Tesco 500/650T HCI(S) 750/1205HP Installation Manual
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Tesco 500/650T HCI(S) 750/1205HP Installation Manual

Tesco 500/650T HCI(S) 750/1205HP Installation Manual

Top drive system
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Installation Guide
HCI(S) Top Drive System
500/650T HCI(S) 750/1205HP
D
N
: 880002 R
A
OCUMENT
AME
EV

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Summary of Contents for Tesco 500/650T HCI(S) 750/1205HP

  • Page 1 Installation Guide HCI(S) Top Drive System 500/650T HCI(S) 750/1205HP : 880002 R OCUMENT...
  • Page 2 This page has been left blank intentionally .
  • Page 3 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...

  • Page 4: Revision Information

    EVISION NFORMATION NSTALLATION UIDE Revision Information Version Date Description of Changes Rev A 31 March 2004 HCI(S) release of manual version compiled in FrameMaker © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 5: Table Of Contents

    Inspection-General Notes............31 880002 R 500/650T HCI(S) 750/1205HP ©...
  • Page 6 Appendix D: Hand Signals for Boom Equipment Operation ..... D-1 © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 7: Chapter 1: About This Document

    • tripping • freeing stuck pipe • load path inspections Maintenance Guide • maintenance/service schedules • component disassembly and reassembly Tesco manufactured parts and part numbers Parts List troubleshooting Troubleshooting Guide (where available) • electrical schematics System schematics • hydraulic schematics •...
  • Page 8 BOUT OCUMENT NSTALLATION UIDE This page has been left blank intentionally . © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 9: Chapter 2: Pre-Installation Activities

    • 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. OWER...

  • Page 10: Pre-Installation

    2.Generator 2 8. V-door 3.Generator 3 9. Power unit 4.SCR/Master Control Centre 10.Possible power unit placement 5.Possible fuel location 11.Optional power unit placement 6.Typical air location 12.Probable location for cable protection © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 11: Electrical Considerations

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 12: Equipment Inspection (Pre-Installation)

    QUIPMENT NSPECTION 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.

  • Page 13: Chapter 3: Rig Up Procedure

    2.Generator 2 8. V-door 3.Generator 3 9. Power unit 4.SCR/Master Control Centre 10.Possible power unit placement 5.Possible fuel location 11.Optional power unit placement 6.Typical air location 12.Probable location for cable protection 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 14: How To Place Of The Power Unit Components

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 15: Optimal Placement Of The Hose Saddle

    • 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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 16: How To Install The Hose Hanging Saddle And Service Loop

    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.

  • Page 17: Figure 3-3: Hci Hose Saddle Capture Clamp Configurations

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 18: Figure 3-4: Hoisting The Hose Saddle

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...
  • Page 19 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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 20: Torque Arrest System

    The pad eye is typically placed 29 in. (73.66 cm) back from the crown cluster centre. It is eas- iest to install the pad eye when the mast is down. Discuss installation procedures with a Tesco representative as part of pre-installation activities.

  • Page 21: Torque Arrest System Configuration

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 22: Sample Calculation

    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.
  • Page 23 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.
  • Page 24 36. Attach the stabilization devices to the torque track as shown in the illustrations starting on the following page. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 25: Figure 3-7: Torque Arrest System - Permanent Installation

    NSTALLATION UIDE ROCEDURE Figure 3-7: Torque Arrest System - Permanent Installation 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 26: Figure 3-8: Torque Arrest System - Portable Installation

    ROCEDURE NSTALLATION UIDE Figure 3-8: Torque Arrest System - Portable Installation If your rig set-up requires a customized stabilization installation, contact Tesco. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 27: Counter-Balance System

    “wave” back and forth in the derrick. This movement can break the clevises off the counter- balance cylinders. Shackles at both ends prevent this movement from damaging the cylinders. 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 28: How To Install The Counter-Balance System

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...
  • Page 29 Note: You cannot complete the following portion of the counter-balance installa- tion procedures until the top drive is installed, the hydraulic circuit is connected, and the driller's panel is operational. 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 30: How To Set The Counter-Balance Cushion Height

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 31: How To Install A 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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 32: Top Drive

    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). © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 33: Driller's Panel

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 34: Safety Air Interlocks

    5.Air line 11.Control box for the brake handle 6.Drawworks 1. Shut off the air supply from the compressor to the drum clutch control. Note: Use an isolator valve if necessary. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 35: About The Mud Pump Interlock

    Before you attempt to install this safety interlock, discuss equipment requirements and opera- tional considerations with a qualified Tesco representative. Caution: The mud pump interlock is not used with pumps that are driven by traction motors.
  • Page 36 ROCEDURE NSTALLATION UIDE This page has been left blank intentionally . © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 37: Chapter 4: System Inspection And Start Up

    • 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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 38: System Start Up

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 39: Prime Mover

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 40: How To Start The Engine

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 41: Closed-Loop Hydraulic System

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 42: How To Make Up The Swivel

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 43: Figure 4-1: Making Up The Swivel

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 44: Top Drive Robotic Functions

    Note: Confirm that the control for the auxiliary pump at the driller’s panel is func- tioning properly. 6. Use the controls at the driller’s panel to test all robotic functions for correct opera- tion. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 45: Chapter 5: Rig Out Procedure

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 46: Figure 5-1: Breaking Out The Swivel

    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). © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 47: How To Break Difficult Connections

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 48: Alternative Breakout Method

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 49: How To Remove The Top Drive

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 50: How To Remove The Service Loop

    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 posi- tion the capture clamp before you install the hanging saddle in the mast. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 51: Figure 5-3: Service Loop Removal

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 52: How To Remove The Power Unit

    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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 53: List Of Figures

    Figure 5-3: Service Loop Removal ........... . 45 880002 R 500/650T HCI(S) 750/1205HP ©...
  • Page 54 IST OF IGURES NSTALLATION UIDE This page has been left blank intentionally . © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 55: List Of Tables

    Table D-1: Hand Signals for Boom Operation........D-1 880002 R 500/650T HCI(S) 750/1205HP ©...
  • Page 56 IST OF ABLES NSTALLATION UIDE This page has been left blank intentionally . © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 57: Index

    (customer) placement factors using heat to break connections inspecting equipment top drive pre-installation break swivel connection inspection 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...
  • Page 58 NDEX NSTALLATION UIDE installation torque arrest system before you install components configuration sample calculation determine the configuration installation removing 39, 43 torque track torque track mounting warnings before start up © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 59: Appendix A: Pre-Installation Checklist

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...
  • Page 60 2 x 8 ft. 18/4 drawworks interlock cable 2 x 8 ft. 18/4 splitter box cable Torque Arrest Extend frame System Torque bushing Torque beam and T-bar Torque track Hanging sling assembly © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 61: Table B-1: Top Drive Inspection List

    Ensure the reel lock is locked into position. Valves Open Ensure all the required valves are in the OPEN position. Service Loop Inspect Ensure all wear points are protected and secure. Protection 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 62: Table B-3: Power Unit Inspection - Modine

    Ensure all filters are in place. Table B-6: Power Unit Inspection - Filter Manifold Headers Component Activity Steps Inspect 1. Ensure there are no visible leaks. 2. Ensure all equipment is in place and secure. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 63: Table B-7: Power Unit Inspection - Pump Drive/Pumps

    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. 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...
  • Page 64 ISUAL NSPECTION HECKLISTS NSTALLATION UIDE This page has been left blank intentionally . © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 65: Appendix C: Sling Load Ratings

    67,600 50,700 135,200 117,100 95,600 67,600 2 ¼ 84,000 63,000 168,000 145,500 118,800 84,000 2 ½ 104,000 78,000 208,000 180,100 147,000 104,000 2 ¾ 122,000 91,500 244,000 211,300 172,500 122,000 880002 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...

  • Page 66: Table C-2: Rope Diameter Efficiencies

    Rope Diameter Efficiency 1/4 in. and smaller 5/16 in. – 3/4 in. 7/8 in. – 1 in. 1-1/8 in. – 1-1/2 in. 1-5/8 in. – 2 in. 2-1/8 in. and larger © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 67: 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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...
  • Page 68 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. © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

  • Page 69: Appendix D: Hand Signals For Boom Equipment Operation

    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 R 500/650T HCI(S) 750/1205HP © , 2004 TESCO CORPORATION...
  • Page 70 IGNALS FOR QUIPMENT PERATION NSTALLATION UIDE Table D-1: Hand Signals for Boom Operation This Signal Means This Move Carriage In Move Carriage Out © , 2004 500/650T HCI(S) 750/1205HP 880002 R TESCO CORPORATION...

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