Installation Guide HCI(S) Top Drive System 500/650T HCI(S) 750/1205HP DOCUMENT NAME: 880002 REV A This page has been left blank intentionally . 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 © 2004 Contact Information Corporate Head Office 6204 - 6A St. S.E. Calgary, AB T2H 2B7 Canada www.tescocorp.com Telephone: (403) 233-0757 Fax: (403) 252-3362 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 III REVISION INFORMATION INSTALLATION GUIDE Revision Information Version Date Description of Changes Rev A HCI(S) release of manual version compiled in FrameMaker 31 March 2004 ©TESCO CORPORATION, 2004 IV 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE TABLE OF CONTENTS TABLE OF CONTENTS Chapter 1: About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chapter 2: Pre-Installation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rig Installation and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power/Service Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Equipment Inspection (Pre-installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 3: Rig Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Equipment Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Optimal Placement of the Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How to Place of the Power Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Optimal Placement of the Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 How to Install the Hose Hanging Saddle and Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Before You Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Torque Arrest System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Torque Arrest System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 How to Determine the Torque Track Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Sample Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 How to Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Before You Install the Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 How to Install the Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 How to Set the Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 How to Install a Counter-Balance Block Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 How to Install the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Driller's Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 How to Install the Driller’s Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Safety Air Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 How to Install the Drawworks Interlock and Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 About the Mud Pump Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Chapter 4: System Inspection and Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspection-General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 V TABLE OF CONTENTS INSTALLATION GUIDE Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 System Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Power Unit: Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 How to Start the Electrical System for the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Before You Start the Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 How to Start the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Closed-Loop Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 How to Make up the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Top Drive Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Chapter 5: Rig Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 How To Break the Top Drive/Swivel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 How to Break Difficult Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 How to Use the Breakout Function to Break Difficult Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 How to Use Heat to Break the Top Drive/Swivel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Alternative Breakout Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 How To Remove the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 How to Remove the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 How To Remove the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 How to Remove the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Appendix A: Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B: Visual Inspection Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C: Sling Load Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Appendix D: Hand Signals for Boom Equipment Operation . . . . . . . . . . . . . . . . . . . . . D-1 ©TESCO CORPORATION, 2004 VI 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE CHAPTER 1: ABOUT THIS DOCUMENT This document contains information on how to install the Hydraulic Compact Integrated (HCI(S)) 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 include the following: • • • • • • • • • perform a pre-installation assessment and equipment check place equipment install the service loop and connecting 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 • • • • 880002 REV A Maintenance Guide Tesco manufactured parts and part numbers Parts List troubleshooting Troubleshooting Guide (where available) electrical schematics hydraulic schematics cooling schematics gearbox lubrication schematics System schematics available options and spares Tesco Representative 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 1 ABOUT THIS DOCUMENT INSTALLATION GUIDE This page has been left blank intentionally . ©TESCO CORPORATION, 2004 2 500/650T HCI(S) 750/1205HP 880002 REV A 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 • counter-balance system • components and subs (top drive to drill string, top drive to swivel) • service connection lengths and specific accessories • air/electric safety interlocks • torque arrest system components • hose saddle hanging requirements • mud hose extension and 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 The following figures illustrates the connection considerations to address before the top drive system arrives on location. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 3 PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE Figure 2-1: Power, Air and Fuel Connections - Option 1 1.Generator 1 2.Generator 2 3.Generator 3 4.SCR/Master Control Centre 5.Possible fuel location 6.Typical air location 7. Possible standpipe location 8. V-door 9. Power unit 10.Possible power unit placement 11.Optional power unit placement 12.Probable location for cable protection Figure 2-2: Power, Air and Fuel Connections - Option 2 1.Generator 1 2.Generator 2 3.Generator 3 4.SCR/Master Control Centre 5.Possible fuel location 6.Typical air location ©TESCO CORPORATION, 2004 4 7. Possible standpipe location 8. V-door 9. Power unit 10.Possible power unit placement 11.Optional power unit placement 12.Probable location for cable protection 500/650T HCI(S) 750/1205HP 880002 REV A 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 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. • For the 1205 hp prime mover, maximum consumption is 60 gallons (U.S.) per hour (227 litres per hour) • For the 760 hp prime mover, maximum consumption is 45 gallons (U.S.) per hour (170 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. 4. Install fuel return lines should be installed to return circulated fuel to the tank. Air Considerations 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 5 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, 2004 6 500/650T HCI(S) 750/1205HP 880002 REV A 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: HCI Optimal Equipment Placement 1.Generator 1 2.Generator 2 3.Generator 3 4.SCR/Master Control Centre 5.Possible fuel location 6.Typical air location 880002 REV A 7. Possible standpipe location 8. V-door 9. Power unit 10.Possible power unit placement 11.Optional power unit placement 12.Probable location for cable protection 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 7 RIG UP PROCEDURE INSTALLATION GUIDE 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. How to Place of 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. Using a crane or loader, place the prime mover on the rig matting. Note: The prime mover is heavier and more difficult to manoeuvre than the mechanical module, so it should be placed first. The prime mover side of the power unit is normally placed away from the hose saddle. The reel side of the power unit is normally placed towards the hose saddle. 4. Place the filter, cooling, fuel storage and hose reel sections where required. 5. If necessary, install bolts to secure all skids. Note: Units send to locations in North America might be assembled prior to shipment. 6. Connect the following items: Connect This From Here To Here Engine shutdown cables (after the sections are assembled) Power unit section Power unit section 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) 7. 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. ©TESCO CORPORATION, 2004 8 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 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 [[65 ft.-75 ft. (19.8m-22.9m) above the rig floor if the mast height is 130 ft.-145 ft. (39.6m-44.2m)], • 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. Note: Attach protective equipment to any points that might be subject to wear during top drive operations. Figure 3-2: HCI Hose Saddle Placement Service Loop Approximately 75 ft. (22.86 m) between the top drive and the capture clamp for the hose saddle Hose Saddle Mounted 65-75 ft. (19.81-22.86 m) above the drill floor (depending on the height of the racking platform and the length of the sling) Standpipe Hose Power Unit Located on the 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 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 9 RIG UP PROCEDURE INSTALLATION GUIDE 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 3,000 lbs. 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. 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. 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. 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 hose saddle capture clamp. ©TESCO CORPORATION, 2004 10 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE Figure 3-3: HCI Hose Saddle Capture Clamp Configurations 1. Hydraulic supply/return line 2. Case drain/auxiliary return line 3. 37 multi-conductor cable 4. Auxiliary hydraulics supply line 5. Hydraulic supply/return line An additional set of inserts is used to accommodate the additional hydraulic supply and return lines. Table 3-1: HCI - Cable and Hoses for 1205 HP Prime Movers Quantity Description 4 2 in. high pressure closed loop hoses (2 supply, 2 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 Table 3-2: HCI - Cable and Hoses for 750 HP Prime Movers Quantity Description 2 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 11 RIG UP PROCEDURE INSTALLATION GUIDE Figure 3-4: Hoisting the Hose Saddle Figure 3-5: Position the Hose Saddle 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 3,000 lbs (1360.8 kg). 10. Use the floor tugger or crane to lower the saddle until the weight transfers to the hanging sling. ©TESCO CORPORATION, 2004 12 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 13 RIG UP PROCEDURE INSTALLATION GUIDE 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 20,000 lb. (9,072 kg) plus the recommended safety factor for overhead equipment). The pad eye is typically placed 29 in. (73.66 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 are 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: • one 18.5 ft. (5.6m) top section with an adjustable pinned insert or adjustable cable sling hanging assembly • 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 The total length of the torque track sections is 145 ft. (44.2m). Obtain additional length (one 8 ft. (2.4m) section) by lengthening the top-section pinned insert or cable sling. Purchase additional torque track sections to accommodate larger masts. The following two sections of torque track are also included: • one 1.3 ft. (.4m) deflector section (bull nose) • one 2 ft. (.6m) 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. ©TESCO CORPORATION, 2004 14 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 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. (.8m) minimum to 11 ft. maximum (3.4m)) Note: Shorter configurations are safer and more practical. • the location of any upper strongback that may interfere with the vertical hanging of the torque track Figure 3-6: Torque Arrest System Configuration How to Determine the Torque Track Configuration Sketch and calculate the following on paper before you connect sections of torque track. 1. Place the bottom of the deflector section 9 ft.-10 ft. (2.7m-3.0m) 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.-11 ft. (1.5 m-3.4 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 calculation. 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 15 RIG UP PROCEDURE INSTALLATION GUIDE Sample Calculation If the mast height is 142 ft. (43.3m): 1. 142 ft. less 9 ft. (2.7 m) (height above rig floor for deflector section) = 133 ft. (40.6 m) 2. 133 ft. less 2.5 ft. (.76 m) (minimum hang assembly length) = 130.5 ft. (39.8 m) 3. 130.5 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 1 18.5 18.5 Standard Tracks 4 74 (18.5 x 4) 92.5 10 ft. section 1 10 102.5 5 ft. section 1 5 107.5 *Bolted section 1 18.5 126 Deflector 1 1.3 127.3 Pinned Section Length or Hanging Assembly 1 Set to 6 feet 133.3 142 (mast height) - 133.3 = 8.7 feet above the rig floor) *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 3-7 on page 19 and Figure 3-8 on page 20. 1. Ensure the hanging pad-eye for the torque track is installed in the crown. Note: Normal placement for a standard track is 29 in. back from the crown cluster 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 a 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 12 ft. and 18 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. ©TESCO CORPORATION, 2004 16 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 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 hanging assembly carries the total weight of the torque track. 6. Use the calculation method described in “How to Determine the Torque Track Configuration” on page 15 to calculate the required torque track section configuration. Note: When the torque track is suspended, the bottom of the deflector section should be 9 ft. off the floor. 7. When the rig-up for the torque track sections is determined, set and secure the calculated pinned insert location, or adjust the hanging assembly to the appropriate length. 8. Bolt the top section of torque track to the second section of torque track. 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, consult with a Tesco representative before installation. 9. Use the rig floor tuggers to hoist the first track section up to the floor. 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. 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. 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. Install all the studs and lower nuts before you connect the sections. Note: You cannot install the studs after the track sections are connected. 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 17 RIG UP PROCEDURE INSTALLATION GUIDE 21. Torque the bolts to 350 ft·lbs. 22. Repeat steps 17.–21. 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. 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, 29 in. back from the hole centre. 33. Tighten the lock nut on the hanging assembly. 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 traveling equipment and swivel are attached to the blocks · the counter-balance system is installed 35. Install stabilization systems. Note: Install stabilization mechanisms on all available strongback beams.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 illustrations starting on the following page. ©TESCO CORPORATION, 2004 18 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE Figure 3-7: Torque Arrest System - Permanent Installation 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 19 RIG UP PROCEDURE INSTALLATION GUIDE Figure 3-8: Torque Arrest System - Portable Installation If your rig set-up requires a customized stabilization installation, contact Tesco. ©TESCO CORPORATION, 2004 20 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE COUNTER-BALANCE SYSTEM Before You Install the Counter-Balance System Determine the following as part of the measurement/pre-installation activity: • the inside diameter of the clamp insert on the swivel bail • counter-balance block mounting method Figure 3-9: Inside Diameter of the Bail Clamp Insert Measure along this section to determine the inside diameter of the bail clamp insert. Use a block saddle or block plates (at owner's discretion) to mount the counter-balance system. The most common/most preferred method of mounting uses block plates. Mount these before the mast is raised or during top drive rig-up. To mount the counter-balance plates, you must drill and tap 12 holes (1 in. x 2-1/2 in. deep) in the block side plates. Caution: When you install the counter-balance cylinders, use shackles on both ends of the cylinders to connect them to the swivel bail clamps and the counter-balance hang plates. This prevents damage to the counter-balance cylinders under the following circumstances: If you extend the top drive quickly, or stop and start the traveling blocks quickly, this causes the blocks to “wave” back and forth in the derrick. This movement can break the clevises off the counterbalance cylinders. Shackles at both ends prevent this movement from damaging the cylinders. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 21 RIG UP PROCEDURE INSTALLATION GUIDE How to Install the Counter-Balance System Figure 3-10: Counter-Balance System Components 1. 8.5 ton shackle 2. Counter-balance cylinder 3. 8.5 ton shackle 4. Swivel bail clamp and insert 5. Counter balance block plate 6. If more length is required, add short slings or shackles here. Perform this procedure after the torque tracks and T-bar are installed and after the swivel is attached to the blocks. Note: If you intend to use block plates, you can mount them when the blocks are rigged down. See steps 4.–7. below. Caution: Modifications to the blocks should meet or exceed all safety specifications for the operating area and operating conditions. 1. Determine the position of the counter-balance swivel bail clamps. Note: Position the swivel bail clamps close to the centre of the swivel bail. If the clamps must be placed off centre, then a lower position is preferable. 2. Mount the swivel bail clamps. Note: Ensure that the bail clamp inserts are sized to match the bail diameter. 3. Attach an 8-1/2 ton shackle to both ends of the counter-balance cylinders. Caution: Always use shackles to attach the counter-balance cylinders to the block and the bail. Never use rigid connections. 4. Ensure the cylinders are in the fully retracted position. Measure the total length of cylinder/shackles assembly, then add 8 in. to determine the overall length. ©TESCO CORPORATION, 2004 22 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 5. Use this overall length to determine where to place the block plate. Note: Mount the block plates so that the cylinders hang vertically when they are attached to the swivel bail clamps. If the length of the cylinder/shackle assembly is not long enough to accommodate this placement, then attach short slings to the swivel end of the assembly. Incorrect Correct 6. Use a magnetic base drill to drill and tap six holes into each of the main side plates of the block: 1 in. in diameter and 2-1/2 in. deep. Note: If you are installing the counter-balance system by using a block saddle, see “How to Install a Counter-Balance Block Saddle” on page 25. 7. Attach the two block plates. Note: Determine the width of the side plates during rig measurement. If you receive wider plates, then drill and cut them to the required width on site. 8. Attach the top counter-balance shackles to the block plate. Note: Install the cylinders with the shaft end down. 9. Extend the counter-balance cylinders. 10. Attach the bottom counter-balance shackles to the swivel bail clamps. Note: You cannot complete the following portion of the counter-balance installation procedures until the top drive is installed, the hydraulic circuit is connected, and the driller's panel is operational. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 23 RIG UP PROCEDURE INSTALLATION GUIDE Figure 3-11: Counter-Balance System Interface 1. Accumulators: N2-Nitrogen and Oil 2. Counter-balance cylinder 3. Needle Valve 4. Auxiliary system quickcoupler How to Set the Counter-Balance Cushion Height 1. Connect the hydraulic hoses from the counter-balance manifold on the torque bushing to both counter-balance cylinders. Note: The top drive must be hoisted to the racking platform before the following steps can be executed. This is to ensure that the weight of the mud hoses and service loop are added to the weight of the top drive. 2. Connect the hydraulic hose for the elevator-open circuit to the counter-balance charge hose on the torque bushing. 3. Shut off the auxiliary pump. 4. At the driller’s panel, turn the ELEVATOR switch to CLOSE. 5. Open the needle valve on the counter-balance manifold. Note: This relieves all pressure on the counter-balance system. 6. Check the nitrogen pressure in the counter-balance accumulators. Note: The accumulators must be charged to 1200 psi. Caution: Ensure the counter-balance relief valve is set at 1800 psi. 7. Close the needle valve on the counter-balance manifold. 8. Start the auxiliary pump. 9. Open the elevators. At the driller’s panel, push and hold the ELEVATOR SAFETY OPEN button, and turn the ELEVATOR switch to OPEN. 10. Open the needle valve and monitor the swivel bail and becket. 11. Continue to increase pressure to the counter-balance system until the counter-balance cylinders lift the swivel bail 1-1/2 in. to 2 in. above the becket. 12. Close the needle valve. 13. At the driller's panel, turn the AUX PUMP switch to OFF. 14. At the driller's panel, cycle the ELEVATOR switch to OPEN, then to CLOSE. Note: This relieves any pressure in the system. ©TESCO CORPORATION, 2004 24 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 15. Remove the charge hose for the elevator from the counter-balance manifold. 16. Reconnect the hydraulic hose for the elevator to the quick-connect coupler on the elevator. 17. Lower the top drive. How to Install a Counter-Balance Block Saddle Block saddles are not permanently attached to the block. They are assembled using the following procedure. 1. Lift the top section of the block saddle and place it on top of the blocks. 2. Attach slings to the to the four end lugs on the block saddle. Note: Use 4-3/4 ton shackles to attach the slings. 3. Install a crossbar on each side of the blocks. 4. Attach two slings to each crossbar. 5. Attach the counter-balance cylinders to the crossbar lugs using 8-1/2 ton shackles. Figure 3-12: Counter-Balance Block Saddle 1. Block saddle on top of the blocks, Step 1 2. Attach slings to the lugs, Step 2 3. Install a crossbar and attach slings, Steps 3 and 4 4. Front view of the blocks 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 25 RIG UP PROCEDURE INSTALLATION GUIDE TOP DRIVE How to Install the Top Drive Caution: Before you move the top drive onto the rig floor, ensure the following conditions exist: · The swivel is attached to the blocks. · The counter-balance hardware is installed. 1. Use the blocks or a crane to move the top drive to the rig floor. Note: If you use the blocks, 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. 2. Position the top drive over the hole centre. 3. Lower the swivel. 4. Check for proper thread matching between the top drive and the swivel. Apply thread compound for tool joints to all threaded connections. Note: A cross-over sub is required. Determine the required sub when completing the rig measurement package. 5. Use hand tongs to join the top threaded connection of the top drive to the swivel. Note: This is a left-handed thread connection. For more information on making up the swivel, refer to “How to Make up the Swivel ” on page 36. Caution: The connection between the top drive and the swivel is not torqued at this point. To perform this step, both the drive system and driller's panel must be operational. Warning! Do not move the traveling blocks up and down in the derrick until the connection between the top drive and the swivel is properly torqued. Note: See also “How to Install the Driller’s Panel” on page 27. 6. Raise the blocks to support the weight of the top drive. Warning! Do not lift the top drive off the floor. 7. Remove the pins from the handling frame of the top drive (four in total). 8. Lift the top drive until it is clear of the handling frame. 9. Use the floor tugger to remove the handling frame from the rig floor. 10. Apply a thin film of Never-Seez™ or grease to all pins. 11. Use the blocks to position the top drive so that it joins with the extend frame. Note: Align the ears on the top drive with the arms on the extend frame and pin them in place. 12. Remove the pin that holds 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. 13. Lower the top drive to the rig floor. 14. Reposition the T-bar so the top drive sits over hole centre, then secure it in place (if required). ©TESCO CORPORATION, 2004 26 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 15. Fully torque the T-bar clamp to secure the T-bar in position. 16. Locate the service loop. Note: The service loop should be attached to the hand rail. If the service loop has not been installed, see “How to Install the Hose Hanging Saddle and Service Loop” on page 10. 17. Join the following cables and hoses for the service loop to the top drive. • supply and return hoses for the closed loop hydraulic system (there will be 2 or 4, depending on the type of prime mover you have) • supply hose for the auxiliary hydraulic system • return hose for the case drain and auxiliary hydraulic system • 37C multi-conductor control cable 18. After all hoses and cables for the service loop are attached, check the position of the service loop. 19. Check all hose connections again. 20. Ensure that all the required valves are in the open position. 21. Torque the connection between the top drive and the swivel to the required specification. Note: The driller’s panel must be active and the power unit must be operational before you can perform this step. See “How to Install the Driller’s Panel” on page 27. 22. When the top drive and driller's panel are connected, continue with additional setup procedures, or begin rig commissioning. 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 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 27 RIG UP PROCEDURE INSTALLATION GUIDE 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). SAFETY AIR INTERLOCKS 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 3-13: 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. ©TESCO CORPORATION, 2004 28 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG UP PROCEDURE 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 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. 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. Caution: The mud pump interlock is not used with pumps that are driven by traction motors. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 29 RIG UP PROCEDURE INSTALLATION GUIDE This page has been left blank intentionally . ©TESCO CORPORATION, 2004 30 500/650T HCI(S) 750/1205HP 880002 REV A 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 cable cable/hose reel driller’s panel WARNINGS • Install a saver sub in the grabber on the top drive before you test for hydraulic leaks or operate any robotics function. • Before starting any pumps, ensure that all appropriate valves on tanks and pumps are open. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 31 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 detailed 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 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 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 • motor for the re-circulation pump 4. Check the skid transformer on the power unit for damage. 5. Set the breaker labeled TRANSFORMER to ON. This will activate the power supply. 6. Set the breaker labeled LIGHT to ON (if applicable). 7. Find the breaker labeled 120V FOR 24V POWER SUPPLY. Switch the 24V breaker to ON. 8. Set the breaker labeled ENGINE HEATER to ON, then check the operation of the heater. Note: If ambient temperatures are below 0°C, run the engine heater for four hours before you start the prime mover. ©TESCO CORPORATION, 2004 32 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE SYSTEM INSPECTION AND START UP 9. Set the breaker labeled TANK HEATER to ON. Note: Hydraulic oil should be heated to a minimum of 12°C before you operate the top drive. If ambient temperatures are below 10°C, keep the heater for the oil tank running during top drive operations. 10. Set the breaker labeled COOLING FAN to ON. 11. 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. 12. Check the oil level in the hydraulic oil storage tank. 13. Ensure that any required hydraulic oil valves are in the ‘open’ position. 14. Briefly activate the auxiliary pump (use the AUX PUMP switch). 15. 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. 16. 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. 17. Set the auxiliary pump 3-position switch to HAND; this will turn the auxiliary pump ON. 18. Ensure that the flow meter near the Modine cooler is registering flow. 19. 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. Ensure that all cooling lines for the gearbox are properly connected. 5. Check the coolant level. Caution: Only check the coolant level when the engine is cold. 6. Ensure that the valves on the suction line from the hydraulic oil tank to the charge pumps are open. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 33 SYSTEM INSPECTION AND START UP INSTALLATION GUIDE 7. Connect the supply and return hoses for the closed-loop system to the top drive. Caution: Ensure that all isolation valves are open. 8. 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, 2004 34 500/650T HCI(S) 750/1205HP 880002 REV A 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 280-400 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 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 14-18 rpm. 7. Use the remote pressure gauge at the driller’s panel to monitor the loop pressure. Note: This pressure should be between 400-500 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. 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 35 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) • high tank temperature shutdown (>165°F) 20. Verify that the automatic cooling fan is functioning properly. How to Make up the Swivel Before you make up (connect) the top drive and swivel, perform the following steps: • SET torque must be set to 35,000 ft·lbs (refer to the torque chart for your unit to determine the correct differential pressure). • Make up the rig tong to fit the swivel box. Caution: If the swivel box is larger than 6-5/8 in. Reg LH, then use the rig tongs to make up the connection between the swivel and the cross-over sub. Make up the connection at floor level. Caution: Ensure the connection is properly doped. 1. Use the tugger line to hoist the make-up tong to the same height as the swivel shaft (typically 12-15’ above the rig floor) 2. Attach a back-up sling from the make-up tong to a sturdy location in the derrick. Note: This sling absorbs the torque as the connection between the top drive and the swivel tightens. Ensure the anchor point is at the same elevation as the tong, and that the anchor point is secure. 1. Mast leg 2. Back-up sling 3. Hang sling 3. Make up the tong to the swivel box connection. ©TESCO CORPORATION, 2004 36 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE SYSTEM INSPECTION AND START UP 4. Use chains to secure the bottom of the top drive into position at floor height. Note: Attach the chains around the grabber leg only. It is not advisable to chain the quill. The chains prevent the top drive from moving when you apply torque to the connection between the swivel and the top drive. Chain the grabber leg only Note: It is also possible to secure the top drive using the following steps: a. Pick up a joint of heavyweight drill pipe. b. Use a saver sub to connect the drill pipe and the top drive. c. Set the pipe in the slips, low in the table. d. Ensure that the rotary table is free to turn. Figure 4-1: Making up the Swivel 1. Tugger line 2. Back-up sling 3. Tong 4. Top drive 5. Connect stabilization chains here, if required 6. Heavy weight drill pipe 5. Use the PUMPS–DECR/INCR switch to reduce the speed to 0 rpm. 6. Set the MODE switch to DRILL. 7. Set the PUMPS–REV/FWD switch to FWD. 8. Ensure that the make-up tong and other equipment are positioned correctly. 9. Move all personnel to safe areas, well away from any moving equipment. Allow only essential personnel on the rig floor. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 37 SYSTEM INSPECTION AND START UP INSTALLATION GUIDE 10. Use the PUMPS–DECR/INCR switch to slowly increase the speed. Pressure will rise as the speed increases. Warning! If the connection does not progress properly, turn the PUMPS–REV/FWD switch to the neutral position. 11. Monitor the differential torque gauge. 12. When the pressure rises enough to generate 35,000 ft·lbs of torque, set the PUMPS–REV/FWD switch to the neutral position. 13. Allow the differential pressure to reduce to zero. 14. Remove the back-up sling, and lower the make-up tong. 15. Remove the top drive stabilization mechanism (chains, heavy weight drill pipe or both). 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, 2004 38 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE CHAPTER 5: RIG OUT PROCEDURE The top drive rig-out (removal) procedure is divided into the following separate activities: • • • • • break out the top drive/swivel connection remove the top drive remove the torque arrest system remove the service loop prepare the power unit Refer to the following section, “How To Break the Top Drive/Swivel Connection”, for information on how to remove the top drive from the rig floor. 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. HOW TO BREAK THE TOP DRIVE/SWIVEL CONNECTION This procedure is not required if the optional integrated swivel is installed. It is best to connect the top drive to a single length of heavy-weight drill pipe before you attempt to break out the connection between the top drive and the swivel. The heavy-weight pipe provides lateral stability for the top drive during break out. Lower the drill pipe as far as possible through the rotary table before you set the slips. Ensure that the rotary table is free to rotate. If heavy-weight drill pipe is not available, lower the top drive as far as possible and chain it in place to stabilize it. Caution: Before you begin this procedure, do the following: · set the torque and speed setting for Connect-Reverse mode · remove the elevators and elevator links 1. Set the back-up tong to fit the swivel crossover sub. 2. Attach a tugger line to the back-up tong. 3. Hoist the tong until it reaches the height of the crossover sub. 4. Attach a sling from the back-up tong to a secure point in the mast. Note: Ensure the sling attachment is at the same height as the back-up tong. This sling will absorb and transfer the torque back to the mast. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 39 RIG OUT PROCEDURE INSTALLATION GUIDE 5. Position the back-up tong on the swivel crossover sub. Figure 5-1: Breaking Out the Swivel 1. Tugger line 2. Back-up sling 3. Tong 4. Top drive 5. Connect stabilization chains here, if required 6. Heavy weight drill pipe 6. Set the MODE switch to CONN. 7. Set the PUMPS–REV/FWD switch to REV. 8. Allow the tongs to tighten on the crossover sub. 9. Ensure that all elements of the break-out apparatus function properly. 10. Push and hold the BREAKOUT button. 11. Monitor the pressure gauge for the differential pressure. The pressure should increase to the maximum available. 12. As soon as the connection loosens, release the BREAKOUT button and turn the PUMPS–REV/FWD switch to neutral. Caution: The connection should undo 1/4 to 1/2 turn of the sub only. Do not allow the swivel to disconnect any further than 1/2 turn. Note: Refer to “How to Break Difficult Connections” on page 41 if the connection does not loosen. 13. Remove the back-up tong from the crossover sub and lower it to the rig floor. 14. Remove the device used to stabilize the top drive (heavy-weight drill pipe, chains or both). ©TESCO CORPORATION, 2004 40 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG OUT PROCEDURE How to Break Difficult Connections How to Use the Breakout Function to Break Difficult Connections 1. If the top drive/swivel connection does not loosen after 15-20 seconds of breakout torque application, release the BREAKOUT button. 2. Allow the pumps to cool for 10 seconds, then try again. If the connection does not break on the fourth attempt, try heating the connection box on the top drive. If possible, heat the connection using steam. Refer to the following procedure for details. How to Use Heat to Break the Top Drive/Swivel Connection If normal breakout procedures fail, you might need to use heat to loosen the connection.Do not apply heat until after standard breakout procedures have been attempted. Danger! Use caution when using steam or other heat sources. Warning! Never heat the quill to temperatures higher than described in this procedure. Caution: The goal of this procedure is to warm the box connection quickly and evenly. This will cause the box connection to swell outward, away from the pin. If the warming procedure takes too long, heat will transfer from the box connection to the pin connection, and the connection will not loosen. 1. Ensure that you have all required tools. These include the following: • heating equipment (steam heat is preferred, however, a propane torch or welding torch with a ‘rosebud’ heating tip may also be used) • 300°F heat-sensitive marking pen 2. Ensure that the rig tongs are in the ready position. 3. Begin rotating the quill slowly (4-5 rpm). 4. Apply heat evenly from the bottom of the thread to the top of the box connection. See Figure 5-2 on page 42. Caution: Never hold the heat source in a single spot. Caution: Frequently check the metal temperature by using the heat pen. 5. Heat the quill until it is very warm (approximately 225-250°F above the ambient temperature). Warning! If the mark from the heat pen melts, stop heating immediately! Applying too much heat will severely damage the quill (the quill material will harden and become brittle). 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 41 RIG OUT PROCEDURE INSTALLATION GUIDE 6. Quickly initiate the standard breakout procedures when you reach the desired temperature. Warning! The mark from the heat pen will melt when the metal temperature reaches 300°F. NEVER continue heating after this temperature is reached. Figure 5-2: Top Drive/Swivel Connection 1. Cross-over sub 2. Quill 3. Box 4. Pin Heat the thickest part of the box connection (A), then work downward to the thinnest part (B). Heat the connection evenly. Alternative Breakout Method If no heat source is available, you can use the following procedure to break the top drive/ swivel connection. You can also use this procedure to break out the swivel if power to the top drive is not available. 1. Extend the top drive over the mousehole. 2. Lower the top drive so that the grabber rests on the rig floor. 3. Remove the lower lift cylinder pin on the grabber. 4. Disconnect the grabber open/close hydraulic lines at the grabber. 5. Ensure the ends of all hoses are clean and capped. 6. Hoist the top drive. Note: The disconnected grabber should be moved and stabilized immediately. 7. Disconnect the hydraulic lines to the grabber lift cylinder at the cylinder itself. Ensure the ends of the hoses are clean and capped. 8. Remove the upper grabber lift cylinder pin and remove the grabber lift cylinder. 9. Return the top drive to the hole centre. 10. Position the upper tong on the swivel or the crossover sub. ©TESCO CORPORATION, 2004 42 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG OUT PROCEDURE 11. Position the break-out tong on the lower saver sub on the top drive. Note: Ensure that a die lock clamp is in place. If not, place the tong on the lower section of the mudsaver valve. 12. Use the rig tongs to break the upper connection. Continue to the next procedure if you are removing the top drive from the rig floor. How To 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. HOW TO 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 “How To Remove the Top Drive” on page 43. 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 43 RIG OUT PROCEDURE INSTALLATION GUIDE 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) 10-15’ 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. HOW TO 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. ©TESCO CORPORATION, 2004 44 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE RIG OUT PROCEDURE 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. Figure 5-3: 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. 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 45 RIG OUT PROCEDURE INSTALLATION GUIDE HOW TO 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. ©TESCO CORPORATION, 2004 46 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE LIST OF FIGURES LIST OF FIGURES Figure 2-1: Power, Air and Fuel Connections - Option 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 2-2: Power, Air and Fuel Connections - Option 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 3-1: HCI Optimal Equipment Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Figure 3-2: HCI Hose Saddle Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Figure 3-3: HCI Hose Saddle Capture Clamp Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 3-4: Hoisting the Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 3-5: Position the Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 3-6: Torque Arrest System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 3-7: Torque Arrest System - Permanent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Figure 3-8: Torque Arrest System - Portable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Figure 3-9: Inside Diameter of the Bail Clamp Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Figure 3-10: Counter-Balance System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Figure 3-11: Counter-Balance System Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 3-12: Counter-Balance Block Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 3-13: Drawworks Override Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 4-1: Making up the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 5-1: Breaking Out the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Figure 5-2: Top Drive/Swivel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 5-3: Service Loop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 47 LIST OF FIGURES INSTALLATION GUIDE This page has been left blank intentionally . ©TESCO CORPORATION, 2004 48 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE LIST OF TABLES LIST OF TABLES Table 1-1: Where to Find More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Table 3-1: HCI - Cable and Hoses for 1205 HP Prime Movers. . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Table 3-2: HCI - Cable and Hoses for 750 HP Prime Movers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Table B-1: Top Drive Inspection List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Table B-2: Power Unit Inspection - Cable Reel/Service Loop. . . . . . . . . . . . . . . . . . . . . . . . B-1 Table B-3: Power Unit Inspection - Modine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Table B-4: Power Unit Inspection - Tranter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Table B-5: Power Unit Inspection - Oil Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Table B-6: Power Unit Inspection - Filter Manifold Headers . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Table B-7: Power Unit Inspection - Pump Drive/Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Table B-8: Power Unit Inspection - Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Table B-9: Power Unit Inspection - Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Table B-10: Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Table C-1: Maximum Safe Working Loads (Pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Table C-2: Rope Diameter Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Table D-1: Hand Signals for Boom Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 49 LIST OF TABLES INSTALLATION GUIDE This page has been left blank intentionally . ©TESCO CORPORATION, 2004 50 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE INDEX INDEX B breaking connections warning, 41 C connection breaking top drive/swivel, 39 connections breaking difficult, 41 use heat to break, 41 counter balance block saddle installation, 25 counter balance system before you install, 21 block saddle, 25 installation, 21 installation procedure, 22 preventing damage, 21 general notes, 31 installation hose hanging saddle, 10 pre-installation measurement, 3 rig measurement, 3 service loop, 10 M measurement rig, 3 mechanical module placement during rig up, 7 mud pump interlock, 29 P damage pre-installation inspection, 6 difficult connections, 41 driller’s panel installation, 27 power connection requirements, 3 power module placement during rig up, 7 power unit placement procedure, 8 pre-installation inspection, 6 main power connection requirements, 3 measurement, 3 E R D equipment hose saddle, 9 inspecting, 6 inspecting for damage, 6 placement during rig up, 7 placement of power unit, 8 spotting, 7 H heavy weight drill pipe, 37, 38 hose reel, 31 hose saddle installation, 10 optimal placement, 9 placement factors, 9 I inspecting equipment pre-installation, 6 inspection 880002 REV A rig out, 39 rig up equipment spotting, 7 S safety air interlocks installation, 28 saver sub, 31, 37 service loop, 39 calculate length, 10 installation, 10 removing, 44 swivel break top drive connection, 39 making up (customer), 36 using heat to break connections, 41 T top drive break swivel connection, 39 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 51 INDEX INSTALLATION GUIDE installation, 26 torque arrest system before you install, 14 components, 14 configuration sample calculation, 16 determine the configuration, 15 installation, 14 removing, 39, 43 torque track, 16 torque track mounting, 16 W warnings before start up, 31 ©TESCO CORPORATION, 2004 52 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE PRE-INSTALLATION CHECKLIST APPENDIX A: PRE-INSTALLATION CHECKLIST Use the following checklist before beginning installation procedures. Component Description Containers Containers 1, 2, and 3 Top Drive Transportation stand Date Initials Main Frame Pipe Handler Gearbox Gearbox oil level Rineer/manifold Top Drive hoses Auxiliary system (11-Station Manifold and solenoids) Mudsaver valve Link Tilt cylinders Power Unit Prime mover Pump drive Pumps Filter manifold Flow meters AC distribution center/control panel System fittings Auxiliary pump and motor Cooling fan/Modine Re-circulation pump Oil tank Oil tank level Return filters (top of tank) High pressure plumbing Tranter plate exchangers 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 A-1 PRE-INSTALLATION CHECKLIST INSTALLATION GUIDE Component Description Service Loop Hose hanging saddle Date Initials Urethane inserts Hose reel Hose reel control Slings, shackles, and safety pins Driller’s Panel Instrumentation Switches Connectors Internal wiring Auxiliary hoses 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) Main Fluid Hoses 2 x 225 ft. 5,000 psi hose (2 in.) (750 hp) 2 x 15 ft. 5,000 psi hose (2 in.) Main Fluid Hoses 4 x 225 ft. 5,000 psi hose (2 in.) (1205 hp) 2 x 15 ft. 5,000 psi hose (2 in.) Other Cables 2 x 160 ft. 37C robotics control 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 Torque Arrest System Extend frame Torque bushing Torque beam and T-bar Torque track Hanging sling assembly ©TESCO CORPORATION, 2004 A-2 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE VISUAL INSPECTION CHECKLISTS APPENDIX B: VISUAL INSPECTION CHECKLISTS Use this checklist after installation procedures are complete, but before you start the system. 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. Main Frame 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. 1. 11-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. Table B-2: Power Unit Inspection - Cable Reel/Service Loop 880002 REV A 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. 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 B-1 VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE Table B-2: Power Unit Inspection - Cable Reel/Service Loop Component Activity Steps 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 - Modine 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 - Tranter Component Activity Steps All Inspect Ensure there are no visible leaks. Table B-5: 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-6: 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, 2004 B-2 500/650T HCI(S) 750/1205HP 880002 REV A INSTALLATION GUIDE VISUAL INSPECTION CHECKLISTS Table B-7: 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-8: 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-9: 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-10: Driller’s Panel 880002 REV A 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. 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 B-3 VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE This page has been left blank intentionally . ©TESCO CORPORATION, 2004 B-4 500/650T HCI(S) 750/1205HP 880002 REV A 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 880002 REV A 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 1¼ 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 1½ 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 1¾ 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 2¼ 84,000 63,000 168,000 145,500 118,800 84,000 2½ 104,000 78,000 208,000 180,100 147,000 104,000 2¾ 122,000 91,500 244,000 211,300 172,500 122,000 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 C-1 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 in. – 3/4 in. 90% 7/8 in. – 1 in. 85% 1-1/8 in. – 1-1/2 in. 80% 1-5/8 in. – 2 in. 75% 2-1/8 in. and larger 70% ©TESCO CORPORATION, 2004 C-2 500/650T HCI(S) 750/1205HP 880002 REV A 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 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 D-1 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, 2004 D-2 500/650T HCI(S) 750/1205HP 880002 REV A 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 880002 REV A 500/650T HCI(S) 750/1205HP ©TESCO CORPORATION, 2004 D-3 HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE Table D-1: Hand Signals for Boom Operation This Signal Means This Move Carriage In Move Carriage Out ©TESCO CORPORATION, 2004 D-4 500/650T HCI(S) 750/1205HP 880002 REV A