EMI 400 250 Ton Instalation Guide

DOCUMENT NAME: 880044 REV 1

Installation Guide

EMI 400 Top Drive System

250TON EMI 400HP

INSTALLATION GUIDE COPYRIGHT AND DISCLAIMER

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 2007I

Tesco Corporation (“Tesco”) has made every effort to ensure that this document contains accurate and current documentation for the Tesco top drive, however, the document is intended to be used in conjunction with a complete training program and on-site supervision and Tesco does not warrant or guarantee that the information contained herein is either complete or accurate in every respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together with its directors, officers, employees and agents from and against all liability for personal injury, death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document.

Tesco Corporation © 2007

Contact InformationCorporate Head Office

6204 - 6A St. S.E.Calgary, AB T2H 2B7

Canadawww.tescocorp.com

Telephone: (403) 692-5700Fax: (403) 692-5710

http://www.tescocorp.com

REVISION INFORMATION INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 1II

Revision Information

Version Date Description of Changes

Rev 0 Jan 2006 Release

Rev 1 March 2007 References to Mechanical Module changed to Auxiliary Hydraulic Power Unit and other minor updates as per ECN-122-0009

INSTALLATION GUIDE

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 2007III

TABLE OF CONTENTS

LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2: PRE-INSTALLATION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Rig Installation and Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Power/Service Connection Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Power Requirements (Rig AC Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Fuel Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Air Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Equipment Inspection (Pre-installation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 3: RIG UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Equipment Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Optimal Placement of the Power Module and Auxiliary Hydraulic Power Unit . . . . . . . . . . . . . . . . . 7How to Place the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Optimal Placement of the Service Loop Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Optimal Placement of the Cable/Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

How to Install the Cable Roller Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How to Install the Service Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

How to Install the Service Loop: Option 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11How to Install the Service Loop: Option 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Before You Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Torque Arrest System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Torque Arrest System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

How to Determine the Torque Track Configuration (where an application drawing is not supplied) . . . . . . . . . . . . 18Sample Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

How to Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

How to Install the EMI 400 Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Extend Arm Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

How to Set the Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Driller's Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

How to Install the Driller’s Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

TABLE OF CONTENTS INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 1IV

Safety Air Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

How to Install the Drawworks Interlock and Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31About the Mud Pump Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

CHAPTER 4: SYSTEM INSPECTION AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Inspection-General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Supply Power and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

System Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Table of Circuit Breakers and Main Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Support Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

How to Start the Generator (if supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Preliminary Checks and ESD Shutdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38How to Apply 600 VAC Transformer Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Power up the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39How to Check Phase Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39How to Check the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40How to Test the ESD on the Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Final Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

How to Reset the OEMV3000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

About Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42How to Modify Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

CHAPTER 5: RIG OUT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Remove the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Remove the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Remove the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Disconnect the Power and Auxiliary Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

APPENDIX A: PRE-INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

APPENDIX B: VISUAL INSPECTION CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

APPENDIX C: SLING LOAD RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

APPENDIX D: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION. . . . . . . . . . . . . . . . .59

APPENDIX E: TRIP AND WARNING CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

APPENDIX F: DRIVE DATA MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

INSTALLATION GUIDE

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 2007V

Navigating Menus and Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Monitoring the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

TABLE OF CONTENTS INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 1VI

sabok

New Stamp

INSTALLATION GUIDE

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 2007VII

LIST OF FIGURES

Figure 2-1: Power connection with rig AC bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Figure 2-2: Power connection with integrated generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Figure 3-1: EMI 400 optimal equipment placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Figure 3-2: EMI 400 hose saddle placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Figure 3-3: Service loop installation (option 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure 3-4: EMI 400roller saddle cable capture clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Figure 3-5: Cable/hose saddle clamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Figure 3-6: Front and end views of saddle, hose, and service loop. . . . . . . . . . . . . . . . . . . . . 14Figure 3-7: EMI 400 cable/hose saddle capture clamp configuration . . . . . . . . . . . . . . . . . . . 14Figure 3-8: Hoisting the hose saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Figure 3-9: Positioning the hose saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Figure 3-10: Torque arrest system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Figure 3-11: Torque arrest system - permanent installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Figure 3-12: Link locks in locked and unlocked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Figure 3-13: EMI Top Drive capture clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Figure 3-14: Counter-balance system interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Figure 3-15: EMI counter-balance cushion height; yoke and split block interface . . . . . . . . . . . 29Figure 3-16: Drawworks override installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Figure 4-1: Recommended supply power and grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figure 4-2: Change phase rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Figure 5-1: Setting the swivel link locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Figure 5-2: Spooling the service loop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Figure 5-3: Spooling the service loop 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Figure F-1: Drive Data Manager. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Figure F-2: Navigating Menus and Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Figure F-3: Entering the Parameter Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Figure F-4: Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

LIST OF FIGURES INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 1VIII

sabok

New Stamp

INSTALLATION GUIDE

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 2007IX

LIST OF TABLES

Table 1-1: Where to find more information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Table B-1: Top drive inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Table B-2: Power module inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Table B-3: Auxiliary hydraulic power unit inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Table B-4: Cable/hose reel inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Table B-5: Driller’s panel inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Table C-1: Maximum safe working loads (pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Table C-2: Rope diameter efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Table D-1: Hand signals for boom operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Table E-1: Trip Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Table E-2: View Warnings and Trips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Table E-3: History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Table F-1: Parameters in Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

LIST OF TABLES INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 1X

sabok

New Stamp

INSTALLATION GUIDE

880044 REV 1250TON EMI 400HP ©TESCO CORPORATION, 20071

CHAPTER 1: ABOUT THIS DOCUMENT

This document contains information on how to install the 250TON EMI 400HP top drive, power module, auxiliary hydraulic power unit, torque arrest system, and service loop.

You can alter the installation sequence described in this document to accommodate current rig activity. The procedures described in this document provide instuctions on how to do the fol-lowing:

• perform a pre-installation assessment and equipment check• place equipment• install the service loop and connect services• install the torque arrest system• install the counter-balance system• install the top drive• connect the driller's panel and safety interlocks• perform a system inspection and commission the unit• rig out

Table 1-1: Where to find more information

For information on Refer to

system components System Description

• setting torque and speed• driller's panel functions and operating descriptions• making connections• drilling ahead• tripping• freeing stuck pipe

Operations Guide

• load path inspections• maintenance/service schedules• component disassembly and reassembly

Maintenance Guide

Tesco manufactured parts and part numbers Parts List

• electrical schematics• hydraulic schematics• cooling schematics• gearbox lubrication schematics

System schematics

available options and spares Tesco Representative

ABOUT THIS DOCUMENT INSTALLATION GUIDE

©TESCO CORPORATION, 2007 250TON EMI 400HP 880044 REV 12

sabok

New Stamp

INSTALLATION GUIDE

880044 REV 1 250TON EMI 400HP ©TESCO CORPORATION, 20073

CHAPTER 2: PRE-INSTALLATION ACTIVITIES

RIG INSTALLATION AND MEASUREMENT

To ensure that top drive installation progresses smoothly, complete a detailed rig measurement package before ordering equipment. Rig measurement packages are available from Tesco.

Accurate rig measurement helps you do the following:• Determine an equipment placement plan• Determine the best method for installing the top drive• Identify specialized equipment requirements, including the following:

• torque track hanging pad eye• components and subs (top drive to drill string)• cable lengths and specific accessories• air/electric safety interlocks• torque arrest system components• roller saddle or cable/hose saddle mounting requirements• mud hose connection• standpipe extension

Ask a qualified Tesco representative to help you complete the rig measurement package. This will help to ensure that the equipment will fit properly within your rig’s configuration.

POWER/SERVICE CONNECTION REQUIREMENTS

Discuss the following items with a qualified Tesco representative before you request shipment of the top drive system:

• size and output of all generators• type and model of the distribution/SCR systems

The top drive system requires a 600 VAC, 60 Hz power supply. Where the power supply is 50 Hz, an optional package can be installed during the manufacturing process, upon customer request. If the top drive unit is equipped with an integrated generator, then the connection requirements for fuel and air should be considered.

The following figures illustrate the connection considerations to address before the top drive system arrives on location.

PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE


Figure 2-1: Power connection with rig AC bus

Figure 2-2: Power connection with integrated generator

INSTALLATION GUIDE PRE-INSTALLATION ACTIVITIES


Main Power Requirements (Rig AC Bus)1. Determine a location for the power and mechanical modules.

Note: If the rig configuration has not been finalized, then select two possible loca-tions for the power module.

2. Determine where the main disconnect breaker panel will be located.Note: The best location provides room for service personnel and some shelter from the weather.

3. Determine the distance from the AC-Bus to the breaker panel.4. Determine the distance from the breaker to the power module.5. Determine if any special equipment is required. Examples: penetration or plug

boards.Note: This equipment is required if the three-phase power cables must pass through walls on their way from the main breaker to the power module.

6. Determine if cable tray or suitable space is available to accommodate three-phase power cables (from the breaker to the power module).Note: If adequate space is not available, determine what materials would be required to protect the cables from the breaker to the power module.

7. If the customer is providing the main power supply (interconnection package), consult Tesco.

Fuel Considerations

If the top drive unit is equipped with an integrated generator, then the connection requirements for fuel and air should be considered.

1. Determine the location and type of the fuel supply.Note: The fuel connector line should be 1 in. minimum, and it should be able to supply enough fuel for the power unit’s maximum consumption. The fuel return line should also be 1 in. minimum.• For the Detroit Diesel 635 hp Genset, maximum consumption is 22.8 gallons per

hour (86 liters per hour).2. Determine the required length of the fuel line. Determine the route it will take

from the fuel supply to the power unit.Note: Avoid routing the fuel line where it might become damaged or pinched.

3. Verify the quality of the fuel supply.Note: Poor fuel quality might require special treatment. For example, fuel line heaters might be required in areas where diesel fuel contains high levels of paraf-fin.

Air Considerations

If the top drive unit is equipped with an integrated generator, then the connection requirements for fuel and air should be considered.

1. Determine if the air supply is adequate.Note: 100 psi minimum with a 1 in. supply line

PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE


2. Verify the quality of the air supply.Note: If you are in an area with high humidity, then a moisture trap might be required to remove moisture from the starter’s air supply.

3. Determine the required length and route of the air supply line.Note: Avoid routing the line where it might become damaged or pinched. If you place the air receiver close to the power unit, this might help it start more easily.

EQUIPMENT INSPECTION (PRE-INSTALLATION)

Tesco inspects all top drive equipment before shipping, however, some damage might occur while equipment is in transit.

It is important to identify any shipping damage as quickly as possible. This allows you to make necessary repairs, order equipment replacements, and optimize system readiness.

As part of a pre-installation equipment inspection, do the following:• Check all shipping containers for damage. External damage may indicate damage to con-

tents.• Visually inspect all principle components for damage or missing parts.• If the top drive system is shipped with fluid levels at full, check the fluid levels. Low

fluid levels may indicate a leak in the hydraulic, cooling, or lubrication system.

A sample equipment checklist is included in “Appendix A: Pre-Installation Checklist”.

INSTALLATION GUIDE


CHAPTER 3: RIG UP PROCEDURE

EQUIPMENT PLACEMENT

Optimal Placement of the Power Module and Auxiliary Hydrau-lic Power Unit

Placement of the power and mechanical modules is similar regardless of whether the power is supplied by the rig or by an independent generator. The following diagram shows the optimal placement of the power module and auxiliary hydraulic power unit. This placement is consid-ered ideal for the following reasons:

• The distance from the main disconnect breaker to the power module is short.• The placement allows straight-line access from the cable reel to the cable/hose saddle.• The power module is in the aft position (closest to the generators).• The service loop cable connections are outboard of the rig.

Note: You can easily secure excess service loop cable on the roof of the power module when it is in this position.

• There is easy access to the power module waterfall.• The auxiliary hydraulic power unit is placed close to the power unit and the connections

of the auxiliary hydraulic hose are easily accessible.

RIG UP PROCEDURE INSTALLATION GUIDE


Although the location of the power module depends on the rig configuration, the factors listed above should be considered when placing equipment.

How to Place the Power Module1. Ensure the ground surface is level; remove any major obstructions.2. Install rig matting or another secure material under the equipment location.

Note: Ensure the rig matting extends far enough beyond the equipment to provide a walkway for outside service activity.

3. Using a crane or loader, place the power module on the rig matting.4. Move the auxiliary hydraulic power unit to a location within 30 ft of the power

module.5. Connect the following cords from the auxiliary hydraulic power unit to the incom-

ing cable panel on the power module:• 1 x Power cable

6. 1 x Sensor cableConnect the auxiliary hydraulic power module to the hose reel motor.

Figure 3-1: EMI 400 optimal equipment placement

INSTALLATION GUIDE RIG UP PROCEDURE


Optimal Placement of the Service Loop Reel

The service loop reel acts as a spooling and storage device for electrical cables and auxiliary hydraulic hoses; it is not required during top drive operations. After the hoses and cables are moved onto the saddle and connected to the power unit and top drive, then you can move the hose reel from the installation location to any convenient storage area.

“Figure 3-1: EMI 400 optimal equipment placement” shows the optimal location for the hose reel during installation of the service loop. This position is considered optimal for the follow-ing reasons:

• There is a clear view of the cable/hose saddle.• There is straight-line access from the hose reel to the cable/hose saddle.

Although the placement indicated on the illustration is considered optimal, placement of the reel is determined by the available space on site. Always ensure that the selected path is free of sharp edges and corners that can damage the service loop.

Optimal Placement of the Cable/Hose Saddle

The following illustration shows the optimal placement of the cable/hose saddle. This place-ment is considered ideal because the cable/hose saddle is situated as follows:

• High enough to prevent cables from landing on the rig floor when top drive is lowered:• If the mast is 100 ft. - 125 ft. (30.5 m-38.1 m), it is 55 ft. - 65 ft. (16.8 m-19.8 m)

above the rig floor.• If the mast height is 130 ft.-145 ft. (39.6 m-44.2 m), it is 75 ft.-85 ft.(22.9 m-25.9 m)

above the rig floor.• Low enough to allow the top drive to reach the rig floor without straining or damaging

cables.• Where there is straight-line cable access from the power unit.

Note: This position is a low activity area for overhead equipment. Accidental damage to cables is less likely to occur when the roller saddle is placed here.



Although the arrangement shown here is considered optimal, placement of the cable roller sad-dle is determined by several factors:

• mast height• strongback location and type• length of traveling equipment (drill string, compensator, blocks, and swivel)• available cable length (maximum service loop length is 225 ft. (68.6 m) unless otherwise

requested)• power module location

How to Install the Cable Roller Saddle1. Use a crane or other available lifting equipment to move the cable roller saddle to

the rig floor.2. Use a tugger or cat line to hoist the roller saddle to a predetermined location on the

mast.3. Mount the cable roller saddle to the strongback.

Note: The strongback type determines which mounting hardware you should use. Discuss mounting requirements during the rig measurement and pre-installation analysis.

Figure 3-2: EMI 400 hose saddle placement



HOW TO INSTALL THE SERVICE LOOP

There are typically two options to installing the service loop:• Option 1: The service loop needs to be strung through the mast structure. A roller saddle

should be used as the service loops are typically ‘pulled’ over the roller saddle and through the mast structure.

• Option 2: The service loop is hung outside the mast structure and does not have to pass through the mast structure. The service loop is clamped to a cable/hose saddle and hoisted up beside the mast.

How to Install the Service Loop: Option 1

Use this procedure to string the service loop through the mast structure by using a roller sad-dle.

1. Use a crane or other available lifting equipment to move the cable roller saddle to the rig floor.

2. Use a tugger or cat line to hoist the roller saddle to a predetermined location on the mast.

3. Mount the cable roller saddle to the strongback.Note: The strongback type determines which mounting hardware you should use. Discuss mounting requirements during the rig measurement and pre-installation analysis.

4. Place the reel in a location where you have a clear view of the roller saddle.

Figure 3-3: Service loop installation (option 1)



5. Connect the auxiliary hydraulic power unit to the storage reel using the 35 ft extension hoses.Note: If you need to unreel hoses and the Auxiliary Hydraulic System is not avail-able, you can manually unreel the hoses by connecting the two quick couplers closest to the hose reel motor. This allows oil to free-flow through the motor, hoses, and quick couplers. If you use this technique, the motor free-wheels (no reel brake is available).

6. Ensure the auxiliary pump is operational.Note: If the unit is connected to an independent generator, ensure the fuel and air supply lines are connected.Note: When connecting to the main electrical power, ensure that 600 VAC power is established with correct phase rotation and that electrical power is available for the hydraulic pump at the auxiliary hydraulic power unit.

7. Bundle the ends of all the cables and hoses together in a soft sling.8. On the rig floor, thread the tugger line through the snatch block.9. Attach the sling to the tugger line.

Note: Verify that the slings are long enough to pass over the roller saddle and extend to the service reel. If adequate sling length is not available, see “How to Install the Service Loop: Option 2” on page 13.

10. Thread the slings over the roller saddle.11. Attach the sling to the soft sling on the service loop.12. Use the tugger to begin spooling out the service loop.

Note: Use the hydraulic reel controls to hold back or feed the line as required.13. Spool out the correct length of service loop (enough to reach from the reel side of

the roller saddle to the rig floor plus 2 ft.), then install the mast cable capture clamp as follows:a. Use slings to attach the back plate of the capture clamp to the mast.b. Position the urethane inserts on the back plate.c. Position the cables and plates as indicated in Figure 3-4 on page 12.d. Tighten all bolts to prevent cables and hoses from slipping, then install the

cotter pins in the bolts. Figure 3-4: EMI 400roller saddle cable capture clamp

1. Power cord2. Spare3. Power cord4. Power cord5. GND cable6. Blower motor cable7. Spare8. Sensor cable9. Auxiliary Hydraulic

Return10.Auxiliary Hydraulic

Pressure11.Robotics Cable12.Spare



14. Pull the remaining portion of the service loop over the roller saddle and down to the rig floor.

15. Use slings to secure the mast cable capture clamp assembly to the mast approxi-mately 2 ft. below the roller saddle on the reel side.

16. Connect the service loop cables and hoses at the top drive, the power module, and the auxiliary hydraulic power unit.Note: The auxiliary supply/return quick couplers are located on the auxiliary hydraulic power unit. The power, sensor, robotics and ground cables are con-nected to the appropriate receptacles in the supply waterfall of the power module. These cables and hoses cannot be connected until the top drive is mounted to the torque track. The cable to the driller’s panel cannot be connected until the driller’s panel is mounted on the drill floor.

How to Install the Service Loop: Option 2

Use this option when the service loop does not need to be strung through the mast structure.

1. Ensure that the auxiliary hydraulic fluid lines are connected to the hose reel con-trol.

2. Use a soft sling to bundle the end of the service loop.3. Attach the bundled end to the cable of the floor tugger or loader.4. Use the hose reel and tugger to lay out the length the of service loop that will

travel with the top drive.5. Measure the length of the service loop, starting at the hose or cable ends. Keep the

service loop tidy, and ensure the ends of all hydraulic hoses and cables are as even with each other as possible.

Note:

Figure 3-5: Cable/hose saddle clamping location

1 - Cable and hose ends2 - Hose saddle

When the hose saddle is in place, the hoses to the top drive should reach the rig floor, and approximately 3 ft. of hose should be lying on the floor.



6. When the correct length has been spooled off the reel, insert the hoses and cable in the cable/hose saddle capture clamp.

7. Connect the hose saddle to the cable of the floor tugger or crane.

Figure 3-6: Front and end views of saddle, hose, and service loop

Figure 3-7: EMI 400 cable/hose saddle capture clamp configuration

1. Hydraulic return hose2. Hydraulic pressure hose3. Cord “T”4. Cord “A”5. Phase 1 power cable6. Phase 2 power cable7. Phase 3 power cable8. Ground cable9. Blower motor power cable



8. Hoist the saddle and hoses into position below the racking platform.Note: Hoist the saddle slightly higher than its final position.

9. Install the hanging sling for the hose saddle at the racking platform.Note: Attach the hanging sling to the pad eye with a shackle, or wrap it around a suitable beam.

10. Use a shackle to attach the hose saddle to the hanging sling.Note: The hose saddle sling must be strong enough to hold loads of more than 2,000 lbs (907.2 kg).

Figure 3-8: Hoisting the hose saddle

Figure 3-9: Positioning the hose saddle



11. Use the floor tugger or crane to lower the saddle until the weight transfers to the hanging sling.

12. Install a back-up safety sling around the hose saddle.

Caution: This back-up sling is considered critical safety equip-ment.

13. Lower the crane or floor tugger cable.14. Attach the crane or floor tugger cable to the sling at the free end of the service

loop.15. Hoist the free end of the service loop to the rig floor and secure it in place until it

can be connected to the top drive and driller's panel.

TORQUE ARREST SYSTEM

Before You Install the Torque Arrest System

Install a hanging pad eye in the crown before you install the torque arrest system. This pad eye must be designed and installed to support the hanging weight of the entire torque assembly (safe working load of 15,000 lb. (6804 kg) plus the recommended safety factor for overhead equipment).

The pad eye is typically placed 22.5 in. (57.15 cm) back from the crown cluster centre. It is easiest to install the pad eye when the mast is down. Discuss installation procedures with a Tesco representative as part of pre-installation activities.

Danger! Design and installation of the pad eye should meet or exceed all safety specifications for the operating area and operating conditions.

A variety of stabilization devices can be used to hold the torque arrest system in place during operations. It is easiest to install the stabilization systems before raising the mast.

Torque Arrest System Components

A standard torque arrest system includes the torque beam, T-bar, and the following torque track sections (typical). The number of torque track sections depends on the free working height of the mast and is shown on the application drawing supplied with the top drive system:

• one adjustable hanging sling



• one cable clamp mount and cable capture clamp• one 18.5 ft. (5.6m) reversible, bolted, bottom torque track section• five 18.5 ft. (5.6m) standard torque track sections• one 10 ft. (3.1m) torque track section• one 5 ft. (1.5m) torque track section

Obtain additional length by lengthening the top section hanging sling. Purchase additional torque track sections to accommodate larger masts.

The following two sections of torque track are also included:• one 1.3 ft. (0.4 m) deflector section (bull nose)• one 2 ft. (0.6 m) torque track section

Caution: Never subject these sections to torque. Mount them below the torque beam only.

The deflector section is always mounted at the bottom. Its tapered design assists in mounting the torque bushing onto the torque track.

Torque Arrest System Configuration

You must know the following before you can determine the torque track configuration:• height of the hanging pad eye for the torque track, measured from the rig floor (A)• position (height above rig floor) where the torque beam and T-bar will be mounted (B)• length of the hanging assembly for the torque track, including hanging swivel, nut, and

shackles (2.5 ft. minimum (.8 m) to 15 ft. (4.6 m) maximum)Note: Shorter configurations are safer and more practical.Note: Correct calculations will help ensure that the torque bushing will not come off of the torque tube when the blocks are fully hoisted to the crown.

• the location of any upper strongback that may interfere with the vertical hanging of the torque trackNote: If the torque track is to remain in the mast during rig moves, match the torque track connections to the mast connections wherever possible.



How to Determine the Torque Track Configuration (where an application drawing is not supplied)

Sketch and calculate the following on paper before you connect sections of torque track.

1. Place the bottom of the deflector section 7 ft.-8 ft. (2.1 m-2.4 m) above the drill floor (C).

2. Place the bottom bolted section of torque track above the deflector section.Note: Ensure that a suitable strongback for mounting the torque beam and T-bar is available somewhere along the length of the bolted section of torque track. Remember that the bolted section is reversible.

3. Stack the track sections (18.5 ft., 5 ft. and 10 ft. sections) until you reach 5 ft.-15 ft. (1.5 m-4.6 m) from the pad eye.

4. Determine the length of hanging assembly required.Note: Ensure that the length of hanging assembly is incorporated into the calcula-tion.

5. Calculate the height of the torque bushing to ensure that it will not come off the top end of the torque track when it is in the uppermost position.

Sample Calculation

If the mast height is 102 ft. (31.1 m):

1. 102 ft. less 7 ft. (height above the rig floor for the deflector section) = 95 ft. (29.0 m)

2. 95 ft. less 2.5 ft. (minimum hang sling length) = 92.5 ft. (28.2 m)3. 92.5 ft divided by 18.5 = five full length tubes; this does not include the deflector

section.

Figure 3-10: Torque arrest system configuration



Torque beam desired height = 11 ft. (3.4 m)

The rig up would be as follows:

* The bolted track section would be run with the bolt section down, below the standard track sections and 10 ft. and 5 ft. sections. The deflector track section would be mounted below the bolted section.

How to Install the Torque Arrest System

Use this procedure to install the torque arrest track system. Refer to Figure 3-11 on page 22.

1. Ensure the hanging pad-eye for the torque track is installed in the crown.Note: Normal placement for a standard track is 22.5 in. back from the crown clus-ter centre.

2. Assemble the torque beam, T-bar, and T-bar clamp.

Warning! Assemble the above with the T-bar at mid-length. This balances the assembly during lifting.The assembly should not be fully torqued, but it should hold the T-bar securely in place.

3. Use the tugger to move the torque beam onto the drill floor and up to the lowest, most practical strongback beam.Note: Install the torque beam low in the mast. Attach it to a large beam anywhere between 10 ft. and 16 ft. above the drill floor. If you install it any higher, you might require additional stabilization below the torque beam. Tesco can supply additional stabilization, if required.

4. Use four clamps to mount the torque beam to the selected supporting beam.Note: On a permanent installation, you may weld the anchor beam clamp onto the mast.

5. Slide the T-bar to the most rearward position.Note: Always mount the T-bar on top of the torque beam. If possible, mount it so the T-bar sits approximately 1/8 in. above the T-bar clamp so that the torque hang-ing assembly carries the total weight of the torque track.

6. Use the calculation method described in “How to Determine the Torque Track Configuration (where an application drawing is not supplied)” on page 18 to cal-culate the required torque track section configuration.Note: When the torque track is suspended, the bottom of the deflector section should be 7 ft.-8 ft. off the floor.

Track Part Qty Length (ft.) Total Length (ft.)

Hanging Track 1 18.5 18.5

Standard Tracks 2 37 (18.5 x 2) 55.5

10 ft. section 1 10 65.5

5 ft. section 1 5 70.5

Bolted* section 1 18.5 89

Deflector 1 1.3 90.3

Hanging Assembly 1 Set to 3 feet 90.3



7. Set and secure the calculated pinned insert location (if used), or adjust the hanging assembly to the appropriate length.• Hanging Assembly: Thread the cable of the hanging sling assembly through the

hole in the top of the top track section. Fasten the clamp plate to the cable at the appropriate location so the hanging sling assembly has the required length as determine in previous calculations.

Caution: Torque sling bolt clamps to 230 ft·lbs.

Note: When you tighten the sling clamp bolts, ensure that the sling is compressed evenly along its length. It will take several repetitions to ensure that the clamping force is distributed evenly across all of the cable clamps.Note: Use a soft sling to hold the sling in place so that it will be easily accessible when the torque track is lifted to the hanging pad eye.

8. Use the rig floor tuggers to hoist the first track section up to the floor.Note: On most rigs, two full-length sections of torque track can be assembled on the ground before being lifted to the rig floor. If the rig is very small, you will have to bring the torque track lengths to the rig floor one at a time.Note: As the first section is installed, make up additional sections on the ground.

9. Lower the first track section through the rotary table or mousehole.Note: If the rotary table is too small to permit the torque track to pass through, use an alternate location on the rig floor. If no alternate location exists, mate the sec-tions above the rig floor.

10. Lower the blocks and install two handling slings on the torque track.Note: Thread the slings through the block becket and attach them to the top track using the handling assembly for the torque track.

Caution: Attach the top section of track such that the top portion of track extends above the blocks. This allows the hanging assembly to reach the pad eye without crowning out the blocks.

11. Place a ratchet strap around the top of the blocks and thread it around the torque track.

12. Use the ratchet strap to pull the blocks and track together.Note: This immobilizes the track section and keeps it hanging vertically as it trav-els up the mast.

13. Hoist the blocks until they support the weight of the torque track.14. Remove the floor tugger.15. Hoist the blocks until the bottom of the first section is 8 ft. above the drill floor.16. Connect the floor tugger to the second section of torque track and hoist it to the rig

floor.17. Lower the second section of track through the rotary table or into the mousehole

until it reaches the appropriate level for connecting to the upper section (which is currently suspended from the blocks).

18. Install all the studs and lower nuts before you connect the sections. Note: You cannot install the studs after the track sections are connected.

19. Lower the blocks and upper section of track and connect the two sections. Bolt the sections together, ensuring a flush connection.Note: Coat all bolts with an anti-seize compound before installation.



20. Torque the bolts to 350 ft·lbs.21. Repeat steps 16.–20. until all sections are connected and supported by the blocks.

Note: The last section that is installed is typically composed of the reversible bolted section, the deflector section and, if required, the two-foot track section.

22. Use a ratchet strap to secure the extend arms of the torque bushing in place.23. Attach a tugger to the torque bushing and move the bushing onto the drill floor.

Note: Ensure that the extend frame is down.24. Position the torque bushing over hole centre.25. Use the blocks to lower the assembled torque track and stab it through the torque

bushing.26. When the torque bushing is in position, pin it in place.

Note: Ensure that the top drive pin ends are at least 8 ft. above the drill floor. If the torque bushing is too tight to move freely along the torque track, adjust the torque bushing by adding additional shim packs. To ensure a proper fit, periodi-cally check the bushing during the first few days of operation.

27. After the torque bushing is installed, raise the blocks to the crown. 28. Connect the hanging assembly of the torque track to the pad eye.

29. When the hanging assembly is connected to the pad eye, lower the blocks until the weight of the track is transferred to the pad eye.Note: Do not remove the handling assembly yet. Use the blocks to raise and lower the torque track while you make the fine adjustments required to connect the T-bar to the bolted section.

30. Connect the T-bar to the bolted section of the torque track. Caution: When you connect the bolted section of the torque track, ensure you suspend the full weight of the torque track from the pad eye.

Note: If the T-bar and bolted sections are not vertically aligned, then use the blocks to hoist the track. While the track weight is suspended from the blocks, adjust the hanging swivel as required. Up to 2 in. of adjustment is available in the hanging assembly and the lock nut.

31. When all T-bar fastening bolts are tight, move the T-bar to the correct position in the T-bar seat and tighten the clamp to hold it in position.Note: Hang the centre of the torque track vertically, 22.5 in. back from the hole centre.

32. Tighten the lock nut on the hanging assembly.33. Remove the handling assembly at the crown and lower the blocks.34. Install stabilization systems.

Note: These are most easily installed when the mast is down, but can also be installed during rig-up.

35. Attach the stabilization devices to the torque track as shown in the following illus-trations.



Figure 3-11: Torque arrest system - permanent installation



If your rig set-up requires a customized stabilization installation, contact Tesco.

TOP DRIVE

How to Install the EMI 400 Top Drive

Before you move the top drive onto the rig floor, ensure the swivel yoke link with integral counter-balance is installed in the top drive and is securely supported by the top drive handling frame.

1. Using blocks or a crane, move the top drive to the rig floor.Note: If using the block, attach a hold-back line from the handling frame of the top drive to a loader or cat line tugger. Use the line to prevent the top drive from swinging when it is lifted off the rig floor.

Caution: Always attach the hoisting line to the top drive handling frame and not to any part of the top drive when the top drive is installed in the handling frame.

2. Position the top drive over the hole center.3. Lower the blocks and remove the lifting sling.4. Lower the blocks further and install the top drive yoke into the block hook or

beckett.5. Raise the blocks to support weight of the top drive.

Caution: Do not lift the top drive off the floor.

1 Torque track 7 Extend arms

2 3 way stabilizer 8 T-Bar

3 “F” clamp 9 T-Bar bolts

4 Nuts, washers, and Redi-rod 10 Torque anchor beam

5 Extend frame 11 Torque track (bolted section)

6 Torque bushing 12 Torque anchor beam clamps



6. Remove the pins on the handling frame of the top drive (three or four in total, depending on the unit type).Caution: Ensure the link locks are set so that the top drive will not tilt forward. See Figure 3-12.

7. Lift the top drive until it is clear of the handling frame.8. Use the floor tugger to remove the handling frame from the rig floor.9. Use the blocks to position the top drive so that it can be joined to the extend

frame. Note: Align the ears on the top drive with the extend frame and extend arms and pin them in place.

10. Remove the pin that is holding the torque bushing in place on the torque track.Note: The weight of the top drive and torque bushing are now suspended from the blocks.

11. Remove the link locks so that the links can swivel freely.12. Lower the top drive to the rig floor.13. Check if the top drive hangs vertical. If not, refer to the “Extend Arm Adjustment

Procedure” on page 26.14. Reposition the T-bar so the top drive sits over the hole center, and secure it in

place (if required).

Figure 3-12: Link locks in locked and unlocked position

Link locks in locked position Link locks in unlocked position



15. Tighten the T-bar connection to secure it in place.16. Locate the service loop. It should have been installed before this point. If the ser-

vice loop has not been installed, see “How to Install the Service Loop: Option 1” on page 11.

17. Connect the following hoses and cables for the service loop to the top drive:• supply and return hoses for the auxiliary hydraulic system• one sensor cable• one robotics cable• one blower motor and heater cable• one ground cable• 3 IC #313 cables

18. When all service loop hoses and cable are attached, check the loop position.• The loop should be off the floor.• There should not be any snagging/interference.

19. Re-check all hose connections.20. Ensure that all required valves are open.21. When the top drive and driller's panel are connected, continue with additional set-

up procedures, or begin rig commissioning.Note: The counter-balance cushion height can be set after all support systems are running. The cushion height must be set before any drilling operations start. See “How to Set the Counter-Balance Cushion Height” on page 27.

Figure 3-13: EMI Top Drive capture clamp

1. Blower Motor Power2. Ground3. Power Phase 34. Power Phase 25. Power Phase 16. Cord “A” (robotics cable)7. Cord “T” (sensor cable)8. Hydraulic Pressure9. Hydraulic Return



Extend Arm Adjustment Procedure

The aim of this procedure is to ensure that the top drive hangs vertical and is aligned with the hole centre. Firstly, adjust the extend arms to ensure the top drive is vertical. Secondly, adjust the torque track to align the top drive with the hole centre.

1. Start with the extend frame retracted in and a joint in the rotary table.2. Move the grabber box up to the point where the bottom end of the saver sub is

protruding through the grabber box.3. Lower the top drive so that it is just above the joint in the rotary table (2”~6”).4. Place a level on the top drive upper grabber leg to determine how the extend arms

(extend or retract) will have to be adjusted. The top drive should hang vertically; if adjustment is required, loosen the jam nuts on the extend arm clevises.

5. Remove the upper extend arm pins and unbolt the split flanges in the extend arms.

Warning! Use a cat line to support the top drive so it does not tilt forward and to enable easy access and adjustment.

6. Adjust the arms appropriately by adding or removing shims. This is a trial and error process that requires guesswork. Ensure the extend arms are equal length by ensuring the same amount of shims are installed in both extend arms.

7. Tighten the split flange bolts and re-pin the extend arms to the torque bushing.8. Visually inspect the level. If satisfactory, as judged by the level, continue to the

next step. If the top drive is not satisfactorily level, repeat steps 4. through 8. until the top drive is vertical (this is a trial and error process and may take 3 to 4 adjust-ments before the top drive is vertical).

9. Torque the jam nuts appropriately (2300 ft-lbs dry, 1725 ft-lbs lubed) with a wrench and ensure the retaining cap screws are installed on the lower extend arm pins.

10. Visually inspect the alignment of the saver sub with the joint in the rotary table. If they are not aligned, adjust the torque track by adjusting the T-bar in the T-bar clamp.Note: The torque track stabilizers must be adjusted accordingly to ensure the torque track hangs parallel to hole centre.



COUNTER-BALANCE SYSTEM

How to Set the Counter-Balance Cushion Height

The following conditions must exist before the following portion of the counter-balance instal-lation can be completed.

• The top drive must be installed.• The hydraulic circuit must be connected.• The driller’s panel must be operational.• The top drive must be positioned at the racking platform.

1. Connect the hose quick-coupler for the elevator to the charge fitting for the counter-balance system.

2. Shut off the auxiliary pump.3. Set the ELEVATOR switch (at the driller’s panel) to CLOSE.4. Open the needle valve on the counter-balance manifold.

Note: This relieves all pressure on the counter-balance system.5. Check the nitrogen pressure, and adjust if required.

Note: The nitrogen pressure must be 1250 psi.6. Ensure the counter-balance relief valve is set at 2000 psi.7. Close the needle valve on the counter-balance manifold.8. Start the auxiliary pump.9. Set the ELEVATOR switch (driller’s panel) to OPEN, and push and hold the

ELEVATOR SAFTEY–OPEN button.Note: This will send 1500 psi hydraulic pressure to the needle valve on the counter-balance manifold.

Figure 3-14: Counter-balance system interface

1. Accumulators: N2-Nitrogen and Oil

2. Counter-balance cylinder3. Needle Valve4. Auxiliary system quick-

coupler



10. Slowly open the needle valve and allow the hydraulic oil to charge the counter-balance system.

11. Monitor the counter-balance cushion by watching the gap that develops between the swivel bail and the block hook.

12. Continue to charge the system until the gap is 1-1/2 in. to 2 in.13. Close the needle valve.14. Shut off the auxiliary pump.

Note: This will allow the oil pressure in the auxiliary system to decrease.15. Set the ELEVATOR switch to OPEN, then to CLOSE. This will relieve any pres-

sure in the system.



16. Remove the elevator hydraulic hose from the counter-balance manifold.Caution: If you disconnect a quick coupler while there is pressure in the system, it will be extremely difficult to reconnect the coupler.

DRILLER'S PANEL

How to Install the Driller’s Panel

The location you select for the driller’s panel should be as follows:• within reach of the driller• where there is an unobstructed view of the rig floor

Figure 3-15: EMI counter-balance cushion height; yoke and split block interface



• in a safe position

The bottom of the driller's panel is equipped with a four-bolt mounting plate. Use this to attach the control panel to a custom-built pedestal or existing framework. Some on-site fabrication of a mounting site might be required.

1. Locate the position for the driller's panel.2. Fabricate a mounting location if required.3. Drill bolt holes in the mounting location.

Note: A second mounting plate is provided to use as a template.

Caution: To avoid damaging components, avoid mounting the driller's panel in a location that is exposed to vibration.

4. Install a 4-twisted-pair control cable from the driller's panel to the power module.5. Mount the brake handle control box to the brake handle.6. Connect the brake handle control box to the driller's panel.

Note: The driller's panel has three labeled extension cords with military connec-tors. Use the correct cord (cord F).

SAFETY AIR INTERLOCKS

For detailed information about safety interlocks, refer to the schematics for your unit and/or contact a qualified Tesco representative.



How to Install the Drawworks Interlock and Override

The drum clutch interlock stops the air supply to the drum clutch so that the driller cannot hoist the top drive while the grabber is closed. Use the push button on the brake handle to override this lockout feature. You cannot install the drawworks interlock override until the driller's panel is in place.

1. Shut off the air supply from the compressor to the drum clutch control.Note: Use an isolator valve if necessary.

2. Disconnect the hose for the drum clutch air supply from the control valve.3. Connect the air supply hose to an air/electric solenoid valve.

Note: If two air supply hoses are present, connect each hose to an air/electric sole-noid valve (one for low clutch and one for high clutch).

4. Connect the air supply from the air/electric solenoid valve to the drum clutch air control valve.

5. Connect an electric cable from the air/electric solenoid valve to the extension cord at the driller's panel. The cord is labeled “Cord C”.Note: If two air/electric solenoid valves are required, use a splitter to establish a connection from both valves to the driller's panel.

6. Ensure the control box for the brake handle is connected to the driller's panel.

Figure 3-16: Drawworks override installation

1. Supply air2. Air/Electric solenoid valve3. Air line4. Drum clutch valve5. Air line6. Drawworks

7. Driller’s panel8. Grabber Open/Close switch9. Elevator button10.Grabber override button11.Control box for the brake handle



About the Mud Pump Interlock

The mud pump air interlock is designed to disallow operation of the mud pump unless the mudsaver valve is open.

Before you attempt to install this safety interlock, discuss equipment requirements and opera-tional considerations with a qualified Tesco representative.

INSTALLATION GUIDE


CHAPTER 4: SYSTEM INSPECTION AND START UP

INSPECTION-GENERAL NOTES

When the installation procedures are complete, perform a visual inspection of the complete system.

Caution: Perform visual inspections before applying power to the system.

Inspection checklists for the following are included in “Appendix B: Visual Inspection Check-lists”.

• top drive• power module• auxiliary hydraulic power unit• control cables• power cables• driller’s panel

SYSTEM INSPECTION AND START UP INSTALLATION GUIDE


WARNINGS

Electrical

If client-supplied power is not 600VAC, 60 Hz, discuss necessary system changes with a qual-ified Tesco representative.

Danger! Electrical voltages of different potentials are used throughout the Tesco top drive components (600VAC, 208VAC, 120VAC, 840VDC, 5–24VDC). ONLY qualified personnel should install, maintain, and/or troubleshoot the electrical systems. A severe safety hazard exists for personnel not accustomed to, or familiar with, electrical hazards and procedures.

Danger! There are high voltage capacitors installed in the OEMV3000 Drive power module. Wait at least five minutes after disengaging power to the drive before performing any testing or repairs in the module. The capacitors require time to drain their stored electrical energy.

Supply Power and Grounding

Grounding methodology has always been a challenge because of differing interpretations of the rules and understanding of intent. On-site conditions such as add-on buildings fed from a common power source or a separate power source and/or power sources not requiring a neutral conductor all have specific grounding criteria that must be met. Tesco has strived to maintain a safe “standard” method of grounding so that its implementation becomes familiar to all per-sonnel installing these systems.

The following is Tesco's recommended grounding method when a ground fault detection sys-tem is not incorporated into the service supply.

Tesco incorporates a “single point” ground system when we provide the power source to Tesco loads and/or add-on loads. Furthermore, when an “isolated” system (a power system that is not conductively connected to the distribution system, as in the case of separate generator but most commonly a transformer), is incorporated into our system of power supply, it is intended that all ground paths be connected to the common ground electrode/s.

INSTALLATION GUIDE SYSTEM INSPECTION AND START UP


It is

impe

rativ

e th

at th

e gr

ound

ing

met

hodo

logy

show

n ab

ove

be a

dher

ed to

whe

n us

ing

a de

sign

ated

gen

erat

or a

s the

mai

n po

wer

serv

ice

supp

ly fo

r the

Te

sco

top

driv

e sy

stem

. Sin

ce th

e se

para

te g

ener

ator

supp

lyin

g po

wer

to th

e Te

sco

equi

pmen

t doe

s not

inco

rpor

ate

a gr

ound

faul

t det

ectio

n sy

stem

(and

w

heth

er th

e rig

em

ploy

s a g

roun

d fa

ult d

etec

tion

syst

em o

r not

) it i

s req

uire

d th

at th

e ge

nera

tor s

yste

m n

eutra

l be

grou

nded

at o

ne p

oint

onl

y vi

a th

e m

ain

grou

nd b

us a

nd g

roun

d ro

ds. W

hen

two

or m

ore

pow

er sy

stem

s are

em

ploy

ed, a

“co

mm

on sy

stem

gro

undi

ng c

ondu

ctor

” sh

all b

e in

stal

led

unle

ss se

para

te

grou

ndin

g is

supp

lied

for e

ach

such

syst

em, i

n w

hich

cas

e th

e gr

ound

ing

for t

he in

divi

dual

syst

ems s

hall

be in

terc

onne

cted

. The

refo

re, a

sepa

rate

gro

und

cabl

e m

ust b

e in

stal

led

betw

een

the

rig's

grou

nd g

rid a

nd th

e ge

nera

tor g

roun

d gr

id. D

ue to

this

“lin

k”, t

he g

roun

d ro

ds a

t the

gen

erat

or m

ay b

e el

imin

ated

, bu

t Tes

co re

com

men

ds th

at th

ey re

mai

n.

Figu

re 4

-1: R

ecom

men

ded

supp

ly p

ower

and

gro

undi

ng



Other• Ensure the gearbox breather is installed and the ball valve is opened prior to operating.

Note: The breather may not be installed for shipping purposes and some new units may have the ball valve handle wired closed.

• Close the main breaker MB12 to turn the hydraulic tank heater on. When the tempera-ture reaches 10ºC, the heating circuit will be shut off automatically.

• Ensure that all electrical components are free of frost and condensation before system start up. Do this by opening all cabinet doors inside the power module and heating the building to at least 50o Fahrenheit (10° Celsius) for eight hours. 208V power is required to operate the building HVAC unit.

• Install a saver sub in the grabber on the top drive before you test for hydraulic leaks or operate any robotics function.

Caution: You cannot start the hydraulic pump if the Emergency Shut Down (E.S.D.) is activated (either of two red buttons: one on the driller’s panel and one on the door of the main panel control system).

• Before you start any pumps, ensure that all appropriate valves on tanks and pumps are open.

SYSTEM START UP

After you have completed all visual inspections, begin the system start up process.This section provides instructions on how to do the following:

• power up support systems• power up the drive system• test the robotics functions and operations of the top drive

Danger! The information presented in this section is a guide ONLY. It is not intended to replace complete training on the use of high voltage equipment.

Note: Refer to the electrical schematics supplied with your unit.

Table of Circuit Breakers and Main Breakers

Refer to the electrical schematics for your unit to confirm breaker details.

CB (circuit breakers)Breaker Type and Number FunctionCB1

CB1 (inside the power module main panel)

CB2 (in 120/208V distribution panel)

CB3 Power module building receptacle

CB4

CB9 Motor heater

CB12/14/16 Power module building HVAC



Support Systems

How to Start the Generator (if supplied)1. Ensure that all fuel and air connections are secure.2. Ensure that the following are set to OFF.

• main service interface breaker• all main drive breakers in the power module building• all switches

3. Check all oil and coolant levels. Ensure the generator battery is above 22 volt.

4. Ensure that the following are clear of any obstructions or protective packing material:• radiator• air intakes• exhaust

5. Ensure all cabling and controls are in good operating condition (no noticeable damage).

6. Engage the air starter for one short burst without starting the engine.Note: This ensures the engine is free to roll over.

7. Set the controls to Start, and start the engine.8. When the engine is running, check the oil pressure and rpm.

Caution: Ensure the oil pressure and rpm are within normal operating parameters.

9. Allow the engine to warm up.Note: The warm up time required varies depending on the ambient operating temperature.

10. Increase the rpm to the rated speed (1800 rpm).11. Engage the disconnect breaker for the main generator.

Note: This applies only if the generator has its own service disconnect breaker and the system also incorporates a Tesco specified main service disconnect (see step 13.).

12. Adjust the generator controls for frequency and voltage (600 VAC and 60 Hz).13. Switch the main service disconnect breaker to ON (if applicable). This is the

Tesco specified main service disconnect that feeds the power module building.

MB (main breakers)Breaker Type and Number FunctionMB1 OEMV2000 drive system power

MB2

MB3 (in 600V distribution panel) Spare

MB4 (in 600V distribution panel) 15kVA 600:208/120V transformer



Top Drive

Preliminary Checks and ESD Shutdown Test1. Ensure all breakers in the power module are set to OFF.2. Ensure that 600VAC power is present at the main service interface breaker.3. Verify that the Emergency Shut Down cable is connected.4. Switch the main service interface breaker to ON.5. Ensure that 600VAC power is present on the outgoing cables to the power module.

Note: Check this on the terminal lugs in the Interface Breaker cabinet under the interface breaker.

6. Ensure that the ‘SERVICE BREAKER CLOSED’ indicator light for rig power is illuminated. Note: The light is located on the door of the main panel in the power module building.

7. Push the E.S.D.push button to test the Emergency Shut Down circuit. Caution: This should trip the main service interface breaker.

8. Re-set the E.S.D. push button and repeat steps 4.through 6.

How to Apply 600 VAC Transformer Power

Use this procedure to provide power for the lighting, receptacles, and controls (120/208V and 15/24VDC). The top drive start up procedure is the same whether you use a generator supplied by Tesco or rig power.

1. Ensure that ALL breakers and switches for the power module are set to OFF.2. Switch the main breaker MB6that is feeding the 9 KVA transformer to the on

position.Note: This breaker energizes the transformer that provides power to the power module lighting, receptacles, and controls. Refer to the electrical schematics for your unit for more detailed information.

3. Inside the 120/208V distribution panel, switch the following circuit breakers to the on position:• Motor controls (Turn the heater on only if the temperature is below 0ºC)• 120VAC and 15/24VDC control power• Lights and receptacles• HVAC

4. Set the light switch to the on position.Note: This switch is located on the wall of the power module .

5. Turn the DC power switch to ON. Thewhite ‘DC POWER AVAILABLE’ light should illuminate.Note: The DC power breaker is located inside the door of the main panel in the power module.

6. Proceed to the following section: “Power up the drive system”.



Power up the drive system1. Verify that the EDS on the driller’s panel is not activated.2. Close the main breaker MB1 on drive panel to power up the drive system. To

close MB1:• Charge the spring of the main breaker until the indicator changes its color to

YELLOW.• Push the green ‘PUSH ON’ button to close the breaker.

3. On the left side of driller’s panel, turn the ‘ENABLE’ switch to ‘OFF’.4. Press the ‘RESET’ button on the left side of driller’s panel to clear any trips and

warning in the drive system.5. Ensure that the green ‘READY’ light on driller’s panel illuminates.6. Verify that the ‘ENCODER’ switch inside the power module main panel is at

‘NORMAL’ position.7. Proceed to the following section: “How to Check Phase Rotation”.

How to Check Phase Rotation

Use this procedure to ensure that the phase rotation is correct, and that all pumps, fans, and motors turn in the proper direction. Do not use pump motors to check phase rotation.

1. Switch motor starter 1M and 2M to ON.2. Make sure all switches on driller’s panel are set to neutral position.3. Turn the ‘ENABLE’ switch to ‘ON’.4. Set the ‘Set Speed’ and ‘Set Torque’ to zero using SPEED DECR and TORQUE

DECR switch.5. Turn the ‘QUILL’ switch to either REV or FWD to activate the fans for drive sys-

tem and top drive.6. Ensure that the top drive is not rotating.7. Perform a visual check to ensure that the fan for OEM drive rotates clockwise.8. Ensure that the blower motor for the top drive rotates counter-clockwise when

viewed from above.9. Turn the ‘QUILL’ switch back to neutral position.10. If the direction of the fan is incorrect, do the following:

a. Shut off the main breaker MB1 and shut off the power at the main service breaker.

b. At the power module (service supply waterfall), remove the feed cable(s) from phase A and B.

c. Install the phase A cable(s) into the phase B input(s).d. Install the phase B cable(s) into the phase A input(s).e. Retest to verify the fan is rotating in the correct direction (steps 1.to 9.).



f. Retag the cabling to the current (correct) configuration.

11. Proceed to the following section: “How to Check the Hydraulic System”, below.

How to Check the Hydraulic System1. Install a saver sub in the grabber on the top drive.

Caution: Never close the grabber unless there is a saver sub or tool joint for it to close on. Closing the grabber when it is empty severely damages the grabber cylinder.

Caution: Install a saver sub to prevent the piston on the grabber cylinder from making contact with the gland nut on the grabber cyl-inder body. When this happens, the gland nut is pushed out of the cylinder body.

2. In the 600V distribution panel, set the starter 3M for the auxiliary pump to ON.3. Set the switch on the driller’s panel for the auxiliary pump to ON.

The green light should illuminate.

4. Check and record the circulating pressure (it should be 400-600 psi at normal operating temperature).

5. Inspect the lines for leaks.6. Shut off the auxiliary pump.7. Check the auxiliary tank level and fill it, if required.

Note: Oil from the top drive hydraulic lines returns to the tank when the system is idle. This might cause tanks to appear over-full. Check the fluid levels before you start the system and when the system is running.

How to Test the ESD on the Driller’s Panel

When activated, the ESD on the driller’s panel will trip off the main breaker MB1 for drive system and turn off the auxiliary hydraulic pump.

1. Set the ENABLE switch on the driller’s panel to the OFF position.2. Verify the main breaker MB1 and the hydraulic pump are set to ON.3. Press the ESD on the driller’s panel.

Figure 4-2: Change phase rotation

Phase Input A

Phase Input B

Phase Input C

A

B

C

Original

B

A

C

Change to



4. Verify that the main breaker MB1 has been tripped off.5. Verify that the hydraulic pump has been turned off.6. To reset the ESD, pull the button to the UP position.

Final Start Up

When all critical systems are started and operating properly, you can start the top drive.

Before you proceed, confirm that all the following systems are operating correctly: • cooling fans for OEM drive and the top drive

After confirming that all systems are operating correctly, perform the following steps:

1. Ensure that the Drive Data Manager indicates ‘Drive healthy’ status.Note: The green ‘HEALTHY’ indicator illuminates.

2. Check the indicators on the driller’s panel. The following lights should be on:• Ready• Module On• System temperature

3. At the driller’s panel, set the ENABLE switch to ON.4. Check the rotation and torque (at low settings) to confirm proper operation.

Caution: If you are using a customer-supplied swivel, it will not be properly connected to the top drive. Conduct operational checks at very low rpm, and only in the Forward setting. If you rotate in Reverse when the swivel is not fully connected, the swivel might unscrew at the connection with the top drive (and the top drive may fall to the rig floor).

How to Reset the OEMV3000 Drive

You can use the following procedure if the OEMV3000 Drive System trips “off line” because an internal protection system has been activated. This procedure assumes that the system has sustained no damage and that supply power of 600VAC is present.

1. Set all switches on the driller's panel to the neutral position.2. Turn the ENABLE switch on the driller's panel to the OFF position (disable).3. Ensure the following:

• The communication between PLC and drive works properly• There are no loose wires for encoder• The fans for the top drive and drive system work properly• The SYSTEM TEMP light is solid on

4. Check the fault information in Drive Data Manager and refer to the table “Appen-dix E: Trip and Warning Codes”.

5. Press the RESET button on the driller’s panel to reset faults after the faulty condi-tions have been removed.

6. Turn the OFF/CONTROL/PRECH switch on the main panel to PRECH.



7. Return to the driller's panel and turn the ENABLE switch to the ON position. The green READY light will illuminate.

8. Continue with regular operations.9. Continue to attempt to determine why the unit tripped off line. Make note of all

relevant drilling conditions that existed before the breakers tripped.

Drive Parameters

About Drive Parameters

You can modify the following drive parameters (torque and speed settings) from the driller’s panel:

• Drill Forward – Torque and Speed• Drill Reverse – Torque and Speed• Connect Forward – Torque and Speed• Connect Reverse – Torque and Speed• Breakout – Speed

Set the drive parameters (torque and speed) to minimize the possibility of injury to personnel and damage to drilling equipment. For example, limit the torque setting for Drill–Forward mode to prevent the drill string twisting off while drilling. Set the speed and torque for Con-nect mode to promote proper make up of tool joints and to prevent damage to threads and seal faces caused by over-torquing.

Limit the rotation speed and torque of the pipe handler to ensure the pipe handler rotates at a safe speed and stops rotating when it achieves the pre-set torque.

The drive system will not surpass the programmed torque and speed settings during operation. If you need to change the settings, use the following procedure. The steps required to set or adjust a setting are the same for all functions.

How to Modify Drive Parameters1. At the driller’s panel, turn the ENABLE switch to OFF.2. Insert the key into the DRIVE SET keyed switch.3. Turn and hold the key in the SET position.4. Select and set the required function using the following table:

To set this Perform these steps

Drill Forward Torque

1. Set the MODE switch to DRILL. 2. Set the QUILL switch to FWD. 3. Use the TORQUE switch to increase or decrease the SET TORQUE

reading on the digital gauge on the driller’s panel. Set this limit at 2,000 ft·lbs less than the lowest connected joint torque setting (see Connect–Forward Torque). Consult with the Rig Manager or Oil Company Representative to determine the proper setting. If you use a downhole mud motor, the torque set limit must be higher than the maximum output of the mud motor. Refer to ‘Mud Motors in Slide Drilling Operations’ within the Operations Guide for your unit.



5. Release the DRIVE SET keyed switch.6. Remove the key.7. Set the ENABLE switch to ON.

Drill Reverse Speed and Torque

1. Set the MODE switch to DRILL. 2. Set the QUILL switch to REV. 3. Use the SPEED switch to increase or decrease the SET SPEED reading

on the digital gauge on the driller’s panel.Tesco recommends 10 rpm or less.

4. Use the TORQUE switch to increase or decrease the SET TORQUE reading on the digital gauge on the driller’s panel.Tesco recommends 5-8,000 ft.⋅lbs or less, depending on drill string configuration.

Connect Forward Speed and Torque

1. Set the MODE switch to CONN. 2. Set the QUILL switch to FWD.3. Use the SPEED switch to increase or decrease the SET SPEED reading

on the digital gauge on the driller’s panel. Tesco recommends 15 rpm or less.

4. Use the TORQUE switch to increase or decrease the SET TORQUE reading on the digital gauge on the driller’s panel.Use the torque requirements for the drill string connections to determine this setting.

Connect Reverse Speed and Torque

1. Set the MODE switch to CONN. 2. Set the QUILL switch to REV.3. Use the SPEED switch to increase or decrease the SET SPEED reading

on the digital gauge on the driller’s panel.Tesco recommends 15 rpm or less.

4. Use the TORQUE switch to increase or decrease the SET TORQUE reading on the digital gauge on the driller’s panel.Tesco recommends 8,000 ft⋅lbs or less.

Pipe HandlerForwardSpeed andTorque

1. Set the MODE switch to CONN.2. Set the QUILL switch to FWD.3. Push and hold the PIPE HANDLER ROTATE button.4. Use the SPEED switch to increase or decrease the SET SPEED reading

on the digital gauge on the driller’s panel.Tesco recommends 5 rpm.

5. Use the TORQUE switch to increase or decrease the SET TORQUE reading on the digital gauge on the driller’s panel.Tesco recommends 5,000 ft·lbs or less.

Pipe HandlerReverseSpeed andTorque

1. Set the MODE switch to CONN.2. Set the QUILL switch to REV.3. Push and hold the PIPE HANDLER ROTATE button.4. Use the SPEED switch to increase or decrease the SET SPEED reading

on the digital gauge on the driller’s panel.Tesco recommends 5 rpm.

5. Use the TORQUE switch to increase or decrease the SET TORQUE reading on the digital gauge on the driller’s panel.Tesco recommends 5,000 ft·lbs or less.



sabok

New Stamp

INSTALLATION GUIDE


CHAPTER 5: RIG OUT PROCEDURE

The top drive rig-out (removal) procedure is divided into the following separate activities:• remove the top drive• remove the torque arrest system• remove the service loop• prepare the power module and auxiliary hydraulic power unit

When the rig-out procedures are complete, store all equipment in shipping containers. For more information on long term storage, please consult the Maintenance Guide for your unit type.

REMOVE THE TOP DRIVE

1. Move the top drive handling frame to the rig floor.2. Locate a pin position on the torque track and pin the torque bushing to the torque

track.Note: This pin connection holds the torque bushing in place when it is discon-nected from the top drive.

3. Set the swivel link locks.

Figure 5-1: Setting the swivel link locks

Link locks in locked position

Link locks in unlocked position

RIG OUT PROCEDURE INSTALLATION GUIDE


4. Disconnect the top drive from the extend frame.5. Hoist the top drive.6. Position the top drive handling frame over the hole center.7. Lower the top drive into the handling frame and pin it in place.8. Disconnect all service loop items from the top drive.9. Remove the top drive from the rig floor.

Caution: Connect the hoisting cable to the top drive handling frame and not to any part of the top drive or yoke.

REMOVE THE TORQUE ARREST SYSTEM

This procedure assumes that the top drive is disconnected from the swivel and removed from the rig floor.

Note: If you intend to reinstall the top drive into the existing mast, leave the torque track stabilization equipment in place. If you do not plan to reinstall the top drive, remove the stabilization equipment when you lower the mast.

1. Connect the tugger to the torque bushing and extend frame. Take the weight of the load with the tugger.Note: The bushing will be pinned near the bottom of the torque track.

2. Remove the pin and carefully lower the torque bushing off the bottom of the torque track and onto the rig floor.

3. Use the tugger to move the bushing out the V-door.4. Run two torque track handling slings through the becket of the blocks.5. Attach the pick-up pin of the torque track to the slings.6. Raise the blocks to the crown.7. Connect the torque track to the blocks by placing the pick-up pin of the torque

track through the hole in the torque track. Then, attach the slings to both sides of the pick-up pin.

8. With the slings and pick-up pin in position, hoist the blocks to transfer the weight of the torque track from the torque track hanging assembly to the block slings.

9. Unbolt the T-bar from the torque track.10. Loosen the T-bar clamp.11. Slide the T-bar to its most rearward position.

Note: This prevents the T-bar from obstructing the torque track during disassembly.

12. Re-tighten two bolts on the T-bar clamp.13. Disconnect the hanging assembly from the pad eye in the crown.14. Use the blocks to lower the torque track through the rotary table until the first

flanged connection is at working height.

INSTALLATION GUIDE RIG OUT PROCEDURE


15. Use a 4-3/4 ton shackle through the stabilizer attachment bar (on the back of the torque track) to attach the rig tugger to the bottom section of track. This will hold it in place while it is unbolted.Caution: If a wellhead is not installed, ensure that the casing bowl is covered to prevent objects from falling into the hole.

16. Hoist the remaining track (suspended from the blocks) 10-15 ft. above the rig floor.

17. Use the rig tugger (already attached) to lift the bottom section of track out of the rotary table and off the rig floor.

18. Repeat steps 14.-17. for each section of torque track.19. Remove the handling slings from the blocks and hoist the blocks clear of the rig

floor.20. Connect the tugger line to the T-bar/torque anchor beam.21. Loosen and remove the anchor beam clamps.22. Use the tugger to lower the T-bar/torque anchor beam and move it off the rig

floor.

REMOVE THE SERVICE LOOP

Use the following procedure if the service loop is not strung through the mast and hangs off from a cable/hose saddle.

1. Position the cable storage reel in a convenient location for spooling.Note: There should be straight-line access from the reel to the cable/hose saddle.

2. Disconnect all service cables and hoses from the plug board on the power unit and auxiliary hydraulic power unit.

3. Move the disconnected ends to the storage reel.Note: Clean and protect cable and hose ends.

4. Attach the tugger line to the cable/hose saddle.5. Disconnect the cable/hose saddle from the mast.6. Connect the hydraulic control lines from the auxiliary hydraulic power unit to the

storage reel.7. Begin to spool the cables and hoses onto the reel.8. When all the slack is taken up, lower the cable/hose saddle while continuing to

spool.9. Stop spooling when the cable/hose saddle reaches the storage reel.10. Mark the location of the cable/hose saddle on the hoses with tape or paint.11. Remove the cable/hose saddle from the service loop.12. Spool the remainder of the service loop onto the storage reel.



Use the following procedure if the service loop is strung through the mast and over a roller saddle.

1. Use a soft sling to bundle all service loop cables and hoses that are at the rig floor.2. Connect the sling to the floor tugger.3. Remove any service loop stabilization slings that are currently installed.4. Position the cable storage reel in a convenient location for spooling.

Note: Position the cable reel so that there is straight-line access from the reel to the cable roller saddle.

5. Connect the hydraulic control lines from the auxiliary hydraulic power unit to the storage reel.

6. Disconnect all service loop cables and hoses from the plugboards on the power module and auxiliary hydraulic power unit.

7. Move the ends of the disconnected cables and hoses to the storage reel.Note: Clean and protect all cable and hose ends.

Caution: Use the cable storage reel for all main power cables, hydraulic hoses, and multi-conductor cables.

8. Hoist the floor tugger to take the weight from the cable capture clamp on the roller saddle.

9. Remove the slings that hold the capture clamp in place in the mast.Note: Do not disassemble or loosen the capture clamp. Lower it to the ground with the remainder of the service loop.

10. Place the ends of the service loops cables and hoses on the reel.

Figure 5-2: Spooling the service loop 1

INSTALLATION GUIDE RIG OUT PROCEDURE


11. Begin to spool the hoses and cables at the reel.12. When all slack is taken up, lower the floor tugger while you continue to spool.13. When the capture clamp reaches the reel, stop spooling and lowering.14. Use tape or paint to mark all cables to indicate the position of the capture clamp.

Note: When the top drive is reinstalled, use these markings to position and con-nect the capture clamp before drawing the service loop up into the mast.

15. Remove the capture clamp.16. Spool the remainder of the hose onto the storage reel.

Note: You might need to reconfigure the sling arrangement so that you can spool all cable onto the reel.

17. Remove the cable roller saddle from the mast.18. Disconnect the gauge cable from the driller’s panel and power module.19. Remove the interlocks from the drawworks and mud pumps (if required).20. Remove the driller’s panel from the rig floor.

Note: To prevent damage to switches and meters, ensure the panel is wrapped or boxed prior to storage.

Figure 5-3: Spooling the service loop 2



DISCONNECT THE POWER AND AUXILIARY HYDRAULIC POWER UNIT

1. Lock out the main breaker.2. Disconnect the power to the power module.3. Bundle all power cables.

Note: Clean and protect all connectors.4. Remove the Emergency Shut Down cable from the power module.5. Remove and manually spool the hydraulic hoses that are connected to the cable

storage reel.6. Disconnect the auxiliary hydraulic power unit from the power unit.

INSTALLATION GUIDE PRE-INSTALLATION CHECKLIST


APPENDIX A: PRE-INSTALLATION CHECKLIST

Use the following checklist to check for possible damage during shipment before beginning installation procedures.

Component Description Date Initials

Containers Containers 1, 2, 3

Top Drive Transportation stand

Top drive guard

Pipe Handler

Gearbox

Gearbox oil level

Motor Cabling

Top Drive hoses

Auxiliary system (11-Station Manifold and solenoids)

Encoder

Power Module Drive Data Manager

Dynamic braking unit and braking resistors

15kVA, 600: 120/208V transformer

HVAC unit

600V distribution panel

120/208V distribution panel

Auxiliary hydraulic unit

Pump and sensor wiring

Systems fittings and hoses

Auxiliary pump and motor

Filter housings

Pump quick connect fittings

Hydraulic reservoir

Service Loop Cable/hose saddle

Hoses Hose reel

1×225 ft auxiliary return hose

1×225 ft auxiliary supply hose

2×35 ft auxiliary jumper hoses

PRE-INSTALLATION CHECKLIST INSTALLATION GUIDE


Main Power Cables

1× 4/0 ground cable, 225 ft long

×3-conductor 4/0 225 ft cables

1 x 225 ft. 37-conductor robotics control cable

1 x 225 ft. motor sensor feedback cable

1 x 225 ft. #14.7C motor blower cable

3 x 313 Kcm 225 ft. cables

Other Cables 1×225 ft 37-conductor robotics control cable

1×225 ft motor sensor feedback cable

1×150 ft 4TWP driller’s panel instrumentation Cable B

1×150 ft 18/4 emergency shutdown cable (if required)

1x 29 ft. #14.7C pump skid power cable

1 x 29 ft. #18.4 pump skid sensor cable

Driller’s Panel Instrumentation

Switches

Connectors

Internal wiring

Torque Arrest System

Extend frame

Torque bushing

Torque beam and T-bar

Torque track

Hanging sling assembly

Accessories (if purchased)

Main service interface breaker

Crimping tool (if required)

Elevators

Elevator inserts

Elevator links

Saver subs

Component Description Date Initials

INSTALLATION GUIDE VISUAL INSPECTION CHECKLISTS


APPENDIX B: VISUAL INSPECTION CHECK-LISTS

Use this checklist after installation procedures are complete, but before you start the system.

Danger! Do the following before proceeding with the checklists:

1. Ensure that all power to the top drive is shut off and locked out.2. Ensure the gearbox breather is installed and the ball valve is opened prior to oper-

ating.Note: The breather may not be installed for shipping purposes and some new units may have the ball valve handle wired closed.

Before you complete the following checklist, ensure that all electrical connections are:• clean and free of moisture

Table B-1: Top drive inspection list

Component Activity Steps

Sensors and Wiring

Inspect the sensors and wiring. 1. Open the motor junction box .2. Inspect the wiring to the following:

• Encoder• RTDs• Pressure switchNote: Look for damage to wiring and ensure all the connections are tight.

3. Replace the desiccant pack if necessary.

Motor Cabling Check the motor cabling. 1. Remove the access covers on the junction boxes.

2. Check wiring to the Motor.Check for cable discol-oration (as a result of heatdamage).

3. Ensure that motor lugs and other terminations are tight.Note: 120 in.-lb for lugs, 96 in.-lb for set screws.

4. Ensure the junction box gaskets are in good con-dition and will seal properly.

5. Restore the access covers to their original posi-tion on the junction box.

Top Drive Hoses Check the auxiliary hydraulic hoses and gearbox lubrication hoses.

1. Inspect all hoses including service loop.2. Tighten the fittings as necessary.3.

Lubrication Ensure lubrication is adequate. 1. Check the gearbox oil level.Note: The oil level should reach the level line on the inspection window.

2. Grease all lubrication points.

VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE


• properly torqued and fully locked

Table B-2: Power module inspection list


Wiring Check all power module wiring. 1. Check connections for damage or decay. Tighten if required.

Note: Ensure that connections are properly torqued.

2. Check the AC feed connections.3. Check the switch & breaker wiring.4. Check interface wiring.

Breakers Check that the trip voltage is set correctly for all main breakers.

1. Verify the breaker UV trip voltage.2. Verify the breaker current trip level.

Plugboard (Waterfall)

Check all connections. 1. Check the motor leads from the drive to the plug-board.

2. Check the plugboard lugs.

Table B-3: Auxiliary hydraulic power unit inspection list


Wiring Systems Checl all electrical wiring to the Auxiliary Hydraulic Power Unit

Check the following cord ends for condition and cleanliness:

• power cables• sensor cables

Fluid Systems Check hydraulic systems 1. Check the following for condition, cleanliness, and tightness:• auxiliary hydraulics system fittings

2. Ensure tank drain valve is closed.3. Check hydraulic fluid level in reservoir.

Mechanical Check the mechanical components of the module

1. Check for proper rotation of the pump motor.

Table B-4: Cable/hose reel inspection list


Service Loop Inspect all cables and hoses 1. Inspect all cables and hoses for the following:• cuts• abrasions• signs of stretching

Service Loop Terminations

Inspect all connectors and fittings

1. Inspect all connectors for pin damage.2. Ensure that all pin connectors are properly

seated.3. Ensure that all connectors are clean and free of

moisture.

INSTALLATION GUIDE VISUAL INSPECTION CHECKLISTS


Table B-5: Driller’s panel inspection list


Driller’s Panel Inspect the panel and all of its connectors

1. Inspect all switches.2. Inspect all instrumentation.3. Inspect all connectors.4. Ensure that all cords are functioning.5. Ensure there is desiccant pack in the control

panel.

VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE


sabok

New Stamp

INSTALLATION GUIDE SLING LOAD RATINGS


APPENDIX C: SLING LOAD RATINGS

Table values below are for slings with eyes and thimbles in both ends, as well as Flemish Spliced Eyes and mechanical sleeves.

Caution: Reduce loads if hand-tucked spliced eyes are used. Reduce loads by 20% if eyes are formed by cable clips.

Table C-1: Maximum safe working loads (pounds)

Safety Factor = 5

Rope Diameter

Single Vertical Hitch

Single Choker Hitch

Single Basket Hitch (vertical legs)

2-leg Bridle Hitch and Single Basket Hitch with legs included

60 in. 45 in. 30 in.

3/16 600 450 1,200 1,050 850 600

¼ 1,100 825 2,200 1,900 1,550 1,100

5/16 1,650 1,250 3,300 2,850 2,350 1,650

3/8 2,400 1,800 4,800 4,150 3,400 2,400

7/16 3,200 2,400 6,400 5,550 4,500 3,200

½ 4,400 3,300 8,800 7,600 6,200 4,400

9/16 5,300 4,000 10,600 9,200 7,500 5,300

5/8 6,600 4,950 13,200 11,400 9,350 6,600

¾ 9,500 7,100 19,000 16,500 13,400 9,500

7/8 12,800 9,600 25,600 22,200 18,100 12,800

1 16,700 12,500 33,400 28,900 23,600 16,700

1 1/8 21,200 15,900 42,400 36,700 30,000 21,200

1 ¼ 26,200 19,700 52,400 45,400 37,000 26,200

1 3/8 32,400 24,300 64,800 56,100 45,800 32,400

1 ½ 38,400 28,800 76,800 66,500 54,300 38,400

1 5/8 45,200 33,900 90,400 78,300 63,900 45,200

1 ¾ 52,000 39,000 104,000 90,000 73,500 52,000

1 7/8 60,800 45,600 121,600 105,300 86,000 60,800

2 67,600 50,700 135,200 117,100 95,600 67,600

2 ¼ 84,000 63,000 168,000 145,500 118,800 84,000

2 ½ 104,000 78,000 208,000 180,100 147,000 104,000

2 ¾ 122,000 91,500 244,000 211,300 172,500 122,000

SLING LOAD RATINGS INSTALLATION GUIDE


If you use a choker hitch, multiply the previous table values by 3/4.

If you use a double basket hitch, multiply the previous table values by 2.

Table C-2: Rope diameter efficiencies

Rope Diameter Efficiency

1/4 in. and smaller 95%

5/16 to 3/4 in. 90%

7/8 to 1 in. 85%

1-1/8 to 1-1/2 in. 80%

1-5/8 to 2 in. 75%

2-1/8 in. and larger 70%

INSTALLATION GUIDE HAND SIGNALS FOR BOOM EQUIPMENT OPERATION


APPENDIX D: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION

The following chart contains examples of typical signals used by the signalman during boom equipment operations. If your project requires special signals, agree on what they will be before you begin operations.

Boom operators will not respond to unclear signals.

Designate one signalman before operation begins. The boom operator accepts signals only from the designated signalman.

Table D-1: Hand signals for boom operation

This Signal Means This

Use Load LineTap fist on head, then use regular signals.

Use Whip LineTab elbow with one hand, then use regular signals.

Raise Load

Lower Load

HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE


Raise Load Slowly

Lower Load Slowly

Raise Boom

Lower Boom

Raise Boom and Lower LoadExtend thumb upward and flex fingers in and out as long as load movement is required.

Lower Boom and Raise LoadExtend thumb downward and flex fingers in and out as long as load movement is required.

SwingExtend arm. Use forefinger to indicate direction of swing.



INSTALLATION GUIDE HAND SIGNALS FOR BOOM EQUIPMENT OPERATION


StopExtend forearm and hand in horizontal position. Make a slicing motion.

Dog Everything

Emergency Stop

Travel (Both Tracks)Use both fists to make a circular motion to indicate the direction of travel (forward or backward).

Travel (One Track)Raise fist to indicate which side of the track to lock. Move the other fist in a circular motion to indicate the direction of travel (forward or backward)

Open Clamshell Bucket

Close Clamshell Bucket



HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE


Move Carriage In

Move Carriage Out



INSTALLATION GUIDE TRIP AND WARNING CODES


APPENDIX E: TRIP AND WARNING CODES

Table E-1: Trip Codes

Trip Code Description Trip Code Description

1 Interlock 30 Drive ID Violation

2 Reference Loss 57 Overspeed

3 DC Overvolts 58 Current Control Fault

4 DC Undervolts 59 Motor Calibration Failure

5 Timed Overload 60 Unsuitable Motor

6 Over Temperature 61 Encoder Loss

7 Instantaneous Overcurrent 62 User Trip 1

8 U-Phase - Overcurrent 63 FIP Loss

9 U-Phase - HW Overtemp 64 Load Fault - High

10, 11 As 8, 9 for V-Phase 65 Load Fault - Low

12, 13 As 8, 9 for W-Phase 66 Motor PTC

14 Encoder PS Fail 67 DB Resistor

15 Auxiliary +/- 15 V Fail 68 Reserved

16 Auxiliary 24 V Fail 70 Datumize Error

17 Unidentified PIB 71 Speed Feedback Loss

18 History Restore Fail 72 Over Frequency

19 New Drive 73 User Trip 2

20 Parameter Edits Lost 93-99 Unknown Trip

21 Motor Themostat 100-149 Reserved

22 Motor I2T 150 PWM Error

23 RS232 Loss 151 DB Overcurrent Trip

24 RS485 Loss 152 DB Hardware Overtemp Trip

25 Internal Reference Fail 200 CAN, 1, Loss - see P61.43

26 Under Temperature 6931-5674-92153-199

(Relate to DELTA systems. Refer to Software Manual T1679EN.)27 Keypad Loss/Removed

28 Current Imbalance

29 Precharge Failure

TRIP AND WARNING CODES INSTALLATION GUIDE


Table E-2: View Warnings and Trips

Viewing Warnings and Trips Menu 10

Parameter View

10.00-10.09 Warning Nos. 1-10

10.10-10.19 Trip Nos. 1-10

10.20-10.29 Trip History Nos. 1-10

10.30 Secs Since Trip

10.31 Hours Since Trip

10.32 CF10 - User Trip 1

10.33 CF112 - User Trip 2

10.34 CF9 - Trip Reset

Table E-3: History

History

The drive is equipped with a 10-channel history recorder.

Menu 26 - Allows set-up of the log

Menu 27 - Allows playback of the log

INSTALLATION GUIDE DRIVE DATA MANAGER


APPENDIX F: DRIVE DATA MANAGER

The Drive Data Manager is a multi-purpose unit which provides keypad functions and a 4-line, 20-digit display. It also includes four LEDs which show the status of the drive. The Drive Data Manager is mounted on the main panel inside the power building.

Functions of the Drive Data Manager include:• Set and display drive parameters• Monitor drive status• Indict warnings and trips• Track history

Figure F-1 shows the Drive Data Manager and describes the functions of indicators and keys.

DRIVE DATA MANAGER INSTALLATION GUIDE


Figure F-1: Drive Data Manager



Navigating Menus and Parameters

Use the 4-way navigation key to browse through menus and parameters.

As an example, navigating Menu 1 is shown in Figure F-2. Other menus are treated in exactly the same way.

If the parameter number is known, it can be entered directly as shown in Figure F-3:

Figure F-2: Navigating Menus and Parameters

Figure F-3: Entering the Parameter Number



Editing Parameters

Figure F-4 shows an example of editing parameter P2.00. Follow the same procedure to edit other parameters.

The parameters of EMI 400 drive system is protected by security code to prevent accidental editing. Only parameters of menu 1, menu 10, and menu 27 are accessible for monitoring and display purpose. Parameters in these three menus are read-only. Menu 1 is configured to dis-play key parameters and status of the drive, menu 10 for warning and trip information, and menu 27 for history log.

Figure F-4: Editing Parameters



Monitoring the Drive

The Drive Data Manager has the function of monitoring and displaying the operation status of the drive system and Menu 1 is configured for such purpose. The table below lists the parame-ters in Menu 1.

Table F-1: Parameters in Menu 1

Parameter Units Function Description

P1.00 % Top speed Speed feedback

P1.01 % Nominal Torque demand

P1.02 A Motor current

P1.03 kW Motor power

P1.04 V Motor voltage

P1.05 Status word

P1.06 Warning

P1.07 Trip No. 1

P1.08 Trip No. 2

P1.10 % Top speed Speed reference

P1.11 % Nominal Torque reference

P1.12 Control word

P1.16 V DC link voltage

P1.17 % Drive FLC Drive current

P1.18 Degree Motor angle

P1.19 rpm Motor nominal speed

P1.20 Motor power factor

P1.21 rpm Max speed forward

P1.22 rpm Max speed reverse

P1.23 rpm Min speed forward

P1.24 rpm Min speed reverse

P1.25 % Top speed/s Acceleration rate forward

P1.26 % Top speed/s Deceleration rate forward

P1.27 English User Text Language

P1.28 A Drive nominal current

P1.29 % Overload Duty

P1.30 Number of Delta



sabok

New Stamp

INSTALLATION GUIDE


INDEX

Numerics600 VAC power, 34600V power, 36600VAC

applying power, 38

Aair considerations, 5air intakes, 37air starter, 37auxiliary hydraulic power unit, 45

disconnecting, 50placement during rig up, 7

auxiliary pump, 40

Bbattery, 37blocks, 24

Ccable roller saddle

optimal placement, 9placement factors, 10placement procedure, 10

coolant levels, 37counter balance system

installation, 27

Ddamage

pre-installation inspection, 6danger

electrical warnings, 34driller's control panel, 36, 49driller’s panel

installation, 29drive module, 36, 38drive parameters

connect reverse, 43drill forward torque, 42modifying, 42set connect forward, 43set drill reverse speed and torque, 43

Eelectrical

warnings, 34

Emergency Shut Down, 36equipment

cable roller saddle, 9inspecting, 6inspecting for damage, 6placement during rig up, 7placement procedure, 8spotting, 7

equipment placementauxiliary hydraulic power unit, 7power module, 7service loop reel, 9

ESD See Emergency Shut DownESD test

top drive, 38exhaust, 37

Ffinal start up, 41fuel considerations, 5

Ggenerator, 37

starting, 37

Hhydraulic system

checking, 40

Iinspecting equipment

pre-installation, 6inspection

general notes, 33installation

pre-installation measurement, 3rig measurement, 3

installing drawworks interlock and override, 30

Mmain panel control system, 36measurement

rig, 3mud pump interlock, 32

Ooptimal placement

INDEX INSTALLATION GUIDE


auxiliary hydraulic power unit, 7power module, 7

Pphase rotation

checking, 39power

checklist, 4connection requirements, 3supplying to equipment, 38

power module, 45disconnecting, 50placement during rig up, 7placement procedure, 8

pre-installationinspection, 6main power connection requirements, 3main power requirements checklist, 4measurement, 3

Rradiator, 37rig out, 45

disconnect auxiliary hydraulic power unit, 50disconnect power module, 50

rig upequipment spotting, 7

Ssafety air interlocks

installation, 30saver sub, 36service loop, 45

installation option 1, 11installation option 2, 13removing, 47

service loop reeloptimal placement, 9

speedset connect forward, 43set connect reverse, 43set drill reverse, 43

start upfinal phase, 41

support systemsstart up, 37

Ttop drive

preliminary checks and ESD test, 38starting, 38

torque

set connect forward, 43set connect reverse, 43set drill forward, 42set drill reverse, 43

torque arrest systembefore you install, 16components, 16configuration sample calculation, 18determine the configuration, 17installation, 16removing, 45, 46torque track, 19

torque bushing, 24torque track

mounting, 19transformer power

applying, 38

Wwarnings

before start up, 34condensation, 36electrical, 34other, 36

Documents

EMI 400 250 Ton Instalation Guide