2_Tesco Top Drive Safety Manual

Bulletin 20900e

TOP DRIVES CASING DRILLING™ CASING RUNNING

The Drilling Innovation Company™www.tescocorp.com

Top Drive Rig Floor SafetyOrientation

Doghouse Manual

The Drilling Innovation Company™Email: [email protected] Web: www.tescocorp.com

Corporate Headquarters6204 - 6A Street S.E.

Calgary, Alberta, Canada T2H 2B7Tel: 403 233-0757 • Fax: 403 252-3362

World Wide Operations11330 Brittmoore Park DriveHouston, Texas, USA 77041

Tel: 713 849-5900 • Fax: 713 849-0075

Printed in C

anada / April 2004 / T

CD

ue to ongoing product development, all specifications are subject to change w

ithout notice.

Top Drive Rig FloorSafety Orientation

TESCO CORPORATIONWELL SITE OPERATIONS

6204-BURBANK ROAD S.E.CALGARY, ALBERTACANADA T2H 2C2

Phone: 403 720 2858Fax: 403 203 2295

Web:www.tescocorp.comemail: [email protected]

Printed in Canada / Dec. 2002 TC120©Tesco Corporation

The Drilling Innovation Company™

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 19Page 2 Top Drive Rig Floor Safety Orientation Doghouse Manual

TABLE OF CONTENTSC H A P T E R 5MAKING CONNECTIONS

Safety 12Breaking Out 12Making Up Singles 12Making Up Doubles 12Making Up Triples 13

C H A P T E R 6OPERATIONS

Drilling 13Tripping 14Cold Climate 14Reaming 15Working Tight Hole 15Jarring 16Running Casing 16Cementing 16

CHAPTER 7TOP DRIVE CONSIDERATIONS

Slip and Cut Drilling Line 17Maintenance 17

DISCLAIMER 17

INTRODUCTION FOR DRILLERS 4

C H A P T E R 1RIGGING UP THE EQUIPMENT

Torque System 4Power Module 5Service Loop 6Top Drive 6

C H A P T E R 2COMPONENT IDENTIFICATION

Top Drive 7

C H A P T E R 3THE DRILLERS PANEL

Description 8Position 8Indicator Lights 8Safety Interlocks 9

C H A P T E R 4CONTROLS AND ROBOTICS

Clearance and Visibility 10Extend 10Link Tilt 10Grabber 10Grabber Lift 10Pipe Handler 10Elevators 11Mud Saver Valve and Actuator 11


INTRODUCTIONFOR DRILLERS

This manual is intended toprovide basic informationonly, and does not constitutea comprehensive guide tothe functioning or operationof a Tesco Top Drive. It is tobe used only in conjunctionwith the orientation and onsite supervision provided byTesco personnel. The TescoTop Drive Technician mustbe notified of any concernsor incidents involving Tescoequipment and its operation.

OTHER THAN ASDESCRIBED IN THEPRECEDING PARAGRAPH,

TESCO CORPORATION, ITS AFFILIATEDCOMPANIES ANDEMPLOYEES ASSUME NORESPONSIBILITY FOR USEOF THE INFORMATIONCONTAINED IN THISMANUAL.

At Tesco, we put a lot of effortinto developing ways to makedrilling a well more efficient.Training the operators to runthe equipment in the mosteffective manner makes thejob easier by reducingdowntime and safer byeliminating the risk of injury toworkers.

This manual will provide youwith information to present to your crew during apre-job safety meeting or whenever you need toreinforce what you already know.

Chapter 1RIGGING UP THEEQUIPMENTThe Torque System:After measuring the rig and determining the torquesystem configuration, the top drive technician will requirethe help of a select number of crewmembers. As adriller, it’s up to you to choose workers who are confidentworking at heights and follow instructions well. A wellthought out pre-job meeting and the right people canmake rigging up the top drive much easier and safer.The torque system includes the following:

1. Torque Track2. Torque Anchor Beam3. T-Bar

In the next few pages we will describe the parts of thetorque system, what they do and some effective waysof installing them.

Torque Track:

The torque track consists of varying lengths of track.Each section is designed to fit another by lining up theflanges and tightening the bolts. The length of the trackdepends on the size of the rig mast but in all cases thebottom of the track, called the deflector section, shouldbe between 7 and 8 feet from the floor. The track ishung by attaching an adjustable hanging cluster to apad eye that has been welded to the crown’s beams.The bottom of the track is secured to the derrick bybolting on the T-bar and fastening it in to the torqueanchor beam. Using turnbuckles we can center thetrack and provide rigidity along the length of the derrick.The turnbuckles are attached to the torque track andderrick using clamps or by welding in pad eyes on thederrick beams prior to rig up.

In some cases our technicians may pre-assemble thetorque track on the ground and hoist up to 2 sections atonce. When hoisting the torque track, goodcommunication and the use of a hold back line arerequired.

Once the first section of track has been lifted to the drillfloor with the tugger line, it is then lowered through therotary table so that the top of the track can be attachedto the traveling block. After raising the track above thefloor with the blocks, the rest of the track sections canbe hoisted to the floor and placed in the rotary tableindividually and bolted into the previous sections.


Chapter 7Top DriveConsiderationsSlip and Cut Drilling Line:Some daily rig operations change when a rig is fittedwith a top drive. Some simple procedures that yourcrew has performed regularly will need to be adjustedto consider top drive issues.

To slip and cut drilling line, obviously the weight of thetop drive cannot hang from the same line as the blocksalone did. The top drive technician will assist you indetermining the length of a block-hanging sling to beinstalled in the derrick to a suitable beam so that thetop drive is positioned at floor level. If your rig is alreadyfitted with a block-hanging sling, the sling and the eyeon the blocks should be rated to support the weight ofthe top drive as well as the traveling block. The topdrive will have to be connected to the drillstring and setin the slips as low as the block-hanging sling will allow,to help distribute the additional weight of the top drive.

Note – When performing a slip and cut with a topdrive it is possible to pump fluid into the well ifnecessary.

Important – The blocks should never be hung froma floor tugger.

Top Drive Maintenance:The regular daily maintenance and inspections on thetop drive do not have to interfere with rig operations. Inorder to keep the top drive running safely and efficiently,up to 15 minutes every tour must be available to servicethe equipment. The top drive technician’s knowledgeof drilling allows him to choose a ‘window of opportunity’to do this when the top drive is accessible from a ladderon the rig floor, while minimizing the impact on thecustomer’s operation.

If any service or repairs need to be done on the topdrive, all of the drawworks controls and the driller’spanel must be locked out and tagged to ensure thesafety of the personnel.

Important – The top drive technician must benotified of any concerns or incidents involvingTesco equipment.

DisclaimerThis manual is intended to provide basic informationonly, and does not constitute a comprehensiveguide to the functioning or operation of a Tesco TopDrive. It is to be used only in conjunction with theorientation and on site supervision provided byTesco personnel. The Tesco Top Drive Technicianmust be notified of any concerns or incidentsinvolving Tesco equipment and its operation.

OTHER THAN AS DESCRIBED IN THEPRECEDING PARAGRAPH, TESCOCORPORATION, ITS AFFILIATED COMPANIESAND EMPLOYEES ASSUME NORESPONSIBILITY FOR USE OF THEINFORMATION CONTAINED IN THIS MANUAL.

Tesco Corporation (“Tesco”) has made every effortto ensure that this manual describes the basicknowledge needed to provide a quick reference fortop drive operators.

This manual is to be used in conjunctionwith an orientation and on sitesupervision.

When the torque track is fastened together in the lengthrequired to allow the top drive to travel between thehighest and lowest points in the derrick, it then needsto be secured to the crown. This is done by attachingthe hanging cluster at the top of the track to a welded-on pad eye with a shackle.Next we need to position the torque track so that wecan fasten the t-bar to it and make sure that the torqueanchor beam will accept it as well.

Once the torque track is in place the turnbuckles needto be attached to it and secured in predeterminedlocations on the derrick strongbacks. Using theseadjustable, locking turnbuckles we can center the trackand help provide rigidity along the length of it.

When the torque system is installed it should be straightand at the proper distance from well center and the rigfloor.

Torque Anchor Beam:The torque anchor beamaccepts the torque directlyfrom the quill and transfers itto the derrick. On some rigswe can weld the anchor inplace, on others we need toinstall the beam using clamps.The beam is usually attachedto the lowest strongbackwhere the energy can bedisplaced across the widestpoint of the derrick. Periodicinspection of the welds or theclamps tightness must beperformed to prevent any

movement of the torque track.

Position the hoisting sling and tugger line on the centerof the load. Carefully raise the anchor beam to theappropriate strongback.

The top drive technician will need assistance to positionthe anchor beam on the strongback and hold it in placeuntil the clamps can be secured.

Safety - Make sure all workers are connected to anapproved fall arrest system.

T-Bar:The T-bar is a solid steel arm that bolts on to the torquetrack at it’s lowest point and takes the drilling torquefrom the top drive and transfers it through the anchorbeam and across the derrick.

The T-bar can be installedin the torque anchor assoon as the beam issecured to the derrick.

The T-bar can also bebolted on to the torquetrack just before the track

is hung from the crown when the bolt pattern section oftrack is at a comfortable height.

When the T-bar is attached to the torque track andthe track is hanging from the pad eye at the crown,the T-bar should be just slightly higher than theanchor. This way, when the anchor clamp istightened down it will pull the track into tension.

After all the main components of the torque system areinstalled the turnbuckles can be adjusted to straightenthe track.

Note: All shackles, turnbuckles, and similar items shouldbe secured with cotter pins or safety wires, to preventaccidental loosening.

The Power Module:The Tesco hydraulictop drive comes with abuilding containing aprime mover thatdrives a series ofv a r i a b l edisplacement, bi-directional hydraulicpumps. These pumpssend hydraulic flowthrough a closed

loop, high-pressure system to the top drive motor(s),which provide quill rotation before returning to the skidto be filtered. Additional gear pumps send hydraulicflow through an auxiliary system to the top drive,operating the various robotic functions as well ascirculate oil through a filtration and cooling systembefore returning to the reservoir. The power modulealso contains an electrical panel, which accepts a 480


By decreasing forward pump pressure, there will notbe enough hydraulic flow to rotate the pipe. Now, slowly‘increase’ the pumps until the pipe begins to rotate.Maintain enough pressure on the hydraulic gauge tohold drillstring in torsion without reaching the torquerelief setting on the top drive. When maintaining statictorque over extended time periods, it is recommendedto increase the pumps to a value less than the torquerelief setting and allow the pumps to control the desiredtorque. If the top drive torque relief is activated, thehydraulic oil passing through the relief over time, willcreate excessive heat. The hot oil may, in turn, activatea power unit shut down, resulting in an untimely torquerelease of the drill string.

The power module is equipped with numeroussafety shutdowns. When the hydraulic oil reachesthe high oil temperature shutdown setting, the primemover will shut down. This should be avoided,especially in situations where hole problems areencountered.

Continue working the drillstring while maintaining torquewith the top drive until a free point is established. Whenthe pipe begins to rotate at this torque setting keepraising and lowering pipe in the free point increasingthe travel distance until the obstruction is cleared.

Jarring:If jarring is required, the torque applied to the drillstringwill need to be released. By slowly decreasing the quilltorque shown on the hydraulic gauge, the reactivetorque in the string will overcome the quill torque andthe pipe will, in a controlled manner, rotate in reverseuntil torsion is released. Once this is done, set the slipsin order to break out the top drive.

Tesco does not recommend jarring with thedrillstring connected to the quill. The drillstringshould be suspended from the elevators beforejarring commences.

Disconnect hydraulic hoses at the elevator quickconnects to reduce the chances of elevators openingaccidentally.

After any jarring is done the top drive technician willneed the time to perform a visual inspection of the topdrive components and fill out a ‘Post Jarring Checklist’.In the event of excessive jarring a load path inspectionmay need to be performed at the earliest convenience.

Logging:When using the hydraulic elevators to support a wireline sheave, disconnect the hydraulic hoses at theelevator quick connects to reduce the chances ofaccidental opening.

Note: The hoses should also be disconnected to preventaccidental opening in any other operation where theelevators support a load other than the drillstring (forexample, when a set of secondary elevators aresupported from a nubbin in the hydraulic elevators).

Running Casing:Using the top drive forrunning casing offerssome advantages overconventional methods.At the customer ’srequest, Tesco canprovide a crossover subto connect the quill tothe casing, eliminatingthe need to rig-upchiksans and fil l uphoses. The top drive

also provides pipe handling functions to make handlingcasing much simpler and safer.

Cementing:Unless it is absolutely necessary, never attempt tocement through the top drive. With the exception ofthis rule, cementing with a top drive is similar toconventional methods.

or 600 volt AC input from the rig’s generators andconverts it to other voltages that operate the electricalcomponents of the top drive system. When spottingthe power module, it must be lifted using proper hoistingtechniques and placed in an ideal position for the serviceloop to reach the derrick. If the service reel is notattached to the power module skid, then it should beplaced on rig matting with the power module andconnected to the auxiliary hydraulic system.

The Service Loop:The service loop sends and receives electricalcommunication from the power unit and the driller’spanel as well as hydraulic flow to and from the top drive.It is critical that these lines not be damaged due toimproper lifting or obstructions in the derrick. Once theservice loop has been installed, observe its movementalong the entire travel of the top drive.

The service loop should make no contact with anypart of the rig.

Using a soft hoisting sling and the floor tugger, theoperator will raise the service loop into the derrick whilethe top drive technician reels out enough slack to installthe lines into the hose saddle and capture clamp.

Once the hose saddle position has been determined itis then attached to the derrick. The rig design and topdrive model will determine where the saddle is located.

A safety sling should always be installed around thehose saddle and hoses, and then attached to either awelded in pad eye or a suitable beam. Safety slingsshould also be installed between the hose ends andthe top drive.

The Top Drive:The top drive is a heavy, unbalanced load and shouldbe carefully handled to prevent injury or equipmentdamage. The top drive technician should always bepresent to oversee any loading or unloading of Tescoequipment.

Once the top drive arrives on location, it should beplaced on the catwalk so that it can be hoisted to the rigfloor using 2 point, load rated slings attached to theblocks. A hold back line should be used to prevent thetop drive from shifting once it is lifted.

Before the top drive is raisedto the rig floor, the torquebushing and extend frameneed to be installed onto thetorque track and pinned inplace.

With the top drive standpositioned over hole centerand secured to the derricklegs using chains andboomers, the swivel can nowbe properly doped andthreaded into the quill with achain tong.

On top drives equippedwith an integrated swivel,the swivel bail or yoke is

directly installed into the becket or block hook.

Now the top drive can be lifted from the transport standby raising the blocks and the transport stand removedfrom the rig floor.

Using the blocks, line-up the pin holes between theextend frame and the top drive and insert the drive pinsand keepers.

With the weight of the top drive hanging on the overheadblocks and swivel, remove the torque bushing pin.

The top drive technician will connect the service loop tothe top drive and install the driller’s panel.

With the power unit now running and the service loopand drillers panel connected to the top drive, we cannow make up the swivel to the specified torque. To dothis the off-drillers side tongs must be raised to therequired height to bite against the swivel or cross overand back up slings attached to a suitable point on thederrick.

It is critical that the bottom of the top drive besecured with a cross chain on the grabber leg or ajoint of heavy weight drill pipe connected to thesaver sub and set in the slips - or both. Torqueshould always be applied to the swivel connectionin ‘drill mode’ and only the required personnel todo the job should remain on the rig floor.


Tip: If the top drive will rotate and everything else isoperating normally, double check that the cold climatebutton has not been accidentally operated.

Reaming:Back reaming out of the hole is one of the greatestfeatures the Tesco top drive provides. These stepsshould be followed before commencing:

Note – Reaming is to commence only at operator’sdiscretion and until the driller is experienced withthis operation, the Tesco technician should bealerted.

1. Ensure the correct saver sub is installed on the topdrive and keep it properly doped while reaming orback-reaming.

2. Connect the top drive to the drillstring.3. Open the mud saver valve.4. Start the mud pumps and establish circulation.5. Remove the slips.6. Select ‘drill’ mode.7. Pumps ‘forward’ Set quill speed to 30-40 RPM.8. Hoist the drill string and close the elevators on

the stand.9. Work the drill string until free of obstruction.

When you are ready to rack the stand in the derrick,the procedure is as follows:

1. Stop rotation.2. Stop the mud pumps.3. Set the slips.4. Break out the lowest connection with the rig tongs.5. Hoist stand out of the stump and allow the pipe to

drain.6. Close the mud saver valve.7. Lower the stand to approximately 2 inches above

the rotary table.8. Ensure the grabber is in position at the top tool joint.9. Close the grabber and break out the top drive.10. Once the top drive is unscrewed from the pipe, open

the grabber and the stand will rest on the floor.11. Hoist the top drive until the elevators pick up the

stand.12. Link tilt forward until the derrickhand has control of

the stand and it has been placed in the birdbath.13. Open the elevators.

14. Link tilt back to vertical.15. Lower the top drive to the floor and continue back

reaming if necessary.

If an obstruction is encountered when tripping in thehole, or if for any reason it is necessary to establishcirculation, i.e. well control, the top drive can beconnected to the drillstring quickly by following thesesteps:1. If an obstruction is encountered, hoist until the

drillstring is free, and a connection is at floor level.2. Set the slips.3. Lower the top drive and guide the top tool joint into

the grabber. Set backup tongs on tool joint at floorlevel.

4. Select ‘connection’ mode.5. Rotate the top drive into the top tool joint and

shoulder it up.6. Make up the connection to the specified torque.7. Open the mud saver valve.8. Remove the tongs and the slips.9. Start the mud pumps and establish circulation.10. Select ‘drill’ mode.11. Set quill speed to 30-40 RPM.12. Ream through the obstruction until the string is free.13. Lower top drive to the floor and disconnect the

topdrive – see, break out connection procedures.

Working Tight Hole:It is important to know that when torque is appliedto the drillstring you cannot pull up to the maximumforce that the pipe is rated for. The top drivetechnician will provide information on specificclasses of tubulars and their torsion/tensionthresholds.

In tight hole situations, it will be necessary to free thepipe using the top drive. With the top drive, the abilityto maintain mud pump flow, raise and lower the drillstringand hold torque all at the same time is possible. It isrecommended that when working tight hole, sometorque can be applied to the drillstring.

This is best done by selecting:

1. ‘Drill’ mode2. ‘Decrease’ pumps3. ‘Forward’ pumps4. Slowly ‘Increase’ pumps

Chapter 2Component IdentificationTop Drive:


The amount of loop pressure needed to hold thedrillstring when the grabber is opened will change asdepth, and angle of build increase. This is why youshould record a downhole torque history, because thex value will be easier to predict.

Turn the string to the left by decreasing loop pressure(‘decrease pumps’), and, if there is not much reactivetorque present, select ‘reverse’ until positioning iscomplete, then close the grabber.

Note: The maximum reverse torque is set to preventthe string unscrewing. Do not engage the ‘breakout’function or the drillstring could come apart.

Tripping:The Tesco top drive reduces the amount of time andwork involved in tripping and reaming by giving you theability to thread into the drillstring at any point in thederrick. This is useful when encountering hole problemswhile tripping (for instance, pulling tight, bridging off orwhen a kick is evident). In short, any time when theneed to pump fluid into the well exists, it can be donewithout having to position the drillstring at floor level inorder to install the kelly.

Tripping pipe with a top drive is similar to conventionalmethods, with the exception that the robotic functionsease pipe-handling procedures. At no time is itnecessary for the rig crew to position the elevators oropen and close them. The link tilt function can pushthe stand of pipe to be racked to the worker, both onthe rig floor and to the derrickhand. When running inthe hole, the derrickhand does not need to lean out tothrow the stand in the elevators; he can simply easethe stand into the elevators, which are extended towardhim. Once the stand is placed in the elevators, theycan be closed hydraulically. After the stand is racked inthe derrick or added to the string the links should bereturned to the vertical hanging position by selectingthe ‘float’ function.Important – The links and elevators should neverbe manually operated by a worker.

Cold Climate:When the hydraulic top drive is working in a freezingenvironment, the oil quickly becomes thick and this willreduce its effectiveness. While drilling, the heat fromthe top drive motor(s) warms the oil enough so that thisis not a concern, but whenever the quill is not rotating,such as when you are slide drilling or tripping, the cold

climate function should be used. To activate coldclimate follow these steps:1. Push in the cold climate button (on the left side of

the drillers panel).2. Select engine speed ‘slow’.3. ‘Drill’ mode.4. ‘Forward’ pumps.5. ‘Increase or decrease’ pumps, to maintain 700psi

on the hydraulic pressure gauge.

When the cold climate button is pushed in it de-energizes the circuit to the top drive speed control valveand allows the flow of loop oil to pass through the motormanifold and circulates the closed loop system withoutturning the quill.

Selecting engine speed slow brings the prime mover toidle speed for cold climate operation. This saves overallwear and tear on the engine when it has a low load onit.

Drill mode allows you to control the hydraulic pumpsinternal swash plates, which command the amount ofoil flow to maintain 700psi.

Forward pumps directs the oil flow in such a way that itpasses through the maximum amount of filtration beforegoing through the pumps again.

Follow these steps in order to properly disengage thecold climate function:

1. ‘Neutral’ pumps.2. ‘Connection’ mode.3. ‘Neutral’ engine speed.4. Pull out the cold climate button.

By selecting neutral pumps, the flow of hydraulic oil isstopped.

Important: Never push out the cold climate buttonwithout the preceding 3 steps.Connection mode keeps the prime mover at an idlewhen the engine speed is switched to neutral.

After pulling out the cold climate button the top drivecan now return to normal operation.

Chapter 3The Rosemount Gauge receives a milliamp signal froma pressure transducer located on the top drive. The

transducer measures the differential between the highand low pressure sides of the top drive hydraulicmotor(s). This measurement gives you the mostaccurate torque reading while drilling, when thehydraulic oil in the loop is in a high flow state.

The Hydraulic Pressure Gauge is used primarily toset the torque reliefs, which control the amount of torquethat can be applied to the quill. This gauge is also veryaccurate when making and breaking connections, whenthe hydraulic oil in the loop is in a semi-static conditionand pressure losses are at a minimum.

Indicator Lights:There are indicator lights installed in the driller’s panelreminding you that a function is, or has been performed.The response to an illuminated indicator light shouldbe:

Stop - Why it is illuminated and how will it effectfurther operations?

There are indicator lights for the following:DC Power This green light should be illuminated at alltimes, indicating that the power supply to the driller’spanel is on.

Grabber When the grabber is closed, the light willcome on and will not go off until ‘grabber open’ isselected.

Valve When the mud saver valve is closed, the lightwill come on will not go out until ‘valve open’ is selected.

The Drillers PanelDescription:The drillers panelis a stainless steele n c l o s u r eequipped with allof the controls,indicator lights,mounts, gaugesand connectorsrequired to operatethe top drive fromthe driller ’sposition. All of thecontrols are 24volts DC electricover hydraulic. The two main cables to the panel are37 pin conductor cables with each wire serving a specificfunction. One 37-pin cable connects the power moduleto the driller’s panel and the other connects the top drivewith the driller’s panel. The four smaller cables are 4 or5 pin Amphenol connectors which control input to thesafety interlocks, overrides and digital gauges for quilltorque and RPM.

Positioning:When deciding whereto mount the driller’spanel it is importantthat your view of the rigfloor from the driller’sposition is notobstructed and thatyou can reach thecontrols well enough to

operate the drawworks and top drive simultaneously.All of the cables to the panel should be routed in such amanner that moving parts will not damage them andthey should be elevated from the floor.

Instrument Gauges:There are two digital gauges on the driller’s panel, theRPM Gauge that meters quill rotation and theRosemount Gauge, which reads quill torque. Separatefrom the driller’s panel is the Hydraulic PressureGauge, which reads the closed loop pressure in psi.The RPM Gauge gives an exact reading of the quillspeed.


Note: If the rig floor is too large to pickup singles fromthe v-door with the link tilt and extend, it is still possibleto make double (or triple) connection. Make a singleconnection as described above. Raise the top driveand joint of pipe. Place another joint of pipe in themousehole and make up as per ‘off-bottom’ connection.Repeat if a ‘triple’ is required.

Although it is possible to make up triple stands in themouse hole with the top drive, it may be moreefficient to make up stands in advance and leavethem racked in the derrick if drilling with triple standsis required.

Chapter 6OperationsDrilling:When drilling ahead with a top drive, adhere to the samesafety and operating practices and procedures as withconventional rotary drilling.

Rotating Once you have made a connection and theslips have cleared the table, select ‘valve open’ and startup the mud pump, then select ‘drill’ mode immediately.The preset functions in connection mode will be disabledand now you can manipulate the quill RPM by selecting‘forward’ and ‘increasing or decreasing’ the pumps.

Slide Drilling In order to hold toolface while sliding,you must close the grabber on the saver sub, allow thegrabber cylinder to pressure-up, and then switch the‘pumps – forward/reverse’, to neutral. The grabber lightwill remain on.

When sliding, the grabber is closed and the hoistingclutch interlock is activated. In order to work thedrillstring you must push and hold the ‘override’ buttonon the brake handle control box while hoisting. Thisallows the drawworks drum clutch to engage.

When running a mud motor, keep accurate records ofthe reactive torque (motor pressure) in the string. Atany given time, you may need to orient the toolface ofthe downhole motor. To do this the grabber will need tobe opened; if you do not track downhole torque history,turning the string in small increments will be impossible.Assuming that you know the amount of torque present,follow these steps to orient the toolface:

1. Select ‘drill forward’.2. Decrease the pumps so that x psi (the pressure equal

to the reactive torque) is present on the hydraulicpressure gauge.

3. Select ‘grabber open’.4. If the value of x provides enough torque, the string

should not turn.

Turn the string to the right by selecting:

5. ‘Increase pumps’ until the pipe turns very slowly andunder control.

6. When you have achieved the new orientation, quicklyclose the grabber.

Auxiliary Pump This amber light will illuminate if theauxiliary pump is already running and then a roboticfunction is selected. This indicates that the hydraulicpressure needed to operate the robotics has beendelivered. If you notice that the light is on, check to seeif any switches have been left in the energized state.When the pump is left pressured-up, the oil return isrestricted and the oil must pass over a relief. Whenthis occurs, the hydraulic oil will quickly become veryhot and the pump may eventually fail.

If a robotic function is selected and this light doesnot come on, the function has not occurred.

Pipe Handler Unlock When the pipe handler isunlocked, a proximity switch located on the top drivewill activate a light on the drillers panel, indicating thelocking assembly has been disabled. There is also aninterlock associated with this circuit that will bedescribed in the following section. (Tesco Model HCIonly)

Safety Interlocks:An interlock is a term used to describe an electricalinput from one function that prevents the use of anotherby cutting off the flow of electrical current. Interlocksare used on the top drive to minimize the possibility ofan unsafe condition. The following describes whichfunctions have interlocks, how they work and why:

Grabber When the grabber is switched to the closedposition, a signal is sent to the drawworks interlockinstalled in the rig’s drawworks console. This device isa solenoid actuated air valve, which closes and cuts offthe air supply to the hoisting clutch controls. This willprevent the accidental lifting of the blocks when the topdrive quill is not connected to the tool joint against whichgrabber has been closed (i.e. after a connection hasbeen broken). The grabber is not designed to acceptany significant amount of load; this could result in pullingthe grabber components from the top drive. Override– In order to hold toolface while directional drilling, thegrabber will remain closed on the top tool joint. If thedrillstring needs to be worked while holding toolface,the grabber close interlock must be overridden. To dothis, push and hold the red button, located on thebrake handle control box and hoist simultaneously.

Mud Saver Valve When the valve is switched to closean interlock exactly like thedrawworks one is energized to cutoff the air supply to the mud pumpclutch controls. This preventsaccidentally starting of the mud pumpand dead-ending pump flow againstthe mud saver valve.

Connection Mode/Forward To make a connection,the driller’s panel must be switched to ‘connection’mode. When in this mode, several preset functionsoccur and the drawworks interlock is part of thosefunctions. Once the tool joint has been made up tospecified torque, it would be possible to leave the topdrive in ‘forward’ and hoist the drillstring to remove theslips. The drillstring would then turn and the slip handlescould injure the floorhands trying to remove them. Theinterlock cuts off the air supply to the hoisting clutch,preventing this from happening. Once the slips havebeen removed, do not switch to ‘forward’ until ‘drill’mode has been selected.

Pipe Handler The improper use of the pipe handlercan have serious consequences, but with safetyinterlocks and proper training we can minimize the riskof any incidents. When the pipe handler “unlock” isactuated, a proximity switch locks out the quill rotationunless the pipe handler caution (rotate) button is pushedand held while in ‘connection forward or reverse’.(Tesco Top Drive Model HCI, ECI &EMI only)


Chapter 5connection instead of the top drive. In this method a“working single” remains on the top drive.

Note: Make sure that all connections are properlydoped.

Making Up Singles:Extend out and stab into the mousehole single. Latchthe rig tong on to mousehole single and rotate the quillforward to shoulder up the connection.

Important – Do not torque the connection in themousehole with the top drive.

Carefully retract the top drive into the torque track whilehoisting out of mousehole. Position the new singleabove hole center and slowly lower it into the stump.Latch the rig tong on the stump and rotate the quillforward to make up the connection to the specifiedtorque. The torque value will be read on both thehydraulic pressure gauge and the Rosemount gauge.

Similar procedures are used for an ‘off-bottomconnection’, but extra care must be taken when hoistingto retract the top drive and avoid contact with themonkey-board.

Making Up Doubles:Using the floor tugger, install one single in themousehole and another single on the v-door leftconnected to the tugger. Extend top drive over themousehole and link tilt forward so that the elevatorscan close on the v-door single. Hoist the v-door singleabove the rig floor and stab it into the mousehole single.Shoulder up the connection by using either a chain tongor by carefully guiding the top of the new stand into thetop drive with the link tilt function and rotate the quilluntil both connections have shouldered up. Use the rigtongs to back up the single in the mousehole whilemaking up a connection with the top drive.

Important - Do not torque connection in themousehole with the top drive.

Now, carefully retract top drive into the torque track whilehoisting out of the mousehole. Ensure top drive andblocks are clear of monkey-board. Position the newstand above hole center and slowly lower it into thestump. Latch the rig tong on to the stump and rotatethe quill forward and make up both connections to thespecified torque.

Making ConnectionsSafety:Making connections with a Tesco top drive greatlyreduces time and manpower needed to get back tobottom and drilling ahead. We can add pipe to thedrillstring in single joints and double or triple stands.When making a connection, many tasks are beingperformed by the top drive and it is critical that allpersonnel are aware of pinch point locations andstand clear of the top drive. All connection torquevalues must be agreed upon by the customer prior todrilling, and a connection worksheet signed. The Tescotechnician sets the torque parameters and these cannotbe exceeded.

Breaking Out:The top drive can be drilled down to floor height byopening the elevators and selecting link tilt ‘back’. Tomake a connection, rotation is stopped, the mud pumpsare turned off, the slips set, and drillers panel set to‘connection’ mode.

Know the weight of the top drive and overheadhoisting equipment. This amount should be readon the weight indicator gauge when the slips areset. If you have less than the weight of the top driveon the weight indicator, the counter balance systemwill not be able to lift the top drive out of the threadbox and thread damage will occur. If you have morethan the weight of the top drive reading on theweight indicator, the threads will be damaged andthe top drive could bounce out of the threads andalso damage the seal face.

Once the mud pump SPM and standpipe pressuregauge read zero, it is safe to close the mud saver valve.Switch the grabber to ‘close’, wait for the dies to set,and then select ‘reverse’. The connection will not breakuntil the ‘break out’ button is pushed and held. Oncethe connection has broken, the break out button canbe released and the grabber opened. Continuereversing until the connection is completely unthreadedand the counter balance system has gently lifted thetop drive saver sub out of the thread box.

If preferred, connections can be made ‘off bottom’ byhoisting one single through the table, before setting theslips. The rig tongs must be used to break the

Chapter 4and the top drive stalls. Return the ‘pumps’ switch fromforward to neutral and allow the pressure on thehydraulic gauge to bleed off below 1000psi beforeselecting grabber ‘open’.

Allow 5 seconds for the grabber to fully open beforeswitching the grabber to neutral.

Grabber Lift (Tesco Top Drive Model HMI, notequipped): A hydrauliccylinder, located in thegrabber leg, raises andlowers the grabber to therequired height for backing-up the tool joint. Alwaysposition the grabber at thetop tool joint before raisingthe top drive from the floorlevel. If for any reason,such as having to begin atrip before the stand hasbeen drilled, you can simplyclose the grabber to break-out of the stand at themonkeyboard height

without having to guess whether or not the grabber isin the correct position.

Pipe Handler In order to turn the elevators in thedirection needed for a certain operation, the pipe handlerwill have to be used. To perform this, proper operationis critical for worker and equipment safety.

The following steps must be followed beforeunlocking the pipe handler:• All personnel must clear the area of the top drive,

elevators, and links.• Link tilt vertical (if possible, latch the elevators on the

pipe).• Pumps to ‘neutral’.• Pipe handler ‘unlock’ and return to neutral.• Grabber ‘close’ (on the saver sub).• Pumps ‘forward’ or ‘reverse’.• Push ‘pipe handler – caution’ button (rotate)

The pipe handler section of the top drive will now rotateup to 360 degrees at 4 RPM. Once the orientation ofthe pipe handler is correct, these steps must befollowed to disengage pipe handler rotation.• Release ‘rotate or caution’ button.• Pumps to neutral.


• Grabber ‘open’.• Pipe handler ‘lock’ and return to neutral - a visualconfirmation is critical to ensure the lockingmechanism has fully engaged the lock ring gear.The top drive can now return to normal operation.

Hydraulic Elevators The Tesco top drive comesequipped witha u t o m a t i celevators, whicheliminate theneed to have aperson manuallyoperate them.This gives theability to open

and close the elevators on extremely tall stands of BHAand reduces worker exposure to additional hazardsassociated with manual operation of the elevators. The3-position switch must be turned to ‘open’ and a safetypush button held at the same time with no load in theelevators for them to open. This way, selecting thewrong switch cannot accidentally open the elevators.The elevators can be closed by either switching to ‘close’on the drillers panel or by pushing the close buttonlocated on the brake handle control box. When closingthe elevators, visually confirm the latch has closed.

Mud Saver Valve and Actuator Tesco top drivesincorporate a double ballmud saver valve with aremote actuator to act asboth a mud saver and as anemergency blow outprevention valve. Theactuator is designed toallow you to open or closethe mud saver valve at any

point in the derrick. It is critical that the actuator isnever functioned while the quill is rotating; this willdamage the internal components and lead to failure ofthe actuator. When you select valve ‘close’ the actuatorwill close with up to 5000 psi of hydrostatic well borepressure against it. Once you have selected valve ‘open’the actuator will open and cannot be closed again for 7seconds. This prevents the accidental re-closure of thevalve once the mud pumps have been started.

Controls and RoboticsClearance and Visibility:The top drive takes up much more space on the rigfloor than a kelly would, so this work area must be keptclear of obstacles that may interfere with the movementof the top drive and that of the personnel. When thetop drive is moving through the derrick, you must beaware of it’s position at all times. Because you are notalways able to see the top drive, the other members ofyour crew must also watch and be aware of the topdrive’s position and movement at all times.

Note: If you are unsure about any situation, stopand ask for help. This will save more time in theend and reduce the likelihood of an incidentoccurring.

Robotic Functions:Extend This feature allows the top drive to reachforward over the mouse hole, giving it the ability to makeup stands in the mouse hole for drilling as well as aidingthe process of handling tools to and from the v-door.Note: An optional extend alarm is available if requested.This device provides an alarm if the top drive isextended.

Note: If you leave the top drive extended out whilehoisting with blocks, the top drive could makecontact with the monkey board.

Link Tilt Commonly known as ‘the bails’, the links canbe tilted to move the elevators up to 35 degrees forwardand 55 degrees back from vertical, extending the reachof the top drive to perform many tasks associated withpipe handling.

Grabber The grabber acts like a back-up tong andcloses onto a tool joint to arrest the reactive torque whenmaking up or breaking out a connection.

Rule of thumb: Allow 10 seconds for the grabberto close before applying torque.When breaking out, close the grabber and leave theswitch in the ‘close’ position until the connection breaks.Then open it while reversing out of the thread box. Thisway, you can hoist out of the tool joint once completelyun-threaded without the interlock disabling the hoistingclutch. For making-up a joint, leave the grabber switchin the ‘close’ position until the specified torque is reached

Chapter 4and the top drive stalls. Return the ‘pumps’ switch fromforward to neutral and allow the pressure on thehydraulic gauge to bleed off below 1000psi beforeselecting grabber ‘open’.

Allow 5 seconds for the grabber to fully open beforeswitching the grabber to neutral.

Grabber Lift (Tesco Top Drive Model HMI, notequipped): A hydrauliccylinder, located in thegrabber leg, raises andlowers the grabber to therequired height for backing-up the tool joint. Alwaysposition the grabber at thetop tool joint before raisingthe top drive from the floorlevel. If for any reason,such as having to begin atrip before the stand hasbeen drilled, you can simplyclose the grabber to break-out of the stand at themonkeyboard height

without having to guess whether or not the grabber isin the correct position.

Pipe Handler In order to turn the elevators in thedirection needed for a certain operation, the pipe handlerwill have to be used. To perform this, proper operationis critical for worker and equipment safety.

The following steps must be followed beforeunlocking the pipe handler:• All personnel must clear the area of the top drive,

elevators, and links.• Link tilt vertical (if possible, latch the elevators on the

pipe).• Pumps to ‘neutral’.• Pipe handler ‘unlock’ and return to neutral.• Grabber ‘close’ (on the saver sub).• Pumps ‘forward’ or ‘reverse’.• Push ‘pipe handler – caution’ button (rotate)

The pipe handler section of the top drive will now rotateup to 360 degrees at 4 RPM. Once the orientation ofthe pipe handler is correct, these steps must befollowed to disengage pipe handler rotation.• Release ‘rotate or caution’ button.• Pumps to neutral.


• Grabber ‘open’.• Pipe handler ‘lock’ and return to neutral - a visualconfirmation is critical to ensure the lockingmechanism has fully engaged the lock ring gear.The top drive can now return to normal operation.

Hydraulic Elevators The Tesco top drive comesequipped witha u t o m a t i celevators, whicheliminate theneed to have aperson manuallyoperate them.This gives theability to open

and close the elevators on extremely tall stands of BHAand reduces worker exposure to additional hazardsassociated with manual operation of the elevators. The3-position switch must be turned to ‘open’ and a safetypush button held at the same time with no load in theelevators for them to open. This way, selecting thewrong switch cannot accidentally open the elevators.The elevators can be closed by either switching to ‘close’on the drillers panel or by pushing the close buttonlocated on the brake handle control box. When closingthe elevators, visually confirm the latch has closed.

Mud Saver Valve and Actuator Tesco top drivesincorporate a double ballmud saver valve with aremote actuator to act asboth a mud saver and as anemergency blow outprevention valve. Theactuator is designed toallow you to open or closethe mud saver valve at any

point in the derrick. It is critical that the actuator isnever functioned while the quill is rotating; this willdamage the internal components and lead to failure ofthe actuator. When you select valve ‘close’ the actuatorwill close with up to 5000 psi of hydrostatic well borepressure against it. Once you have selected valve ‘open’the actuator will open and cannot be closed again for 7seconds. This prevents the accidental re-closure of thevalve once the mud pumps have been started.

Controls and RoboticsClearance and Visibility:The top drive takes up much more space on the rigfloor than a kelly would, so this work area must be keptclear of obstacles that may interfere with the movementof the top drive and that of the personnel. When thetop drive is moving through the derrick, you must beaware of it’s position at all times. Because you are notalways able to see the top drive, the other members ofyour crew must also watch and be aware of the topdrive’s position and movement at all times.

Note: If you are unsure about any situation, stopand ask for help. This will save more time in theend and reduce the likelihood of an incidentoccurring.

Robotic Functions:Extend This feature allows the top drive to reachforward over the mouse hole, giving it the ability to makeup stands in the mouse hole for drilling as well as aidingthe process of handling tools to and from the v-door.Note: An optional extend alarm is available if requested.This device provides an alarm if the top drive isextended.

Note: If you leave the top drive extended out whilehoisting with blocks, the top drive could makecontact with the monkey board.

Link Tilt Commonly known as ‘the bails’, the links canbe tilted to move the elevators up to 35 degrees forwardand 55 degrees back from vertical, extending the reachof the top drive to perform many tasks associated withpipe handling.

Grabber The grabber acts like a back-up tong andcloses onto a tool joint to arrest the reactive torque whenmaking up or breaking out a connection.

Rule of thumb: Allow 10 seconds for the grabberto close before applying torque.When breaking out, close the grabber and leave theswitch in the ‘close’ position until the connection breaks.Then open it while reversing out of the thread box. Thisway, you can hoist out of the tool joint once completelyun-threaded without the interlock disabling the hoistingclutch. For making-up a joint, leave the grabber switchin the ‘close’ position until the specified torque is reached

Auxiliary Pump This amber light will illuminate if theauxiliary pump is already running and then a roboticfunction is selected. This indicates that the hydraulicpressure needed to operate the robotics has beendelivered. If you notice that the light is on, check to seeif any switches have been left in the energized state.When the pump is left pressured-up, the oil return isrestricted and the oil must pass over a relief. Whenthis occurs, the hydraulic oil will quickly become veryhot and the pump may eventually fail.

If a robotic function is selected and this light doesnot come on, the function has not occurred.

Pipe Handler Unlock When the pipe handler isunlocked, a proximity switch located on the top drivewill activate a light on the drillers panel, indicating thelocking assembly has been disabled. There is also aninterlock associated with this circuit that will bedescribed in the following section. (Tesco Model HCIonly)

Safety Interlocks:An interlock is a term used to describe an electricalinput from one function that prevents the use of anotherby cutting off the flow of electrical current. Interlocksare used on the top drive to minimize the possibility ofan unsafe condition. The following describes whichfunctions have interlocks, how they work and why:

Grabber When the grabber is switched to the closedposition, a signal is sent to the drawworks interlockinstalled in the rig’s drawworks console. This device isa solenoid actuated air valve, which closes and cuts offthe air supply to the hoisting clutch controls. This willprevent the accidental lifting of the blocks when the topdrive quill is not connected to the tool joint against whichgrabber has been closed (i.e. after a connection hasbeen broken). The grabber is not designed to acceptany significant amount of load; this could result in pullingthe grabber components from the top drive. Override– In order to hold toolface while directional drilling, thegrabber will remain closed on the top tool joint. If thedrillstring needs to be worked while holding toolface,the grabber close interlock must be overridden. To dothis, push and hold the red button, located on thebrake handle control box and hoist simultaneously.

Mud Saver Valve When the valve is switched to closean interlock exactly like thedrawworks one is energized to cutoff the air supply to the mud pumpclutch controls. This preventsaccidentally starting of the mud pumpand dead-ending pump flow againstthe mud saver valve.

Connection Mode/Forward To make a connection,the driller’s panel must be switched to ‘connection’mode. When in this mode, several preset functionsoccur and the drawworks interlock is part of thosefunctions. Once the tool joint has been made up tospecified torque, it would be possible to leave the topdrive in ‘forward’ and hoist the drillstring to remove theslips. The drillstring would then turn and the slip handlescould injure the floorhands trying to remove them. Theinterlock cuts off the air supply to the hoisting clutch,preventing this from happening. Once the slips havebeen removed, do not switch to ‘forward’ until ‘drill’mode has been selected.

Pipe Handler The improper use of the pipe handlercan have serious consequences, but with safetyinterlocks and proper training we can minimize the riskof any incidents. When the pipe handler “unlock” isactuated, a proximity switch locks out the quill rotationunless the pipe handler caution (rotate) button is pushedand held while in ‘connection forward or reverse’.(Tesco Top Drive Model HCI, ECI &EMI only)


Chapter 5connection instead of the top drive. In this method a“working single” remains on the top drive.

Note: Make sure that all connections are properlydoped.

Making Up Singles:Extend out and stab into the mousehole single. Latchthe rig tong on to mousehole single and rotate the quillforward to shoulder up the connection.

Important – Do not torque the connection in themousehole with the top drive.

Carefully retract the top drive into the torque track whilehoisting out of mousehole. Position the new singleabove hole center and slowly lower it into the stump.Latch the rig tong on the stump and rotate the quillforward to make up the connection to the specifiedtorque. The torque value will be read on both thehydraulic pressure gauge and the Rosemount gauge.

Similar procedures are used for an ‘off-bottomconnection’, but extra care must be taken when hoistingto retract the top drive and avoid contact with themonkey-board.

Making Up Doubles:Using the floor tugger, install one single in themousehole and another single on the v-door leftconnected to the tugger. Extend top drive over themousehole and link tilt forward so that the elevatorscan close on the v-door single. Hoist the v-door singleabove the rig floor and stab it into the mousehole single.Shoulder up the connection by using either a chain tongor by carefully guiding the top of the new stand into thetop drive with the link tilt function and rotate the quilluntil both connections have shouldered up. Use the rigtongs to back up the single in the mousehole whilemaking up a connection with the top drive.

Important - Do not torque connection in themousehole with the top drive.

Now, carefully retract top drive into the torque track whilehoisting out of the mousehole. Ensure top drive andblocks are clear of monkey-board. Position the newstand above hole center and slowly lower it into thestump. Latch the rig tong on to the stump and rotatethe quill forward and make up both connections to thespecified torque.

Making ConnectionsSafety:Making connections with a Tesco top drive greatlyreduces time and manpower needed to get back tobottom and drilling ahead. We can add pipe to thedrillstring in single joints and double or triple stands.When making a connection, many tasks are beingperformed by the top drive and it is critical that allpersonnel are aware of pinch point locations andstand clear of the top drive. All connection torquevalues must be agreed upon by the customer prior todrilling, and a connection worksheet signed. The Tescotechnician sets the torque parameters and these cannotbe exceeded.

Breaking Out:The top drive can be drilled down to floor height byopening the elevators and selecting link tilt ‘back’. Tomake a connection, rotation is stopped, the mud pumpsare turned off, the slips set, and drillers panel set to‘connection’ mode.

Know the weight of the top drive and overheadhoisting equipment. This amount should be readon the weight indicator gauge when the slips areset. If you have less than the weight of the top driveon the weight indicator, the counter balance systemwill not be able to lift the top drive out of the threadbox and thread damage will occur. If you have morethan the weight of the top drive reading on theweight indicator, the threads will be damaged andthe top drive could bounce out of the threads andalso damage the seal face.

Once the mud pump SPM and standpipe pressuregauge read zero, it is safe to close the mud saver valve.Switch the grabber to ‘close’, wait for the dies to set,and then select ‘reverse’. The connection will not breakuntil the ‘break out’ button is pushed and held. Oncethe connection has broken, the break out button canbe released and the grabber opened. Continuereversing until the connection is completely unthreadedand the counter balance system has gently lifted thetop drive saver sub out of the thread box.

If preferred, connections can be made ‘off bottom’ byhoisting one single through the table, before setting theslips. The rig tongs must be used to break the

Chapter 3The Rosemount Gauge receives a milliamp signal froma pressure transducer located on the top drive. The

transducer measures the differential between the highand low pressure sides of the top drive hydraulicmotor(s). This measurement gives you the mostaccurate torque reading while drilling, when thehydraulic oil in the loop is in a high flow state.

The Hydraulic Pressure Gauge is used primarily toset the torque reliefs, which control the amount of torquethat can be applied to the quill. This gauge is also veryaccurate when making and breaking connections, whenthe hydraulic oil in the loop is in a semi-static conditionand pressure losses are at a minimum.

Indicator Lights:There are indicator lights installed in the driller’s panelreminding you that a function is, or has been performed.The response to an illuminated indicator light shouldbe:

Stop - Why it is illuminated and how will it effectfurther operations?

There are indicator lights for the following:DC Power This green light should be illuminated at alltimes, indicating that the power supply to the driller’spanel is on.

Grabber When the grabber is closed, the light willcome on and will not go off until ‘grabber open’ isselected.

Valve When the mud saver valve is closed, the lightwill come on will not go out until ‘valve open’ is selected.

The Drillers PanelDescription:The drillers panelis a stainless steele n c l o s u r eequipped with allof the controls,indicator lights,mounts, gaugesand connectorsrequired to operatethe top drive fromthe driller ’sposition. All of thecontrols are 24volts DC electricover hydraulic. The two main cables to the panel are37 pin conductor cables with each wire serving a specificfunction. One 37-pin cable connects the power moduleto the driller’s panel and the other connects the top drivewith the driller’s panel. The four smaller cables are 4 or5 pin Amphenol connectors which control input to thesafety interlocks, overrides and digital gauges for quilltorque and RPM.

Positioning:When deciding whereto mount the driller’spanel it is importantthat your view of the rigfloor from the driller’sposition is notobstructed and thatyou can reach thecontrols well enough to

operate the drawworks and top drive simultaneously.All of the cables to the panel should be routed in such amanner that moving parts will not damage them andthey should be elevated from the floor.

Instrument Gauges:There are two digital gauges on the driller’s panel, theRPM Gauge that meters quill rotation and theRosemount Gauge, which reads quill torque. Separatefrom the driller’s panel is the Hydraulic PressureGauge, which reads the closed loop pressure in psi.The RPM Gauge gives an exact reading of the quillspeed.


Note: If the rig floor is too large to pickup singles fromthe v-door with the link tilt and extend, it is still possibleto make double (or triple) connection. Make a singleconnection as described above. Raise the top driveand joint of pipe. Place another joint of pipe in themousehole and make up as per ‘off-bottom’ connection.Repeat if a ‘triple’ is required.

Although it is possible to make up triple stands in themouse hole with the top drive, it may be moreefficient to make up stands in advance and leavethem racked in the derrick if drilling with triple standsis required.

Chapter 6OperationsDrilling:When drilling ahead with a top drive, adhere to the samesafety and operating practices and procedures as withconventional rotary drilling.

Rotating Once you have made a connection and theslips have cleared the table, select ‘valve open’ and startup the mud pump, then select ‘drill’ mode immediately.The preset functions in connection mode will be disabledand now you can manipulate the quill RPM by selecting‘forward’ and ‘increasing or decreasing’ the pumps.

Slide Drilling In order to hold toolface while sliding,you must close the grabber on the saver sub, allow thegrabber cylinder to pressure-up, and then switch the‘pumps – forward/reverse’, to neutral. The grabber lightwill remain on.

When sliding, the grabber is closed and the hoistingclutch interlock is activated. In order to work thedrillstring you must push and hold the ‘override’ buttonon the brake handle control box while hoisting. Thisallows the drawworks drum clutch to engage.

When running a mud motor, keep accurate records ofthe reactive torque (motor pressure) in the string. Atany given time, you may need to orient the toolface ofthe downhole motor. To do this the grabber will need tobe opened; if you do not track downhole torque history,turning the string in small increments will be impossible.Assuming that you know the amount of torque present,follow these steps to orient the toolface:

1. Select ‘drill forward’.2. Decrease the pumps so that x psi (the pressure equal

to the reactive torque) is present on the hydraulicpressure gauge.

3. Select ‘grabber open’.4. If the value of x provides enough torque, the string

should not turn.

Turn the string to the right by selecting:

5. ‘Increase pumps’ until the pipe turns very slowly andunder control.

6. When you have achieved the new orientation, quicklyclose the grabber.

Chapter 2Component IdentificationTop Drive:


The amount of loop pressure needed to hold thedrillstring when the grabber is opened will change asdepth, and angle of build increase. This is why youshould record a downhole torque history, because thex value will be easier to predict.

Turn the string to the left by decreasing loop pressure(‘decrease pumps’), and, if there is not much reactivetorque present, select ‘reverse’ until positioning iscomplete, then close the grabber.

Note: The maximum reverse torque is set to preventthe string unscrewing. Do not engage the ‘breakout’function or the drillstring could come apart.

Tripping:The Tesco top drive reduces the amount of time andwork involved in tripping and reaming by giving you theability to thread into the drillstring at any point in thederrick. This is useful when encountering hole problemswhile tripping (for instance, pulling tight, bridging off orwhen a kick is evident). In short, any time when theneed to pump fluid into the well exists, it can be donewithout having to position the drillstring at floor level inorder to install the kelly.

Tripping pipe with a top drive is similar to conventionalmethods, with the exception that the robotic functionsease pipe-handling procedures. At no time is itnecessary for the rig crew to position the elevators oropen and close them. The link tilt function can pushthe stand of pipe to be racked to the worker, both onthe rig floor and to the derrickhand. When running inthe hole, the derrickhand does not need to lean out tothrow the stand in the elevators; he can simply easethe stand into the elevators, which are extended towardhim. Once the stand is placed in the elevators, theycan be closed hydraulically. After the stand is racked inthe derrick or added to the string the links should bereturned to the vertical hanging position by selectingthe ‘float’ function.Important – The links and elevators should neverbe manually operated by a worker.

Cold Climate:When the hydraulic top drive is working in a freezingenvironment, the oil quickly becomes thick and this willreduce its effectiveness. While drilling, the heat fromthe top drive motor(s) warms the oil enough so that thisis not a concern, but whenever the quill is not rotating,such as when you are slide drilling or tripping, the cold

climate function should be used. To activate coldclimate follow these steps:1. Push in the cold climate button (on the left side of

the drillers panel).2. Select engine speed ‘slow’.3. ‘Drill’ mode.4. ‘Forward’ pumps.5. ‘Increase or decrease’ pumps, to maintain 700psi

on the hydraulic pressure gauge.

When the cold climate button is pushed in it de-energizes the circuit to the top drive speed control valveand allows the flow of loop oil to pass through the motormanifold and circulates the closed loop system withoutturning the quill.

Selecting engine speed slow brings the prime mover toidle speed for cold climate operation. This saves overallwear and tear on the engine when it has a low load onit.

Drill mode allows you to control the hydraulic pumpsinternal swash plates, which command the amount ofoil flow to maintain 700psi.

Forward pumps directs the oil flow in such a way that itpasses through the maximum amount of filtration beforegoing through the pumps again.

Follow these steps in order to properly disengage thecold climate function:

1. ‘Neutral’ pumps.2. ‘Connection’ mode.3. ‘Neutral’ engine speed.4. Pull out the cold climate button.

By selecting neutral pumps, the flow of hydraulic oil isstopped.

Important: Never push out the cold climate buttonwithout the preceding 3 steps.Connection mode keeps the prime mover at an idlewhen the engine speed is switched to neutral.

After pulling out the cold climate button the top drivecan now return to normal operation.

or 600 volt AC input from the rig’s generators andconverts it to other voltages that operate the electricalcomponents of the top drive system. When spottingthe power module, it must be lifted using proper hoistingtechniques and placed in an ideal position for the serviceloop to reach the derrick. If the service reel is notattached to the power module skid, then it should beplaced on rig matting with the power module andconnected to the auxiliary hydraulic system.

The Service Loop:The service loop sends and receives electricalcommunication from the power unit and the driller’spanel as well as hydraulic flow to and from the top drive.It is critical that these lines not be damaged due toimproper lifting or obstructions in the derrick. Once theservice loop has been installed, observe its movementalong the entire travel of the top drive.

The service loop should make no contact with anypart of the rig.

Using a soft hoisting sling and the floor tugger, theoperator will raise the service loop into the derrick whilethe top drive technician reels out enough slack to installthe lines into the hose saddle and capture clamp.

Once the hose saddle position has been determined itis then attached to the derrick. The rig design and topdrive model will determine where the saddle is located.

A safety sling should always be installed around thehose saddle and hoses, and then attached to either awelded in pad eye or a suitable beam. Safety slingsshould also be installed between the hose ends andthe top drive.

The Top Drive:The top drive is a heavy, unbalanced load and shouldbe carefully handled to prevent injury or equipmentdamage. The top drive technician should always bepresent to oversee any loading or unloading of Tescoequipment.

Once the top drive arrives on location, it should beplaced on the catwalk so that it can be hoisted to the rigfloor using 2 point, load rated slings attached to theblocks. A hold back line should be used to prevent thetop drive from shifting once it is lifted.

Before the top drive is raisedto the rig floor, the torquebushing and extend frameneed to be installed onto thetorque track and pinned inplace.

With the top drive standpositioned over hole centerand secured to the derricklegs using chains andboomers, the swivel can nowbe properly doped andthreaded into the quill with achain tong.

On top drives equippedwith an integrated swivel,the swivel bail or yoke is

directly installed into the becket or block hook.

Now the top drive can be lifted from the transport standby raising the blocks and the transport stand removedfrom the rig floor.

Using the blocks, line-up the pin holes between theextend frame and the top drive and insert the drive pinsand keepers.

With the weight of the top drive hanging on the overheadblocks and swivel, remove the torque bushing pin.

The top drive technician will connect the service loop tothe top drive and install the driller’s panel.

With the power unit now running and the service loopand drillers panel connected to the top drive, we cannow make up the swivel to the specified torque. To dothis the off-drillers side tongs must be raised to therequired height to bite against the swivel or cross overand back up slings attached to a suitable point on thederrick.

It is critical that the bottom of the top drive besecured with a cross chain on the grabber leg or ajoint of heavy weight drill pipe connected to thesaver sub and set in the slips - or both. Torqueshould always be applied to the swivel connectionin ‘drill mode’ and only the required personnel todo the job should remain on the rig floor.


Tip: If the top drive will rotate and everything else isoperating normally, double check that the cold climatebutton has not been accidentally operated.

Reaming:Back reaming out of the hole is one of the greatestfeatures the Tesco top drive provides. These stepsshould be followed before commencing:

Note – Reaming is to commence only at operator’sdiscretion and until the driller is experienced withthis operation, the Tesco technician should bealerted.

1. Ensure the correct saver sub is installed on the topdrive and keep it properly doped while reaming orback-reaming.

2. Connect the top drive to the drillstring.3. Open the mud saver valve.4. Start the mud pumps and establish circulation.5. Remove the slips.6. Select ‘drill’ mode.7. Pumps ‘forward’ Set quill speed to 30-40 RPM.8. Hoist the drill string and close the elevators on

the stand.9. Work the drill string until free of obstruction.

When you are ready to rack the stand in the derrick,the procedure is as follows:

1. Stop rotation.2. Stop the mud pumps.3. Set the slips.4. Break out the lowest connection with the rig tongs.5. Hoist stand out of the stump and allow the pipe to

drain.6. Close the mud saver valve.7. Lower the stand to approximately 2 inches above

the rotary table.8. Ensure the grabber is in position at the top tool joint.9. Close the grabber and break out the top drive.10. Once the top drive is unscrewed from the pipe, open

the grabber and the stand will rest on the floor.11. Hoist the top drive until the elevators pick up the

stand.12. Link tilt forward until the derrickhand has control of

the stand and it has been placed in the birdbath.13. Open the elevators.

14. Link tilt back to vertical.15. Lower the top drive to the floor and continue back

reaming if necessary.

If an obstruction is encountered when tripping in thehole, or if for any reason it is necessary to establishcirculation, i.e. well control, the top drive can beconnected to the drillstring quickly by following thesesteps:1. If an obstruction is encountered, hoist until the

drillstring is free, and a connection is at floor level.2. Set the slips.3. Lower the top drive and guide the top tool joint into

the grabber. Set backup tongs on tool joint at floorlevel.

4. Select ‘connection’ mode.5. Rotate the top drive into the top tool joint and

shoulder it up.6. Make up the connection to the specified torque.7. Open the mud saver valve.8. Remove the tongs and the slips.9. Start the mud pumps and establish circulation.10. Select ‘drill’ mode.11. Set quill speed to 30-40 RPM.12. Ream through the obstruction until the string is free.13. Lower top drive to the floor and disconnect the

topdrive – see, break out connection procedures.

Working Tight Hole:It is important to know that when torque is appliedto the drillstring you cannot pull up to the maximumforce that the pipe is rated for. The top drivetechnician will provide information on specificclasses of tubulars and their torsion/tensionthresholds.

In tight hole situations, it will be necessary to free thepipe using the top drive. With the top drive, the abilityto maintain mud pump flow, raise and lower the drillstringand hold torque all at the same time is possible. It isrecommended that when working tight hole, sometorque can be applied to the drillstring.

This is best done by selecting:

1. ‘Drill’ mode2. ‘Decrease’ pumps3. ‘Forward’ pumps4. Slowly ‘Increase’ pumps

When the torque track is fastened together in the lengthrequired to allow the top drive to travel between thehighest and lowest points in the derrick, it then needsto be secured to the crown. This is done by attachingthe hanging cluster at the top of the track to a welded-on pad eye with a shackle.Next we need to position the torque track so that wecan fasten the t-bar to it and make sure that the torqueanchor beam will accept it as well.

Once the torque track is in place the turnbuckles needto be attached to it and secured in predeterminedlocations on the derrick strongbacks. Using theseadjustable, locking turnbuckles we can center the trackand help provide rigidity along the length of it.

When the torque system is installed it should be straightand at the proper distance from well center and the rigfloor.

Torque Anchor Beam:The torque anchor beamaccepts the torque directlyfrom the quill and transfers itto the derrick. On some rigswe can weld the anchor inplace, on others we need toinstall the beam using clamps.The beam is usually attachedto the lowest strongbackwhere the energy can bedisplaced across the widestpoint of the derrick. Periodicinspection of the welds or theclamps tightness must beperformed to prevent any

movement of the torque track.

Position the hoisting sling and tugger line on the centerof the load. Carefully raise the anchor beam to theappropriate strongback.

The top drive technician will need assistance to positionthe anchor beam on the strongback and hold it in placeuntil the clamps can be secured.

Safety - Make sure all workers are connected to anapproved fall arrest system.

T-Bar:The T-bar is a solid steel arm that bolts on to the torquetrack at it’s lowest point and takes the drilling torquefrom the top drive and transfers it through the anchorbeam and across the derrick.

The T-bar can be installedin the torque anchor assoon as the beam issecured to the derrick.

The T-bar can also bebolted on to the torquetrack just before the track

is hung from the crown when the bolt pattern section oftrack is at a comfortable height.

When the T-bar is attached to the torque track andthe track is hanging from the pad eye at the crown,the T-bar should be just slightly higher than theanchor. This way, when the anchor clamp istightened down it will pull the track into tension.

After all the main components of the torque system areinstalled the turnbuckles can be adjusted to straightenthe track.

Note: All shackles, turnbuckles, and similar items shouldbe secured with cotter pins or safety wires, to preventaccidental loosening.

The Power Module:The Tesco hydraulictop drive comes with abuilding containing aprime mover thatdrives a series ofv a r i a b l edisplacement, bi-directional hydraulicpumps. These pumpssend hydraulic flowthrough a closed

loop, high-pressure system to the top drive motor(s),which provide quill rotation before returning to the skidto be filtered. Additional gear pumps send hydraulicflow through an auxiliary system to the top drive,operating the various robotic functions as well ascirculate oil through a filtration and cooling systembefore returning to the reservoir. The power modulealso contains an electrical panel, which accepts a 480


By decreasing forward pump pressure, there will notbe enough hydraulic flow to rotate the pipe. Now, slowly‘increase’ the pumps until the pipe begins to rotate.Maintain enough pressure on the hydraulic gauge tohold drillstring in torsion without reaching the torquerelief setting on the top drive. When maintaining statictorque over extended time periods, it is recommendedto increase the pumps to a value less than the torquerelief setting and allow the pumps to control the desiredtorque. If the top drive torque relief is activated, thehydraulic oil passing through the relief over time, willcreate excessive heat. The hot oil may, in turn, activatea power unit shut down, resulting in an untimely torquerelease of the drill string.

The power module is equipped with numeroussafety shutdowns. When the hydraulic oil reachesthe high oil temperature shutdown setting, the primemover will shut down. This should be avoided,especially in situations where hole problems areencountered.

Continue working the drillstring while maintaining torquewith the top drive until a free point is established. Whenthe pipe begins to rotate at this torque setting keepraising and lowering pipe in the free point increasingthe travel distance until the obstruction is cleared.

Jarring:If jarring is required, the torque applied to the drillstringwill need to be released. By slowly decreasing the quilltorque shown on the hydraulic gauge, the reactivetorque in the string will overcome the quill torque andthe pipe will, in a controlled manner, rotate in reverseuntil torsion is released. Once this is done, set the slipsin order to break out the top drive.

Tesco does not recommend jarring with thedrillstring connected to the quill. The drillstringshould be suspended from the elevators beforejarring commences.

Disconnect hydraulic hoses at the elevator quickconnects to reduce the chances of elevators openingaccidentally.

After any jarring is done the top drive technician willneed the time to perform a visual inspection of the topdrive components and fill out a ‘Post Jarring Checklist’.In the event of excessive jarring a load path inspectionmay need to be performed at the earliest convenience.

Logging:When using the hydraulic elevators to support a wireline sheave, disconnect the hydraulic hoses at theelevator quick connects to reduce the chances ofaccidental opening.

Note: The hoses should also be disconnected to preventaccidental opening in any other operation where theelevators support a load other than the drillstring (forexample, when a set of secondary elevators aresupported from a nubbin in the hydraulic elevators).

Running Casing:Using the top drive forrunning casing offerssome advantages overconventional methods.At the customer ’srequest, Tesco canprovide a crossover subto connect the quill tothe casing, eliminatingthe need to rig-upchiksans and fil l uphoses. The top drive

also provides pipe handling functions to make handlingcasing much simpler and safer.

Cementing:Unless it is absolutely necessary, never attempt tocement through the top drive. With the exception ofthis rule, cementing with a top drive is similar toconventional methods.

INTRODUCTIONFOR DRILLERS

This manual is intended toprovide basic informationonly, and does not constitutea comprehensive guide tothe functioning or operationof a Tesco Top Drive. It is tobe used only in conjunctionwith the orientation and onsite supervision provided byTesco personnel. The TescoTop Drive Technician mustbe notified of any concernsor incidents involving Tescoequipment and its operation.

OTHER THAN ASDESCRIBED IN THEPRECEDING PARAGRAPH,

TESCO CORPORATION, ITS AFFILIATEDCOMPANIES ANDEMPLOYEES ASSUME NORESPONSIBILITY FOR USEOF THE INFORMATIONCONTAINED IN THISMANUAL.

At Tesco, we put a lot of effortinto developing ways to makedrilling a well more efficient.Training the operators to runthe equipment in the mosteffective manner makes thejob easier by reducingdowntime and safer byeliminating the risk of injury toworkers.

This manual will provide youwith information to present to your crew during apre-job safety meeting or whenever you need toreinforce what you already know.

Chapter 1RIGGING UP THEEQUIPMENTThe Torque System:After measuring the rig and determining the torquesystem configuration, the top drive technician will requirethe help of a select number of crewmembers. As adriller, it’s up to you to choose workers who are confidentworking at heights and follow instructions well. A wellthought out pre-job meeting and the right people canmake rigging up the top drive much easier and safer.The torque system includes the following:

1. Torque Track2. Torque Anchor Beam3. T-Bar

In the next few pages we will describe the parts of thetorque system, what they do and some effective waysof installing them.

Torque Track:

The torque track consists of varying lengths of track.Each section is designed to fit another by lining up theflanges and tightening the bolts. The length of the trackdepends on the size of the rig mast but in all cases thebottom of the track, called the deflector section, shouldbe between 7 and 8 feet from the floor. The track ishung by attaching an adjustable hanging cluster to apad eye that has been welded to the crown’s beams.The bottom of the track is secured to the derrick bybolting on the T-bar and fastening it in to the torqueanchor beam. Using turnbuckles we can center thetrack and provide rigidity along the length of the derrick.The turnbuckles are attached to the torque track andderrick using clamps or by welding in pad eyes on thederrick beams prior to rig up.

In some cases our technicians may pre-assemble thetorque track on the ground and hoist up to 2 sections atonce. When hoisting the torque track, goodcommunication and the use of a hold back line arerequired.

Once the first section of track has been lifted to the drillfloor with the tugger line, it is then lowered through therotary table so that the top of the track can be attachedto the traveling block. After raising the track above thefloor with the blocks, the rest of the track sections canbe hoisted to the floor and placed in the rotary tableindividually and bolted into the previous sections.


Chapter 7Top DriveConsiderationsSlip and Cut Drilling Line:Some daily rig operations change when a rig is fittedwith a top drive. Some simple procedures that yourcrew has performed regularly will need to be adjustedto consider top drive issues.

To slip and cut drilling line, obviously the weight of thetop drive cannot hang from the same line as the blocksalone did. The top drive technician will assist you indetermining the length of a block-hanging sling to beinstalled in the derrick to a suitable beam so that thetop drive is positioned at floor level. If your rig is alreadyfitted with a block-hanging sling, the sling and the eyeon the blocks should be rated to support the weight ofthe top drive as well as the traveling block. The topdrive will have to be connected to the drillstring and setin the slips as low as the block-hanging sling will allow,to help distribute the additional weight of the top drive.

Note – When performing a slip and cut with a topdrive it is possible to pump fluid into the well ifnecessary.

Important – The blocks should never be hung froma floor tugger.

Top Drive Maintenance:The regular daily maintenance and inspections on thetop drive do not have to interfere with rig operations. Inorder to keep the top drive running safely and efficiently,up to 15 minutes every tour must be available to servicethe equipment. The top drive technician’s knowledgeof drilling allows him to choose a ‘window of opportunity’to do this when the top drive is accessible from a ladderon the rig floor, while minimizing the impact on thecustomer’s operation.

If any service or repairs need to be done on the topdrive, all of the drawworks controls and the driller’spanel must be locked out and tagged to ensure thesafety of the personnel.

Important – The top drive technician must benotified of any concerns or incidents involvingTesco equipment.

DisclaimerThis manual is intended to provide basic informationonly, and does not constitute a comprehensiveguide to the functioning or operation of a Tesco TopDrive. It is to be used only in conjunction with theorientation and on site supervision provided byTesco personnel. The Tesco Top Drive Technicianmust be notified of any concerns or incidentsinvolving Tesco equipment and its operation.

OTHER THAN AS DESCRIBED IN THEPRECEDING PARAGRAPH, TESCOCORPORATION, ITS AFFILIATED COMPANIESAND EMPLOYEES ASSUME NORESPONSIBILITY FOR USE OF THEINFORMATION CONTAINED IN THIS MANUAL.

Tesco Corporation (“Tesco”) has made every effortto ensure that this manual describes the basicknowledge needed to provide a quick reference fortop drive operators.

This manual is to be used in conjunctionwith an orientation and on sitesupervision.

Bulletin 20900e

TOP DRIVES CASING DRILLING™ CASING RUNNING

The Drilling Innovation Company™www.tescocorp.com

Top Drive Rig Floor SafetyOrientation

Doghouse Manual

The Drilling Innovation Company™Email: [email protected] Web: www.tescocorp.com

Corporate Headquarters6204 - 6A Street S.E.

Calgary, Alberta, Canada T2H 2B7Tel: 403 233-0757 • Fax: 403 252-3362

World Wide Operations11330 Brittmoore Park DriveHouston, Texas, USA 77041

Tel: 713 849-5900 • Fax: 713 849-0075

Printed in C

anada / April 2004 / T

CD

ue to ongoing product development, all specifications are subject to change w

ithout notice.

Documents

2_Tesco Top Drive Safety Manual