HMIS Top Drive System

Transcription

1 Installation Guide HMIS Top Drive System 250TON HMIS 475HP DOCUMENT NAME: REV 3

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3 INSTALLATION GUIDE COPYRIGHT AND DISCLAIMER 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 Information Corporate Head Office 3993 W. Sam Houston Parkway No., Suite 100 Houston, Texas, USA Telephone: (713) Fax: (713) REV 3 250TON HMIS 475HP TESCO CORPORATION, 2007 I

4 REVISION INFORMATION INSTALLATION GUIDE Revision Information Version Date Description of Changes Rev A May 2004 General Engineering updates and additions Rev 1 April 2007 General Updates Rev 2 Oct 2007 Added caution symbols to all warnings and caution notes. Added more safety warnings. Rev 3 Nov 2007 New revision to remove CE-ATEX standards from manual. TESCO CORPORATION, TON HMIS 475HP REV 3 II

5 INSTALLATION GUIDE TABLE OF CONTENTS LIST OF FIGURES V LIST OF TABLES VII CHAPTER 1: ABOUT THIS DOCUMENT CHAPTER 2: PRE-INSTALLATION ACTIVITIES Rig Installation and Measurement Power/Service Connection Requirements Electrical Considerations Fuel Considerations Air Considerations Equipment Inspection (Pre-installation) CHAPTER 3: RIG UP PROCEDURE Equipment Placement Optimal Placement of the Power Unit How to Place the Power Unit Components Optimal Placement of the Hose Saddle How to Install the Hose Hanging Saddle and Service Loop Torque Arrest System Before You Install the Torque Arrest System Torque Arrest System Components Torque Arrest System Configuration How to Determine the Torque Track Configuration (where an application drawing is not supplied) Sample Calculation How to Install the Torque Arrest System Top Drive How to Install the HMI Top Drive Counter-Balance System How to Set the Counter-Balance Cushion Height Driller's Panel How to Install the Driller s Panel Safety Air Interlocks How to Install the Drawworks Interlock and Override About the Mud Pump Interlock CHAPTER 4: SYSTEM INSPECTION AND START UP Inspection-General Notes REV 3 250TON HMIS 475HP TESCO CORPORATION, 2007 III

6 TABLE OF CONTENTS INSTALLATION GUIDE Warnings System Start Up Power Unit: Electrical System How to Start the Electrical System for the Power Unit Prime Mover Before You Start the Prime Mover How to Start the Engine Closed-Loop Hydraulic System Top Drive Robotic Functions CHAPTER 5: RIG OUT PROCEDURE Remove the Top Drive Remove the Torque Arrest System Remove the Service Loop Remove the Power Unit APPENDIX A: PRE-INSTALLATION CHECKLIST APPENDIX B: VISUAL INSPECTION CHECKLISTS APPENDIX C: SLING LOAD RATINGS APPENDIX D: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INDEX ENGINEERING SIGN-OFF TESCO CORPORATION, TON HMIS 475HP REV 3 IV

7 INSTALLATION GUIDE LIST OF FIGURES Figure 2-1: Power, air and fuel connections - option Figure 2-2: Power, air and fuel connections - option Figure 3-1: HMI optimal equipment placement Figure 3-2: HMI hose saddle placement Figure 3-3: HMIS cable/hose saddle clamping location Figure 3-4: HMIS hose saddle capture clamp configuration Figure 3-5: Hoisting the hose saddle Figure 3-6: Positioning the hose saddle Figure 3-7: Torque arrest system configuration Figure 3-8: F-clamp and turnbuckle assembly Figure 3-9: Counter-balance system interface Figure 3-10: Drawworks override installation Figure 5-1: Service loop removal REV 3 250TON HMIS 475HP TESCO CORPORATION, 2007 V

8 LIST OF FIGURES INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 VI

9 INSTALLATION GUIDE LIST OF TABLES Table 1-1: Where to find more information Table 3-1: HMI - cable and hoses for 460 and 475 HP prime movers Table B-1: Top drive inspection list Table B-2: Power unit inspection - cable reel/service loop Table B-3: Power unit inspection - oil cooler Table B-4: Power unit inspection - oil storage tank Table B-5: Power unit inspection - filter manifold headers Table B-6: Power unit inspection - pump drive/pumps Table B-7: Power unit inspection - electrical panel Table B-8: Power unit inspection - prime mover Table B-9: Driller s panel Table C-1: Maximum safe working loads (pounds) Table C-2: Rope diameter efficiencies Table D-1: Hand signals for boom operation REV 3 250TON HMIS 475HP TESCO CORPORATION, 2007 VII

10 LIST OF TABLES INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 VIII

11 INSTALLATION GUIDE CHAPTER 1: ABOUT THIS DOCUMENT This document contains information on how to install the 250TON HMIS 475HP top drive, 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 following: 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 system start up rig out Table 1-1: Where to find more information For information on system components setting torque and speed driller's panel functions and operating descriptions making connections drilling ahead tripping freeing stuck pipe load path inspections maintenance/service schedules component disassembly and reassembly TESCO manufactured parts and part numbers electrical schematics hydraulic schematics cooling schematics gearbox lubrication schematics available options and spares Refer to System Description Operations Guide Maintenance Guide Parts List System schematics TESCO Representative REV 3 250TON HMIS 475HP TESCO CORPORATION,

12 ABOUT THIS DOCUMENT INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 2

13 INSTALLATION GUIDE 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: swivel bail clamps torque track hanging pad eye components and subs (top drive to drill string) service connection lengths and specific accessories air/electric safety interlocks torque arrest system components hose saddle hanging 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: diesel fuel interface with rig fuel supply starter air supply from rig electrical power 480VAC 100 amp recommended (60 amp minimum) 60 Hz or 380 VAC 50 Hz REV 3 250TON HMIS 475HP TESCO CORPORATION,

14 PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE The following figures illustrate the connection considerations to address before the top drive system arrives on location. Note: If the customer is providing the main power supply (interconnection package), consult TESCO. Figure 2-1: Power, air and fuel connections - option 1 Figure 2-2: Power, air and fuel connections - option 2 TESCO CORPORATION, TON HMIS 475HP REV 3 4

15 INSTALLATION GUIDE PRE-INSTALLATION ACTIVITIES Electrical Considerations 1. Determine a location for the power unit. Note: If the rig configuration has not been finalized, select two possible locations for the power unit. The power unit should be placed on the same side of the rig as the standpipe. 2. Determine the distance from the 480V, 100 amp plug at the motor control centre (MCC) to the power unit. Note: The standard power cable length is 250 ft. (76.2 m). 3. Determine if any special equipment is required. Examples: penetration or plug boards. Note: This equipment is required if the power cables must pass through walls on their way from the MCC breaker to the power unit. 4. Determine if a cableway or suitable space is available to accommodate the power cable that starts at the MCC breaker and goes to the power unit. Note: If adequate space is not available, determine what materials would be required to protect the cables from the breaker to the power unit. 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 Caterpillar 460 hp prime mover, maximum consumption is 21 gallons (U.S.) per hour (79.5 litres per hour) For the Detroit Diesel 475 hp prime mover, maximum consumption is 22.8 gallons (U.S.) per hour (86 litres 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 paraffin. 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 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 REV 3 250TON HMIS 475HP TESCO CORPORATION,

16 PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE 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 contents. 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. TESCO CORPORATION, TON HMIS 475HP REV 3 6

17 INSTALLATION GUIDE CHAPTER 3: RIG UP PROCEDURE EQUIPMENT PLACEMENT Optimal Placement of the Power Unit The following diagram shows the optimal placement of the power unit. This placement is considered ideal for the following reasons: The power unit is located on the same side as the standpipe. The placement allows straight-line access from the cable reel to the roller saddle. The cooling fans are not obstructed. There is adequate space in front of and behind the power unit (15 ft.). There is working access for personnel around the perimeter (3 ft. on each side). Figure 3-1: HMI optimal equipment placement Although the location of the power unit depends on the rig configuration, it is important that you consider the factors discussed above when you place the equipment. If space is very limited, you can order an optional stacking kit to mount the hydraulic oil storage tank, cooler and cable reel on top of the prime mover, pump drive, and filter manifold. Note: If you require a stacking kit, you must specify this requirement well before the unit is shipped REV 3 250TON HMIS 475HP TESCO CORPORATION,

18 RIG UP PROCEDURE INSTALLATION GUIDE How to Place the Power Unit Components 1. 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. Use a crane or loader to place the prime mover on the rig matting. 4. Connect the following items: Connect This From Here To Here 37C electrical control cable Power unit Driller s panel Closed loop high pressure supply and return lines Hose reel Filter manifold Diesel fuel line Fuel source Prime mover Air line Air source Diesel engine starter 480VAC (or 600VAC) power electrical cable Power unit Master Control Centre (MCC) 5. Connect the auxiliary hydraulic fluid lines from the auxiliary quick-connectors to the hose reel control. Note: Auxiliary hydraulic power is required to spool off the service loop when you install the hose hanging saddle. Optimal Placement of the Hose Saddle The following illustration shows the optimal placement of the hose saddle. This placement is considered ideal because the hose saddle is situated as follows: High enough to prevent cables or hoses from landing on the rig floor when top drive is lowered: If the mast height is 100 ft.-125 ft. (30.5m-38.1m), it is 55 ft.-65 ft. (16.8m-19.8m) above the rig floor. Low enough to allow the top drive to reach the highest position in the mast without straining or damaging hoses, Where the service hoses will follow the mud (Kelly) hose and reduce the risk of the service hoses interfering with the overhead equipment as the top drive travels up and down the mast, and Where the hose will not be damaged during top drive operations. TESCO CORPORATION, TON HMIS 475HP REV 3 8

19 INSTALLATION GUIDE RIG UP PROCEDURE Attach protective equipment to any points that might be subject to wear during top drive operations. Figure 3-2: HMI hose saddle placement For Triple: Service Loop: Approximately ft. between top drive and hose saddle capture clamp For Double: Service Loop: Approximately ft. between top drive and hose saddle capture clamp ft. Hose Saddle: Mounted ft. above drill floor (depending on racking platform height and sling length) Hose Saddle: Mounted ft. above drill floor (depending on racking platform height and sling length) Standpipe Hose Power Unit: Located on standpipe side Although the arrangement shown here is considered optimal, placement of the cable roller saddle is determined by several factors: mast height racking platform height length of traveling equipment (drill string, compensator, blocks, and swivel) saddle hanging mechanism and configuration available hose length (standard hose length is 225 ft.(76.2 m) unless otherwise requested) power unit location How to Install the Hose Hanging Saddle and Service Loop TESCO recommends that you suspend the hose saddle from a pad eye attached to the racking platform. If no pad eye is available, wrap a sling around a secure beam at the racking platform. The hose saddle can be shackled to the sling and suspended from the beam. The total weight suspended from the sling or pad eye is The hose saddle includes a clamp that holds the service loop cable and hoses in place at the racking platform. The hoses and cable are clamped into the saddle at ground level, then the saddle is hoisted into position. Before you begin this procedure, you must calculate the length of service loop that will travel with the top drive. 1. Ensure that the auxiliary hydraulic fluid lines are connected to the hose reel control. Note: Hydraulic power is required to un-spool the service loop for connection to the hose saddle REV 3 250TON HMIS 475HP TESCO CORPORATION,

20 RIG UP PROCEDURE INSTALLATION GUIDE 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 of the service loop that will travel with the top drive. Note: Measure the length of the service loop, starting at the hammer union hydraulic connectors. Keep the service loop tidy, and ensure the ends of all hydraulic hoses are as even with each other as possible. Figure 3-3: HMIS cable/hose saddle clamping location 1 - Hammer union hydraulic connectors 2 - Hose saddle When the hose saddle is in place, the hoses to the top drive should reach the rig floor, and approximately 3 ft. (.9 m) of hose should be lying on the floor. 5. When the correct length has been spooled off the reel, insert the hoses and cable in the cable/hose saddle capture clamp. Figure 3-4: HMIS hose saddle capture clamp configuration 1. Hydraulic supply/return line 2. Hydraulic supply/return line 3. Auxiliary and case drain return line 4. Auxiliary supply hose multi-conductor cable for robotic functions TESCO CORPORATION, TON HMIS 475HP REV 3 10

21 INSTALLATION GUIDE RIG UP PROCEDURE Table 3-1: HMI - cable and hoses for 460 and 475 HP prime movers Quantity Description 2 1-1/2 in. high pressure closed loop hoses (1 supply, 1 return) 1 3/4 in. auxiliary hydraulic supply hose 1 1-1/4 in. auxiliary and case drain return line 1 37 multi-conductor cable for robotic functions 6. Connect the hose saddle to the cable of the floor tugger or crane. 7. Hoist the saddle and hoses into position below the racking platform. Note: Hoist the saddle slightly higher than its final position. Figure 3-5: Hoisting the hose saddle Figure 3-6: Positioning the hose saddle REV 3 250TON HMIS 475HP TESCO CORPORATION,

22 RIG UP PROCEDURE INSTALLATION GUIDE 8. 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. 9. 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). 10. Use the floor tugger or crane to lower the saddle until the weight transfers to the hanging sling. 11. Install a back-up safety sling around the hose saddle.! Caution: This back-up sling is considered critical safety equipment. 12. Lower the crane or floor tugger cable. 13. Attach the crane or floor tugger cable to the sling at the free end of the service loop. 14. 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. 15. Bring the 160 ft. (48.8 m) 37C control cable, connected to the main panel on the power unit, to the drill floor. 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 5,000 lb. (2,268 kg) plus the recommended safety factor for overhead equipment). The pad eye is typically placed 18 in. (45.72 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. TESCO CORPORATION, TON HMIS 475HP REV 3 12

23 INSTALLATION GUIDE RIG UP PROCEDURE 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 three 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 The total length of the torque track sections is 91 ft. (27.7m).Obtain additional length by lengthening the top section hanging sling. Purchase additional torque track sections to accommodate larger masts. One 1.3 ft. (.4m) deflector section (bull nose) of torque track is included.! Caution: Never subject the deflector section to torque. Mount it 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 track Note: If the torque track is to remain in the mast during rig moves, match the torque track connections to the mast connections wherever possible REV 3 250TON HMIS 475HP TESCO CORPORATION,

24 RIG UP PROCEDURE INSTALLATION GUIDE Figure 3-7: Torque arrest system configuration A = Mast height from rig floor to water table (underside of crown) B = Height of T-Bar and anchor beam C = Clearance beneath torque track deflector (to be a minimum of 7 ft) D = Length of torque track hanging assembly E = Distance from top of travelling block down to top of torque bushing F = Distance from bottom of torque bushing down to bottom of elevator G = Stump height above rig floor 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 8 ft-10 ft (ideally) above the drill floor, but no less than 7 ft (min) and no more than dimension F+G (max) to ensure it does not come off the bottom end of the torque track when it is in the lowermost position. 2. Place the bottom bolted section of torque track above the deflector section such that it coincides with elevation B. 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), ideally, from the pad eye. Note: Dimension D is to be no more than dimenstion E to ensure that it will not come off the top end of the torque track when it is in the uppermost position. 4. Determine the length of hanging assembly required. Note: Ensure that the length of hanging assembly is incorporated into the calculation. TESCO CORPORATION, TON HMIS 475HP REV 3 14

25 INSTALLATION GUIDE RIG UP PROCEDURE Sample Calculation If the mast height is 142 ft. (43.3m): ft. less 9 ft. (2.7 m) (height above rig floor for the deflector section) = 133 ft. (40.6 m) ft. less 2.5 ft. (.76 m) (minimum hang assembly length) = ft. (39.8 m) ft. divided by 18.5 ft. = 7 full-length tracks; this does not include the deflector section. Torque beam desired height = 11 ft. (3.4 m) The rig up would be as follows: Track Part Qty Length (ft.) Total Length (ft.) Hanging Track Standard Tracks 4 74 (18.5 x 4) ft. section ft. section *Bolted section Deflector **Pinned Section Length or Hanging Assembly 1 Set to 6 feet *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. **Hanging assembly length should not be more than 1 ft longer than the height differential between the top of the travelling block to the top of the torque bushing. How to Install the Torque Arrest System Use this procedure to install the torque arrest track system. Refer to Figure 3-8 on page Ensure the hanging pad-eye for the torque track is installed in the crown. Note: Normal placement for a standard track is 18 in. back from the crown cluster centre. 2. Assemble the torque beam, T-bar, and T-bar clamp.! 142 (mast height) = 8.7 feet above the rig floor) 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 REV 3 250TON HMIS 475HP TESCO CORPORATION,

26 RIG UP PROCEDURE INSTALLATION GUIDE 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. 6. Use the calculation method described in How to Determine the Torque Track Configuration (where an application drawing is not supplied) on page 14 to calculate 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. 7. When the torque track section rig-up is determined, set and secure the calculated hanging sling length.!! 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. 8. Fasten the hanging sling plate to the top section of torque track. 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. 9. 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. 10. 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 sections above the rig floor. 11. 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. 12. Place a ratchet strap around the top of the blocks and thread it around the torque track. 13. Use the ratchet strap to pull the blocks and track together. Note: This immobilizes the track section and keeps it hanging vertically as it travels up the mast. 14. Hoist the blocks until they support the weight of the torque track. 15. Remove the floor tugger. TESCO CORPORATION, TON HMIS 475HP REV 3 16

27 INSTALLATION GUIDE RIG UP PROCEDURE! 16. Hoist the blocks until the bottom of the first section is 8 ft. above the drill floor. 17. Connect the floor tugger to the second section of torque track and hoist it to the rig floor. 18. 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). 19. Use chains to secure the second section in place, or place a strong bar through the back strap of the torque track. 20. 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. 21. Torque the bolts to 350 ft lbs. 22. Repeat steps 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. 23. Use a ratchet strap to secure the extend arms of the torque bushing in place. 24. Attach a tugger to the torque bushing and move the bushing onto the drill floor. Note: Ensure that the extend frame is down. 25. Position the torque bushing over hole centre. 26. Use the blocks to lower the assembled torque track and stab it through the torque bushing. 27. 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, periodically check the bushing during the first few days of operation. 28. After the torque bushing is installed, raise the blocks to the crown. 29. Connect the hanging assembly of the torque track to the pad eye. 30. 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. 31. 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. 32. 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,18 in. back from the hole centre. 33. Tighten the lock nut on the hanging assembly REV 3 250TON HMIS 475HP TESCO CORPORATION,

28 RIG UP PROCEDURE INSTALLATION GUIDE 34. Remove the handling assembly at the crown and lower the blocks.! Caution: Before you move the top drive onto the rig floor, ensure the following is in place: the swivel yoke link (with an integral counter-balance) is installed in the block becket the accumulators are facing the torque track the gauge, coupler and valve are facing the driller s side 35. Install stabilization systems. Note: Three sets are usually installed: one at the top strongback, one at the racking platform, and one between the racking platform and the torque beam. These are most easily installed when the mast is down, but can also be installed during rig-up. 36. Attach the stabilization devices to the torque track as shown in the following illustrations. TESCO CORPORATION, TON HMIS 475HP REV 3 18

29 INSTALLATION GUIDE RIG UP PROCEDURE If your rig set-up requires a customized stabilization installation, contact TESCO. Figure 3-8: F-clamp and turnbuckle assembly REV 3 250TON HMIS 475HP TESCO CORPORATION,

30 RIG UP PROCEDURE INSTALLATION GUIDE TOP DRIVE How to Install the HMI Top Drive Before you move the top drive onto the rig floor, ensure the following conditions exist: You have installed the swivel yoke link (with integral counter-balance) in the becket of the block. The accumulators are facing the torque track, and the gauge, coupler and valve face the driller s side. 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. Connect the links of the swivel yoke to the swivel on the top drive. Note: The grease zerks (on the pins of the yoke link) must face the load. 5. Raise the blocks to support weight of the top drive. Caution: Do not lift the top drive off the floor. 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. 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. 14. Reposition the T-bar so the top drive sits over the hole center, and secure it in place (if required). TESCO CORPORATION, TON HMIS 475HP REV 3 20

31 INSTALLATION GUIDE RIG UP PROCEDURE 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 service loop has not been installed, see Figure 3-2 on page Connect the following hoses and cables for the service loop to the top drive: supply and return hoses for the closed-loop hydraulic system supply hose for the auxiliary hydraulic system return hose for the case drain and auxiliary hydraulics system 37C control cable, 225 ft. 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. four at the top drive: 2 on the hoses, 2 on the top drive five at the hose reel: 2 on the reel, 2 on the hoses, 1 on the auxiliary line 21. When the top drive and driller's panel are connected, continue with additional setup 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 22. COUNTER-BALANCE SYSTEM Figure 3-9: Counter-balance system interface 1. Accumulators: N2-Nitrogen and Oil 2. Counter-balance cylinder 3. Needle Valve 4. Auxiliary system quickcoupler REV 3 250TON HMIS 475HP TESCO CORPORATION,

32 RIG UP PROCEDURE INSTALLATION GUIDE How to Set the Counter-Balance Cushion Height The following conditions must exist before the following portion of the counter-balance installation 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 800psi. 6. Ensure the counter-balance relief valve is set at 1200 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 ELE- VATOR SAFTEY OPEN button. Note: This will send 1500 psi hydraulic pressure to the needle valve on the counter-balance manifold. 10. Slowly open the needle valve and allow the hydraulic oil to charge the counterbalance system. TESCO CORPORATION, TON HMIS 475HP REV 3 22

33 INSTALLATION GUIDE RIG UP PROCEDURE! 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. (the yoke pin should now be located in the center of the slotted eye of the link). 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 pressure in the system. 16. Remove the elevator hydraulic hose from the counter-balance manifold. Warning! 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 driller s panel cannot be connected to the top drive until the hose saddle and service loop have been installed. 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 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. Locate the 225 ft. 37C control cable. Note: This cable is installed in the hose saddle with the service loop. 5. Connect the cable to the driller s panel. 6. Connect the second 37C control cable coming from the power unit to the driller s panel. 7. Mount the brake handle control box to the brake handle. 8. Connect the brake handle control box to the driller's panel. Note: The driller's panel has three labeled extension cords with military connectors. Use the correct cord (cord F) REV 3 250TON HMIS 475HP TESCO CORPORATION,

34 RIG UP PROCEDURE INSTALLATION GUIDE 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. Figure 3-10: Drawworks override installation 1. Supply air 2. Air/Electric solenoid valve 3. Air line 4. Drum clutch valve 5. Air line 6. Drawworks 7. Driller s panel 8. Grabber Open/Close switch 9. Elevator button 10.Grabber override button 11.Control box for the brake handle 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 C-cord solenoid valve. Note: If two air supply hoses are present, connect each hose to an air/electric solenoid 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. TESCO CORPORATION, TON HMIS 475HP REV 3 24

35 INSTALLATION GUIDE RIG UP PROCEDURE 5. Connect an electric cable from the air/electric solenoid valve to the extension cord at the driller's panel. The cord is labeled C-Drawworks. 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. 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 operational considerations with a qualified TESCO representative REV 3 250TON HMIS 475HP TESCO CORPORATION,

36 RIG UP PROCEDURE INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 26

37 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 Checklists. top drive power unit control cables cable/hose reel driller s panel WARNINGS 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. Install a saver sub in the grabber on the top drive before you test for hydraulic leaks or operate any robotics function. Before you start any pumps, ensure that all appropriate valves on tanks and pumps are open REV 3 250TON HMIS 475HP TESCO CORPORATION,

38 SYSTEM INSPECTION AND START UP INSTALLATION GUIDE 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 the power unit electrical system power up the diesel prime mover test the closed-loop hydraulic system test the robotics functions and operations of the top drive Note: Refer to the electrical schematics supplied with your unit. Power Unit: Electrical System! Danger! Only qualified electrical personnel should test the power supply and AC power circuits. How to Start the Electrical System for the Power Unit 1. Ensure that the main breaker that supplies the power is in the off position. 2. Connect the power cable from the power unit to the Motor Control Centre (MCC). Note: Power supply should be as follows: Normal 480 VAC 100 amp recommended (60 amp minimum) 60 Hz Optional 380 VAC 100 amp recommended (60 amp minimum) 50 Hz! Danger! Only qualified electrical personnel should test the power supply and AC power circuits. 3. Ensure that all cables from the following items to the electrical cabinet on the power unit are in place and correctly connected: motor for the fan motor for the auxiliary pump skid transformer on the power unit 4. Set the breaker labeled TRANSFORMER to ON. This will activate the power supply. 5. Set the breaker labeled LIGHT to ON (if applicable). 6. Find the breaker labeled 120V FOR 24V POWER SUPPLY. Switch the 24V breaker to ON. TESCO CORPORATION, TON HMIS 475HP REV 3 28

39 INSTALLATION GUIDE SYSTEM INSPECTION AND START UP 7. Set the breaker labeled ENGINE HEATER to ON, then check the operation of the heater. Note: If ambient temperatures are below 32 Fahrenheit (0 Celsius), run the engine heater for four hours before you start the prime mover. 8. Set the breaker labeled COOLING FAN to ON. 9. Use the cooling fan on/off switch to activate the fan briefly. Check the fan for proper rotation. Note: If the cooling fan does not rotate in the required direction, then the incoming phases of the power supply must be switched. First, SHUT OFF THE MAIN POWER SUPPLY, then switch two of the incoming power phases at the incoming fuses of the main panel.! Caution: If you switch the phases, ensure the incoming power cables are correctly labeled. 10. Check the oil level in the hydraulic oil storage tank. 11. Ensure that any required hydraulic oil valves are in the open position. 12. Briefly activate the auxiliary pump (use the AUX PUMP switch). 13. Listen for correct operation. Note: If the pump does not operate properly, check for correct rotation of the pump. Monitor the motor-to-pump coupler to confirm the direction of rotation. 14. Ensure that the lines for the auxiliary supply and case drain return are connected to the top drive. Note: If you connect the auxiliary supply and return lines to the top drive, you can test the system by connecting the supply and return jumpers to the hose reel. 15. Set the auxiliary pump 3-position switch to HAND; this will turn the auxiliary pump ON. 16. Ensure that the flow meter near the oil cooler is registering flow. 17. When electrical power connection has been confirmed, continue with the procedure for starting the prime mover. Prime Mover Before You Start the Prime Mover 1. Ensure the supply lines for the air and rig fuel are connected to the prime mover. 2. Check the oil level for the engine. 3. Check the oil level for the pump drive. 4. Check the coolant level.! Caution: Only check the coolant level when the engine is cold. 5. Ensure that the valves on the suction line from the hydraulic oil tank to the charge pumps are open REV 3 250TON HMIS 475HP TESCO CORPORATION,

40 SYSTEM INSPECTION AND START UP INSTALLATION GUIDE 6. Connect the supply and return hoses for the closed-loop system to the top drive.! Caution: Ensure that all isolation valves are open. 7. Use the Kill/E.S.D. (Emergency Shut Down) button at the driller s panel to test the operation of the rig savers.! Caution: After you test the rig savers, reset them to the fully open position. How to Start the Engine 1. At the driller s panel, set the MODE switch to CONN. Note: The prime mover will start to operate at low rpm. 2. Start the prime mover engine by using one of the following procedures. Caterpillar Engines 1. Engage the air starter for one short burst (approximately three seconds). Note: Do this to ensure that the unit will turn over easily. 2. Hold the manual shut-off knob in the RUN position. Note: The knob is located on the left side of the engine above the air starter. 3. Engage the air starter until the fuel charge pressure gage indicates that pressure is present. 4. With the shut-off knob in the RUN position, press the air starter and hold it until the engine starts. Note: If the engine does not start in ten seconds, release the air starter and try again. If, after three attempts, the engine does not start, refer to the Maintenance Guide and the Troubleshooting Guide for your unit. Detroit Diesel Engines 1. Engage the air starter for one short burst (approximately three seconds). Note: Do this to ensure that the unit will turn over easily. 2. Engage the air starter until the charge pressure gage indicates that pressure is present. 3. Turn the POWER switch to ON. The POWER switch is located on the Detroit Operator's Panel. 4. Monitor the red and yellow lights.! Caution: These lights will extinguish when the unit is ready to start. Do not start the unit until these lights are extinguished. 5. When the lights extinguish, press the air starter and hold it until the engine starts. Note: If the engine does not start in ten seconds, release the air starter and try again. If, after three attempts, the engine does not start, refer to the Maintenance Guide and the Troubleshooting Guide for your unit. TESCO CORPORATION, TON HMIS 475HP REV 3 30

41 INSTALLATION GUIDE SYSTEM INSPECTION AND START UP After the engine is running, perform the following steps. 1. Check the fuel charge pressure.! Caution: If, after 30 seconds of operation, the charge pressure fails to rise to psi, deactivate the engine. Refer to the Maintenance Guide and the Troubleshooting Guide for your unit for information on charge pressure. 2. Check the closed-loop system for leaks. Closed-Loop Hydraulic System Use the following procedure to test the close-loop hydraulic system. 1. Start the prime mover according to the previous procedures. 2. Go to the driller s panel. 3. Ensure that the quill on the top drive is unobstructed. Note: Ensure that personnel are clear of the top drive. 4. Set the MODE switch to DRILL. Note: The prime mover should increase to the maximum rated speed (approximately 2100 rpm). 5. Set the MODE switch to CONN. Note: The idle speed of the engine should decrease. 6. Set the PUMPS REV/FWD switch to FWD.! Caution: The MODE switch must be set to CONN. Note: The quill should begin rotating at rpm. 7. Use the remote pressure gauge at the driller s panel to monitor the loop pressure. Note: This pressure should be between psi. If the loop pressure rises above 700 psi, set the PUMPS REV/FWD switch to neutral, then check the quill for obstruction. If no obstruction is observed, ensure all valves are in the proper position. Note: In cold weather, the oil will be more viscous, which might cause the loop pressure to rise above normal. 8. The top drive should now be rotating at Connect-Forward speed. Go to the power unit. 9. Check the flow meters for the closed loop (2). Note: All values on the meters should be within 5% of each other. 10. Ensure that the reservoir level for the hydraulic oil remains adequate. 11. Return to the driller s panel. 12. Set the PUMPS REV/FWD switch to neutral. 13. Set the MODE switch to DRILL (low speed). 14. Set the PUMPS DECR/INCR switch to DECR and hold this position for ten seconds. Note: If the speed setting for the pumps has been left at a high rpm, this will reduce the speed to a safe level. 15. Set the PUMPS REV/FWD switch to FWD REV 3 250TON HMIS 475HP TESCO CORPORATION,

42 SYSTEM INSPECTION AND START UP INSTALLATION GUIDE 16. Use the PUMPS DECR/INCR switch to increase the speed in small increments until the quill begins to rotate slowly. 17. When proper quill operation is confirmed, turn the PUMPS REV/FWD switch to neutral. 18. Remove the cover from the tank level switch. Note: This allows you to access the float-activated micro-switch for the tank level. 19. Operate the switch by hand. Note: This switch should interrupt the fuel supply to the prime mover. If the switch works properly, then the wiring for the following emergency shutdowns is correct and working: low oil reservoir level shutdown high loop temperature shutdown (>190 F)(>88 C) high tank temperature shutdown (>165 F)(>74 C) 20. Verify that the automatic cooling fan is functioning properly. Top Drive Robotic Functions Test the robotic functions for the top drive before you start drilling operations. 1. Start the auxiliary pump at the power unit. 2. Check the meter for the return flow. Note: The return flow should be approximately 6 gpm. 3. Make a note of the circulating pressure. Note: Circulating pressure is valuable information for troubleshooting. 4. Go to the driller s panel. 5. Use the AUX PUMP switch to select OFF, then select ON. Note: Confirm that the control for the auxiliary pump at the driller s panel is functioning properly. 6. Use the controls at the driller s panel to test all robotic functions for correct operation. TESCO CORPORATION, TON HMIS 475HP REV 3 32

43 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 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 disconnected from the top drive. 3. Disconnect the top drive from the extend frame. 4. Hoist the top drive. 5. Position the top drive handling frame over the hole center. 6. Lower the top drive into the handling frame and pin it in place. 7. When the top drive is secured properly in the handling frame, use the chain tongs to disconnect the swivel connection. 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 REV 3 250TON HMIS 475HP TESCO CORPORATION,

44 RIG OUT PROCEDURE INSTALLATION GUIDE 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. See Remove the Top Drive on page 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. 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) 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 for each section of torque track. TESCO CORPORATION, TON HMIS 475HP REV 3 34

45 INSTALLATION GUIDE RIG OUT PROCEDURE 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 1. Connect a sling to the hose saddle. 2. Connect the sling on the hose saddle to the floor tugger. 3. Raise the floor tugger until it takes the weight of the hose saddle. 4. Remove the hanging sling for the hose saddle and the safety line. 5. Use the floor tugger to lower the hose saddle and service loop to the rig floor. 6. Use the hose reel controls to reel in the hydraulic hoses as they are lowered. 7. When the saddle reaches the rig floor, stop lowering and spooling. 8. Remove the service loop elements from the capture clamp. 9. Use tape or paint to mark all hoses where they were held by the capture clamp. Note: If you reinstall the top drive on the same mast, use these markings to position the capture clamp before you install the hanging saddle in the mast. 10. Continue to spool the service loop onto the hose reel. Note: Ensure that the ends of all cables and hoses are clean and properly protected.! Caution: Do not store multi-conductor cables on the hose reel REV 3 250TON HMIS 475HP TESCO CORPORATION,

46 RIG OUT PROCEDURE INSTALLATION GUIDE Figure 5-1: Service loop removal 11. Disconnect the control cable from the driller s panel and spool it onto a separate reel. 12. Disconnect the second control cable from the driller s panel. This control cable comes from the power unit. 13. Remove the interlocks from the mud pumps and drawworks (if applicable), and disconnect the interlock cables from the driller s panel. 14. Remove the driller s panel from the rig floor. Note: Wrap or box the driller s panel before putting it into storage. This will help prevent damage to switches and meters. 15. Disconnect the all quick-connectors for the cooling system that run between the mechanical and power modules. TESCO CORPORATION, TON HMIS 475HP REV 3 36

47 INSTALLATION GUIDE RIG OUT PROCEDURE REMOVE THE POWER UNIT The power unit may be moved in its assembled state (on a bed truck, for example), or you may dismantle it for alternative methods of shipping. Use the following procedure to separate the power unit components. 1. Close all isolator valves. 2. Disconnect the suction lines that lead to the pump drive. Note: Disconnect these at the hammer unions. Use a basin or absorbent pads to catch any fluid that might spill. 3. Turn off all electrical breakers. 4. Disconnect all air and fuel lines. 5. Disconnect any shutdown connections between the pump drive and the filter manifold/oil reservoir. 6. Remove the bolts that connect the sections of the power unit. 7. Secure all hoses and loose items to the power unit. Note: Ensure that no loose parts can fall or catch under the skid during transport REV 3 250TON HMIS 475HP TESCO CORPORATION,

48 RIG OUT PROCEDURE INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 38

49 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, and 3 Top Drive Power Unit Service Loop Transportation stand Main Frame Gearbox Gearbox oil level Rineer/manifold Top Drive hoses Auxiliary system (11-Station Manifold and solenoids) Mudsaver valve Link Tilt cylinders Prime mover Pump drive Pumps Filter manifold Flow meters AC distribution center/control panel System fittings Auxiliary pump and motor Cooling fan/oil cooler Re-circulation pump Oil tank Oil tank level Return filters (top of tank) High pressure plumbing Tranter plate exchangers Hose hanging saddle Urethane inserts Hose reel Hose reel control Slings, shackles, and safety pins REV 3 250TON HMIS 475HP TESCO CORPORATION,

50 PRE-INSTALLATION CHECKLIST INSTALLATION GUIDE Component Description Date Initials Driller s Panel Auxiliary hoses Main Fluid Hoses (750 hp) Main Fluid Hoses (1205 hp) Other Cables Other Cables Torque Arrest System Instrumentation Switches Connectors Internal wiring 1 x 225 ft. auxiliary return hose (1-1/4 in.) 1 x 225 ft. auxiliary supply hose (3/4 in.) 2 x 10 ft. auxiliary jumper hoses (1 in. - R2) 2 x 225 ft. 5,000 psi hose (2 in.) 2 x 15 ft. 5,000 psi hose (2 in.) 4 x 225 ft. 5,000 psi hose (2 in.) 2 x 15 ft. 5,000 psi hose (2 in.) 2 x 160 ft. 37C robotics control cable 1 x 225 ft. 37C robotics control cable 1 x 225 ft. 18 TP motor sensor cable 1 x 225 ft. blower motor/heater cable 3 x 225 ft. motor power cables 1 x 225 ft. motor ground cable 2 x 8 ft. 18/4 mud pump interlock cable 2 x 8 ft. 18/4 drawworks interlock cable 2 x 8 ft. 18/4 splitter box cable Extend frame Torque bushing Torque beam and T-bar Torque track Hanging sling assembly TESCO CORPORATION, TON HMIS 475HP REV 3 40

51 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 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. Table B-1: Top drive inspection list Component Activity Steps Quill Inspect the listed components. 1. Quill 2. Ringfeder/locking segments to gearbox 3. Load nut and locking pins 4. Mudsaver 5. Load collar stops (set) 6. Saver sub 7. Locking clamps High Pressure Closed Loop Hydraulics Inspect the listed components. 1. Motor manifold 2. Hydraulic hoses (ensure all are in the correct place) 3. All flange bolts on the high pressure piping 4. Rineer motor fluid connections 5. Lines and hammer unions for the high pressure service loop 6. Safety sling or chain (ensure it is installed) Grabber Inspect the listed components. 1. The safety chain is installed. 2. All drilled bolts are safety wired. 3. Hoses are installed and routed correctly. Extend Frame Mount Inspect all pins and bolts. 1. Check for missing fasteners. 2. Check the ears on the extend frame for damage. Robotics Inspect the listed components Station manifold Station manifold 2. Solenoids and wiring 3. Auxiliary hydraulic hosing 4. 37C control cable 5. All fittings (for tightness and correct engagement) Gearbox Inspect the listed items. 1. Check for leaks. 2. Check the oil level REV 3 250TON HMIS 475HP TESCO CORPORATION,

52 VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE Table B-2: Power unit inspection - cable reel/service loop Component Activity Steps Reel Lock Inspect Ensure the reel lock is locked into position. Valves Open Ensure all the required valves are in the OPEN position. Service Loop Protection Inspect Ensure all wear points are protected and secure. Service Loop Inspect cables and hoses. Inspect cables and hoses for the following: cuts abrasions signs of stretching Service Loop Terminations Inspect connectors and fittings. 1. Inspect connectors for damage to the pins. 2. Ensure that all pin connectors are correctly seated. 3. Check the threads on all brass fittings. 4. Ensure that all connectors are clean and free of moisture. Table B-3: Power unit inspection - oil cooler Component Activity Steps Cooling Core Inspect Ensure the cooling core is clear and undamaged. Fan/motor Inspect 1. Ensure the guard is in place. 2. Ensure all parts are secure. Table B-4: Power unit inspection - oil storage tank Component Activity Steps Valves Inspect Ensure all valves are set to the correct position. Return Filters Inspect Ensure all filters are in place. Table B-5: Power unit inspection - filter manifold headers Component Activity Steps All Inspect 1. Ensure there are no visible leaks. 2. Ensure all equipment is in place and secure. TESCO CORPORATION, TON HMIS 475HP REV 3 42

53 INSTALLATION GUIDE VISUAL INSPECTION CHECKLISTS Table B-6: Power unit inspection - pump drive/pumps Component Activity Steps Pump Drive Inspect Check the oil level. All Inspect Ensure all equipment is in place and secure. Table B-7: Power unit inspection - electrical panel Component Activity Steps All Inspect 1. Ensure all wiring is in place. 2. Ensure all terminal connections are tight. 3. Check for moisture and remove if necessary.! Danger! Only qualified electrical personnel should check electrical equipment. Table B-8: Power unit inspection - prime mover Component Activity Steps Cooling/Radiator Inspect 1. Ensure there are no visible leaks or damage. 2. Check the coolant level. 3. Check all fan belts and drive belts. Engine Inspect 1. Check the oil level. 2. Ensure that the exhaust system is in place and tightly connected. 3. Ensure the fuel line is in place and correctly connected. Starter Inspect Ensure the air line is in place and correctly connected. Table B-9: Driller s panel Component Activity Steps Driller s Panel Inspect panel and connectors. 1. Inspect all switches. 2. Ensure all switches are in the neutral position. 3. Inspect all instrumentation. 4. Inspect all connectors. 5. Ensure that all the cords are operational. 6. Activate the heat tape if there is moisture in the panel REV 3 250TON HMIS 475HP TESCO CORPORATION,

54 VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE TESCO CORPORATION, TON HMIS 475HP REV 3 44

55 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/ ,200 1, ¼ 1, ,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, ,700 12,500 33,400 28,900 23,600 16, /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, /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, /8 45,200 33,900 90,400 78,300 63,900 45,200 1 ¾ 52,000 39, ,000 90,000 73,500 52, /8 60,800 45, , ,300 86,000 60, ,600 50, , ,100 95,600 67,600 2 ¼ 84,000 63, , , ,800 84,000 2 ½ 104,000 78, , , , , REV 3 250TON HMIS 475HP TESCO CORPORATION,

56 SLING LOAD RATINGS INSTALLATION GUIDE Table C-1: Maximum safe working loads (pounds) 2 ¾ 122,000 91, , , , ,000 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% TESCO CORPORATION, TON HMIS 475HP REV 3 46

57 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 Line Tap fist on head, then use regular signals. Use Whip Line Tab elbow with one hand, then use regular signals. Raise Load Lower Load REV 3 250TON HMIS 475HP TESCO CORPORATION,

58 HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE Table D-1: Hand signals for boom operation This Signal Means This Raise Load Slowly Lower Load Slowly Raise Boom Lower Boom Raise Boom and Lower Load Extend thumb upward and flex fingers in and out as long as load movement is required. Lower Boom and Raise Load Extend thumb downward and flex fingers in and out as long as load movement is required. Swing Extend arm. Use forefinger to indicate direction of swing. TESCO CORPORATION, TON HMIS 475HP REV 3 48

59 INSTALLATION GUIDE HAND SIGNALS FOR BOOM EQUIPMENT OPERATION Table D-1: Hand signals for boom operation This Signal Means This Stop Extend 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 REV 3 250TON HMIS 475HP TESCO CORPORATION,