ADS-10D

Automated Drawworks System

Service Manual

SM00980
Revision A
© Copyright 2003 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 1

Specifications 2

Maintenance 3

Troubleshooting 4

Glossary 5
1 General Information

2 Specifications

3 Maintenance

4 Troubleshooting

5 Glossary
 General Information

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
ADS-10D Automated Drawworks System . . . . . . . . . . . . . . . . . 1-8
Automated Drawworks Components . . . . . . . . . . . . . . . . . . . . 1-10 3
Oil Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
LH Pneumatic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
RH Pneumatic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Brake Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
LH or RH Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 4
Peripheral Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
ADS Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
ADS Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 5
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Braking Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Lowering the Block - Tripping . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Lowering the Block - Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Lowering the Block - During Power Failure . . . . . . . . . . . . . . . . 1-24
Hoisting the Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Torque Transfer Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

ADS-10D
 General Information

Varco
 General Information

Intended Audience
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 1
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 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
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 Varco® documentation.

ADS-10D 1-3
 General Information

Safety Requirements
Varco® equipment is installed and operated in a controlled drilling rig environment
involving hazardous situations. Proper maintenance is important for safe and reliable
1 operation. Procedures outlined in Varco® 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.

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.

!
Personnel should wear protective gear during installation,
maintenance, and certain operations.

Contact the Varco® Drilling Equipment 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. Varco® 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 Varco®.

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.

1-4 Varco
 General Information

Safety Requirements
Replacing Components
† Verify that all components (such as cables, hoses, etc.) are tagged and labeled 1
during assembly and disassembly 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 injury to personnel.
Routine Maintenance
Equipment must be maintained on a 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 its intended purpose.

ADS-10D 1-5
 General Information

Description
The ADS-10D Automated Drawworks System (ADS) is used for hoisting the traveling
equipment of a drilling rig to remove and insert tubulars into the well bore.
1
The ADS is a gear-driven drawworks with VFD-controlled AC motors and multi-plate
friction brakes. Optional resistive (regenerative) braking via the main motors can be
applied to augment the friction brakes. The drawworks components are mounted on a
unitized skid. The driller, at an operator control station, uses a dedicated joystick and
switches to remotely operate the ADS through a Varco® Integrated Control Instrument
System (V-ICIS).

Wire Rope Drum

The wire rope drum is supported by two bearing carries mounted to a structural steel
skid. The drum is fitted with Lebus grooving for customer-specified wire. A crown saver
toggle valve is located above the drum. The valve is located where it can be activated
by the wire rope, just short of the point at which a crown collision would occur. When the
valve is activated it sends a signal to a crown saver pressure switch which alerts the
control system to stop the drum.

Gearboxes (Dry Sump)

The 1500 HP, single-speed, double-reduction gearboxes transfer power between the
AC motors and the wire rope drum. Mounted on the clutch shaft is a pneumatically-
released, spring-operated, multi-disc clutch that transmits torque between the first and
second gear reduction. The clutch must be engaged for all velocity control by the motors
during hoisting and lowering. Lubricating oil for the gears and bearings is supplied by an
external electrical pump system with a frame-mounted reservoir.

Gearboxes (Wet Sump)

Same as the dry sump geabox type except lubricating oil for the gears is supplied by the
sump inside the gearbox. Lubricating oil for the bearings is supplied by an external lube
system.

Clutch
The clutch provides the opportunity to disengage the drive motors from the drumshaft.
This is used in ESD situations to reduce the (motor) inertia that the plate disc brakes
must retard. It is also used when electrical repairs or maintenance is being performed,
and it is necessary to tune the VFDs by running motors, or change motors.

AC Motors
The ADS uses 1150 HP (continuous rating), variable speed AC motors to drive the wire
rope drum through the gearboxes. The motors are coupled to the gearboxes with double
spherical gear drive couplings. The wide range of motor speed allows the ADS to
achieve a broard range of hoisting speeds. Using multiple motors increases hoisting
capability.

Motor Blowers
The motor blowers provide open loop, forced-air cooling to the AC motors.

1-6 Varco
 General Information

Description
Friction Brakes
The brake is a combination spring and air-operated, multi-plate disc brake. It applies
braking to the drum during operations as well as parking braking. Two braking methods
1
are available to the operator: dynamic breaking using the friction brakes, and
regenerative braking through the AC motors.
One brake is mounted at each end of the drumshaft. The rotating brake discs are spline-
coupled to the drumshaft, and the brake housing is attached to the skid. Each brake has
three water-cooled discs for dynamic braking control and a single, air-cooled brake disc
for added static parking and emergency stopping capacity.

Rotary Encoders
Rotary encoders provide speed and block position information. Encoders are direct-
coupled to each motor and are coupled to the clutch shaft by a drive belt.

Sensing and Feedback Devices

Sensing devices are used to monitor equipment functions. Sensor device outputs are
sent to the control system where they are processed to provide feedback for closed-loop
control and to display status information to the driller. Several types of sensing devices
are used. The various sensing and feedback devices and their locations are illustrated in
Chapter 4, Troubleshooting, Electrical Components Diagram.

ADS Control System

The ADS control system processes all data from the operator controls to the drawworks,
and all feedback from the drawworks to the operator. The processed data is used to
control all drawworks functions and inform the operator of drawworks operations and
status. The control system also provides these safety features:
‰ Drill line protection
‰ Collision protection
‰ Equipment protection
Optional Desert Kit
An optional desert kit includes sand filters on the blowers and 55 C ambient-rated
ancillary motors (blower motors and lube oil pump motor) and main AC motors.

ADS-10D 1-7
 General Information

ADS-10D Automated Drawworks

System
1
i
Derrick-mounted periphery
components not shown

OC
K
Control
System
ERL IDE
INT ERR H
OV SWITC
KEY

K
OC
ERL IDE

J-Box
INT ERR
OV

R
WE
PO OR
LAT
ISO

CO
P/N

MANUFAREF
MANU.
DATE

FREQUEN
ELECTR
:
VOLTAGE CE:
AMPS:
UPS UPS AMPS:
NON
Q
-10 TEM
AHS SYS
OL

ICAL
O
8
NTR: 3015448-DECKER/TOTC

M-D/T CTURER :
: MARTIN
TBD
: 4/02RATING 220Hz
60
2A
20 A
VAC
CE Panel

Gearbox 2 RH Pneumatic
Dry Sump Panel
Transfers power between
AC motor to the drumshaft RH Brake
Multi-plate disc brake.
Wire Rope Drum Provides primary
Spools the wire rope braking.
Gearbox 1
Dry Sump
Transfers power
between AC motor
to the drumshaft
Brake Release
Control Valve
J-Box
Panel

Air In
Water
Out
Water
In

Skid
Oil Lube
System
Components
Dry Sump
Filter
LH Brake
Lubricator Multi-plate disc brake. Well Center
Water
Provides primary braking.
LH Pneumatic Out Front View of Drawworks
Panel Water
In
Air In
LH Brake
Control Box

1-8 Varco
 General Information

ADS-10D Automated Drawworks

System
1

AC Motor A
Motor Blower
Intake
Typical

Blower
Motor A

AC Motor B

AC Motor A
J-Box

Blower
Motor B

AC Motor B
J-Box
AC Motor
RH Brake Exhaust Duct
Control Box Typical

Coupling Rear View of Drawworks

Lubricator Under Cover
Typical

Filter
i
1. Periphery components not shown.
2. Drawworks-related, vendor-supplied
equipment not shown.
3. AC motor J-Boxes are part of motor.

ADS-10D 1-9
 General Information

ADS-10D Automated Drawworks

System (Optional Desert Kit
1 Features)

Motor Blower
Intake
Blower Typical
AC Motor B
Motor A
Air Filter Gearbox 2
Blower Wet Sump
Motor B
Transfers power between
AC motor to the drumshaft
Air Filter

AC Motor A

Gearbox 1
Wet Sump
Transfers power
between AC motor
to the drumshaft

Oil Lube
System
Components
Wet Sump

Oil Lube
System
Components
Wet Sump

1-10 Varco
 General Information

Automated Drawworks Components

Oil Lube System (Dry Sump Gearbox)
1

To RH
Gearbox

Return Oil
Temperature
RTD RH Gearbox
Oil Return Line

Low-Low-Level
Oil Fill
Sensor
Port
Low-Level Senses critical
Sensor level of lube oil
Senses level
of lube oil
To LH
Gearbox

Filter
Removes contaminates
from lube oil
Return Oil
Temperature
RTD

To
Reservior
Vent
LH Gearbox
Oil Return Line

Access
Cover
Reservoir
Holds 80 gallons
Pressure of lube oil.
Transducer Has internal baffels
to settle air out of oil.
Ball Valve
Oil Drain Plug
Manual shutoff valve.
Located on bottom
Be sure to close this
of reservior
valve before replacing
Pump/Motor
lube components.
Pumps lube oil
to gearbox Oil Drain
Valve
Filter Clog
Indicator
Check
Valve

ADS-10D 1-11
 General Information

Automated Drawworks Components

Oil Lube System (Wet Sump Gearbox)
1

Pump/Motor

Spin-On
Filter
Test
Fitting

Ball
Valve

Pressure
Gage

Check
Pressure Check Spin-On Valve
Transducer Valve Filter

Test
Fitting

Ball
Valve

Pump/Motor

1-12 Varco
 General Information

Automated Drawworks Components

LH Pneumatic Panel
1

Warning
Label

Clutch/Crown
Saver Control Pressure
Gage

Crown Saver
Overide
Soldnoid Valve Test
Fitting

Clutch No.1
Engage
Soldnoid Valve
Ball Valve
Shown in
auto brake
Short Exhaust control position
Muffler
2 places

Parking
Brake No.1
Solenoid Valve

Air
Exhaust

ADS-10D 1-13
 General Information

Automated Drawworks Components

RH Pneumatic Panel
1

Clutch/Crown Pressure
Saver Control Gage

Test
Fitting

Clutch No.2
Engage Ball
Soldnoid Valve Valve
Shown in auto
brake control position
Short Exhaust
Muffler
2 places

i Parking Brake No.2

Solenoid Valve
Ball valve toggle handle
Handle vertical = Local brake control (Manual)
Handle horizontal = remote brake control (Auto) Air
Exhaust

1-14 Varco
 General Information

Automated Drawworks Components

Brake Control Boxes
1
RH Brake
Control Box

Enclosure

LH Brake
Control Box

Breather
Drain

Manifold

Cover

3-Way
Ball Valve

Short
Exhaust

ADS-10D 1-15
 General Information

Automated Drawworks Components

LH or RH Brake
1

Brake Front
View

Flow Servo Feedback

Control Pressure Transducer
Valve Provides feedback to
service brake controller
Water-Out
Manifold

Brake Water Cooling

RTD Outlet
In-Line Relief
Monitors water outlet
Valve
temperature from
2 places
service brake

Brake Water Cooling

RTD Inlet
Monitors water inlet
temperature to
service brakes

Brake Rear
View
Water-In
Manifold
Brake Cooling Water
Differential Pressure Transmitter
Monitors water flow
through service brake

1-16 Varco
 General Information

Peripheral Components
Peripheral components are ADS-related components that are mounted elsewhere on
the derrick. These components could include:
1
‰ Guide rail proximity J-box (installed on Fingerboard)
‰ Guide rail reference proximity sensors
‰ Standpipe pressure transmitter
‰ Deadline anchor pressure transmitter

ADS-10D 1-17
 General Information

ADS Control System

The control system processes

1 all data from operator controls.
The processed data is used to
direct ADS operations and provide
operational status.

MAINTENANCE MAINTENANCE
CPU
MODE MODE KEYSWITCH
RUNNING
ACTIVE OFF ON

VARCO

External ADS-10D CONTROL SYSTEM

VARCO P/N
M/D TOTCO P/N
MANUFACTURER
MANU. REF
: 30172263
:
: M/D TOTCO
:

Controls POWER
DATE

VOLTAGE:
FREQUENCE:
UPS AMPS:
: MM/YY
ELECTRICAL RATING
230 VAC
60 Hz
N/A

CAUTION POWER ON
ISOLATOR
NON UPS AMPS: 30 A

TO AVOID ACTIVATING THE

E-STOP SYSTEM WHEN
RESTORING POWER TO THIS
CONTROL SYSTEM:

1. PUSH AND HOLD POWER ON

PUSHBUTTON.
2. TURN POWER ISOLATOR TO
"ON" POSITION.
3. WHEN GREEN INDICATOR
IS ILLUMINATED, RELEASE
PUSHBUTTON.

Power
Supplies Exterior View
Circuit
Breakers

1 1

Single Board
2 2
3 3

1
2
3
1
2
3 OK
PS1 OK
PS2 OK
PS3

Computer 1
2
3
4
5
6
1
2
3
4
5
6
230V VOLTAGE
SELECTOR
230V VOLTAGE
SELECTOR
230V VOLTAGE
SELECTOR

25A 1A 1A 1A 2A 6A 6A 6A 6A
1 1
2 2
3 3
4 4
5 5
6 6

1 1 6ES7 307-1BA00-0AA0 6ES7 307-1BA00-0AA0 6ES7 307-1BA00-0AA0

2 2

1 1
2 2

Analog I/O Modules,

Relays Digital I/O Modules,
SF DP
BUSF
SIEMENS SM 322
32X24VDC,0.5A
SM 321
32X24VDC,DI
SM 332
AO4 X 12 BIT
SM 331
AI8 X 9-15 BIT
Interface Module
0 0 0 0 0 0
ON
1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
4 4 4 4 4 4
5 5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
8
9
10
SIMATIC 11
ET 200M 0 0 0 0 0 12
1 1 1 1 1 13
2 2 2 2 2

Ethernet
14
3 3 3 3 3 15
4 4 4 4 4 16
5 5 5 5 5 17
6 6 6 6 6 18
7 7 7 7 7 19
20
2 3 4

Fast Connect
Outlet
RL1
1
2
3
4
5
6
1
2
3
4
5
6
Terminal Blocks
S3
L+ M PE M5
7 7

(Typical)
8 8
SIEMENS SIEMENS RL2 9
10
9
10
SINEC L2FO OLM SINEC L2FO OLM
11 11
RL3 12 12
RJ-45 FAST-CONNECT

A1 B1 A1 B1

1 1
RL4 2
3
2
3

Optical Link
4 4
OLM1 OLM2 RP1 RL5 5
6
5
6
L3 7
8
7
8
SIEMENS
RS 485-REPEATER
RL6 9 9

Modules
A2 B2 A2 B2
1 1
2 2
3 3
4 4
5 5
1 1 6 6
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10 1 1
2 2
3 3
1 1 4 4
2 2
3 3
4 4 1 1
5 5 2 2
6 6 3 3
7 7 4 4
8 8
9 9
10 10 1 1
11 11 2 2
12 12 3 3
13 13 4 4
14 14
15 15 1 1

RS-485
16 16 2 2
3 3
1 1 4 4
2 2
3 3 1 1
4 4 2 2
5 5 3 3

Repeater
6 6 4 4
7 7
8 8
9 9
FIBER PATCH PANEL 10
11
10
11
1
2
3
1
2
3
12 12 4 4
13 13
14 14
15 15 1 1
16 16 2 2
3 3
4 4
1 1
2 2
3 3

Fiber Patch Interior View

Panel Door Removed

1-18 Varco
 General Information

Controls and Indicators

ADS Control System
1

CPU Running Manufacturer's

Indicator L1 Label
Green

Filter
Exhaust

MAINTENANCE MAINTENANCE
CPU
MODE MODE KEYSWITCH
RUNNING
Maintenance Mode ACTIVE OFF ON

Active Indicator L2
VARCO
ADS-10D CONTROL SYSTEM Maintenance Mode
VARCO P/N : 30172263

Red
M/D TOTCO P/N
MANUFACTURER
MANU. REF
:
: M/D TOTCO
:
Keyswitch S2
DATE : MM/YY
ELECTRICAL RATING
VOLTAGE: 230 VAC
FREQUENCE: 60 Hz
UPS AMPS: N/A
POWER
CAUTION POWER ON
ISOLATOR
NON UPS AMPS: 30 A

TO AVOID ACTIVATING THE

E-STOP SYSTEM WHEN
Power On RESTORING POWER TO THIS
CONTROL SYSTEM:
Power Isolator
Indicator 1. PUSH AND HOLD POWER ON
PUSHBUTTON. Switch S1
2. TURN POWER ISOLATOR TO
"ON" POSITION.
3. WHEN GREEN INDICATOR
IS ILLUMINATED, RELEASE
PUSHBUTTON.

Fan
Drawing Air

ADS-10D 1-19
 General Information

Controls and Indicators

ADS Control System
1
i
INTERLOCK OVERRIDE is used primarily during
maintenance and troubleshooting functions.

Control/Indicator Function
POWER ISOLATOR switch Controls application of power to the cabinet.
S1
MAINTENANCE MODE Key-operated switch. This switch is turned on to override the system
KEYSWITCH OFF ON S2 interlocks. Used when performing maintenance.
CPU RUNNING indicator L1 Illuminates solid green to indicate the Central Processing Unit (CPU)
(green) in the SBC is processing data.
MAINTENANCE MODE Illuminates solid red to indicate the MAINTENANCE MODE
ACTIVE indicator L2 (red) KEYSWITCH is in the ON position.
POWER ON indicator Illuminates solid to indicate power is applied to system.
Manufacturers label Provides manufacturers part number and electrical rating
information.

i
There is no need to set any switches inside the control
system cabinets. Internal controls were set at the factory,
or during installation and commissioning of the equipment.
However, when replacing components, such as circuit
cards or modules, always check that the switch settings on
the replacement item matches the settings on the item
being removed.

1-20 Varco
 General Information

Operation Overview

The ADS is operated semi-automatically, meaning the operator is in constant control of 1

the ADS through use of a joystick and switches whose outputs are fed to the drawworks
through the control system.
Modes of operation are selected during initial setup and configuration of the equipment.
This is done through the V-ICIS operator control screen. (Refer to the V-ICIS User’s
Manual for more details.)

i
The joystick is spring-loaded so it returns to center position
when released, which is the off position for safety.

The joystick is used as a velocity control where the speed of hoisting or lowering the
traveling equipment is proportional to the displacement of the joystick handle. The
operational positions of the joystick are listed below.

Desired Joystick ADS Response

Operation Position
Lowering with motors Forward from Angle of joystick position determines the command
or dynamic brakes center position speed of the traveling assembly.
Hoisting with motors Back from Angle of joystick position determines the command
center position speed of the traveling assembly.

Actual speed is determined by the hook weight and

position of travelling assembly, limited by angle of
joystick from center position.

ADS control switches are located on the V-ICIS control panel. They are described
below.

Control/Indicator Function
ADS PARKING BRAKE Turns parking brake on/off and selects operation in automatic mode
switch using the OFF/AUTO and ON switch positions.
OVERRIDE indicator Illuminates when system interlocks have been overridden.
EMERGENCY STOP Used in an emergency situation. When pressed, the following
pushbutton switch (located events occur:
on the right control panel) 1. Shuts off power to the ADS.
2. Spring-applied brake actuator vented (brakes applied).
3. Motor VFDs off.
4. Clutch remains engaged.

ADS-10D 1-21
 General Information

Operation Overview
Operating Modes
1 Normal Mode
This mode is used for most operations. When the system is in the Normal Mode, joystick
control is scaled to the driller-defined maximum speeds. All position-based travel limits
are active.

Slow Mode
This mode is used for fine position control. When the system is in Slow Mode, joystick
control is scaled for 10 % of the maximum settings. All position-based travel limits are
active.

Slip and Cut Mode

The Slip and Cut Mode is used when replacing worn wire rope. When the system is in
Slip and Cut Mode, operating speed is limited to a maximum fast-line speed of 60 ft/min,
and all position-based travel limits and safety interlocks are disabled. A warning is
displayed on the drillers screen when the Slip and Cut Mode is active. All braking
functions remain normal.

Block Position Calibration Mode

The driller enters this mode by selecting it on V-ICIS. When the system is in Block
Position Calibration Mode, all position-based travel limits and safety interlocks are
disabled and the driller is notified of this condition. The lower travel limit and upper travel
limit are disabled until the block position calibration is completed.

Electronic Driller Modes

The driller enters this autodrilling mode by selecting it on V-ICIS. There are four
autodrilling modes. These modes can be activated individually or in combination to
optimize drilling control. The system uses motor dynamic braking as required for the
following operations (mechanical braking is used to perform control in the ROP Mode).
‰ Rate of Penetration (ROP) Mode - controls the rate of decent of the traveling
equipment while drilling to a preset rate of penetration. This mode is useful when
setting the bit on the bottom, or when drilling soft formations where controlling the
penetration rate is important in drilling a consistent hole. ROP Mode takes
precedence over other modes.
‰ Weight on Bit (WOB) Mode - controls the rate of decent of the traveling equipment
to maintain a preset weight on the drill bit.
‰ Torque Mode - controls the rate of decent to maintain a preset torque limit of the
top drive. This mode is useful for increasing the life of the drill bits, and can also
be used to reduce the possibility and effects of slip-stick.
‰ Delta P Mode - controls the rate of decent of the traveling equipment to maintain a
preset pressure in the standpipe. This mode is only used with down-hole motors.
The delta standpipe pressure is an indication of the drill bits reaction torque into
the formation.

1-22 Varco
 General Information

Operation Overview
Electronic Driller Modes
Examples of using a combination of modes are as follows. In either example, torque can
be added to reduce the occurence of slip-stick:
1
‰ The combination of ROP and WOB modes are used to smoothly control the
movement of the drill string and maintain constant WOB.
‰ The combination of ROP and Delta P modes are used when drilling with constant
torque on down-hole motors while limiting the maximum rate of penetration.
Braking Modes
Parking Brake Mode
This mode is used by the driller to support the load using the Varco® friction brake for
long periods of time, or when the driller is not present at the drillers operator station.
The control system enters the Park Brake Mode when the driller activates the parking
brake switch, or automatically, due to a period of inactivity at zero speed command
(joystick is left at center-position).
If the driller activates the parking brake switch while the block is moving, the block
decelerates at maximum rate according to the velocity profile by the motors. When the
drum is stopped, the friction brake sets. Once the friction brake is supporting the load,
the torque limit to the VFD is zeroed.
If the parking brake was applied due to inactivity time-out, or by the Park Brake switch,
the operator must toggle the Park Brake switch to the OFF position to disengage the
Park Brake Mode. When the Park Brake Mode is disengaged, the load is transferred
from the friction brake to the AC motors (refer to Torque Transfer Sequence).

Brake Mode
This mode is used by the driller to support the load using the Varco® friction brake for
short periods of time when the driller does not want to support the load using the AC
motors, such as when the rig crew is working below the block.
To enter the Brake Mode the driller moves the joystick to the Brake position (detent to
right). To disengage and release the brake, the driller moves the joystick back to the
zero speed (center) position. At this time the load is transferred back to the AC motors.
(refer to Torque Transfer Sequence).

Stopped Mode
The driller must release the park brakes before moving the block in any direction.
Releasing the park brakes causes the load to be transferred from the brakes to the AC
motors. Once the motors are holding the load, the system is considered to be in the
Stopped Mode. All normal operations of hoisting and lowering begins and ends with the
system in Stopped Mode and the load being held by the AC motors. If the block is left in
the Stopped Mode without any movement for three minutes the system automatically
transition from stopped to park. (Note that the three minute Stopped Mode time is site-
configurable.)

ADS-10D 1-23
 General Information

Principles of Operation
The control system controls acceleration, velocity, and deceleration of the traveling
assembly in both the hoisting and lowering directions while maintaining safe and reliable
1 operation. By following a velocity profile, the control system optimizes the driller’s ability
to maximize the speed of trips between positions in the mast/derrick (between the travel
limits). Travel of the block assembly following the full velocity profile (from upper travel
limit to the lower travel limit and back again) is described in the paragraphs below, for
operation under normal conditions.

Definitions
Lower Deceleration Point
When lowering, the lower deceleration point is the lowest position at which regenerative
braking can be utilized to safely stop the block assembly without passing the lower
travel limit. The lower deceleration point is calculated by adding the calculated stopping
distance for downward travel to the lower travel limit position. Stopping distance is
calculated based on available braking torque (from brakes and motors), system inertia,
lines strung, hookload, and block position.

Lower Travel Limit

The lower travel limit is the driller defined position of lower most travel. The control
system will not allow the lower travel limit position to be set below the known position of
the drill floor. The control system, as part of the Zone Management System (ZMS),
automatically adjusts the lower travel limit based on the information regarding the
position of other equipment that can enter the zone in which the block travels.

i
It is the responsibility of the driller to to ensure the lower
travel limit setting is adequate to prevent equipment
hanging below the blocks and from striking other
equipment or the drill floor.

Hoisting Deceleration Point

When hoisting, the hoisting deceleration point is the uppermost position at which the
block begins deceleration to safely stop the blocks without passing the upper travel limit
and keep tension in the drill line. The hoisting deceleration point is calculated by
subtracting the stopping distance from the upper travel limit. Stopping distance is
calculated based on available braking torque (from brakes and motors) and system
inertia, lines strung, hookload, and block position.

1-24 Varco
 General Information

Principles of Operation
Definitions
Upper Travel Limit 1
The upper travel limit is the driller-defined position of uppermost travel. Just as the
control system assists the driller in preventing floor collisions, it also assists in
preventing crown collisions by not allowing an upper travel limit to be set above what is
known by the control system to be the maximum height before striking the crown block.

Regenerative Braking
Regenerative braking is the use of the motors, in generator mode, to provide the braking
function. When regenerative braking is in use the power generated is returned to the DC
bus. If this results in an increase in voltage on the bus, because there is insufficient load
on the bus to absorb power, chopper circuits feed power from the DC bus to a resistor
bank. In the case of a chopper or resistor failure, the control system reduces the
available braking power figure accordingly and uses the reduced power to calculate
maximum lowering velocity and stopping distance.

Velocity Control
The VFD system works as a velocity control system. The information on the position of
the joystick is sent to the VFD as a maximum desired motor speed, as limited by the
velocity profile. The center position of the joystick represents zero velocity (stationary
drum). The difference between the desired velocity and the actual velocity is an error
signal used by the control system.

Lowering the Block - Tripping

Reaching Lowering Velocity
When the driller commands downward travel of the block from a stopped condition
(where the brakes support the load), the control system performs a torque transfer
sequence and begin to accelerate the drum using the motors. The control system
calculates the maximum safe downward acceleration to prevent birdnesting the drill line
on the drum. Based on the calculated acceleration, the control system provides the
appropriate speed and torque limit commands to the VFD system. The velocity
command is ramped as calculated by the control system until either the velocity
indicated by the position of the joystick or a maximum velocity, as limited by the
equipment, is achieved.

Maintaining Maximum Velocity

The maximum velocity is determined from the position and inertia of the load, and the
available braking capacity of the motors and the friction brake. Once the block has been
accelerated to its maximum lowering velocity, that velocity is maintained, and overspeed
is prevented, by using the velocity control of the VFD system (regenerative braking) and
the friction brake.

ADS-10D 1-25
 General Information

Principles of Operation
Lowering the Block - Tripping
1 Stopping
As the driller continues to command lowering, the block assembly continues to travel
down at maximum velocity until reaching the lower travel limit. The driller can stop the
block assembly before it reaches the lower travel limit by returning the joystick to center-
position, thereby commanding zero velocity. The block assembly decelerates to zero
velocity according to the velocity profile. Sufficient motor torque is applied to hold the
load in place.

Lowering the Block - Drilling

After the proper parameters have been entered the drilling ahead task, the operator
raises the string off the slips by moving the joystick back. The VFDs are activated and
the AC motors begin to ramp up torque. Dynamic pads are engaged as the torque builds
and the static brake released.
Once the torque value needed to hold the drill string has been achieved the brakes are
released and the string rises. After the slips are disengaged, the driller moves the
joystick back to neutral, and the motors hold the string stationary. The driller engages
the electronic driller, releases the joystick and the ADS takes over the drilling control.
After the stand is drilled down, the parking brakes are engaged (static), and slips are
set. The connection is broken out, the driller pulls back on the joystick to hoist up the Top
Drive System (TDS). Once at the TDS is at its upper limit, a new stand of pipe is
inserted and TDS spins in and makes up both connections.

Lowering the Block - During Power Failure

When a total power outage occurs you can lower the traveling block by manual
operation of the brake release control valve as follows:

Actuating the hand lever on the brake release control

valve releases the brake. This control is for emergency
use only.

1. At both pneumatic panels, verify the pressure gages indicate zero pressure.
2. At both pneumatic panels and both brake control boxes, rotate the handle on the
3-way ball valves to the MANUAL position for local control.
3. At the LH pneumatic panel, slowly move handle on the brake release control valve
to lower the load. Release handle to stop lowering.
4. Return control to automatic mode (remote operation) by rotating the handle on all
3-way ball valves back to the AUTO position.

1-26 Varco
 General Information

Principles of Operation
Hoisting the Block
Releasing Brakes 1
When the driller commands upward travel of the block from a stopped condition (where
the brakes support the load), the control system performs a torque transfer sequence
and begin to accelerate the drum using the motors. The velocity command is ramped as
calculated by the control system until either the velocity indicated by the position of the
joystick or a maximum velocity, as limited by the hookload and available power is
achieved.

Maintaining Maximum Velocity

The maximum velocity is determined from the position and inertia of the load, and the
available braking capacity of the motors. Once the block has been accelerated to the
maximum hoisting velocity, that velocity is maintained, and overspeed is prevented, by
using the velocity control of the VFD system.

Deceleration and Stopping

When the block reaches the hoisting deceleration point the velocity command is ramped
to zero and regenerative braking torque, if required, is applied to decelerate the load
safely to the upper travel limit, as calculated to prevent fouling or birdnesting the drill
line. When the velocity drops to zero, sufficient motor torque is applied to hold the load
in place.

Torque Transfer Sequence

The torque (or load) transfer sequence is a method of smoothly transitioning from a
friction brake-held load to a load supported by the AC motors. The transition is
accomplished by sending a small hoisting speed command (about five RPM at the
motor) and a torque limit to the VFD system. This calculated torque limit is based on
hookload, number of lines and number of motors, and is of a magnitude large enough to
support the load (excessive torque could cause damage to the ADS and related
equipment).
Once the feedback torque from the motors equals the calculated torque limit, the friction
brake is ramped to zero over a short period of time. As the brakes are being released
and as soon as the system detects movement in the hoist direction, the speed
command is ramped to zero and the torque limit is ramped to maximum. Ramping of the
torque limit in this manner, as opposed to instantaneous changes, prevents transients
that could cause unnecessary and undesirable gearbox vibration should the drum begin
to rotate in the lowering direction, the brakes are reset and the torque transfer torque
limit is increased before trying again. The torque transfer sequence is repeated three
times before an alarm is generated.

ADS-10D 1-27
 General Information

Principles of Operation
Protection Features
1 Although the drillers experience and skill provides the primary safety functions, the
controls system provides the secondary functions described below.

Drill Line Protection

i
The driller is ultimately responsible for accelerating and
decelerating in a manner that does not damage the drill
line.

This protection is designed to give maximum life to the drill line. Drum acceleration when
lowering is limited, based on hookload and the number of lines strung, to a value that
keeps tension on the drill line. Deceleration is also limited when hoisting to keep a
similar tension on the drill line.

Drill Line Pull Limit Protection

This protection prevents excessive tension on the drill line. The control system monitors
the measured hookload against the driller-entered hookload value. The driller-entered
value is used to determine the maximum torque limits for each motor. These values limit
the acceleration of the system and prevent over-pull on stuck pipe.

Collision Protection

i
The driller is ultimately responsible for operating the ADS
in a manner that avoids collisions with the crown, drill floor,
or other drilling equipment.

This protection is designed to avoid collisions with the crown block, drill floor, or other
drilling equipment. Deceleration limits when lowering are calculated based on the
hookload, number of motors assigned, and number of lines strung. Deceleration limits
when hoisting are based on the acceleration required to keep tension on the drill line.
From these deceleration limits, and known system time delays, stopping distances are
calculated. The Zone Management System (ZMS) and driller-entered travel limits define
the allowable zones of travel for the traveling assembly. The combination of the
deceleration limits, calculated stopping distances, and driller-entered limits define the
velocity profile, or safe operating envelope. The control system uses this information to
control the movement of the traveling assembly and allow operating the system at the
highest acceptable speeds while keeping the systems within the operating limits of the
associated equipment.

1-28 Varco
 General Information

Principles of Operation
Protection Features
Equipment Protection 1
Various parameters are monitored to ensure that the equipment is operating properly
and will not be damaged by loss of utilities. Major parameters being monitored include:
‰ Lube oil pressure
‰ Brake air pressure
‰ Rig supply air pressure
‰ Brake cooling water temperatures
‰ VFD and AC motor parameters
Loss of these services or components, or operation outside the recommended limits of
these components, may cause the control system to enter a fault mode and stop the
ADS until the problem is corrected. For some faults, a driller-initiated override is
available to allow the block to move at maximum speed if the driller determines that the
overall safety of the rig is best served by continuing to operate the ADS, or associated
equipment.

ADS-10D 1-29
 General Information

Principles of 0peration
Protection Features
1 Emergency Stop (E-stop)
The control system can initiate two types of emergency stops:
1. Stopping the ADS by immediate removal of power, as in an uncontrolled stop.
When this type of E-stop is generated the system simultaneously dumps all air
from the spring-applied brakes and send all VFDs to coast. Conditions that lead to
this type of E-stop include:
‰ Activation of driller’s E-stop pushbutton switch
‰ ADS Control System failure
‰ Activation of the crown saver switch
‰ Loss of communications with remote I/O block controlling brake bypass
solenoid valves

2. A controlled stop with power available to the ADS to achieve the stop, then
removal of power when the stop is achieved. When this type of E-stop is
generated the system sets the velocity setpoint to zero and set the system for
maximum deceleration. After zero speed is accomplished the system dumps all
air from the spring-applied brakes and send all VFDs to coast. Conditions that
lead to this type of E-stop include:
‰ VFD PLC fault
‰ Block speed mismatch (command vs achieved)
‰ Failed torque transfer sequence (motor/brake)
‰ Low air pressure
‰ Block movement while stopped (creep)
‰ Loss of communication to the VFDs

i
The driller can override the control system by pressing an
override pushbutton on the operators control station. When
the ADS is in override mode, all position safeties are
inactive and the drawworks is allowed to operate at a
maximum speed of 50 ft/min only.

1-30 Varco
 General Information

Reference Material
Vendor documents are provided for additional information on the ADS and its
components, and ADS operation.
1

ADS-10D 1-31
 General Information

1-32 Varco
 Specifications

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Component Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 1
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Horsepower Modes and Hoisting Performance . . . . . . . . . . . . . 2-5

ADS-10D
 Specifications

Varco
 Specifications

Specifications
Physical Specifications
Size: Height (max.) 101 in.
Width (max.) 120 in.
Length (max.) 296 in.
Weight 100,000 lb max.

Component Specifications 2
AC motor: Power rating (max.) 1,400 HP (Intermittent)
1,150 HP (Continuous)
Speed (max) 3,000 RPM
Cooling (each 3,000 SCFM air
motor)
Gearbox: Type Single-speed, double-reduction, parallel shaft
Ratios: 10.71:1 overall (Dry Sump)
10.69:1 overall (Wet Sump)
2.90:1 first stage (input) (Dry Sump)
2.77:1 first stage (input) (Wet Sump)
3.69:1 second stage (Dry Sump)
3.86:1 second stage (Wet Sump)
Torque rating 11,000 ft lb (input shaft) (Dry Sump)
13,500 ft lb (input shaft) (Wet Sump)
Weight 13,000 lb (Dry Sump)
14,250 lb (Wet Sump)
Brake:
Brake size 4-plate, 36-inch diameter
Dynamic braking Type 3-disc, water-cooled, pressure-applied brake
system:
Emergency & Type Spring-applied, air-cooled, pneumatically-
Parking brake: released multi-disc brake (engages three
dynamic discs (noted above) and the single
air-cooled disc)
Minimum rig air 135 psi
pressure required
Maximum dynamic 183,750 ft lb
braking torque at
120 psi
Air quality (per ISA Max. particle size: 5 micron
Standard S7.3-1981):

Dew point: 10º C below minimum ambient

temperature, and not to exceed 2º C in any
case
Brake cooling: Flow rate to each 195 GPM
brake - water

ADS-10D 2-3
 Specifications

Specifications
Component Specifications
Brake: (cont) Brake cooling 6.0 M BTU/hr (total continuous)
system heat
dissipation capacity
required
Power rating 1950 hp each (150º F max. outlet water
(continuous) temperature and 50º F max. temperature
2 rise)
Water inlet pressure 40 psi max.
Wire rope Wire rope diameter Per customer specification
drum:
Drum core diameter Per customer specification
Drum length Per customer specification
Grooving Lebus
Wire rope: Type 6 x 19 Extra Improved Plow Steel (EIPS)
Specification API Specification 9A, Specification for Wire
Rope

Power Requirements
Electrical
Control system 120V AC, 60 Hz, 15A

Pneumatic
Pressure 135 psi (min)

2-4 Varco
 Specifications

Specifications
Horsepower Modes and Hoisting
Performance

i
The following illustrations are for 1 1/2-inch diameter rope
on a 36-inch diameter drum.
2

ADS-10D (2000 HP)

3rd Layer Hoisting Performance
Intermittent - (Zone 2 Application)
1,000,000

900,000

800,000

700,000
Hook Load (Pounds)

600,000

500,000
8 Lines

400,000 10 Lines

12 Lines
300,000

200,000

100,000

0
0 100 200 300 400 500
Hook Speed (Ft/Min)

ADS-10D 2-5
 Specifications

Specifications
Horsepower Modes and Hoisting
Performance

ADS-10D (1500 HP)

3rd Layer Hoisting Performance
Single Motor Max Performance Intermittent - (Safe Area Application)
700,000

600,000

500,000
Hook Load (Pounds)

400,000

300,000 8 Lines

10 Lines

200,000 12 Lines

100,000

0
0 100 200 300 400 500
Hook Speed (Ft/Min)

2-6 Varco
 Maintenance

General Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Inspecting Load-Carrying Components . . . . . . . . . . . . . . . . . . . 3-4
Monthly Inspection (Dry Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Monthly Inspection (Wet Sump) . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Inspection Every Six Months (Overall) . . . . . . . . . . . . . . . . . . . . 3-7 2
Inspection Every Six Months (Dry Sump) . . . . . . . . . . . . . . . . . . 3-8
Inspection Every Six Months (Wet Sump) . . . . . . . . . . . . . . . . . 3-9
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Lubrication After First Month of Operation (Dry Sump) . . . . . . . 3-13 3
Lubrication After First Month of Operation (Wet Sump) . . . . . . 3-14
Lubrication Every Six Months (Dry Sump) . . . . . . . . . . . . . . . . 3-15
Lubrication Every Six Months (Wet Sump) . . . . . . . . . . . . . . . . 3-18
Lubrication When Bearings Make Noise . . . . . . . . . . . . . . . . . . 3-21
Lubrication After Major Overhaul(Dry Sump) . . . . . . . . . . . . . . 3-22 4
Lubrication After Major Overhaul (Wet Sump) . . . . . . . . . . . . . 3-23
Replacing ADS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 5
Gearbox Coupling Hub Replacement . . . . . . . . . . . . . . . . . . . . 3-30
Motor Coupling Hub Replacement . . . . . . . . . . . . . . . . . . . . . . 3-32
Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
AC Motor and Blower Replacement . . . . . . . . . . . . . . . . . . . . . 3-34
Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Brake Gear Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Locking Collar Torquing Procedure . . . . . . . . . . . . . . . . . . . . . 3-39
Encoder and Encoder Belt Replacement . . . . . . . . . . . . . . . . . 3-40
Worn Wire Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Alignment and Adjustment Procedures . . . . . . . . . . . . . . . . . . 3-44
AC Motor/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Air Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

ADS-10D
 Maintenance

Varco
 Maintenance

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 supplier manuals for maintenance
procedures and schedules for the vendor equipment.

3
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.

ADS-10D 3-3
 Maintenance

Inspection Procedures
The inspection procedures assume normal operating conditions. Some conditions
(excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may
warrant more frequent inspection intervals. Perform the maintenance procedures
indicated, as warranted by the inspection.

Inspecting Load-Carrying Components

Because the load-carrying components are critical to performance, Varco recommends
performing visual inspections on a regular basis.
Visually inspect all load-carrying components for corrosion, fatigue, or other
deterioration. If you detect any excessive wear and tear on any component, replace the
component.
The criteria and interval for inspection of load-carrying components are determined by
3 your installation manager and by local regulatory requirements.

i
Before checking pneumatic lines, make sure that the power
is off and pneumatic pressure is removed from the ADS.

3-4 Varco
 Maintenance

Inspection Procedures
Monthly Inspection (Dry Sump)

Brake
• Check brake friction
linings for wear
(Refer to vendor manual)
Replace if necessary

Sight
Gauge
Oil Lube System

Filter/Lubricator
• Check air filter (Both sides)
Replace if necessary
• Check oil level
Top off oil level

Filter Element
• Check filter element
Replace filter element
if indicator shows
orange after resetting

ADS-10D 3-5
 Maintenance

Inspection Procedures
Monthly Inspection (Wet Sump)
Desert Kit Air Cleaners
Brake
( If Applicable)
• Check brake friction
• Check that drain is not linings for wear
blocked or obstructed (Refer to vendor manual)
(Drains are located on Replace if necessary
frontside)
Clear if necessary

Gearbox
3 • Check oil level at sight
guage
Fill if necessary

Oil Lube System

Filter Element
Sight • Check filter element
Gauge Replace filter element
if indicator shows
Filter/Lubricator orange after resetting
• Check air filter (Both sides)
Replace if necessary
• Check oil level
Top off oil level

Oil Lube System

Filter Element
• Check filter element
Replace filter element
if indicator shows
orange after resetting

3-6 Varco
 Maintenance

Inspection Procedures
Inspection Every Six Months (Overall)
Overall ADS-10D J-Boxes
• Inspect for loose or missing hardware • Inspect for loose or missing
Tighten or replace hardware
Tighten or replace
• Inspect for loose cables, hoses, tube
connections and pinched or broken lines. • Inspect for loose cables or
Tighten, repair or replace wiring connections
Tighten
• Inspect for abrasion, pinching, kinking,
cracking or excessive bending or twisting
of electrical cables
Repair or replace
• Inspect for damaged or leaking valves,
plugs, and fittings
Replace

! 3
Before checking hoses for damage,
make sure all ADS components are
stationary and OVERRIDE function is off.

Encoders
• Inspect for loose, worn
or cracked timing belts
Tighten or replace

Wire Rope
• Inspect for frayed or worn wire rope
(Refer to API recommended practice 9B)
Remove worn section

Brakes
• Inspect discs, friction liners, wear plates
and springs for excessive wear, pitting or
cracking (Refer to vendor manual)
Sensors and Switches Replace
• Inspect for broken or dirty sensors, loose
mountings or damaged wiring connections
Clean, tighten or replace as necessary
• Inspect for broken switches, loose
mountings or damaged wiring connections !
Tighten or replace as necessary
If an E-Stop has been activated due to an emergency,
the braking system should be inspected for wear
and possible need for adjustment before continuing operation.

ADS-10D 3-7
 Maintenance

Inspection Procedures
Inspection Every Six Months (Dry Sump)

Gearbox
• Inspect gearbox oil
seals for excessive leaks
Replace as necessary

Motor
• Inspect motor per
vendor manual
Replace

Rope Clamp
• Inspect for loose hardware
and clamp cracks
Repair or replace as necessary

Oil Lube System

Clutches
• Inspect for air leaks
and friction disk wear
(Refer to vendor manual)
Repair as necessary

Pump/Motor
• Dirty or clogged strainer
(Located in oil reservior)
Clean

3-8 Varco
 Maintenance

Inspection Procedures
Inspection Every Six Months (Wet Sump)

Gearbox
• Inspect gearbox oil
seals for excessive leaks
Replace as necessary

Motor
• Inspect motor per 3
vendor manual
Replace

Rope Clamp
• Inspect for loose hardware
and clamp cracks
Repair or replace as necessary

Clutches
• Inspect for air leaks
and friction disk wear
(Refer to vendor manual)
Repair as necessary

ADS-10D 3-9
 Maintenance

Lubrication Procedures

Recommended Lubricants
Recommended Gear Oils

Manufacturer -6° to 16° C 7° to 30° C Above 21° C

(20° to 60° F) (45° to 85° F) (Above 70° F)

Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320

Chevron NL Gear 68 NL Gear 150 NL Gear 320

Exxon Spartan EP68 Spartan EP150 Spartan EP320

3 Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320

Mobil MobilGear 626 MobilGear 629 MobilGear 632

Shell Omala 68 Omala 150 Omala 320

Statoil Loadway EP68 Loadway EP150 Loadway EP320

Texaco Meropa 68 Meropa 150 Meropa 320

Total Carter EP 68 Carter EP 150 Carter EP 320

Union Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP

Viscosity Index

AMGA 2EP 4EP 6EP

ISO Viscosity 68 150 320

Grade

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

Do not use gear oils in air lubricators. Use Parker Hannifin,

Type F442, or equivalent.

3-10 Varco
 Maintenance

Lubrication Procedures

Recommended Lubricants
Recommended General Purpose Lubricants

Manufacturer Below -20° C Above -20° C

(Below -4° F) (Above -4° F)

Castrol - MP Grease

Chevron Avi-Motive W Avi-Motive

Exxon Lidok EP1 Lidok EP2

Gulf Gulf Crown EP31 Gulf Crown EP32 3

Mobil Mobilux EP1 Mobilux EP2

Shell Alvania EP1 Alvania EP2

Statoil Uniway EP1N Uniway EP2N

Texaco Multifak EP1 Multifak EP2

Total Multis EP1 Multis EP2

Union Unoba EP1 Unoba EP2

Viscosity Index

NGLI 1 2

ADS-10D 3-11
 Maintenance

Lubrication Procedures

Recommended Lubricants
Recommended Grease

Manufacturer Description Used on

Shell Cyprina RA AC motors

Texaco Regal AFB-2 AC motors

Exxon Andok BR AC motors

Shell Super Duty, NLGI Grade 2 Lithium Motor couplings,

3 12-Hydroxystearate, Thickened Drum

i
Additional recommended greases for the motor couplings
are listed in the vendor manual.

Recommended Oil for Air Lubricator

Manufacturer Description

Parker Hannifin Type F442

Texaco Regal R&O 32

Sun Company SUNVIS 932

Union 76 Union 76 Turbine Oil 32

i
Refer to Alignment and Adjustment Procedures for
instructions on adjusting air lubricator oil delivery.

3-12 Varco
 Maintenance

Lubrication Procedures
Lubrication After First Month of Operation
(Dry Sump)
Changing Oil
1. Drain oil from reservoir into suitable
container, by opening oil drain valve.
2. Drain residual oil through drain plug
on bottom of reservoir.
3. Remove access cover and clean
strainers inside reservoir.
4. Replace gearbox oil through oil fill port
following first month of operation.
5. Select gear oil listed in recommended
lubricants, based on expected ambient
conditions for next six months. 3

Oil Fill
Port

Access Cover

Reservoir
Holds 80 gallons of lube oil
Oil Drain Plug
Replace Filter Located on bottom of reservoir
Element Oil Drain
Valve

ADS-10D 3-13
 Maintenance

Lubrication Procedures
Lubrication After First Month of Operation
(Wet Sump)

Changing Oil
Oil Fill 1. Drain oil from gearbox into suitable
Port container, by opening oil drain valve.
2. Replace gearbox oil through oil fill port
following first month of operation. Fill
gearbox until oil shows in sight glass.
3 3. Select gear oil listed in recommended
lubricants, based on expected ambient
conditions for next six months.

Oil Drain
Valve

Sight
Glass

Replace Filter
Element

3-14 Varco
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Dry Sump)
Changing Oil

1. Drain oil from reservoir into suitable

container, by opening oil drain valve.
2. Drain residual oil through drain plug
on bottom of reservoir.
3. Remove access cover and clean
strainers inside reservoir.
4. Replace gearbox oil through oil fill port
following six months of operation.
5. Select gear oil listed in recommended
lubricants, based on expected ambient
conditions for next six months.
3

Replace
Reservoir
Breather Oil Fill
Port

Access Cover

Reservoir
Holds 80 gallons of lube oil
Oil Drain Plug
Replace Filter Located on bottom of reservoir
Element Oil Drain
Valve

ADS-10D 3-15
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Dry Sump)

Coupling
Cover Coupling
1. Remove coupling cover.
Coupling 2. Remove port G and H solid plugs.
Cover 3. Orient port G in the 3 or 9-o'clock
position.
4. Pump grease into port G and stop
when grease begins to exit port H.
5. Replace solid plugs when done.

3 i
Use Shell Super Duty Grease, NLGI Grade 2 Lithium
12-Hydroxystearate Thickened or Equivalent.
Refer to Amerigear 200 Series Felxiable Couplings, Installation,
Lubrication and Maintence Instructions.

Coupling
Cover Port G

Coupling Port H

3-16 Varco
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Dry Sump)

3
Drum Grease Fittings
Grease up to a point where lubricant flows externally.
Use Shell Super Duty Grease. NLGI Grade 2.
Lithium 12-Hydroxystearate thickened or equivalent.

Front View without Covers

ADS-10D 3-17
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Wet Sump)

Changing Oil
Oil Fill 1. Drain oil from gearbox into suitable
Port container, by opening oil drain valve.
2. Replace gearbox oil through oil fill port
following six months of operation. Fill
gearbox until oil shows in sight glass.
3. Select gear oil listed in recommended
lubricants, based on expected ambient
3 conditions for next six months.

Oil Drain
Valve

Sight
Glass

Replace Filter
Element

3-18 Varco
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Wet Sump)

Coupling
Cover Coupling
1. Remove coupling cover.
Coupling 2. Remove port G and H solid plugs.
Cover 3. Orient port G in the 3 or 9-o'clock
position.
4. Pump grease into port G and stop
when grease begins to exit port H.
5. Replace solid plugs when done.

i 3
Use Shell Super Duty Grease, NLGI Grade 2 Lithium
12-Hydroxystearate Thickened or Equivalent.
Refer to Amerigear 200 Series Felxiable Couplings, Installation,
Lubrication and Maintence Instructions.

Coupling
Cover Port G

Coupling Port H

ADS-10D 3-19
 Maintenance

Lubrication Procedures
Lubrication Every Six Months (Wet Sump)

3
Drum Grease Fittings
Grease up to a point where lubricant flows externally.
Use Shell Super Duty Grease. NLGI Grade 2.
Lithium 12-Hydroxystearate thickened or equivalent.

Front View without Covers

3-20 Varco
 Maintenance

Lubrication Procedures
Lubrication When Bearings Make Noise

Motor Encoder Side

1. Remove upper and lower solid plugs.
2. Pump grease into upper port and stop
when grease begins to exit lower port. Upper
3. Replace solid plugs. Plug

Lower
Plug

Motor Output Shaft Side

1. Remove port A and B solid plugs.
2. Pump only the amount of grease
required to stop skidding or
screeching of rollers or bearings into
port A. Normally 10 to 20 pumps of a
typical grease gun.
3. Replace solid plugs.

i
Motor bearings are packed at the factory.
Port B When motors have sat for a while, grease
Plug will settle to the bottom of the bearing housing.
This may cause some of the rollers to skid or
Port A screech. Bearings need to be greased only
Plug if they are skidding.
Use Shell Cyprina RA,Texaco Regal AFB-2,
or Exxon Andok BR Grease

ADS-10D 3-21
 Maintenance

Lubrication Procedures
Lubrication After Major Overhaul (Dry
Sump)
Changing Oil

1. Drain oil from reservoir into suitable

container, by opening oil drain valve.
2. Drain residual oil through drain plug
on bottom of reservoir.
3. Remove access cover and clean
strainers inside reservoir.
4. Replace gearbox oil through oil fill port
following a major overhaul.
5. Select gear oil listed in recommended
3 lubricants, based on expected ambient
conditions for next six months.

Replace
Reservoir
Breather Oil Fill
Port

Access Cover

Reservoir
Holds 80 gallons of lube oil
Oil Drain Plug
Replace Filter Located on bottom of reservoir
Element Oil Drain
Valve

3-22 Varco
 Maintenance

Lubrication Procedures
Lubrication After Major Overhaul (Wet
Sump)

Changing Oil
Oil Fill 1. Drain oil from gearbox into suitable
Port container, by opening oil drain valve.
2. Replace gearbox oil through oil fill port
following a major overhaul. Fill
gearbox until oil shows in sight glass.
3. Select gear oil listed in recommended 3
lubricants, based on expected ambient
conditions for next six months.

Oil Drain
Valve

Sight
Glass

Replace Filter
Element

ADS-10D 3-23
 Maintenance

This page left blank intentionally

3-24 Varco
 Maintenance

Replacing ADS Components

Always make sure power is removed from ADS before

removing and replacing components.

i
When replacing components, use the assembly drawings
contained in the Technical Drawings Package. Use only
Varco-supplied replacement parts. 3

Ensure ADS operational area is clear of personnel and

equipment before reapplying power.

Special Tools
The following special tools are needed to repair the drawworks:
‰ Gearbox InstallationTool
‰ Brake Gear Removal Tool
‰ Motor/Brake Alignment Tool
‰ Clutch Removal Tool
‰ Coupling Hub Removal Tool
‰ Pressure Gage Kit
Preparation
Before replacing any component do the following safety steps:
1. Isolate ADS from the pneumatic power supply.
2. Reduce pneumatic pressure to zero.
3. Isolate all electrical power from ADS.

ADS-10D 3-25
 Maintenance

Replacing ADS Components

Gearbox Replacement

Gearbox removal
!
. Move brake control box away from brake area as follows:
a. Remove retaining clamps from all hoses routed to the Use care in lifting gearboxes suspected
brake control box. of being faulty. It is recommended to
b. Remove bolts that secure base of brake control box hoist by the unused, upper hole near
mounting panel to skid. the gearbox link. Damaged parts may
c. Carefully move brake control box, with hoses attached, separate from the gearbox assembly
away from brake area. Temporarily secure brake control when lifting
box to skid. i
2. Remove coupling and brake/clutch covers.
The gearbox is full of oil. Oil may spill Brake/Clutch
3. Decouple the AC motors. out if the gearbox is tipped too far, or is Cover
4. Disconnect lube oil inlet and return lines from gearbox and laid down.
3 cap open lines.
5. Disconnect water, air lines and cables from gearbox and Coupling
brake. Cover
6. Remove brake.
7. Remove brake gear hub from drumshaft. Refer to
brake gear hub replacement procedure.
8. Remove access cover to locking collar and remove locking
collar.
9. Remove encoder assembly from clutch.
0. Attach hoist to gearbox hoisting point.
1. Disconnect gearbox link from gearbox.
2. Lift narrow end of gearbox upwards and rotate gearbox
into a teardrop position. Gearbox
3. Apply light machine oil to the drumshaft outboard of
gearbox.
4. Place two hydraulic jacks between gearbox and drum
housing, with the jacks resting on the drum housing and
gearbox oil seal retainer. Brake Drumshaft
Control Box
5. Jack the gearbox until it is free of the bevel on the
drumshaft.
6. Carefully guide gearbox off the drumshaft. Watch
clearance between gearbox and skid.
Locking Collar

Gearbox
Link
Brake Locking Collar
Brake Gear Cover Coupling
Hub

Key
Key Retaining
Plate

3-26 Varco
 Maintenance

Brake
Brake/Clutch
Cover

Key Retaining
Plate

Key
Locking
Collar
Coupling
Cover
Brake Gearbox Link 3
Clutch Gear
Gearbox and Hub
Drumshaft Encoder

Locking Collar Hoisting

Cover Point

Brake
Control Box
Gearbox
Link

Coupling

Gearbox Coupling
Link
Half
Coupling

Half
Coupling
Locking Collar

Half Ring

Half Ring
Insert

ADS-10D 3-27
 Maintenance

Replacing ADS Components

Gearbox Replacement

Gearbox replacement i
Use gearbox installation tool for gearbox
1. Lubricate drumshaft with a thin coat of light machine oil replacement. The locking collar must be
(no grease). Coat the 10-degree tapered shoulder on installed prior to lifting the gearbox into
the drumshaft (gearbox seat) with a thin layer of Moly position on the shaft. Do not tighten
grease. locking collar until gearbox is in final
2. Attach sling to gearbox and lift gearbox into position on installation position.
the drumshaft. Lift small end of gearbox.
3. Push gearbox onto drumshaft until it can no longer go
on freely.
Brake/Clutch
4. Install locking collar onto gear shaft coupler. Bolt
Cover
heads face outboard.
3 5. Install gearbox installation tool.
6. Tighten nuts on mounting assembly until gear is pushed Coupling
onto taper on main gear. Refer to the Technical Drawing Cover
Package for the proper location of gearbox.
7. Lower small end of gearbox until gearbox link can be
installed.
8. With gearbox tool still in place, perform the locking
collar torquing procedure.
9. Replace locking collar cover, brake gear hub, key, key
retaining plate, brake, brake/clutch cover, coupling,
coupling cover and brake control box.

Gearbox

Drumshaft

Brake
Control Box

Locking Collar

Key
Key Retaining
Plate
Brake

Gearbox
Link
Locking Collar
Brake Gear Cover Coupling
Hub

3-28 Varco
 Maintenance

Brake
Brake/Clutch
Cover

Key Retaining
Plate

Key
Locking
Collar
Coupling
Cover
Brake Gearbox Link
Clutch Gear 3
Gearbox and Hub
Drumshaft Encoder

Locking Collar Hoisting

Cover Point

Brake Gearbox
Control Box Link

Coupling

Gearbox Coupling
Link
Half
Coupling

Half
Coupling
Locking Collar

Half Ring

Half Ring
Insert

ADS-10D 3-29
 Maintenance

Replacing ADS Components

Gearbox Coupling Hub Replacement
Removal
Special Tools:
‰ Hub Removal Tool
‰ Hydraulic Jack, Small
‰ Rose Bud Torch
‰ Temperature Stick

3 Failure to remove grease from the hub may result in a

grease fire when heating the hub for removal.

1. Disconnect coupling and clean hub of grease.

2. Disconnect O-ring retainer on gearbox side of sleeve and remove O-ring.
3. Secure coupling sleeve to gearbox with heavy wire to prevent sleeve from falling
once the hub is removed.
4. Slide coupling sleeve fully toward gearbox.
5. Install hub removal tool, less jack and one stud.

Use caution when handling the heated hub.

6. Using a rose bud torch, heat the hub to 275º F. Use temperature stick to verify
temperature.
7. Install jack, spacer plates (as required) and forth stud.
8. Pull hub off of shaft using jack to assist removal.

3-30 Varco
 Maintenance

Replacing ADS Components

Gearbox Coupling Hub Replacement
Installation
Special Tools:
‰ Hub Removal Tool
‰ Hydraulic Jack, Small
‰ Rose Bud Torch
‰ Temperature Stick

1. Install flat plate (part of hub removal tool) to coupling hub.

Use caution when handling the heated hub.

2. Using a rose bud torch, heat the hub to 350º F. Use temperature stick to verify
temperature.
3. Install coupling sleeve onto hub, then install assembly onto gearbox shaft.
4. Slide hub until flat plate bears against end of gearbox shaft.
5. Hold in place until hub cools sufficiently to grip the shaft.
6. Allow hub to cool to ambient temperature.
7. Install O-ring and O-ring retainer.
8. Pack coupling with grease (refer to Lubrication Procedures).
9. Couple the coupling halves and torque bolts (refer to the ADS Assembly Drawing).
10. Grease the couplings (refer to Lubrication Procedures).

ADS-10D 3-31
 Maintenance

Replacing ADS Components

Motor Coupling Hub Replacement
Removal
Special Tools:
‰ Hub Removal Tool

1. Disconnect coupling.
2. Disconnect O-ring retainer on motor side of sleeve and remove O-ring.
3. Install hub removal tool and remove hub in accordance with motor manufacturer’s
manual.
Installation
3
Special Tools:
‰ Hub Removal Tool
‰ Rose Bud Torch
‰ Temperature Stick

1. Install hub in accordance with motor manufacturer’s manual, with an advance of

0.050 inch. To retain coupling, use installation supplies listed in Varco Drawing
115040.

Use caution when handling the heated hub.

2. Hold in place until hub cools sufficiently to grip the shaft.

3. Allow hub to cool to ambient temperature.
4. Install O-ring and O-ring retainer.
5. Pack coupling with grease (refer to Lubrication Procedures).
6. Couple the coupling halves and torque bolts (refer to the ADS Assembly Drawing).
7. Grease the couplings (refer to Lubrication Procedures).

3-32 Varco
 Maintenance

Replacing ADS Components

Clutch Replacement

Removal
1. Remove encoder assembly (refer to Encoder and Encoder Belt Replacement
Procedure).
2. Remove clutch plug assembly.
3. Remove clutch in accordance with clutch manufacturer’s manual.

Installation
1. Install clutch in accordance with clutch manufacturer’s manual.
3
2. Install clutch plug assembly.
3. Install encoder assembly (refer to Encoder and Encoder Belt Replacement
Procedure).

ADS-10D 3-33
 Maintenance

Replacing ADS Components

AC Motor and Blower Replacement
Optional Air Filters
Mounts between AC motor and Blower
blower motor. Motor
with Extension
Coupling
Cover

Blower
Motor

AC Motor

Coupling
3 Cover

AC Motor

Coupling

Coupling

3-34 Varco
 Maintenance

Replacing ADS Components

AC Motor and Blower Replacement

Coupling A and B Blower Motor

Half 1. Remove attaching hardware at AC
Coupling motor and the base of blower motor.
2. Retain gasket.
3. Attach lifting device and remove blower
motor assembly.
Half
Coupling
3
AC Motor
1. Disconnect electrical.
2. Remove motor coupling cover.
3. Unbolt and separate motor coupling
AC Motor Attachment halves.
AC
Motor 4. Remove attaching hardware at base
of AC motor. (Note position of shims.
Place in same position when installing
AC motor. Refer to alignment
procedure in Mechanical Installation
Bolt Kit Drawing.)
4 places 5. Back out all adjusting bolts and lock
nuts.
6. Remove AC motor.
Washer
4 places

Vertical
Adjusting Bolt
and Jam Nut
4 places

Horizontal
Adjusting Bolt
and
Jam Nut
8 places

Washer
4 places

Lock
Washer
4 places
Shim
4 places Nut
Shim as required 4 places

ADS-10D 3-35
 Maintenance

Replacing ADS Components

Brake Replacement
To remove and replace the brake on the brake gear, refer to the vendor manual for
installation, operation and maintenance instructions.
.

i
When installing the brake make sure that the required
mounting hardware are of the proper grade and quantity.

3
!
Proper alignment of the brake is necessary to make sure
that the friction discs track properly. Improper alignment
results in excessive wear to the material and mating
surfaces. Align the brake to the limits shown in the
Adjustment and Alignment Procedure.

Excessive grease may contaminate the friction material,

resulting in erratic response or loss of torque.

3-36 Varco
 Maintenance

Replacing ADS Components

Brake Gear Hub Replacement

Drumshaft

Brake Gear
Hub

Stud,Washer
and Nut
4 places
3

Adapter
Plate
Removal
1. Remove Key Retaining Plate.
2. Install brake gear removal tool as follows:
a. Install studs into threaded holes on brake gear.
b. Install adapter plate onto studs and retain with Key Retaining
nuts and washers. Plate
c. Install jack between shaft and adapter plate.
3. Attach lifting device to brake gear (capable of
withstanding 400°F heat).
4. Heat brake gear to 350°F (use temperature stick to
verify temperature). i
5. Pull gear off shaft using jack. To remove brake gear from drumshaft,
the brake must be removed first.

ADS-10D 3-37
 Maintenance

Replacing ADS Components

Brake Gear Hub Replacement

3
Drumshaft

Brake Gear
Hub

Stud,Washer
and Nut
4 places

Hub Key

Adapter
Plate

Replacement
1. Install adapter plate flush against the end of the brake gear.
2. Heat brake gear to 400°F.
3. Attach lifting device to brake gear (capable of withstanding
400°F heat).
Key Retaining
4. With key already installed on shaft, install brake gear onto Plate
shaft until the adapter plate contacts the drum shaft.
5. Hold in place until gear cools sufficient to grip shaft.
6. Allow gear to cool to ambient temperature.
7. Remove adapter plate.
8. Reinstall key retaining plate.

3-38 Varco
 Maintenance

Replacing ADS Components

Locking Collar Torquing Procedure

i
Hold brake gear and gearbox in place with gearbox tool until locking collar is seated
and torqued. Mark one of the hex head bolts to establish a starting point.
It is important to recheck each bolt to make sure that they are all at the same torque
value before moving to the next torque value. As each bolt is tightened the hub
locking collar rings draw closer together and the previously torqued bolts could lose
3
their set torque value. Only when each of the 16 bolts are of the same torque value is
it permissible to proceed to the next value. This could take two to three attempts.

1
16 2

15 3

Torque Procedure
14 4
1. Position locking collar onto gear coupler.
2. Hand tighten bolt numbers. 3, 11, 15, and
7 to hold locking collar in place until
13 Locking Collar 5 torquing procedure is started.
3. Going in a CW or CCW direction starting
with bolt number 1, torque each bolt to 25
ft-lbs first, then to each of the following
12 6 values in secession:
50 ft-lbs
75 ft-lbs
11 7 100 ft-lbs
150 ft-lbs
10 8 200 ft-lbs
9 250 ft-lbs
300 ft-lbs
350 ft-lbs
362 ft-lbs
4. Remove gearbox tool when locking
collar has been fully tightened.

ADS-10D 3-39
 Maintenance

Replacing ADS components

Encoder and Encoder Belt Replacement

i
The depth of disassembly depends upon the component
being replaced. The illustration on the facing page shows
the order of disassemby of encoder-related components.

If replacing encoder(s) be sure to replace the O-ring(s).

3
!
Do not push on encoder shaft. Do not drop encoder.
Handle encoder carefully.

Replacement of Encoder Assembly

Removal
1. Remove all electrical power to the encoder assembly being removed.
2. Loosen nut at bottom end of encoder link.
3. Remove nut that attaches encoder link to encoder assembly. Swing encoder link
out of way.
4. Disconnect the encoder cables at its J-box.
5. Remove the retaining ring from the end of encoder shaft.
6. Pull encoder assembly away from gearbox and take it to a clean area for further
disassembly if necessary.
Replacement
1. Place encoder assembly onto shaft on gearbox. Carefully push in the encoder
assembly until end of shaft sticks out of encoder hollow shaft.
2. Insert retaining ring onto end of shaft.
3. Attach encoder link to encoder assembly using nut.
4. Tighten nut at bottom of encoder link.
5. Connect encoder cables to its J-box.

3-40 Varco
 Maintenance

Replacing ADS Components

Encoder and Encoder Belt Replacement

Retaining
Ring

3
Nut
Outer Encoder Inner Encoder
Belt Path Belt Path

Encoder Hollow Encoder

Link Shaft Inner
Encoder Drive
Pulley
Outer Tension
Encoder Arm Inner
Encoder Belt

O-Ring
Outer
Encoder Belt
Outer
Encoder Drive
Pulley

Washer
Cap Screw
Inner
Encoder
(if equipped)
O-Ring
Pivot
Shaft
Spring
Post
Set
Screw
Set
Drive Pulley Drive
Screw
Pulley
Guard
Plate Tension
Spring

Cover
Cover
Gasket

ADS-10D 3-41
 Maintenance

Replacing ADS Components

Encoder and Encoder Belt Replacement
Replacement of Outer Encoder Belt
Remove cover to gain access to the outer encoder belt, then replace belt as follows:
1. Reduce tension on the belt by turning tension arm away from belt, or by detaching
one end of tension spring from its post.
2. Remove belt from pulleys.

i
Reattach tension spring to its retaining post if necessary.

3 3. Install replacement belt around pulleys. Reduce tension on the belt by turning
tension arm away from belt. Be sure to thread belt to the inside of tension arm
pulley. (See belt path shown in illustration.)
Replacement of Inner Encoder Belt
Remove cover to gain access to the inner encoder belt, then proceed as follows:
1. Remove outer encoder belt.
2. Remove guard plate.
3. Reduce tension on the belt by turning tension arm away from belt, or by detaching
one end of tension spring from its post.
4. Remove belt from pulleys.
5. Install replacement belt around pulleys. Reduce tension on the belt by turning
tension arm away from belt. Be sure to thread belt to the inside of tension arm
pulley. (See belt path shown in illustration.)
6. Install guard plate.
7. Install outer encoder belt and cover.

3-42 Varco
 Maintenance

Replacing ADS Components

Worn Wire Rope Replacement

i
Wire rope should be maintained in accordance with API
Specification 9B, Recommended Practice on Application,
Care, and Use of Wire Rope for Oilfield Service.

Before installing the wire rope on the drum, the driller must
operate the ADS sufficiently to become familiar with the
controls, the screen displays, and the response of the
system to operator input commands.

1. Pull wire rope through the slot in the drum flange, from inside of flange to outside
3
of flange.
2. Attach wire rope clamp to tail of wire rope. Leave approximately three inches
(76 mm) of wire rope extending out of clamp.
3. Apply Blue Loctite and tighten the six nuts to 450 to 500 ft lb. (610 to 678 Nm).
Tighten the bolts in a cris-cross pattern, starting in the center of the 6-bolt (main)
section, and in multiple stages to insure uniform tightening of the clamp.
Recommend a minimum of three stages: 25%, 50% and 100% torque.
4. Wrap wire line around drum by turning the drum using the driller control station.
Apply greatest amount of pretension available when wrapping wire rope on the
drum. Ensure the number of dead wraps on the drum, when the travelling block is
at its lowest possible position in the derrick, is at least equivalent to the number of
lines strung on the blocks (minimum eight full wraps with eight lines strung).
5. Once the drum is fully spooled, raise and lower the blocks through the full derrick
travel to seat the rope properly onto the drum. Observe that smooth, proper
spooling is taking place, with no gaps or jumping, and that the rope does not climb
the flange when changing layers.
6. Adjust the crown saver switch by loosening the clamp bolts and moving the switch
to the desired position. Tighten bolts when switch is in position.

i
The crown saver switch helps prevent collisions with the
derrick crown when hoisting. It is set to limit the amount of
wire rope that is taken onto the drum, to a point well short
of where the block collides with the crown.

ADS-10D 3-43
 Maintenance

Alignment and Adjustment

Procedures
AC Motor/Gearbox

Special Tools:
Motor/Brake Alignment Tool
1. Measure distance between hub faces.
2. Shim motor as required to meet 0.004 maximum TIR.
3. Attach dial indicator to motor hub and indicate outside diameter of gearbox hub.
Rotate motor shaft (hub) and measure runout. Maximum runout is 0.008 TIR.
4. Shim motor as required.
3
5. Torque motor bolts.
6. Recheck alignment and adjust as required.

3-44 Varco
 Maintenance

Alignment and Adjustment

Procedures
AC Motor/Gearbox

3
Top View
Covers not shown for clarity
Parallel runout of
coupling hubs outer
diameters to be
.008 TIR
Coupling
Hubs

Faces of motor and

gearbox coupling hubs
to be in angular
alignment within .004 TIR
Top View
Coupling sleeves not shown

ADS-10D 3-45
 Maintenance

Alignment and Adjustment

Procedures
Brake Assembly
The brakes should be aligned to prevent uneven pad wear on the brake discs and
pulsating motion of the drum as it lowers the load. Brake alignment and adjustment is
required to maintain optimal operating conditions.
Special Tools:
Motor/Brake Alignment Tool

i
3 The parking brake must be released and the wire rope
slack during this alignment procedure.

Angular (Runout) Alignment

Proper angular alignment ensures the drumshaft and brake assembly have even
loading throughout shaft rotation. This is the most critical of the alignment parameters.

Parallel (Runout) Alignment

Parallel alignment ensures that the rotating discs are concentric to the mating surface of
the static friction plates. Proper concentricity results in even contact throughout the
entire surface of the brake discs, which allows for smoother braking action.

Axial Spacing Alignment

Axial spacing alignment prevents the brake assembly from contacting the brake hub’s
locking collar while in operation.

Adjustment Screws
Upon completion of the required alignments, all the adjustments screws must be backed
off by 1/8 of a turn. This is required to allow the brakes to have room to self-align with
the varying load conditions of the drumshaft (within the established limits, see
engineering drawings for tolerance limits).

3-46 Varco
 Maintenance

Alignment and Adjustment

Procedures
Brake Assembly
Brake Alignment Adjust Angular
Alignment
1. Release parking brake. Brake Surface
Angular Misalignment = .025 TIR Max.
2. Attach dial indicator to shaft and Relative To Shaft
indicate perpendicular face of brake.
Rotate shaft and measure runout.
Maximum runout is .025.
3. Adjust leveling screws as required.
4. Attach dial indicator to shaft and Adjust Parallel
indicate parallel inside face of brake Offset Alignment
support bracket. Rotate shaft and
measure runout. Maximum runout is Parallel Misalignment = .010 TIR Max.
.010. Relative To Shaft 3
5. Shim brake support pads as required.
6. Torque brake support pad bolts.
7. Recheck alignment and adjust as
required. Shaft
Surface
8. Retract leveling screws 1/8 turn and
torque jam nut.

Pivot Brackets
2 places
Move brackets within bolt clearances
to set both horizontal angle
and horizontal position

Adjustment
Screws
2 places
Use screws to set
vertical angle

Jam Nut

Shim
Use shims under pivot brackets
to set vertical position

ADS-10D 3-47
 Maintenance

Alignment and Adjustment

Procedures
Air Lubricator
Air
Lubricator

Adjustment
Knob

3
Dome
Glass

Airflow occurs periodically through the air

lubricator and only for one second per brake
release. This air demand is created whenever
the brake disengages. The air lubricator is set
correctly when one drop of oil falls for every 40
brake releases.(Every drop visible in the dome
glass goes downstream.)

Procedure
1. Adjust the oil delivery by turning the
knob on top of the air lubricator
clockwise (less drops per minute) or
counterclockwise (more drops per
minute).
2. Rapidly engage and disengage the
brake 40 times while observing dome
glass for oil drops. Adjust the knob for
one drop of oil per 40 brake releases.

Pneumatic Panel
Rear View

3-48 Varco
 Maintenance

Testing
The break-in tests are performed when the gearbox or brake is replaced. Both types of
break-in tests require removal of wire rope from the drum.

Gearbox
Low Torque Warm up
1. Disengage parking brakes
2. Adjust motors and dynamic brakes until motors are operating at 500 rpm (hoist)
and 1250 ft-lbs input shaft torque per motor. Maintain this power/rpm for 30
minutes.
3. After 30 minutes, stop the motors and reverse motor direction, repeating steps 1
through 4. Maintain this power/rpm for 30 minutes.

3
i
While running the motors (regardless of direction), make
sure the ADS is operating smoothly with no binding or
unusual noises.

4. Stop the motors and disengage the dynamic brake. Visually inspect gears for any
signs of mechanical malfunction.
Brake
Wear-in the brake friction surfaces in accordance with the Wear-in Procedures
contained in the vendor manual.

ADS-10D 3-49
 Maintenance

3-50 Varco
 Troubleshooting

Troubleshooting Fault Symptoms . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Running Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Helpful Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting the Overall ADS . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Troubleshooting the AC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Troubleshooting Brake Problems . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Electrical Components Locations . . . . . . . . . . . . . . . . . . . . . . . . 4-8 2
Troubleshooting the Control System . . . . . . . . . . . . . . . . . . . . 4-16
Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

ADS-10D
 Troubleshooting

Varco
 Troubleshooting

Troubleshooting Fault Symptoms

Potential component failures fall into the following categories:
‰ Electrical components
‰ Mechanical components
‰ Pneumatic components
To help determine the nature of the problem use the troubleshooting tables contained in
this chapter. Supporting illustrations are provided to show component locations.

i
The troubleshooting procedures in this chapter do not
necessarily cover all possible symptoms. The tables
provide an insight to typical symptoms, their possible
causes, and which components to check as the most likely
candidates causing the fault.

Running Diagnostics
Diagnostics are valuable troubleshooting tools. Use the instructions contained in the
4
V-ICIS User’s Manual to run ADS diagnostics.

Helpful Documents
The Technical Drawings Package contains assembly drawings for component locations,
and electrical and pneumatic schemetic diagrams for signal tracing. In addition, there
are vendor manuals available with this service manual.
The following drawings and schematics are useful in troubleshooting:
‰ ADS-10D Assembly Drawing
‰ ADS-10D Instrument Index
‰ ADS-10D Single Line Cable Diagram
‰ ADS-10D Fluids/Air Interconnect Diagram
‰ ADS-10D Electrical Interconnect Diagram
‰ ADS-10D Control System Assembly
Special Tools
The following special tools are needed to troubleshoot the drawworks:
‰ Pressure Gage Kit

ADS-10D 4-3
 Troubleshooting

Troubleshooting the Overall ADS

Symptom Probable cause Remedy

ADS does not Command is not allowed by the Check V-ICIS screen for fault indication.
respond to operator software
inputs
Mechanical interference or 1. Make sure the load on the wire rope is
failure not jammed or interfering with the rig
structure or other pieces of equipment.
2. Check that the brake disengages when
activated.
Damaged or faulty gearbox Check V-ICIS screen for an encoder fault
encoder indication. Replace the gearbox encoder.
Brake control system fault Send a discrete pressure command
through the V-ICIS and compare to
displayed pressure. If pressures are off by
more than 2 psi, repair/replace valve,
and/or control circuit board.

4 VFD fault If a fault is displayed on the VFD, refer to

the third-party vendor documentation.
The drum does not Brake alignment Check for proper brake alignment.
rotate smoothly when
lowering on the brakes
Excessive vibration Brake control instability Listen for an audible buzz from servo
valve indicating rapid and excessive
shuttling of valve spool. Repair/replace
valve and /or control circuit board.
Motor alignment Check for proper motor alignment to
gearbox.

4-4 Varco
 Troubleshooting

Troubleshooting the AC Motor

Symptom Probable cause Remedy

AC motors do not Command is not allowed by the Check V-ICIS screen for warning or
rotate software interlock condition.
Mechanical interference or 1. Make sure neither the drum or the load
failure on the drum is binding on rig.
2. Check for obstructions in wire rope
sheaves.
3. Check that the brake disengages when
activated.
Damaged or faulty encoder Check V-ICIS screen for an encoder fault.
Replace the encoder if faulty.
VFD fault If a fault is displayed on the VFD, refer to
the vendor documentation.
Brakes do not release Troubleshoot the brake assembly.
Motor overheats Blower motor Blower motor is not working. Replace
blower motor.
Blower impeller Check that the impeller rotates with
4
blower motor rotation. Air should be
entering motor through louver and exiting
motor through slits near motor output
shaft.
Main motor air temp switch Check electrical connection and settings
noted in Alarm and Fault Response
Specification. Replace faulty temp switch.
Blower differential pressure Check electrical connection and settings
switch noted in Alarm and Fault Response
Specification. Replace faulty pressure
switch.

ADS-10D 4-5
 Troubleshooting

Troubleshooting Brake Problems

Symptom Probable cause Remedy

Brake does not Command is not allowed by Check V-ICIS screen for warning or
engage/disengage the software interlock condition.
Mechanical interference or 1. Make sure the brake disc are not
failure jammed by mechanical interference or
corrosion.
2. Check for obstructions between the
rotor discs and stators.
3. Check for brake alignment.
Damaged or faulty encoder Check V-ICIS screen for an encoder fault.
Replace the encoder.
Inadequate pneumatic 1.Check for pneumatic input supply to the
pressure ADS by checking rig pressure displayed
on V-ICIS screen, or by checking
pressure at test point. Use pressure gage
kit.
2. Check the directional solenoid valves
4 (SOVs) on the brake control panels:
a. Check valve operator coils are
energized by confirming magnetism.
b. Check down stream pressure as
valves are actuated to confirm proper
operation.
Replace if faulty.
3. Check the proportional solenoid valves
(pilot valves (PV)). Replace if faulty.
4. Check the appropriate control system
circuit for proper connectivity. Repair or
reconnect as required.
Emergency/ Parking Command is not allowed by Check V-ICIS screen for warning or
brake function does the software interlock condition.
not disengage
Inadequate pneumatic 1.Check for pneumatic input supply to the
pressure ADS by checking rig pressure displayed
on V-ICIS screen, or by checking
pressure at test point. Use pressure gage
kit.
2. Check the directional solenoid valves
(SOVs) on the brake control panels:
a. Check valve operator coils are
energized by confirming magnetism.
b. Check down stream pressure as
valves are actuated to confirm proper
operation.
Replace if faulty.
3. Check the proportional solenoid valves
(pilot valves (PV)). Replace if faulty.
4. Check the appropriate control system
circuit for proper connectivity. Repair or
reconnect as required.

4-6 Varco
 Troubleshooting

Troubleshooting Brake Problems

Symptom Probable cause Remedy

Emergency/ Parking Parking brake disengage Check parking brake pressure displayed
brake function does solenoid in the pneumatic on V-ICSI, or at test point as solenoid
not disengage (cont) control box valve is acuated. Use pressure gage kit. If
praking brake pressure is not within 5 psi
of the V-ICIS displayed rig pressure,
replace fauly valve.
Digital input module 1. Check module for proper settings.
2. Check for connection of wire and
cables.

ADS-10D 4-7
 Troubleshooting

Electrical Components Locations

i
Non-electrical components
Brake No.1 Air Supply may be shown for clarity
Pressure Transmitter
0-200 psi

Parking Brake No.1

Pressure Transmitter
0-200 psi
4

Crown Saver Air

Pressure Switch
20-200 psi

Brake Water Cooling See Oil Lube System, Chapter 1,

Differential Pressure for Electrical Component
Transmitter No.1 Location
0-50 psid
Ensures adequate brake
water cooling is available
Front View

4-8 Varco
 Troubleshooting

Crown Saver Toggle Valve Brake No.2 Air Supply

Pneumatic valve. Pressure Transmitter
When contacted by the wire rope 0-200 psi
it causes the clutch to be released
and applies the spring-applied brake.

Parking Brake No.2

Pressure Transmitter
0-200 psi
4

Brake Water Cooling Ambient Air

Differential Pressure Temperature
Transmitter No.2 RTD
0-50 psid Monitors temperature
Ensures adequate brake of ambient air
water cooling is available

ADS-10D 4-9
 Troubleshooting

Electrical Components Locations

Remote I/O Transmitter AC Motor B

J-Box J-Box Air Exhaust
RTD
Monitors temperature
of exhaust air from
AC motor B

Intermediate Intermediate Blower B AC Motor B AC Motor B

Auxiliary Encoder Differential Space Heater Incremental
J-Box J-Box Pressure Switch Prevents condensation Encoder
2-80 inches WC in AC motor B when Provides position
Monitors cooling motor is not in use and speed signal
air flow to AC motor B to VFD for close
Rear View loop control

4-10 Varco
 Troubleshooting

AC Motor A
Air Exhaust
RTD
Monitors temperature
of exhaust air from
AC motor A

Auxiliary Power
J-Box

4
Power Supply
J-Box

AC Motor A AC Motor A Blower A

Incremental Space Heater Differential
Encoder Prevents condensation Pressure Switch
Provides position in AC motor A when 2-80 inches WC
and speed signal motor is not in use Monitors cooling
to VFD for close air flow to AC motor A
loop control

ADS-10D 4-11
 Troubleshooting

Electrical Components Locations

Incremental AC Motor A Blower Motor A

Encoder J-Box Drive motor for hoisting, Provides cooling air
Located under lowering and deceleration for AC motor A
LH Brake Panel of traveling assembly
J-Box

LH Pneumatic
Panel J-Box

4
Absolute Encoder
Provides both absolute
position and speed of
traveling assembly
Absolute Encoder
Primary to instantaneous
speed signal for
velocity profiling

Brake No. 1 (Feedback)

Pressure Transmitter
0-200 psi

Brake Water Cooling

RTD Outlet No. 1 Brake

Top View

4-12 Varco
 Troubleshooting

Blower Motor B AC Motor B Incremental

Provides cooling air Drive motor for hoisting, Encoder J-Box
for AC motor B lowering and deceleration Located under
of traveling assembly RH Brake Panel
J-Box

RH Pneumatic
Panel J-Box

4
Absolute Encoder
Provides both absolute
position and speed of
traveling assembly

Brake No. 2 (Feedback) Brake Water Cooling

Pressure Transmitter RTD Outlet No. 2 Brake
0-200 psi

ADS-10D 4-13
 Troubleshooting

Electrical Components Locations

LH Servo Valve
J-Box
and
LH Servo Brake Control
Brake Proportional
J-Box
Valve No.1
Provides proportional
control pressure to
service brake

See LH Pneumatic
Panel, Chapter 1,
for Electrical
4 Component
Location

Brake Water
Cooling RTD Inlet

Bypass No.1 Brake

Solenoid Valve

Gearbox No. 1 Lube Oil

RTD

Left Side View

4-14 Varco
 Troubleshooting

Electrical Components Locations

RH Servo Brake Control

J-Box

See RH Pneumatic
Panel, Chapter 1,
for Electrical
Component
Location 4
RH Servo Valve
J-Box
and
Brake Proportional
Valve No. 2
Provides proportional
control pressure to
service brake.

Bypass No.2 Brake

Solenoid Valve

Gearbox No. 2
Lube Oil
RTD

Right Side View

ADS-10D 4-15
 Troubleshooting

Troubleshooting the Control System

Troubleshooting the control system requires that you first determine if any of the
components of the ADS are at fault, or if the control system is at fault. To do so, first
check the inputs to the control system then ascertain if the corresponding output was
energized. If the control system inputs and outputs are normal, then one or more of the
ADS components is the probable malfunction.
The location and description of control system components are provided to help you
troubleshoot to a faulty component in the control system. Also note that some cards and
modules have their own status and error indicators. These indicators can be used to
troubleshoot control system faults.

i
When replacing cards or modules, always set replacement
card switch settings to match those of the card being
replaced.

4-16 Varco
 Troubleshooting

Troubleshooting the Control System

Control System Components

Door Power Circuit

Switch Supplies Breakers
PS1-PS3 CB1-CB9

1
2
3
1
2
3
Analog Input
1
2
3
1
2
3 OK
PS1 OK
PS2 OK
PS3 Module,
1
2
3
4
1
2
3
4
230V VOLTAGE
SELECTOR
230V VOLTAGE
SELECTOR
230V VOLTAGE
SELECTOR
Analog Output
Module,
5 5
6 6

25A 1A 1A 1A 2A 6A 6A 6A 6A
1 1
2 2
3
4
3
4
Digital Input
4
5 5
6 6

1
2
1
2
6ES7 307-1BA00-0AA0 6ES7 307-1BA00-0AA0 6ES7 307-1BA00-0AA0
Module,
1
2
1
2
Digital Output
Module,
Profibus-DP
Single Board Interface Module
Computer SF DP
SIEMENS SM 322
32X24VDC,0.5A
SM 321
32X24VDC,DI
SM 332
AO4 X 12 BIT
SM 331
AI8 X 9-15 BIT

SBC BUSF

ON
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
5 5 5 5 5 5

Relays
6 6 6 6 6 6
7 7 7 7 7 7
8
9
10
SIMATIC 11
ET 200M 0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
0
1
2
3
4
12
13
14
15
16
RL1-RL6
5 5 5 5 5 17
6 6 6 6 6 18
7 7 7 7 7 19
20
2 3 4

Spares

RS-485
1 1

Repeater RL1
2
3
4
5
6
2
3
4
5
6
Terminal Blocks
RP1 S3
(Typical)
L+ M PE M5
7 7
8 8
SIEMENS SIEMENS RL2 9
10
9
10
SINEC L2FO OLM SINEC L2FO OLM
11 11
RL3 12 12

Optical Link
RJ-45 FAST-CONNECT

A1 B1 A1 B1

1 1
RL4 2
3
2
3
4 4

Modules OLM1 OLM2 RP1

SIEMENS
L3
RL5
RL6
5
6
7
8
9
5
6
7
8
9

OLM1, OLM2
RS 485-REPEATER
A2 B2 A2 B2
1 1
2 2
3 3
4 4
5 5
1 1 6 6
2 2
3 3

Ethernet 4
5
6
7
8
4
5
6
7
8

Fast Connect
9 9
10 10 1 1
2 2
3 3
1 1 4 4
2 2

Outlet 3
4
5
6
7
3
4
5
6
7
1
2
3
4
1
2
3
4
8 8
9 9
10 10 1 1
11 11 2 2
12 12 3 3
13 13 4 4
14 14
15 15 1 1
16 16 2 2
3 3
1 1 4 4
2 2
3 3 1 1
4 4 2 2
5 5 3 3
6 6 4 4
7 7
8 8
9 9
FIBER PATCH PANEL 10
11
10
11
1
2
3
1
2
3
12 12 4 4
13 13
14 14

Fiber Patch 15
16

1
15
16

1
1
2
3
4
1
2
3
4

Panel 2
3
2
3

FPP

ADS-10D 4-17
 Troubleshooting

Troubleshooting the Control System

Control System Components
Component Function
Circuit Breakers:
CB1 25-amp main circuit breaker. Protects AC input line to control system.
CB2 1-amp circuit breaker. Protects AC input line to power supply PS3.
CB3 1-amp circuit breaker. Protects AC input line to power supply PS1.
CB4 1-amp circuit breaker. Protects AC input line to power supply PS2.
CB5 1-amp circuit breaker that protects enclosure fan, via door switch
DS1.
CB6 6-amp circuit breaker that protects AC input line to a remote I/O
device, such as remote power supply J-box.
CB7 6-amp circuit breaker that protects AC input line to a remote I/O
device, such as remote power supply J-box.
CB8 Spare 6-amp circuit breaker.
CB9 Spare 6-amp circuit breaker.
4
Door Switch DS1 Switches the cooling fan on if the door is closed.
Emergency stop relays: Used in ESD circuits to disable equipment controlled by the control
RL1 and RL5 system whenever any ESD pushbutton switch is activated.
Fan Supplies cooling air to enclosure components.
Fiber PatchPanel FPP 8-port patch panel for fiber optic cables to optical link modules.
Connects to VFDs and ADS remote I/O J-box.
Interface and Processing Mounted on Siemens S7 300 Programmable Logic Controller (PLC)
Modules: DIN rail, these modules convert or condition the input/output (I/O)
signals between the control system and the ADS.
Analog Input Module Converts input torque signal (analog) from Top Drive into digital
signal used by the SBC.
Analog Output Module Converts digital signals into an analog rig sense hookload signal.
Digital Input (D/I) Module 16-bit digital input module. Receives status inputs from the E-Stop
relay contacts.
Digital Output (D/O) Module Provides status signals to E-Stop relays RL1 and RL5.
PROFIBUS-DP Interface Conditions interface signals between the control system modules and
Module ADS, via the PROFIBUS.
Optical Link Modules: Provides fiber optic PROFIBUS interface between the control system
OLM1 and OLM2 and the driller’s chair via the ADS deck remote I/O J-box.
Power Supplies:
PS1 2-amp power supply. Provides 24V DC power to the following:
•PROFIBUS-DP Interface Module
•Optical Link Modules OLM1, OLM2
•Repeater RP1

4-18 Varco
 Troubleshooting

Troubleshooting the Control System

Control System Components
Component Function
Power Supplies: (cont)
PS2 2-amp power supply. Provides 24V DC power to the following:
•Digital Input Module
•Digital Output Module
•Analog Output Module
•E-Stop Relays
•CPU RUNNING Indicator L1
•MAINTENANCE MODE ACTIVE indicator L2
PS3 2-amp power supply. Provides 24V DC power to the Single Board
Computer.
Repeater RP1 Amplifies data signals on the PROFIBUS.
Single Board Computer (SBC) This is the Central Processing Unit (CPU) of the control system. The
(also known as the ATC) SBC handles all data between the ADS and the rig operator. Data to/
from the CPU is conditined by the analog and digital interface
modules. 4
Terminal blocks Provides terminal points for the electrical cables/wires that connect
the control system components to the ADS.

ADS-10D 4-19
 Troubleshooting

4-20 Varco
 Glossary

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
User Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
1

ADS-10D
 Glossary

Varco
 Glossary

Definitions
The following are definitions of the acronyms, abbreviations, and terminologies used in
this manual. Standard acronyms and abbreviations, such as AC, DC, in., ft-lb, etc., and
industry-standard terminologies are not listed.
ADS - Automated Drawworks System.
CPU - Central Processor Unit.
E-Stop - Emergency Stop.
GB - Gearbox
HMI - Human-Machine Interface. Nomenclature for the drillers screen. Usually a third-
party component.
Hoisting Deceleration Point - When hoisting, the hoisting deceleration point is the
uppermost position at which the block begins deceleration to safely stop the blocks
without passing the upper travel limit and keep tension on the drill line.
J-box - Junction box.
Lower Deceleration Point - When lowering, the lower deceleration point is the lowest
point at which regenerative braking can be utilized to safely stop without passing the
lower travel limit.
Lower Travel Limit - The lower travel limit is the operator-defined position of lower most
travel. The control system will not allow the lower travel limit position to be set below the
know position on the rig floor. It is the responsibility of the operator to ensure the lower
travel limit position is adequate to prevent equipment hanging below the blocks, or the
top drive from hitting the floor or other equipment.
5
PLC - Programmable Logic Controller. This function is made up of individual cards/
modules.
PROFIBUS - Process Field Bus. A network that allows ADS devices to communicate
over a common bus without the need for specially designed interfaces.
Regenerative Braking - Defined as the use of the ac motors, in generator mode, to
provide braking.
ROP - Rate of Penetration
RTD - Resistive Thermal Device. A device that measures temperature.
Upper Travel Limit - The upper travel limit is the operator-defined position of uppermost
travel. The control system will not allow the upper travel limit to be set above the known
maximum height before hitting the crown block, thus preventing crown collisions.
VFD - Variable Frequency Drive. Normally a customer-supplied item. The VFD works as
a velocity control system.
V-ICIS - Varco Integrated Control and Information System.
WOB - Weight on Bit.
ZMS - Zone Management System. A system of monitoring and managing the movement
of equipment within its predefined operational space to prevent interference and
collisions with the rig structure and other equipments.

ADS-10D 5-3
 Glossary

User Notes
1. Do not substitute Viton for Mill-Right oil seals.

5-4 Varco
 Glossary

User Notes

ADS-10D 5-5
 Glossary

User Notes

5-6 Varco