFD
VFD
VFD
VFD
TD-PNJB01
TD-N03
2
7C x 1.5 mm
-
-
-
N.I.S.
TD-HTR-01
DRILL MOTOR HEATER #1
TD-N04
7C x 1.5 mm2
-
-
-
N.I.S.
TD-HTR-02
DRILL MOTOR HEATER #2
TD-P08
4C x 2.5 mm
2
-
-
-
POWER
TD-MOT-03
TD-P06
4C x 2.5 mm2
-
-
-
POWER
TD-P07
CAB-N03A
CAB-N03
CAB-N03B
TD-LOOP 2
4C x 2.5 mm2
3 TSP x 16 AWG
3 TSP x 16 AWG
3 TSP x 16 AWG
124457-75-4-4-B
-
-
POWER
N.I.S.
N.I.S.
N.I.S.
POWER
TD-P01C
TD-P02C
TD-P03C
TD-P04C
TD-P01D
TD-P02D
TD-P03D
TD-P04D
TD-LOOP 1
TD-P01A
TD-P02A
TD-P03A
TD-P04A
TD-P01
TD-P02
TD-P03
TD-P04
TD-P01-U
TD-P02-V
TD-P03-W
TD-P04-G
TD-N20
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
1C x 4/0 AWG
3C x 777MCM + 3C x 2/0 AWG
1C x 646MCM
1C x 646MCM
1C x 646MCM
1C x 444MCM
1C x 646MCM
1C x 646MCM
1C x 646MCM
1C x 4/0 AWG
1C x 646MCM
1C x 646MCM
1C x 646MCM
1C x 4/0 AWG
2
3 TSP x 1.0 mm
2
18C x 2.5 mm
TD-P05C
18C x 2.5 mm2
TD-P05A
TD-P05
TD-P05B
TD-LOOP 3
TD-N01
TD-N01A
TD-N01B
18C x 2.5 mm2
20C x 12 AWG
20C x 12 AWG
4 TSP x 14 AWG + 30C x 12 AWG
4 TSP x 14 AWG + 30C x 12 AWG
4 TSP x 14 AWG + 30C x 12 AWG
4 TSP x 14 AWG + 30C x 12 AWG
TD-N05
DATE 11/1/2011 2:07:54 PM
CABLE SCHEDULE, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
LOCATION
TAG NO.
BLOCK DIAG.
REMARKS
CABLE
DWG. NO.
SHT.
DWG. NO.
SHT.
SUPPLIED BY
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
MAST PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
TOP DRIVE VFD
TOP DRIVE VFD
TOP DRIVE VFD
TOP DRIVE VFD
INSTRUMENT J-BOX
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
5
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
NOV
TD-PNJB01
INSTRUMENT J-BOX
10620480-DIA
2
10620482-DIA
3
NOV
TD-PNJB01
INSTRUMENT J-BOX
10620480-DIA
2
10620482-DIA
3
NOV
HYDRAULIC PUMP MOTOR
TD-PNJB01
INSTRUMENT J-BOX
10620480-DIA
2
10620482-DIA
3
NOV
TD-MOT-04
RT. BLOWER MOTOR
TD-PNJB01
INSTRUMENT J-BOX
10620480-DIA
2
10620482-DIA
3
NOV
TD-MOT-05
DFT-NJB100
CAB-N03
-
LT. BLOWER MOTOR
DRILL FLOOR TOOL REMOTE I/O CABINET
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
TOP DRIVE PLUG PANEL
TD-PNJB01
CAB-N03B
-
INSTRUMENT J-BOX
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
ASSIGNMENT CUBICLE TD/RT
MAST PLUG PANEL
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
2
2
2
2
2
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
3
2,12
2
2
3
NOV
NOV
NOV
NOV
NOV
-
LOCATION
INTERCONNECT
124459-01-20
-
-
POWER
TD-PNJB01
INSTRUMENT J-BOX
124458-100-B
30183284-75-4-4-B
123985-100-B
122718-01-20
-
-
POWER
POWER
POWER
N.I.S.
N.I.S.
N.I.S.
N.I.S.
TD-P05
TD-N01
TD-LOOP 3
MAST PLUG PANEL
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
TOP DRIVE PLUG PANEL
MAST PLUG PANEL
DRILLER'S CABIN PLUG PANEL
TOP DRIVE PLUG PANEL
TOP DRIVE PLUG PANEL
10620480-DIA
2
10620482-DIA
3
NOV
GRASSHOPPER PLUG PANEL
AC DRIVE HOUSE PLUG PANEL
600VAC MCC
MAST PLUG PANEL
DRILLER'S CABIN PLUG PANEL
DRILL FLOOR TOOL REMOTE I/O CABINET
INSTRUMENT J-BOX
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
10620480-DIA
2
2
2
2
2
2
2
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
10620482-DIA
3
3
3
4
4,8
8
4
NOV
NOV
NOV
NOV
NOV
NOV
NOV
3C x 1.5 mm
2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
TD-N06
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
PS-01
RT BLOWER DIFF. PRESSURE SWITCH
10620480-DIA
3
10620482-DIA
4
NOV
PS-02
LEFT BLOWER DIFF. PRESSURE SWITCH
10620480-DIA
3
10620482-DIA
4
TD-N07
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
NOV
PS-03
IBOP PRESSURE SWITCH
10620480-DIA
3
10620482-DIA
4
NOV
TD-N08
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
PS-04
LUBE OIL PRESSURE SWITCH
10620480-DIA
3
10620482-DIA
4
NOV
TD-N09
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-01
BRAKE ON SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N10
3C x 1.5 mm
2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-02
ROTATE RIGHT SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N11
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-03
ROTATE LEFT SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N12
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-04
IBOP CLOSE SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N13
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-05
TORQUE WRENCH CLAMP SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N14
7C x 1.5 mm2
10054266-001
M20 (A)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-06
LINK TILT EXTEND SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N15
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-07
LINK TILT "DRILL" SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N16
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-08
LINK TILT "FLOAT" SOLENOID
10620480-DIA
3
10620482-DIA
4
NOV
TD-N17
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-09
STAND JUMP SOLENOID
10620480-DIA
3
10620482-DIA
5
NOV
TD-N18
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
SOV-10
Bx ELEVATOR OPEN SOLENOID
10620480-DIA
3
10620482-DIA
5
NOV
TD-N21
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
TDS-PNJB01
INSTRUMENT J-BOX
PS-05
Bx ELEVATOR PRESSURE SWITCH
10620480-DIA
3
10620482-DIA
4
NOV
TD-N30
1 TSP x 1.0 mm
2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
PS-15
CRT SLIPS SET PRESSURE SWITCH
10620480-DIA
4
10620482-DIA
6
NOV
TD-N31
1 TSP x 1.0 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
PS-16
CRT SJ ELEVATOR CLOSED PRESSURE SWITCH
10620480-DIA
4
10620482-DIA
6
NOV
TD-N32
1 TSP x 1.0 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
PS-17
CRT STOP LOWERING PRESSURE SWITCH
10620480-DIA
4
10620482-DIA
6
NOV
TD-P05B
MCC
TD-N01A
DFT-NJB100
TD-PNJB01
SHEET
2 OF 3
DWG NO
10620483-IDX
REV
01
DATE 11/1/2011 2:07:54 PM
CABLE SCHEDULE, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
FROM
CABLE ID
CABLE
NOV
GLAND
GLAND
CABLE
TAG NO.
CONSTRUCTION
PART NO.
SIZE
P/N
TYPE
TAG NO.
TO
LOCATION
TAG NO.
BLOCK DIAG.
LOCATION
INTERCONNECT
REMARKS
CABLE
DWG. NO.
SHT.
DWG. NO.
SHT.
SUPPLIED BY
TD-N25
3C x 1.5 mm
2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
SOV-15
CRT SLIPS UP SOLENOID
10620480-DIA
4
10620482-DIA
6
NOV
TD-N26
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
SOV-16
CRT ELEVATOR OPEN SOLENOID
10620480-DIA
4
10620482-DIA
6
NOV
TD-N27
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
SOV-17
CRT LINK TILT EXTEND SOLENOID
10620480-DIA
4
10620482-DIA
6
NOV
TD-N28
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
SOV-18
CRT LINK TILT DRILL SOLENOID
10620480-DIA
4
10620482-DIA
6
NOV
TD-N29
3C x 1.5 mm2
10054266-001
M20 (O)
10054938-001
N.I.S.
-
CRT PLUG
SOV-19
CRT LINK TILT FLOAT SOLENOID
10620480-DIA
4
10620482-DIA
6
NOV
TD-LOOP 5
24C x 1.5 mm2
-
-
-
N.I.S.
TD-N34B
TOP DRIVE PLUG PANEL
TD-N34
MAST PLUG PANEL
10620480-DIA
4
10620482-DIA
6
NOV
TD-N34
24C x 1.5 mm2
-
-
-
N.I.S.
TD-LOOP 5
MAST PLUG PANEL
TD-N34A
DRILLER'S CABIN PLUG PANEL
10620480-DIA
4
10620482-DIA
6,14
NOV
TD-N34A
24C x 1.5 mm2
-
-
-
N.I.S.
TD-N34
DRILLER'S CABIN PLUG PANEL
DFT-NJB100
DRILL FLOOR TOOL REMOTE I/O CABINET
10620480-DIA
4
10620482-DIA
14
NOV
TD-N34B
24C x 1.5 mm2
-
-
-
N.I.S.
TD-LOOP 5
TOP DRIVE PLUG PANEL
-
CRT PLUG
10620480-DIA
4
10620482-DIA
6
NOV
TD-LOOP 4
7 TSP x 1.0 mm2
-
-
-
N.I.S.
TD-N33B
TOP DRIVE PLUG PANEL
TD-N33
MAST PLUG PANEL
10620480-DIA
4
10620482-DIA
6
NOV
TD-N33
7 TSP x 1.0 mm2
-
-
-
N.I.S.
TD-LOOP 4
MAST PLUG PANEL
TD-N33A
DRILLER'S CABIN PLUG PANEL
10620480-DIA
4
10620482-DIA
6,13
NOV
TD-N33A
7 TSP x 1.0 mm2
-
-
-
N.I.S.
TD-N33
DRILLER'S CABIN PLUG PANEL
DFT-NJB100
DRILL FLOOR TOOL REMOTE I/O CABINET
10620480-DIA
4
10620482-DIA
13
NOV
TD-N33B
7 TSP x 1.0 mm2
-
-
-
N.I.S.
TD-LOOP 4
TOP DRIVE PLUG PANEL
CRT PLUG
10620480-DIA
4
10620482-DIA
6
NOV
TD-D1001
TD-P1001
TD-P1002
PROFIBUS
3C x 12 AWG
3C x 12 AWG
-
-
-
DATA
POWER
POWER
DFT-NJB100
DFT-NJB100
DFT-NJB100
DRILL FLOOR TOOL REMOTE I/O CABINET
DRILL FLOOR TOOL REMOTE I/O CABINET
DRILL FLOOR TOOL REMOTE I/O CABINET
MTC #1
MTC #1
MTC #1
MULTI TOOL CONTROLLER CABINET #1
MULTI TOOL CONTROLLER CABINET #1
MULTI TOOL CONTROLLER CABINET #1
10620480-DIA
10620480-DIA
10620480-DIA
4
4
4
10620482-DIA
10620482-DIA
10620482-DIA
16
16
16
NOV
NOV
NOV
ANT-D1001
TD-S33
LMR400, COAX
3C x 0.75 mm2
10077615-001
-
-
-
DATA
I.S.
DFT-NJB100
LT-02
DRILL FLOOR TOOL REMOTE I/O CABINET
LINK CYLINDER LINEAR TRANSDUCER
TDS-SJB01
OMNI ANNTENA
FLEX POWER NODE
10620480-DIA
10620480-DIA
4
10620482-DIA
10620482-DIA
15
7
-
SHEET
3 OF 3
NO BLOCK
DWG NO
NOV
NOV
10620483-IDX
REV
01
MJOB-8375
TDS-11SA
NEXT ASSY
USED ON
APPLICATION
This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P.,
its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes
only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of
this information to others is not permitted without the express written consent of NOV. This document is to be
returned to NOV upon request and in any event upon completion of the use for which it was loaned. This
document and the information contained and represented herein is the copyrighted property of NOV.
© National Oilwell Varco
CURRENT
TITLE
I/O MAP, TDS-11SA
AC IDEAL RIG 135
INITIAL
DRAWN
B. BOEPPLE
CHECKED
R. MOENCH
SIZE
APPVD
R. MOENCH
B
DATE
11/1/2011
SCALE
DWG NO
REV
10620484-IDX 01
NONE
WT LBS
SHEET
1 OF 3
D74DCF0051-TPL-001 (REV B)
DATE 11/1/2011 2:13:31 PM
I/O MAP, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
I/O
SIGNAL
ADDRESS
TYPE
NETWORK NODE
ID
No.
I/O DESCRIPTION
I/O
1 FUNCTION
0 FUNCTION
10DI0.0
NIS 24 vdc
DP1
10
TD-PS-01 STATUS
POS 1(1)
STATUS OK
PS FAILURE
10DI0.1
NIS 24 vdc
DP1
10
TD-PS-02 STATUS
10DI0.2
NIS 24 vdc
DP1
10
TD-CAT 0 E-STOP
POS 1(5)
POS 1(4)
STATUS OK
E-STOP NOT ENGAGED
PS FAILURE
E-STOP ENGAGED
10DI0.3
NIS 24 vdc
DP1
10
TD-CAT 2 E-STOP
POS 1(8)
E-STOP NOT ENGAGED
E-STOP ENGAGED
10DI0.4
NIS 24 vdc
DP1
10
TD-DRILL MTR#1 (RIGHT) OVERTEMP SW
POS 3(1)
MOTOR TEMP OK
MOTOR TEMP HIGH
10DI0.5
NIS 24 vdc
DP1
10
TD-DRILL MTR#2 (LEFT) OVERTEMP SW
10DI0.6
NIS 24 vdc
DP1
10
TD-RIGHT BLOWER MOTOR PRESS SW
POS 3(5)
POS 3(4)
MOTOR TEMP OK
TD AIR FLOW OK
MOTOR TEMP HIGH
TDS AIR FLOW LOW
10DI0.7
10DI1.0
NIS 24 vdc
NIS 24 vdc
DP1
DP1
10
10
TD-LEFT BLOWER MOTOR PRESS SW
POS 3(8)
TD AIR FLOW OK
TDS AIR FLOW LOW
TD-IBOP PRESS SW
10DI1.1
NIS 24 vdc
DP1
10
TD-LUBE OIL PRESS SW
POS 4(1)
POS 4(5)
IBOP CLOSED
LUBE OIL PRESSURE OK
IBOP OPEN
LUBE OIL PRESSURE LOW
10DI1.2
NIS 24 vdc
DP1
10
TD-Bx ELEVATOR CLOSED PRESS SW
POS 4(4)
Bx ELEVATOR CLOSED
Bx ELEVATOR ARMED OR OPEN
10DI1.3
NIS 24 vdc
DP1
10
SPARE
POS 4(8)
10DI1.4
NIS 24 vdc
DP1
10
SPARE
-
-
10DI1.5
NIS 24 vdc
DP1
10
SPARE
POS 5(1)
POS 5(5)
-
-
10DI1.6
NIS 24 vdc
DP1
10
SPARE
POS 5(4)
-
-
10DI1.7
NIS 24 vdc
DP1
10
SPARE
POS 5(8)
-
-
10DI8.0
NIS 24 vdc
DP1
10
TD-CRT SLIPS SET PRESS SW
10DI8.1
NIS 24 vdc
DP1
10
TD-CRT SJ ELEVATOR CLOSED PRESS
POS 19(1)
POS 19(5)
CRT SLIPS SET
CRT ELEVATOR CLOSED
CRT SLIPS NOT SET
CRT ELEVATOR ARMED OR OPEN
10DI8.2
NIS 24 vdc
DP1
10
TD-CRT STOP LOWERING PRESS SW
POS 19(4)
CRT LOWERING
10DI8.3
NIS 24 vdc
DP1
10
SPARE
POS 19(8)
CRT STOPPED LOWERING
-
10DI8.4
NIS 24 vdc
DP1
10
SPARE
-
10DI8.5
NIS 24 vdc
DP1
10
SPARE
POS 20(1)
POS 20(5)
-
-
10DI8.6
NIS 24 vdc
DP1
10
SPARE
POS 20(4)
-
-
10DI8.7
NIS 24 vdc
DP1
10
SPARE
POS 20(8)
-
-
10DQ0.0
NIS 24 vdc
DP1
10
TD-BRAKE ON SOLENOID
POS 7(1)
10DQ0.1
NIS 24 vdc
DP1
10
TD-ROTATE RIGHT SOLENOID
POS 7(5)
BRAKE APPLIED
TD ROTATES RIGHT
BRAKE RELEASED
TD STOPS
10DQ0.2
NIS 24 vdc
DP1
10
TD-ROTATE LEFT SOLENOID
TD ROTATES LEFT
TD STOPS
10DQ0.3
NIS 24 vdc
DP1
10
TD-IBOP CLOSE SOLENOID
10DQ0.4
NIS 24 vdc
DP1
10
TD-TORQUE WRENCH SOLENOID
POS 8(1)
POS 8(5)
POS 9(1)
IBOP CLOSED
RLA JOGS, SHOT PIN ENGAGES, TORQUE WRENCH CLAMPS
LAST STATE
TORQUE WRENCH RELEASE
10DQ0.5
NIS 24 vdc
DP1
10
TD-LINK TILT EXTEND SOLENOID
POS 9(5)
LINK TILT MOVES TO “EXTEND” POSITION OR FLOATS
LINK TILT STOPS
10DQ0.6
NIS 24 vdc
DP1
10
TD-LINK TILT DRILL SOLENOID
POS 11(1)
LINK TILT MOVES TO “DRILL” POSITION OR FLOATS
LINK TILT STOPS
10DQ0.7
NIS 24 vdc
DP1
10
TD-LINK TILT FLOAT SOLENOID
POS 11(5)
LINK TILT MOVES TO “FLOAT” POSITION OR FLOATS
LINK TILT STOPS
10DQ1.0
NIS 24 vdc
DP1
10
TD-STAND JUMP SOLENOID
10DQ1.1
NIS 24 vdc
DP1
10
TD-Bx ELEVATOR OPEN SOLENOID
POS 12(1)
POS 12(5)
COUNTER BALANCE CYLINDERS RETRACT
Bx ELEVATOR OPEN
COUNTER BALANCE CYLINDERS EXTENDS
Bx ELEVATOR ARMED OR CLOSED
10DQ1.2
NIS 24 vdc
DP1
10
SPARE
POS 13(1)
-
-
10DQ1.3
NIS 24 vdc
DP1
10
SPARE
POS 13(5)
-
-
LOCATION
ENG.
UNITS
SHEET
2 OF 3
MIN ENG. MAX ENG. SETPOINTS REMARKS
UNITS
UNITS
-
DWG NO
10620484-IDX
REV
01
DATE 11/1/2011 2:13:31 PM
I/O MAP, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
I/O
SIGNAL
ADDRESS
10DQ1.4
TYPE
NIS 24 vdc
NETWORK NODE
ID
DP1
No.
10
I/O DESCRIPTION
I/O
1 FUNCTION
0 FUNCTION
SPARE
POS 15(1)
-
10DQ1.5
NIS 24 vdc
DP1
10
SPARE
POS 15(5)
-
-
10DQ1.6
NIS 24 vdc
DP1
10
SPARE
POS 16(1)
-
-
10DQ1.7
NIS 24 vdc
DP1
10
SPARE
POS 16(5)
-
-
10DQ8.0
NIS 24 vdc
DP1
10
TD-CRT SLIPS UP SOLENOID
10DQ8.1
NIS 24 vdc
DP1
10
TD-CRT ELEVATOR OPEN SOLENOID
POS 22(1)
POS 22(5)
SLIPS UP
ELEVATOR OPEN
SLIPS DOWN
ELEVATOR ARMED OR CLOSED
10DQ8.2
NIS 24 vdc
DP1
10
TD-CRT LINK TILT EXTEND SOLENOID
POS 23(1)
LINK TILT MOVES TO “EXTEND” POSITION OR FLOATS
LINK TILT STOPS
10DQ8.3
NIS 24 vdc
DP1
10
TD-CRT LINK TILT DRILL SOLENOID
POS 23(5)
LINK TILT MOVES TO “DRILL” POSITION OR FLOATS
LINK TILT STOPS
10DQ8.4
NIS 24 vdc
DP1
10
TD-CRT LINK TILT FLOAT SOLENOID
POS 24(1)
LINK TILT MOVES TO “FLOAT” POSITION OR FLOATS
10DQ8.5
NIS 24 vdc
DP1
10
SPARE
POS 24(5)
-
LINK TILT STOPS
-
10DQ8.6
NIS 24 vdc
DP1
10
SPARE
POS 25(1)
-
-
10DQ8.7
NIS 24 vdc
DP1
10
SPARE
POS 25(5)
-
-
10IB2
DATA
DP1
10
STATUS BYTE
POS 17
-
-
POS 17
-
-
LOCATION
ENG.
UNITS
10IB3
DATA
DP1
10
STATUS BYTE
10IB4
DATA
DP1
10
VALUE BYTE
POS 17
-
10IB5
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
10IB6
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
10IB7
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
POS 17
-
-
10QB2
DATA
DP1
10
CONTROL BYTE
10QB3
DATA
DP1
10
SETPOINT BYTE
POS 17
-
10QB4
DATA
DP1
10
SETPOINT BYTE
POS 17
-
-
10QB5
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
10QB6
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
10QB7
DATA
DP1
10
RESERVED BYTE
POS 17
-
-
SHEET
3 OF 3
MIN ENG. MAX ENG. SETPOINTS REMARKS
UNITS
UNITS
DWG NO
10620484-IDX
REV
01
NOTES:
UNLESS OTHERWISE SPECIFIED
1. THIS DOCUMENT BEST VIEWED THROUGH MS EXCEL.
2. THE STATUS COLUMN AND REVISION LETTER CORRESPONDS
TO THE MOST CURRENT CHANGE TO RESPECTIVE LINE (ROW).
MJOB-8375
TDS-11SA
NEXT ASSY
USED ON
APPLICATION
This document contains proprietary and confidential information which belongs to National-Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned
for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use
of this design or distribution of this information to others is not permitted without the express written
consent of NOV. This document is to be returned to NOV upon request and in any event upon
completion of the use for which it was loaned. This document and the information contained and
represented herein is the copyrighted property of NOV. © National Oilwell Varco
CURRENT
INITIAL
TITLE
HAZARDOUS AREA INDEX, TDS-11SA
AC IDEAL RIG 135
DRAWN
B. BOEPPLE
CHECKED
R. MOENCH
SIZE
APPVD
R. MOENCH
B
DATE
11/1/2011
SCALE
DWG NO
REV
10620485-IDX 01
NONE
WT LBS
SHEET
1 OF 3
D74DCF0050-TPL-001 (REV B)
NOV
TAG NO.
NOV
P/N:
DESCRIPTION
DATE 11/1/2011 2:16:16 PM
HAZARDOUS AREA INDEX, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
LOCATION
MANUFACTURER
MANUFACTURER
P/N:
HAZARDOUS
RATING
HAZARDOUS
ZONE
CERTIFICATION
AGENCY
CERTIFICATE
No.
TEMP.
RATING
IP
RATING
MATERIAL
BLOCK DIAG.
DWG. NO.
SHT.
INTERCONNECT
DWG. NO.
SHT.
ASSOCIATED
COMPONENT
REMARKS
TDS-11SA
TD-MOT-01
108235
DRILL MOTOR ASSEMBLY
TD-11SA
RELIANCE ELECTRIC
108235
EEx nC II T3
ZONE 2
EPSILON
04ATEX1284X
-20ºC TO +50ºC
IP40
CAST IRON
10620480-DIA
2
10620482-DIA
2
TD-MOT-02
108235
DRILL MOTOR ASSEMBLY
TD-11SA
RELIANCE ELECTRIC
108235
EEx nC II T3
ZONE 2
EPSILON
Ex95Y4141X
-20ºC TO +50ºC
IP40
CAST IRON
10620480-DIA
2
10620482-DIA
2
TD-MOT-03
109755-2
HYDRAULIC PUMP MOTOR
TD-11SA
RELIANCE ELECTRIC
109755-2
CLASS 1, DIV 1, GRP D
-
UL
E10822 (N)
-25ºC TO +40ºC
IP56
CAST IRON
10620480-DIA
2
10620482-DIA
3
TD-MOT-04
30172028-1
RT. BLOWER MOTOR
TD-11SA
RELIANCE ELECTRIC
6283074
CLASS 1, DIV 1, GRP D
-
UL
E10822 (N)
-25ºC TO +40ºC
IP56
CAST IRON
10620480-DIA
2
10620482-DIA
3
TD-MOT-05
30172028-1
LT. BLOWER MOTOR
TD-11SA
RELIANCE ELECTRIC
6283074
CLASS 1, DIV 1, GRP D
-
UL
E10822 (N)
-25ºC TO +40ºC
IP56
CAST IRON
10620480-DIA
2
10620482-DIA
3
TD-PNJB01
110139
INSTRUMENT J-BOX
TD-11SA
HOFFMAN
A-1412NFSS
-
-
UL
-
-
NEMA 4X
304SS
10620480-DIA
2
10620482-DIA
3
PS-01
76841
RT. BLOWER DIFF
PRESSURE SWITCH
TD-11SA
UNITED ELEC CONTROLS
J120K-15642
CLASS 1, DIV 1 & 2, GRP B,CD
-
UL
E40857(N)
-40ºC TO +71ºC
IP66
-
10620480-DIA
3
10620482-DIA
4
PS-02
76841
LT. BLOWER DIFF
PRESSURE SWITCH
TD-11SA
UNITED ELEC CONTROLS
J120K-15642
CLASS 1, DIV 1 & 2, GRP B,CD
-
UL
E40857(N)
-40ºC TO +71ºC
IP66
-
10620480-DIA
3
10620482-DIA
4
PS-03
83095-1
IBOP PRESSURE SWITCH
TD-11SA
UNITED ELEC CONTROLS
J120-15643
CLASS 1, DIV 1 & 2, GRP B,CD
-
UL
E40857(N)
-40ºC TO +71ºC
IP66
-
10620480-DIA
3
10620482-DIA
4
PS-04
87541-1
LUBE OIL PRESSURE
SWITCH
TD-11SA
UNITED ELEC CONTROLS
J120-15646
CLASS 1, DIV 1 & 2, GRP B,CD
-
UL
E40857(N)
-40ºC TO +71ºC
IP66
-
10620480-DIA
3
10620482-DIA
4
PS-05
83095-2
B & V ELEVATOR
PRESSURE SWITCH
TD-11SA
UNITED ELEC CONTROLS
J120-15644
CLASS 1, DIV 1 & 2, GRP B,CD
-
UL
E40857(N)
-40ºC TO +71ºC
IP66
-
10620480-DIA
3
10620482-DIA
4
S0V-01
127908-D2
BRAKES ON SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
S0V-02
127908J2
ROTATE RIGHT SOLENOID
TD-11SA
ATOS
DHA/UL-0713/NPT 24DC/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-03
127908J2
ROTATE LEFT SOLENOID
TD-11SA
ATOS
DHA/UL-0713/NPT 24DC/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-04
127908-D2
IBOP CLOSE SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SHEET
2 OF 3
DWG NO
10620485-IDX
REV
01
DATE 11/1/2011 2:16:16 PM
HAZARDOUS AREA INDEX, TDS-11SA
AC IDEAL RIG 135
NATIONAL OILWELL VARCO
DESCRIPTION
LOCATION
MANUFACTURER
MANUFACTURER
P/N:
HAZARDOUS
RATING
HAZARDOUS
ZONE
CERTIFICATION
AGENCY
CERTIFICATE
No.
TEMP.
RATING
IP
RATING
MATERIAL
BLOCK DIAG.
DWG. NO.
SHT.
INTERCONNECT
DWG. NO.
SHT.
127908-D2
TORQUE WRENCH
SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-06
127908J2
LINK TILT EXTEND
SOLENOID
TD-11SA
ATOS
DHA/UL-0713/NPT 24DC/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-07
127908J2
LINK TILT DRILL SOLENOID
TD-11SA
ATOS
DHA/UL-0713/NPT 24DC/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-08
127908-D2
LINK TILT FLOAT
SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
4
SOV-09
127908-D2
STAND JUMP SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
5
SOV-10
127908-D2
Bx ELEVATOR OPEN
SOLENOID
TD-11SA
ATOS
DHA/UL-0631/2/NPT 240C/20
CLASS 1, DIV 1
-
UL
TBS
-
IP66
CAST IRON
10620480-DIA
3
10620482-DIA
5
SOV-15
TBD
CRT SLIPS UP SOLENOID
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
SOV-16
TBD
CRT ELEVATOR OPEN
SOLENOID
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
SOV-17
TBD
CRT LINK TILT EXTEND
SOLENOID
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
SOV-18
TBD
CRT LINK TILT DRILL
SOLENOID
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
SOV-19
TBD
CRT LINK TILT FLOAT
SOLENOID
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
PS-15
30178379
CRT SLIPS SET PRESSURE
SWITCH
TD-11SA
UNITED ELEC CONTROLS
-
CLASS 1, DIV 1 & 2, GRP A,B,CD
ZONE 1
DEMKO
03ATEX0252466X
-50ºC TO +80ºC
IP66
SS
10620480-DIA
4
10620482-DIA
6
PS-16
-
CRT SJ ELEVATOR
CLOSED PRESSURE
SWITCH
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
PS-17
-
CRT STOP LOWERING
PRESSURE SWITCH
TD-11SA
-
-
-
-
-
-
-
-
-
10620480-DIA
4
10620482-DIA
6
LT-02
10077587-001
LINK CYLINDER LINEAR
TRANSDUER
TD-11SA
ROTA
LTSY02621.SHB1804
EXII 1G, Eex ia IIC T4
ZONE 1
ATEX
BASOATEX1322
-20ºC TO +85ºC
-
SS
10620480-DIA
4
10620482-DIA
7
TDS-SJB01
10509113-001
BANNER FLEX POWER
NODE
TD-11SA
BANNER ENGINEERING
14428
Ex ia IIC T4
ZONE 0
LCIE
08ATEX6098X
-40ºC TO +70ºC
IP68
PLYCARBONATE
10620480-DIA
4
10620482-DIA
7
NOV
TAG NO.
NOV
P/N:
SOV-05
SHEET
3 OF 3
ASSOCIATED
COMPONENT
DWG NO
REMARKS
10620485-IDX
REV
01
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.2
Top Drive Assembly
www.nov.com
8
N O TES
7
-
U N LESS
O T H E R W IS E
S P E C IF IE D :
1. REF: SYSTEM
S C H E M A T IC
124222.
2 . L U B R IC A T E
ALL B O LTS
D
6
3
(R P ) =
4
PRESSURE
O IL
A IR
5
REPLAC EM AN T
S W IT C H
PART, 1
YEAR
SPARES.
-
18
PSI + 0, - 2
PRESURE
S W IT C H
-
1000
PSI ± 100
PRESSURE
S W IT C H
-
4 "W C
± .5 "W C
P S I (F A L L IN G ).
P S I (R IS IN G ).
AT
REV
2
1
1
S O L E N O ID
C O IL
VO LTAG E
&
VO LTAG E
FREQUENC Y
VARC O
P / N IT E M
D
NO.
A
24VDC
114174
10
B
-
-
-
TA B LE
B L O W E R / H Y D R A U L IC
D E S IG N A T O R V O L T A G E & Q T Y
FREQUENC Y
A S S E M B L Y . M IN IM U M
575VAC
60 Hz
(T E F C )
60
DELETED
3
(F A L L IN G ).
P O T A L L R E C E P T A C L E S W IT H P O T T IN G C O M P O U N D (IT E M 6 3 )
P E R IN S T R U C T IO N S (IN C L U D E D W IT H P O T T IN G C O M P O U N D ).
AFTER
TA B LE
D E S IG N A T O R
S E T T IN G S :
S W IT C H
6. M EGGER ALL AC - M O TO R LEADS
R E S IS T A N C E : 2 M E G O H M S .
7
4
A L L B O L T S W IT H A N T I- S E IZ E C O M P O U N D . T O R Q U E
P E R V A R C O S P E C . D S 0 0 0 0 8 A N D L O C K W IR E .
PRESSURE
IB O P
5
G.
1
2
M O TO R
VARC O
P/N:
114113- 2
VO LTAG E
IT E M
NO.
D E S C R IP T IO N
P U M P / M O TO R
R EF 30172028- 1 B LO W ER
ASSY
M O TO R
30188268 - XXXX
1
8
B A S IC
8
C
9
B L O W E R M O T O R A S S E M B L E D A T M O T O R / H O U S IN G
R E F E R E N C E D R A W IN G N O . 1 2 0 9 0 0 .
REPLAC ES
E X IS T IN G
ASSEM B LY
LEVEL
S O L E N O ID
H ARDW ARE
TA B LE
10
M OVED
Q TY
TO
SU B - ASSY
SHOWN
ARE
FOR
S E R V IC E
30182634.
REFERENCE
O N LY.
P/N
LO O P / P O W ER
VARC O
P/N:
B L O W E R / H Y D R A U L IC
3
C O N N EC TO R
B RAC KET
IT E M
NO.
D E S IG N A T O R
Q TY
R
( R IG H T H A N D )
1
3 0 1 8 3 2 7 2 - R B R K T , S E R V IC E
1
127652- 501
B R AC K ET, C O N N EC TO R
80
L
1
30183272- L
B R K T , S E R V IC E
57
1
127652- 502 B R AC K ET, C O N N EC TO R
(LE F T
H AN D)
C O IL V O L T A G E
(S E E T A B L E 1 )
D E S C R IP T IO N
LO O P
POWER
56
LO O P
C
M OTOR VOLTAGE
(S E E T A B L E 2 )
C ON N EC TOR, B RAC K ET
(S E E T A B L E 3 )
81
B
B
A
U N LESS
30183077
NEXT
TD S - 1 1 S A/ C R T
ASSY
USED
O T H E R W IS E
M A C H IN E D
MAX
250
DRAW N
8
7
6
5
4
S P E C IF IE D
TO RC H
1000
CURRENT
ON
A P P L IC A T IO N
UNLESS
O T H E R W IS E
CUT
MAX
S P E C IF IE D
IN IT IA L
A G LO C K N E R
C HEC KED
H LIM
APPVD
H LIM
DATE
5/16/07
3
A
T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D
C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O
IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D
P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F
D IM E N S IO N S A R E IN IN C H E S
N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E
O R IN P A R T , O R U S E O F T H IS D E S IG N O R
.X X ± .0 3
.X X X ± .0 1 0
.X ± .1
D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS
N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N
A N G L E S ± .5 °
C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS
D O N O T S C A L E D R A W IN G
D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T
U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT
W A S L O A N E D . T H IS D O C U M E N T A N D T H E
IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN
IS T H E C O P Y R IG H T E D P R O P E R T Y O F
N A T IO N A L - O IL W E L L , L .P .
R IG S O LU TIO N S
1 0 0 0 0 R IC H M O N D A V E .
H O U S TO N , TE X A S 7 7 0 4 2 U .S .A .
(7 1 3 ) 3 4 6 - 7 5 0 0
2
T IT L E :
E L E C T R IC A L P A C K A G E ,
TD S - 1 1 S A (C R T3 5 0 )
SC ALE:
WT
P R O J E C T IO N :
LB S:
1/8
D R A W IN G
900
S IZ E :
D
SH EET:
1 OF 4
R E V IS IO N :
NUMBER:
30188268
-
1
DC F0022
(R E V
D)
7
8
D
C
6
E L E C / M A N IF O L D
SU B - ASSY
5
1
30182634
1
119888- 100- 38 C AB LE
2
50810- R- C
W ASH ER, FLAT
145
4
51803- C
NUT
144
4
50003- 6- C5D
SC REW , C AP- H EX
9
50649- 61
SCREW
18
56609- 11
T E R M IN A L
2
56612- 01
S P IC E
1
56611- 8
E L B O W , 4 5 ° IN T
-
D ELETED
138
-
D ELETED
137
3
55008- 12- C5D
SCREW, HEX
12
50182- 8- 03
S C R EW , C AP - B U TTO N
4
D
146
TR AY
10
1
143
H EAD
142
W IR E
141
R IN G
140
NUT
139
ELEC T
H EAD
ASSY
E A R T H IN G
ASSY
94
18
86872- 20- S
L O C K W A S H E R , IN T E R N A L
S TAR
48
4
94872- 4
C O N N EC TO R
93
1
86872- 25- S
L O C K W A S H E R , IN T E R N A L
S TAR
47
-
D ELETED
92
3
16
50908- C
W ASH ER, LO C K - REGU LAR
46
16
50804- R- C
W AS H ER , FLAT- R EG U LAR
91
16
50904- C
W ASH ER, LO C K - REGU LAR
45
8
50004- 10- C5D
SC REW , C AP- H EX
90
14
50906- C
W ASH ER, LO C K - REGU LAR
44
1
115911
C AB LE
89
5
50910- C
W ASH ER, LO C K - REGU LAR
43
1
115910
B R A C K E T , M O U N T IN G , C A B L E
88
6
50912- C
W ASH ER, LO C K - REGU LAR
42
87
6
50012- 16- C5D
SC REW , C AP- H EX
H EAD
41
50606- 8- C
SC REW , C AP- FLAT
H EAD
40
2
50010- 52- C5D
SC REW , C AP- H EX
H EAD
39
-
D ELETED
50005- 4- C5D
SC REW , C AP- H EX
H EAD
37
8
50004- 8- C5D
SC REW , C AP- H EX
H EAD
36
12
50006- 8- C5D
SC REW , C AP- H EX
H EAD
35
81
2
50008- 20- C5D
SC REW , C AP- H EX
H EAD
34
80
2
50010- 10- C5D
SC REW , C AP- H EX
H EAD
33
79
4
50008- 10- C5D
SC REW , C AP- H EX
H EAD
32
78
1
50010- 44- C5D
SC REW , C AP- H EX
H EAD
31
50006- 10- C5D
SC REW , C AP- H EX
H EAD
30
15FT
135
H EAD
C A B L E , P IG T A IL
118866
1
136
C AP
2
W ASH ER, LO C K
56609- 25
T E R M IN A L , W IR E - R IN G
133
2
50910- S
-
D ELETED
132
-
D ELETED
28
51804- C
N U T, H EX- S ELF
131
4
50206- B
20
50004- 8- C5
SCREW, HEX
SEE
TA BLE
10
A
SEE
TR AY
87074- 8- B
3
130
H EAD
118993
134
C AP
(4 2
C A B L E , 7 0 m m2
BOSS
H EAD
LU G, C O PPER
COMP
B R A C K E T , M O U N T IN G , C A B L E
P L U G , O - R IN G
(U N C - 2 B )
B AR
115909
56531- 8- S
LK G
COND) 95
122718- 01- 20
1
1
TR AY
TR AY
Y E LLO W W / G R E E N TR A C E R
-
S TAR
N U T, H EX
B RASS
H AN D
B R A C K E T , C O N N E C T O R - R IG H T
3
H AN D
16
50006- 12- C5D
-
D ELETED
125
-
D ELETED
124
4
50008- 8- C5D
SC REW , C AP- H EX
-
D ELETED
123
1
115720
LAB EL, C O N N EC TO R
-
D ELETED
122
-
D ELETED
121
A/R 53200- 242
C O M P O U N D , L O C K IN G
-
D ELETED
120
-
D ELETED
119
-
D ELETED
118
-
D ELETED
117
-
D ELETED
116
1
53219- 3
F IT T IN G , G R E A S E - S T R A IG H T
-
D ELETED
115
2
116427
S T U D , G R O U N D IN G
-
D ELETED
114
-
D ELETED
-
D ELETED
113
A/R
Z 6 0 0 0 .8
L O C K W IR E
Ø .0 3 1
-
D ELETED
112
1
56541- 32
K IT , S P L IT
FLAN GE
-
D ELETED
111
10
50905- C
W ASH ER, LO C K - REGU LAR
64
-
D ELETED
110
5
3M
63
-
D ELETED
109
10
3
126
C AP
4
78002
C L A M P , S E R V IC E
50008- 16- C5D
LOOP
SC REW , C AP- H EX
B RAC KET
H EAD
77
H EAD
56516- 12- 8- S
R ED U C ER , TU B E
1
56525- 12- 12S
T E E , S W IV E L
1
56509- 12- S
N U T, S H O R T
4
56606- 8
3
108
-
D ELETED
(B LU E )
P O T T IN G
3 7 °/ 3 7 °/ 3 7 °
25
72
18
86871- 20
W ASH ER, N YLO N
S E A L IN G
71
1
78317- 50
LO C K N U T
23
22
EXTEN D ED
68
(N O T
( IN C L U D E S
SHOWN)
66
COMPOUND
ELB O W , C APPED
62
61
50012- 16- C5D
SC REW , C AP- H EX
59
4
50004- 14- C5D
SC REW , C AP- H EX
105
-
D ELETED
1
110022- 1R
C O N N E C T O R , S IN G L E
P IN , P O W E R , R E D
104
SEE
TA BLE
3
B R K T , S E R V IC E
LO O P - LEFT
1
110022- 1W
C O N N E C T O R , S IN G L E
P IN , P O W E R , W H T
103
SEE
TA BLE
3
B R K T , S E R V IC E
L O O P - R IG H T
1
110022- 1B
C O N N E C T O R , S IN G L E
P IN , P O W E R , B L K
102
A/R
Z6001
L O C K W IR E
Ø .0 5 1
(N O T
SHOWN)
55
5
83444- 03
GLAN D, C AB LE, ARM O RED, 20m m
101
A/R
Z 6 0 0 0 .9
L O C K W IR E
Ø .0 4 7
(N O T
SHOWN)
54
1
83444- 07
GLAN D, C AB LE, ARM O RED, 32m m
100
10
110078- L18
C AB LE, S AFETY
( Ø .0 3 2 )
(N O T
SHOWN)
53
1
78317- 32
LO C K N U T
99
10
110078- FL2
C AB LE, S AFETY
(F E R R U LE ) (N O T
SHOWN)
52
1
86872- 32- S
L O C K W A S H E R , IN T E R N A L
98
3
86625- 02
GLAN D, C AB LE
-
JAC K E TE D (U L)
51
1
86871- 32
W ASH ER, N YLO N
S E A L IN G
4
86625- 01
GLAN D, C AB LE
-
JAC K E TE D (U L)
50
1
124459- 01- 20
C A B L E , P IG T A IL
ASSY
86872- 50- S
L O C K W A S H E R , IN T E R N A L
PART
NO.
D E S C R IP T IO N
L IS T
OF
M A T E R IA L
Q TY
REQD
FOR
BSC
ASSY
REF
Q TY
O N LY
IT E M S
ARE
IN
SUB - ASSY
PART
58
NO.
H AN D
S TAR
L IS T
OF
1
78317- 25
LO C K N U T
78317- 20
LO C K N U T
1
129991- 07
GLAN D, EExe
ARM OU RED
C AB LE, 50m m
20
1
83444- 05
GLAN D, EExe
ARM OU RED
C AB LE, 25m m
19
13
83444- 01
GLAN D, EExe
ARM OU RED
C AB LE, 20m m
18
30183272- 07
P LATE
56626- 03
C A B L E , S H IP B O A R D - T W IS T E D / S H IE L D E D
1
25FT
1 0 1 5 9 F T 2 4 1 F T 5 6 6 2 5 - 1 .5 - 0 3
49
17
B RAC KET
5 6 6 2 5 - 2 .5 - 0 4
C A B L E , S H IP B O A R D - M U L T IC O R E
13
2
76841
PRESSURE
S W IT C H , A IR
12
4
1
87541- 1
PRESSURE
S W IT C H , O IL
11
4
1
83095- 1
PRESSURE
S W IT C H , IB O P
10
-
D ELETED
8
53301- 10- 6
-
D ELETED
10
1
10
1
10
1
9
S C R E W , D R IV E - T Y P E
6
5
U
8
7
110143
P L A T E , M O U N T IN G - J - B O X / M A N IF O L D
6
4
112711
P LATE, M O TO R
5
1
115202
N AM EP LATE, C O N N EC TO R
124994
J- B O X
SEE
TA BLE
1
M A N IF O L D
SEE
TA BLE
2
P U M P / M O TO R
PART
NO.
W A R N IN G
2
ASSY
ASSY
1
ITE M
NO.
D E S C R IP T IO N
L IS T
Q TY R E Q D
OF
4
3
ASSEM B LY
A
M A T E R IA L
M A T E R IA L
Q TY
REQD
FOR
BSC
ASSY
REF
Q TY
O N LY
IT E M S
ARE
IN
SUB - ASSY
30182634
Q TY
REQD
FOR
BSC
ASSY
REF
Q TY
O N LY
IT E M S
ARE
IN
SUB - ASSY
S IZ E
DWG
NO
SC ALE
7
14
H EAD
D
8
15
C A B L E , S H IP B O A R D - M U L T IC O R E
4
10 66FT
B
16
50008- 16- C 5D SC REW , C AP- H EX
56
ITE M
NO.
21
3
3
57
H AN D
D E S C R IP T IO N
Q TY R E Q D
30182634
H EAD
24
18
1
H A R D W A R E )6 5
2
Q TY R E Q D
10
69
106
1
27
26
D ELETED
ITE M
NO.
B U S H IN G , R E D U C IN G , E L E C T R IC A L
S E A L IN G
-
COND) 96
56600- 12- 8
S E A L IN G
60
(1 8
28
4
W ASH ER, N YLO N
W ASH ER, LO C K - REGU LAR
COMP
B U S H IN G , R E D U C IN G , E L E C T R IC A L
W ASH ER, N YLO N
50912- C
9
56600- 16- 12
86871- 25
2
10
3
86871- 50
107
97
D ELETED
1
70
C
29
-
1
D ELETED
S TAR
2
38
73
67
A/R 127386
4
75
END
IN T
2
76
-
H EAD
10
74
1
2
82
B R AC K ET, C O N N EC TO R - LEFT
3
TA BLE
-
127
H EAD
10
83
D ELETED
SCREW, HEX
10
84
W ASH ER, LO C K
-
128
C AP
10
86
50008- 12- C5D
H EAD
10
85
(B R AS S )
4
SCREW, HEX
1
2
147
129
B
3
4
3
2
30182634
REV
30188268
1/8
WT
LB S
2 OF 4
SHEET
1
DC F0022
(R E V
D)
7
8
6
5
4
3
1
2
51
134
28
2X
140
131 4X
141 6X
12 REF
142 3X
D
4X
4X
131
143
130
96
130 4X
63 A/R
5
13
144
131 4X
130 4X
5
1 0 2 (B L K )
131 4X
63 A/R
1 0 3 (W H T )
D
130 4X
5
63 A/R
1 0 4 (R E D )
95
8 0 (R IG H T
H AND
C O N F IG . O N L Y )
4
4X
C
C O N F IG . O N L Y )
4X
55 A/R
C O N F IG . O N L Y )
LEFT
H AND
6
C
65
32 4X 2PL
4
128
9
4
46
9
80
FOR
R IG H T
81
FOR
LEFT
H AND
(O P P O S IT E
S ID E )
46
32
H AND
AND
8
A/R 55
(L E F T
R IG H T
75
59 2X
60 2X
REF
B O TH
94
H AND 81
(L E F T
146
8
57
55
H AND
C O N F IG . O N L Y
C O N F IG . O N L Y
REF
REF
4X
A/R
33
43
2X
145
(R IG H T
A/R 55
B
17
56
3X 78
H AND
C O N F IG . O N L Y )
14
6X 41
68
3X
73
ONE
PER
M O TO R
46
B
6X 42
147
10
4X
REF
10
5X
REF
37
20
64
19
101
22
REF
25
10
21
18
24
21
48
11X
5
35
49
A
6
28
21
97
24
98
48
REF
10
56
FOR
57
F O R L E F T H A N D C O N F IG . O N L Y
(O P P O S IT E S ID E )
41
8X
A/R
42
R IG H T
H AND
C O N F IG . O N L Y
99
2X
34
1
HAND
S E R V IC E
LO O PS
140
2X
141
6X
142
3X
A
SHOWN
S IZ E
D
SC ALE
7
6
REF
51
R IG H T
8
REF
46
13
REF
4X
44
18
10
A
10
55
100
4
REF
10
48
A
26
47
24
REF
69
23
5
4
3
2
DWG
REV
NO
30188268
1/8
WT
LB S
3 OF 4
SHEET
1
DC F0022
(R E V
D)
7
8
6
5
4
(B L O W E R
M O TO R
ASSEM B LED
AT
3
M O T O R / H O U S IN G
ASSEM B LY
P/N
1
2
120900)
D
D
(R E F
12
ASSEM B LED
4X 36
2X
ENCODER
2X 50
115299
(C O N N E C T O R
M O T O R / H O U S IN G
ASSEM B LY
B
4X 45
AT
P/N
P/N
PART
120900)
OF
P LU G -
D IG IT A L E N C O D E R )
15
A/R 55
B
16
8 1 (R E F
-
LEFT
H AND
C O N F IG . O N L Y )
(M O T O R
POWER
V IE W
C AB LES)
B-B
SC ALE: N ON E
C
C
68
SEE
D E T A IL
REF
C
82 2X
85
88
4X 135
93
2X
8X 91
86
4X
89
6
35
REF
84
10
TO
EARTH
B AR
(IT E M
94)
44
5 7 (R E F
-
LEFT
H AND
C O N F IG . O N L Y )
17
B
3X
10
14
46
2X 40
87
10
REF
30
2X
B
44
REF
4X 135
8X 91
6
66 131 45 105 11
A/R
C
SC ALE
2 PL
1/1
50
147
4X
REF
D E T A IL
10 62
REF
27 2X
9X
50
139
50
15
10
137
4X
45
39
2X
43
31
A/R 55
43
36
A
A/R 66
LEFT
HAND
A
A
V IE W A - A
3
S E R V IC E
LO O PS
8
10
15 9X
REF
SHOWN
S IZ E
D
SC ALE
8
7
6
5
4
3
2
DWG
REV
NO
30188268
1/8
WT
LB S
4 OF 4
SHEET
1
DC F0022
(R E V
D)
8
7
N O TES: U N LESS
1.
AP P LY
O T H E R W IS E
A N T I- S E IZ E
2
GREASE
P O IN T S .
6
5
4
3
2
1
S P E C IF IE D
AND
TO RQ UE
ALL B O LTS
PER
D S 0 0 0 0 8 , L O C K W IR E
ALL B O LTS.
A L L S E R V IC E
2
4X
D
D
A
2
3
4
C O N F IG U R A T IO N
5
A
DASH
5
A
5
A
3
15X
4
15X
6
AR
NO
SETB AC K
TAB LE
D E S C R IP T IO N
-BSC
3 0 .0 0
-500
3 3 .7 5
-501
3 9 .5 0
T Y P IC A L A P P L IC A T IO N W H E N B L O C K IS
N A R R O W S ID E T O G U ID E B E A M
S P E C IA L U S E D O N L Y F O R T W O O R D E R S .
SEE CC 128579 & 128952
-502
3 9 .5 0
S T A N D A R D V E R S IO N
3 9 .5 0 " S E T B A C K S
-503
4 1 .0 0
F IR S T U S E D O N
T A L IS M A N C L A Y M O R E
C
FOR
A
C
1
7
12
2
1
-
-
-
-
124539-503
C A R R IA G E
A S S Y , R IG H T , 4 1 .0 0 " S E T B A C K
13
1
-
-
-
-
124538-503
C A R R IA G E
A S S Y , L E F T , 4 1 .0 0 " S E T B A C K
12
-
1
-
-
-
124539-502
C A R R IA G E
A S S Y , R IG H T , 3 9 .5 0 " S E T B A C K
11
-
1
-
-
-
124538-502
C A R R IA G E
A S S Y , L E F T , 3 9 .5 0 " S E T B A C K
10
-
-
2
-
-
141510
C A R R IA G E
S P A C E R , 3 9 .5 0 " S E T B A C K
9
-
-
-
1
-
124539-500
C A R R IA G E
A S S E M B L Y , R IG H T , 3 3 .7 5 " S E T B A C K
8
-
124538-500
C A R R IA G E
A S S E M B L Y , L E F T , 3 3 .7 5 " S E T B A C K
7
L O C K W IR E
Ø .0 5 1
6
8
B
13
5 4X
-
-
-
1
A/R
A/R
A/R
A/R
A/R Z6001
4
4
8
4
4
51222-12-16
P IN , S P IR A L
15
15
24
15
15
939390-10
W ASH ER , FLAT
15
15
24
15
15
50016- 20- C 5D SC REW , C AP- H EX
C A R R IA G E
A S S Y , R IG H T , 3 0 .0 0 " S E T B A C K
C A R R IA G E
A S S Y , L E F T , 3 0 .0 0 " S E T B A C K
-
-
1
-
1
124539
-
-
1
-
1
124538
- 503
- 502
- 501
- 500
- BSC
PART
Q TY
5
U N LESS
R IG H T S ID E
V IE W
7
6
TD S - 9 S
ASSY
UNLESS
O T H E R W IS E
M A C H IN E D
MAX
250
5
USED
4
TO RC H
1000
CUT
MAX
O T H E R W IS E
CURRENT
DRAW N
S P E C IF IE D
3
2
1
IT E M
D E S C R IP T IO N
S P E C IF IE D
OF
NO.
IN IT IA L
M .C L A R K
J .M A R T IN E S
C HEC KED
B .B R A M A N
N .W E S T
APPVD
B .B R A M A N
N .W E S T
5/9/07
3/26/98
DATE
3
A
M A T E R IA L S
T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D
C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O
IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D
P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F
D IM E N S IO N S A R E IN IN C H E S
N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E
O R IN P A R T , O R U S E O F T H IS D E S IG N O R
.X X ± .0 3
.X X X ± .0 1 0
.X ± .1
D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS
N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N
A N G L E S ± .5 °
C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS
D O N O T S C A L E D R A W IN G
D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L -
ON
A P P L IC A T IO N
OF
TD S - 9 S / 11S
8
TD S - 1 1 S
119953
NEXT
L E F T S ID E
REAR
119954
4
H EAD
NO.
L IS T
A
H ARDENED
REQD
A
B
O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T
U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT
W A S L O A N E D . T H IS D O C U M E N T A N D T H E
IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN
IS T H E C O P Y R IG H T E D P R O P E R T Y O F
N A T IO N A L - O IL W E L L , L .P .
R IG S O LU TIO N S
1 0 0 0 0 R IC H M O N D A V E .
H O U S TO N , TE X A S 7 7 0 4 2 U .S .A .
(7 1 3 ) 3 4 6 - 7 5 0 0
2
T IT L E :
C A R R IA G E ,
SC ALE:
WT
LB S:
1/4
D R A W IN G
1300
P R O J E C T IO N :
PACKAGE
S IZ E :
D
SH EET:
1 OF 5
R E V IS IO N :
NUMBER:
30124540
H
1
DC F0022
(R E V
D)
8
7
6
5
4
3
1
2
D
D
2
8
C
C
B
B
A
A
V IE W A - A
-BSC
1
7
D
SHOWN
S IZ E
D
SC ALE
8
7
6
5
4
3
2
DWG
REV
NO
1/4
WT
LB S
30124540
H
1300 SHEET
2 OF 5
1
DC F0022
(R E V
D)
8
7
6
5
4
3
1
2
D
D
9
2
C
C
B
B
3 9 .5 0
S ETB AC K
A
1
V IE W A - A
A
7
D
- 501 SHOWN
(S P E C IA L )
S IZ E
D
SC ALE
8
7
6
5
4
3
2
DWG
REV
NO
1/4
WT
LB S
30124540
H
1300 SHEET
3 OF 5
1
DC F0022
(R E V
D)
8
7
6
5
4
3
1
2
D
D
11
C
C
B
B
3 9 .5 0 1
SETB AC K
A
1
V IE W A - A
- 502
A
7
D
SHOWN
S IZ E
D
SC ALE
8
7
6
5
4
3
2
DWG
REV
NO
1/4
WT
LB S
30124540
H
1300 SHEET
4 OF 5
1
DC F0022
(R E V
D)
8
7
6
5
4
3
1
2
D
D
11
C
C
B
B
4 1 .0 0 1
SETB AC K
A
A
1
V IE W A - A
- 503
7
D
SHOWN
S IZ E
D
SC ALE
8
7
6
5
4
3
2
DWG
REV
NO
1/4
WT
LB S
30124540
H
1300 SHEET
5 OF 5
1
DC F0022
(R E V
D)
8
7
6
5
4
3
NOTES: UNLESS OTHERWISE SPECIFIED
CONFIGURATION TABLE
1.
ADJUST TO ALLOW LIGHT CONTACT WITH ITEM 21.
2.
LUBRICATE ALL JAM NUTS (ITEM 13) & (ITEM 7) WITH GREASE,
TORQUE JAM NUTS (ITEM 7: 300 LBS) (ITEM 13: 400 LBS)
20 2X
19
3. LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND,
D
1
A/R 2X
27
24
2X
26
2X
2X
23
4X
25
4X
26
1
10
4X
12 3X
14 3X
7
4X 34
6
2
28 3X
4
31 3X
18 2X
8X
6
2
8X
7
7
8X
4
2
2X
13
2X
8
2X
5
5
13
8
2X
2X
2
2X
34 2X
22
B
USED WITH ADDITIONAL SPACER
9.2
-500
33.75
-502
39.50
-503
41.00
13.0
STD FOR 39.50" SETBACKS
D
18.7
20.2
16
2X
17
2X
(ITEM 27)
C
34 4X
30.00
REF DIM A
15
(20.8)
3
-BSC
DESCRIPTION
FOR SPECIAL 39.50" SETBACK
33 -503
5. PACK WITH GREASE PRIOR TO ASSY.
11 2X
SETBACK
-BSC
30 -502
4. GREASE CAM FOLLOWERS AFTER ASSY.
6. DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 31.
DASH NO
29 -500
32 6X
AND TORQUE TO DS00008. DO NOT LOCKWIRE.
2X
1
2
10
10
10
10
53201
FITTING, GREASE (1/8"-27 NPT)
34
1
-
-
-
124535-503
CARRIAGE, (LEFT), 41.00" SETBACK
33
6
6
6
6
51219-2
FERRULE, CABLE
32
3
3
3
3
51402-12-S
PIN, COTTER
31
-
1
-
-
124535-502
CARRIAGE, (LEFT), 39.50" SETBACK
30
-
-
1
-
124535-500
CARRIAGE, (LEFT), 33.75" SETBACK
29
3
3
3
3
50812-N-C
WASHER, FLAT
28
1
1
1
1
113370
STRAP, ACCUMULATOR, Ø6"
27
6
6
6
6
50908-C
WASHER, LOCK-REGULAR
26
4
4
4
4
50008-10-C5D
SCREW, HEX HD. CAP, 1/2 UNC X 1.25
25
2
2
2
2
50108-10-CD
SCREW, CAP-SOCKET HD. 1/2 UNC X 1.25
24
2
2
2
2
88710
STRAP
23
1
1
1
1
125727-2
PLATE
22
2
2
2
2
125727-1
PLATE
21
2
2
2
2
30152845
PIN
20
1
1
1
1
51220-2
CABLE RETAINING Ø.063
2
2
2
2
125727-3
FERRULE BAR
72" LONG
18
2
2
2
2
50906-C
WASHER, LOCK-REGULAR
17
2
2
2
2
50006-5-C5D
SCREW, HEX HD. CAP
16
1
1
1
1
129375
BRACKET, ANGLE
15
C
19
3
3
3
3
30179918
BOLT, SHOULDER SOCKET HD (UNC-3A)
4
4
4
4
80569
NUT, JAM, 2"-12 UN-2B
(MODIFIED)
13
3
3
3
3
50512-C
NUT, HEX SLOTTED
12
2
2
2
2
30157306
PIN, LINCH Ø.188
11
4
4
4
4
109944
BUSHING, FLANGED, 2.75 ID
10
4
4
4
4
51132-C
WASHER, LOCK, HI-COLLAR, 2" DIA.
8
8
8
8
8
55324-C
NUT, HEX-JAM (1.50-12 UNF-2B)
7
8
8
8
8
30158767-04
BEARING, CAM FOLLOWER
6
2
2
2
2
30155438
CAM FOLLOWER 6" DIA
5
8
8
8
8
51024-C
WASHER, LOCK - 1.5"
4
2
2
2
2
124537
BOGEY
3
2
2
2
2
112875
PIN, BOGEY PIVOT
2
-
-
-
1
124535
CARRIAGE, (LEFT), 30.00" SETBACK
B
14
9
(A)
21 2X
(68.0)
A
CONFIG
-503 -502 -500
TDS-9S
PRODUCT:
TOLERANCES ARE:
INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY
FINISH
250
6
5
4
FRACTIONS
DEG
± 1/16
BREAK EDGES .02/.03
CURRENT
TOL > ±.06
1000
INITIAL
A. PHILLIPS
JOHN MARTINEZ
H. LIM
NEIL WEST
APPVD
H. LIM
NEIL WEST
1/26/10
3/17/98
3
1
ITEM
NO.
DESCRIPTION
OF
MATERIAL
A
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
TITLE:
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED
CHECKED
DRAWN
DATE
7
±.03
650
UNLESS OTHERWISE SPECIFIED
TOL < ±.06
X.XX
± 1/2
ANGLES
DO NOT SCALE DRAWING
WT LBS:
ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED
±.1
X.XXX ±.010
SIMILAR TO:
INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE
X.X
NO.
LIST
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.
124540
NEXT ASSY:
8
PART
QTY REQD
BSC SHOWN
END ITEM:
7
BSC
TO NOV UPON REQUEST OR UPON COMPLETION OF THE
CARRIAGE ASSEMBLY, LEFT
USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
IS THE COPYRIGHTED PROPERTY OF NOV.
SCALE:
RIG SOLUTIONS
DWG NO.
MECHANICAL ENGINEERING
2
1/4
PROJECTION:
SIZE:
D
SHT:
1
124538
1
REV:
OF
1
AA
DRAWN IN ACAD
RS-MECH_D-TPL-001
8
7
6
2
4
3
CONFIGURATION TABLE
INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE
ADJUST TO ALLOW FREE MOTION OF ITEM 21.
DASH NO
SETBACK
-BSC
30.00 & 39.50
ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED
LUBRICATE ALL JAM NUTS (ITEM 13) WITH GREASE,
DESCRIPTION
3.
LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND,
AND TORQUE TO DS00008. DO NOT LOCKWIRE.
2X
REF DIM A
USED WITH ADDITIONAL SPACER
9.2
FOR SPECIAL 39.50" SETBACK
TORQUE JAM NUTS 300 TO 400 ft-lbs.
D
1
2
INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY
8
NOTES: UNLESS OTHERWISE SPECIFIED
1
5
4
GREASE CAM FOLLOWERS AFTER ASSY.
5
PACK WITH GREASE PRIOR TO ASSY.
6
DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 25.
7.
(OBSOLETE DWG 124539) CARRIES REVISION HISTORY FOR THIS DWG
1
-BSC
23 -500
-500
33.75
-502
39.50
-503
41.00
D
13.0
STD FOR 39.50" SETBACKS
18.7
20.2
24 -502
27 -503
3
8
(20.5)
C
C
2X 11
4X 15
4X 10
6
4X 29
1
3X 14
4
3X 16
6X
17
8X
2
6
2
8X
7
8
8X
4
2
2X 19
2X
13
2X
8
2X
5
15
4X
29 4X
5
2X
13
2X
8
2X
28
2X
2
2X 20
B
3X 22
15 2X
3X 25
12
29 2X
2X 18
10
10
10
10
GREASE CAP
GREASE CAP
29
2
2
2
2
53000-2-C
PLUG EXT. PIPE CTSK/HEX
28
1
-
-
-
124536-503
CARRIAGE, (RIGHT), 41.00" SETBACK
27
DELETED
26
3
3
3
3
51402-12-S
PIN, COTTER
25
-
1
-
-
124536-502
CARRIAGE, (RIGHT), 39.50" SETBACK
24
-
-
1
-
124536-500
CARRIAGE, (RIGHT), 33.75" SETBACK
23
3
3
3
3
50812-N-C
WASHER, FLAT
22
2
2
2
2
125727-1
PLATE
21
2
2
2
2
30152845
PIN
20
4
4
4
4
51220-2
CABLE RETAINING Ø.063, 48" LONG
19
2
2
2
2
125727-3
FERRULE BAR
18
6
6
6
6
51219-2
FERRULE CABLE
17
3
3
3
3
50512-C
NUT, HEX-SLOTTED (UNF-2B)
16
10
10
10
10
53201
FITTING, GREASE (1/8"-27 NPT)
15
3
3
3
3
30179918
BOLT, SHOULDER SOCKET HD (UNC-3A) (MODIFIED)
14
4
4
4
4
80569
NUT, JAM, 2"-12 UN-2B
13
1
1
1
1
125727-2
PLATE
12
2
2
2
2
30157306
PIN, LINCH Ø.188
11
4
4
4
4
109944
BUSHING, FLANGED, 2.75 ID
10
4
4
4
4
51132-C
WASHER, LOCK, HI-COLLAR, 2" DIA.
8
8
8
8
8
55324-C
NUT, HEX-JAM (1.50-12 UNF-2B)
7
8
8
8
8
30158767-04
BEARING, CAM FOLLOWER
6
2
2
2
2
30155438
CAM FOLLOWER, 6"
5
8
8
8
8
51024-C
WASHER, LOCK - 1.5"
4
2
2
2
2
124537
BOGEY
3
2
2
2
2
112875
PIN, BOGEY PIVOT
2
-
-
-
1
124536
CARRIAGE, (RIGHT), 30.00" SETBACK
B
9
(A)
-503 -502 -500 BSC
PART NO.
QTY REQD
21 2X
A
(68.0)
TDS-9S
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
END ITEM:
124540
NEXT ASSY:
-BSC SHOWN
FINISH
5
4
±.03
± 1/2
ANGLES
FRACTIONS
DEG
± 1/16
BREAK EDGES .02/.03
CURRENT
TOL > ±.06
1000
INITIAL
A. PHILLIPS
JOHN MARTINEZ
H. LIM
NEIL WEST
APPVD
H. LIM
NEIL WEST
1/26/10
3/17/98
3
A
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
TITLE:
CARRIAGE ASSEMBLY, RIGHT
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED
CHECKED
DRAWN
DATE
6
X.XX
650
UNLESS OTHERWISE SPECIFIED
250
±.1
DO NOT SCALE DRAWING
WT LBS:
TOL < ±.06
X.X
X.XXX ±.010
SIMILAR TO:
7
NO.
LIST OF MATERIALS
PRODUCT:
8
1
ITEM
DESCRIPTION
TO NOV UPON REQUEST OR UPON COMPLETION OF THE
USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
IS THE COPYRIGHTED PROPERTY OF NOV.
SCALE:
RIG SOLUTIONS
DWG NO.
MECHANICAL ENGINEERING
2
1/4
PROJECTION:
SIZE:
D
SHT:
1
30124539
1
REV:
OF
1
U
DRAWN IN ACAD
RS-MECH_D-TPL-001
8
7
6
5
4
3
2
1
N O T E S U N L E S S O T H E R W IS E S P E C IF IE D
1.
L U B R IC A T E A L L O - R IN G W IT H G R E A S E O R H Y D R A U L IC
O IL A T A S S E M B L Y .
2.
T H E S E P L A S T IC P L U G S A R E R E M O V E D A T T H IS L E V E L
A N D R E P L A C E D W IT H IT E M 1 4 # 5 6 5 1 9 - 1 2 - 1 2 S
D
3.
4.
NO
TO RQ U E ALL B O LTS PER DS00008.
PO RTS
P O S IT IO N
D
#3
C L E A N C L E V IS A N D R O D T H R E A D S , A P P L Y B L U E .
L O C T IT E , A N D T O R Q U E T O 3 0 0 - 3 5 0 L B - F T .
5.
T A G W IT H V A R C O P A R T N U M B E R A N D R E V IS IO N L E T T E R .
6.
R E P L A C E B O L T S IN C L U D E D IN IT E M 3 W IT H IT E M 1 0 .
7.
P E E N P R O T R U D IN G T H R E A D S T O P R E V E N T N U T S
2 .0 0
REF
F R O M B A C K IN G O F F .
12
1
6
1
PO RTS
P O S IT IO N
6
#4
C
C
2PL
7
2
4
7
4PL
4
6
3
8
9
10
1
11
{
1
12
4PL
Ø 1 .3 7 5
1
REF
6
5
B
B
2 .5 0
PO RTS
REF
2
P O S IT IO N
2 4 .1 8 0
FU LLY
#1
RETRAC TED
4
2
56519-12-12-S
ELB O W , O - R IN G B O SS/ 37°
14
Z6001
LO C K W IR E Ø .05 1
13
2
50516-C
N U T, H EX SLO TTED
12
4
50906-C
LO C K W ASH ER
11
4
50006-12-C5D
SC R EW
10
1
1 1 0 0 7 8 - FL2
C AB LE, SAFETY, FER R U LE Ø .032
9
1
1 1 0 0 7 8 - L3 6
C AB LE, SAFETY, Ø .032
8
2
51437-16-S
P IN , C O TTER
7
3
87196-12-S
P LU G , SAE- 1 2 H EX SO C K ET
6
1
30172176-502
P IN , C LEVIS, C YLIN D ER , C O U N TER B ALAN C E
5
1
30172176- BSC
P IN , C LEVIS, C YLIN D ER , C O U N TER B ALAN C E
4
1
94681-12
B LIN D FLAN G E K IT, C O D E 6 1
3
1
111935
C LEVIS, R O D EN D , C YLIN D ER , C O U N TER B ALAN C E
2
1
110687
C YLIN D ER , 4", C 'B AL
A/R
2
PART
Q TY
NO.
P AR T FLAG S
PO RTS
P O S IT IO N
T R A C E A B IL IT Y
C R IT IC A L L O A D
P A T H IT E M
C E R T IF IC A T IO N
R E Q U IR E D
#2
SPARE PART
C O M M IS S IO N IN G
IN S U R A N C E
A R E IN
DO NOT
ANG ULAR
T H IS
C O N T A IN S
DOC UMENT
IN F O R M A T IO N
PURPOSE
5
4
3
NOR
W R IT T E N
F
MAY
P R O P R IE T A R Y
N E IT H E R
USED
FO R
P E R M IS S IO N
TO LERANC E
BE
M A N U F A C T U R IN G
FRO M
VARC O
K. N G U YEN
JER R Y
J
PREPARED
BY
TO
CUT
-
-
-
-
110131
TDS-9S
NEXT
PRODUC T
OTHERS
PURPOSES
T IT L E
FO R
SUC H
ANY
W IT H O U T
IN T E R N A T IO N A L , IN C .
D. STEPH ENS
C HEC KED
2
A
F IN IS H E S
± 0° 30'
IN F O R M A T IO N , A N D
D IS C L O S E D
SURFACE
*TO RC H C UT
1000 MAX
.X ± .1 C A N B E * T O R C H
.X X ± .0 3 0
.X X X ± .0 1 0
SC ALE
DOC UMENT
LTR
6
NO.
M A T E R IA L S
M A C H IN E D
250 MAX
IN T E R P R E T D IM E N S IO N S &
T O L E R A N C E S P E R A N S I Y 1 4 .5 &
A B B R E V IA T IO N S P E R A N S I Y 1 .1
IN C H E S
T H IR D A N G LE P R O JE C T IO N
7
OF
D IM E N S IO N S U N L E S S O TH E R W IS E S P E C IF IE D
O P E R A T IO N A L
8
IT E M
M A T E R IA L
REQD
L IS T
A
1
D E S C R IP T IO N
BY
ASSY
C Y L IN D E R
S IZ E
DOC UMENT
8/19/03
JP SJ
2/15/95
SC ALE
W E IG H T
DATE
1/2
-
R e le a s e d
-
BY
NO.
R E V IS IO N
110704
D
D. STEPH ENS
APPROVED
ASSEM B LY,
C OU N TERB ALAN C E
LB SH EET
08/26/2003
1
F
OF
1
0 8 :4 9 :5 6 A
1
DC F0022
(R E V
B)
8
N O TES: U N LESS
1.
7
O T H E R W IS E
6
5
4
3
2
1
S P E C IF IE D .
(D E L E T E D )
D
D
C
C
B
Z6001
10 10
50812-N-C
10 10
50912-C
10 10
C O N F IG U R A T IO N
-BSC
STANDARD FO R
3 0 .0 , 3 3 .7 5 &
SET
-395
TABLE
3 9 .5 0
B AC KS
U S E D F O R T W O 3 9 .5 0
SET B AC K O R D ER S O N LY
SEE
CC
128597
&
2
-
117089-395
W ASH ER , FLAT
12
W ASH ER , LO C K - R EG U LAR
11
1
1
121483
4
4
4
IN S T A L L A T IO N
8
51402-12
C O TTER
(1 / 8
7
4
50512-C
NUT, H EX
4
4
30177155
SC REW , C AP
-
2
117089
1
1
1
1
HEX
H EAD
5
W E LD M E N T S U P P O R T, U P P E R G U AR D / W E D G E
3
1
3 017 13 18 - 5 00
W E LD M E N T S U P P O R T, U P P E R G U AR D / W E D G E
2
1
12 08 8 7
PART
G UARD, M O TO R
NO.
H O U S IN G
1
D E S C R IP T IO N
IT E M
NO.
M A T E R IA L
REQD
C O M M IS S IO N IN G
O P E R A T IO N A L
IN S U R A N C E
OF
D IM E N S IO N S U N L E S S O TH E R W IS E S P E C IF IE D
A R E IN
IN T E R P R E T D IM E N S IO N S &
T O L E R A N C E S P E R A N S I Y 1 4 .5 &
A B B R E V IA T IO N S P E R A N S I Y 1 .1
IN C H E S
DO NOT
.X ± .1 C A N B E * T O R C H
.X X ± .0 3 0
.X X X ± .0 1 0
SC ALE
DOC UMENT
ANG ULAR
T H IS
C O N T A IN S
DOC UMENT
IN F O R M A T IO N
PURPOSE
G
LTR
MAY
NOR
W R IT T E N
T H IR D A N G LE P R O JE C T IO N
3
-
6
3 017 13 18 - 5 01
SPARE PART
4
SLO TTED
4
C R IT IC A L L O A D
P A T H IT E M
C E R T IF IC A T IO N
R E Q U IR E D
5
-
NOM)
SU P P O R T, LO W ER
T R A C E A B IL IT Y
6
P IN
P R O P R IE T A R Y
N E IT H E R
USED
FO R
P E R M IS S IO N
TO LERANC E
BE
M A N U F A C T U R IN G
VARC O
TO
OTHERS
PURPOSES
M A T E R IA L S
SURFACE
A
F IN IS H E S
M A C H IN E D
250 MAX
*TO RC H C UT
1000 MAX
-
T IT L E
± 0° 30'
IN F O R M A T IO N , A N D
D IS C L O S E D
FRO M
CUT
FO R
SUC H
ANY
W IT H O U T
IN T E R N A T IO N A L , IN C .
119954
-
119953
TDS-9S
NEXT
PRODUC T
ASSY
GU ARD, M OTOR
S IZ E
DOC UMENT
B . R IC E
B . R IC E
02/15/05
JP SJ
JP SJ
5/97
SC ALE
W E IG H T
DATE
1/4
310
R e le a s e d
-
C HEC KED
2
BY
APPROVED
BY
NO.
R E V IS IO N
120917
D
H . SETH
BY
H O U S IN G ,
PAC KAGE
T. SPARKS
PREPARED
B
10
L A B E L , L IN K
P AR T FLAG S
7
HD
9
L IS T
8
13
SU P P O R T, LO W ER
QTY
A
Ø .0 5 1
50012- 18- C 5D SC REW , C AP- H EX
-395 -BSC
128952
L O C K W IR E
A/R A/R
LB SH EET
06/05/2003
1
G
OF
3
1 0 :4 9 :1 6 A
1
DC F0022
(R E V
B)
8
7
6
4
5
3
2
1
(4 4 .6 )
D
D
(IT E M
4)
2X
4
(IT E M
10
4)
11
4X
12
1
(IT E M
1)
(4 5 .0 )
(IT E M
2
C
3)
C
3
10
11
6X
5
12
A/R
6
13
4X
7
12 08 8 7
B
B
(5 4 .2 )
8
A
A
BSC
T H IS
DOCUMENT
IN F O R M A T IO N ,
N E IT H E R
7
6
5
4
AND
C O N T A IN S
SUC H
D IS C L O S E D
NOR
PURPOSES
W IT H O U T
VARC O
8
BE
PURPOSE
USED
W R IT T E N
IN T E R N A T IO N A L ,
3
P R O P R IE T A R Y
IN F O R M A T IO N
TO
O TH E R S
FOR
M AY
FOR
ANY
T IT L E
S IZ E
GU ARD, M OTOR
P E R M IS S IO N
H O U S IN G ,
PAC KAGE
M A N U F A C T U R IN G
FROM
DOC UMENT
NO.
R E V IS IO N
120917
D
SC ALE
SHEET
1/4
IN C .
2
R e le a s e d
-
06/05/2003
2
OF
G
3
1 0 :4 9 :1 6 A
1
DC F0022
(R E V
B)
8
7
6
4
5
3
2
1
D
D
(IT E M
9)
2X
9
10
11
4X
12
C
C
(5 4 .5 )
10
11
6X
12
13
A/R
B
B
12 08 8 7
A
A
- 395
T H IS
DOCUMENT
IN F O R M A T IO N ,
N E IT H E R
7
6
5
4
AND
C O N T A IN S
SUC H
D IS C L O S E D
NOR
PURPOSES
W IT H O U T
VARC O
8
BE
PURPOSE
USED
W R IT T E N
IN T E R N A T IO N A L ,
3
P R O P R IE T A R Y
IN F O R M A T IO N
TO
O TH E R S
FOR
M AY
FOR
ANY
T IT L E
S IZ E
GU ARD, M OTOR
P E R M IS S IO N
H O U S IN G ,
PAC KAGE
M A N U F A C T U R IN G
FROM
DOC UMENT
NO.
R E V IS IO N
120917
D
SC ALE
SHEET
1/4
IN C .
2
R e le a s e d
-
06/05/2003
3
OF
G
3
1 0 :4 9 :1 5 A
1
DC F0022
(R E V
B)
8
7
N O TES: U N LESS
1.
REM OVE
2.
M ARK
BOX
3.
DO
4.
30123290
NOT
O T H E R W IS E
ALL B U R R S
W IT H
6
5
VARC O
SH ARP
PART
EDGES
8.
.0 3 .
P A C K IN G
2
1
K IT S :
A. 30123290- PK
NUMBER.
C O N S IS T IN G
P A IN T .
RATED
AT
7 ,5 0 0
P S I (1 1 ,2 5 0
5
B AND
6
P L A C E D E S S IC A N T (IT E M 1 5 ) IN S ID E
B O R E (R E M O V E B E F O R E U S E ).
7.
TO
TO
IN
W ATERPRO O F
OF
P L A S T IC , A N D
W ASH
(S T A N D A R D )
OF: 1X
2X
1 2 3 2 9 2 - 2 P A C K IN G S E T
5 1 3 0 0 - 3 4 8 - F O - R IN G
P S I B U R S T ).
D
ASSEM B LY, B AG
3
S P E C IF IE D
AND
PRESSURE
4
BOX
9 . (O B S O L E T E
DWG
10. GREASE
TO
BE
11. -1000
ASSY
1 2 3 2 9 0 ) C A R R IE S
R E V IS IO N
H IS T O R Y
FOR
T H IS
Ø 9 .0
DWG.
D
(1 4 x 9 x 9 ).
USED
IS
S H E L L C Y P R IN A
RA.
P IP E
IS
O B SO LETE, U SE
30123290-BSC.
IN C R E A S E S E A L A N D P IP E L IF E IT IS R E C O M M E N D E D
G R E A S E P A C K IN G B O X E V E R Y T O U R (T W IC E D A IL Y ).
10
B AND
9
PLAC E
O - R IN G
W ASH
P IP E
IN S ID E
BORE
FOR
ASSY
FOR
S H IP M E N T
S H IP M E N T
1 1 .0
2
GOOSENEC K
FAC E
C
C
6
BSC
O N LY
7
-C88
O N LY
20
S H IP P IN G
BSC
O N LY
8
R E Q U IR E M E N T S
SC ALE: 1/ 2
(3 .0 )
5
H AN D PAC K ALL
S E A L S W / IT E M # 1 4
1 REFREF
C O M PLETELY
F IL L V O ID
(1 4 .4 )
(1 1 .1 )
3
30150084
C-88
C O ATED
20
W R E N C H , W A S H P IP E
19
-
-
123292-3
P A C K IN G
-
-
30123289- TC
P IP E , W A S H
1
1
86268
D E S S IC A N T
(N O T
SHOWN)
15
A/R
56005-1
G R E A S E ,G E - M T R (S H E L L / T E x x o n )
(N O T
SHOWN)
14
1
1
30123564
SCREW, SOCKET
1
1
53219-1
F IT T IN G , G R E A S E -
1
1
30123562
R IN G , S N A P
2
2
51300-348-F
O - R IN G
1
1
123292-2
P A C K IN G
-
1
30123289
P IP E , W A S H - 3
1
1
30123288
R IN G , H O L D IN G , 3 " W A S H
1
1
30123287
SP AC ER , LO W ER , 3 " W ASH
2
2
30123286
S P A C E R , M ID D L E , 3 " W A S H
P IP E
4
1
1
123285
SPAC ER, UPPER, 3" W ASH
P IP E
3
1
1
123284
NUT, 3" W ASH
30123563
B O X , P A C K IN G A S S Y , 3 " W A S H P IP E
1
PART
D E S C R IP T IO N
S E A L K IT
-
(5
PER
SET)
3 IN . B O R E (H A R D )
N IT R IL E / A R IM ID E
TUNG STEN
18
C O ATED 17
D ELETED
11
B
3 0 1 2 3 2 8 9 - C 8 8 P IP E , W A S H - 3 " B O R E , C - 8 8
R E FR E F R E F
6
(.0 4 )
10
16
D ELETED
1
4
12
1 REF 1
- C 88 - 1000 B SC
M A IN S H A F T
L IN E R
QTY
FAC E
(.3 1 2
HEX
SOC KET)
?
T R A C E A B IL IT Y
?
C R IT IC A L L O A D
P A T H IT E M
?
C E R T IF IC A T IO N
R E Q U IR E D
U N LESS
PLAC E
8
P IP E
BORE
O - R IN G
FOR
IN S ID E
S H IP M E N T
D IM E N S IO N S
.X
NEXT
7
SPARE PART
5
9
6
C O M M IS S IO N IN G
5
?
O P E R A T IO N A L
?
IN S U R A N C E
O T H E R W IS E
IN T E R P R E T D IM / T O L P E R
ASSY
USED
U N LESS
O T H E R W IS E
M A C H IN E D
250
M AX
± .1
.X X
DO
NOT
ARE
± .0 3
AN G LES
ON
A P P L IC A T IO N
W ASH
13
M A T E R IA L
1000
M AX
/
.X X X
HEAT
TREAT
S T R A IG H T
3
12
EXT.
11
9
S E A L K IT
OF
(5
IN C H
PER
SET)
8
N IT R IL E / C O T T O N
BORE
7
P IP E
6
P IP E
5
P IP E
2
IT E M
NO.
M A T E R IA L
M A T E R IA L S
V A R C O IN T E R N A T IO N A L , IN C .
A L L R IG H T S R E S E R V E D
± .0 1 0
IN A N Y W A Y W ITH O U T TH E W R ITTE N C O N S E N T O F V A R C O .
V A R C O O W N S A L L R IG H TS TO TH IS W O R K A N D IN TE N D S
TO E N F O R C E ITS R IG H TS U N D E R TH E C O P Y R IG H T L A W S
A S A P U B L IS H E D W O R K .
A
D R A W IN G
CURRENT
DRAW N
C HEC KED
T IT L E
W A S H P IP E
ASSEM B LY, 3" B O R E
IN IT IA L
M . S A Z O H .O L S T Y N S K I
E. DEU TSC H
JPSJ
APPVD
B . B RAM AN
JPSJ
DATE
09/20/04
11/97
S IZ E
D
SC ALE
4
NOSE
Y 1 4 .5 M TH IS D O C U M E N T M A Y N O T B E C O P IE D O R R E P R O D U C E D
IN C H E S
T H IR D A N G L E
P R O J E C T IO N
CUT
F IN IS H
ASM E
C O P Y R IG H T C
± .5 °
SC ALE
S P E C IF IE D
TO RC H
IN
S P E C IF IE D
HD-DOG
10
L IS T
P AR T FLAG S
A
NO.
REQD
B
2
DWG
NO
N TS
REV
30123290 H
WT
LB S
85 SHEET
1 OF 1
1
DC F0022
(R E V
C)
8
7
6
5
4
3
2
1
NOTES: UNLESS OTHERWISE SPECIFIED
1. CLEAN OUT ALL HOSES PRIOR TO ASSEMBLY.
2. CYCLE CYLINDERS AFTER INSTALLATION OF HOSES
AND PRIOR TO ATTACHING TO HOOK.
D
3. FOLLOW ADJUSTMENT PROCEDURES IN SERVICE MANUAL.
4
D
SEE DRAWING 112190 FOR ADDITIONAL COUNTERBALANCE
COMPONENTS.
C
C
CONFIGURATION TABLE
4
-HOOK
CONFIGURED FOR USE WITH HOOKS.
-BLOCK
CONFIGURED FOR USE WITH BLOCKS
-BECKET
CONFIGURED FOR USE WITH BECKET
B
B
DRAWING, COUNTERBALANCE PACKAGE (BECKET)
SHACKEL (13.5 TON)
9
80392
LINK CONNECTING
7
80390
CHAIN 9 LINK
6
1
112190-DWG
DRAWING, COUNTERBALANCE PACKAGE
5
2
-
96575
SHACKLE
4
-
1
-
117076
BEAM, COUNTERBALANCE
3
-
-
2
76717
PEAR LINK
2
-
2
2
51405-18-S
PIN, COTTER
BECKET
BLOCK
HOOK
1
-
-
95030-DWG
2
-
-
88484
2
-
-
2
-
-
-
1
-
8
1
PART NO.
DESCRIPTION
QTY REQD
ITEM
MATERIAL
NO.
LIST OF MATERIALS
A
PART FLAGS
TRACEABILITY
CRITICAL LOAD
PATH ITEM
CERTIFICATION
REQUIRED
SPARE PART
COMMISSIONING
OPERATIONAL
INSURANCE
DIMENSIONS UNLESS OTHERWISE SPECIFIED
ARE IN
INTERPRET DIMENSIONS &
INCHES
TOLERANCES PER ANSI Y14.5 &
DO NOT
SCALE
DOCUMENT
6
5
4
3
.XX ±.030
*TORCH CUT
1000 MAX
-
-
TITLE
.XXX ±.010
ANGULAR TOLERANCE ±0° 30'
INFORMATION MAY NEITHER BE DISCLOSED TO OTHERS FOR ANY
-
-
KIT, TRAVELING
112190
TDS-9S
EQUIPMENT ATTACHMENT
NEXT ASSY
PRODUCT
PURPOSE NOR USED FOR MANUFACTURING PURPOSES WITHOUT
WRITTEN PERMISSION FROM VARCO INTERNATIONAL, INC.
B
LTR
7
A
FINISHES
ABBREVIATIONS PER ANSI Y1.1
.X ±.1 CAN BE *TORCH CUT
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION, AND SUCH
THIRD ANGLE PROJECTION
8
SURFACE
MACHINED
250 MAX
A. PHILLIPS
B. KRUEGER
B. KRUEGER
5/5/09
JRM
B.SHUMSKI
B.SHUMSKI
7/96
PREPARED BY
CHECKED BY
APPROVED BY
DATE
2
SIZE
DOCUMENT NO.
REVISION
118244
D
SCALE
WEIGHT LB
1/10
125
20020219.09070623
SHEET
1
1
B
OF
2
DCF0022 (REV B)
8
7
6
5
4
3
2
1
BLOCK ASSEMBLY
TYPICAL
D
D
BECKET ASSEMBLY
HOOK ASSEMBLY
TYPICAL
TYPICAL
C
C
4
2X
4
2
3
1
2X
4
4
2X
6
2X
7
2X
8
32.7 FULLY EXTENDED
31.5 AS SHOWN
24.2 FULLY RETRACTED
B
B
A
A
THIS
DOCUMENT
CONTAINS
PROPRIETARY
TITLE
SIZE
INFORMATION, AND SUCH INFORMATION MAY
NEITHER
BE
DISCLOSED
PURPOSE
NOR
USED
PURPOSES
WITHOUT
TO
FOR
OTHERS
FOR
WRITTEN
PERMISSION
KIT, TRAVELING
ANY
MANUFACTURING
FROM
EQUIPMENT ATTACHMENT
VARCO INTERNATIONAL, INC.
8
7
6
5
4
3
2
DOCUMENT NO.
REVISION
118244
D
SCALE
SHEET
2
1/10
20020219.09070623
1
B
OF
2
DCF0022 (REV B)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.3
Pipe Handler and Adapter Kits
www.nov.com
8
7
6
5
4
3
2
1
NOTES: UNLESS OTHERWISE SPECIFIED
1.
2
D
DELETED
LOCTITE AND TORQUE CLEVIS PER NOV DESIGN SPECIFICATION
D
3DS00082 SECTION 5
3
IMPRESSION STAMP VARCO PART NUMBER APPROXIMATELY
WHERE SHOWN.
4.
PAINT PER VARCO SPECIFICATION VPS00001,
COLOR - YELLOW. MASK ALL THREADS AND BORES.
5.
(OBSOLETE DWG 119592) CARRIES REVISION HISTORY FOR THIS DWG.
6
PEEN CYLINDER TIE ROD THREADS AT TOP OF NUTS. 4 PLACES
SAE #12
SAE #12
1
3
3
1.55
C
C
2
5
2
5
4
4
B
B
3
6
22.000 FULLY RETRACTED
(4.500 SQ)
32.30 FULLY EXTENDED
2
51435-16
PIN, COTTER
5
2
50512-C
NUT,HEX SLOTTED
4
2
30172154
PIN, CYLINDER MOUNTING
3
1
103141-7
CLEVIS
2
1
119416
1
CYLINDER, HYDRAULIC
PART NO.
DESCRIPTION
QTY REQD
ITEM
MATERIAL
NO.
LIST OF MATERIALS
A
TDS-9S/11SA
PH-50/75
NEXT ASSY:
117820/30157366
PRODUCT:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
END ITEM:
X.X
±.1
X.XX
±.03
X.XXX ±.010
SIMILAR TO:
FINISH
A. PHILLIPS
DRAWN
TOL > ±.06
1000
8
7
6
5
4
NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
TO NOV UPON REQUEST OR UPON COMPLETION OF THE
TITLE:
ASSEMBLY, HYDRAULIC CYLINDER
USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
H. OLSTYNSKI IS THE COPYRIGHTED PROPERTY OF NOV.
B. KRUEGER
JPSJ
APPVD
B. KRUEGER
JPSJ
10/1/09
12/2/96
3
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED
CHECKED
DATE
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
INITIAL
A
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
BREAK EDGES .02/.03
CURRENT
UNLESS OTHERWISE SPECIFIED
250
FRACTIONS
DEG
± 1/16
DO NOT SCALE DRAWING
WT LBS:
TOL < ±.06
± 1/2
ANGLES
SCALE:
RIG SOLUTIONS
MECHANICAL ENGINEERING
2
DWG NO.
PROJECTION:
SIZE:
D
SHT:
1
30119592
1
REV:
OF
1
L
DRAWN IN ACAD
RS-MECH_D-TPL-001
8
7
N O T E S : (U N L E S S
1 . IT E M
O T H E R W IS E
4 , S P R IN G , T O
2. STO RE
AS
A
6
5
4
3
2
1
S P E C IF IE D )
BE
COMPRESSED
.3 5
AS
IN S T A L L E D
SET
D
D
1
2X
3
C
C
2X
3 017 2 17 8
11
B
B
7
4X
2
5
2X
2X
8X
6
8
9
2X
2X
50508-C
NUT, H EX
SLO TTED
12
2
30172178
P IN , G U ID E
ARM
11
A/R
Z6001
W IR E , L O C K , .0 5 1
2
51402-8-S
P IN , C O T T E R
4
12
2
10
8
50908-C
50810-N-S
8
50008-13-C5D
2
76445
R E T A IN E R
5
2
76443
S P R IN G
4
2
76442
G U ID E , A R M
3
1
125059
G U ID E , S T A B B IN G , G A T E
1
125057
G U ID E , S T A B B IN G , C L A M P
W ASH ER , LO C K
C AP
SCREW, HEX
NO.
T R A C E A B IL IT Y
C R IT IC A L L O A D
P A T H IT E M
C E R T IF IC A T IO N
R E Q U IR E D
SPARE PART
C O M M IS S IO N IN G
O P E R A T IO N A L
IN S U R A N C E
5
4
3
OF
D IM E N S IO N S U N L E S S O TH E R W IS E S P E C IF IE D
A R E IN
IN T E R P R E T D IM E N S IO N S &
T O L E R A N C E S P E R A N S I Y 1 4 .5 &
A B B R E V IA T IO N S P E R A N S I Y 1 .1
IN C H E S
DO NOT
.X ± .1 C A N B E * T O R C H
.X X ± .0 3 0
.X X X ± .0 1 0
SC ALE
DOC UMENT
ANG ULAR
T H IS
C O N T A IN S
DOC UMENT
IN F O R M A T IO N
PURPOSE
MAY
NOR
W R IT T E N
C
N E IT H E R
USED
FO R
P E R M IS S IO N
TO LERANC E
P R O P R IE T A R Y
BE
D R IL L E D
6
H EAD
2
1
C YL
IT E M
M A T E R IA L
NO.
M A N U F A C T U R IN G
FRO M
VARC O
H . SETH
PREPARED
BY
TO
OTHERS
PURPOSES
M A T E R IA L S
SURFACE
M A C H IN E D
250 MAX
*TO RC H C UT
1000 MAX
T IT L E
FO R
SUC H
ANY
W IT H O U T
IN T E R N A T IO N A L , IN C .
B . R IC E
30157287
PH-75
30122000
PH-100
NEXT
PRODUC T
ASSY
B . R IC E
08/06/04
D . S E N E V IR A T N E D . S E N E V IR A T N E 5 / 1 2 / 9 8
C HEC KED
2
A
F IN IS H E S
CUT
± 0° 30'
IN F O R M A T IO N , A N D
D IS C L O S E D
K. N G U YEN
LTR
6
8
7
D E S C R IP T IO N
T H IR D A N G LE P R O JE C T IO N
7
S E R IE S
REQD
P AR T FLAG S
8
REG
W ASH ER , FLAT, N AR R O W
L IS T
A
9
4
PART
Q TY
10
D IA
BY
APPROVED
BY
S T A B B IN G
G U ID E
Ø 6 .2 5 - 7 .5 0
T O O L J O IN T
1
- 5
FH )
2
(N C
S IZ E
50
DOC UMENT
ASSY.
NO.
R E V IS IO N
125158
D
SC ALE
W E IG H T
DATE
1/2
75
R e le a s e d
-
LB SH EET
08/09/2004
1
C
OF
1
1 1 :1 7 :3 4 A
1
DC F0022
(R E V
B)
8
7
N O TES: U N LESS
1.
C LEAN
2.
C O N N E C T IO N
P R IO R
3.
AN D
TO
O T H E R W IS E
L U B R IC A T E
TH READS
ALL P AR TS
B EFORE
S H A L L R E M A IN
PAC K
W AVE
S P R IN G
C A V IT Y
100%
W IT H
56003
GREASE
O P E R A T IN G
&
THE
A
5.
RECORD
M A T E R IA L T R A C E A B IL IT Y
C RAN K
S L ID IN G
F IT
ASSEM B LY.
AN D
B ALL TO
B ETW EEN
TH E
TW O
PARTS.
IN F O R M A T IO N
PER
TS000205.
6.
IN C L U D E D
W IT H
"R E P A IR
K IT - C O M P L E T E ".
7.
IN C L U D E D
W IT H
"R E P A IR
K IT -
8.
TEST
9.
M A X IM U M
W O R K IN G
T E M P E R A T U R E : 2 0 0 °F
10.
M A X IM U M
W O R K IN G
P R E S S U R E : 1 5 ,0 0 0 p s i (1 0 3 4
11.
O R IE N T A T IO N O F IN T E R N A L H E X A N D P O IN T E R O N
C RAN K M U ST B E AS SH OW N . EN SU RE TH AT TH E
"R IG H T H A N D " C R A N K , IT E M 4 O R 5 , IS IN S T A L L E D
A D J A C E N T T O T H E L U B R IC A T IO N P O R T A S S H O W N .
M IN IM U M
SOFT
D E S C R IP T IO N
B EST
VALVE
ASSY.
N/A
R E P A IR
K IT -
C O M P LETE
R E P A IR
K IT -
SOFT
TS000205.
BORE
D IA M E T E R
3 .0 6
IN C H E S
(9 3 °C )
SEALS
NO.
KSI
VARC O
NO.
110103-500
N/A
N/A
114859
N/A
114859-1
NO.
KSI
VARC O
NO.
-502, H2S, 15
B EST
NO.
1
KSI
VARC O
NO.
110103-501
N/A
N/A
114859
N/A
114860-2
29
27
14
12
25
18
N/A
114859-1
N/A
114860-1
28
26
13
11
23 24
17
110103-502
65021520
77408
65021520
77408
65021520
77408
SEAT
65021523
79489-14
65021523
79489-14
65021523
79489-14
WRENC H-
NUT
65060325
89141-18
65060325
89141-18
65060325
89141-18
C RANK
2
IN F O R M A T IO N
- 501, NAM , 15
B EST
3
P U LLER -
WRENC H-
S E A L S ".
22
33
3
D
21
4X
b a r)
30
C LSD
(R E F ).
UP
12.
- 500, STD , 15
ASSEM B LY.
PROTEC TED
B A L L C A V IT Y
D U R IN G
ENSURE
PER
4
REFERENC E
IN S T A L L A T IO N .
SM OOTH
5
S P E C IF IE D
IN S P E C T
4.
D
6
OPEN
11
(2 2 .5 0 )
C
4
2
6
1
5 / 8 " A .P .I. R E G
RH
16
15
31
C
32
5
6
4
5 / 8 " A .P .I. R E G
RH
15
33
SEE
D E TA IL
"A "
16
2
1
1
4
2
(7 .3 7 5 )
2
1
2
1
1
4
1
4
2
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
4
4
2
2
2
2
2
2
1
1
1
1
1
1
2
2
1
2
B
1
1
1
4
31
32
15
16
4
15
6
2
16
7
2
2
(1 0 .7 5 )
1
1
VARC O
PART NO. 110103- XXX
CW
6
5 / 8 " R E G . R .H .
1 5 ,0 0 0
S/N
6
P S I IB O P
1
-502
CW
-501
A
1
-500
11
110050
NEXT
PH-50
ASSY
USED
O T H E R W IS E
M A C H IN E D
MAX
250
7
6
5
4
S P E C IF IE D
TO RC H
1000
CUT
MAX
5
D E T A IL
"A "
PART
NO.
D E S C R IP T IO N
S P E C IF IE D
APPVD
DATE
IN IT IA L
-
B . B R A M A N D .S E N E V IR A TN E
11/21/06
3
77369-5
91137-10
89453-1
89141-1
91137-12
89453-17
90441-10
89453-16
90441-9
96439-1
96439
65060625
89453-13
89141-13
89453-3
89141-3
89453-9
89141-9
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
89453-12
89141-12
89453-11
89141-11
89453-8
89141-8
BEST
PART
NUMBER
IT E M
NO.
T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D
C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O
D .H IR U LK A R Q U IG L E Y 2 / 1 / 9 5
B .R IC E
20
16
B O D Y , IB O P
B O D Y , IB O P
O T H E R W IS E
C HEC KED
3
110102
CURRENT
DRAW N
A P P L IC A T IO N
UNLESS
9
IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D
P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F
D IM E N S IO N S A R E IN IN C H E S
N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E
O R IN P A R T , O R U S E O F T H IS D E S IG N O R
.X X ± .0 3
.X X X ± .0 1 0
.X ± .1
D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS
N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N
A N G L E S ± .5 °
C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS
D O N O T S C A L E D R A W IN G
D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L -
ON
19
15
4
TH R E A D P R O TE C TO R - 6 5 / 8 " (N O T S H O W N )
P LU G , P R ESSU R E
6
7
R E T A IN IN G R IN G (H 2 S )
R E T A IN IN G R IN G
N YLO N P LU G
7
B A C K - U P R IN G
B A C K - U P R IN G
O - R IN G
O - R IN G
SEAL, U - C U P
SEAL, U - C U P
S T A B IL IZ E R , S E A L R IN G
B A C K - U P R IN G
B A C K - U P R IN G
O - R IN G
O - R IN G
7
S P R IN G , W A V E
S P R IN G , W A V E
6
SET, SEAT/ B ALL
SET, SEAT/ B ALL
B A C K - U P R IN G
7
B A C K - U P R IN G
7
O - R IN G
7
O - R IN G
7
SLEEVE, C R AN K
SEAL, C R O W N
7
SEAL, C R O W N
C R A N K , O P E R - L .H .
C R A N K , O P E R .- L .H .
C R A N K , O P E R .- R .H .
C R A N K , O P E R .- R .H .
6
REQD
U N LESS
L O W S T R E S S S T A M P U S IN G 1 / 4 " H IG H L E T T E R S
A S S H O W N . S E E R E F . IN F O . T A B L E A B O V E
F O R P A R T N O . S T A M P "C W " IN C IR C L E
AS SHOW N
4
8
65020193
650210B0
65060192
65060191
65060492
65060199
65060197
65060198
65060196
65060696
65060695
96438
65021193
65021191
65021192
65021190
65021491
65021490
30177893
30177204
65060794
65060792
65060793
65060791
98895
65060691
65060690
114901
110128
30114902
110118
1
XXXXXX
5 / 8 " R E G . R .H .
QTY
8
10
3
2/6/95
O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T
U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT
W A S L O A N E D . T H IS D O C U M E N T A N D T H E
IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN
IS T H E C O P Y R IG H T E D P R O P E R T Y O F
N A T IO N A L - O IL W E L L , L .P .
R IG S O LU TIO N S
1 0 0 0 0 R IC H M O N D A V E .
H O U S TO N , TE X A S 7 7 0 4 2 U .S .A .
(7 1 3 ) 3 4 6 - 7 5 0 0
2
B
A
T IT L E :
6
A S S E M B L Y , U P P E R IB O P
5/ 5" X 6 5/ 8", PH- 50
SC ALE:
WT
P R O J E C T IO N :
LB S:
2/3
D R A W IN G
260
S IZ E :
D
SH EET:
1 OF 1
R E V IS IO N :
NUMBER:
110103
F
1
DC F0022
(R E V
D)
4
N O TES: U N LESS
1.
PRESS
O T H E R W IS E
RO LLER
H O U S IN G , IT E M
D
2.
ASSEM B LE
IT E M
3.
C AM
2 , U S IN G
STAM P
2
3
S P E C IF IE D
B E A R IN G , IT E M
1, TO
N O TED
5 , IN T O
C RANK
DEPTH .
F O L L O W E R , IT E M
IT E M
1
8. TO RQ U E
"9 8 8 9 8 " A P P R O X IM A T E L Y
4, TO
C RANK
ARM,
TO
300
IN - L B
M IN .
WHERE
SHOWN.
D
2
6
C
C
3
7
1
B
B
1
3
A/R
53200- 271
C O M P O U N D , L O C K IN G
8
1
51300- 220- B
O - R IN G
7
1
53201
F IT T IN G , G R E A S E , S T R A IG H T (.1 2 5 - 2 7 N P T )
6
1
79825
RO LLER
5
1
79824
C AM
1
99168
SPAC ER
1
98899
ARM, C RANK
1
98897
C RANK
.1 5 5
2
4
5
QTY
PART
REQD
B E A R IN G
FO LLO W ER
3
P AR T F LAG S
T R A C E A B IL IT Y
NO.
C R IT IC A L L O A D
P A T H IT E M
C E R T IF IC A T IO N
R E Q U IR E D
S P AR E P AR T
C O M M IS S IO N IN G
O P E R A T IO N A L
IN S U R A N C E
DO NOT
DOC UMENT
AN G U LAR
TH IS
C O N TA IN S
DOC UMENT
IN F O R M A TIO N
PURPOSE
3
M AY
NOR
W R ITTE N
B
N E ITH E R
USED
FOR
P E R M IS S IO N
TO LER AN C E
P R O P R IE TA R Y
BE
TO
M A N U F A C TU R IN G
FROM
VARC O
CUT
O TH E R S
PURPOSES
SUCH
FOR
ANY
W ITH O U T
IN TE R N A TIO N A L , IN C .
HYOUNG
L IM
J. P O P E
PREPARED
2
(M A C H IN IN G )
1
BY
IT E M
M A T E R IA L
NO.
M A T E R IA L S
SURFAC E
F IN IS H E S
A
*TO R C H C U T
1000 MAX
M A C H IN E D
250 MAX
-
-
98903
PH60d
98900
PH60d
T IT L E
± 0° 30'
IN F O R M A TIO N , A N D
D IS C L O S E D
K. NGUYEN
LTR
4
.X ± .1 C A N B E * T O R C H
.X X ± .0 3 0
.X X X ± .0 1 0
S C ALE
TH IR D A N G LE P R O JE C TIO N
DC F0020B 1
OF
IN T E R P R E T D IM E N S IO N S &
T O L E R A N C E S P E R A N S I Y 1 4 .5 &
A B B R E V IA T IO N S P E R A N S I Y 1 .1
IN C H E S
2
D E S C R IP T IO N
D IM E N S IO N S U N L E S S O T H E R W IS E S P E C IF IE D
AR E IN
(M A C H IN IN G )
H O U S IN G
L IS T
A
4
NEXT
ASSY
HYOUNG
PRODUCT
L IM
B . P R IO R
C HEC KED
BY
APPROVED
BY
3/7/03
7/93
DATE
R e le a s e d
ASSEM B LY,
EXTERNAL
S IZ E
DOC UMENT
C
R E V IS IO N
98898
SC ALE
W E IG H T
LB SH EET
1/1
-
C RANK
NO.
03/13/2003
1
1
B
OF
1
0 8 :2 6 :5 2 A
DC F0021
(R E V
B)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.4
Service Loops and Derrick Kits
www.nov.com
8
6
7
N O TES: U N LESS
O T H E R W IS E
4
3
1
2
S P E C IF IE D
1.
A L L IT E M S
TO
2.
USE
7, 8, 9, AND
IT E M S
BE
5
S H IP P E D
LO O SE
10
TO
IN
T H E IR
ATTAC H
O R IG IN A L C O N T A IN E R S .
IT E M
4
TO
EARTH
C O NDUC TO R.
D
LEN G TH
(R E F )
IT E M S
1, 2, 3
IT E M
D
4
C
C
IT E M
5
IT E M
6
B
TAB LE
I
124977-XXX-XX
VARC O
DASH NO.
C AB LE
L E N G T H (F T )
TO TAL
W E IG H T (L B )
-50
50
450
-75
75
675
-100
100
900
-125
125
1125
-150
150
1400
-175
175
1650
-200
200
1800
2
2
78310-1
W A S H E R , B E L L E V IL L E , 1 / 2 "
10
2
2
50808-R-S
W ASH ER , FLAT, 1 / 2 "
9
2
2
50208-S
N U T , S E L F - L O C K IN G ,1 / 2 "
8
2
2
50008-12-S
SCREW, HEX
7
1
1
124458-XXX-B
C AB LE
ASSY, AUX
POWER
(1 8
C O N D .)
6
1
1
123985-XXX-B
C AB LE
A S S Y , C O M P O S IT E
(4 2
C O N D .)
5
-
1
125093-XXX
C AB LE
A S S Y , E A R T H IN G
MCM)
4
-
1
114724- RED- XXX
C A B L E A S S Y , P O W E R , W / C O N N E C T O R , R E D (6 4 6 M C M )
3
-
1
114724- W H T- XXX
C A B L E A S S Y , P O W E R , W / C O N N E C T O R , W H T (6 4 6 M C M )
2
-
1
1 1 4 7 2 4 - B LK - XXX
C A B L E A S S Y , P O W E R , W / C O N N E C T O R , B L K (6 4 6 M C M )
(M U L T IC O N D U C T O R
C AB LE
C AB LES
O N LY)
LEN G TH
(S E E
TAB LE
B A S IC
P/N
I)
Q TY
NO.
O T H E R W IS E
S P E C IF IE D
ASSY
USED
CURRENT
DRAW N
R. HOLLADAY
IN IT IA L
T. PHAM
RET URNED
M A C H IN E D
MAX
250
5
4
S P E C IF IE D
TORCH
1000
CUT
MAX
CHECKED
APPV D
DATE
M. MASLYAR
L. MOLLETT
10 / 4 / 0 6
04/23/98
A
INF ORMAT ION
IS
REQUEST
C ONT AINE D
T HE
T IT L E :
C A B L E K IT , J U M P E R
( H O U S E T O D E R R IC K L O O P )
NAT IONAL AND
IN
ANY
EV ENT
UPON C OMPL E T ION OF T HE US E F OR W HIC H
W AS L OANE D . T HIS D OC UME NT AND T HE
AND
C OPY RIGHT E D
IT
REPRESENT ED
PROPERT Y
OF
SCALE:
L , L .P .
S . C U R L E E N A T I O N A L - O I L W ERLIG
S O LU TIO N S
M. MASLYAR
3
TO
O I L W E L L , L .P . U P O N
HE RE IN
O T H E R W IS E
NO.
M A T E R IA L S
T HIS D OC UME NT C ONT AINS PROPRIE T ARY AND
C ONF ID E NT IAL INF ORMAT ION W HIC H B E L ONGS T O
I N T E R P R E T D I M / T O L P E R A S M E Y 1 4 .5 M N A T I O N A L - O I L W E L L , L .P . I T I S L O A N E D F O R
L IMIT E D PURPOS E S ONL Y AND RE MAINS T HE
D IM E N S IO N S A R E IN IN C H E S
P R O P E R T Y O F N A T I O N A L - O I L W E L L , L .P .
RE PROD UC T ION, IN W HOL E OR IN PART , OR US E
.X ± .1
.X X ± .0 3
.X X X ± .0 1 0
OF T HIS D E S IGN OR D IS T RIB UT ION OF T HIS
INF ORMAT ION T O OT HE RS IS NOT PE RMIT T E D
A N G L E S ± .5 °
W IT HOUT T HE E X PRE S S W RIT T E N C ONS E NT OF
D O N O T S C A L E D R A W IN G
N A T I O N A L - O I L W E L L , L .P . T H I S D O C U M E N T I S T O
ON
A P P L IC A T IO N
UNLESS
OF
1
IT E M
D E S C R IP T IO N
BE
NEXT
6
(4 4 4
REQD
L IS T
T D S - 9 / 11S A
7
1/2"
-MC BSC
UNLESS
8
1
MC
PART
A
1 / 2 "X
B
1 0 0 0 0 R IC H M O N D A V E .
H O U S TO N , TE X A S 7 7 0 4 2 U .S .A .
(7 1 3 ) 3 4 6 - 7 5 0 0
2
WT
1/ 4
D R A W IN G
LBS:
TABLE 1
P R O J E C T IO N :
S IZ E :
D
SHEET:
1 OF 1
R E V IS IO N :
NUMBER:
124977
D
1
DCF0022
(R E V
D)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.5
Rigging
www.nov.com
8
7
N O TES: U N LESS
1.
APPLY
6
O T H E R W IS E
S P E C IF IE D :
53200- 242
L O C T IT E
(B L U E ) T O
TH READS
OF
5
IT E M
14, TO RQ U E
PER
DS
4
00008
AN D
3
2
1
10
L O C K W IR E .
D
D
B
B
D E T A IL
A
2X
LOW ER
C O N N E C T IO N
PLATE
ON
7
M AST
6
3
C
C
2X
5
4
2X
3
7
SEE
D E T A IL
S E C T IO N
A
B-B
2X
4X
4X 4X
4X
11
12
16
14
10FT Z6001
1
B
15
2X
2
8
2X 13
9
2
30178991
4
50016-44-C 8D C AP-SC REW , HEX HEAD
14
2
30178940
B O LTIN G , P LA TE
13
4
50816-W -C-5
W A S H E R , F LA T, W - S E R IE S
12
51016- C
W A S H E R , LO C K
11
2
51605- 20- S
P IN , R O LL
10
8
30158499- 04
S LE E V E , W IR E R O P E
9
4'
51220- 3
C A B LE , N Y LO N C O A TE D
8
4
1 1 8 8 4 4 - 1 6 - 2 0 B U S H IN G , 1 .0 0 ID X 1 .2 5 0 , F IB E R G LID E
7
2
30154386
P IN , P IV O T, TIE B A C K
6
2
30154385
H O O K , TIE B A C K
5
P IN , R E TA IN E R
4
2
30154684
4
1 1 8 8 3 6 - 1 6 - 3 2 B U S H IN G , TH R U S T, 1 .0 X 2 .0 X .O 6 , F IB E R G LID E
3
2
117496- 2
P IN , LY N C H
2
1
30178882
TIE B A C K , M A C H IN E , W E LD M E N T
NO.
O T H E R W IS E
S P E C IF IE D
OF
T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D
C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O
N A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D
P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F
N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E
O R IN P A R T , O R U S E O F T H IS D E S IG N O R
D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS
N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N
C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS
D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T
U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT
W A S L O A N E D . T H IS D O C U M E N T A N D T H E
IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN
IS T H E C O P Y R IG H T E D P R O P E R T Y O F
N A T IO N A L - O IL W E L L , L .P .
IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 M
D IM E N S IO N S A R E IN IN C H E S
.X X ± .0 3
.X X X ± .0 1 0
.X ± .1
A N G L E S ± .5 °
D O N O T S C A L E D R A W IN G
NEXT
ASSY
USED
DRAW N
A P P L IC A T IO N
UNLESS
O T H E R W IS E
M A C H IN E D
MAX
250
8
7
6
5
4
S P E C IF IE D
TO RC H
1000
CURRENT
ON
CUT
MAX
IN IT IA L
M . S H U LTZ
M . SH U LTZ
C HEC KED
R. CHOU
R. CHOU
APPVD
R. CHOU
R. CHOU
12/08/05
11/09/05
DATE
3
R IG S O LU TIO N S
1 0 0 0 0 R IC H M O N D A V E .
H O U S TO N , TE X A S 7 7 0 4 2 U .S .A .
(7 1 3 ) 3 4 6 - 7 5 0 0
2
B
1
D E S C R IP T IO N
L IS T
Q TY R E Q D
U N LESS
15
P LA TE , S P A C E R
4
PART
A
16
LO C K W IR E , .0 5 1 D IA .
IT E M
NO.
M A T E R IA L
M A T E R IA L
A
T IT L E :
T IE B A C K ,
SC ALE:
WT
LB S:
1/4
D R A W IN G
P R O J E C T IO N :
K IT
S IZ E :
D
SH EET:
1 OF 1
R E V IS IO N :
NUMBER:
30178883
A
1
DC F0022
(R E V
D)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Section 4.6
Accessories
www.nov.com
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 5.0
Mechanical Spares List
www.nov.com
TDS-11SA
AC IDEAL RIG
MECHANICAL
SPARES LIST
NOTES:
1.
M614003010-1
2.
M614003010-2
3.
M614003010-3
Recommended Commissioning Spares
Recommended Operational Spares
Recommended Insurance Spares
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS
TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT
THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
CURRENT
DRAWN
CHECKED
TITLE
SPARES LIST, MECHANICAL
AC IDEAL RIG, TDS-11SA
INITIAL
H. LIM
D. STEPHENS
SIZE
APPVD
H. LIM
A
DATE
3/27/09
SCALE
DWG NO
REV
M614003010-SPL-001
NONE
WT LBS
SHEET
1
01
OF
5
DCF0045 (REV B)
-1
Recomm.
Commission
Spare
-2
Recomm.
Operational
Spare
-3
Recomm.
Insurance
Spare
Where
Used
Description
Where Used
-
1
1
-
120900
120900
Motor Housing Assy
Motor Housing Assy
98290 Liner, Upper Stem, Std. Bore
-
1
-
120900
Motor Housing Assy
98291 Seal, Polypak
-
1
-
120900
Motor Housing Assy
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
120900
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Motor Housing Assy
Part No.
Description
Motor Housing
Assy
30173521 Bearing Isolator
30154362 Shield, Bearing
91250-1
77039
30123290
Z6001
53003-16
53219-2
51300-277-B
51300-425-B
109523
108216-12
118217-40L60
118217-40R60
109555
109528
30122104
117603-1
121272-2
121272-1
120117
115299
120119-2
120119-1
30151875-504
Seal, Oil
Seal
Assembly, Wash Pipe
Lockwire, .051
Plug, Magnetic
Fitting, Grease
O-Ring, Cover/Bearing Ret.
Seal, Hammer Lug Union
Adapter, S-Pipe
Ball Valve
Drilling Motor Assy, LH
Drilling Motor Assy, RH
Rotor, Brake
Brake, Caliper Disc
Heat Exchanger, Oil
Pump Assembly, Lube
Tube Assembly, Breather
Tube Assembly, Breather
Belt, Timing
Encoder, Digital
Pulley, Timing
Pulley, Timing
Shotpin Assembly
-
1
1
1
168 ft
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
-
Reservoir Assy
30113165
108119-16B
71613
51300-038-B
110132
110191-501
Valve, Relief-Popoff
Sight Gage
Reservoir Breather
O-Ring
Gasket
Bladder, Reservoir (5 gallons)
-
1
1
1
1
1
1
-
110068
110068
110068
110068
110068
110068
Reservoir, Assembly
Reservoir, Assembly
Reservoir, Assembly
Reservoir, Assembly
Reservoir, Assembly
Reservoir, Assembly
Pipe, Wash, 3 Inch Bore
Packing Seal Kit, Standard
Ring, Snap
Wrench, Washpipe
-
1
5
1
1
-
30123290
30123290
30123290
30123290
Wash Pipe Assembly
Wash Pipe Assembly
Wash Pipe Assembly
Wash Pipe Assembly
Wash Pipe
Assembly
30123289
123292-2
30123562
53303-14
SIZE
DWG NO
A
SCALE
REV
M614003010-SPL-001
NONE
WT LBS
SHEET
2
01
OF
5
DCF0045 (REV B)
Part No.
Description
-1
Recomm.
Commission
Spare
-2
Recomm.
Operational
Spare
-3
Recomm.
Insurance
Spare
Where
Used
Description
Where Used
2
8
1
2
1
2
-
1
1
1
1
2
4
4
1
1
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
30157366
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler Package
Pipe Handler
Package
125098
30125094
30125097
98898
110042
107052
30119592
30122367
119139
Tube Assembly
Tube Assembly
Tube Assembly
Crank Assembly
Shell, Actuator, IBOP
Lock Tab
Cylinder, Hydraulic Assembly
U-Bolt, 500 Ton
U-Bolt, 350 Ton
114859
114859-1
99498-2
99498-1
110103-500
114706-500
Upper IBOP Repair Kit – Complete
Upper IBOP Repair Kit – Soft Seals
Lower IBOP Repair Kit – Complete
Lower IBOP Repair Kit – Soft Seals
Upper IBOP Valve
Lower IBOP Valve
-
Brake, Caliper
Disc
109528-1
109528-2
109528-3
109528-4
109528-5
109528-6
Friction Pads (2 required)
Seal Kit
Heavy Duty Spring (4 required)
Screw, Return Spring (4 required)
Pin, Guide (4 required)
Bleed Screw Assembly
4
-
8
1
8
8
8
1
-
109528
109528
109528
109528
109528
109528
Brake, Caliper Disc
Brake, Caliper Disc
Brake, Caliper Disc
Brake, Caliper Disc
Brake, Caliper Disc
Brake, Caliper Disc
O-Ring
O-Ring
Glyd Ring Rotary, 11.000 Rod
Piston Ring
Ring, Thrust
Glyd Ring Rotary, 11.500 Rod
Glyd Ring Rotary, 10.000 Rod
Seal, Wiper
Retainer Ring
Bushing, Turcite
Bushing
Bearing, Flanged
Relief Valve
Seal
Bushing, Flanged
-
1
1
1
1
10
1
1
2
2
2
2
2
1
1
1
-
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
30173277
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Rotating Link Adapter
Bearing, Self Lubrication
Bearing, Self Lubrication
Bearing, Self Lubrication
Roller
Cylinder Assy, IBOP Actuator
-
2
2
2
2
-
1
30157288
30157288
30157288
30157288
30157288
Torque Arrestor Assy
Torque Arrestor Assy
Torque Arrestor Assy
Torque Arrestor Assy
Torque Arrestor Assy
Rotating Link
500 Ton
51300-273-B
51300-381-B
30119319
30173156
30119357
30119143
118375
119547
30117775-2
119358
115176
112754-130
53250-5
77039
112754-116
PH-75 Torque
Arrestor Assy
118844-16-08
118844-16-12
118844-22-22
71847
125594
SIZE
DWG NO
A
SCALE
REV
M614003010-SPL-001
NONE
WT LBS
SHEET
3
01
OF
5
DCF0045 (REV B)
Part No.
Description
-1
Recomm.
Commission
Spare
-2
Recomm.
Operational
Spare
-3
Recomm.
Insurance
Spare
Where
Used
30157287
30157287
30157287
30157287
Description
Where Used
PH-75 Clamp
Cylinder
72219
72220
72221
30158690
Seal, Piston
Seal, Rod
Ring, Wiper
Ring, Stabilizer
-
2
2
2
2
-
Hydraulic
Package
30173216-1
30111013
110562-1
110563-1
110564-1
Filter Element, Hydraulic
Filter, 60 micron
Counterbalance Accumulator
System Accumulator
Accumulator
2
1
-
2
1
-
1
1
1
Hydraulic Package
Hydraulic Package
Hydraulic Package
Hydraulic Package
Hydraulic Package
Pump Motor
Assembly
114113
Motor Assy
-
-
1
Pump Motor Assy
Electric
Package
30172028
83095-1
87541-1
76841
53219-3
83095-2
Motor Blower
Pressure Switch, IBOP
Pressure Switch
Pressure Switch, Air
Fitting, Grease
Pressure Switch
-
-
1
1
1
1
1
1
Electrical Package
Electrical Package
Electrical Package
Electrical Package
Electrical Package
Electrical Package
Solenoid Valve
Solenoid Valve
Valve, Relief
Hydraulic Motor
Valve, Relief
Relief Valve, Low Flow
Reducing/Relieving Valve
Cavity plug, T-13A Short
Relief Valve, Ventable
1
1
-
2
2
2
1
1
3
1
1
1
-
114174
114174
114174
114174
114174
114174
114174
114174
114174
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Pilot – To – Open Check Valve
Differential Unloading Valve
Reducing / Relieving Valve
Flow Control Valve
Pilot – To – Close Check Valve
Check Valve
Check Valve
Logic Cartridge
Relief Valve
Cavity Plug, T-11A Short
Manual Valve, 3-pos. , Zero Leak
-
4
1
1
1
1
2
3
3
1
1
1
-
114174
114174
114174
114174
114174
114174
114174
114174
114174
114174
114174
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold Assy
Manifold
127908-D2
127908-J2
94520-1AN
30158011
94522-1EN
111664-1EN
109858-1AN
93667-M13
P6140000631AN
107029-175N
107028-1ANB
99353-1AN
98402-800D
94537-130N
94536-230N
94536-14N
94534-1CXN
94520-1NN
93667-M11
110538-5
SIZE
DWG NO
A
SCALE
Clamp Cylinder
Clamp Cylinder
Clamp Cylinder
Clamp Cylinder
REV
M614003010-SPL-001
NONE
WT LBS
SHEET
4
01
OF
5
DCF0045 (REV B)
Part No.
Description
-1
Recomm.
Commission
Spare
-2
Recomm.
Operational
Spare
-3
Recomm.
Insurance
Spare
Where
Used
Description
Where Used
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
124539
124538
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage Assy, Right
Carriage Assy, Left
Carriage
Package
109944
Bushing, Flange
-
8
-
30155438
Cam Followers 6”
-
-
2
30158767-04
Cam Followers 4”
-
-
16
55324-C
Nut
-
-
16
51132-C
Washers
-
-
2
51024-C
Washers
-
-
16
80569
Nut
-
-
2
112875
Bogey Pin
-
-
2
109944
Bushing
-
2
-
30152845
Retaining Pins
-
4
-
30157306
Lynch Pins
-
4
-
Counterbalance
Kit
108894-P40
94522-21N
108894-B40
108894-G20
108894-Y4
108894-Z677
94536-175N
92654
112825
110704
110703
Seal, Piston
Relief Valve Cartridge
Body Seal
Rod & Gland Seal
Rod & Gland Wrench
Spanner Wrench
Check Valve
Check Valve
Cartridge
Cylinder Assy, Counterbalance
Cylinder Assy, Counterbalance
-
1
1
1
1
1
1
2
1
1
-
1
1
110687
110703
110687
110687
110687
110687
111712
111712
111712
112190
112190
Cylinder
Cylinder Assy
Cylinder
Cylinder
Cylinder
Cylinder
Pre-Fill Valve Assy
Pre-Fill Valve Assy
Pre-Fill Valve Assy
Counterbalance Kit
Counterbalance Kit
-
2
2
2
-
30154688
30154688
30154688
Guide Beam Kit
Guide Beam Kit
Guide Beam Kit
-
-
1
30183283
Service Loop Kit
-
-
1
30183283
Service Loop Kit
-
-
1
30183283
Service Loop Kit
Guide Beam Kit
117496-1
Lynch Pin
117783
Retainer Pin
117782
Joint Pin
Service Loops
30175017-75Power Service Loop
4-3-B
30183284-75Control Service Loop
4-4-B
30183959-75Aux Power Service Loop
4-4-B
SIZE
DWG NO
A
SCALE
REV
M614003010-SPL-001
NONE
WT LBS
SHEET
5
01
OF
5
DCF0045 (REV B)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 6.0
Control Spares List
www.nov.com
TDS-11SA
AC IDEAL 135
SPARES LIST/KIT,
ELECTRICAL
NOTES:
RIG/PLANT
1.
10620488-1
Recommended Commissioning Spares
2.
10620488-2
Recommended Operational Spares
3.
10620488-3
Recommended Insurance Spares
NEXT ASSY
PRODUCT
MJOB-8375
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
REMARKS
MAIN TAG NUMBER
DISCIPLINE
CLIENT PO NUMBER
This document contains proprietary and confidential information
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV.
Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained
and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
National Oilwell Varco
11000 Corporate Centre Drive
Houston, Texas 77041 (USA)
Phone + 281-854-0400
Fax + 281-854-0607
CLIENT DOCUMENT NUMBER
DOCUMENT NUMBER
REV
Client Document Number
10620488-SPL
02
www.nov.com
Document number
Revision
Page
Template Name
10620488-SPL
02
2
ORA_SPL_TPL.doc
REVISION HISTORY
02
11/22/2011
Corrected Part Numbers
R. MOENCH
B. BOEPPLE R. MOENCH
01
11/1/2011
Initial Release
B. BOEPPLE
R. MOENCH R. MOENCH
Rev
Date (mm.dd.yyyy)
Reason for issue
CHANGE DESCRIPTION
Revision
01
02
Change Description
First issue
Corrected Part Numbers to Match Assemblies
D7440000254-TPL-001/01
www.nov.com
Prepared
Checked
Approved
Document number
Revision
Page
Template Name
10620488-SPL
02
3
ORA_SPL_TPL.doc
-1
Recom.
Commission
Spare
-2
Recom.
Operational
Spare
-3
Recom.
Insurance
Spare
Where
Used
Part No.
Description
76841
BLOWER MOTOR PRESSURE
SWITCHES
-
1
2
-
83095-1
IBOP PRESSURE SWITCH
-
1
1
-
87541-1
LUBE OIL PRESSURE SWITCH
-
1
1
-
83095-2
Bx ELEVATOR CLOSED
PRESSURE SWITCH
-
1
1
-
127908-D2
SOLENOID VALVES
-
2
9
-
127908-J2
SOLENOID VALVES
-
1
4
-
93939
FRAME DOLLY RETRACTED
PROX SWITCH (OPTIONAL)
-
-
1
-
98263
BARRIER I.S. (OPTIONAL)
-
-
2
108616-6
115299
TD MOTOR INCREMENTAL
ENCODER
1
2
2
-
10064178-096
SUPPLY MODULE DC 24V/FUSE
1
1
6
10540174-001
10064178-040
4 CH DIGITAL INPUT MODULE
DC 24V
1
3
6
10540174-001
10064178-053
2 CH DIGITAL OUTPUT
MODULE DC 24V, 2.0A
3
6
12
10540174-001
10064178-032
INCREMENTAL ENCODER
MODULE
1
1
1
10540174-001
10044752-001
RIM SS2 ENCODER SPLITTER
1
1
1
10540174-001
10064178-086
PROFIBUS DP/V1 12 MBd
FIELDBUS COUPLER
1
1
1
10540174-001
10042793-001
PROFIBUS CONNECTOR
2
2
2
10540174-001
10044170-001
24VDC POWER SUPPLY 10A
1
1
2
10540174-001
10052294-001
SW, CAM, DISC, 4P, 32A
-
1
1
10540174-001
10049691-001
RLY, SPDT, 24VDC (RLY), 10A
AT 250VAC
2
4
4
10540174-001
10505066-007
CB 10A, 2P, 480VAC
1
2
2
10540174-001
10064194-029
FUSE, 6A, 125V, 5 x 20mm
2
2
2
10540174-001
D7440000254-TPL-001/01
www.nov.com
Description
Where Used
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
TDS-11SA TOP
DRIVE
BARRIER I.S./N.I.S.
J-BOX
TD-MOT-01
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
Document number
Revision
Page
Template Name
Part No.
Description
10620488-SPL
02
4
ORA_SPL_TPL.doc
-1
Recom.
Commission
Spare
-2
Recom.
Operational
Spare
-3
Recom.
Insurance
Spare
Where
Used
10066667-001
TB-6.2MM, GRAY UT4
5
5
5
10540174-001
10065802-001
TB-GROUND BLOCK, UT-4-PE
5
5
5
10540174-001
10066985-001
TB-5.2MM, GRAY, UT2.5
5
5
5
10540174-001
10044673-001
PWR-SPLY REDUNDANT
1
1
1
10540174-001
10064178-070
MODULE, END, FIELDBUS
1
2
2
10540174-001
10068104-001
SPLITTER CABLE
-
1
1
10540174-001
10077584-001
DATA STATION PLUS
PROTOCOL
-
1
1
10540174-001
10077585-001
PROFIBUS DP CARD
-
1
1
10540174-001
10512924-001
BANNER WIRELESS GATEWAY
-
1
1
10540174-001
10072732-001
ANTENNA-OMNI
-
-
1
10540174-001
10064179-004
TB-C/B, 4 AMP, THERMALMAGNETIC
1
1
1
10540174-001
D7440000254-TPL-001/01
www.nov.com
Description
Where Used
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
DRILL FLOOR
TOOL REMOTE I/O
CABINET
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 7.0
Electrical Trouble Shooting Guide
www.nov.com
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 8.0
TDS-11SA, Pocket Guide
www.nov.com
LUBRICATION
LUBRICATION
LUBRICATION
LUBRICATION
LUBRICATION
LUBRICATION
LUBRICATION
LUBRICATION
ACCESSORY TOOLS
ACCESSORY TOOLS
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
34
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 9.0
TDS-11SA VFD Operation Manual
www.nov.com
Operation Manual
TDS11 VFD Operation Manual
REFERENCE
RIG/PLANT
REFERENCE DESCRIPTION
TDS11
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
111
REMARKS
MAIN TAG NUMBER
CLIENT PO NUMBER
CLIENT DOCUMENT NUMBER
www.nov.com
DISCIPLINE
This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or
distribution of this information to others is not permitted without the
express written consent of National Oilwell Varco. This document is
to be returned to National Oilwell Varco upon request and in any
event upon completion of the use for which it was loaned.
 National Oilwell Varco
National Oilwell Varco
Rig Solution Group
1530 W. Sam Houston Pky N
Houston, Texas 77043 (USA)
Phone + 713-935-8000
Fax + 713-346-7426
DOCUMENT NUMBER
REV
D25TDS11-MAN-001
01
Document number
Revision
Page
D25TDS11-MAN-001
01
2
REVISION HISTORY
01
15.08.2006
Rev
Date (dd.mm.yyyy)
INFORMATION
CHANGE DESCRIPTION
Revision
01
Change Description
First Issue
www.nov.com
Reason for issue
CRR
ML
CRR
Prepared
Checked
Approved
Document number
Revision
Page
Technical Manual
Air-Cooled AC Drives
Model 800AC
www.nov.com
D25TDS11-MAN-001
01
3
Document number
Revision
Page
D25TDS11-MAN-001
01
4
TABLE OF ONTENTS
1
2
SAFETY INSTRUCTIONS ................................................................................................ 6
1.1
General ................................................................................................................... 6
1.2
Safety Symbols ....................................................................................................... 6
1.3
Basic Safety Precautions ........................................................................................ 7
INTRODUCTION ............................................................................................................... 9
2.1
3
Abbreviations and Definition ................................................................................... 9
SYSTEM DESCRIPTION ................................................................................................ 10
3.1
Input/Output Reactor ............................................................................................ 11
3.2
Input Rectifier........................................................................................................ 11
3.3
DC Bus ................................................................................................................. 16
3.4
Inverter ................................................................................................................. 16
3.5
Braking Chopper and Resistor Bank..................................................................... 39
3.6
Assignment Contactors ......................................................................................... 42
3.7
AC Induction Motors – Basic Principle of Operation ............................................. 43
3.8
PLC and interface for the Drilling Control System (DCS)...................................... 46
3.9
Technical Data ...................................................................................................... 49
3.9.1 Weights and Dimensions........................................................................... 49
3.9.2 Performance Data ..................................................................................... 52
4
OPERATING INSTRUCTIONS ....................................................................................... 53
4.1
CONTROL PANEL ............................................................................................... 53
4.1.1 Panel operation mode keys and displays .................................................. 54
4.1.2 Status Row ................................................................................................ 54
4.1.3 Drive control from panel ............................................................................ 55
4.1.4 Actual signal display mode ........................................................................ 56
4.1.5 Parameter mode ....................................................................................... 60
4.1.6 Function mode .......................................................................................... 61
4.1.7 Drive selection mode ................................................................................. 65
4.1.8 Reading and entering of Boolean values on the display ........................... 65
4.2
INITIAL MOTOR OPERATION SETUP ................................................................ 67
4.2.1 Visual Inspection ....................................................................................... 67
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Document number
Revision
Page
D25TDS11-MAN-001
01
5
4.2.2 Configure Drive ......................................................................................... 67
4.2.3 General Set-up Procedures....................................................................... 70
5
6
INSTALLATION .............................................................................................................. 94
5.1
Mechanical Installation ......................................................................................... 94
5.2
Electrical Installation ............................................................................................. 94
TROUBLESHOOTING .................................................................................................... 98
6.1
Warning and fault indications ................................................................................ 98
6.1.1 Programmable protection functions ........................................................... 98
6.1.2 Preprogrammed faults ............................................................................. 100
6.1.3 Warning messages generated by the drive ............................................. 101
6.1.4 Warning messages generated by the control panel ................................ 105
6.1.5 Fault messages generated by the drive .................................................. 106
7
MAINTENANCE ............................................................................................................ 110
8
OPERATOR SKILLS AND TRAINING ......................................................................... 111
www.nov.com
Document number
Revision
Page
1
D25TDS11-MAN-001
01
6
SAFETY INSTRUCTIONS
Read the entire Safety Summary located in the ABB operation maintenance manuals prior to
performing any operations or maintenance to this equipment.
The following safety instructions must be followed when installing, operating and servicing the National
Oilwell air-cooled AC drives. If ignored, damage may occur to the operator and equipment. Read
these safety instructions before working on the system.
1.1
General
Safety is everyone’s business and must be of primary concern at all times during any
operations or maintenance. Knowing the guidelines covered in this manual will help to
provide for the safety of the individual, for the group and for the proper operation of the
equipment. Only qualified personnel who are well versed in safety procedures should
ever be allowed to operate and/or maintain this piece of equipment. If this guideline is
strictly followed, this will minimize problems. Safety summaries and safety
procedures can never replace good common sense. As detailed as some of these
documents may be, some situations will require good common sense. Recognize all
standard safety symbols. Understand their importance, read them carefully and make
sure you understand their meaning. If something is unclear, ask. Do not take chances
with your life and others.
1.2
Safety Symbols
There are three types of safety instructions used throughout this manual and on the
equipment: warnings, cautions and notes. Look for these standard safety terms and
conventions that point out items of importance to the safety of the individual as well as
others that may be in the area:
WARNING safety notes MUST be followed carefully.
Failure to do so may result in catastrophic equipment
failure resulting in SERIOUS INJURY or DEATH.
*
CAUTION safety notes are also very important and
should be followed carefully. Failure to do so may
*
Recommended safety conventions. American Petroleum Institute
www.nov.com
Document number
Revision
Page
D25TDS11-MAN-001
01
7
result in EQUIPMENT DAMAGE and/or PERSONAL
INJURY.
NOTE
NOTE is used to notify personnel of information that
is IMPORTANT but NOT HAZARD RELATED.
1.3
Basic Safety Precautions
As mentioned earlier, all personnel performing operations or maintenance tasks of any
kind should be trained in both general safety and hazard recognition around a drilling rig,
as well as specific instructions pertaining to the particular rig they are working. All
operators and maintenance personnel should be versed in the specifics regarding
performance characteristics and limitations of all rig equipment.
Any personnel who intend to operate the unit needs to be both qualified and trained on
the AC drive operating controls and have a thorough understanding of the limitations and
functions of this piece of rig equipment.
All personnel should be protected from exposed mechanical dangers such as guards
fabricated from expanded metal and other similar hazards. Safeguards such as keeping
hands, hair, clothing, jewelry, rags, tools, etc. away from all moving parts should be
familiar and a part of all activities.
Do not attempt equipment operation with inadequate visibility. Poor lighting can
aggravate this, as can bad weather conditions, or other reasons. If you cannot see what
you are doing, then do not do it!
Operating and maintenance personnel should wear suitable protective clothing in addition
to any other personal safety devices that conditions may dictate.
Equipment used in heavy lifting and moving of the unit and accessories during operations
must be sufficiently rated to handle the weights involved.
Promote good safety measures at all times around the equipment and throughout all
phases of operations. It is the equipment owners’ / operators’ responsibility to establish
good safety measures including personnel training and enforcement of safety practices.
The first person hurt by poor safety practices is most commonly the operator in the field.
www.nov.com
Document number
Revision
Page
D25TDS11-MAN-001
01
8
Operating instructions tend to be general in nature to
make them clear and easy to understand, giving
minimal details on individual component operation.
If the operator is not thoroughly familiar with all
control functions, equipment limits, and safety
features – DO NOT OPERATE THIS EQUIPMENT.
www.nov.com
Document number
Revision
Page
2
D25TDS11-MAN-001
01
9
INTRODUCTION
This manual is intended for personnel who plan the installation, install, commission, use and service of
the system. A fundamental knowledge of electricity, wiring, electrical components and electrical
schematic symbols is required.
This technical manual includes data and information concerning the National Oilwell air cooled series of
Variable Speed Drive Systems (VSDS) referred to as the model 800AC. National Oilwell VSDS are
built from adjustable speed frequency converters, inverters, or combinations of both. This manual is
written to include all of these devices and their respective system components. All National Oilwell AC
variable speed drive systems are similar, but there are many variations according to each customer’s
specific requirements. Therefore, it is recommended that the user review the reference document list in
conjunction with this manual so that a thorough understanding of your specific system is ensured.
The basic function of a model 800AC system is to convert a fixed frequency 3 phase AC voltage into a variable frequency, variable voltage
source that is utilized to control motor speed and torque. To accomplish this, the model 800AC utilizes the following three steps:



Standard three phase 50 or 60 Hz voltage is converted from AC to DC by 3-phase, full
wave rectifiers.
The DC voltage is inverted to variable frequency / variable voltage by the inverters.
The variable frequency / variable voltage output is applied to a motor to control speed and
braking.
The rectifier installed in the model 800AC system is composed of individual diode
semiconductors arranged in a full wave rectifier bridge. These diodes are mounted on a finned
heat sink which utilizes an electric powered fan motor for cooling. The inverters in the model
800AC systems utilize the ABB model ACS800 inverter modules. These modules are
combined to form the inverter or drive part of the system. More detailed information about the
individual components, software, or systems can be found later in this manual, in vendor
supporting documents or from the factory upon request.
2.1
Abbreviations and Definition
ASIC
Application Specific Integrated Circuit
AHD
Active Heave Draw works
CW
Clockwise
CCW
Counter Clock Wise
CCS
Cyberbase Control System
DCS
Driller’s Control System
DW
Draw works
FDS
Functional Design Specification
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GPM
Gallons per minute
HMI
Human-Machine Interface
HP
Horsepower
Hz
Hertz
IGBT
Insulated Gate Bipolar Transistor
LED
Light Emitting Diode
MMI
Man-Machine Interface
MCC
Motor Control Center
MP
Mud Pump
M/U
Make Up
P&ID
Piping & Instrument Diagram
PHE
Plate Heat Exchanger
PLC
Programmable Logic Controller
PSI
Pounds per Square Inch
PWM
Pulse Width Modulation
RAM
Random Access Memory
RISC
Reduced Instruction Set Computer
SVM
Space Vector Modulation
STEP7
Siemens PLC Programming Software
TD
Top drive
VFD
Variable Frequency Drive
FC
Frequency Converter
VSDS
Variable Speed Drive System
DB
Dynamic Braking
VAR
Volt-Amp Reactive
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Converter An arrangement of solid-state devices that converts AC power to DC power
Operator
3
The person assigned the responsibility of physically operating and
maintaining the equipment
SYSTEM DESCRIPTION
A typical Model 800AC drive system (VSDS) includes most or all of the following components:
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Input/Output Reactor
Input Rectifier
DC Bus
Inverter (VFD)
Braking Chopper and Resistor Bank
Assignment Contactors
AC Induction Motors – Basic principle of operation
PLC and Interface for the Drilling Control System (DCS)
If you are not sure about what equipment is installed in your particular system, review the
electrical drawings referenced in the job specific detail drawings and document list.
3.1
Input/Output Reactor
Input reactors are used in most systems to reduce the current ripple on the DC bus.
Reducing the current ripple extends the bus capacitor lifetime. Input reactors also
attenuate harmonics that are injected onto the AC bus by the rectifier bridge. Line
reactors are generally dimensioned to provide 3% impedance at full load current, but may
be less than this depending upon the source impedance of the system in which they are
installed. Most input reactors are iron core, 3 phase inductors, but some systems utilize 3
single-phase reactors in order to save space.
The primary function of the output reactor is to filter the output waveform of the inverter.
The output reactor reduces motor temperature and audible noise caused by high
frequency switching of the inverter. In addition, it reduces the risk of motor bearing
currents and provides short circuit protection for the motor.
3.2
Input Rectifier
The input rectifier transforms incoming AC voltage into DC voltage using a three-phase
full wave diode bridge arrangement. The most basic three-phase bridge arrangement
utilizes 6 diodes arranged as follows:
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Figure 3-1: Basic Three-Phase Rectifier Bridge
In the arrangement above, two of the diodes are “on” at a time. The diodes turn “on”
when they are forward biased. The AC input supply voltage determines which diodes are
forward biased at a given time. During operation, diodes A+ and C-, C- and B+, B+ and
A-, A- and C+, C+ and B-, B- and A+ are forward biased at the same times. The resulting
output of this operation is a DC output voltage with magnitude related to the AC input
voltage magnitude.
Various voltage sources are possible when using an AC drive. Transformers are used
primarily in offshore applications, and generally have multiple secondary windings. The
multiple winding supply transformer steps down incoming generator voltage to either 480
or 600/690 volts, depending on the system. Multi-winding transformers are used in high
power offshore systems. Multiple phase-shifted windings make it possible to build VSDS
systems that introduce very low harmonic distortion to the system supply bus. The most
common power source for a portable land based VSDS are synchronous generators.
The number and size of the generators varies from one system to another, however
nearly all are 3 phase, 600VAC generators.
Model 800 VSDS rectifiers typically fall within two basic classes, 6-pulse and 12-pulse.
Both the 6 and 12 pulse diode bridges are built using assemblies made from 6
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semiconductor diodes in a 3 phase, full wave bridge arrangement. A 6-pulse rectifier is
built from a single assembly, while a 12 pulse bridge is constructed using two 6-pulse
assemblies. In the 12-pulse arrangement, the two 6-pulse assemblies are supplied from
the secondary of a ||/Y transformer whose secondary outputs are phase shifted by 30
electrical degrees. Occasionally, 24 pulse rectifiers systems are built using dual 12 pulse
rectifiers and 2 ||/Y transformers, where each is phase shifted at the primaries +/- 7.5
electrical degrees. The 6-pulse rectifier is shown in figure 3-1 on the previous page.
Figure 3-2 below shows the 12-pulse rectifier with an inter-phase reactor for load sharing.
6 P u lse
R e ctifie r
O p tio n a l
In te rp h a se
R e a cto r
+
6 p u lse T ra n sfo rm e r
To AC
M a in s
1 2 P u lse D C
O u tp u t
6 P u lse
R e ctifie r
-
Figure 3-2: 12 Pulse Diode Rectifier with Inter-phase Reactor
The inter-phase reactor balances current in 12 pulse rectifiers by forcing current sharing
between the  and Y bridges of the system. Current can become unbalanced in the
rectifiers when there are slightly different impedances in the  and Y windings of the
transformer.
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The relationship between the AC input voltage and the output voltage of the 6-pulse
rectifier is given by the equation VLL x 1.35 = Vdc. For a 12 pulse rectifier, the relationship
is VLL x 1.39 = Vdc For either bridge, the unloaded DC value is approximately equal to the
peak RMS value of the input voltage, or VLL x 1.414 = Vdc . The following table (3-1)
shows some typical DC voltages for various inputs:
Input Voltage - RMS
line to line
6 Pulse Average DC
Output Voltage
12 Pulse Unloaded
DC output Voltage
480
648
667
600
810
848
690
932
960
Table 3-1: AC-DC Rectifier Voltages
Note that under heavy load, the drive’s DC link voltage may drop slightly. The DC link
voltage can be monitored at the drive controller keypad in the main monitor menu.
The following figures show the output waveforms of the 6 and 12-pulse rectifier bridges.
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Figure 3-3: 6 Pulse Rectifier Bridge Output Waveform, Vin = 600VAC
Figure 3-4: 12 Pulse Rectifier Bridge Output Waveform: Vin = 600VAC
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DC Bus
The Model 800AC VSDS systems may utilize a common DC bus. This means that 2 or
more inverters are connected to the DC bus via disconnect switches and share a one or
more rectifier bridges. There are certain advantages to the common DC bus, the most
important being input power is conserved when one or more of the motors in the system
are braking while others are motoring. An AC motor that is braking behaves as a
generator, and its power is returned to the DC bus by the inverter. Therefore, the power
required to operate the VSDS is reduced by utilizing the energy required to brake the
VSDS motors. The net power supplied to the VSDS by the system generators is the load
power less the regenerated power. For example, if 2 motors are consuming 1500 kW
while another motor is braking and supplying 700kw to the DC bus, the net power
required to run the system is 1500 – 700 = 800kW. Therefore, the system generators
need only supply 800kW and 700kW have been conserved during the braking cycle.
A DC link reactor may be used on systems with a common DC bus. This device is similar
to an input reactor in that its purpose is to smooth the current ripple on the DC bus. DC
link reactors are typically smaller than input reactors.
Systems containing only one inverter cubicle typically will not require a DC bus. In these
systems the output of the input rectifier is usually cabled to the input of the inverters
directly. Please refer to the job specific drawings for more information.
3.4
Inverter
The inverter section is the output section of the VSDS and is composed of IGBT
semiconductor switches and electrolytic capacitors mounted on aluminum heat sinks.
The IGBT collectors and emitters are electrically connected between the positive and
negative DC busses, respectively. They are switched on and off in a specific sequence to
produce a three phase output voltage of variable amplitude and frequency. The switching
technique employed in National Oilwell VSDs is a variation of Pulse Width Modulation
(PWM) used in high performance motor control. By varying the duration of the switching
pulses, the inverter can directly control the magnitude of the motor voltage, and in so
doing control motor current and torque. The fundamental frequency of the Model 800AC
is adjustable from 0 to 300 Hz.
The inverter converts filtered DC into variable frequency, variable voltage three phase
AC. An inverter cubicle contains a single 2 pole disconnect switch, a pre-charge circuit,
protective fusing, one or more IGBT inverter modules, and a digital control module with
keypad.
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The output current of the voltage source inverter is nearly sinusoidal and can be
measured with any quality current probe. If measuring the output current, be sure to
adjust the inverter’s output frequency to within the tolerance range of the current probe,
as most current probes are designed to work at frequencies between 40 and 60 Hz.
Unlike the current, the inverter’s output voltage is non-sinusoidal and cannot be
measured with ordinary test instruments. Fortunately, the line-to-line output voltage can
be viewed on the DCM’ s LCD display by accessing the motor voltage parameter in the
monitor menu.
Figure 3-5: Inverter Power Units
Inverter Main Circuit Components and Operation – Model 800AC VSDS
Each inverter cubicle is supplied DC voltage through either the input rectifier bridge directly, or
a common DC bus.
Pre-charge Circuit
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The pre-charge circuit is designed to gradually charge the DC bus capacitors and avoid
damaging them. Voltage transients applied to capacitors produce sharp temperature rises and
may cause them to rupture or explode. There are several different pre-charge methods
employed depending on the system, but the general principle is the same for all. In every
case, a resistance is temporarily inserted between the DC source and the capacitor bank so
that the charging current is limited to a safe level. All drives are pre-charged before the main
rectifier’s power is directly applied to the drive. Never attempt to bypass or defeat the precharge circuit or serious damage to the converter could result.
Pressing the “Push to Charge” button initiates the capacitor pre-charge sequence. The
operator can monitor the pre-charge status via the “DC Bus Charged” lamp. The purpose of
the capacitor bank is to filter the rectified DC voltage and supply magnetizing VARs to the
motor. The pre-charge circuit is utilized to prevent damage to the capacitor bank that would
otherwise occur if the main rectifier’s output voltage were suddenly applied. Recall that a
capacitor acts like a short circuit to a voltage transient; therefore the pre-charge circuit is
designed to charge the capacitors slowly. It does this by temporarily inserting a resistance
between the capacitor bank and the applied main rectifier voltage. By controlling the charging
current, the pre-charge circuit gradually increases the voltage of the capacitor bank. It typically
takes between 500ms-1s for the DC bus to reach nominal voltage. The AINT board senses the
rising DC voltage, which reports the voltage level to the control module. Although it takes less
than a second to reach nominal DC voltage, it may take many additional seconds for the
control module to indicate that pre-charge is complete. The control module will then close a
contact which controls the “DC Bus Charged” lamp. Once the
”DC Bus Charged” lamp is lit, the operator may close the disconnect switch (or circuit breaker)
which connects the main DC supply bus directly to the inverter’s DC link. (Note: please refer
to the job specific details. Not all systems contain disconnect switches in the inverter cubicles.
Pre-charge circuit operation may vary.)
Inverter Control
Each Inverter module contains 3 output phases each consisting of a set of full-bridge IGBT’s
and associated gate-firing and measurement electronics. With motor and cable attached, the
IGBTs have a voltage rise time of between 3 and 5kV/uS. The switching frequencies are nonadjustable on the Model 800, fixed at 1.5kHz. Parallel 1000 amp fuses protect each of the
inverter units. These fuses act to limit fault current between inverter units in the event of an
internal short circuit.
An RDCU drive control unit controls each inverter module used in a Model 800AC VSDS.
These units are found behind the swing out compartment in the door of a VSD cubicle.
Communication between the RDCU and each inverter unit is made through a fiber optic link.
Fiber optical lines are run from the RDCU unit to an optical branching unit, then from the
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branching unit to each inverter. Fiber optic connections can be made to its internal AINT
board on the front face of the inverter modules.
The inverter is controlled, protected, and monitored by a Digital Control Module (DCM). The
DCM is responsible for all motor control operations and inverter bridge control. The control
module is loaded with a firmware file. This file contains the all-necessary motor control
programs as well as the DCM’s operating system.
The two basic embedded motor control programs to choose from in the model 800AC inverter
are open and closed loop control. Figures 3-6a and 3-6b show the two main components of
the DCM installed in a NOI VSDS system.
Figure 3-6a: Motor Control Board (RDCU)
Figure 3-6b: Display/Keypad
The DCM receives inverter bridge feedback from the AINT board via a fiber optic
communication link. IGBT current, DC link voltage, and heat-sink temperatures are the
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primary feedback signals processed by the AINT board and transmitted to the DCM. Phase
current is sensed directly at the IGBTs by the measurement boards, which have the added
responsibility of delivering gate pulses to the IGBTs. Based on input speed commands, load
torque, motor speed, the DCM adjusts the switching patterns of the IGBTs so that the
commanded motor speed and torque is realized.
The DCM itself consists of a RMIO board and a LCD control panel. The RMIO board is
designed with 3 open slots for I/O extension modules in addition to a section with designated
I/O used with predetermined external signals. Slot 1 may host one of many option modules
including: I/O extension (RAIO, RDIO), pulse encoder interface (RTAC), or Fieldbus adapter
(RPBA). Slot 2 can house either I/O extension (RAIO, RDIO) or a pulse encoder interface
(RTAC). Option module slot 3 is configured for a DDCS communication option module
(RDCO-02). In addition, a keypad with an LCD display is mounted to the face of the control
module’s enclosure via ADP1-01 adapter. The next two figures show the DCM control
interface (3-7) and the typical I/O connections (3-8).
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Figure 3-7: Control Interface of Inverter Unit
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STANDARD APPLICATION PROGRAM I/O
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Figure 3-8: External Control Connections
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Data Sheet 3-1: RMIO Board Technical Specifications
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Figure 3-9: Isolation and Grounding Diagram
Figure 3-9 above details the proper isolation and grounding arrangements to be followed. Care should be
taken to ensure all signal grounds are as per this arrangement.
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Option Modules / Extended I/O
Profibus-DP Adapter Module (RPBA-01)
The PROFIBUS-DP Adapter module is an optional device designed to enable the connection of a drive to a
PROFIBUS network. Each drive connected to the PROFIBUS network through an RPBA-01 module is
considered a slave device. The RPBA-01 PROFIBUS-DP Adapter module allows the following:






Give control commands to the drive
Start,Stop, Run Enable, etc…
Feed a motor speed or torque reference to the drive
Read status information and actual valures from the drive
Change drive parameter values
Reset a drive fault
Figure 3-10: RPBA-01 Option Module
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The Profibus cable is connected to the connector labeled X1 on the RPBA-01 module. The diagram and
table below depict the connector pin allocation. This configuration follows PROFIBUS standard.
Table 3-2: X1 Connector Pin Allocation for the RPBA-01 Module
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Bus termination is achieved by switching on a DIP switch located on the front of the RPBA-01 module. Bus
termination prevents signal reflections from the cable ends. If the module is the first or last module on the
network, bus termination must be set to ON. If using PROFIBUS specific D-sub connectors with built in
termination, the RPBA-01 termination must be switched off. Figure 3-11 below shows the DIP switch
details.
***Note: The built-in termination circuitry of the RPBA-01 is of the active type, so the module has to be
powered for the termination to work. If the module needs to be switched off during operation of the
network, the bus can be terminated by connecting a 220 ohm, 1/4 W resistor between the A and B lines.
Figure 3-11: Bus Termination DIP Switch
Rotary node address selectors on the RPBA-01 module are used to select the node address number of the
drive. Each node address number is of decimal type ranging in value from 01 to 99. The left selector
represents the first digit and the right selector the second digit. Node addresses may be changed while
operating, but the module must be re-initialized for changes to take effect.
***Note: If 00 is selected, the node number is defined by a parameter in the fieldbus parameter group of
the drive.
Figure 3-12: Node Selectors
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The diagram below is a demonstration of PROFIBUS network wiring. The PROFIBUS cable shields are
directly earthed at all nodes. All cable is standard PROFIBUS cable consisting of a twisted pair and
screen.
Figure 3-13: Cable Connection and Grounding Diagram for Standard Profibus Cable
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Pulse Encoder Interface Module (RTAC-01)
The RTAC-01 Pulse Encoder Interface Module allows a digital pulse encoder feedback to be used for
determining accurate motor speed or position. In most NOI Model 800AC systems the RTAC-01 module
will be installed in slot 2 on the RMIO board. Signal and power connection is automatically made through a
38-pinm connector, upon installation of the module.
Figure 3-14: RTAC-01 Module Layout
Table 3-3 on the next page details the terminal designations for the encoder module. Most
NOI model 800AC systems supply power to the encoder module using an external 24VDC
power supply. When this is the case, the external 24VDC power supply should be connected
to terminal X1-5 and the factory installed jumper across X1-5 and X1-6 should be removed.
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Table 3-3: Encoder Board Terminal Definitions and Signal Descriptions
***Note: Encoder inputs can be used with encoders having +15V to +24V signal levels.
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DDCS Communication Module (RDCO-02)
A DDCS Communication Module may be used in NOI Model 800AC systems where a
Master/Slave drive configuration is desired. The DDCS module offers an optical communication
link between 2 drives. There are four fiber optical channels available on the DDCS module
designated as shown below. DDCS modules will be installed in Slot 3 on the drive RMIO board.
CH1 – Overriding system (e.g. fieldbus adapter)
CH1 – I/O extensions
CH2 – Master/Follower link
CH3 – PC tools (such as Drive Ware)
Figure 3-15: RDCO-02 Module Layout
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Branching Unit (NDBU-44C)
The NDBU-44C Branching Unit (shown in figure 3-16) is used to link the AINT boards of multiple inverter
power units to one DCM. The optical inputs and outputs of the module are separated into sections labeled
CH1-4 and AMC. Each of the optical channels has a transmitter and receiver. A channel is assigned to
each inverter and then two optical cables are run between each inverter unit and the NDBU-42 module.
Figure 3-16: NBDU-44C Module Layout
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The TXD connector on the NPBU-44C unit is cabled to the RXD connector on the Inverter AINT board.
The RXD connector on theNPBU-44C unit is cabled to the TXD connector. The RXD and TXD connectors
are distinguished by color: Black= RXD and Gray=TXD. The AMC channel of the NDBU unit is cabled to
the RMIO board of the DCM. Figure 3-17 on the next page shows an actual picture of the front of an
inverter module where the fibers are connected to the AINT board.
Figure 3-17: AINT Board Connections on the Front Face of the Inverter Power Unit
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Motor Control
The firmware program is the interface between the user I/O and the motor control program. Its job
is to process all external control inputs such as start, stop, motor direction, and speed. The
processed input data is then passed from the firmware program to the motor control program.
Likewise, the firmware program receives information from the motor control program about such
things as the inverter output current, motor speed, and DC bus volts, and passes it back to
keypad display or the fieldbus. User control is most commonly exercised via fieldbus, but discrete
control signals are also commonly used. The fieldbus protocol used with most NOI equipment is
Profibus DP. Figure 3-18 is an inverter control block diagram illustrating the basic control theory
of the Model 800AC.
T y p ic a l In v e rte r B lo c k D ia g ra m
            
      
                 

  
             
                   

L IN E R E A C T O R
  
 
      
      
SHAFT
ENCODER
  

   
   
0





B U S C A P A C IT O R S
 
         
D C L IN K
         
IN P U T R E A C T O R
      
    
FREQ UENCY CO NVERTER
Figure 3-18 Frequency Converter / Inverter Control
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Multi-motor Modes of Operation
There are two basic modes of operation that are used by National Oilwell when motors are
operated in parallel. The first mode is known as master/follower mode, the second mode
simply parallel inverter units. Each has certain advantages and disadvantages and they are
utilized accordingly in each application.
When a common shaft mechanically couples two or more motors, the optimum solution is for
the associated inverters to force load sharing among the respective motors. This can be
achieved using the master/follower mode of operation, in which the master drive is given a
speed reference by the PLC or hardwired input. The remaining ‘followers’ receive a torque
reference from the master drive via the controller’s system bus. In this way, the follower drives
all receive the same torque reference as the master, insuring that load sharing is achieved. In
this mode, the master drive is a “speed master” while those receiving their torque references
from the master are known as “torque followers”. If one motor or drive is lost in a two drive
system while in operating in master/follower mode, the remaining drive will automatically be
configured to operate in master mode as soon as the other is removed from the fieldbus, or
has it’s input power removed. Master/follower mode of operation is generally employed where
precise load sharing between motors is required. An example of such an application is a multimotor drawworks.
The second most commonly applied mode of operation employs dividing the output of one
drive between multiple motors. In this mode of operation a single drive receives a speed
reference, and generates an internal torque reference according to the load. Load sharing is
achieved by virtue of the mechanical coupling between motors. Each motor receives the same
voltage and current output as its counter part. This mode of operation is used quite frequently
in dual motor top drives and mud pumps. It is also used in active heave drawworks
applications where operation of the drawworks must continue without interruption. The reason
this method is preferred to master/follower mode in a multi-motor system (more than 2 on a
common shaft) is that in the event of a motor or drive fault, it is not necessary to re-wire or reconfigure the drive’s system bus in order to continue operation. With this method, the drive
only responds to a single speed reference and is never looking to another drive for a torque
reference in order to function.
Motor Control Modes
There are two basic types of motor control available from the National Oilwell VSDs. Open
loop frequency control, or scalar control is the first method, and generally applied to motors
connected to pumps, fans or other applications in which precise torque control isn’t required. In
this type of control, the digital control module operates without speed feedback, and simply
applies a constant ratio of voltage to output frequency. Without speed feedback, the DCM has
no direct knowledge of the rotor slip or position. Consequently, precise speed and torque
control in open loop is not possible. This mode of operation is still adequate where high
starting torque is not required, such as a pump.
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The second method of motor control is known as closed loop speed control. In this mode, the
DCM receives speed feedback via an incremental encoder, which is normally mounted on the
motor shaft. In this mode of operation, precise speed and torque control is possible
throughout the entire speed range of the inverter. This mode of operation is quite useful in
applications that require holding a load stationary, such as a drawworks or a crane, as well as
in applications where the motor operates above its base speed. For closed loop control to be
successful, the encoder must supply information about rotor position and speed. Closed loop
speed control is the most efficient and precise means of controlling a 3-phase induction motor.
Closed loop speed control is used on all National Oilwell drawworks, cranes, pipe-handling
equipment, and top drives. It may or may not be employed on other drilling machinery,
depending on the customer’s performance requirements for the installed system. The
summary of the major physical components of each inverter can be found in the following
table.
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INVERTER COMPONENT SUMMARY
Device
Function
Pre-charge Circuit
Digital Control
Module
(DCM)
User interface with the inverter. The keypad is used for changing drive
operating parameters, monitoring drive data, and issuing control
commands.
Bus Capacitors
Provide filtering of the DC bus voltage and furnish magnetizing VARs to
the motor
Insulated Gate
Bipolar Transistors
(IGBT) (qty 2-6
modules per
inverter)
Converts DC voltage into 3-phase AC voltage of variable frequency and
amplitude.
AINT board
Controls inverter firing and serves as an interface between the IGBT
measurement boards and the digital control module.
Table 3-4: Inverter component summary
3.5
Braking Chopper and Resistor Bank
The brake chopper is a semiconductor switch used to reduce the DC link voltage when
the motors are overhauling. The set point varies depending on the system voltage and
the application. The proper set point for your system may be found on the parameter list
in the Operating Parameters section of the manual.
All AC drives installed on a drawworks, TD, or cranes employ a DB chopper of some kind.
Some, but not all AC driven mud pumps also employ a braking chopper, depending on
the nature of the drilling program, and the type of pump used. Generally speaking,
drawworks and cranes require full braking capacity from the DB choppers and resistor
banks, so they tend to be sized quite differently than systems that require only intermittent
use or light braking. Stand-alone TD choppers are typically rated to provide longer
deceleration ramps and braking cycles than a drawworks or crane, but their operation is
the same.
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Figure 3-19 on the next page illustrates the basic configuration of a chopper unit. Note
that the braking resistor is connected to the (+) DC bus and the collector of the lower
IGBT switch, so that the lower switch provides the path between the braking resistor and
the (–) DC bus. The upper switch is unused in this arrangement.
In current NOI systems that do not require intensive dynamic braking, the choppers used
are typically air cooled, non-programmable, “dumb” units that trigger on a fixed voltage.
These units carry an 80kW to 400kW continuous rating, and are not re-configurable.
There may or may not be an external DCM.
Dynamic braking or electrical braking is achieved by forcing an AC motor to operate as an
induction generator. This occurs whenever the inverter’s output frequency is less than
the corresponding rotor speed. A common example of this is when the load drives a
motor, and the commanded inverter frequency is slower than the actual motor speed. In
this mode of operation, the inverter issues firing pulses and supplies magnetizing VARs to
the stator. As long as the inverter supplies the stator with a magnetic field, the motor will
operate as generator. When acting in this manner, the interaction between the stator’s
rotating magnetic field and the induced magnetic field in the rotor will generate a torque
that opposes the load torque. As soon as the inverter is stopped (firing pulses are
suppressed), the stator and rotor magnetic fields will collapse and all braking torque will
be lost. The power flow between the inverter and the motor is such that real power flows
from the motor to the drive, while reactive power flows from the drive to the motor.
The AC current flowing back to the drive is rectified by the inverter’s fly back diodes and
flows into the inverter’s DC bus as direct current. The direct current charges the DC link
capacitors, causing DC bus voltage to rise. Once the voltage reaches a pre-determined
set point, the chopper will switch on and connect the braking resistor bank across the
positive and negative DC bus terminals. In addition to lowering the DC bus voltage, the
braking choppers and resistor banks will dissipate the excess power in the resistor bank.
The total dissipated power in the resistor, inverter, and motor will equal the braking power
applied to the load.
In systems that share a DC bus and chopper(s), the other inverters may consume much
of the regenerated energy, in which case the braking chopper is only required to dissipate
the excess power. Mechanical braking is only needed for emergency braking or for
parking the load when the AC Drive is stopped. In general, the dynamic braking power
and torque can reach 150-175% of the motor’s nominal ratings over brief periods of time
in hoisting applications, or where very short deceleration ramps are used. The shorter
the deceleration ramp, the higher the peak braking torque and power will be.
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Figure 3-19: Typical DC Chopper Circuit
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Assignment Contactors
Assignment contactors are used to control the inverter output to meet system needs.
One inverter can be switched between two or more motors, or one motor can be switched
between two or more inverters. The number of contactors varies depending on the
system’s requirements. Not all systems utilize assignment contactors. Figure 3-20
shows a few possibilities for assignment contactors.
M
M
M
M
T Y P IC A L A S S IG N M E N T C O N T A C T O R
ARRANGEM ENTS
Figure 3-20 Sample Output Contactor Single Line Drawing
Assignment contactors are either 3-phase AC contactors, or constructed from individual, single
phase contactors. The VSDS PLC ordinarily controls their operation, but they are electrically
interlocked to prohibit undesirable states in the event of a PLC malfunction.
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The following components are not considered part of the VSD, but a working knowledge of how
they operate and the function they serve is useful in understanding and maintaining the variable
speed drive system.

One or more 3-phase AC induction motors. Ordinarily, each VSD powers a single motor
at a time.

Drilling Control System (DCS). The Drilling Control System provides the MMI for the
driller and interfaces with the Model 800 VSDS to provide control of drilling equipment
and to receive feedback information.
3.7
AC Induction Motors – Basic Principle of Operation
The motors controlled by the Model 800AC VSDS are used to operate specific rig equipment,
such as the drawworks, top drive, pumps, cranes, etc. The most commonly used motor is the 3phase “squirrel cage” induction motor. In most drilling systems, the motors are open frame and
are cooled by an external blower, that forces cooling air directly onto the rotor and stator windings.
Some motors installed on cranes are closed frame, and cooled using a combination of channels
cut into the stator frame with fans mounted on the non-load end of the motor. In both types, the
cooling blowers and fans are controlled from independent voltage sources located in the VSDS.
Since the motor’s main shaft is not used to drive a cooling fan or blower, these motors may
operate indefinitely at very low speeds as long as the cooling fans are functioning.
Induction motors have certain characteristics that distinguish themselves from DC motors,
including:




They require little maintenance other than periodic lubrication of the bearings.
They are intrinsically safe – they don’t generate arcing or sparks as with DC motors.
They are capable of holding full torque at zero speeds indefinitely without sustaining
damage to internal components.
Generator operation (for braking purposes) is somewhat easier with an AC induction motor
than a DC motor.
The induction motor is composed of two main parts: a stator winding and a rotor. The stator is a
set of copper coils wound into slots in the motor frame. As its name implies, it is stationary. The
leads of the stator are connected to the 3 phase terminals of inverter. The stator windings are
spatially arranged so that a 3-phase voltage source establishes a rotating magnetic field around
the rotor. Stators are made up of pole pairs, so the minimum number of poles is 2. Nearly all AC
drilling motors have 6 poles, however 4 pole motors are also commonly found on cranes and
winches.
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The squirrel cage rotor is made of copper or aluminum bars that are held in place by the motor
bearings at each end of the motor frame. Rotation is caused by the interaction of magnetic fields
between the stator and the rotor. Specifically, the rotating magnetic fields of the stator induce a
voltage in the rotor bars, which cause a current to flow in the rotor. In turn, the rotor current
generates its own magnetic field, which attempts to align itself with the stator field. It is the relative
motion between the stator and rotor magnetic fields that generates motor torque. Rotor speed is
dependent on both the stator frequency and the motor load. Rotor speed is related to the stator
frequency by the formula:
Synchronous Rotor Speed =
(120 x stator frequency)
Number of poles
It’s important to note the rotor’s fields never actually catch up with the stator fields; instead the
rotor turns at some speed slower than the synchronous speed. So in practice, the actual speed of
the rotor will differ from the synchronous speed, and is referred to as the motor slip. Slip is usually
expressed as a percentage, and in which case it is expressed by the formula:
%Slip = (Synchronous speed – Actual speed) x 100
Synchronous Speed
The nominal or base speed of the motor expresses actual rotor speed for a fully loaded motor
running at base frequency, usually 60 Hz. Therefore the rated slip of the motor can be found from
this number, and it is at the rated slip the nameplate full load current, torque, and power apply.
The nominal speed is usually found on the manufacturer’s nameplate. The following table lists
motor nameplate information that is required input to the inverter’s DCM parameter list:
MOTOR PARAMETER
UNIT
EXPLANATION / DEFINITION
Nominal Voltage
VAC
Rated RMS line to line voltage
Nominal Frequency
Hz
Field Weakening point
Nominal Speed
RPM
No load motor speed @
nominal frequency
Nominal Current
AAC
Full load current
Nominal Power
KW
Rated Power [kW] = (HP x
746)/1000
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Power Factor (cos phi)
N/A
Typically 0.85
Maximum Safe Speed
RPM
Highest speed at which motor
should be operated
Table 3-5 Required Motor Nameplate Data
There are 2 basic regions of operation for an induction motor. The first region is between 0 RPM
and the nominal motor speed, and is known as the constant torque region. The second region is
between the motor’s nominal speed and it’s maximum speed, and is known as the constant
horsepower region.
In the constant torque region, the stator voltage is applied linearly with increasing frequency, so
that the ratio of Voltage/stator frequency is held constant. Full (rated) voltage is applied when the
motor speed is equal to the nominal nameplate speed. At this point, the FC has reached its
voltage limit (output voltage cannot exceed input voltage), so the converter’s voltage is held
constant as the stator frequency is increased. As frequency increases, the induction motor’s
back-emf increases, and stator current begins to drop off because the difference between the
converter’s output voltage and the motor’s opposing voltage becomes less. As current drops off,
so does torque, but the horsepower remains constant even as torque drops off because the speed
is increasing. Figure 1-9 illustrates these 2 regions.
14000
T Y P IC A L S P E E D V S T O R Q U E P R O F IL E
OVERLOAD TORQUE
O F A N IN D U C T IO N M O T O R
M O T O R T O R Q U E (L b -F t)
12000
10000
RATED TORQUE
8000
CONSTANT HORSEPOW ER
R E G IO N
CONTANT
T O R Q U E R E G IO N
6000
4000
2000
2450 M ax. RPM
0
0
200
400
600
800
1000
1200
1400
1600
1800
2000
M O TO R SPEED ( RPM )
Figure 3-21 Typical Induction Motor Curve
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2200
2400
2600
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The motor receives varying voltage and frequency from the IGBTs. Lowering the VFDs output
frequency will change the motor’s speed. When the load forces the motor to rotate faster than the
applied inverter frequency, the motor becomes a generator and converts rotational energy into
electrical power. This electrical power is fed to the DC Bus via the inverter phase cells. The brake
choppers and braking resistors then dissipate the excess power as heat.
3.8
PLC and interface for the Drilling Control System (DCS)
The Drilling Control System is based on the Siemens S7 300 family of modular mini-PLCs. The PLC
provides the link between the operator and the inverter either through a touch screen or other control
panel. The PLC is responsible for controlling the inverter’s start, stop, and speed commands based on the
user input, load conditions, and other system information. The PLC communicates with the inverter using
the Profibus DP protocol, and therefore can access information from the converter and provide information
to it. Among other things, the PLC may be used to change the inverter’s operating parameters, monitor
and control the cooling system, manage system power, and report system alarm/system fault data to the
operator. The PLC acts as the bridge between the MMI (Man-Machine Interface) console and the VFDS
system components. A typical DCS is illustrated in below in Figure 3-22.
Fig. 3-22 Sample Drilling Control System with Supervisory PLC
The Siemens S7 PLC is usually located in the Incomer cubicle, or its own PLC cubicle. The PLC
communicates with the other devices over a PROFIBUS communications network. There is I/O located on
the PLC rack, as well as Remote I/O racks typically located in the MCC and the Operator Console. The
purpose of having remote is to reduce the number of wires that need to be run between the field, the MCC,
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and the PLC cubicle. By using remote I/O only the 2 wire PROFIBUS cable needs to be run. For remote
racks located far away from the PLC, such as in the operator’s console that is normally located on the drill
floor, fiber optic cables are used instead of the hard-wired system. In this case, an Optical Link Module is
used to convert from the Profibus signal to the fiber optic communications.
The variable inverters and the choppers also communicate with the PLC over the same PROFIBUS
network. Each device on the network has a unique address to distinguish itself to the PLC.
The Operator’s Console allows the operator to control the system with devices such as switches, throttles
and potentiometers. The console also displays system status with pilot lights and gauges. These inputs
and outputs are wired into a remote I/O rack that is connected to the PLC over the Profibus network.
The PLC also switches on the auxiliary motors by controlling the motor starters. Some systems may
include a remote I/O rack that controls this action.
Based on the operator’s commands, the PLC sends commands to the drives. By communicating over the
PROFIBUS network, the PLC can start the drive, send it speed and torque commands, as well as read
back drive’s status information. The status information includes items such as voltage, current, run status
and fault information. This information inside the PLC is usually sent to a touchscreen or remote
monitoring system for troubleshooting purposes.
The following table contains the fault and alarm codes and descriptions that can be read by the PLC.
FAULT/WARNING BUFFER READ BY THE PLC
Fault
ACS 800 TEMP
AI< MIN FUNC
BRAKE ACKN
COMM MODULE
DC OVERVOLT
EARTH FAULT
ENCODER A<>B
ENCODER ERR
IN CHOKE TEMP
MOTOR STALL
MOTOR TEMP
MOTOR 1 TEMP
MOTOR 2 TEMP
PANEL LOSS
SHORT CIRC
THERMISTOR
UNDERLOAD
DC UNDER VOLTAGE
EXTERNAL FLT
I/O COMM
MOTOR PHASE
OVERCURRENT
OVERFREQ
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ID NUMBERS 95-99
Code
4210
8110
ff74
7510
3210
2330
7302
7301
ff81
7121
4310
4312
4313
5300
2340
4311
Ff6a
3220
9000
7000
ff56
2310
7123
Comment
Inverter Temp
Check Field Bus
Short circuit
See sub codes
Check encoder module wiring
(programmable fault fcn)
(not used typically)
(not used typically)
(progammable fault fcn)
(progammable fault fcn)
(progammable fault fcn)
Check mains and fuses
(progammable fault fcn)
Check fiber on CH1
(progammable fault fcn)
Check encoder/Accel time
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PANEL LOSS
PPCS LINK
SUPPLY PHASE
5300
5210
3130
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(progammable fault fcn)
Check fibres at AINT board
Check mains for imbalance
Table 3-6: PLC Fault/Alarm code Reference Table
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Technical Data
The following table (3-7) includes technical specifications about the National Oilwell inverters and
choppers. If more information is required, please consult the National Oilwell Factory in Houston,
Texas.
MODEL 800 INVERTER
Parameter
Specification Unit
Environmental/Mechanical
Ambient Operating Temperature
Reduced Output (1%/1C)
Storage Temperature
Transportation
Relative Humidity (no condensation)
Altitude (w/o derating)
Altitude (w/ derating)
TYPICAL CHOPPER UNIT
Parameter
Environmental/Mechanical
0/32 to +50/122 C/F
+40/104 to +50/122
-40/-40 to +70/158 C/F
-40/-40 to +70/158 C/F
5< 95%
0..3000/0..1000 Ft/M
3000..12000/1000..4000 Ft/M
Ambient Operating Temperature
Storage Temperature
Relative Humidity (no condensation)
Altitude (w/o derating)
-10/14 to +40/104 C/F
-40/-40 to +70/158 C/F
5< 95%
3300/1000 Ft/M
Specification
Unit
Table 3-7 National Oilwell Technical Specifications
3.9.1 Weights and Dimensions
The components of a Model 800AC VSDS will vary from job to job. Assignment
cubicles, if utilized, may contain different numbers of contactors. The number of
VFDs may vary also, as will the size of the cooling system. The item that can vary
the most is the incomer cubicle, depending on whether it is multi-pulse and what it’s
amperage capacity is. Refer to the weight and outline dimensions as shown on the
drawings for each job-specific system. A general guideline for dimensions of
individual component cubicles of the system is as follows:
CUBICLE DIMENSIONS
HEIGHT
WIDTH
DEPTH LAND
DEPTH
OFFSHORE
INVERTER (2X Inverter units)
90” / 2286mm
24” / 559 mm
38” / 966mm
50” / 1270mm
INVERTER (3X Inverter units)
90” / 2286mm
36” / 559 mm
38” / 966mm
50” / 1270mm
INVERTER (4X Inverter units)
90” / 2286mm
48” / 559 mm
38” / 966mm
50” / 1270mm
CUBICLE
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INCOMER (powering up to 4 Inverters)
ASSIGNMENT
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90” / 2286mm
24” / 914mm
38” / 966mm
50” / 1270mm
90” / 2286mm
30” / 762mm
38” / 966mm
50” / 1270mm
Table 3-8 National Oilwell Cubicle Typical Weights and Dimensions
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Inverter Module Dimensions and Diagrams
INVERTER UNIT PHYSICAL DIMENSIONS
MODEL
W1
H1
MODEL 800AC
9.6450
54.4880
[in]
D1
21.1800
MODEL 600/630/6000 INPUT TERMINALS
Figure 3-23 Inverter Model Outline Drawings and Dimensions
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3.9.2 Performance Data
The following table (3-9) provides some fundamental performance information about National
Oilwell VSDs.
Ratings
Nominal ratings
Drive type
UN=690 V
ACS800-104-0580-7
ACS800-104-1160-7
ACS800-104-1740-7
ACS800-104-2320-7
ACS800-104-3490-7
Icont.max
IMAX
A (AC)
A
486
953
1414
1866
2770
724
1419
2107
2780
4127
Light-overload use Heavy-duty use
IN
IHD
A
A
467
914
1358
1792
2659
362
710
1053
1390
2063
Frame Noise level Heat dissipation Air flow
R8i
2xR8i
3xR8i
4xR8i
6xR8i
kW
m /h
73
74
75
76
78
7.0
14.0
21.0
28.0
42.0
1200
2400
3600
4800
7200
Table 3-9 Inverter Model Performance Data Summary
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OPERATING INSTRUCTIONS
The Inverters are normally controlled from the Driller’s Cabin via Profibus DP. During normal
operation, the operator will provide start / stop commands and speed references, and monitor
the performance of the equipment as it operates. No other operator interactions are normally
required. The control keypad mounted on the front of the Inverter cubicles allows local
monitoring and parameter adjustments of the Inverters. The details of this keypad are listed
below. More information regarding the keypad and control unit is available in the ABB User
Manual.
4.1
CONTROL PANEL
The control panel is the link between the ABB frequency converter and the user. The ABB control
panel features an alphanumeric display with 4 lines of 20 characters. There are four modes of
operations:




Actual Signal Display Mode (ACT key)
Parameter Mode (PAR key)
Function Mode (FUNC key)
Drive Selection Mode (DRIVE key)
The operation mode of the panel dictates the uses of the arrow keys and ENTER. The drive
control keys are described below
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Figure 4-1: Illustrates the ABB control panel and control keys
4.1.1 Panel operation mode keys and displays
Figure 4-2: Panel Operation
4.1.2 Status Row
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Figure 4-3: Description of status row
4.1.3 Drive control from panel
The user may elect to control the drive by control panel as described below:
 Start, stop, and change direction of motor
 Give the motorspeed reference or torque reference
 Reset the fault and warning messages
 Change between local and external drive control
The drive can always be controlled from the control panel while the drive is under local
control and the status row is visible on the display. The next figure shows how to start, stop
and change direction and how to set a speed reference both from the control panel.
Figure 4-4: Start, Stop and Change Direction from Keypad
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Figure 4-5: Setting a Speed Reference from Keypad
4.1.4 Actual signal display mode
While in Actual Signal Display Mode, the user may:
 Show three actual signals on the display at a time
 Select the actual signals to display
 View the fault history
 Reset the fault history
The panel will enter Actual Signal Display Mode automatically within one minute if the
keypad is left alone.
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Figure 4-6: Selecting Actual Signals to the Display
Figure 4-7: Displaying Full Name of Actual Signals
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Figure 4-8: Displaying Fault History
***Note: Fault history cannot be reset if there are active faults or warnings.
Figure 4-9: Resetting an Active Fault
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Fault history updates information on current events (faults, warnings, and resets) of
the drive. Below demonstrates how events are displayed in the fault history.
Figure 4-10: Displaying Events
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4.1.5 Parameter mode
In the Parameter Mode, the user may:
 View parameter values
 Alter parameter settings
Figure 4-11: How to Select a Parameter and Change the Value
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4.1.6 Function mode
In the Function Mode, the user can:
 Start a guided procedure for adjusting the drive settings (assistants)
 Upload the drive parameter values and motor data from the drive to the panel
 Download group 1 to 97 parameter values and motor data from the drive to the
panel
 Adjust the contrast of the display
Below is an example of how the Motor Setup task can be executed with Start-up
Assistant.
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Figure 4-12: Motor Set-up with Start-up Assistance
Uploading data from the drive to the control panel
Note:
 Upload before downloading
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
Ensure the program versions of the destination drive are the same as
the versions of source drive, see parameters 33.01 and 33.02
 Before removing the panel from a drive, ensure the panel is in remote
operating mode (change with the LOC/REM key)
 Stop the drive before downloading
_____________________________________________________________
___
Before upload, repeat the following steps in each drive:
 Setup the motors
 Activate the communication to the optional equipment (See parameter
group 98 OPTION MODULES)
Before upload, do the following in the drive from which the copies are to be
taken:
 Set the parameters in groups 10 to 97 as preferred
 Proceed to the upload sequence (below)
Figure 4-13: Uploading Data from the Drive to the Panel
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Downloading data from the control panel to the drive
Figure 4-14: Downloading Data from the Panel to the Drive
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Figure 4-15: Setting the Contrast of the Display
4.1.7 Drive selection mode
**Not applicable to NOI Model 800 VSDS systems. This mode would allow users to select
drive of interest if multiple drives were to share one control panel.
4.1.8 Reading and entering of Boolean values on the display
Some actual values and parameters are packed Boolean, i.e. each individual bit has
a defined meaning (explained at the corresponding signal or parameter). On the
control panel, packed Boolean values are read and entered in hexadecimal format.
In this example, bits 1, 3 and 4 of the packed Boolean value are ON:
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Figure 4-16: Example of Reading Boolean Values
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INITIAL MOTOR OPERATION SETUP
The following steps are to be performed prior to running a motor for the first time.
1. Verify the machine’s lubrication system is functioning properly, if applicable.
2. Verify the machine’s associated auxiliary motors are functioning properly bye briefly
energizing them from the MCC or local control panel. Ensure the motor blower rotation is
correct.
3. Ensure the motor is un-loaded. Verify the motor/machine brakes are operation if so
equipped, and any shipping bolts installed to lock the rotor have been removed.
4. Verify that the motor cables and motor have undergone an appropriate insulation test by
a trained electrician or technician.
5. Verify the motor’s frame is solidly earthed.
6. If equipped with an encoder, verify the encoder shaft coupling is tight and properly
installed. Carefully inspect the encoder cable and verify it is properly terminated, in
accordance with the electrical drawings. Verify the encoder cable is run at least 12” from
any of the AC motor’s phase conductors.
4.2.1 Visual Inspection
A visual inspection of the entire system should be performed before any other steps are taken
during the system set-up. The system should be inspected for any damage that may have occurred
during shipping or unpacking. Verify there are no loose electrical connections in both the control
and main circuits of the entire system. Be sure to correct any problems before proceeding.
4.2.2 Configure Drive
Each VFD of a NOI VSDS system must be specifically configured for the intended application. The
following sections briefly describe the drive configuration procedure.
4.2.2.1 Inverter Drive Size
Under normal conditions, the inverter size dimensioning parameters only need to be set once; and
this is done at the factory prior to shipping the drive. When the drive is powered up, pressing the
“Drive” button on the Control Panel can check the inverter size. If the inverter size is incorrect, it
must be corrected before the Motor ID run can be performed. To do this, please contact NOI in
order to obtain the information on reconfiguring drive size.
4.2.2.2 Performing a Motor ID Run
A Motor ID run should be performed before any other action is taken with the drive. The motor data
should be entered from the information found on the motor nameplate.
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4.2.2.2.1 Entering Motor Data
The motor data can be entered in two ways. The first is by going to Parameter group 99 and
entering the data as it appears on the motor nameplate. The second method is to press the “Func”
button on the Control Panel and then selecting “Motor Set-up.” This will begin the Start-up
Assistant, which will guide you through the motor set-up. The parameters should be set-up as
follows:

99.01 Language
English or English AM
If English is chosen, the motor nominal power must be in kilowatts, and if
English AM is chosen, the nominal power is in horsepower.

99.02 Application Macro
This should be set to “Factory” unless the drive will be acting as a slave drive. In a
slave drive, this is set this to “T-Ctrl” (Torque Control)

99.03 Application Restore

99.04 Motor Control Mode
DTC
In most cases DTC (Direct Torque Control) will be suitable.

99.05 Motor Nominal Voltage

99.06 Motor Nominal Current (off motor nameplate)

99.07 Motor Nominal Frequency (off motor nameplate)

99.08 Motor Nominal Speed

99.09 Motor Nominal Power (off motor nameplate)

99.10 Motor ID Run
Standard
The standard ID run will achieve the best accuracy. The motor must be uncoupled
from the load. The procedure will take about 1 minute, however times will vary so
do not be alarmed. If motor ID Run has not completed within 5 minutes, then look at
Group 20 limit parameters as described below that may interfere with the ID Run
profile. The drive will spin the motor and will run between 50% and 80% of the motor
nominal speed, so make sure it is safe to spin the motor. Note that the motor is
accelerated at a very fast ramp during the ID Run, thus the motor will tend to rock do
to the rotor inertia. Make sure that the motor is placed on a solid base. The Motor
ID Run is always operated in the Forward direction according to the drive phasing,
so make sure the motor rotation during the test is consistent with forward rotation of
the load/machine. If motor rotation is reversed with respect to the load, interchange
any 2 motor cable phases after the ID Run is complete.
No
(off motor nameplate)
(off motor nameplate)
Before performing the ID run, other parameters must be checked. See the following
section.
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4.2.2.3 Parameters for Motor ID Run
4.2.2.3.1 Group 20
Go to Parameter Group 20 “Limits” and check the following parameters:

Parameter 20.02 Maximum Speed
The default for this is motor nominal speed. It should be kept there for the ID run.

Parameter 20.03 Maximum Current
The default for this is two times the motor nominal current. For the ID run it needs to be
greater than the nameplate value

Parameter 20.04 Torque Max Lim 1
This needs to be at least 100%. It is best to keep it at default (300%) for the ID run.

Parameter 20.05 Overvoltage Control
This should be set turned ON for the ID run. Under normal operation of the drive, if there is
a chopper and brake resistor in the system, this should be turned off in order for the chopper
to turn on.
4.2.2.3.2 Remove PROFIBUS Control
Profibus control must also be removed from the system. In order to do this, check the following
parameters:

Parameter 10.01 EXT1 STRT/STP/DIR
This should be set to “Keypad” during the ID run.

Parameter 11.03 EXT REF1 SELECT
This should be set to “Keypad” during the ID run.

Parameter 11.02 EXT1/EXT2 SELECT
This should be set to “EXT1” during the ID run.
4.2.2.3.3 Run Enable
In Parameter Group 16 “System Control Inputs,” set parameter 16.01 “Run Enable” to “YES” during
the ID run.
4.2.2.3.4 Encoder
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If an encoder is being used for speed feedback for the control of the drive, the encoder must be
disabled during the ID run. By default, the encoder is not activated; Parameter 98.01 ENCODER
MODULE will be set to “NO”. If the encoder feedback was already enabled by setting parameter
98.01 to a value other than “NO”, then disable the speed feedback of the encoder by going to
Parameter Group 50 “Encoder Module” and set Parameter 50.06 “Encoder FB Sel” to “Internal”
during the ID run. If motor rotation has been proven to be correct, then while the ID Run is running
it is also beneficial to check the encoder wiring. To do this, compare ACTUAL SIGNALS 2.18
SPEED MEASURED (Encoder measured RPM) to 1.02 SPEED (drive’s internal calculated speed).
Both numbers should be approximately equal and with the same polarity. If rpm does not match
then check accuracy of encoder configuration in Group 50 ENCODER MODULE or look for
improper wiring or encoder supply voltage (RTAC-01 module does not work with 5V DC encoder
signals). If polarity is opposite, and motor rotation is correct, then swap “A” for “B” and “A-“ for “B-“
on the encoder feedback wiring. Note, “Z and Z-“ wires are unused in the ABB drives.
4.2.2.3.5 Master/Follower
If the drive that you are working on is set up in the follower mode, this must be disabled in order to
perform the ID run. In order to do this, go to Parameter Group 60 “Master/Follower” and change
parameter 60.01 “Master Link Mode” to “Not in Use.” Also remember to set Parameters 10.01,
11.02, 11.03 as described above.
4.2.2.3.6 Start Interlock
The Start Interlock must be active to start the ID run. To do this, place a jumper between X22:8 and
X22:11.
4.2.2.4 Starting the Motor ID Run
In order to start the motor ID run, put the Keypad in the Local mode by pressing the “Loc/Rem” key
on the Panel. An “L” should appear in the upper left hand corner of the display. Return to
Parameter Group 99 and change parameter 99.10 “Motor ID Run” and choose “Standard.”
Once this is chosen, the screen should read “**Warning** ID Run Sel.” After pressing the green
button to start the ID run the screen will read “**Warning** Motor Starts.” During the ID Run, the
screen will read “**Warning** ID Run.” By pressing the “ACT” key on the keypad, you can monitor
the drive current and speed. When the ID run finishes, the screen will read “**Warning** ID Done.”
4.2.2.5 ID Run Completed
Once the ID run has been completed, the parameters that have been changed can be returned to
their original values. Now the drive can be customized for the current application.
4.2.3 General Set-up Procedures
The following procedure assumes that main power is available to the VSDS. It also assumes all
normal procedures relating to resistance and insulation tests have been performed on the VSDS
cabinet, supply bus, and the motors it powers. Each VSDS undergoes a system hi-potential test at
the factory; however it is important to inspect the main power source network prior to starting the
VFD.
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1. Before attempting to energize the inverters, verify that the VSDS system preliminary
startup procedure has been followed. See the Reference Documents section for the
appropriate procedure.
2. Verify that the inverter is isolated from its main power source.
3. Inspect all main power connections and verify they agree with the system drawings.
Inspect each connection and Verify the motor cables not connected to the inverter, either
at the plug panel, or at the motor itself.
4. Inspect all control connections to the inverter and verify they agree with the system
drawings. Inspect each connection for tightness.
5. Ensure no condensation is evident on the inverter’s phase cells or electronics.
6. Ensure all fiber optic lines and control cables are properly installed according to VFD
module interconnect drawings.
7. Ensure that all inverter cubicle doors are closed.
All VSDS cubicle doors must remain closed while the system is energized
8. Connect converter to the main power supply by closing the feeder circuit breaker or main
disconnect switch. Verify that the control panel has powered up and no fault or warning
message is displayed. If the display indicates a warning or fault message, see the
troubleshooting section and clear the fault before proceeding.
9. Using either the keypad or the Drive Windows commissioning tool, set the parameters
according to the requirements of your application. See the Reference Document list for
the proper parameters if these are not known.
10. Start the drive from the control console and monitor the output frequency on the keypad
from the Actual Signal Display Mode. Issue a frequency reference from the operator’s
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console and verify that the converter output frequency follows the reference. If this does
not occur, refer to the troubleshooting section for assistance.
11. EMERGENCY STOP While the inverter is running activate the Emergency Stop switch for
the drive. Usually this is located on the users remote console. If operating properly, the
drive will stop issuing firing pulses and the output frequency will drop to 0. Be sure the
emergency stop logic is working properly before proceeding to run any motors.
12. From the operator’s console, stop the inverter and remove power by opening the circuit
breaker or main disconnect switch. The LCD display should go blank within 1 minute
after removing power from the inverter. Wait at least 3 minutes after the LCD goes blank
before opening the cubicle doors or touching the drive. Always use a voltmeter to check
the converter’s DC bus before proceeding.
13. Lockout the inverter’s CB or main power source. Connect the motor cables to the inverter
output at the appropriate panel. Make certain the motor/machine brakes are released,
and there is no load on the motor.
14. Restore power to the inverter, verify there are no faults displayed, and start the drive from
the console. Give a forward speed reference to the inverter and verify the rotation of the
motor is correct. If not, reverse any two phases at the motor and re-test.
15. Speed Feed Back: Change encoder module parameter 50.06 to ENCODER. While
monitoring both actual and estimated speed on the keypad, give the drive a speed
reference and verify the following Table:
Variable
Direction
Speed Reference
Forward
Output Frequency (hz)
Positive
Estimated Speed (rpm)
Positive, equal to Speed Reference
Actual Speed (rpm)
Positive, equal to Estimated Speed
Speed Reference
Reverse
Output Frequency (hz)
Negative
Estimated Speed (rpm)
Negative, equal to Speed Reference
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Actual Speed (rpm)
Negative, equal to Estimated Speed
Table 4-1: Variable VS. Direction
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The proper motor start sequence is diagramed in Figure 4-15 below. The diagram shows the
relationship between several drive parameters and the role they play in that sequence.
Ts Start torque at brake release (Parameter 42.07 and 42.08)
tmd Motor magnetizing delay
tod Brake open delay (Parameter 42.03)
ncs Brake close speed (Parameter 42.05)
tcd Brake close delay (Parameter 42.04)
Figure 4-15: Drive/Motor Starting Sequence (w/ brake control function)
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Table 4-2 Actual Drive Signals
No. Name/Value
Description
01 ACTUAL SIGNALS
01.01 PROCESS VARIABLE
Basic signals for monitoring of the drive.
Process variable based on settings in parameter group 34
PROCESS VARIABLE.
01.02 SPEED
Calculated motor speed in rpm. Filter time setting by parameter
34.04.
01.03 FREQUENCY
Calculated drive output frequency.
01.04 CURRENT
Measured motor current.
01.05 TORQUE
Calculated motor torque. 100 is the motor nominal torque. Filter
time setting by parameter 34.05.
01.06 POWER
Motor power. 100 is the nominal power.
01.07 DC BUS VOLTAGE V
Measured intermediate circuit voltage.
01.08 MAINS VOLTAGE
Calculated supply voltage.
01.09 OUTPUT VOLTAGE
Calculated motor voltage.
1=1V
01.12 EXTERNAL REF 2
Temperature of the heatsink.
External reference REF1 in rpm. (Hz if value of parameter 99.04 is
SCALAR.)
External reference REF2. Depending on the use, 100% is the motor
maximum speed, motor nominal torque, or maximum process
reference.
1 = 1 °C
01.13 CTRL LOCATION
Active control location. (1,2) LOCAL; (3) EXT1; (4) EXT2.
01.14 OP HOUR COUNTER
Elapsed time counter. Runs when the control board is powered.
01.10 ACS 800 TEMP
01.11 EXTERNAL REF 1
FbEq
1=1
-2000 = -100% 2000 =
100% of motor abs. max.
speed
-100 = -1 Hz
100 = 1 Hz
10= 1 A
-10000 = -100% 10000 =
100% of motor
nom. torque
0 = 0%
1000 = 100% of motor
nom. power
1=1V
1=1V
1 = 1 rpm
0 = 0%
10000 = 100%
See Descr.
1=1h
01.15 KILOWATT HOURS
kWh counter.
Application block output signal. E.g. the process PID controller
01.16 APPL BLOCK OUTPUT output when the PID Control macro is active.
Status of digital inputs. Example: 0000001 = DI1 is on, DI2 to DI6
01.17 DI6-1 STATUS
are off.
1 = 100 kWh
0 = 0%
10000 = 100%
Value of analogue input AI1.
1 = 0.001 V
01.19 AI2 [mA]
Value of analogue input AI2.
1 = 0.001 mA
01.20 AI3 [mA]
1 = 0.001 mA
01.21 RO3-1 STATUS
Value of analogue input AI3.
Status of relay outputs. Example: 001 = RO1 is energized, RO2
and RO3 are de-energized.
01.22 AO1 [mA]
Value of analogue output AO1.
1 = 0.001 mA
01.23 AO2 [mA]
Value of analogue output AO2.
Feedback signal for the process PID controller. Updated only when
parameter 99.02 = PID CTRL
Feedback signal for the process PID controller. Updated only when
parameter 99.02 = PID CTRL
01.18 AI1 [V]
01.24 ACTUAL VALUE 1
01.25 ACTUAL VALUE 2
Deviation of the process PID controller, i.e. the difference between
the reference value and the actual value. Updated only when
01.26 CONTROL DEVIATION parameter 99.02 = PID CTRL.
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1 = 0.001 mA
0 = 0% 10000
-10000 = -100%
10000 = 100%
-10000 = 100% 10000 =
100%
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01.27 APPLICATION MACRO Estimated motor temperature.
01.28 EXT AO1 [mA]
Value of output 1 of the analogue I/O extension module (optional).
01.29 EXT AO2 [mA]
Value of output 2 of the analogue I/O extension module (optional).
IGBT maximum temperature in inverter no. 1 (used only in high
01.30 PP 1 TEMP
power units with parallel inverters).
IGBT maximum temperature in inverter no. 2 (used only in high
01.31 PP 2 TEMP
power units with parallel inverters).
IGBT maximum temperature in inverter no. 3 (used only in high
01.32 PP 3 TEMP
power units with parallel inverters).
IGBT maximum temperature in inverter no. 4 (used only in high
01.33 PP 4 TEMP
power units with parallel inverters).
01.34 ACTUAL VALUE
Process PID controller actual value. See parameter 40.06.
01.35 MOTOR 1 TEMP
Measured temperature of motor 1. See parameter 35.01
01.36 MOTOR 2 TEMP
Measured temperature of motor 2. See parameter 35.04.
0 / No Inversion
1 = 0.001 mA
1 = 0.001 mA
1 = 1 °C
1 = 1 °C
1 = 1 °C
1 = 1 °C
0 = 0% 10000 = 100%
1 = 1 °C
1 = 1 °C
1 = 1 °C
01.37 MOTOR TEMP EST
Estimated motor temperature.
Value of analogue input AI5 read from AI1 of the analogue I/O
extension module (optional). A voltage signal is also displayed in
01.38 AI5 [mA]
mA (instead of V).
Value of analogue input AI6 read from AI2 of the analogue I/O
extension module (optional). A voltage signal is also displayed in
01.39 AI6 [mA]
mA (instead of V).
Status of digital inputs DI7 to DI12 read from the digital I/O
extension modules (optional). E.g. value 000001: DI7 is on, DI8 to
01.40 DI7-12 STATUS
DI12 are off
Status of the relay outputs on the digital I/O extension modules
(optional). E.g. value 0000001: RO1 of module 1 is energized.
01.41 EXT RO STATUS
Other relay outputs are de-energized.
Motor actual speed in percent of the Absolute Maximum Speed. If
01.42 PROCESS SPEED REL parameter 99.04 is SCALAR, the value is the relative actual output
frequency.
Motor run time counter. The counter runs when the inverter
01.43 MOTOR RUN TIME
modulates. Can be reset by parameter 34.06.
Running time of the drive cooling fan.
Note: The counter can be reset by the DriveWindow PC tool.
01.44 FAN ON-TIME
Resetting is recommended when the fan is replaced.
01.45 CTRL BOARD TEMP
No. Name/Value
Control board temperature.
Description
02 ACTUAL SIGNALS
Speed and torque reference monitoring signals.
02.01 SPEED REF 2
Limited speed reference. 100% corresponds to the Absolute
Maximum Speed of the motor.
02.02 SPEED REF 3
Ramped and shaped speed reference. 100% corresponds to the
Absolute Maximum Speed of the motor.
Speed controller output. 100% corresponds to the motor nominal
torque.
02.09 TORQ REF 2
02.10 TORQ REF 3
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Torque reference. 100% corresponds to the motor nominal torque.
1 = 0.001 mA
1 = 0.001 mA
1=1
1=1
1=1
1 = 10 h
10
FbEq
0 = 0%
20000 = 100% of
motor absolute max.
speed
20000 = 100%
0 = 0%
10000 = 100% of
motor nominal torque
10000 = 100%
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02.13 TORQ USED REF
02.14 FLUX REF
02.17 SPEED ESTIMATED
02.18 SPEED MEASURED
03 ACTUAL SIGNALS
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Torque reference after frequency, voltage and torque limiters. 100%
corresponds to the motor nominal torque.
Flux reference in percent.
10000 = 100%
Estimated motor speed. 100% corresponds to the Absolute
Maximum Speed of the motor.
Measured motor actual speed (zero when no encoder is used).
100% corresponds to the Absolute Maximum Speed of the motor.
Data words for monitoring of fieldbus communication (each signal is
a 16-bit data word).
20000 = 100%
03.01 MAIN CTRL WORD
A 16-bit data word.
03.02 MAIN STATUS WORD
A 16-bit data word.
03.03 AUX STATUS WORD
A 16-bit data word.
03.04 LIMIT WORD 1
A 16-bit data word.
03.05 FAULT WORD 1
A 16-bit data word.
03.06 FAULT WORD 2
A 16-bit data word.
03.07 SYSTEM FAULT
A 16-bit data word.
03.08 ALARM WORD 1
A 16-bit data word.
03.09 ALARM WORD 2
A 16-bit data word.
03.11 FOLLOWER MCW
A 16-bit data word.
03.12 INT FAULT INFO
A 16-bit data word.
10000 = 100%
20000 = 100%
03.13 AUX STATUS WORD 3 A 16-bit data word.
03.14 AUX STATUS WORD 4 A 16-bit data word.
03.15 FAULT WORD 4
A 16-bit data word.
03.16 ALARM WORD 4
A 16-bit data word.
03.17 FAULT WORD 5
A 16-bit data word.
03.18 ALARM WORD 5
A 16-bit data word.
3.20 LATEST FAULT
Fieldbus code of the latest fault.
3.21 2. LATEST FAULT
Fieldbus code of the 2nd latest fault.
3.23 3. LATEST FAULT
Fieldbus code of the 3rd latest fault.
3.24 4. LATEST FAULT
Fieldbus code of the 4th latest fault.
3.25 5. LATEST FAULT
Fieldbus code of the 5th latest fault.
3.26 LATEST WARNING
Fieldbus code of the latest warning.
3.27 2. LATEST WARNING
Fieldbus code of the 2nd latest warning.
3.28 3. LATEST WARNING
Fieldbus code of the 3rd latest warning.
3.29 4. LATEST WARNING
Fieldbus code of the 4th latest warning.
3.30 5. LATEST WARNING
Fieldbus code of the 5th latest warning.
09 ACTUAL SIGNALS
Signals for the Adaptive Program
09.01 AI1 SCALED
20000 = 10 V
Value of analogue input AI1 scaled to an integer value.
09.02 AI2 SCALED
Value of analogue input AI2 scaled to an integer value.
09.03 AI3 SCALED
Value of analogue input AI3 scaled to an integer value.
09.04 AI5 SCALED
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Value of analogue input AI5 scaled to an integer value.
20000 = 20
mA
20000 = 20
mA
20000 = 20
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mA
09.05 AI6 SCALED
Value of analogue input AI6 scaled to an integer value.
09.06 DS MCW
09.07 MASTER REF1
09.08 MASTER REF2
09.09 AUX DS VAL1
09.10 AUX DS VAL2
09.11 AUX DS VAL3
Control Word (CW) of the Main Reference Dataset received from
the master station through the fieldbus interface
Reference 1 (REF1) of the Main Reference Dataset received from
the master station through the fieldbus interface
Reference 2 (REF2) of the Main Reference Dataset received from
the master station through the fieldbus interface
Reference 3 (REF3) of the Auxiliary Reference Dataset received
from the master station through the fieldbus interface
Reference 4 (REF4) of the Auxiliary Reference Dataset received
from the master station through the fieldbus interface
Reference 5 (REF5) of the Auxiliary Reference Dataset received
from the master station through the fieldbus interface
20000 = 20
mA
0 ... 65535
(Decimal)
-32768 ...
32767
-32768 ...
32767
-32768 ...
32767
-32768 ...
32767
-32768 ...
32767
Table 4-3 Relevant Drive Parameters/Selections
Index
Name/Selection
10 START/STOP/DIR
10.01 EXT1
STRT/STP/DIR
NOT SEL
Description
FbEq
The sources for external start, stop and direction control
Defines the connections and the source of the start, stop and direction
commands for external control location 1 (EXT1).
No start, stop and direction command source.
Start and stop through digital input DI1. 0 = stop; 1 = start. Direction is
fixed according to parameter 10.3 DIRECTION.
WARNING! After a fault reset, the drive will start if the start signal is
ON.
Start and stop through digital input DI1. 0 = stop, 1 = start. Direction
through digital input DI2. 0 = forward, 1 = reverse. To control direction,
parameter 10.03 DIRECTION must be REQUEST.
WARNING! After a fault reset, the drive will start if the start signal is
ON.
Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through
digital input DI2. 1 -> 0: Stop. Direction of rotation is fixed according to
parameter 10.03 DIRECTION.
Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through
digital input DI2. 1 -> 0: Stop. Direction through digital input DI3. 0 =
forward, 1 = reverse. To control direction, parameter 10.03 DIRECTION
must be REQUEST.
Pulse start forward through digital input DI1. 0 -> 1: Start forward. Pulse
start reverse through digital input DI2. 0 -> 1: Start reverse. Pulse stop
through digital input DI3. 1 -> .0.: stop. To control the direction,
parameter 10.03 DIRECTION must be REQUEST.
1
DI6
See selection DI1.
7
DI6, 5
See selection DI1, 2.
Control panel. To control the direction, parameter 10.03 DIRECTION
must be REQUEST.
8
COMM.CW
Fieldbus Control Word.
10
DI7
See selection DI1
11
DI1
DI1, 2
DI1P, 2P
DI1P, 2P, 3
DI1P, 2P, 3P
KEYPAD
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3
4
5
6
9
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DI7, 8
See selection DI1, 2.
12
DI7P, 8P
See selection DI1P, 2P.
13
DI7P, 8P, 9
See selection DI1P, 2P, 3.
14
DI7P, 8P, 9P
See selection DI1P, 2P, 3P.
15
PARAM 10.04
Source selected by 10.04
Defines the connections and the source of the start, stop and direction
commands for external control location 2 (EXT2).
16
10.02 EXT2
STRT/STP/DIR
NOT SEL
See parameter 10.01.
1
DI1
See parameter 10.01.
2
DI1, 2
See parameter 10.01.
3
DI1P, 2P
See parameter 10.01.
4
DI1P, 2P, 3
See parameter 10.01.
5
DI1P, 2P, 3P
See parameter 10.01.
6
DI6
See parameter 10.01.
7
DI6, 5
See parameter 10.01.
8
KEYPAD
See parameter 10.01.
9
COMM.CW
See parameter 10.01.
10
DI7
See parameter 10.01.
11
DI7,8
See parameter 10.01.
12
DI7P, 8P
See parameter 10.01.
13
DI7P, 8P, 9
See parameter 10.01.
14
DI7P, 8P, 9P
See parameter 10.01.
15
PARAM 10.05
Source selected by 10.05
Enables the control of direction of rotation of the motor, or fixes the
direction.
16
10.03 DIRECTION
FORWARD
Fixed to forward
1
REVERSE
Fixed to reverse
2
REQUEST
Direction of rotation control allowed
3
11 REFERENCE
SELECT
Panel reference type, external control location selection and external
reference sources and limits
11.01 KEYPAD REF SEL
Selects the type of the reference given from panel.
Speed reference in rpm. (Frequency reference (Hz) if parameter 99.04
is SCALAR.)
REF2(%)
%-reference. The use of REF2 varies depending on the application
macro. For example, if the Torque Control macro is selected, REF2 is
the torque reference.
11.02 EXT1/EXT2 SELECT Defines the source from which the drive reads the signal that selects
between the two external control locations, EXT1 or EXT2.
DI1 thru DI6
Digital input DI1 – D6. 0=EXT1, 1=EXT2
REF1(rpm)
1
2
1-6
EXT1
Decel Time 2
7
EXT2
COMM.CW(11)
DI7 thru DI12
PARAM 11.09
11.03 EXT REF1 SELECT
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Sp.ref interp TC
Fieldbus Control Word, bit 11.
See selection DI1
Source selected by parameter 11.09.
Selects the signal source for external reference REF1
8
9
10-15
16
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Page
KEYPAD
VARIOUS AI and
JOYSTICK SELECTIONS
COMM. REF
11.04 EXT REF1
MINIMUM
0… 18000 rpm
11.05 EXT REF1
MAXIMUM
0 ... 18000 rpm
12 CONSTANT
SPEEDS
**********
D25TDS11-MAN-001
01
81
Control panel. The first line on the display shows the reference value.
1
See parameter 11.03
See parameter 11.03.
Defines the minimum value for external reference REF1 (absolute
value). Corresponds to the minimum setting of the source signal used.
Setting range in rpm. (Hz if parameter 99.04 is SCALAR.)
Example: Analogue input AI1 is selected as the reference source
(value of parameter 11.03 is AI1). The reference minimum and
maximum correspond the AI minimum and maximum settings as
follows:
EXT REF1 Range
2-19, 21-38
20
Note: If the reference is given through fieldbus, the scaling differs from
that of an analogue signal. See the chapter Fieldbus control for more
information.
Defines the maximum value for external reference REF1 (absolute
value). Corresponds to the maximum setting of the used source signal.
Setting range. (Hz if value of parameter 99.04 is SCALAR.)
See parameter 11.04. 1 . 18000
Constant speed selection and values. An active constant speed
overrides the drive speed reference.
Note: If parameter 99.04 is SCALAR, the constant speeds are given in
Hertz and only speeds 1 to 5 and speed 15 are in use.
GROUP NOT TYPICALLY USED IN NOI APPLICATIONS
1 … 18000
1... 18000
**********
13 ANALOGUE
INPUTS
The analogue input signal processing
GROUP NOT TYPICALLY USED IN NOI APPLICATIONS
14 RELAY OUTPUTS Status information indicated through the relay outputs, and the relay
operating delays
**********
14.01 RELAY RO1
OUTPUT
NOT USED
READY
RUNNING
FAULT
FAULT(-1)
FAULT(RST)
STALL WARN
STALL FLT
MOT TEMP WRN
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Selects a drive status indicated through relay output RO1. The relay
energizes when the status meets the setting.
Not used.
Ready to function: Run Enable signal on, no fault.
Running: Start signal on, Run Enable signal on, no active fault.
Fault
Inverted fault. Relay is de-energized on a fault trip.
Fault. Automatic reset after the autoreset delay. See parameter group
31 AUTOMATIC RESET.
Warning by the stall protection function. See parameter 30.10.
Fault trip by the stall protection function. See parameter 30.10.
Warning trip of the motor temperature supervision function. See
parameter 30.04.
**********
1
2
3
4
5
6
7
8
9
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Page
MOT TEMP FLT
D25TDS11-MAN-001
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Fault trip of the motor temperature supervision function. See parameter
30.04.
12\0
ACS TEMP WRN
Warning by the drive temperature supervision function: 115 °C (239°F).
11
ACS TEMP FLT
Fault trip by the drive temperature supervision function: 125 °C(257°F).
Fault or warning active
Warning active
Motor rotates in reverse direction.
Drive is under external control.
External reference REF 2 is in use.
A constant speed is in use. See parameter group 12 CONSTANT
SPEEDS.
The intermediate circuit DC voltage has exceeded the overvoltage limit.
The intermediate circuit DC voltage has fallen below the undervoltage
limit.
Motor speed at supervision limit 1. See parameters 32.01 and 32.02.
Motor speed at supervision limit 2. See parameters 32.03 and 32.04.
Motor current at the supervision limit. See parameters 32.05 and 32.06.
External reference REF1 at the supervision limit. See parameters 32.11
and 32.12.
External reference REF2 at the supervision limit. See parameters 32.13
and 32.14.
Motor torque at supervision limit 1. See parameters 32.07 and 32.08.
Motor torque at supervision limit 2. See parameters 32.09 and 32.10.
The drive has received the start command.
The drive has no reference.
The actual value has reached the reference value. In speed control, the
speed error is less or equal to 10% of the nominal motor speed.
Process PID controller variable ACT1 at the supervision limit. See
parameters 32.15 and 32.16.
Process PID controller variable ACT2 at the supervision limit. See
parameters 32.17 and 32.18.
The relay is controlled by fieldbus reference REF3. See the chapter
Fieldbus control.
Source selected by parameter 14.16.
On/Off control of a mechanical brake. See parameter group 42 BRAKE
CONTROL.
Selects the drive status to be indicated through relay output RO2. The
relay energizes when the status meets the setting.
12
13
14
15
16
17
See parameter 14.01.
See parameter 14.01.
Source selected by parameter 14.17.
See parameter 14.01.
Selects the drive status to be indicated through relay output RO3. The
relay energizes when the status meets the setting.
1-32
33
34
35
See parameter 14.01.
See parameter 14.01
The motor is magnetized and ready to give nominal torque (nominal
magnetizing of the motor has been reached).
User Macro 2 is in use.
See parameter 14.01.
Source selected by parameter 14.18.
See parameter 14.01.
1-3, 5-30
4
FAULT/WARN
WARNING
REVERSED
EXT CTRL
REF 2 SEL
CONST SPEED
DC OVERVOLT
DC UNDERVOLT
SPEED 1 LIM
SPEED 2 LIM
CURRENT LIM
REF 1 LIM
REF 2 LIM
TORQUE 1 LIM
TORQUE 2 LIM
STARTED
LOSS OF REF
AT SPEED
ACT 1 LIM
ACT 2 LIM
COMM.REF3(13)
PARAM 14.16
BRAKE CTRL
14.02 RELAY RO2
OUTPUT
SELECTIONS SAME AS
14.01
COMM. REF3(14)
PARAM 14.17
BRAKE CTRL
14.03 RELAY RO3
OUTPUT
SELECTIONS SAME AS
14.01
FAULT
MAGN READY
USER 2 SEL
COMM. REF3(15)
PARAM 14.18
BRAKE CTRL
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18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
31
32
33
34
35
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15 ANALOGUE
OUTPUTS
**********
D25TDS11-MAN-001
01
83
Selection of the actual signals to be indicated through the analogue
outputs. Input signal processing.
GROUP NOT TYPICALLY USED IN NOI APPLICATIONS
**********
16 SYSTEM CTRL
INPUTS
Run Enable, parameter lock etc.
Sets the Run Enable signal on, or selects a source for the external Run
Enable signal. If Run Enable signal is switched off, the drive will not
start or stops if it is running. The stop mode is set by parameter 21.07.
YES
Run Enable signal is on
DI1
External signal required through digital input DI1. 1 = Run Enable.
DI2 thru DI12
See selection DI1.
COMM.CW(3)
External signal required through the Fieldbus Control Word (bit 3).
PARAM 16.08
Source selected by parameter 16.08.
16.04 FAULT RESET SEL Selects the source for the fault reset signal. The signal resets the drive
after a fault trip if the cause of the fault no longer exists.
NOT SEL
Fault reset only from the control panel keypad (RESET key).
16.01 RUN ENABLE
1
2
3-7, 9-14
8
15
1
DI1
DI2 thru DI12
COMM.CW(7)
ON STOP
Reset through digital input DI1 or by control panel:
- If the drive is in external control mode: Reset by a rising edge of DI1.
- If the drive is in local control mode: Reset by the RESET key of the
control panel.
See selection DI1.
Reset through the fieldbus Control Word (bit 7), or by the RESET key of
the control panel.
Reset along with the stop signal received through a digital input, or by
the RESET key of the control panel.
2
2-7, 10-15
8
9
20 LIMITS
Drive operation limits.
Defines the allowed minimum speed. The limit cannot be set if
parameter 99.04 = SCALAR.
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
-18000 / (no. of pole pairs) . Minimum speed limit
Par. 20.02 rpm
20.02 MAXIMUM SPEED Defines the allowed maximum speed. The value cannot be set if
parameter 99.04 = SCALAR.
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
20.01 MINIMUM SPEED
-18000 / (no. of pole pairs) . Maximum speed limit
Par. 20.01 rpm
20.03 MAXIMUM
Defines the allowed maximum motor current in percent of the rated
CURRENT
heavy-duty use output current (I2hd).
0.0… 200.0% · Ihd
Current limit
20.04 TORQ MAX LIM1
Defines the maximum torque limit 1 for the drive.
0.0… 600.0%
Value of limit in percent of motor nominal torque.
20.05 OVERVOLTAGE
Activates or deactivates the overvoltage control of the intermediate DC
CTRL
link. Fast braking of a high inertia load causes the voltage to rise to the
overvoltage control limit. To prevent the DC voltage from exceeding the
limit, the overvoltage controller automatically decreases the braking
torque.
Note: If a brake chopper and resistor are connected to the drive, the
controller must be off (selection NO) to allow chopper operation.
OFF
Undervoltage control deactivated.
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1 = 1 rpm
1 = 1 rpm
0… 20000
0… 60000
0
Document number
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Page
ON
20.07 MINIMUM FREQ
-300.00 . 50 Hz
20.08 MAXIMUM FREQ
D25TDS11-MAN-001
01
84
Undervoltage control activated.
Defines the minimum limit for the drive output frequency. The limit can
be set only parameter 99.04 = SCALAR.
Minimum frequency limit.
Note: If the value is positive, the motor cannot be run in the reverse
direction.
Defines the maximum limit for the drive output frequency. The limit can
be set only if parameter 99.04 = SCALAR
-50… 300.00 Hz
20.11 P MOTORING LIM
0… 600%
20.12 P GENERATING
LIM
-600… 0%
20.13 MIN TORQ SEL
MIN LIM1
DI1
DI2 thru DI12
AI1
AI2 thru AI6
PARAM 20.18
NEG MAX TORQ
20.14 MAX TORQ SEL
MAX LIM1
DI1
DI2 thru DI12
AI1
AI2
PARAM 20.19
20.15 TORQ MIN LIM1
-600.0… 0.0%
21 START/STOP
21.01 START FUNCTION
AUTO
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Maximum frequency limit
Defines the allowed maximum power fed by the inverter to the motor.
Power limit in percent of the motor nominal power
65535
-30000 .
5000
-5000 .
30000
0… 60000
Defines the allowed maximum power fed by the motor to the inverter.
Power limit in percent of the motor nominal power
Selects the minimum torque limit for the drive.
Value of parameter 20.15.
Digital input DI1. 0: Value of parameter 20.15. 1: Value of parameter
20.16.
See selection DI1.
Analogue input AI1. See parameter 20.20 on how the signal is
converted to a torque limit.
See selection AI1.
Limit given by 20.18
Inverted maximum torque limit defined by parameter 20.14
Defines the maximum torque limit for the drive.
Value of parameter 20.14.
Digital input DI1. 0: Value of parameter 20.04. 1: Value of parameter
20.17.
See selection DI1.
Analogue input AI1. See parameter 20.20 on how the signal is
converted to a torque limit.
See selection AI1.
Limit given by 20.19
Defines the minimum torque limit 1 for the drive.
Value of limit in percent of motor nominal torque
-60000 . 0
0… 60000
Start and stop modes of the motor.
Selects the motor starting method.
Automatic start guarantees optimal motor start in most cases. It
includes the flying start function (starting to a rotating machine) and the
automatic restart function (stopped motor can be restarted immediately
without waiting the motor flux to die away). The drive motor control
program identifies the flux as well as the mechanical state of the motor
and starts the motor instantly under all conditions.
Note: If parameter 99.04 = SCALAR, no flying start or automatic restart
is possible by default. The flying start feature needs to be activated
separately by parameter 21.08.
1
1
2
3-13
14
15-18
19
20
1
2
3-13
14
15-18
19
Document number
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Page
DC MAGN
CNST DC MAGN
D25TDS11-MAN-001
01
85
DC magnetizing should be selected if a high break-away torque is
required. The drive pre-magnetizes the motor before the start. The premagnetizing time is determined automatically, being typically 200 ms to
2 s depending on the motor size. DC MAGN guarantees the highest
possible break-away torque.
Note: Starting to a rotating machine is not possible when DC
magnetizing is selected.
Note: DC magnetizing cannot be selected if parameter 99.04 =
SCALAR.
Constant DC magnetizing should be selected instead of DC
magnetizing if constant pre-magnetizing time is required (e.g. if the
motor start must be simultaneous with a mechanical brake release).
This selection also guarantees the highest possible break-away torque
when the pre-magnetizing time is set long enough. The premagnetizing time is defined by parameter 21.02.
Note: Starting to a rotating machine is not possible when DC
magnetizing is selected.
Note: DC magnetizing cannot be selected if parameter 99.04 =
SCALAR.
WARNING! The drive will start after the set magnetizing time
has passed although the motor magnetization is not completed. Ensure
always in applications where a full break-away torque is essential, that
the constant magnetizing time is long enough to allow generation of full
magnetization and torque.
21.02 CONST MAGN TIME Defines the magnetizing time in the constant magnetizing mode. See
parameter 21.01. After the start command, the drive automatically premagnetizes the motor the set time.
30.0… 10000.0 ms
Magnetising time. To ensure full magnetising, set this value to the same
value as or higher than the rotor time constant. If not known, use the
rule-of-thumb value given in the table below:
2
3
30… 10000
21.03 STOP FUNCTION
COAST
RAMP
21.07 RUN ENABLE
FUNC
RAMP STOP
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Selects the motor stop function.
Stop by cutting of the motor power supply. The motor coasts to a stop.
WARNING! If the mechanical brake control function is on, the
application program uses ramp stop in spite of the selection COAST
(see parameter group 42 BRAKE CONTROL).
Stop along a ramp. See parameter group 22 ACCEL/DECEL.
Selects the stop mode applied when the Run Enable signal is switched
off. The Run Enable signal is put into use by parameter 16.01.
Note: The setting overrides the normal stop mode setting (parameter
21.03) when the Run Enable signal is switched off.
WARNING! The drive will restart after the Run Enable signal
restores (if the start signal is on).
The application program stops the drive along the deceleration ramp
defined in group 22 ACCEL/DECEL.
1
2
1
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Page
COAST STOP
OFF2 STOP
OFF3 STOP
21.09 START INTRL
FUNC
OFF2 STOP
OFF3 STOP
22 ACCEL/DECEL
22.01 ACC/DEC SEL
ACC/DEC 1
ACC/DEC 2
DI1
DI2 thru DI12
PAR 22.08&09
22.02 ACCEL TIME 1
0.00… 1800.00 s
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D25TDS11-MAN-001
01
86
The application program stops the drive by cutting off the motor power
supply (the inverter IGBTs are blocked). The motor rotates freely to
zero speed.
WARNING! If the brake control function is on, the application
program uses ramp stop in spite of the selection COAST STOP (see
parameter group 42 BRAKE CONTROL).
The application program stops the drive by cutting off the motor power
supply (the inverter IGBTs are blocked). The motor rotates freely to
zero speed. The drive will restart only when the Run Enable signal is on
and the start signal is switched on (the program receives the rising
edge of the start signal).
The application program stops the drive along the ramp defined by
parameter 22.07. The drive will restart only when the Run Enable is on
and the start signal is switched on (the program receives the rising
edge of the start signal).
Drive running: 1 = Normal operation. 0 = Stop by coasting.
Drive stopped: 1 = Start allowed. 0 = No start allowed.
Restart after OFF2 STOP: Input is back to 1 and the drive receives
rising edge of the Start signal.
Drive running: 1 = Normal operation. 0 = Stop by ramp. The ramp time
is defined by parameter 22.07 EM STOP RAMP.
Drive stopped: 1 = Normal start. 0 = No start allowed.
Restart after OFF3 STOP: Start Interlock input = 1 and the drive
receives rising edge of the Start signal.
Acceleration and deceleration times.
Selects the active acceleration/deceleration time pair.
Acceleration time 1 and deceleration time 1 are used. See parameters
22.02 and 22.03.
Acceleration time 2 and deceleration time 2 are used. See parameters
22.04 and 22.05.
Acceleration/deceleration time pair selection through digital input DI1. 0
= Acceleration time 1 and deceleration time 1 are in use. 1 =
Acceleration time 2 and deceleration time 2 are in use.
See selection DI1.
Acceleration and deceleration times given by parameters 22.08 and
22.09
Defines the acceleration time 1 i.e. the time required for the speed to
change from zero to the maximum speed.
- If the speed reference increases faster than the set acceleration rate,
the motor speed will follow the acceleration rate.
- If the speed reference increases slower than the set acceleration rate,
the motor speed will follow the reference signal.
- If the acceleration time is set too short, the drive will automatically
prolong the acceleration in order not to exceed the drive operating
limits.
Acceleration time
2
3
4
1
2
1
2
3
4-14
15
0… 18000
Document number
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Page
22.03 DECEL TIME 1
0.00… 1800.00 s
22.07 EM STOP RAMP
TIME
D25TDS11-MAN-001
01
87
Defines the deceleration time 1 i.e. the time required for the speed to
change from the maximum (see parameter 20.02) to zero.
- If the speed reference decreases slower than the set deceleration
rate, the motor speed will follow the reference signal.
- If the reference changes faster than the set deceleration rate, the
motor speed will follow the deceleration rate.
- If the deceleration time is set too short, the drive will automatically
prolong the deceleration in order not to exceed drive operating limits. If
there is any doubt about the deceleration time being too short, ensure
that the DC overvoltage control is on (parameter 20.05).
Note: If a short deceleration time is needed for a high inertia
application, the drive should be equipped with an electric braking option
e.g. with a brake chopper and a brake resistor.
Deceleration time
Defines the time inside which the drive is stopped if
- the drive receives an emergency stop command or
- the Run Enable signal is switched off and the Run Enable function has
value OFF3 (see parameter 21.07).
The emergency stop command can be given through a fieldbus or an
Emergency Stop module (optional). Consult the local ABB
representative for more information on the optional module and the
related settings of the
Standard Application Program
0.00… 2000.00 s
Deceleration time
27 BRAKE
CHOPPER
Control of the brake chopper. For more information, see the Brake
Chopper User's Manual (code: 3AFE 64273507 [English])
27.01 BRAKE CHOPPER
CTL
OFF
ON
Activates the brake chopper control.
Inactive
Active. Note: Ensure the brake chopper and resistor are installed and
the overvoltage control is switched off (parameter 20.05).
30 FAULT
FUNCTIONS
Programmable protection functions
30.10 STALL FUNCTION
Selects how the drive reacts to a motor stall condition. The protection
wakes up if:
- the motor torque is at the internal stall torque limit (not useradjustable)
- the output frequency is below the level set by parameter 30.11 and
- the conditions above have been valid longer than the time set by
parameter
30.12.
The drive trips on a fault.
The drive generates a warning. The indication disappears in half of the
time set by parameter 30.12.
Protection is inactive.
Activates the motor phase loss supervision function
The drive generates a warning.
The drive trips on a fault.
Selects how the drive reacts in a fieldbus communication break, i.e.
when the drive fails to receive the Main Reference Data Set or the
Auxiliary Reference Data Set. The time delays are given by parameters
30.19 and 30.21.
Protection is active. The drive trips on a fault and stops the motor as
defined by parameter 21.03.
Protection is inactive.
FAULT
WARNING
NO
30.17 EARTH FAULT
WARNING
FAULT
30.18 COMM FLT FUNC
FAULT
NO
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0… 18000
0… 200000
0
6553
1
2
3
0
65535
1
2
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Page
CONST SP 15
LAST SPEED
D25TDS11-MAN-001
01
88
Protection is active. The drive generates a warning and sets the speed
to the value defined by parameter 12.16.
WARNING! Make sure that it is safe to continue operation in
case of a communication break.
Protection is active. The drive generates a warning and freezes the
speed to the level the drive was operating at. The speed is determined
by the average speed over the previous 10 seconds.
WARNING! Make sure that it is safe to continue operation in
case of a communication break.
42 BRAKE
CONTROL
42.01 BRAKE CTRL
OFF
ON
42.02 BRAKE
ACKNOWLEDGE
OFF
DI5
DI6
DI11
DI12
42.07 START TORQ REF
SEL
NO
AI1
AI2-AI6
PAR 42.08
42.08 START TORQ REF
-300… 300%
50 ENCODER
MODULE
Control of a mechanical brake. The function operates on a 100 ms time
level. For the function description, see the chapter Program features.
Activates the brake control function.
Inactive
Active
Activates the external brake on/off supervision and selects the source
for the signal. The use of the external on/off supervision signal is
optional.
Inactive
Active. Digital input DI5 is the signal source. DI5 = 1: The brake is
open. DI5 = 0: the brake is closed.
See DI5.
See DI5.
See DI5.
Selects the source for the motor starting torque reference applied at the
brake release. The value is read in percent of the motor nominal torque.
No source selected. This is the default value
Analogue input AI1
Analogue input AI2-6
Defined by parameter 42.08.
Defines the motor starting torque at brake release if parameter 42.07
has value PAR 40.28.
Torque value in percent of the motor nominal torque
Encoder connection. Visible only when a pulse encoder module
(optional) is installed and activated by parameter 98.01.
The settings will remain the same even though the application macro is
changed.
50.01 PULSE NR
0… 29999 ppr
50.02 SPEED MEAS
MODE
A -B DIR
States the number of encoder pulses per one revolution.
Pulse number in pulses per round (ppr)
A -
Channel A: positive and negative edges calculated for speed. Channel
B: not used.
Channel A: positive and negative edges are calculated for speed.
Channel B: direction.
All edges of the signals are calculated.
3
4
1
2
1
2
3
4
5
1
2
3-6
7
-30000… 30000
0… 29999
Defines how the encoder pulses are calculated.
Channel A: positive edges calculated for speed. Channel B: direction.
1
A - B DIR
A - B -
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2
3
4
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50.03 ENCODER FAULT
WARNING
FAULT
50.05 ENCODER DDCS
CHANNEL
CHANNEL 1
CHANNEL 2
50.06 SPEED FB SEL
INTERNAL
ENCODER
51
COMMUNICATION
MODULE
52 STANDARD
MODBUS
**********
60 MASTER/
FOLLOWER
60.01 MASTER LINK
MODE
NOT IN USE
MASTER
FOLLOWER
D25TDS11-MAN-001
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Defines the operation of the drive if a failure is detected in
communication between the pulse encoder and the pulse encoder
interface module, or between the module and the drive. Encoder
supervision function activates if either of the following conditions is
valid:
-There is a 20% difference between the estimated speed and the
measured speed received from the encoder.
- No pulses are received from the encoder within the defined time (see
parameter 50.04) and the motor torque is at the allowed maximum
value.
The drive generates a warning indication.
The drive trips on a fault, gives a fault indication and stops the motor.
Defines the fibre optic channel of the control board from which the drive
program reads the signals coming from the pulse encoder interface
module. The setting is valid only if the module is connected to the drive
via the DDCS link ( i.e. not to the option slot of the drive).
Signals via channel 1 (CH1). The pulse encoder interface module must
be connected to CH1 instead of CH2 in applications where CH2 is
reserved by a Master station (e.g. a Master/Follower application). See
also parameter 70.03.
Signals via channel 2 (CH2). Can be used in most cases.
Defines the speed feedback value used in control.
Calculated speed estimate
Actual speed measured with an encoder
The parameters are visible and need to be adjusted, only when a
fieldbus adapter module (optional) is installed and activated by
parameter 98.02. For details on the parameters, refer to the manual of
the fieldbus module. These parameter settings will remain the same
even though the macro is changed.
The settings for the Standard Modbus Link. See the chapter Fieldbus
control.
GROUP NOT TYPICALLY USED IN NOI APPLICATIONS
1
65535
1
2
65535
**********
Master/Follower application. For more information, see the chapter
Program features and a separate Master/Follower Application Guide.
Defines the role of the drive on the Master/Follower link.
The Master/Follower link is not active.
Master drive
Follower drive
1
2
3
70 DDCS CONTROL Settings for the fibre optic channels 0, 1 and 3.
70.01 CHANNEL 0 ADDR Defines the node address for channel 0. No two nodes on-line may
have the same address. The setting needs to be changed when a
master station is connected to channel 0 and it does not automatically
change the address of the slave. Examples of such masters are an
ABB Advant Controller or another drive.
1… 125
Address.
70.02 CHANNEL 3 ADDR Node address for channel 3. No two nodes on-line may have the same
address. Typically the setting needs to be changed when the drive is
connected in a ring which consists of several drives and a PC with the
DriveWindow® program running.
1… 254
Address.
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1… 125
1… 254
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70.03 CH1 BAUDRATE
8 Mbits
4 Mbits
2 Mbits
1 Mbits
70.04 CH0 DDCS HW
CONN
RING
STAR
83 ADAPT PROG
CTRL
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The communication speed of channel 1. Typically the setting needs to
be changed only if the pulse encoder interface module is connected to
channel 1 instead of channel 2. Then the speed must be changed to 4
Mbits. See also parameter 50.05.
8 megabits per second
4 megabits per second
2 megabits per second
1 megabits per second
Selects the topology of the channel 0 link
Devices are connected in a ring.
Devices are connected in a star.
Control of the Adaptive Program execution. For more information, see
the Adaptive Program Application Guide (code: 3AFE 64527274
[English]).
0
1
2
3
0
1
83.01 ADAPT PROG CMD Selects the operation mode for the Adaptive Program.
STOP
START
EDIT
Stop. The program cannot be edited.
Run. The program cannot be edited.
Stop to edit mode. Program can be edited.
****NOTE: Edit mode must be selected on the target and source when
trying to download an adaptive program.*****
84 ADAPTIVE
PROGRAM
- selections of the function blocks and their input connections.
- diagnostics
THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS
OTHER THAN QUALIFIED NOI PERSONEL
**********
84 ADAPTIVE
PROGRAM
**********
**********
Storage of the Adaptive Program constants and messages.
THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS
OTHER THAN QUALIFIED NOI PERSONEL
**********
98 OPTION
MODULES
98.01 ENCODER
MODULE
NTAC
NO
RTAC-SLOT1
RTAC-SLOT2
RTAC-DDCS
98.02 COMM. MODULE
LINK
NO
FIELDBUS
ADVANT
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Activates the communication to the optional pulse encoder module. See
also parameter group 50 ENCODER MODULE.
Communication active. Module type: NTAC module. Connection
interface: Fibre optic DDCS link.
Note: Module node number must be set to 16.
Inactive
Communication active. Module type: RTAC. Connection interface:
Option slot 1 of the drive
Communication active. Module type: RTAC. Connection interface:
Option slot 2 of the drive.
Communication active. Module type: RTAC. Connection interface:
Option module rack of the drive (communicates with the drive through a
fibre optic DDCS link).
Note: Module node number must be set to 16.
Activates the external serial communication and selects the interface.
No communication
The drive communicates via a fieldbus adapter module in option slot 1
of the drive, or via CH0 on the RDCO board. See also parameter group
51 COMMUNICATION MODULE.
The drive communicates with an ABB Advant OCS system via CH0 on
the RDCO board (optional). See also parameter group 70 DDCS
CONTROL.
1
2
3
4
5
1
2
3
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STD MODBUS
CUSTOMISED
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The drive communicates with a Modbus controller via the Modbus
Adapter Module (RMBA) in option slot 1 of the drive. See also
parameter 52 STANDARD MODBUS.
The drive communicates via a customer specified link. The control
sources are defined by parameters 90.04 and 90.05.
4
5
99 START-UP DATA Language selection. Definition of motor set-up data.
99.01 LANGUAGE
ENGLISH(AM)
99.02 APPLICATION
MACRO
FACTORY
HAND/AUTO
PID-CTRL
T-CTRL
SEQ CTRL
USER 1 LOAD
USER 1 SAVE
USER 2 LOAD
USER 2 SAVE
99.05 MOTOR NOM
VOLTAGE
½… 2 · UN
99.06 MOTOR NOM
CURRENT
0… 2 · I2hd
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Selects the display language.
American English. If selected, the unit of power used is HP instead of
kW.
Selects the application macro. See the chapter Application macros for
more information.
Note: When you change the default parameter values of a macro, the
new settings become valid immediately and stay valid even if the power
of the drive is switched off and on. However, backup of the default
parameter settings (factory settings) of each standard macro is still
available. See parameter 99.03.
1
Factory for basic applications
Two control devices are connected to the drive:
- device 1 device communicates through the interface defined by
external control location EXT1.
- device 2 communicates through the interface defined by external
control location EXT2.
- EXT1 or EXT2 is active at a time. Switching through a digital input.
PID control. For application in which the drive controls a process value.
E.g. pressure control by the drive running the pressure boost pump.
Measured pressure and the pressure reference are connected to the
drive.
Torque Control macro
****Note this selection is set on the slave drive, if application utilizes the
master/slave drive arrangement****
Sequential Control macro. For applications that are frequently run
through a pre-defined speed pattern (constant speeds and acceleration
and deceleration ramps).
User 1 macro loaded into use. Before loading, check that the saved
parameter settings and the motor model are suitable for the application.
Save User 1 macro. Stores the current parameter settings and the
motor model.
Note: There are parameters that are not included in the macros. See
parameter 99.03.
User 2 macro loaded into use. Before loading, check that the saved
parameter settings and the motor model are suitable for the application.
Save User 2 macro. Stores the current parameter settings and the
motor model.
Note: There are parameters that are not included in the macros. See
parameter 99.03.
Defines the nominal motor voltage. Must be equal to the value on the
motor rating plate
1
Voltage. Allowed range is 1/2… 2 · UN of the drive
Defines the nominal motor current. Must be equal to the value on the
motor rating plate.
Note: Correct motor run requires that the magnetizing current of the
motor does not exceed 90 percent of the nominal current of the
inverter.
Allowed range: 1/6 . 2 · I2hd of ACS800 (parameter 99.04 = DTC).
Allowed range: 0 . 2 · I2hd of ACS800 (parameter 99.04 = SCALAR).
1=1V
2
3
4
5
6
7
8
9
1 = 0.1 A
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99.07 MOTOR NOM FREQ Defines the nominal motor frequency.
8… 300 Hz
Nominal frequency (50 or 60 Hz typically)
99.08 MOTOR NOM
Defines the nominal motor speed. Must be equal to the value on the
SPEED
motor rating plate. The motor synchronous speed or another
approximate value must not be given instead!
Note: If the value of parameter 99.08 is changed, the speed limits in
parameter group 20 LIMITS change automatically as well.
1… 18000 rpm
Nominal motor speed
99.09 MOTOR NOM
Defines the nominal motor power. Set exactly as on the motor rating
POWER
plate.
0... 9000 kW
Nominal motor power
99.10 MOTOR ID RUN
Selects the type of the motor identification. During the identification, the
drive will identify the characteristics of the motor for optimum motor
control. The ID Run Procedure is described in the chapter Start-up; and
control through the I/O.
Note: The ID Run (STANDARD or REDUCED) should be selected if:
- The operation point is near zero speed, and/or
- Operation at torque range above the motor nominal torque within a
wide speed range and without any measured speed feedback is
required.
Note: The ID Run (STANDARD or REDUCED) cannot be performed if
parameter 99.04 = SCALAR.
NO
No ID Run. The motor model is calculated at first start by magnetizing
the motor for 20 to 60 s at zero speed. This can be selected in most
applications.
Standard ID Run. Guarantees the best possible control accuracy. The
STANDARD
ID Run takes about one minute.
Note: The motor must be de-coupled from the driven equipment.
Note: Check the direction of rotation of the motor before starting the ID
Run. During the run, the motor will rotate in the forward direction.
REDUCED
WARNING! The motor will run at up to approximately 50 . 80%
of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE
TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN!
Reduced ID Run. Should be selected instead of the Standard ID Run:
- if mechanical losses are higher than 20% (i.e. the motor cannot be decoupled from the driven equipment)
- if flux reduction is not allowed while the motor is running (i.e. in case
of a motor with an integrated brake supplied from the motor teminals).
Note: Check the direction of rotation of the motor before starting the ID
Run. During the run, the motor will rotate in the forward direction.
WARNING! The motor will run at up to approximately 50 . 80%
of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE
TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN!
Designates Parameter Group
Typical NOI Application Setting
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800… 30000
1… 18000
0… 90000
1
2
3
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INSTALLATION
This section contains guidelines for installing NOI Model 800AC VSDS systems. This installation
section is not intended to be a step-by-step procedure for installing the system, but more of an overall
guide to aid in the installation. It will be necessary to refer to system drawings and documents for
specific details about sub-systems. Once the system has been installed, the start up procedure should
be followed.
Any information not contained in this document can be found in the system manual or the system
drawings. Any personnel involved in the installation and start up of this system should read all the
documentation to before proceeding with any part of system installation and startup.
5.1
Mechanical Installation
The VSDS system should only be lifted according to the job specific requirements. The systems
may vary depending on customer requirements. Most systems are designed to be lifted either by
forklift, or crane. Most systems lifted by forklift are provided with a lifting base with forklift fork
accommodations typically in the base of the system. Systems that require a crane for movement
typically have lifting bars or eyes for overhead lifting.
Some systems will include shipping splits which are used to reduce the length and weight of the
shipping sections. It is important to ensure that the individual shipping splits are placed in the
correct orientation and bolted tightly together.
5.2
Electrical Installation
The following section provides general guidelines that should be observed before applying power
to the VSDS.
It is important to ensure the VSDS system has the adequate ground connections. For stand
alone systems installed in drilling modules, ensure that the base of the systems is seam welded to
the deck. Also ensure that the cubicle frames are bolted (with star washers if cubicles are painted
metal) properly to the system base. For systems which include a drive house, ensure that the
proper size grounding conductor is installed to the dedicated ground bus on the house.
Ensure the required control connections (encoders, profibus, fiber, etc.) are connected per the job
specific drawings. Also ensure that the shielding on these signals is correct.
The input and output power connections vary from system to system, so it is important to refer to
your job’s electrical drawings in conjunction with this manual. Table 5-1 contains main terminal
markings.
www.nov.com
Terminal
Designator
Definition
Connected to
B+
BU
V
Positive DC bus
Negative DC bus
Inverter output phase A
Inverter output phase B
+ DC main bus
- DC main bus
Motor phase A
Motor phase B
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Inverter output phase C
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Motor phase C
Table 5-1 Inverter Main Terminal Designations
Input power cables to the VSDS should be sized according to the cable schedule provided in the
document package. As a general rule, the cable insulation should be rated for 600V and a
temperature rise of 90C. It is also recommended that multi-core, 3 conductor cable be used to
supply the input rectifiers. If not specified in the cable schedule, the ampacity of the cable should
be adequate to carry the full load of the source which supplies the VSDS. It is recommended that
multi-core, shielded VFD cable be used to connect the VSDS to the motor(s). For a 600V system,
this cable is typically rated for 2000V, and a minimum of a 90 degree Celsius temperature rise.
Be sure to consult the factory if unsure about cable sizes or ratings. See job specific drawings for
exact termination point for input and output cables.
The following list of guidelines should be observed before connecting any cable to the VSDS
1. Before connecting the motor or input cables to the VSDS, a qualified electrician or
service technician should perform insulation tests on the cable. Check both the
phase to ground insulation resistance and the phase to phase insulation resistance.
In both cases, the resistance should be equal to or greater than 1 M
2. Before connecting the cables to the motors, be sure a qualified electrician or service
engineer tests the motor insulation. The phase to ground and phase-to-phase
insulation resistance should be a minimum of 1 M. The test voltage should be
appropriate for the motor’s rated voltage.
3. Do not place the VSDS motor cables near other cables, such as supply or control
cables. Avoid placing the motor cables in long parallel lines with other cables
wherever possible. If motor cables are to be run along other cables, the following
table is a guideline to use for establishing minimum distance between cables:
DISTANCE BETWEEN CABLES
0.3m
(1 foot)
1.0m
(3.3 feet)
SHIELDED CABLE
Less than or equal to 50m (164 feet)
Greater than 50m (164 feet)
Table 5-2 Cable Spacing Guideline
4. Wherever possible, motor cables should cross other cables at 90 angles
Special care must be given to the motor cables. They are unlike standard three phase cables.
Each motor cable contains three drain wires as well as an overall shield.
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Figure 5-1 VFD Motor Cable Drawing
The three phase conductors are connected to the inverter and motor using crimp style lugs and
stainless steel hardware (except in the case where plugs are used). The drain wires and overall
shield should be connected as per the diagram below.
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


Figure 5-2 VFD Motor Cable Connection Diagram
Care should be taken to ensure that the earth cables or overall shield does not make contact with
the phase conductors. This condition will create an electrical short in the cable and damage either
the motor or the inverter. A solid connection to chassis ground must be established for the earth
cables as well as the shield wire. These wires should be connected to an unpainted surface using
crimp style lugs and stainless steel hardware. The length of these wires should be kept to the
shortest length that is possible. The three earth cables are to be connected at both the motor and
AC drives ends to provide the system earth connection. The shield armour connection only
occurs at the inverter end of the cable. The motor end of the cable is left unconnected.
It is important to ensure that all electrical cables have a tight connection. It is advisable to go over
the entire system and check each connection point for loose connections. During shipment, some
of the screws or bolts may have become loose due to vibrations.
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TROUBLESHOOTING
The following troubleshooting guideline is intended to act as an aid to fault tracing in the
inverter. The majority of fault tracing is done through the inverter’s keypad. The information
provided deals with the most common problems you may encounter. Therefore, a familiarity
with the drive’s keypad/LCD display and how to navigate through its various menus is
essential to being able to isolate the source of a problem.
Due to the complex and unique operating environment in which this equipment operates, it is
impossible to anticipate every possible problem and solution. If the equipment continues to
present problems, or if the type of trouble exhibited by the equipment is not covered in this
section, please contact your nearest National Oilwell representative to arrange service.
6.1
Warning and fault indications
The drive is equipped with an internal system for indicating abnormal or failure conditions. In the
event the drive detects an undesirable condition, it will display a warning or fault message on the
control panel display. The latest warnings and faults are recorded together in the Fault History
along with a time stamp identifying when the event occurred. Once the fault has been traced to
its cause and then corrected, the drive may be reset. The drive can be reset by pressing the
RESET key on the keypad, by digital input or fieldbus, or powering down the drive.
6.1.1 Programmable protection functions
AI<Min
AI<Min function defines the drive operation if an analogue input signal falls below the preset
minimum limit.
Settings
Parameter 30.01.
Panel Loss
Panel Loss function defines the operation of the drive if the control panel selected as control
location for the drive stops communicating.
Settings
Parameter 30.02.
External Fault
External Faults can be supervised by defining one digital input as a source for an external
fault indication signal.
Settings
Parameter 30.03.
Motor Thermal Protection
The motor can be protected against overheating by activating the Motor Thermal Protection
function and by selecting one of the motor thermal protection modes available.
The Motor Thermal Protection modes are based either on a motor temperature thermal
model or on an over temperature indication from a motor thermistor.
Motor temperature thermal model
The drive calculates the temperature of the motor on the basis of the following assumptions:
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1. The motor is in the ambient temperature of 30 _C when power is applied to the drive.
2. Motor temperature is calculated using either the user-adjustable or automatically
calculated motor thermal time and motor load curve (see the figures below). The load
curve should be adjusted in case the ambient temperature exceeds 30 °C.
Figure 6-1 Motor Thermal Load Curves
Use of the motor thermistor
It is possible to detect motor overtemperature by connecting a motor thermistor (PTC)
between the +24 VDC voltage supply offered by the drive and digital input DI6. In normal
motor operation temperature, the thermistor resistance should be less than 1.5 kohm
(current 5 mA). The drive stops the motor and gives a fault indication if the thermistor
resistance exceeds 4 kohm__
Settings
Parameters 30.04 to 30.09.
Note: It is also possible to use the motor temperature measurement function. See the
subsection Motor temperature measurement through the standard I/O.
Stall Protection
The drive protects the motor in a stall situation. It is possible to adjust the supervision limits
(frequency, time) and choose how the drive reacts to the motor stall condition (warning
indication / fault indication & stop the drive / no reaction).
Settings
Parameters 30.10 to 30.12.
Underload Protection
Loss of motor load may indicate a process malfunction. The drive provides an under-load
function to protect the machinery and process in such a serious fault condition. Supervision
limits – under-load curve and under-load time - can be chosen as well as the action taken by
the drive upon the under-load condition (warning indication / fault indication & stop the drive
/ no reaction).
Settings
Parameters 30.13 to 30.15.
Motor Phase Loss
The Phase Loss function monitors the status of the motor cable connection. The function is
useful especially during the motor start: the drive detects if any of the motor phases is not
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connected and refuses to start. The Phase Loss function also supervises the motor
connection status during normal operation.
Settings
Parameter 30.16.
Earth Fault Protection
The Earth Fault Protection detects earth faults in the motor, the motor cable or the inverter.
This protection is based on earth leakage current measurement with a summation current
transformer at the input of the converter with the following provisions:
 An earth fault in the mains does not activate the protection.
 In an earthed (grounded) supply, the protection activates in 200 microseconds.
 In floating mains, the mains capacitance should be 1 microfarad or more.
 The capacitive currents due to screened copper motor cables up to 300 metres do
not activate the protection.
Settings
Parameter 30.17.
Communication Fault
The Communication Fault function supervises the communication between the drive and an
external control device (e.g. a fieldbus adapter module).
Settings
Parameters 30.18 to 30.21.
Supervision of optional IO
The function supervises the use of the optional analogue and digital inputs and outputs in
the application program, and warns if the same input (output) is used for two purposes
simultaneously.
Settings
Parameter 30.22.
6.1.2 Preprogrammed faults
Overcurrent
The overcurrent trip limit for the drive is 3.5 · I2hd (rated output current, heavy-duty use
rating).
62
DC overvoltage
The DC overvoltage trip limit is 1.3 ·U1max, where U1max is the maximum value of the
mains voltage range. For 400 V units, U1max is 415 V. For 500 V units, U1max is 500
V. For 690 V units, U1max is 690 V. The actual voltage in the intermediate circuit
corresponding to the mains voltage trip level is 728 VDC for 400 V units, 877 VDC for 500 V
units, and 1210 VDC for 690 V units.
DC undervoltage
The DC undervoltage trip limit is 0.65 · U1min, where U1min is the minimum value of the
mains voltage range. For 400V and 500V units, U1min is 380V. For 690 V units, U1min is
525V. The actual voltage in the intermediate circuit corresponding to the mains voltage trip
level is 334VDC for 400V and 500V units, and 461VDC for 690V units.
Drive temperature
The drive supervises the inverter module temperature. If the inverter module temperature
exceeds 115 °C, a warning is given. The temperature trip level is 125 °C.
Short circuit
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There are separate protection circuits for supervising the motor cable and the inverter short
circuits. If a short circuit occurs, the drive will not start and a fault indication is given.
Input phase loss
Input phase loss protection circuits supervise the mains cable connection status by
detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive is
stopped and a fault indication is given if the ripple exceeds 13%.
Ambient temperature
The drive will not start if the ambient temperature is below -5 to 0 °C or above 73 to 82 °C
(the exact limits vary within the given ranges depending on drive type).
Overfrequency
If the drive output frequency exceeds the preset level, the drive is stopped and a
fault indication is given. The preset level is 50 Hz over the operating range absolute
maximum speed limit (Direct Torque Control mode active) or frequency limit (Scalar Control
active).
Internal fault
If the drive detects an internal fault the drive is stopped and a fault indication is given.
6.1.3 Warning messages generated by the drive
Figure 6-2 Drive Warning Messages
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6.1.4 Warning messages generated by the control panel
Figure 6-3 Control Panel Warning Messages
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6.1.5 Fault messages generated by the drive
Figure 6-4 Drive Fault Messages
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MAINTENANCE
This section reviews general maintenance issues and provides basic guidelines for
consideration in preparing maintenance procedures. These are guidelines only however, and
all items may not apply to every rig or component part. Specific maintenance procedures
and details on replacement parts, filters, etc. are located throughout the Maintenance Manual.
Regular operating personnel may carry out preventive maintenance as outlined in the
Maintenance Manual. Specialists should perform other more complex types of maintenance.
A qualified and experienced mechanic who is familiar with the equipment and the proper use
of appropriate tools to complete each task should perform the disassembly, mechanical
inspection and repair during equipment strip down.
The National Oilwell Model 800 VSDS is designed and constructed to provide many years of
reliable and cost-effective service. The only way this can be achieved is to maintain the
equipment at optimum performance levels. The bottom line is that better maintenance equals
better performance, equals better productivity, equals longer equipment life, and in some
cases, the lives of personnel as well.
The mechanical components used to create the operating systems on this piece of equipment
have been selected to provide the most reliable yet cost-effective operation. Proper
preventative maintenance should be considered an investment in smooth field operations with
minimum downtime. Another consideration should be that when equipment is in the yard or
shop for repairs or strip-down, new parts might be installed at far less expense than when the
equipment is at a field location. In fact, if equipment is on location and the entire operation of
the platform is shut down for emergency repairs, the cost of that repair can be many times that
of a regular overhaul time repair.
Under normal operating conditions, no regular maintenance is required. For systems that are shipped
or moved regularly, it is recommended that the user check the tightness of all electrical connections
after each move is completed. In general, the equipment must be kept clean and free of dust, dirt, or
other contaminants. If the equipment is used in particularly dirty environments, it is recommended that
the equipment is shutdown periodically and cleaned. This should be done with dry, compressed air.
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OPERATOR SKILLS AND TRAINING
The operator shall receive on-the-job training from National Oilwell or a technician experienced in the operation of the Model 800AC VSDS.
The operator shall have experience with the types of operations that the Model 800AC VSDS is to perform. The operator shall ensure that all
safety procedures are followed while operating and maintaining the equipment. The operator shall study the available documentation during
and after training to gain an overall understanding of how the equipment operates and what the limitations of the equipment are. Any
questions about the operation and maintenance of the Model 800AC VSDS not covered in the available documentation should be referred to
National Oilwell, Inc. Additional training regarding the operation and theory of AC drives is available by contacting National Oilwell’s Training
Department at 713-935-8121.
www.nov.com
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 10.0
Reliance Installation, Operating
Manual (180-449)
www.nov.com
Installation, Operation and Maintenance
Of Reliance® Standard Industrial
AC Induction Motors
z 180 – 449 Frames (NEMA)
z 112 – 280 Frames (IEC)
NEXT ASSY
PRODUCT
TDS-9S
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco
CURRENT
DRAWN
T. Harmon
INITIAL
J. Hensley
CHECKED
H. Lim
S. Hansen
APPVD
H. Lim
S. Hansen
07/22/2011
11/01/1996
DATE
TITLE
USER MANUAL
RELIANCE MOTOR MANUAL
180-449 Frames (NEMA), 112-280 Frames (IEC)
SCALE:
WT LBS:
SIZE:
SHT:
AV
DWG NO.:
1 OF 1
REV:
VDR00029
A
D811000457-GEN-001/04
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 11.0
Reliance Installation, Operating
Manual (L210-400)
www.nov.com
Installation, Operation and Maintenance
Of RPM AC Inverter Duty Induction Motors
FL180 – L440 Frames
(Specifically designed for operation with
Adjustable Speed Controls)
NEXT ASSY
PRODUCT
TDS-9S
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco
CURRENT
DRAWN
T. Harmon
J. Hensley
H. Lim
S. Hansen
APPVD
H. Lim
S. Hansen
08/02/2011
11/01/1996
USER MANUAL
BALDOR ƒ RELIANCE MOTOR MANUAL
FRAMES FL180 - L440
INITIAL
CHECKED
DATE
TITLE
SCALE:
WT LBS:
SIZE:
SHT:
AV
DWG NO.:
1 OF 1
REV:
VDR00030
B
D811000457-GEN-001/04
RPM AC Inverter Duty Induction Motors
FL180 - L440 Frames
(Specifically designed for operation with
adjustable Speed Controls)
Installation & Operating Manual
9/08
MN406
Any trademarks used in this manual are the property of their respective owners.
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greater than 3 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greater than 18 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stub Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stub Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Leads Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY . . . . . . . . . . . .
MN406
1-1
1-1
1-1
1-1
1-2
1-2
1-3
1-3
1-4
1-4
1-4
2-1
2-1
2-1
2-1
2-2
2-3
2-3
2-3
2-4
2-4
2-5
2-5
2-6
2-6
2-6
2-6
2-8
2-9
2-10
3-1
3-1
3-1
3-1
3-2
3-3
3-4
Table of Contents i
Section 1
General Information
ii Table of Contents
MN406
Section 1
General Information
Overview
Important:
This manual contains general procedures that apply to BaldorReliance Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt
to perform maintenance procedures until you understand the Warning and Caution statements.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed.
Please contact your Baldor District office for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
NEMA Publication MG‐2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
ANSI C51.5
The National Electrical Code
Local codes and Practices
Limited Warranty
www.baldor.com/support/warranty_standard.as
Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt installation, operation and maintenance of electrical equipment.
Be sure that you are completely familiar with NEMA publication MG‐2, safety standards for construction and
guide for selection, installation and use of electric motors and generators, the National Electrical Code and
local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury.
Only qualified personnel should attempt the installation, operation and maintenance of this equipment.
WARNING:
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING:
Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
WARNING:
The Adjustable Speed Controller may apply hazardous voltages to the motor leads after power to
the controller has been turned off. Verify that the controller is incapable of delivering hazardous
voltages and that the voltage at the motor leads is zero before proceeding. Failure to observe this
precaution may result in severe bodily injury or death.
WARNING:
Be sure the system is properly grounded before applying power. Do not apply AC power before
you ensure that all grounding instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes must be carefully followed.
WARNING:
Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective
devices to reduce harmful effects to your hearing.
WARNING:
Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
WARNING:
This equipment may be connected to other machinery that has rotating parts or parts that are
driven by this equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt to install operate or maintain this equipment.
WARNING:
Do not by‐pass or disable protective devices or safety guards. Safety features are designed to
prevent damage to personnel or equipment. These devices can only provide protection if they
remain operative.
WARNING:
Avoid the use of automatic reset devices if the automatic restarting of equipment can be
hazardous to personnel or equipment.
WARNING:
Be sure the load is properly coupled to the motor shaft before applying power. The shaft key
must be fully captive by the load device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
WARNING:
Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
WARNING:
Incorrect motor rotation direction can cause serious or fatal injury or equipment damage. Be sure
to verify motor rotation direction before coupling the load to the motor shaft.
WARNING:
Motors that are to be used in flammable and/or explosive atmospheres must display the CSA
listed logo. Specific service conditions for these motors are defined in NFPA 70 (NEC) Article 500.
MN406
General Information 1-1
Section 1
General Information
Safety Notice Continued
WARNING:
Pacemaker danger - Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING:
RPM AC permanent magnet motors can induce voltage and current in the motor leads by rotating
the motor shaft. Electrical shock can cause serious or fatal injury. Therefore, do not couple the
load to the motor shaft until all motor connections have been made. During any maintenance
inspections, be sure the motor shaft will not rotate.
WARNING:
Before performing any motor maintenance procedure, be sure that the equipment connected to
the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the
load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of
the motor parts can cause injury or motor damage.
WARNING:
Do not use non UL/CSA listed explosion proof motors in the presence of flammable or
combustible vapors or dust. These motors are not designed for atmospheric conditions that
require explosion proof operation.
WARNING:
UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
WARNING:
C-Face motor is intended for mounting auxiliary equipment such as pumps and gears. When
mounted horizontally Frames FL, RL and L280C thru L360C, and frames L400D thru L4461D must
be supported by the feet and not by the C-Face on D-Flange alone. C-Face motors should be
supported by the feet and not by the C-Face. Installations requiring a horizontally mounted motor
in frames L280C - L440D must be supported by the feet as well as C-Face or D-Flange.
Failure to observe these precautions can result in bodily injury and equipment damage.
Caution:
Use only a shielded motor power cable with a complete circumferential braided or copper
film/tape ground jacket around the power leads. This ground should be secured to the motor
frame from within the motor terminal box and must return without interruption to the drive ground.
In addition, if the motor and coupled equipment are not on a single common metal baseplate, it is
important to equalize the equipment ground potentials by bonding the motor frame to the coupled
equipment using a high frequency conductor such as a braided strap.
Caution:
Do not over-lubricate motor as this may cause premature bearing failure.
Caution:
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution:
If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
Caution:
To prevent equipment damage, be sure that the electrical service is not capable of delivering more
than the maximum motor rated amps listed on the rating plate.
Caution:
If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and
procedure in NEMA MG1 and MG2 standards to avoid equipment damage.
Caution:
Do not use an induction oven to heat noise tested bearings. Arcing between the balls and races
may damage the bearing. Failure to observe this precaution may result in equipment damage.
Caution:
Do not operate motors with a roller bearing unless a radial load is applied so that damage to the
roller bearing does not occur.
Caution:
RPM AC permanent magnet motors with an open enclosure, such as DP-FV, should not be used
where ferrous dust or particles may may be present . Totally enclosed permanent magnet motors
are recommended for these applications.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor District office or an Authorized Baldor Service Center.
Each BaldorReliance motor is thoroughly tested at the factory and carefully packaged for shipment.
Receiving
When you receive your motor, there are several things you should do immediately.
1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part number listed on your
purchase order.
1-2 General Information
MN406
Handling
The motor should be lifted using the lifting lugs or eye bolts provided.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift
only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor. If eye bolts are
used for lifting a motor, be sure they are securely tightened. The lifting direction should not exceed a
20° angle from the shank of the eye bolt. Excessive lifting angles can cause motor damage.
2. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into
holes on top of the cooling hood. These lugs are to be used for hood removal only.
A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.
3. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc.,
it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling
around the mounting base. The entire assembly can be lifted as an assembly for installation.
Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to
lift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slings
or other means must be used to prevent tipping. In any event, the load must be secure before lifting.
If the motor is not put into service immediately, the motor must be stored in a clean, dry area protected
Storage
from extremes of temperature, moisture, shock and vibration.
Storage temperatures of 15°C (50°F) to 50°C (120°F) with a maximum relative humidity of 60% must be
observed.
Preparation for Storage
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does
not experience regular usage while being exposed to normally humid atmospheric conditions is likely to
cause the bearings to rust or rust particles from surrounding surfaces to contaminate the bearings.
The electrical insulation may absorb an excessive amount of moisture leading to the motor winding
failure. The following preparations should be accomplished for storage.
1. Motors are to be kept in their original containers or provided with equivalent protection and stored in a
warehouse free from extremes in temperature, humidity, and corrosive atmosphere.
2. If unusual vibrations exist at the storage location, the motor should be protected with isolation pads.
3. Some motors have a shipping brace attached to the shaft to prevent damage during transportation.
The shipping brace, if provided, must be removed and stored for future use. The brace must be
reinstalled to hold the shaft firmly in place against the bearing before the motor is moved.
4. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.
(Room temperature is the temperature of the room in which it will be installed). The packing provides
insulation from temperature changes during transportation.
5. When the motor has reached room temperature, remove all protective wrapping material from the motor.
6. Motor space heaters (when present) are to be connected and energized whenever there is a
possibility that the storage ambient conditions will reach the dew point. Space heaters are optional.
7. Measure and record the electrical resistance of the winding insulation resistance meter. Minimum
accepted meg ohm level is 5 Meg ohms at 40°C (104°F). If resistance decreases below this level,
contact your Baldor District office. Measure and record these values every 30 days during storage.
8. All breathers and drains are to be operable while in storage and/or the moisture drain plugs removed.
The motors must be stored so the drain is at the lowest point. All breathers and automatic drains must
be operable to allow breathing at points other than through he bearing fits.
9. Coat all external machined surfaces with a rust preventing material. An acceptable product for this
purpose is Exxon Rust Ban # 392.
10. Rotate motor shaft at least 15 turns every three months during storage (more frequently if possible).
11. After the first dielectric withstand test and rotating the shaft, etc., the vapor bag should be re-sealed
by taping it closed with masking or similar tape. Also place new desiccant inside the bag before
closing. The shell should then be placed over the motor and the lag bolts replaced.
12. If a zipper-closing type bag is used instead of the heat-sealed type bag, then zip the bag closed
instead of taping it. Be sure to add new desiccant inside bag after each periodic inspection.
13. When motors are not stored in the original containers, but are removed and mounted on other
machinery, the mounting must be such that the drains and breathers and space heaters are fully
operable. In this respect the drains must be kept at the lowest point in the motor so that all
condensation can automatically drain out. Motor space heaters when present are to be energized
whenever there is a possibility that the storage ambient conditions will reach the dew point. Space
heaters are optional.
MN406
General Information 1-3
Greater than 3 months
All requirements of general preparation and short term storage apply with the following additional
requirements.
Non-Regreaseable Motors
Non-regreasable motors with “Do Not Lubricate” on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types
Upon placing the motor into extended storage (+ 3 months) the following procedure must be performed.
1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket
prior to lubricating the motor.
2. The motor with regreasable bearing must be greased per Table 1-1 .
3. Standard RPM AC Motors in frames FL180, FL210, and FL 250 (IEC frames FDL 112, FDL132 and
FDL160) use double shielded bearings with oversized grease reservoirs that provide lifetime
lubrication with no maintenance.
4. Replace the grease drain plug after greasing.
5. The motor shaft must be rotated a minimum of 15 times after greasing.
6. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months per Table 1-1 to each bearing.
7. Bearings are to be greased at the time of removal from storage.
Table 1-1 Lubrication Volume (Storage)
Vol. in Cubic In. (cm3)
NEMA Frame Size (IEC)
L, RL, FL280, DL, RDL,FDL180
1.0 (16)
L320 thru L360 (200-225)
1.5 (24)
L400 thru L440 (250-280)
2.5 (40)
Greater than 18 months
All requirements of general preparation and short term storage apply with the following additional
requirements.
1. Motor is to be crated in a box similar to Export Boxing but that the “shell” (sides & top of box) must be
secured to the wooden base with lag bolts (not nailed as export boxes are). This design allows the
opening and reclosing the box many times without destroying the “shell”.
2. The Motor will be sealed in an airtight vapor barrier bag with desiccant inside. This airtight bag will
give added protection during shipment of motor to the permanent storage area.
3. After the first electrical resistance of the winding insulation resistance test measurement is recorded,
the bearings are regreased, the shaft is rotated 15 turns, etc., add new desiccant inside bag before
closing the vapor bag and re-seal by taping it closed with masking or similar tape. The shell should
then be placed over the motor and the lag bolts replaced.
4. If a “zipper” type bag is used instead of a heat-sealed type bag, add new desiccant inside bag then
zip the bag closed instead of taping it.
5. Be sure to add new desiccant inside bag after each periodic inspection.
6. Minimize the accumulation of condensed water in and around the storage area.
Removal From Storage
1. Remove all packing material.
2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into
service.
3. Regrease the bearings per Table 1-1 .
1-4 General Information
MN406
Section 2
Installation & Operation
Overview
Installation should conform to the National Electrical Code as well as local codes and practices. When
other devices are coupled to the motor shaft, be sure to install protective devices to prevent future
accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These
protect against accidental contact with moving parts. Machinery that is accessible to personnel should
provide further protection in the form of guard rails, screening, warning signs etc.
RPM AC motors are high performance motors specifically designed for use with adjustable frequency
controllers. The basic design includes Class H insulation, 1.0 service factor, 40°C ambient, continuous
duty. Standard enclosures are totally enclosed blower cooled, totally enclosed fan-cooled, totally
enclosed nonventilated, totally enclosed air over piggy back and drip-proof force ventilated. Many
modifications, and accessories are available. Motors are available as both induction and permanent
magnet construction. RPM AC motors are equipped with metric hardware.
It is important that motors be installed in locations that are compatible with motor enclosure and ambient
conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced
operating life of the motor.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.
1. Open Drip-Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry,
well ventilated and non-corrosive.
2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in
outdoor locations.
Note: Motors located in a damp, moist environment must have space heaters to protect against
condensation when motor is not operating.
Mechanical Installation
WARNING:
C-Face motor is intended for mounting auxiliary equipment such as pumps and gears. When
mounted horizontally Frames FL, RL and L280C thru L360C, and frames L400D thru L4461D must
be supported by the feet and not by the C-Face on D-Flange alone. C-Face motors should be
supported by the feet and not by the C-Face. Installations requiring a horizontally mounted motor
in frames L280C - L440D must be supported by the feet as well as C-Face or D-Flange.
Failure to observe these precautions can result in bodily injury and equipment damage.
Caution:
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution:
If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
Caution:
RPM AC permanent magnet motors with an open enclosure, such as DP-FV, should not be used
where ferrous dust or particles may may be present . Totally enclosed permanent magnet motors
are recommended for these applications.
After storage or after unpacking and inspection to see that all parts are in good condition, do the following:
1. Rotate the motor shaft by hand to be sure there are no obstructions to free rotation.
2. A motor that has been in storage for some time should be tested for moisture (dielectric withstand
insulation test) and relubricated (regreaseable type) prior to being put into service.
3. A motor with roller bearings is shipped with a shaft block. After removing the shaft block, be sure to
replace any bolts used to hold the shaft block in place during shipment that are required in service.
MN406
Installation & Operation 2-1
Table 2-2
Frame
FL180
RL210, FL210
RL250, FL250
L280, FL280, & RL280
L320
L360
L400 & L440
Hole Dia.
(Inch)
Bolt Size
& Thread
0.44
0.44
0.56
0.56
0.69
0.81
1.06
3/ -16
8
3/ -16
8
1/ -13
2
1/ -13
2
5/ -1 1
8
3/ -10
4
7/ -9
8
Recommended Torque
lb-ft for Bolt Grade
SAE 5
SAE 8
33-37
47-53
33-37
47-53
83-93
117-132
83-93
117-132
155-176
200-249
274-310
389-440
434-486
616-689
Stub Shaft Installation
1. Turn off and lock out power to the motor.
2. Remove in-line blower motor and cover assembly by removing the Hex head cap screws on cover (if
enclosure is TEAO-Blower cooled).
NOTE: An extended blower cover maybe required when a feedback device is installed.
Contact your local Baldor District Office for assistance with an in-line blower.
3. Check the motor shaft center hole for chips, dirt, or other residue and clean as required.
4. Apply an even coat of Loctite 271 (red thread lock) to stub shaft thread.
5. Place stub shaft in motor shaft threaded hole and hand tighten.
6. Use a spanner wrench on motor shaft drive end (or alternate means of locking motor shaft), tighten
the stub shaft to 20 lb-ft.
7. Use a dial indicator with .0005” graduations, indicate the stub shaft to within .002” T.I.R., except for
Inland tachometers. Inland tachometer stub shafts must indicate to within .001” T.I.R.
8. Mount feedback device per manufacturer's instructions.
Stub Shaft Removal
1. Turn off and lock out power to the motor.
2. Remove in-line blower motor and cover assembly by removing the Hex head cap screws on cover (if
enclosure is TEAO-Blower cooled).
3. After removal of blower assembly, motor shaft will need to be locked from turning. The use of a
spanner wrench on motor drive shaft or alternate means can be used. Place an open-end wrench on
stub shaft flats and turn counter clockwise (right-hand) threads).
4. Replace blower motor and cover assembly (if TEAO - blower cooled) with the correct extended
blower cover, using the hex head cap screws previously removed.
Mounting Location
All RPM AC motors are designed to be mounted by the “Mounting Feet”.
Use appropriate hardware (not furnished).
The motor should be installed in a location compatible with the motor enclosure and specific ambient.
Allow adequate air flow clearance between the motor and any obstruction. Locate the machine where the
ambient temperature is not over 40°C or 104°F unless otherwise marked on the nameplate and where
clean air has free access to ventilating intake and outlet openings. Except for machines with a suitable
protective enclosure, the location should be clean and dry.
Note: The cooling system on (Non-Finned) frame RPM AC drip proof guarded force ventilated and totally
enclosed, blower cooled motors requires clean air to be forced through ducts which are integral to
the frame. It is important that these air passages be kept clean and that sufficient clearance be
provided on the blower motor air inlets and outlets for unrestricted flow of air.
For Drip-Proof Force Ventilated Enclosures sufficient clearance must be provided on all inlet and
outlet openings to provide for unrestricted flow of air. Separately ventilated motors with exhaust to
ambient (pipe-in only) must have at least 6 inches of clearance between the opening and adjacent
walls or floor.
2-2 Installation & Operation
MN406
The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may
cause vibration, misalignment and bearing damage. All hold down bolts must be the correct grade for the
type of mounting and must be torqued to their recommended value.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
When installation is complete and accurate alignment of the motor and load is accomplished, the base
should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor District Office for further information.
Belted Drive
Motor slide bases or rails, when used, must be securely anchored to the foundation with the proper bolts.
Note: The motor shaft and the load shaft must be parallel and the sheaves aligned.
Coupled Drive
Standard RPM AC Motors will operate successfully mounted on the floor, wall or ceiling, and with the
shaft at any angle from horizontal to vertical. Special mountings may have duty or thrust demands that
may require a different bearing system.
Accurate alignment of the motor with the driven equipment is extremely important.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for
more information. Mechanical vibration and roughness during operation may indicate poor alignment.
Use dial indicators to check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
Note: Roller bearing motors are not suitable for coupled duty applications.
2. End‐Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The motor
bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause
failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1.
Caution:
Do not over tension belts. Over tension of the V-Belts may result in damage to the motor or
driven equipment. Unless otherwise indicated, V-belt load must not exceed values given in Table
2-1 .
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End‐Play Adjustment). Belt
tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage
may occur during starting.
Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet into the
foundation. This will maintain the correct motor position should motor removal be required.
(BaldorReliance motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment.
Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure.
Flanged nuts or bolts may be used as an alternative to washers.
Alignment
MN406
Installation & Operation 2-3
Guarding
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key
ways or set screws. Some satisfactory methods of guarding are:
1. Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate
guarding during normal service.
Electrical Installation
Bypass Mode
All RPM AC motors are inverter duty motors using optimum pole design. They are not intended to be
used in bypass mode (across the line). Consult your Baldor District Office to determine suitability of motor
for specific applications in bypass mode. Permanent magnet motors cannot be run in bypass mode.
WARNING:
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING:
The Adjustable Speed Controller may apply hazardous voltages to the motor leads after power to
the controller has been turned off. Verify that the controller is incapable of delivering hazardous
voltages and that the voltage at the motor leads is zero before proceeding. Failure to observe this
precaution may result in severe bodily injury or death.
Caution:
Use only a shielded motor power cable with a complete circumferential braided or copper
film/tape ground jacket around the power leads. This ground should be secured to the motor
frame from within the motor terminal box and must return without interruption to the drive ground.
In addition, if the motor and coupled equipment are not on a single common metal baseplate, it is
important to equalize the equipment ground potentials by bonding the motor frame to the coupled
equipment using a high frequency conductor such as a braided strap.
1. Single Voltage/Three Lead Motors
Connect leads marked U/T1, V/T2 and W/T3 to the appropriate control output terminals (refer to the
Controller Instruction Manual). See Figure 2‐1.
2. Dual Voltage Motors
Be sure the motor leads are connected properly for “Low” or “High” voltage connection, see Figure
2‐1. Connect leads marked U/T1, V/T2 and W/T3 to the appropriate control output terminals (refer to
the Controller Instruction Manual).
Figure 2‐1 Connection Diagram
Connection Diagram 422927-1
3 Phase Dual Voltage
Low Voltage
High Voltage
P1
P1
Thermo‐
P2
P2
T'Stat
stat
U/T1
U/T1
L1
L1
T7
V/T2
L2
V/T2
L3
W/T3
L2
T8
T4
W/T3
T7
L3
T9
T5
T4
T8
T5
T6
T6
T9
H1
H2
Space Heater
RTD or Thermistor
see Figure 2‐3.
3 Phase Single Voltage
P1
P2
T'Stat
U/T1
L1
V/T2
L2
W/T3
L3
2-4 Installation & Operation
MN406
Leads P1 & P2 are thermostat leads. They are to be connected in series with the holding coil of the motor
controller, which uses a manual momentary start switch.
Thermostat Leads Connection
As a standard feature, RPM AC motors have three (3) normally closed thermostats (one per phase)
connected in series, with leads P1 and P2 terminated in the main conduit box.
To protect against motor overheating, thermostats must be connected to the appropriate controller circuit
(function loss). Failure to connect the thermostats will void the motor warranty. Follow the controller
instruction manual for correct thermostat lead connections.
Blower Motor Connection Three phase blower motors.
RPM AC motors which are blower cooled incorporate an independently powered three phase AC blower
motor to assure continuous cooling air flow regardless of RPM AC motor speed.
The specific RPM AC blower motor depends on frame size and enclosure, see Figures 2‐1 and 2‐2.
Figure 2‐2 Blower Motor Connections
* GND is ground lead normally connects
to ground lug in blower terminal box.
U1=
U2=
V1=
V2=
W1=
W2=
GND=
Black
Green
Blue
White
Brown
Yellow
Green/Yellow*
(Delta)
T6 T4 T5
T1 T2 T3
L1 L2 L3
Low Volts
(Star)
T6 T4 T5
T1 T2 T3
L1 L2 L3
High Volts
(Delta)
(Star)
W2 U2 V2
W2 U2 V2
U1 V1 W1
U1 V1 W1
L1 L2 L3
L1 L2 L3
Low Volts
High Volts
1. Connect the blower leads as shown in the connection diagram supplied with the blower motor, see
Figure 2‐2
2. Connect for low or high voltage as shown in Figure 2‐1.
Grounding In the USA consult the National Electrical Code (NEC), Article 430 for information on grounding of motors
and generators, and Article 250 for general information on grounding. In making the ground connection,
the installer should make certain that there is a solid and permanent metallic connection between the
ground point, the motor or generator terminal housing, and the motor or generator frame.
Caution:
MN406
Motors with resilient cushion rings usually must be provided with a bonding conductor across the resilient
member. Some motors are supplied with the bonding conductor on the concealed side of the cushion ring
to protect the bond from damage. Motors with bonded cushion rings should usually be grounded at the
time of installation in accordance with the above recommendations for making ground connections. When
motors with bonded cushion rings are used in multimotor installations employing group fusing or group
protection, the bonding of the cushion ring should be checked to determine that it is adequate for the
rating of the branch circuit over current protective device being used.
There are applications where grounding the exterior parts of a motor or generator may result in greater
hazard by increasing the possibility of a person in the area simultaneously contacting ground and some
other nearby live electrical parts of other ungrounded electrical equipment. In portable equipment it is
difficult to be sure that a positive ground connection is maintained as the equipment is moved, and
providing a grounding conductor may lead to a false sense of security.
Select a motor starter and over current protection suitable for this motor and its application. Consult motor
starter application data as well as the National Electric Code and/or other applicable local codes.
Use only a shielded motor power cable with a complete circumferential braided or copper
film/tape ground jacket around the power leads. This ground should be secured to the motor
frame from within the motor terminal box and must return without interruption to the drive ground.
In addition, if the motor and coupled equipment are not on a single common metal baseplate, it is
important to equalize the equipment ground potentials by bonding the motor frame to the coupled
equipment using a high frequency conductor such as a braided strap.
Due to the high switching frequencies of inverter controls, the ground connection/path must be low
impedance, not only low resistance. The NEC grounding instructions are intended to protect from low
frequency, high current considerations and are not adequate for grounding of high frequency circuits.
RPM AC induction motors are designed to operate with a high frequency adjustable speed drive. To
avoid damage to the motor and driven equipment due to bearing currents, the motor must be grounded
and bonded properly. A low impedance ground conductor should be used to ground all RPM AC motors.
Failure to ground the motor properly for high frequency transients (1MHz to 10MHz) may result in electric
discharge damage to the motor bearings and/or the driven equipment.
Installation & Operation 2-5
The drive manufacturer should specify a shielded motor power cable that includes a complete
circumferential braided or copper film/tape ground. This ground should be secured to the motor frame
from within the motor terminal box and must return without interruption to the drive ground. In addition, if
the motor and coupled equipment are not on a single common metal baseplate, it is important to equalize
the equipment ground potentials by bonding the motor frame to the coupled equipment using a high
frequency conductor such as a braided strap.
Shipping Blocks
Motors supplied with roller bearings at the drive end are shipped with wooden blocking to prevent axial
movement of the shaft during shipment. Remove the blocking and bolts securing it and discard. Make
sure motor shafts turn freely. If motor is to be reshipped, blocking of bearing is required.
Encoder Connections
Due to the wide variety of brands and types of feedback devices provided for RPM AC motors, please
consult the encoder installation and instruction diagrams provided with the device.
Drain Plugs
If motor is totally enclosed it is recommended that condensation drain plugs be removed. These are
located in the lower portion of the end-shields or bottom of frame on each end for FL180 frame.
Totally enclosed “XT” motors have automatic drains which should be left in place as received.
Drive
RPM AC motors FL180 thru FL/RL250 are supplied with a shaft suitable for a belt or coupled drive.
Belt loads should be verified with maximum allowable radial loads, see “Shaft Loads”.
Proper alignment is critical for long life of bearings, shafts and belts, and minimum downtime.
Misalignment can cause excessive vibration and damaging forces on shaft and bearings. For direct
coupled drives, flexible couplings facilitate alignment. For belt drives, the sheave must be placed as close
as possible to the motor bracket.
Minimum V-Belt Sheave Diameters
Application of Pulleys, Sheaves, Sprockets and Gears on Motor Shafts. To avoid excessive bearing loads
and shaft stresses, belts should not be tightened more than necessary to transmit the rated torque.
The pretension of the V-belt drive should be based on the total tightening force required to transmit the
horsepower divided by the number of belts. This procedure avoids the excessive load caused by
tightening individual belts to a prescribed level recommended by belt manufacturers.
Mounting
In general, the closer pulleys, sheaves, sprockets or gears are mounted to the bearing on the motor shaft,
the less will be the load on the bearing. This will give greater assurance of trouble-free service.
The center point of the belt, or system of V-belts, must not be beyond the end of the motor shaft.
The inner edge of the sheave or pulley rim should not be closer to the bearing than the shoulder on the
shaft but should be as close to this point as possible. The outer edge of a chain sprocket or gear must not
extend beyond the end of the standard motor shaft.
Shaft Extension and Method of Drive
RPM AC frames FL180 - FL/RL250 are supplied with a shaft and bearing system suitable for either
coupled or belted drives. Belt loads should be verified with maximum allowable radial loads, see “Shaft
Loads”. Frames L/FL/RL280-L440 are supplied with larger shafts and roller bearings when belted drives
are specified.
2-6 Installation & Operation
MN406
Caution:
Shaft Loads - Axial and Radial
RPM AC motors are suitable for limited shaft loads as shown in Tables 2-1 and 2-2 .
Recommended maximum thrust loads depend on the mounting position, either horizontal or vertical.
For recommendations for loads in excess of those shown, for higher speeds and special shaft extensions
contact your local Baldor District office.
Use of these radial load capacities requires the accurate calculation of the radial load. Radial
loads for gears, sprockets, and flywheel are usually accurately determined but the radial loads
due to V-belt drives are subject to miscalculations because they do not include all of the
pre-tension load (belt tightening). The calculations of the radial load for a V-belt drive must
include the pre-tension for transmitting the horsepower, pretension for centrifugal force on the
belts, pre-tension for high start torques, rapid acceleration or deceleration, pre-tension for drives
with short act-of-contact between the V-belt and sheave, and low coefficient of friction between
belt and sheave caused by moisture, oil or dust. Over tension of the V-Belts may result in damage
to the motor or driven equipment. Unless otherwise indicated, V-belt load must not exceed
values given in Table 2-1 .
Table 2-1 Radial Load Capacity- No Axial Load
Frame
FL180
FL/RL210
FL/RL250
L280
UL, UFL, URL280
L320
UL320
L360
UL360
L400
UL400
L440
UL440
2500 RPM
445
875
1375
1000
2400
1300
2850
1800
4550
1700
3625
2100
4650
Radial Load Capacities at the End of the Shaft in Lbs.
1750 RPM
1150 RPM
445
445
875
875
1525
1525
1175
1175
2500
2500
1475
1475
2850
2850
2050
2300
4550
4550
1950
2250
4090
4700
2400
2800
4650
4650
850 RPM
445
875
1525
1175
2500
1475
2850
2550
4550
2500
5190
3150
4650
Data for motors with roller bearings at the drive end (back end).
Motors with ball bearings at the drive end are for coupled duty only.
MN406
Installation & Operation 2-7
Table 2--2 Axial Thrust Capacity in Pounds -- for Minimum L--10 Bearing Life
of 10,000 Hrs. With No External Overhung Load
Horizontal Mounting
Vertical Mounting Thrust Down ¡
Vertical Mounting Thrust Up ¡
Frame
FL180
FL/RL210
FL/RL250
L,FL/RL280
L320
L360
L400
L440
2500RPM
1750RPM
1150RPM 850RPM 2500RPM
1750RPM
1150RPM 850RPM 2500RPM
1750RPM
1150RPM 850RPM
430
775
1160
590
705
875
1350
1300
480
880
1310
700
835
1075
1630
1550
480
1015
1520
850
1020
1350
2000
1800
455
805
1205
515
540
570
1110
345
555
905
1410
665
730
850
1500
610
470
970
1465
940
1145
1370
2305
2645
570
1070
1670
1090
1335
1650
2695
2910
480
1125
1680
975
1170
1525
2250
2050
385
705
1050
405
405
380
760
110
630
1005
1580
795
885
1025
1765
825
445
870
1310
830
1010
1180
1955
2410
645
1170
1840
1225
1490
1825
2960
3125
¡ Thrust capacity for vertical mounting includes a constant whose value is plus or minus depending on the direction of the
thrust load. The constant is plus for thrust loads acting upward against the force of gravity and minus for loads acting downward
with gravity.
Optional Accessories
Figure 2-3 Accessory Connections
One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).
Three thermistors are installed in windings.
Leads are labeled TD1--TD6 for shutdown and TD7--TD12 for warning.
RTD CONNECTIONS
One Per Phase
Leads
Phase1Phase2Phase3
Red(or Marked) 1TD1 2TD1 3TD1
White
1TD2 2TD2 3TD2
White
1TD3 2TD3 3TD3
Two Per Phase
Phase1
Phase2
Phase3
Leads
#4
#1
#5
#6
#2
#3
Red(or Marked) 1TD1 2TD1 3TD1 4TD1 5TD1 6TD1
1TD2 2TD2 3TD2 4TD2 5TD2 6TD2
White
1TD3 2TD3 3TD3 4TD3 5TD3 6TD3
White
418057--549
* One bearing RTD is installed in Drive endplate (PUEP), leads are labeled RTDDE.
* One bearing RTD is installed in Opposite Drive endplate (FREP), leads labeled RTDODE.
* Note RTD may have 2--Red/1--White leads; or 2--White/1--Red Lead.
2--8 Installation & Operation
MN406
WARNING:
Incorrect motor rotation direction can cause serious or fatal injury or equipment damage. Be sure
to verify motor rotation direction before coupling the load to the motor shaft.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Caution:
Do not operate motors with a roller bearing unless a radial load is applied so that damage to the
roller bearing does not occur.
First Time Start Up
1. Be sure that all power to motor and accessories is off.
2. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the
motor shaft.
3. Remove all unused shaft keys and loose rotating parts to prevent them from flying off.
4. Verify the mechanical installation is secure. All bolts and nuts are tightened etc., covers and protective
devices are securely in their places.
5. If motor has been in storage or idle for some time, check winding insulation integrity.
6. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical
continuity.
7. Be sure all shipping materials and braces (if used) are removed from motor shaft.
8. Manually rotate the motor shaft to ensure that it rotates freely.
9. Replace all panels and covers that were removed during installation.
10. Momentarily apply power and check the direction of rotation of the motor shaft. If motor rotation is
wrong be sure power is off and change the motor lead connections as follows:.
RPM AC motors are designed to be capable of bi-directional shaft rotation. When voltages in an
A-B-C phase sequence are applied to leads U/T1, V/T2, W/T3 clockwise shaft rotation facing the
opposite drive end will result. If shaft rotation is incorrect, change the direction of rotation as follows:
a. Turn off and lockout all power to the motor and verify that the voltage at the motor leads is zero.
b. Reverse any two of three motor power leads.
c. Restore power.
11. Start the motor and ensure rotation is correct and operation is smooth without excessive vibration or
noise. If so, run the motor for 1 hour with no load connected.
12. Momentarily apply power and check the direction of air flow is in agreement with the “direction of air
flow” arrows mounted on the motor. If directional flow is incorrect be sure power is off and interchange
power leads to T1 and T2 or U1 and V1, Figure 2‐2.
13. After 1 hour of operation, disconnect power and connect the load to the motor shaft.
Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.
14. If motor is totally enclosed fan-cooled or non-ventilated it is recommended that condensation drain
plugs, if present, be removed. These are located in the lower portion of the end-shields.
Totally enclosed fan-cooled “XT” motors are normally equipped with automatic drains which may be
left in place as received.
While operating the motor, observe the performance. It should run smoothly with little noise. The bearings
should not overheat and should reach a leveling off temperature. Any undue noise, overheating, or erratic
performance should be investigated and necessary corrective action taken immediately to prevent serious
dam age. Please contact your Baldor District office.
All RPM AC motors are lubricated before shipment and will operate for a long period before regreasing is
required. The period will vary depending on environmental and service conditions.
Refer to Maintenance section.
Balance
Motors are dynamically balanced to commercial limits unless ordered differently. Balance is done with a
full length 1/2 height shaft key. A full shaft key is shipped with motor. Sheave or coupling should be
balanced with a V2 height shaft key.
Table 2-3 Standard Dynamic Balance Limits
Max. Amplitude in Inches
Highest Rated Speed RPM
3.000 - 4,000
0.0010
1,500 - 2,999
0.0015
1,000 - 1,499
0.0020
Up to 999
0.0025
MN406
Installation & Operation 2-9
WARNING:
WARNING:
WARNING:
WARNING:
Caution:
Caution:
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
Incorrect motor rotation direction can cause serious or fatal injury or equipment damage. Be sure
to verify motor rotation direction before coupling the load to the motor shaft.
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Do not operate motors with a roller bearing unless a radial load is applied so that damage to the
roller bearing does not occur.
RPM AC permanent magnet motors with an open enclosure, such as DP-FV, should not be used
where ferrous dust or particles may may be present . Totally enclosed permanent magnet motors
are recommended for these applications.
Operation
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
During operation observe the motors' performance. It should run smoothly with little noise. The bearings
should not overheat and should reach a normal operating temperature. Any undue noise, overheating, or
erratic performance should be investigated and corrective action taken immediately to prevent serious
damage.
All RPM AC motors are lubricated before shipment and will operate for a long period before regreasing is
required. The period will vary depending on environmental and service conditions.
Refer to Maintenance section of this manual.
Balance
Motors are dynamically balanced to meet the dynamic balance limits of NEMA MG1 Part 7 second for
peak value of the unfiltered velocity in inches per second unless ordered differently. Balance is done with
a full length 1/2 height shaft key. A full shaft key is shipped with motor. Sheave or coupling should be
balanced with a 1/2 height shaft key. Std. Dynamic Balance Limits
Table 2-4 Dynamic Balance
RPM
0-1200
1201-1800
1801-3600
3601-5000
5001-8000
2-10 Installation & Operation
FL180-L440
Velocity (in/sec) Peak
Per NEMA standard
0.15
0.15
0.2
0.2
MN406
Section 3
Maintenance & Troubleshooting
WARNING:
UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING:
Pacemaker danger - Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING:
RPM AC permanent magnet motors can induce voltage and current in the motor leads by rotating
the motor shaft. Electrical shock can cause serious or fatal injury. Therefore, do not couple the
load to the motor shaft until all motor connections have been made. During any maintenance
inspections, be sure the motor shaft will not rotate.
WARNING:
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING:
The Adjustable Speed Controller may apply hazardous voltages to the motor leads after power to
the controller has been turned off. Verify that the controller is incapable of delivering hazardous
voltages and that the voltage at the motor leads is zero before proceeding. Failure to observe this
precaution may result in severe bodily injury or death.
WARNING:
Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot
surfaces. Failure to observe this precaution could result in bodily injury.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3
months, whichever occurs first. Keep the motor clean and the ventilation openings clear.
The following steps should be performed at each inspection:
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease,
water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation.
If the motor is not properly ventilated, overheating can occur and cause early motor failure.
2. Perform a dielectric with stand test periodically to ensure that the integrity of the winding insulation
has been maintained. Record the readings. Immediately investigate any significant decrease in
insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly.
The lubricating ability of a grease (over time) depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the severity of the operating conditions.
Good results can be obtained if the following recommendations are used in your maintenance program.
Relubrication with the shaft stationary and a warm motor is recommended.
Lubrication Procedure
WARNING:
MN406
Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
1. Relubrication with the shaft stationary and a warm motor is recommended. If lubrication must be
done with motor running, stay clear of rotating parts and electrical circuits.
2. Wipe all dirt from the outside of the grease fills and drains.
3. Locate the grease inlet at the top of the bearing hub, clean the area and replace the 1/8-inch pipe
plug with a grease fitting if the motor is not equipped with grease fitting.
4. Remove grease drain plug located opposite the grease inlet.
5. Using a manual grease gun, pump in the recommended grease in the amount shown. This amount
of grease will provide an ample supply of lubricant between lubrication periods for the service
condition listed in Table 3‐5, Table 3‐6 and Table 3‐7. Use only clean, fresh grease from clean
containers and handle so as to keep it clean. In general, mixing of greases is not recommended.
If an incompatible grease is used, the lube system must be repacked completely with the new
grease.
6. Wipe away any excess grease at the grease drain or relief and replace drain plugs.
Maintenance & Troubleshooting 3-1
Type of Grease
See the motor nameplate for replacement grease or oil recommendation.
Use Exxon Polyrex EM or equivalent grease unless motor nameplate specifies special grease.
Amount of grease to be added to RPM AC motors. See Table 3‐7 for relubrication interval.
Table 3‐5 Relubrication Amount
Volume
Weight
Frame Size
in3
cm3
oz
g
L, FL, RL280
1.0
16
0.5
14
L320 - L400
2.0
32
1.0
28
L440
3.0
48
1.5
42
Note: FL/RL180, FL/RL210 and FL/RL250 have maintenance free non regreasable double shielded ball
bearings as standard. The 280-440 frames have open ball bearings, with inner caps as part of
PLS System.
Determine service condition on the basis of the most severe operating parameter; that is temperature,
bearing load, atmosphere, or operating hours per day.
Table 3‐6 Service Condition
Service Condition
Standard
Ambient
-18 °C to 40°C
(0°F to 104°F)
Use/Day
Atmosphere
8
Clean
Severe
-30 °C to 50°C
(-22 °F to 122°F)
8 to 24
Extreme
-54 °C to 65°C
(-65 °F to 149°F)
8 to 24
Medium Dirt,
Abrasives,
Corrosion
Heavy Dirt,
Abrasives,
Corrosion
Bearing Load
Steady
Medium Shock, Vibration
(less than .2 in/sec.)
Heavy Shock, Vibration
(more than .44 in/sec)
- Motors must be specially designed for operation in ambient in this range. Special grease is required.
Table 3‐7 Relubrication Periods For RPM AC Motors - Frames L, FL/RL280 - L440
Maximum Normal
Operating Speed RPM 3450 and higher
2400 thru 3449
1700 thru 2399
800 thru 1699
500 thru 799
499 and lower
Frame
All
L, RL/FL280 thru L440
L, RL/FL280 thru L320
L360 thru L440
UL360 thru UL440
L, FL/RL280 thru L320
L360 thru L440
UL360 thru UL440
L, FL/RL280 thru L320
L360 thru L440
UL360 thru UL440
L, FL/RL280 thru L440
UL360 thru UL440
Relubrication Interval in Months Standard Service
Severe Service
Extreme Service
9
4
1
9
3
1
36
12
3
18
6
2
9
3
1
36
24
8
36
12
3
9
6
1
48
36
12
36
24
8
18
12
4
48
36
12
24
18
6
- Maximum speed occurs more than 30%of operating time.
- For Tandem drives increase frequency of lubrication by multiplying values by 0.8
3-2 Maintenance & Troubleshooting
MN406
Table 3‐8 Troubleshooting Chart
Symptom
Motor will not start
Excessive humming
Motor Over Heating
Possible Causes
Usually caused by line trouble, such
as, single phasing at the starter.
High Voltage.
Eccentric air gap.
Overload. Compare actual amps
(measured) with nameplate rating.
Single Phasing.
Improper ventilation.
Unbalanced voltage.
Rotor rubbing on stator.
Over voltage or under voltage.
Open stator winding.
Grounded winding.
Improper connections.
Bearing Over Heating
Misalignment.
Excessive belt tension.
Excessive end thrust.
Excessive grease in bearing.
Insufficient grease in bearing.
Dirt in bearing.
Vibration
Misalignment.
Rubbing between rotating parts and
stationary parts.
Rotor out of balance.
Resonance.
Noise
Growling or whining
MN406
Foreign material in air gap or
ventilation openings.
Bad bearing.
Possible Solutions
Check source of power. Check overloads, fuses,
controls, etc.
Check input line connections.
Have motor serviced at local Baldor service center.
Locate and remove source of excessive friction in
motor or load.
Reduce load or replace with motor of greater capacity.
Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build‐up on motor. Clean motor.
Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Check air gap clearance and bearings.
Tighten “Thru Bolts”.
Check input voltage at each phase to motor.
Check stator resistance at all three phases for
balance.
Perform dielectric test and repair as required.
Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Check and align motor and driven equipment.
Reduce belt tension to proper point for load.
Reduce the end thrust from driven machine.
Remove grease until cavity is approximately 3/4 filled.
Add grease until cavity is approximately 3/4 filled.
Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Check and align motor and driven equipment.
Isolate and eliminate cause of rubbing.
Have rotor balance checked are repaired at your
Baldor Service Center.
Tune system or contact your Baldor Service Center
for assistance.
Remove rotor and foreign material. Reinstall rotor.
Check insulation integrity. Clean ventilation openings.
Replace bearing. Clean all grease from cavity and
new bearing. Repack with correct grease until cavity
is approximately 3/4 filled.
Maintenance & Troubleshooting 3-3
Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY
Most large frame AC BaldorReliance motors with a 1.15 service factor are designed to operate below a
Class B (80°C) temperature rise at rated load and are built with a Class H winding insulation system.
Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise
should be used as a starting point. Some motors with 1.0 service factor have Class F temperature rise.
The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding
RTD alarm and trip settings should be selected based on these tables unless otherwise specified for
specific applications.
If the driven load is found to operate well below the initial temperature settings under normal conditions,
the alarm and trip settings may be reduced so that an abnormal machine load will be identified.
The temperature limits are based on the installation of the winding RTDs imbedded in the winding as
specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball
or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs - Temperature Limit In 5C (405C Maximum Ambient)
Motor Load
3 Rated Load
Rated Load
to 1.15 S.F.
Class B Temp Rise 3 80°C
(Typical Design)
Alarm
Trip
130
140
140
150
Class F Temp Rise 3 105°C
Alarm
155
160
Trip
165
165
Class H Temp Rise 3 125°C
Alarm
175
180
Trip
185
185
Note: Winding RTDs are factory production installed, not from Mod-Express.
When Class H temperatures are used, consider bearing temperatures and relubrication requirements.
Bearing RTDs - Temperature Limit In 5C (405C Maximum Ambient)
Bearing Type
Grease
Standard
Anti-Friction
Alarm
100
Trip
110
Axial Float
RPM AC motors have a wave spring washer between the drive end bracket and bearing. The opposite
drive end bearing is positioned axially by a float restricting inner cap. Axial float (including bearing
internal clearance) should be within the following limits:
Axial Float -In./Min.
Frame Size
FL180 thru L440
Maximum
In.
mm.
.051
1.29
Minimum
In.
mm.
.013
.33
The L440 frame wavy spring is located on the opposite drive end.
3-4 Maintenance & Troubleshooting
MN406
Figure 3‐4 Cross Section View of Totally Enclosed Blower Cooled Motor
Conduit Box
Blower
Motor
Blower Motor
Conduit Box
Grease Fitting
Ball Bearing
Eye Bolt
BE Bracket
Feedback
Connector
Grease Fitting
Frame/Stator
Rotor
Ball
Bearing
Key
Optional Feedback
Device
Motor
Shaft
Blower Grill
FE Bracket
MN406
Blower Cover
Inner Cap
Inner Cap
Maintenance & Troubleshooting 3-5
3-6 Maintenance & Troubleshooting
MN406
Baldor District Offices Baldor District Offices Baldor District Offices
BALDOR ELECTRIC COMPANY
World Headquarters
P.O. Box 2400 Fort Smith, AR 72901-2400
(479) 646-4711 Fax (479) 648-5792
www.baldor.com
© 2008 Baldor Electric Company
MN406
All rights reserved. Printed in USA
9/08
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 12.0
Motor Housing Assembly Procedure
(TDS-9SA/TDS-11SA)
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FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 13.0
Installation Procedure for TDS
Motor Hub & Pinion Gear
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Installation Procedure for
TDS Motor Brake Hub and TDS/ADS
Pinion Gear
REFERENCE
REFERENCE DESCRIPTION
This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or
distribution of this information to others is not permitted without the
express written consent of National Oilwell Varco. This document is
to be returned to National Oilwell Varco upon request and in any
event upon completion of the use for which it was loaned.
 National Oilwell Varco
www.nov.com
National Oilwell Varco
Rig Solution Group
743 N Eckhoff Street
Orange, CA 92868
Phone + 714 978 1900
Fax + 714 937 5029
DOCUMENT NUMBER
REV
3ASP00073
C
Document number
Revision
Page
3ASP00073
C
2
REVISION HISTORY
C
B
Rev
8/2/11
SEE EN
8/2/11
SEE EN
11/10/09
First Release
Date
Reason for issue
(dd.mm.yyyy)
C Silva
L Rondou
L Rondou
Prepared
T Gormsen T Gormsen
T Gormsen T Gormsen
T Gormsen T Gormsen
Checked Approved
CHANGE DESCRIPTION
Revision
A
B
C
Change Description
First Issue
Where changes have been made in old requirements, a vertical line appears in the margin of the
paragraph affected as shown. New requirements are also shown in this manner.
Where changes have been made in old requirements, a vertical line appears in the margin of the
paragraph affected as shown. New requirements are also shown in this manner.
Removed the statement <and rotate back and forth ¼ to ½ turn three to four times> section 1.5
page 5
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3
The following procedure is designed as a generic procedure for installation of pinion gears and brake hubs
to various TDS/ADS motor styles. The pictorial shows a TDS-11. The other motors may have different
looking fixtures, but the process is the same.
The pictorial can be used as a reference for any style motor.
1
INSTALLATION OF PINION GEAR.
1.1
Measure shaft run out and record actual on The Quality Record 3ASP00073QR1 for the pinion end.
This is for reference only. Total run out after assembly is .005” max. Any measurement that is
approaching .005” should be evaluated prior to assembly.
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1.2
Lightly clean up the shaft using WD-40 and 320 grit sandpaper.
1.3
Clean shaft and internals of pinion gear thoroughly with acetone and lint free wipes.
1.4
Apply Dykem Hispot blue to shaft
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5
1.5
Carefully install pinion gear onto shaft. Pull the gear out approximately one inch and firmly push onto
shaft. The gear and shaft should have a snug fit and not be able to be pulled apart by hand.
1.6
Remove pinion gear from shaft using gear jacks. Tighten jacks against gear alternately
approximately 1/16 to 1/8 turn until gear loosens.
Caution: The gear has a tendency to pop off suddenly. Make sure that the area in front of the
gear is clear and there is a protective mat (i.e. wood, nylon, rubber, etc.) for the gear to land
on. Keep clear of the landing area to prevent personnel injury
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6
Jacks for Gear
removal.
Caution: Use safety
precautions when removing
the gear to avoid injury.
1.7
Inspect pinion gear internal area for a minimum of 85% transfer. Sign off Quality Record
3ASP00073QR1 upon verification of proper fit. If 85% coverage cannot be verified, stop assembly
and evaluate the shaft and gear to determine the cause. Reject discrepant part and obtain
replacement.
Verify minimum
of 85% coverage
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7
1.8
Clean off all Dykem from shaft and pinion gear using acetone and lint free wipes.
1.9
Install gear back onto shaft and lightly pop into place. Measure depth of shaft from the gear face and
record actual on Quality Record 3ASP00073QR1 under the PRE-SHRUNK column.
1.10 Install the installation set fixture onto the pinion gear. Install the dial indicator and lock in place with
set screw. Assure the indicator is set to approximately midrange of its full travel. Bottom the
adjustable screw on the fixture onto the shaft and lock screw in place with its lock nut.
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Bottom
adjustable screw
Lock in place
with lock nut
1.11 Assure the dial indicator is in contact with the adjustable screw, reset if necessary. Zero out the dial
indicator. Loosen the lock nut on the adjustable screw and back off from the shaft to the Initial Gear
Offset dimensional requirement of Table 1 below. Lock the adjustable screw in place and verify the
offset reading has not changed. Readjust if needed.
Adjust to Table 1 offset
requirements for Motor
style being worked on and
lock in place
Caution: Do not use depth
mikes for this measurement
Dial indicator designed for
fixture must be used to
assure proper
measurements
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Motor Style
Initial Gear Offset
Dimension
Final Requirement
after cool down
TDS 9,10 & 11
.062
.068 ± .005
TDS 3,4 & 8
.080
.080 ± .005
TDX-1000
TDX-1250
.080
.085 + .005
Per Specific Motor
Drawing
Table 1
Per Specific Motor
Drawing
ADS
3ASP00073
C
9
1.12 Remove the dial indicator from the fixture. Remove the fixture from the pinion gear.
1.13 Remove pinion gear from shaft using gear jacks. Tighten jacks against gear alternately
approximately 1/16 to 1/8 turn until gear loosens.
Caution: The gear has a tendency to pop off suddenly. Make sure that the area in front of the
gear is clear and there is a protective mat (i.e. wood, nylon, rubber, etc.) for the gear to land
on. Keep clear of the landing area to prevent personnel injury
Caution: Use safety
precautions when removing
the gear to avoid injury.
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10
1.14 Coat the Inside diameter of the pinion gear with a thin coat of Nalco RC. Allow to dry and wipe off
excess.
1.15 Lightly clean up the shaft using WD-40 and 320 grit sandpaper.
1.16 Clean shaft thoroughly with acetone and lint free wipes.
1.17 Coat the outside diameter of the shaft with a thin coat of Nalco RC. Allow to dry and wipe off excess.
1.18 Set the Eddy-Therm heater to 380 degrees Fahrenheit.
1.19 Install pinion gear onto Eddy-Therm and attach temperature probe.
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1.20 Turn on Eddy-Therm and allow to heat up to approximately 200 degrees Fahrenheit. At this point
rotate the gear 180 degrees and continue heating to 380 degrees Fahrenheit. This will help assure
an even heat across the gear.
Caution: Use proper heat
resistant gloves when handling
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12
When the temperature reaches 380 degrees Fahrenheit, check the temperature of both ends of the
gear to assure that it is evenly heated. If necessary, rotate the gear and continue heating until the
gear is evenly heated.
Caution: Use proper heat resistant gloves when handling the gear.
Note: The following steps should be performed as quickly as possible to assure the gear
does not cool excessively prior to installation.
1.21 Remove the pinion gear from the Eddy-Therm and install the set fixture onto the gear.
Caution: Use proper heat
resistant gloves when handling
1.22 Install the gear and fixture onto the shaft swiftly pushing into place until the fixture’s adjustable screw
contacts the shaft.
Assure button
comes into
contact with shaft
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1.23 Remove the set fixture from the assembly. Allow the assembly to cool to room temperature and
measure the offset of the gear and shaft. Record the dimension on the POST SHRUNK column of
the Quality Record 3ASP00073QR1 .
Note: If the shaft is below the gear face, the Post-Shrunk dimension should be subtracted
from the Pre-Shrunk dimension. If the shaft is above the gear face, the dimensions should
be added.
1.24 Record the installed dimension as calculated in the above note. The dimension should meet the
requirements of Table 1 for the Motor style being worked on. If the dimension is out of tolerance, the
assembly must be disassembled and the parts evaluated for conformance to print. Reject and
replace any non conforming parts.
1.25 If the motor style is a TDS 10 or TDS 4 with a straight cut gear, measure run out and record on the
Quality Record 3ASP00073QR1 .
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2.
INSTALLATION OF BRAKE HUB (TDS ONLY).
2.1
Measure shaft runout and record actual on Quality Record 3ASP00073QR1 for the brake end. This
is for reference only. Total run out after assembly is .005” max. Any measurement that is
approaching .005” should be evaluated prior to assembly.
2.2
Lightly clean up the shaft using WD-40 and 320 grit sandpaper.
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15
2.3
Clean shaft and internals of brake hub thoroughly with acetone and lint free wipes.
2.4
Apply Dykem Hispot blue to shaft.
2.5
Carefully install brake hub onto shaft and rotate back and forth ¼ to ½ turn three to four times. Pull
the hub out approximately one inch and firmly push onto shaft. The hub and shaft should have a
snug fit and not be able to be pulled apart by hand.
2.6
Remove brake hub from shaft using gear jacks. Tighten jacks against hub alternately approximately
1/16 to 1/8 turn until hub loosens.
Caution: The hub has a tendency to pop off suddenly. Make sure that the area in front of the
hub is clear and there is a protective mat (i.e. wood, nylon, rubber, etc.) for the hub to land on.
Keep clear of the landing area to prevent personnel injury
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16
Jacks for Hub
removal.
Caution: Use safety precautions
when removing the gear to
avoid injury.
2.7
Inspect brake hub internal area for a minimum of 85% transfer. Sign off Quality Record
3ASP00073QR1 upon verification of proper fit. If 85% coverage cannot be verified, stop assembly
and evaluate the shaft and gear to determine the cause. Reject discrepant part and obtain
replacement.
Verify minimum
of 85% coverage
2.8
Clean off all Dykem from shaft and brake hub using acetone and lint free wipes.
2.9
Install hub back onto shaft and lightly pop into place. Measure depth of shaft from the hub face and
record actual on Quality Record 3ASP00073QR1 under the PRE-SHRUNK column.
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2.10 Install the installation set fixture onto the brake hub. Install the dial indicator and lock in place with
set screw. Assure the indicator is set to approximately midrange of its full travel. Bottom the
adjustable screw on the fixture onto the shaft and lock screw in place with its lock nut.
Bottom
adjustable screw
Lock in place
with lock nut
2.11 Assure the dial indicator is in contact with the adjustable screw, reset if necessary. Zero out the dial
indicator. Loosen the lock nut on the adjustable screw and back off from the shaft to the to the Initial
Hub Offset dimensional requirement of Table 2 below. Lock the adjustable screw in place and verify
the offset reading has not changed. Readjust if needed.
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Adjust to Table 2 offset
requirements for Motor
style being worked on and
lock in place
Caution: Do not use depth
mikes for this measurement
Dial indicator designed for
fixture must be used to
assure proper measurements
Motor Style
TDS 9,10 & 11
TDS 3,4 & 8
TDX-1000
TDX-1250
Initial Hub Offset
Dimension
.052
.080
Final Requirement
after cool down
.054 ± .005
.085 ± .005
.080
.085 + .005
Table 2
2.12 Remove the dial indicator from the fixture. Remove the fixture from the brake hub.
2.13 Remove brake hub from shaft using gear jacks. Tighten jacks against hub alternately approximately
1/16 to 1/8 turn until hub loosens.
Caution: The hub has a tendency to pop off suddenly. Make sure that the area in front of the
hub is clear and there is a protective mat (i.e. wood, nylon, rubber, etc.) for the hub to land on.
Keep clear of the landing area to prevent personnel injury
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Caution: Use safety
precautions when removing
the gear to avoid injury.
2.14 Lightly clean up the shaft using WD-40 and 320 grit sandpaper.
2.15 Clean shaft thoroughly with acetone and lint free wipes.
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2.16 Set the Eddy-Therm heater to 380 degrees Fahrenheit.
2.17 Install brake hub onto Eddy-Therm and attach temperature probe.
Caution: Use proper heat resistant
gloves when handling
2.18 Turn on Eddy-Therm and allow to heat up to approximately 200 degrees Fahrenheit. At this point
rotate the hub 180 degrees and continue heating to 380 degrees Fahrenheit. This will help assure
an even heat across the hub.
Caution: Use proper heat resistant gloves when handling the hub
Caution: Use proper heat resistant
gloves when handling
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21
When the temperature reaches 380 degrees Fahrenheit, check the temperature of both ends of the
gear to assure that it is evenly heated. If necessary, rotate the gear and continue heating until the
gear is evenly heated.
Caution: Use proper heat resistant gloves when handling the gear.
Note: The following steps should be performed as quickly as possible to assure the gear
does not cool excessively prior to installation.
2.19 Remove the brake hub from the Eddy-Therm and install the set fixture onto the gear.
2.20 Install the gear and fixture onto the shaft swiftly pushing into place until the fixture’s adjustable screw
contacts the shaft.
Caution: Use proper heat
resistant gloves when handling
Assure button
comes into contact
with shaft
2.21 Remove the set fixture from the assembly. Allow the assembly to cool to room temperature and
measure the offset of the hub and shaft. Record the dimension on the POST SHRUNK column of
the Quality Record 3ASP00079QR1.
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22
Note: If the shaft is below the hub face, the Post-Shrunk dimension should be subtracted
from the Pre-Shrunk dimension. If the shaft is above the hub face, the dimensions should
be added.
2.22 Record the installed dimension as calculated in the above note. The dimension should meet the
requirements of Table 2 for the Motor style being worked on. If the dimension is out of tolerance, the
assembly must be disassembled and the parts evaluated for conformance to print. Reject and
replace any non conforming parts.
2.23 Measure hub run out and record actual on Quality Record 3ASP00073QR1 for the brake end.
Requirement is .005” maximum. If it exceeds.005” the assembly must be disassembled and the
parts evaluated for conformance to print. Reject and replace any non conforming parts.
www.nov.com
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 14.0
Safety Wiring Procedure
www.nov.com
PROCEDURE
THE USE OF AND APPLICATION OF
SAFETY WIRE FOR SECONDARY
RETENTION
RIG/PLANT
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
REMARKS
MAIN TAG NUMBER
DISCIPLINE
CLIENT PO NUMBER
CLIENT DOCUMENT NUMBER
Client Document Number
This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or
distribution of this information to others is not permitted without the
express written consent of National Oilwell Varco. This document is
to be returned to National Oilwell Varco upon request and in any
event upon completion of the use for which it was loaned.
 National Oilwell Varco
National Oilwell Varco
Rig Solutions
11000 Corporate Centre Dr.
Houston TX 77041 USA
Phone +1 (281) 854-0647
Fax +1 (281) 854-0508
DOCUMENT NUMBER
REV
ASP00019
A
Document number
Revision
Page
ASP00019
A
2
C. SILVA
T. GORMSEN
REVISION HISTORY
A
Rev
15/04/2011
10/03/1995
Date (dd.mm.yyyy)
SEE ECN
First Issue
Reason for issue
CHANGE DESCRIPTION
Revision
A
Change Description
First Issue
SEE ECN
KTK
Prepared
K DAW
Checked
T. GORMSEN
JES
Approved
Document number
Revision
Page
ASP00019
A
3
TABLE OF CONTENTS
1
2
3
4
5
1
SCOPE.............................................................................................................................. 3
APPLICABLE DOCUMENTS ........................................................................................... 4
REQUIREMENTS ............................................................................................................. 4
3.1
MATERIAL AND SIZE ............................................................................................ 4
3.2
GENERAL REQUIREMENTS ................................................................................. 5
3.3
LOCK-WIRING METHODS .................................................................................... 6
3.4
OTHER APPLICATIONS ........................................................................................ 7
3.5
ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8
QA PROVISIONS.............................................................................................................. 9
NOTES .............................................................................................................................. 9
SCOPE
Document number
Revision
Page
ASP00019
A
4
This procedure establishes the method for the selection and application of safety wire.
Lock wiring is the application of wire to prevent relative movement of structure or other
critical components subject to vibration, tension, torque, etc.
This procedure is intended to help eliminate the risk of dropped objects in
components or parts manufactured.
Bolts, Nuts and Screws are the common type of fasteners used on NOV
equipment. They need to be locked (secondary retention) against loss of torque / pretension.
Use of safety wire to prevent rotation of fasteners is a safe and primarily
recommended secondary retention method for fasteners. It is the most preferred
method because it not only prevents fasteners from loosening but also keeps them from
falling in case of primary retention failure (bolt head Breaks off) and effectively prevents
dropped objects.
Note that the secondary retention will work only if the primary retention method is
properly in place, i.e. bolts and screws are tightened and torqued as per specifications,
and there is no play between the mating elements. Secondary retention methods aim in
preventing any compromise in primary retention, loss of pre-tension in assembled
fasteners, loosening and backing out.
Definitions:
Secondary Retention – The means of effectively retaining a fastener/joining component
such that the operating loads do not compromise the integrity of the primary fastening
component.
2
APPLICABLE DOCUMENTS
DS00008-DES
DESIGN TORQUE STANDARDS
Machinery’s Handbook 27th Edition
3
3.1
REQUIREMENTS
MATERIAL AND SIZE
3.1.1 Material
Lock wire must be aircraft quality stainless steel 302/304 condition A.
3.1.2 Lock-wire sizes
Document number
Revision
Page
ASP00019
A
5
a. 0.5080 mm (0.020 inch) diameter
b. 0.8128 mm (0.032 inch) diameter NOV P/N Z6000.8
c. 1.1938 mm (0.047 inch) diameter NOV P/N Z6000.9
d. 1.2950 mm (0.051 inch) diameter NOV P/N Z6001
e. 3.1750 mm (0.125 inch) diameter NOV P/N Z6002
3.2
GENERAL REQUIREMENTS
3.2.1 Safety wire shall be new upon each application.
3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension
when the part tends to loosen.
3.2.3 The lockwire should always be installed and twisted so that the loop around the
head stays down and does not tend to come up over bolt head and leave a slack loop.
3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not
over stressed.
3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns
for .052 wire. More twists will over stress the wire and cause fatigue and breakage.
3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This
pigtail shall be bent back or under to prevent it from becoming a snag.
3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply:
a) No more than three (3) bolts may be tied together.
b) Bolt heads may be tied as shown only when the female thread receiver is
captive.(see figure 1)
c) Lockwire must fill a minimum of 50% of the drilled hole provided for the
use of lockwire.
d) Diameter of lockwire is determined by the thread size of the fastener to be
lockwired.
1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020
inch) wire.
2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm
(0.032 inch) wire.
3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR
1.295mm (0.051) wire.
The larger wire may be used in smaller bolts in cases of convenience, but smaller
wire must not be used in larger fastener sizes.
Document number
Revision
Page
ASP00019
A
6
Figure 1: Safety Wire / Lock Wire
3.3
LOCK-WIRING METHODS
3.3.1 The method involves threading a wire through holes in the fastener to lock it
against being rotated loose. The wire is twisted before being threaded and is locked to
next bolt. Safety wire should be placed in and around bolt head to maintain the pre-load.
The use of safety wire ties is illustrated in figure 1 above. The illustrations assume the
use of right-hand threaded fasteners.
3.3.2 The double-twist method:
The double-twist method of lock-wiring shall be used as the common method of
lock-wiring.
CAUTION: screws in closely spaced geometric which secure hydraulic or air seals, hold
hydraulic pressure, or used in critical areas of clutch mechanism should use double twist
method of lock-wiring. Make sure that the wire is so installed that it can easily be broken
when required in an emergency situation.
3.3.3 Lock-wiring widely spaced multiple groups by the double twist method.
a) When the multiple fasteners are from 4-6 inches apart, three (3) fasteners
shall be the maximum number in a series that can be safety wired
together.
b) When the multiple fasteners are spaced more than 6 inches apart, the
multiple fastener application specified in Figure 1 shall not be used unless
tie points are provided on adjacent parts to shorten the span of the wire to
less than 6 inches.
c) One end of the safety wire shall be inserted through one set of lockwire
holes in the head of the bolt. The other end of the safety wire shall be
looped around the bolt head in the tightening direction.
Document number
Revision
Page
ASP00019
A
7
d) The strands, while taut, shall be twisted until the twisted part is just short of
the nearest hole in the next bolt. The twisted portion shall be within 1/8” of
the holes in each bolt as shown in figure 1 above.
e) After wiring the last bolt, the wire shall be twisted to form a pigtail of 2-4
twists. The excess wire shall be cut off. The pigtail shall be bent back or
under the part to prevent it from becoming a snag.
3.3.4 Single wire method:
The single wire method may be used in a closely spaced, closed geometrical
pattern (triangle, square, circle, etc.) on parts in an electrical system, and in places that
would make the single-method more advisable as shown in figure 2 below. Closely
spaced shall be considered a maximum of two inches between centers. Maximum length
of wire shall not exceed 24” in total length.
Figure 2: Safety Wire / Lock Wire Single
3.4
OTHER APPLICATIONS
Document number
Revision
Page
ASP00019
A
8
3.4.1 Hollow head bolts are safety wired in the manner prescribed for regular bolts.
3.4.2 Drain plugs and cocks may be wired to a bolt, nut, or other part having a free lock
hole in accordance with the general instructions contained herein.
3.4.3 External snap rings may be locked if necessary in accordance with the general
locking principles contained herein.
3.4.4 Internal snap rings shall never be lockwired.
3.4.5 Bolts and hardware may be wired using SAFE-T-Cable. Follow procedure
D744000087-PRO-001.
Safe-T-Cable® can be used similar to Safety/Lock wire to secure Fasteners. The safety
cable installation procedure is shown in Figure. The safety cable comes in pre-cut
lengths with stubs on one end. After sewing through the holes in the fasteners they are
tightened and crimped using a ferrule cartridge and crimping tool.
They are more convenient to use and take only a fraction of the time to secure fasteners
as compared to safety wire as no wire twisting is required. However additional tools like
ferrule cartridge and crimping tool are required. For additional information refer Safe-TCable® (website http://www.dmctools.com/Catalog/safe_t_cable.htm).
Figure 3: Safety Cable Installation Procedure
3.5
ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION
Document number
Revision
Page
4
QA PROVISIONS
5
NOTES
ASP00019
A
9
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 15.0
Design Torque Standard
www.nov.com
DS00008
Design Specification
Design Torque Standard
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS
TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT
THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
CURRENT
DRAWN
TITLE
Design Torque Standard
INITIAL
D.TRUONG
A. Vargas
CHECKED
B.RICE
B. Levay
APPVD
B.RICE
JB
DATE
7/25/11
11.13.1992
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
1
OF
16
DCF0045 (REV B)
NOTES
1. Unless noted, all values are based on light machine oil or anti seize lubricated bolts (not high
pressure lubes)
2. NOV does not recommend assembling bolts dry
3. Proof Strength is 92% of minimum yield strength
4. Torque values given represent 70% to 80% of proof strength
5. Clamp force is based on 75% of proof strength
6. These torque values are to be followed unless otherwise specified
7. If torqueing into aluminum, contact engineering for appropriate torque value.
8. After proper torque has been established in accordance with specification, fasteners shall be
immediately identified as being torqued by either:
a) Being safety wired in accordance with ASP00019 and/or
b) Marked with an “X” using either a red or yellow paint marker.
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
2
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 2
T.S. = 74,000 PSI to ¾” DIA
PROOF STRENGTH = 55,000 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
5.7
6.3
1,320
5/16 – 18
10.5
11.6
2,160
3/8 – 16
19
21
3,200
7/16 – 14
29
32
4,380
1/2 – 13
48
53
5,840
9/16 – 12
67
74
7,500
5/8 – 11
95
105
9,300
3/4 – 10
166
184
13,800
7/8 – 9
157
173
11,400
1–8
238
263
15,000
1 1/8 – 7
333
368
18,900
1 1/4 – 7
475
525
24,000
1 3/8 – 6
627
639
28,600
1 1/2 – 6
827
914
34,800
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
5.7
6.3
11.4
12.6
22
24
33
37
52
58
76
84
105
116
185
205
176
194
257
284
380
420
523
578
703
777
931
1,029
1,500
2,400
3,620
4,900
6,600
8,400
10,600
15,400
12,600
16,400
21,200
26,600
32,500
39,100
SIZE
GRADE 5
T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 85,00 PSI
T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 74,000 PSI
Min.
Torque
(ft-lbf)
7.6
16
29
48
71
105
143
247
409
608
760
1,064
1,387
1,843
Max.
Torque
(ft-lbf)
8.4
18
32
53
79
116
158
273
452
672
840
1,176
1,533
2,037
Clamp
Force
(lb)
2,020
3,340
4,940
6,800
9,050
11,600
14,400
21,300
29,400
38,600
42,300
53,800 7
64,100 7
78,000 7
9.5
18
33
52
86
114
162
285
447
665
836
1,178
1,596
2,090
10.5
20
37
58
95
126
179
315
494
735
924
1,302
1,764
2,310
2,320
3,700
5,600
7,550
10,700
12,950
16,300
23,800
32,400
42,200
47,500
59,600
73,000
87,700
DWG NO
REV
A
SCALE
DS00008
NONE
7
7
7
7
WT LBS
SHEET
F
3
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 8
TENSILE STRENGTH = 150,000 PSI
PROOF STRENGTH = 120,000 PSI
HOLO-KROME
TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 136,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
11.4
12.6
2,860
5/16 – 18
24
26
3,720
3/8 – 16
43
47
7,000
7/16 – 14
67
74
9,550
1/2 – 13
105
116
12,750
9/16 – 12
143
158
16,100
5/8 – 11
209
231
20,350
3/4 – 10
361
399
30,100
7/8 – 9
570
630
41,600
1–8
855
945
54,500 7
1 1/8 – 7
1,216
1,344
68,700 7
1 1/4 – 7
1,729
1,911
87,200 7
1 3/8 – 6
2,261
2,499
104,000 7
1 1/2 – 6
3,002
3,318
126,500 7
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
13.3
17.7
3,280
24
26
5,220
48
53
7,900
75
84
10,700
114
126
14,400
162
179
18,250
228
252
23,000
399
441
33,600
627
693
45,800
950
1,050
59,700
1,368
1,512
77,000
1,900
2,100
96,600
2,584
2,856
118,400
3,382
3,738
142,200
SIZE
7
7
7
7
7
7
Min.
Torque
(ft-lbf)
12
26
47
75
114
163
226
404
651
969
1,349
1,967
2,565
3,411
Max.
Torque
(ft-lbf)
14
28
51
83
126
181
250
446
719
1,071
1,491
2,174
2,835
3,770
Clamp
Force
(lb)
3,240
5,340
7,920
10,850
14,450
18,500
23,000
34,000
47,000
61,700 7
77,800 7
98,700 7
117,800 7
143,200 7
14
29
52
84
124
183
258
451
718
1,064
1,511
2,180
2,926
4,769
16
32
58
92
137
203
286
499
794
1,176
1,670
2,410
3,234
5,271
3,750
5,920
8,050
12,150
16,250
20,700
26,200
38,000
51,900
67,600
87,000
109,400
134,000
201,000
DWG NO
REV
A
SCALE
DS00008
NONE
7
7
7
7
7
7
WT LBS
SHEET
F
4
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
STAINLESS ASTM F593G & F593H
T.S. = 100,000 PSI to 5/8” DIA
PROOF STRENGTH = 59,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
5.7
6.3
1,407
5/16 – 18
11.4
12.6
2,319
3/8 – 16
20.0
22.1
3,429
7/16 – 14
32
36
4,704
1/2 – 13
49
55
6,279
9/16 – 12
72
80
8,054
5/8 – 11
99
109
10,001
3/4 – 10
122
134
10,271
7/8 – 9
197
217
14,207
1–8
295
327
18,635
1 1/8 – 7
418
462
23,462
1 1/4 – 7
590
652
29,797
1 3/8 – 6
773
855
35,516
1 1/2 – 6
1,026
1,134
43,204
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
6.7
7.4
12.4
13.7
22.8
25.2
36
40
56
62
80
88
112
124
136
150
217
239
323
357
469
519
653
721
881
973
1,154
1,276
1,611
2,567
3,885
5,252
7,076
8,983
11,328
11,470
15,652
20,387
26,322
32,995
10,436
49,616
STAINLESS ASTM F593U
TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 95,000 PSI
7
Min.
Torque
(ft-lbf)
8.6
18.1
33.3
52
80
116
160
282
456
684
968
1,366
1,792
2,378
Max.
Torque
(ft-lbf)
9.5
20.0
36.8
58
88
128
176
312
504
756
1,070
1,510
1,980
2,628
Clamp
Force
(lb)
2,266
3,734
5,522
7,574
10,110
12,968
16,103
23,798
32,918
43,179
54,364 7
69,041 7
82,294 7
100,106 7
10.5
20.9
37
59
90
129
181
315
503
748
1,087
1,513
2,040
2,675
11.6
23.1
41
65
100
143
200
349
555
826
1,201
1,973
2,254
2,957
2,594
4,133
6,256
8,457
11,393
14,464
18,240
26,576
36,266
47,239
60,900
76,451
93,694
122,646
7
7
7
7
7
F593
U
F593
G or H
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
5
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 2
T.S. = 74,000 PSI to ¾” DIA
PROOF STRENGTH = 55,000 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
4.3
4.7
1,320
5/16 – 18
7.8
8.7
2,160
3/8 – 16
14.3
15.8
3,200
7/16 – 14
21.4
23.6
4,380
1/2 – 13
36
39
5,840
9/16 – 12
50
55
7,500
5/8 – 11
71
79
9,300
3/4 – 10
125
138
13,800
7/8 – 9
118
130
11,400
1–8
178
197
15,000
1 1/8 – 7
249
276
18,900
1 1/4 – 7
356
394
24,000
1 3/8 – 6
470
520
28,600
1 1/2 – 6
620
685
34,800
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
4.3
4.7
8.6
9.5
16.4
18.1
25
28
39
43
57
63
78
87
139
154
132
146
192
213
285
315
392
433
527
583
698
772
1,500
2,400
3,620
4,900
6,600
8,400
10,600
15,400
12,600
16,400
21,200
26,600
32,500
39,100
SIZE
GRADE 5
T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 85,00 PSI
T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 74,000 PSI
Min.
Torque
(ft-lbf)
5.7
12.1
21.4
36
53
78
107
185
306
456
570
798
1,040
1,382
Max.
Torque
(ft-lbf)
6.3
13.4
23.6
39
59
87
118
205
339
504
630
882
1,150
1,528
Clamp
Force
(lb)
2,020
3,340
4,940
6,800
9,050
11,600
14,400
21,300
29,400
38,600
42,300
53,800 7
64,100 7
78,000 7
7.1
13.5
25
39
64
86
121
214
335
499
627
884
1,197
1,568
7.9
15
28
43
71
95
134
236
370
551
693
977
1,323
1,733
2,320
3,700
5,600
7,550
10,700
12,950
16,300
23,800
32,400
42,200
47,500
59,600
73,000
87,700
DWG NO
REV
A
SCALE
DS00008
NONE
7
7
7
7
WT LBS
SHEET
F
6
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 8
TENSILE STRENGTH = 150,000 PSI
PROOF STRENGTH = 120,000 PSI
HOLO-KROME
TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 136,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
8.6
9.5
2,860
5/16 – 18
17.8
19.7
3,720
3/8 – 16
32
35
7,000
7/16 – 14
50
55
9,550
1/2 – 13
78
87
12,750
9/16 – 12
107
118
16,100
5/8 – 11
157
173
20,350
3/4 – 10
271
299
30,100
7/8 – 9
428
473
41,600
1–8
641
709
54,500 7
1 1/8 – 7
912
1,008
68,700 7
1 1/4 – 7
1,297
1,433
87,200 7
1 3/8 – 6
1,696
1,874
104,000 7
1 1/2 – 6
2,252
2,489
126,500 7
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
10
11
3,280
17.8
19.7
5,220
36
39
7,900
57
63
10,700
86
95
14,400
121
134
18,250
171
189
23,000
299
331
33,600
470
520
45,800
713
788
59,700
1,026
1,134
77,000
1,425
1,575
96,600
1,938
2,142
11,840
2,537
2,804
142,200
SIZE
7
7
7
7
7
7
Min.
Torque
(ft-lbf)
9.3
19
35
56
86
123
170
303
488
727
1,012
1,475
1,924
2,558
Max.
Torque
(ft-lbf)
10.2
21
39
62
95
135
187
335
539
803
1,118
1,630
2,126
2,827
Clamp
Force
(lb)
3,240
5,340
7,920
10,850
14,450
18,500
23,000
34,000
47,000 7
61,700 7
77,800 7
98,700 7
117,800 7
143,200 7
10.7
21
39
63
93
138
194
338
539
798
1,133
1,635
2,195
3,577
11.8
24
43
69
102
152
214
374
595
882
1,252
1,807
2,426
3,953
3,750
5,920
8,050
12,150
16,250
20,700
26,200
38,000
51,900
67,600
87,000
109,400
134,000
201,000
DWG NO
REV
A
SCALE
DS00008
NONE
7
7
7
7
7
7
WT LBS
SHEET
F
7
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
STAINLESS ASTM F593G & F593H
T.S. = 100,000 PSI to 5/8” DIA
PROOF STRENGTH = 59,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
COARSE THREAD SERIES - UNC
Max.
Clamp
Dia-Threads
Min. Torque
Torque
Force
(ft-lbf)
Per Inch
(ft-lbf)
(lb)
1/4 – 20
4.3
4.7
1,407
5/16 – 18
8.6
9.5
2,319
3/8 – 16
15
16.5
3,429
7/16 – 14
24
27
4,704
1/2 – 13
37
41
6,279
9/16 – 12
54
60
8,054
5/8 – 11
74
82
10,001
3/4 – 10
91
101
10,271
7/8 – 9
147
163
14,207
1–8
222
245
18,635
1 1/8 – 7
314
347
23,462
1 1/4 – 7
442
489
29,797
1 3/8 – 6
580
641
35,516
1 1/2 – 6
770
851
43,204
1/4 – 28
5/16 – 24
3/8 – 24
7/16 – 20
1/2 – 20
9/16 – 18
5/8 – 18
3/4 – 16
7/8 – 14
1–4
1 1/8 – 12
1 1/4 – 12
1 3/8 – 12
1 1/2 – 12
FINE THREAD SERIES – UNF
5.0
5.5
9.3
10.2
17.1
18.9
27
30
42
46
60
66
84
93
102
113
162
180
242
268
352
389
489
541
660
730
866
957
1,611
2,567
3,885
5,252
7,076
8,983
11,328
11,470
15,652
20,387
26,322
32,995
40,436
48,616
STAINLESS ASTM F593U
TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 95,000 PSI
7
Min.
Torque
(ft-lbf)
6.4
13.5
24.9
39
60
87
120
212
342
513
726
1,025
1,344
1,783
Max.
Torque
(ft-lbf)
7.1
15
27.6
43
66
96
132
234
378
567
802
1,132
1,485
1,971
Clamp
Force
(lb)
2,266
3,734
5,522
7,574
10,110
12,968
16,103
23,798
32,918
43,179
54,364 7
69,041 7
82,294 7
100,106 7
7.8
15.7
28
44
68
97
135
237
377
561
815
1,135
1,530
2,006
8.7
17.3
31
49
75
107
150
261
417
620
901
1,254
1,691
2,218
2,594
4,133
6,256
8,457
11,393
14,464
18,240
26,576
36,266
47,239
60,990
76,451
93,694
112,646
F593
G or H
7
7
7
7
7
F593
U
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
8
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 4.6
T.S. = 400 MPa
PROOF STRENGTH = 225 MPa
T.S. is for all dia.
CLASS 8.8
T.S. = 830 MPa
PROOF STRENGTH = 600 MPa
T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Diameter - pitch
Min. Torque
(ft-Ibf)
M3 - .5
M3.5 - .6
M4 - .7
M5 - .8
M6 - 1
M8 - 1.25
M10 - 1.5
M12 - 1.75
M14 - 2
M16 - 2
M18 – 2.5
M20 – 2.5
M22 – 2.5
M24 - 3
M27 – 3
M30 - 3.5
M33 – 3.5
M36 – 3.5
M39 - 4
M42 - 4.5
M48 - 5
M56 - 5.5
.4
.6
.9
1.7
2.9
6.9
14
24
38
57
81
112
151
193
280
381
514
656
852
1,059
1,586
2,535
Max.
Torque
(ft-Ibf)
.5
.73
1.1
2.1
3.7
8.9
17
31
48
74
104
145
196
251
365
496
670
857
1112
1380
2069
3310
Clamp
Force
(Ib)
183
247
320
516
732
1,331
2,106
3,055
4,177
5,664
6,975
8,851
10,940
12,746
16,570
20,216
24,961
29,422
35,122
40,363
53,038 7
73,007 7
Min.
Torque
(ft-Ibf)
.9
1.5
2.1
4.3
7.2
17
33
57
91
141
195
274
372
472
690
934
1,267
1,627
2,102
2,599
3,899
6,253
4.6
Max.
Torque
(ft-Ibf)
1.2
1.9
2.9
5.8
9.9
23
47
81
129
199
278
388
524
671
974
1,325
1,787
2,285
2,966
3,681
5,518
8,828
Clamp
Force
(lb)
489
659
854
1,378
1,954
3,550
5,617
8,148
11,141
15,106
18,600
23,604
29,174
33,989
44,186
53,911 7
66,563 7
78,460 7
93,661 7
107,634 7
141,435 7
194,686 7
8.8
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
9
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 10.9
T.S. = 1040 MPa
PROOF STRENGTH = 830 MPa
T.S. is for all dia
Diameter - pitch
Min. Torque
(ft-Ibf)
M3 - .5
M3.5 - .6
M4 - .7
M5 - .8
M6 - 1
M8 - 1.25
M10 - 1.5
M12 - 1.75
M14 - 2
M16 - 2
M18 – 2.5
M20 – 2.5
M22 – 2.5
M24 – 3
M27 – 3
M30 - 3.5
M33 – 3.5
M36 – 4
M39 – 4
M42 - 4.5
M48 - 5
M56 – 5.5
1.3
2.1
3.1
6.2
10.6
25
50
87
138
212
297
414
557
715
1,034
1,408
1,896
2,421
3,145
3,907
5,853
9,352
Max.
Torque
(ft-Ibf)
1.7
2.7
4.0
8.0
13.7
33
65
112
179
275
384
537
726
929
1,347
1,833
2,473
3,161
4,103
5,093
7,633
12,212
Clamp
Force
(Ib)
676
911
1,182
1,906
2,703
4,910
7,771
11,271
15,411
20,897
25,730
53,911
40,358
47,019 7
61,125 7
74,577 7
92,079 7
108,536 7
129,564 7
148,894 7
195,652 7
269,316 7
CLASS 12.9
T.S. = 1220 MPa
PROOF STRENGTH = 970 MPa
T.S. is for all dia.
* Metric socket head screws*
Min.
Max.
Clamp
Torque
Torque
Force
(ft-Ibf)
(ft-Ibf)
(lb)
1.5
2.0
790
2.5
3.1
1,065
3.7
4.7
1,381
7.3
9.4
2,228
12
16
3,159
29
38
5,739
58
76
9,082
101
131
13,172
162
210
18,011
247
321
24,422
347
449
30,070
483
628
38,159
651
848
47,165 7
836
1,086
54,950 7
1,209
1,574
71,435 7
1,646
2,142
87,157 7
2,216
2,890
107,611 7
2,829
3,695
126,843 7
3,675
4,795
151,418 7
4,566
5,952
174,009 7
6,840
8,921
228,654 7
10,930
14,272
314,743 7
10.9
12.9
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
10
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 4.6
T.S. = 400 MPa
PROOF STRENGTH = 225 MPa
T.S. is for all dia.
CLASS 8.8
T.S. = 830 MPa
PROOF STRENGTH = 600 MPa
T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Diameter - pitch
Min. Torque
(ft-Ibf)
M3 - .5
M3.5 - .6
M4 - .7
M5 - .8
M6 - 1
M8 - 1.25
M10 - 1.5
M12 - 1.75
M14 - 2
M16 - 2
M18 – 2.5
M20 – 2.5
M22 – 2.5
M24 - 3
M27 – 3
M30 - 3.5
M33 – 3.5
M36 – 3.5
M39 - 4
M42 - 4.5
M48 - 5
M56 - 5.5
0.3
0.5
0.7
1.3
2.2
5
11
18
29
43
61
84
113
145
210
286
386
492
639
794
1190
1901
Max.
Torque
(ft-Ibf)
0.4
0.6
0.9
1.7
2.8
7
14
23
37
56
79
109
147
188
273
371
501
640
831
1033
1546
2472
Clamp
Force
(Ib)
183
247
320
516
732
1,331
2,106
3,055
4,177
5,664
6,975
8,851
10,940
12,746
16,570
20,216
24,961
29,422
35,122
40,363
53,038 7
73,007 7
Min.
Torque
(ft-Ibf)
0.7
1.1
1.6
3.2
5.4
13
25
43
68
106
146
206
279
354
518
701
950
1220
1577
1949
2924
4690
4.6
Max.
Torque
(ft-Ibf)
0.9
1.5
2.0
4.2
7.0
17
32
56
89
137
190
267
363
460
673
911
1235
1586
2049
2534
3802
6097
Clamp
Force
(lb)
489
659
854
1,378
1,954
3,550
5,617
8,148
11,141
15,106
18,600
23,604
29,174
33,989
44,186
53,911 7
66,563 7
78,460 7
93,661 7
107,634 7
141,435 7
194,686 7
8.8
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
11
OF
16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 10.9
T.S. = 1040 MPa
PROOF STRENGTH = 830 MPa
T.S. is for all dia
Diameter - pitch
Min. Torque
(ft-Ibf)
M3 - .5
M3.5 - .6
M4 - .7
M5 - .8
M6 - 1
M8 - 1.25
M10 - 1.5
M12 - 1.75
M14 - 2
M16 - 2
M18 – 2.5
M20 – 2.5
M22 – 2.5
M24 – 3
M27 – 3
M30 - 3.5
M33 – 3.5
M36 – 4
M39 – 4
M42 - 4.5
M48 - 5
M56 – 5.5
1.0
1.6
2.3
4.7
8.0
19
38
65
104
159
223
311
418
536
776
1056
1422
1816
2359
2930
4390
7014
Max.
Torque
(ft-Ibf)
1.3
2.0
3.0
6.0
10.3
24
49
85
135
207
290
404
543
697
1008
1373
1849
2360
3066
3809
5707
9118
Clamp
Force
(Ib)
676
911
1,182
1,906
2,703
4,910
7,771
11,271
15,411
20,897
25,730
32,652
40,358
47,019 7
61,125 7
74,577 7
92,079 7
108,536 7
129,564 7
148,894 7
195,652 7
269,316 7
CLASS 12.9
T.S. = 1220 MPa
PROOF STRENGTH = 970 MPa
T.S. is for all dia.
* Metric socket head screws*
Min.
Max.
Clamp
Torque
Torque
Force
(ft-Ibf)
(ft-Ibf)
(lb)
1.1
1.5
790
1.9
2.4
1,065
2.8
3.6
1,381
5.5
7.1
2,228
9.0
11.7
3,159
22
28
5,739
44
57
9,082
76
98
13,172
122
158
18,011
185
241
24,422
260
338
30,070
362
471
38,159
488
635
47,165 7
627
815
54,950 7
907
1179
71,435 7
1235
1605
87,157 7
1662
2161
107,611 7
2122
2758
126,843 7
2756
3583
151,418 7
3425
4452
174,009 7
5130
6669
228,654 7
8198
10657
314,743 7
10.9
12.9
The following tables specify torque values for fasteners used
with Nord-Lock washers.
SIZE
DWG NO
REV
A
SCALE
DS00008
NONE
WT LBS
SHEET
F
12
OF
16
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8
Oil
Washer Size
Bolt Size
Pitch
(mm)
NL3
NL4
NL5
NL6
NL8
NL10
NL12
NL14
NL16
NL18
NL20
NL22
NL24
NL27
NL30
NL33
NL36
NL39
NL42
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
.5
.7
.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
Torque
(ft-lbf)
Clamp
(lb)
Graphite
Torque
Clamp
(ft-lbf)
(lb)
1.2
3.0
5.8
10
24
47
82
129
197
276
385
525
664
968
1,322
1,779
2,295
2,960
3,663
540
944
1,529
2,181
4,047
6,295
8,992
12,364
16,861
20,682
26,527
32,822
37,993
49,683
60,474
74,861
88,125
105,211
120,947
1.2
2.7
5.2
9.1
22
43
74
117
177
249
348
474
599
873
1,192
1,600
2,067
2,663
3,297
540
944
1,529
2,181
4,047
6,295
8,992
12,364
16,861
20,682
26,527
32,822
37,993
49,683
60,474
74,861
88,125
105,211
120,947
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 10.9
Oil
Washer
Size
NL3
NL4
NL5
NL6
NL8
NL10
NL12
NL14
NL16
NL18
NL20
NL22
NL24
NL27
NL30
NL33
NL36
NL39
NL42
Bolt Size
Pitch
(mm)
Torque
(ft-lbf)
Clamp
(lb)
Graphite
Torque
Clamp
(ft-lbf)
(lb)
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
.5
.7
.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
1.7
3.9
7.8
14
33
64
110
175
268
375
524
714
903
1,318
1,798
2,422
3,125
4,030
4,988
719
1,259
2,046
2,900
5,171
8,318
12,140
16,636
22,481
27,651
35,070
43,613
50,582
66,094
80,482
99,590
117,350
140,281
160,963
1.5
3.5
6.7
12
29
56
95
151
230
323
451
613
776
1,128
1,542
2,068
2,673
3,440
4,262
SIZE
DWG NO
REV
A
SCALE
764
1,326
2,158
3,057
5,620
8,768
12,814
17,535
23,830
29,225
37,093
46,086
53,505
69,691
84,978
105,211
123,870
148,149
170,180
DS00008
NONE
WT LBS
SHEET
F
13
OF
16
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 12.9
Oil
Washer
Size
NL3
NL4
NL5
NL6
NL8
NL10
NL12
NL14
NL16
NL18
NL20
NL22
NL24
NL27
NL30
NL33
NL36
NL39
NL42
Bolt Size
Pitch
(mm)
Torque
(ft-lbf)
Clamp
(lb)
Torque
(ft-lbf)
Graphite
Clamp
(lb)
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
.5
.7
.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
1.9
4.4
8.7
15
36
72
123
196
298
419
585
797
1,009
1,470
2,005
2,699
3,483
4,490
5,560
877
1,506
2,450
3,462
6,295
9,892
14,613
20,008
26,977
33,272
42,264
52,380
60,698
79,133
96,668
119,598
140,730
168,157
193,336
1.6
3.8
7.4
13
31
61
105
167
252
355
494
670
850
1,235
1,688
2,265
2,927
3,763
4,666
922
1,596
2,585
3,664
6,744
10,566
15,287
21,132
28,551
35,070
44,512
55,303
64,295
83,629
102,063
126,343
148,823
177,599
204,126
NORD-LOCK Stainless Steel with Stainless Steel Bolt A4
Washer
Size
NL3
NL4
NL5
NL6
NL8
NL10
NL12
NL14
NL16
NL18
NL20
NL22
NL24
NL27
NL30
NL33
NL36
NL39
NL42
Bolt Size
Pitch
(mm)
A4-70 w/ Graphite Lube
Torque
Clamp
(ft-lbf)
(lb)
A4-80 w/ Graphite Lube
Torque
Clamp
(ft-lbf)
(lb)
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
.5
.7
.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
0.9
1.9
3.7
7
16
32
54
85
130
183
256
349
441
643
877
1,182
1,525
1,968
2,435
1.2
2.6
5.1
9
21
41
72
114
174
244
341
465
588
858
1,170
1,576
2,034
2,624
3,247
SIZE
337
585
922
1,326
2,473
3,822
5,620
7,644
10,341
12,589
16,186
20,008
23,155
30,124
36,869
45,636
53,729
64,071
73,737
DWG NO
REV
A
SCALE
450
764
1,236
1,754
3,147
5,171
7,419
10,116
13,713
16,861
21,357
26,527
30,799
40,241
49,233
60,698
71,714
85,652
98,241
DS00008
NONE
WT LBS
SHEET
F
14
OF
16
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5
Oil
Graphite
Washer
Size
Bolt
Size
Pitch
(TPI)
Torque
(ft-lbf)
Clamp
(lb)
Torque
(ft-lbf)
Clamp
(lb)
NL3
NL3.5
NL4
NL5
NL1/4”
NL8
NL3/8”
NL11
NL1/2”
NL14
NL16
NL3/4”
NL22
NL 1”
NL30
NL33
NL36
NL39
#5
#6
#8
#10
¼
5/16
3/8
7/16
½
9/16
5/8
¾
7/8
1
1 1/8
1¼
1 3/8
1½
40
32
32
24
20
18
16
14
13
12
11
10
9
8
7
7
6
6
1.1
1.4
2.7
3.9
9.1
18
30
47
73
104
145
254
408
617
771
1075
1410
1860
550
630
970
1,200
2,200
3,600
5,400
7,300
9,800
12,600
15,600
23,100
31,900
41,800
46,400
58,900
70,200
85,500
1.0
1.3
2.4
3.5
8.3
16
28
42
66
94
131
230
369
557
697
969
1,270
1,670
550
630
970
1,200
2,200
3,600
5,400
7,300
9,800
12,600
15,600
23,100
31,900
41,800
46,400
58,900
70,200
85,500
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 8
Oil
Washer Size
Bolt Size
Pitch
(TPI)
Torque
(ft-lbf)
Clamp
(lb)
Graphite
Torque
Clamp
(ft-lbf)
(lb)
NL3
NL3.5
NL4
NL5
NL1/4”
NL8
NL3/8”
NL11
NL1/2”
NL14
NL16
NL3/4”
NL22
NL 1”
NL30
NL33
NL36
NL39
#5
#6
#8
#10
¼
5/16
3/8
7/16
½
9/16
5/8
¾
7/8
1
1 1/8
1¼
1 3/8
1½
40
32
32
24
20
18
16
14
13
12
11
10
9
8
7
7
6
6
1.5
1.9
3.5
5.1
12
24
41
64
99
138
197
346
556
840
1,190
1,660
2,180
2,870
740
840
1,300
1,600
2,900
4,900
7,200
9,800
13,100
16,800
20,900
30,900
42,700
56,000
70,600
89,600
107,000
130,000
1.3
1.7
3.1
4.6
11
21
36
56
86
122
171
299
479
724
1,030
1,430
1,880
2,470
SIZE
DWG NO
REV
A
SCALE
780
890
1,400
1,700
3,100
5,100
7,600
10,400
13,900
17,800
22,100
32,700
45,100
59,200
74,500
94,600
113,000
137,000
DS00008
NONE
WT LBS
SHEET
F
15
OF
16
DCF0045 (REV B)
NORD-LOCK Stainless Steel with ASTM A574 Bolt
Oil
Washer Size
Bolt Size
Pitch
(TPI)
NL3
NL3.5
NL4
NL5
NL1/4”
NL8
NL3/8”
NL11
NL1/2”
NL14
NL16
NL3/4”
NL22
NL 1”
NL30
NL33
NL36
NL39
#5
#6
#8
#10
¼
5/16
3/8
7/16
½
9/16
5/8
¾
7/8
1
1 1/8
1¼
1 3/8
1½
40
32
32
24
20
18
16
14
13
12
11
10
9
8
7
7
6
6
Torque
(ft-lbf)
Clamp
(lb)
Graphite
Torque
Clamp
(ft-lbf)
(lb)
1.7
2.2
3.8
5.8
13
26
45
70
109
148
216
378
607
916
1,300
1,810
2,380
3,140
870
990
1,500
1,900
3,400
5,700
8,400
11,500
15,400
19,800
24,600
36,400
50,200
65,900
83,000
105,000
126,000
153,000
1.6
2.0
3.7
5.5
12
23
39
60
93
141
184
321
514
776
1100
1530
2020
2640
910
1,050
1,600
2,000
3,700
6,000
8,900
12,200
16,300
20,900
26,000
38,400
53,000
69,600
87,700
111,000
133,000
161,000
NORD-LOCK Stainless Steel with ASTM F593 Bolt
Oil
Washer Size
Bolt Size
Pitch
(TPI)
NL3
NL3.5
NL4
NL5
NL1/4”
NL8
NL3/8”
NL11
NL1/2”
NL14
NL16
NL3/4”
NL22
NL 1”
NL30
NL33
NL36
NL39
#5
#6
#8
#10
¼
5/16
3/8
7/16
½
9/16
5/8
¾
7/8
1
1 1/8
1¼
1 3/8
1½
40
32
32
24
20
18
16
14
13
12
11
10
9
8
7
7
6
6
Torque
(ftlb)
Clamp
(lb)
Graphite
Torque
Clamp
(ftlb)
(lb)
5.2
10.3
18
28
43
61
85
104
166
251
356
497
653
859
1,300
2,200
3,300
4,500
6,000
7,700
9,500
9,800
13,500
17,700
22,300
28,300
33,800
41,100
5.2
10.3
18
28
43
61
85
104
166
251
356
497
653
859
SIZE
DWG NO
REV
A
SCALE
1,300
2,200
3,300
4,500
6,000
7,700
9,500
9,800
13,500
17,700
22,300
28,300
33,800
41,100
DS00008
NONE
WT LBS
SHEET
F
16
OF
16
DCF0045 (REV B)
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 16.0
Recommended Lubricants
and Fluids
www.nov.com
Recommended
Lubricants and
Hydraulic Fluids
NOV Drilling System Products
Top Drive Systems
Power Swivel Systems
Iron Roughneck Systems
Hoisting Systems
Mud Pump Systems
Pipe Handling Systems
Rotating Systems
BOP Transporter Systems
Reference
Reference Description
This document contains proprietary and confidential
information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only
and remains the property of NOV. Reproduction, in whole or in National Oilwell Varco
part, or use of this design or distribution of this information to RIG SOLUTIONS
others is not permitted without the express written consent of 11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
www.nov.com
Document Number
Rev.
D811000719-PRO-001
05
D811000719-PRO-001
Revision 05
Revision History
05
15.08.2012
Engineering Update
B. Dominguez
S. Sobreira
R. Luher
04
21.02.2012
Engineering Update
B. Dominguez
B. Levay
B. Levay
03
30.11.2009
Engineering Update
B. Dominguez
P. Williams
P. Williams
02
09.14.2009
Publication update
B. Dominguez
P. Williams
P. Williams
01
10.01.2008
First Issue
TCD
BMD
BDW
Rev
Date (dd.mm.yyyy)
Reason for issue
Prepared
Checked
Approved
www.nov.com
D811000719-PRO-001
Revision 05
Change Description
Revision
Change Description
01
First Issue
02
1. Changed equipment reference to cover page.
2. Added temperature range reference to hydraulic fluids and gear lubricant pour point advisories to
page 1.
3. Changed and added frequency of fluid changes for hydraulic fluids and gear lubricants to pages 4
and 8.
4. Changed Non-Arctic Service heading to Non-Arctic Service Fluids to page 6.
5. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Non-Arctic Service Fluid table
to page 6.
6. Changed Arctic Service heading to Arctic Service Fluids to page 7.
7. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Arctic Service Fluid table to
page 7.
8. Added “SUS” viscosities to best choice supreme grade arctic service hydraulic fluids to
page 7.
9. Added “SUS” viscosities to alternative supreme grade arctic service hydraulic fluids to page
7.
10. Changed gearbox reference and added cross-reference information to operating temperature table
for draining of gear oil to page 8.
11. Added "Conventional" reference to washpipe lubricant recommendation section to page 10.
12. Removed "AC" reference to page 10.
13. Removed grease brand example to page 11.
14. Added External Pinion and Gear Sets section with recommended grease information tables to page
9 and 10.
15. Changed “Viscosity” cell title to “Kinematic Viscosity” cell title in Lubricants and Fluids Reference
Chart to pages 14 and 15.
16. Added "External Pinion and Gear Sets" component lubricant reference to page 15.
17. Removed "AC" reference from drilling motor bearings to page 15.
18. Changed all primary temperature degrees to Celsius and changed all reference temperature
degrees to Fahrenheit.
03
1. Added caution note and contact information note to page 2.
2. Removed oil additive recommendation note to page 15.
04
1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12.
2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13.
3. Moved Air Lubricator Misting Oil section from page 13 to page 17.
4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled:
Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16.
5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.
05
1. Corrected cross-reference page information on page 9 to refer to the table on page 10.
2. Placed ambient temperature minus symbol in front of 9 celsius on column one, row two of
Recommended Gear Oil for the Transmission Gearbox Table (page 10).
3. Placed ambient temperature minus symbol in front of 4 celsius on column one, row three of
Recommended Gear Oil for the Transmission Gearbox Table (page 10).
4. Changed ambient temperature -10 Celsius to -9 Celsius on column two, row three of Recommended
Gear Oil for the Transmission Gearbox Table (page 10).
5. Corrected inverted primary (Celsius) and reference (Fahrenheit) temperature degree call-outs to
column two, row four of Recommended Gear Oil for the Transmission Gearbox Table (page 10).
www.nov.com
D811000719-PRO-001
Revision 05
Page i of i
Table of Contents
General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Fluid Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Non-Arctic Service Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Arctic Service Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gear Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Low-Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Gearbox Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Conventional Washpipe Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Motor Bearings Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
IBOP/Kelly Valve Actuator Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . 1-12
External Pinion & Gear Set Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . 1-13
Wire Rope Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Rope Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Air Lubricator Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lubricants and Fluids Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
i
www.nov.com
D811000719-PRO-001
Revision 05
Page 1 of 20
Lubricants and Hydraulic Fluids
General Recommendations
The lubrication intervals for NOV derrick-mounted equipment are based on lubricant
supplier recommendations, original equipment manufacturer instructions, and engineering
design criteria. Severe conditions such as extreme loads, extreme temperatures, or o
operating in a corrosive atmosphere may require more frequent lubrication intervals.
i
Hydraulic fluids must pour freely at the minimum operating
temperature. The Pour Point temperature of Hydraulic
Fluid should be at least 17°C or (30°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Hydraulic Fluid Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Gear lubricant must pour freely at the minimum operating
temperature. The Pour Point temperature of Gear
Lubricant should be at least 6°C or (10°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Gear Lubricant Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Clean or replace filters whenever lubricants and fluids are
replaced.
!
When adding or changing fluids (gear oil or hydraulic fluid),
take every precaution to prevent fluid contamination. 
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.
1
www.nov.com
Lubricants and Hydraulic Fluids
D811000719-PRO-001
Revision 05
Page 2 of 20
General Recommendations
!
Always use NOV recommended lubricants in your NOV
equipment.
i
Contact an NOV Service Center for additional instructions
if none of the recommended lubricants have the correct
properties for ambient and operating temperatures ranges
at your location.
2
www.nov.com
D811000719-PRO-001
Revision 05
Page 3 of 20
Lubricants and Hydraulic Fluids
General Recommendations
Precautions
Make sure to read and understand the following prior to adding or changing lubricants.
!
Do not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip, creating a slipping hazard.
Release all hydraulic oil pressure by bleeding
accumulators before disconnecting hydraulic lines.
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.
i
Careful handling of all lubricants should always be
practiced. Avoid prolonged contact to skin, splashing into
eyes, ingestion or inhaling of vapor or mist. Refer to the
MSDS (Material Safety Data Sheet) for additional
information.
3
www.nov.com
Lubricants and Hydraulic Fluids
D811000719-PRO-001
Revision 05
Page 4 of 20
General Recommendations
Additional Information
Refer to the following for related information.

The design notes provided on the assembly drawing in the Technical Drawing
Package (TDP) may list lubrication product information and instructions. The TDP is
located in the NOV equipment Owner’s Manual.

There may be a nameplate on the equipment that provides lubrication product
information and instructions.

The original equipment manufacturer’s (vendor) documentation may contain specific
lubrication and hydraulic fluid requirements. Vendor-supplied documentation is
located in the NOV equipment Owner’s Manual.

The Maintenance chapter in the NOV equipment User Manual provides the specific
component lubrication instructions.

The Long-Term Storage section provides lubrication instructions associated with
putting NOV equipment back into service after prolonged storage. This section is
located in the NOV equipment User Manual.
4
www.nov.com
D811000719-PRO-001
Revision 05
Page 5 of 20
Lubricants and Hydraulic Fluids
Hydraulic Fluid
NOV recommends anti-wear (AW) hydraulic fluid of the proper viscosity grade. AW
hydraulic fluid is typically mineral-based and contains anti-wear additives, along with rust
and oxidation inhibitors.
The hydraulic oil viscosity should be adjusted based on expected ambient conditions, refer
to the recommended hydraulic fluid tables for specific hydraulic fluids for start-up and
operating in non-arctic and arctic environments.
Hydraulic Fluid Cleanliness
In order to ensure reliable operation, hydraulic fluid must be maintained at a minimum
particle count (cleanliness) level that meets or exceeds an ISO 4406 rating of 17/15/12
(NAS Class 6 or better). Refer to the following NOV documents for specific instructions
about maintaining hydraulic fluid cleanliness:

FIP00121 – Specification for Fluid Cleanliness and for Cleaning and Flushing
Hydraulic Lines

SM00081 – Hydraulic Fluid Cleanliness Supplement
Change Interval
The hydraulic fluid should be changed after the first initial start-up or if returning the
equipment to service after prolonged storage.

Change all hydraulic fluids yearly or as frequently as operating conditions require.

Fill all hydraulic fluid systems to correct levels with specified lubricants. Refer to the
recommended hydraulic fluid tables for specific hydraulic fluids.
!
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.

Maintain a clean, sludge-free oil of proper viscosity.
Filters
Filters should always be replaced when changing hydraulic fluid. Refer to the Maintenance
chapter (in the NOV equipment User Manual) for filter descriptions and details.

Replace filters every three (3) months or whenever the lubricants are changed.
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Hydraulic Fluid
Inspection

Check the hydraulic fluid level daily.
i
Keep the hydraulic reservoir full at all times. The oil level
should be visible in the sight gauge.

Inspect for leaks daily.

Perform hydraulic system oil analysis once every six (6) months.
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Lubricants and Hydraulic Fluids
Hydraulic Fluid
Non-Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in non-arctic
environments are provide in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
Recommended Hydraulic Fluids for Non-Arctic Service
Operating Temperature Range -12°C to 52°C (10°F to 125°F)
Premium Grade AW Hydraulic Oil (with anti-wear and anti-rust additives)
Best Choice
Kinematic
Viscosity
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity Index
105
Pour Point
-30°C (-22°F)
ISO/ASTM
Viscosity Grade
46
Hydraulic Transmission Oil
Alternative
Kinematic
Viscosity
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity Index
100 (minimum)
Pour Point
-37°C (-35°F)
ISO/ASTM
Viscosity Grade
46
i
Contact an NOV Service Center for additional instructions
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
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Lubricants and Hydraulic Fluids
D811000719-PRO-001
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Hydraulic Fluid
Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in arctic environments
are provide in the following table.
Recommended Hydraulic Fluids for Arctic Service
Operating Temperature Range -40° C to 17°C (-40° F to 63°F)
Supreme Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;
high shear stability)
Best Choice
Kinematic
Viscosity
5.5 cSt @ 100°C (44 SUS @ 210°F)
Viscosity Index
377
Pour Point
-60°C (-76°F)
ISO/ASTM
Viscosity Grade
15
Supreme Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;
high shear stability)
Alternative
Kinematic
Viscosity
3.72 cSt @ 100°C (39 SUS @ 210°F)
Viscosity Index
140
Pour Point
-42°C (-44°F)
ISO/ASTM
Viscosity Grade
15
Premium Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;
high shear stability)
Alternative
Kinematic
Viscosity
6.4 cSt @ 100°C (47.5 SUS @ 210°F)
Viscosity Index
155
Pour Point
-50°C (-58°F)
ISO/ASTM
Viscosity Grade
32
i
Contact an NOV Service Center for additional instructions
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
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Lubricants and Hydraulic Fluids
Gear Oil
You should select gear oil based on the minimum ambient temperature expected before
the next oil change.
!
Using an oil with a viscosity greater than what is required
could reduce oil flow and damage the gearbox. Higher
viscosity oils may also damage the oil pump with excessive
load.
You should use an extreme pressure (EP) gear oil. EP gear oils are typically mineral oils
that contain sulfur-phosphorous additives. Most EP gear oils meet American Gear
Manufacturers Association (AGMA) extreme pressure performance requirements.
i
Check the gearbox oil level daily.
i
Change oil whenever it becomes contaminated. Oil
contamination depends on operating conditions and
temperature. Continuous operation at 180°F (82°C), or
above, will require more frequent oil changes.
Inspection

Inspect the oil level and check for leaks every 250 operating hours.

Examine oil for changes in its appearance and odor.
Change Interval

The gear oil should be thoroughly drained after 500 operating hours or after the first
(1) month of operation, following the initial start-up or if returning the equipment to
service after prolonged storage.

Under normal operating conditions, the gear oil should be changed every six (6)
months, and oil viscosity should be adjusted based on expected ambient conditions
for the next six (6) months.

The gear oil should be drained when at normal operating temperatures. Refer to the
table titled "Recommended Gear Oil for the Transmission Gearbox" on page 10.
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Lubricants and Hydraulic Fluids
Gear Oil
Low-Temperature Operation
Equipment operating in cold areas must be provided with gear oil that circulates freely and
does not cause high torque at start-up. Lubrication viscosity must be low enough to allow
the oil to flow freely at start-up, but high enough to carry the load at operating temperature.
Gearbox Lubricants
The recommended gear oil grades for ambient and operating temperature ranges are
provided in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
Recommended Gear Oil for the Transmission Gearbox
Operating Temperature Range
Ambient Temperature
Gear Oil Minimum
Operating Temperature
Recommended Grade
10°C to 52°C
(50°F to 125°F)
16°C (60°F)
AGMA No. 7 EP, ISO/ASTM VG 460
-9°C to 16°C
(15°F to 60°F)
4°C (25°F)
AGMA No. 6 EP, ISO/ASTM VG 320
-29°C to -4°C
(-20°F to 25°F)
-23°C (-9°F)
AGMA No. 4 EP, ISO/ASTM VG 150
-46°C to -18°C
(-50°F to 0°F)
-40°C (-40°F)
AGMA No. 4 EP, ISO/ASTM VG 100
i
Contact an NOV Service Center for additional instructions
if none of the recommended gear oils have the correct
properties for the ambient and operating temperature
ranges at your location.
10
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Lubricants and Hydraulic Fluids
Grease
General Lubrication
The recommended grease for general preventative maintenance is provide in the following
table.
General Lubricant Recommendation
Ambient Temperature Range 
Above -20°C (above -4°F)
Ambient Temperature Range 
Below -20°C (Below -4°F)
NLGI Grade Number 2
NGLI Grade Number 1
Lithium-based, general purpose, extremepressure grease
Lithium-based, general purpose, extremepressure grease
Conventional Washpipe Lubricating Greases
The recommended washpipe assembly grease for general preventative maintenance is
provide in the following table.
Washpipe Lubricant Recommendation
Moderate Operating Conditions
Extreme Operating Conditions
(High Speed, Pressure, and Fluid Temp.)
NLGI Grade 2
NLGI Grade 3
Non soap-based moly grease
Non soap-based moly grease
NOV Part Number – 7806084
NOV Part Number – 7806663
i
Contact an NOV Service Center for additional instructions
if none of the recommended greases have the correct
properties for the ambient and operating temperature
ranges at your location.
11
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Lubricants and Hydraulic Fluids
D811000719-PRO-001
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Grease
Motor Bearings Lubricating Greases
Some motors are equipped with greased bearings, which must be lubricated at
manufacturer-recommended intervals.
Generally, drilling motors and blower motors are vendor-supplied equipment. The motor
housing may have a nameplate attached to it that provides the recommended lubrication
product, amount to use, and lubrication intervals.
If there is no nameplate, refer to the vendor-supplied documentation in the Owner’s
Manual. If no vendor reference information is supplied, contact an NOV Service Center.

Lubricate the drilling motor and blower motor bearings every six (6) months or as
specified by the original equipment manufacturer, refer to your User Manual or to the
vendor-supplied documentation in the Owner’s Manual.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.
IBOP/Kelly Valve Actuator Lubricating Greases
IBOPs and Kelly valve actuators may be vendor-supplied equipment. The actuator
assembly may have a nameplate that provides the recommended lubrication product,
amount to use, and lubrication intervals.
If there is no nameplate, refer to the vendor documentation in the Owner’s Manual.
If no vendor-supplied reference information is available, use grease with properties that
meet the NLGI Grade 1.5 specification.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.

12
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Lubricants and Hydraulic Fluids
Grease
External Pinion & Gear Set Lubricating
Greases
Lubricate all external pinion and gear sets, such as the following:

Handling Ring Assembly

Repositioner Assembly

Crown Tooth Gear Coupling
Lubricate external pinion and gear sets weekly with a light coating to the entire pinion and
gear set.
The recommended external pinion and gear set grease for general preventative
maintenance is provide in the following tables.
Handling Ring Pinion & Gear Set Lubricant Recommendations
For all environment conditions:
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
Crown Tooth Gear Coupling Lubricant Recommendation
Moderate Operating Conditions
Extreme Operating Conditions 
(High Speed, High Torque)
NLGI Grade Number 1
NGLI Grade Number 2
Lithium-based, general purpose, extremepressure grease
Lithium-based, general purpose, extremepressure grease
Repositioner Pinion and Gear Set Lubricant Recommendation
For all environment conditions:
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
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Lubricants and Hydraulic Fluids
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Wire Rope Lubricant
Lubrication of wire rope at proper intervals will maintain the initial lubrication of the wire
rope equipment. You should use an unleaded extreme pressure lubricant specifically
designed for wire rope lubrication. Wire rope lubricants are typically mineral oils that
contain additives and inhibitors for non sheening, extreme pressure, corrosion, low
temperature flexibility, and low fling off adhesive attributes.
Inspection
Periodically inspect the wire rope and determine the condition of the strand and the
condition of the lubricant coating, and if there is question on either the strand or lubricant
coating the following procedures should be followed:

When performing wire rope lubrication inspection, use appropriate tools, dry clean
rags, and wear protective hand and eye safety equipment when examining or
cleaning the rope. Never use detergents or solvents to clean rope; the use of
solvents can effect or diminish the rope’s lubricant.

Visually inspect the entire length of wire rope for bare rope surface, lubricant build
up, lubrication appearance, and contamination. Refer to the applicable OEM
literature in the User Manual for lubrication and inspection schedules for wire rope
equipment.

Visually and physically examine the entire length of wire rope and determine if its
acceptable for service or requires replacement before re-dressing with rope
lubricant. Refer to the applicable OEM literature in the User Manual for additional
information for wire rope equipment.
i
Always follow all federal, state and local rules, code and
rig-specific wire rope guidelines for inspection and
maintenance of wire rope equipment. Inspection and
lubrication recommendations provided in this supplement
do not take precedence over local rules and regulations,
OSHA regulation, or instructions issued by the
manufactures of wire rope.
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Lubricants and Hydraulic Fluids
Wire Rope Lubricant
Lubricating
Lubricate wire rope equipment frequently. Lubricate whenever rope becomes
contaminated or shows a lack of lubrication. Lubricating depends on operating conditions,
severe conditions such as extreme loads or temperature, corrosive atmosphere, and so on
may require more frequent lubrication.
The following procedure provides basic field dressing for wire rope equipment:

Clean wire rope before lubricating to ensure it is free of contamination, moisture,
and lubricant build up.

Manually brush the rope uniformly as possible with new lubricant over the entire
length of wire rope.
i
The lubricant used must be compatible with the initial
lubricant applied by the wire rope manufacture.

Follow recommendations concerning the temperature of
the wire rope and atmosphere required when applying
lubricant.

The recommended wire rope lubricant for general
preventative wire rope maintenance is provide in the table
titled "Recommended Lubricant for Wire Rope" on page
16. See OEM literature for additional maintenance
information or contact your NOV representative.
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Lubricants and Hydraulic Fluids
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Wire Rope Lubricant
Rope Lubricants
Recommended Lubricant for Wire Rope1
Ambient Temperature Range 
Above 6°C (Above 43°F)
Viscosity
NGLI Grade Number 2
Color
Blue
Texture
Smooth/Creamy
Soap Type
Lithium 12
Mineral Oil
50% Nominal
Oil Separation% (Fed 791-321.1
1.94%
Penetration: mm, (ASTM D217)
305
Viscosity, cST at 40 degrees Centigrade
320
Viscosity, cST at 100 degrees Centigrade
21-23
Dropping Point, C (F)
177 C (350 F)
Low Temperature Flexibility (Section 4.4.4, No
cracks @ 6 degrees C)
Pass
Rust Test, ASTM D-1743
Pass
Salt Fog Corrosion Resistance ASTM B117
1,000 hr. / Pass
Salt Spray, Fed, Standard 791, TM 4001
Pass
Accelerated Weathering (ASTM G 152, 153)
Pass
Load Wear Index (ASTM D2596)
34.43
Adhesive% (Sec.4.6.6 150rpm @ 151 +/-2
leg/F)
99.7
Volatile Matter (2.0% Max.)
1.02
4-Weld, kg
250
4-Ball Wear Diameter, mm, max
0.65
LC50 Value
(Over 25,000 PPM)
1. Coat the wire rope products with a lubricant designed for wire rope lubrication having the recommended properties in the above table such as “Dynagard Blue”, or equivalent.
16
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Lubricants and Hydraulic Fluids
Misting Oil
Air Lubricator Misting Oil
Use misting type oil, 29-35 cSt @ 38°C (136-165 SUS @ 100°F), ISO Viscosity 
Grade 32.
17
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< -7°C (20°F)
EP Grease4
---
---
Grade 100
-46°C to -18°C
(-50°F to 0°F)
> -7°C (20°F)
Grade 150
-29°C to -4°C
(-20°F to 25°F)
Synthetic
Gear Oil
Grade 320
-9°C to 16°C
(15°F to 60°F)
EP Gear Oil
Grade 460
Grade 15
Grade 15
Hydraulic Oil3
Hydraulic Oil3
Grade 10W
Grade 32
Hydraulic Oil2
AT Fluid
Grade 46
Grade 46
ASTM/
ISO-VG/SAE
Hydraulic
Transmission
Oil
Hydraulic Oil1
Lube Type
10°C to 52°C
(50°F to 125°F)
-40°C to 0°C
(-40°F to 32°F)
-30°C to 17°C)
-22°F to 63°F
-12°C to 52°C
(-10°F to 125°F)
Environment
#1
#2
---
---
---
---
---
---
---
---
---
---
NLGI
---
---
---
#4 EP
#6 EP
#7 EP
---
---
---
---
---
---
AGMA
Kinematic
Viscosity
---
---
14.4 cSt @ 100°C
(77.1 SUS @ 210°F)
14.5 cSt @ 100°C
78.1 SUS @ 210°F
24.0 cSt @ 100°C
(120 SUS @ 210°F)
30.3 cSt @ 100°C
(150 SUS @ 210°F)
---
---
149
95
95
95
377
140
3.72 cSt @ 100°C
(39 SUS @ 210°F)
5.5 cSt @ 100°C
(44 SUS @ 210°F)
172
155
6.4 cSt @ 100°C
(47.5 SUS @ 210°F)
7.5 cSt @ 100°C
(51 SUS @ 210°F)
100 min.
105
Viscosity
Index
6.9 cSt @ 100°C
(49 SUS @ 210°F)
6.9 cSt @ 100°C
(49 SUS @ 210°F)
1. Must be Premium Grade with Anti-Rust and Anti-Wear Additives.
2. Must be Premium Shear Stable High VI, anti-wear hydraulic oil.
3. Must be Supreme Grade High Shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives.
4. Lithium base, general-purpose, extreme pressure grease.
Repositioner
Bearing
Gearbox and
Swivel Bearing
Hydraulic
System
Component
Lubricants and Fluids Reference Chart
---
---
-46°C (-50°F)
-23°C (-10°F)
-18°C (0°F)
-7°C (20°F)
-60°C (-76°F)
-42°C (-44°F)
-48°C (-54°F)
-50°C (-58°F)
-37°C (-35°F)
-30°C (-22°F)
Pour Point
Lubricants and Hydraulic Fluids
D811000719-PRO-001
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Primrose Plus
# 327 C
Extreme
Operating
Conditions
---
---
Primrose Plus
# 327
1. For example: Jet-Lube KOPR-KOTE or NOV “Copper Top.”
2. Use the lubrication product specified by the original equipment manufacturer.
3. Polyurea-based grease or as specified by the motor manufacturer.
4. Lithium base, general-purpose, extreme pressure grease.
Conventional
Washpipe
Packing
Grease
#3
#2
#1
#2
---
Moderate
Operating
Conditions
EP Grease4
---
---
> -4°C (20°F)
General
Grease
Bearings
Misting Oil
#2
#1.5
#2
NLGI
Grade 32
---
Metalon 
Hi-Tech 1.5
Grease2
EP Grease3
---
EP Grease1
Lube Type
< -4°C (20°F)
All
Air Lubricators
Blower Motor
Bearings
All
All
IBOP/Kelly
Valve Actuator
Drilling Motor
Bearings
All
Environment
External Pinion
and Gear Sets,
and Elevator
and Main Links
contact
surfaces
Component
ASTM/
ISO-VG/
SAE
---
---
---
---
---
---
---
---
AGMA
---
---
---
Kinematic
Viscosity
---
---
---
---
29-35 cSt @ 38°C
(136-165 SUS @ 100°F)
Lubricants and Fluids Reference Chart
---
---
---
---
125
---
---
---
Viscosity
Index
---
---
---
---
-12°C (10°F)
---
---
---
Pour Point
D811000719-PRO-001
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Lubricants and Hydraulic Fluids
19
> 6°C (43°F)
Environment
Wire Rope
Lubricant1
Lube Type
---
#2
NLGI
---
AGMA
---
Kinematic
Viscosity
---
Viscosity
Index
---
Pour Point
1. Lithium 12 base, containing additives and inhibitors for non sheening, extreme pressure, corrosion, low temperature flexibility, strong adhesion, and low fling off.
Wire Rope
Component
ASTM/
ISO-VG/
SAE
Lubricants and Fluids Reference Chart
Lubricants and Hydraulic Fluids
D811000719-PRO-001
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FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 17.0
Hydraulic Fluid Cleanliness
www.nov.com
Hydraulic
Fluid
Cleanliness
Supplement
SM00081 Rev. C
October 26, 2000
Copyright 2000, Varco International, Inc.
All rights reserved. This publication is the property of
and contains information proprietary to Varco
International, Inc. No part of this publication may be
reproduced or copied in any form or by any means,
including electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of Varco International, Inc.
Product names mentioned in this publication may be
trademarks or registered trademarks of their respective
holders and are hereby acknowledged.
ii
Hydraulic Fluid Cleanliness
SM00081-C
Contents
Supplement
Hydraulic Fluid Cleanliness
Scope .................................................................................................................... 5
Hydraulic Fluid Cleanliness ................................................................................. 6
Hydraulic fluid ............................................................................................... 6
Hydraulic Fluid Contamination ............................................................................ 7
Solid contamination ....................................................................................... 7
Classes of contamination ......................................................................... 7
Measuring the contamination of a system ............................................... 9
Taking samples .................................................................................. 9
Analyzing the samples .......................................................................... 10
Cleanliness during installation ........................................................................... 11
Service loops ................................................................................................ 11
Hydraulic pipe cleaning ............................................................................... 11
Reference documents: ........................................................................... 11
Pipe cleaning (carbon steel): ................................................................. 11
Pipe cleaning (stainless steel) ................................................................ 13
SM00081-C
Contents
iii
October 26, 2000
iv
Hydraulic Fluid Cleanliness
SM00081-C
Supplement
Hydraulic Fluid
Cleanliness
Scope
The purpose of this document is to provide guidance to the installers and users of
Varco’s hydraulically powered equipment and to ensure that each piece of equipment
performs as intended. Prior to connecting Varco equipment to a hydraulic system, the
piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to
minimize hydraulic fluid contamination. The following paragraph defines the
hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to
maintain these cleanliness levels could result in premature equipment damage and
nullification of the equipment warranty.
This document outlines fluid cleanliness measurement and analysis criteria and also
describes procedures for filtering and cleaning a hydraulic system.
Each final assembly item from Varco will be function tested with clean hydraulic fluid
maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid
cleanliness levels will be recorded on Test Specification document (TS00419) for each
piece of equipment prior to shipment.
SM00081-C
Hydraulic Fluid Cleanliness
5
October 26, 2000
Hydraulic Fluid Cleanliness
Hydraulic fluid
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO
4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning
of Varco equipment. After initial system operation, Varco recommends that the
hydraulic supply system be capable of continuously maintaining this level of
cleanliness or better to assure that fluid contamination is not a factor in any component
failure during the desired useful life of the hydraulic powered equipment. The final
level of acceptable cleanliness prior to equipment hook up must be determined by a
hydraulic fluid sample and should be analyzed by a qualified laboratory.
6
Hydraulic Fluid Cleanliness
SM00081-C
Hydraulic Fluid Contamination
Hydraulic Fluid Contamination
Solid contamination
When determining contamination of hydraulic fluids, you must consider the size and
quantity of the solid particle contamination within a representative fluid sample. The
contamination of hydraulic fluids by solid particles is covered by a number of different
classification systems:
❏ ISO DIS 4406
❏ MIL STD 1246 A
❏ NAS 1638
❏ SAE 749 D
❏ CETOP RP 70 H
CLASSES OF CONTAMINATION
The various classes of contamination define the quantity of particles of a certain size in
a 100 ml sample of fluid.
A classification is determined by counting and sizing the contaminating solid particles.
The classification is performed either under a microscope, or by using an electronic
particle counter. The electronic counter method is more objective than using the
microscope.
Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the
contamination can only be ascertained by weight, i.e., by gravimetric analysis.
However, with this method, the individual dirt particles cannot be classified.
SM00081-C
Hydraulic Fluid Cleanliness
7
NAS 1638
(1967)
SAE 749 D
(1963)
Particles
per ml
>10 µm
ACFTD
solids
content
mg/L
26/23
140000
1000
25/23
85000
23/20
14000
21/18
4500
20/18
2400
20/17
2300
20/16
1400
19/16
1200
10
18/15
580
9
6
17/14
280
8
5
16/13
140
7
4
15/12
70
6
3
14/12
40
14/11
35
5
2
13/10
14
4
1
12/9
9
3
0
18/8
5
2
10/8
3
10/7
2.3
10/6
1.4
9/6
1.2
0
8/5
0.6
00
7/5
0.3
6/3
0.14
5/2
0.04
Figure 1.
8
Mil STD
1246 A
(1967)
ISO DIS
4406
or
Cetop RP
70 H
Hydraulic Fluid Cleanliness
1000
100
700
12
500
11
10
300
1
200
0.1
100
1
0.01
Acceptable range for Varco equipment
Acceptable range for Varco equipment
October 26, 2000
50
0.001
Comparison of contamination classifications
SM00081-C
Comparison of contamination classifications
MEASURING THE CONTAMINATION OF A SYSTEM
Solid particle contamination is measured by taking a sample of fluid from the output of
the hydraulic supply system at a location just prior to the Varco equipment and
analyzing it.
The analysis can reveal the following:
❏ Solid particle contamination of fluid delivered by suppliers
❏ Effectiveness of the system filters
❏ Flushing time when commissioning a system
❏ State of the system and any possible damage to components when making regular
checks
Taking samples
Take a sample from a moving fluid (known as dynamic sampling)
Sampling point: Take the sample within a system that is operating and which contains
turbulent flow. (See ISO 4021.)
Since obtaining a fluid sample can be an input for contamination the following general
measures should be utilized when taking a fluid sample.
❏ Utilize continuous flow monitoring equipment that records a cleanliness level over
a period of time whenever possible.
❏ Take a sample of the circulating fluid of a system that is at operating conditions and
temperature. All fluid samples shall be taken from a system test-port fitting using
a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish
a leak point as a fluid source for fluid contamination sampling.
❏ Before attaching the sampling device, carefully flush out the device and clean the
system test-port fitting.
❏ Open sampling device and allow approximately 2 liters of fluid to flow through the
test port prior to sampling the fluid.
❏ Without shutting the test port, open and fill the sterile sampling bottle by holding
it in the continuous fluid stream. Cap and seal the test bottle.
❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit
location.
e Only properly trained personnel should be allowed to take the fluid samples. Errors in
sampling procedures can greatly affect contamination classes below ISO 18/IS.
SM00081-C
Hydraulic Fluid Cleanliness
9
October 26, 2000
ANALYZING THE SAMPLES
Analyzing the fluid samples involves using a microscope to make a quick estimate of
the amount of solid particle contamination. From this assessment, you can roughly
assess the state of the system.
To avoid errors in sampling, conduct particle counting off site. Do not allow rig
personnel to attempt to check the samples at the time of sampling. Send the samples to
an appropriate institute for testing.
Usually, samples are analyzed by means of an electronic particle counter. These
particle counters are employed by major users of hydraulics, manufacturers of
hydraulic filters, and by various institutions. Since testing by an outside source may not
be easily accessible from a rig, you can make a quick assessment of the fluid samples
on the spot by using the assessment test charts in this document.
z Mobile laboratory services can also perform the measurements for customers.
10
Hydraulic Fluid Cleanliness
SM00081-C
Cleanliness during installation
Cleanliness during installation
Service loops
Varco service loops are blown clean in the factory and capped prior to shipment. They
are not flushed. All service loops and hoses should be flushed as part of the overall
hydraulic system prior to connecting Varco equipment.
Hydraulic pipe cleaning
z Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The
following processes are examples of pickling, cleaning, and flushing procedures for
cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and
are provided for information and reference only. Varco is typically not responsible for
any part of the pickling, cleaning, or flushing process of derrick and rig floor piping.
The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe
(carbon or stainless), the condition of the pipe (pickled or not pickled), the types and
levels of contamination, the types and temperatures of the pickling and flushing
solutions in use, and the type of flushing equipment.
REFERENCE DOCUMENTS:
❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and
purification of petroleum fluid hydraulic system.
PIPE CLEANING (CARBON STEEL):
Obtain the following chemicals:
Hydrochloric acid - 35% commercial grade
Alkaline cleaner, KD-500
Potable water - Unless otherwise specified
Passivator - iron phosphate, KO-30
Inhibitor - Rodine 214 for HCL
SM00081-C
Hydraulic Fluid Cleanliness
11
October 26, 2000
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish
or other tough soils should be sandblasted prior to pickling.
Rinse
Rinse carbon steel pipe with potable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at
ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed.
Rinse with potable water until all alkaline cleaner is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH (7.0).
Flush
Begin flushing the piping with the hydraulic power unit until the desired state of
cleanliness is met.
12
Hydraulic Fluid Cleanliness
SM00081-C
Cleanliness during installation
PIPE CLEANING (STAINLESS STEEL)
Use the following recommended procedure for cleaning stainless steel pipe:
Obtain the following chemicals:
Nitric acid - 42% technical grade
Hydrofluoric acid - 35% technical grade
Alkaline cleaner, KD-500
Potable water - unless otherwise specified
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present.
Rinse
Rinse pipe with portable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at
ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH.
Passivate
Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for
approximately one-half the time used in acid pickling.
Rinse
Rinse with potable water until the PH of the effluent equals the pH of the influent.
Dry
Dry with oil-free air until all visible traces of moisture are removed.
Final inspection
Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to
hooking up equipment pump clean hydraulic fluid through the plumbing and measure
the contamination of the system per this specification. Additional flushing and cleaning
may be required if contamination levels do not meet the requirements of this
specification.
SM00081-C
Hydraulic Fluid Cleanliness
13
FINAL DOCUMENTATION
TDS-11SA - Top Drive Drilling System
Chapter 18.0
Service Center Directory
www.nov.com
National Oilwell Varco
Service Center Directory
Reference
Reference Description
This document contains proprietary and confidential
information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only National Oilwell Varco
and remains the property of NOV. Reproduction, in whole
RIG SOLUTIONS
or in part, or use of this design or distribution of this
information to others is not permitted without the express 11000 Corporate Centre Drive
written consent of NOV. This document is to be returned to Houston, TX 77041
NOV upon request or upon completion of the use for which
it was loaned. This document and the information
contained and represented herein is the copyrighted
property of NOV.
© National Oilwell Varco
www.nov.com
Form D811001123-GEN-001/06
Document Number
Rev.
D811001337-DAS-001
04
D811001337-DAS-001
Revision 04
Revision History
04
12.11.2011
Operations update
T. Drake
S. Sobreira
T. Harmon
03
18.01.2011
Operations update
T. Drake
T. Harmon
T. Harmon
02
02.10.2009
Operations update
T. Drake
T. Harmon
P. Williams
01
08.09.2009
First Issue
T. Drake
T. Harmon
P. Williams
Rev
Date (dd.mm.yyyy)
Reason for issue
Prepared
Checked
Approved
Change Description
Revision
Change Description
01
First Issue
02
• Moved Cairo office under North Africa heading.
• Changed address information for India office.
03
• Removed outdated Louisiana contact information.
• Added the new Louisiana service and repair center contact information.
04
•
•
•
•
•
www.nov.com
Updated/added Brazil, Canada, Colombia, UK contact information (page 3 through page 8).
Added North Dakota contact information (page 4).
Updated the contact information for the China office (page 6).
Added addresses and contact information for Singapore and India (page 6).
Updated contact information for NOV Dubai and NOV Abu Dhabi. (page 8).
D811001337-DAS-001
Revision 04
Service Center Directory
SC
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx
Americas
Brazil
National Oilwell Varco do Brasil
Rodovia Amaral Peixoto, s/n KM164,5 - n° 8.500
Imboassica – Macaé – RJ – Brazil
CEP 27925-290
+55 22 2773 0600 (reception)
+55 22 9882 7591 (after hours)
+55 22 9702 8866 (drilling equipment)
+55 22 9974 7056 (PCE / MoComp equipment)
+55 22 9894 6608 (lifting and handling equipment)
+55 22 2773 0635 (repair shop)
+55 22 2773 0675 (inside sales)
+55 22 2123 2452 (tech college)
Canada
NOV Rig Solutions Aftermarket Service, Repair and Rentals (Leduc)
Varco Canada ULC CO 009
6621 – 45 Street
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712 (main)
NOV Rig Solutions Spares (Edmonton)
Varco Canada ULC CO 009
7127 – 56 Ave
Edmonton, Alberta, Canada
T6B 3L2
+1 780 801 1800 (main)
+1 780 619 5579 (24 hour on-call)
Colombia
National Oilwell Varco de Colombia
Bogota, DC
Top Drive Rental and Service
+57 316 875 8748 (mobile)
+57 317 515 3321 (mobile)
3
www.nov.com
Form D811001123-GEN-001/06
SC
Service Center Directory
D811001337-DAS-001
Revision 04
Page 4 of 10
Americas
USA
Colorado
NOV Service and Repair (Colorado)
420 South Ash St.
Fruita, CO 81521
+1 970 858 4522
+1 281 569 3050 (after hours)
Louisiana
NOV Service and Repair (Covington)
73765 Penn Mill Rd.
Covington, LA 70435
+1 985 892 8216 (direct)
+1 800 722 4425 (toll free)
(Cranes: AmClyde, Unit, OS National, Dreco, Kingpost)
+1 985 871 8609 (service)
+1 985 871 8603 (parts
NOV Service and Repair Center (New Iberia)
5212 Highway 90 Service Road West
New Iberia, Louisiana 70560
(All NOV spare parts; legacy Shaffer, Varco, and NOI equipment)
+1 337 374 1400
Minnesota
NOV Service (St. Paul)
240 East Plato Blvd.
St. Paul, Minnesota 55107
(lifting and handling equipment)
+1 651 293 4745 (service)
+1 651 293 4776 (service)
+1 651 293 4600 (parts)
+1 651 293 4603 (parts)
North Dakota
NOV Service, Repair, and Spare Parts
3201 1st Avenue W.
Williston, ND 58801
+1 307 473 8888
+1 281 569 3050 (after hours)
Oklahoma
NOV Service and Repair (Oklahoma City)
7713 North West 3rd St.
Oklahoma City, Oklahoma 73127
+1 405 495 1000
+1 281 569 3050 (after hours)
4
www.nov.com
D811001337-DAS-001
Revision 04
Page 5 of 10
Service Center Directory
SC
Americas
USA
Pennsylvania
NOV Service (Pittsburgh)
1349 Saw Mill Run Blvd.
Pittsburgh, Pennsylvania 15226
+1 412 884 1027
+1 281 569 3050 (after hours)
Texas
NOV Service and Repair (Alice)
2351 Energy Avenue
Alice, Texas 78380
+1 361 668 4154
+1 281 569 3050 (after hours)
NOV Service and Repair (Houston)
5100 North Sam Houston Parkway West
Houston, Texas 77086
+1 281 569 3050 (24/7 technical support)
+1 281 569 3051 (eHawk remote support)
Wyoming
NOV Service and Repair (Casper)
1080 North Robertson Road
Casper, Wyoming 82601
+1 307 473 8888
+1 281 569 3050 (after hours)
Venezuela
NOV Rental and Service (Maturin, Monagas)
Varco International de Venezuela
Top Drive Rental and Service
+58 291 651 6489
+58 414 394 2784 (mobile)
+58 291 651 4384 (fax)
5
www.nov.com
SC
Service Center Directory
D811001337-DAS-001
Revision 04
Page 6 of 10
Asia
China
NOV Service
18th Floor, Raffles City Beijing Office Tower
No. 1, Dongzhimen South Street, Dongcheng District
Beijing 100007 P. R. China
+86 139 0121 9392
+86 800 810 5109 (24/7 technical support)
India
NOV Service and Repair
R-619, TTC Industrial Area
Rabale, MIDC
Navi Mumbai – 400 701
Maharashtra, India
+91 22 3916 9700
+91 982 009 1322
+91 983 349 6154 (after hours)
NOV Machining Centre (Pressure Control)
11A/2 (NP) Sidco Industrial Estate
Ambattur
Chennai, Tamil Nadu, India 600098
+91 44 4285 8074
+91 95 0008 4149 (after hours)
Singapore
NOV Service and Repair
29 Tuas Bay Drive
Singapore 637429
+65 6594 1000
+65 6594 1222 (24/7 technical support)
NOV Machining Centre (Pressure Control)
22 Jalan Terusan
Singapore 619299
+65 6265 1900
+65 9128 2545 (after hours)
6
www.nov.com
D811001337-DAS-001
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Page 7 of 10
Service Center Directory
SC
Europe
France
NOV Service
+33 24 068 3600
+33 24 068 3611
+33 24 068 3600 (after hours)
+33 677 790 943 (after hours)
Norway
NOV Service (Asker)
Blakstadmarka 26
1386 Asker – Norway
+47 6400 5000
+47 6400 5001 (after hours)
NOV Service (Kristiansand)
Skibaasen 2
4636 Kristiansand – Norway
+47 3819 2000
+47 3819 2482 (after hours)
NOV Service (Molde)
Granfjaera 24
6415 Molde – Norway
+47 7120 2020
+47 9169 9664 (after hours)
NOV Repair (Stavanger)
Dusavik Base
Notberget 46
4029 Stavanger – Norway
+47 5781 8181
NOV Service (Stavanger)
Lagerveien 8
4069 Stavanger – Norway
+47 5181 8181
+47 4140 0041 (after hours)
+47 9511 8181 (24/7 eHawk remote support)
Russia
NOV Service and Support
Russia, 119071, Moscow
Leninsky prosp., 15A, 7th floor
+7 495 287 2601 (direct)
+7 495 981 3470 (fax)
+7 985 410 5272 (mobile)
7
www.nov.com
SC
Service Center Directory
D811001337-DAS-001
Revision 04
Page 8 of 10
Europe
UK
NOV Service and Repair (Aberdeen/Montrose)
Forties Road
Montrose
Scotland
DD10 9ET
+44 1674 677222
UK after hours, on-call contacts
+44 (0) 7711 415 485 (mechanical)
+44 (0) 7711 415 484 (electrical)
+44 (0) 7739 170 079 (repair workshop)
+44 (0) 7713 643 012 (spare parts)
+44 (0) 7770 325 333 (distribution)
+44 (0) 7801 078 092 (IMO/MD Totco)
Middle East
UAE
NOV Service and Repair (Abu Dhabi)
Varco Al Mansoori Services LLC
P. O. Box 27011
Abu Dhabi, United Arab Emirates
+971 2 555 2668
+971 2 554 2280 (fax)
+971 2 554 0012 (fax)
+971 50 811 6083 (after hours service)
+971 50 617 1235 (after hours workshop)
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, United Arab Emirates
+971 4 883 8776
+971 4 883 8795 (fax)
+971 56 686 2184 (after hours service on-call)
North Africa
NOV Service (Algeria)
Overseas Equipment Service Africa
BP 852 Zone Industrielle Algerie
Hassi Messaoud Ouargla
Algeria 30500
+213 29 73 1236
+213 29 75 4105 (fax)
8
www.nov.com
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Service Center Directory
SC
Middle East
North Africa
NOV Service and Repair (Badr City)
IMPEC (Sea Harvest Company)
Part B, 47 Acer Area
Badr City, Cairo, Egypt
+20 2 231 08001
+20 2 231 08002
+20 2 231 08003 (fax)
Saudi Arabia
NOV Service and Repair (Dammam)
P. O. Box 20754, Al-Khobar 31952
Al Khobar, Saudi Arabia
Gate No. 2, Makkah Street (opposite of Saudi Electricity Company)
Dammam Second Industrial City
Dammam, Saudi Arabia
+966 3 835 3061
+966 3 830 2453 (fax)
9
www.nov.com
SC
Service Center Directory
D811001337-DAS-001
Revision 04
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10
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