DOCUMENT NAME: 880026 REV A

Installation Guide
HMIS Top Drive System
250TON HMIS 475HP
INSTALLATION GUIDE COPYRIGHT AND DISCLAIMER
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
III
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
REVISION INFORMATION INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
IV
Revision Information
Version Date Description of Changes
Rev A May 2004 General Engineering updates and additions.
INSTALLATION GUIDE TABLE OF CONTENTS
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
V
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Install the Hose Hanging Saddle and Service Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Before You Install the Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Arrest System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque Arrest System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to Determine the Torque Track Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to Install the HMIS Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to Set the Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driller's Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
How to Install the Drillers Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Air Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to Install the Drawworks Interlock and Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
About the Mud Pump Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 4: System Inspection and Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspection-General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Unit: Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
How to Start the Electrical System for the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TABLE OF CONTENTS INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
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Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Before You Start the Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to Start the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Closed-Loop Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Top Drive Robotic Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Chapter 5: Rig Out Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Remove the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Remove the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Remove the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A: Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B: Sling Load Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C: Hand Signals for Boom Equipment Operation . . . . . . . . . . . . . . . . . . . . . C-1
INSTALLATION GUIDE
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
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CHAPTER 1: ABOUT THIS DOCUMENT
This document contains information on how to install the 250TON HMIS 475HP top drive,
power unit, torque arrest system, and service loop.
You can alter the installation sequence described in this document to accommodate current rig
activity. The procedures described in this document 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
Maintenance Guide
Tesco manufactured parts and part numbers Parts List
troubleshooting Troubleshooting Guide (where available)
electrical schematics
hydraulic schematics
System schematics
available options and spares Tesco Representative
ABOUT THIS DOCUMENT INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
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INSTALLATION GUIDE
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CHAPTER 2: PRE-INSTALLATION ACTIVITIES
RIG INSTALLATION AND MEASUREMENT
To ensure that top drive installation progresses smoothly, complete a detailed rig measurement
package before ordering equipment. Rig measurement packages are available from Tesco.
Accurate rig measurement helps you do the following:
Determine an equipment placement plan
Determine the best method for installing the top drive
Identify specialized equipment requirements, including the following:
swivel bail clamps
torque track hanging pad eye
components and subs (top drive to drill string)
service connection lengths and specific accessories
air/electric safety interlocks
torque arrest system components
hose saddle hanging requirements
mud hose 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 rigs configuration.
POWER/SERVICE CONNECTION REQUIREMENTS
Discuss the following items with a qualified Tesco representative before you request shipment
of the top drive system:
diesel fuel interface with rig fuel supply
starter air supply from rig
electrical power
480VAC
100 amp recommended (60 amp minimum)
60 Hz
or
380 VAC
50 Hz
PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE
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The following figures illustrates the connection considerations to address before the top drive
system arrives on location.


Figure 2-1: Power, Air and Fuel Connections - Option 1
Figure 2-2: Power, Air and Fuel Connections - Option 2
INSTALLATION GUIDE PRE-INSTALLATION ACTIVITIES
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
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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 units maximum consumption.
For the Caterpillar 460 hp prime mover, maximum consumption is 21 gallons
per hour (79.5 litres per hour)
For the Detroit Diesel 475 hp prime mover, maximum consumption is 22.8
gallons per hour (86 litres per hour)
2. Determine the required length of the fuel line. Determine the route it will take
from the fuel supply to the power unit.
Note: Avoid routing the fuel line where it might become damaged or pinched.
3. Verify the quality of the fuel supply.
Note: Poor fuel quality might require special treatment. For example, fuel line
heaters might be required in areas where diesel fuel contains high levels of paraf-
fin.
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 starters 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.
PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
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EQUIPMENT INSPECTION (PRE-INSTALLATION)
Tesco inspects all top drive equipment before shipping, however, some damage might occur
while equipment is in transit.
It is important to identify any shipping damage as quickly as possible. This allows you to make
necessary repairs, order equipment replacements, and optimize system readiness.
As part of a pre-installation equipment inspection, do the following:
Check all shipping containers for damage. External damage may indicate damage to con-
tents.
Visually inspect all principle components for damage or missing parts.
If the top drive system is shipped with fluid levels at full, check the fluid levels. Low
fluid levels may indicate a leak in the hydraulic, cooling, or lubrication system.
A sample equipment checklist is included in Appendix A: Pre-Installation Checklist.
INSTALLATION GUIDE
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
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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 con-
sidered 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).

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 lim-
ited, 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.
Figure 3-1: HMIS Optimal Equipment Placement
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TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
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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.
4. Connect the following items:
5. Connect the auxiliary hydraulic fluid lines from the auxiliary quick-connectors to
the hose reel control.
Note: Auxiliary hydraulic power is required to spool off the service loop when
you install the hose hanging saddle.
Optimal Placement of the Hose Saddle
The following illustration shows the optimal placement of the hose saddle. This placement is
considered ideal because the hose saddle is situated as follows:
High enough to prevent cables or hoses from landing on the rig floor when top drive is
lowered [55 ft.-65 ft. (16.8m-19.8m) above the rig floor if the mast height is 100 ft.-125
ft. (30.5m-38.1m)],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 ser-
vice 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.
Connect This From Here To Here
37C electrical control cable Power unit Drillers 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)
INSTALLATION GUIDE RIG UP PROCEDURE
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
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Although the arrangement shown here is considered optimal, placement of the cable roller sad-
dle is determined by several factors:
mast height
racking platform height
length of traveling equipment (drill string, compensator, blocks, and swivel)
saddle hanging mechanism and configuration
available hose length (standard hose length is 225 ft.(76.2 m) unless otherwise
requested)
power unit location
How to Install the Hose Hanging Saddle and Service Loop
Tesco recommends that you suspend the hose saddle from a pad eye attached to the racking
platform. If no pad eye is available, wrap a sling around a secure beam at the racking platform.
The hose saddle can be shackled to the sling and suspended from the beam. The total weight
suspended from the sling or pad eye is 2,000 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.
Figure 3-2: HMIS Hose Saddle Placement
Service Loop:
Approximately 60-65 ft.
between top drive
and hose saddle
capture clamp
Hose Saddle:
Mounted 55-65 ft.
above drill floor
(depending on
racking platform height
and sling length)
Standpipe Hose
Power Unit:
Located on standpipe side
100-125 ft.
For Triple:
Service Loop:
Approximately 50-60 ft.
between top drive
and hose saddle
capture clamp
Hose Saddle:
Mounted 45-55 ft.
above drill floor
(depending on
racking platform height
and sling length)
For Double:
RIG UP PROCEDURE INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
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1. Ensure that the auxiliary hydraulic fluid lines are connected to the hose reel con-
trol.
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.
5. When the correct length has been spooled off the reel, insert the hoses and cable in
the hose saddle capture clamp.
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. of
hose should be lying on the floor.
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880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
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6. Connect the hose saddle to the cable of the floor tugger or crane.
Figure 3-3: HMIS Hose Saddle Capture Clamp Configuration
1. Hydraulic supply/return line
2. Hydraulic supply/return line
3. Auxiliary and case drain return line
4. Auxiliary supply hose
5. 37 multi-conductor cable for robotic
functions
Table 3-1: HMIS - Cable and Hoses for 460 and 475 HP Prime Movers
Quantity Description
2 1-1/2 in. high pressure closed loop hoses (1 supply, 1 return)
1 3/4 in. auxiliary hydraulic supply hose
1 1-1/4 in. auxiliary and case drain return line
1 37 multi-conductor cable for robotic functions
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7. Hoist the saddle and hoses into position below the racking platform.
Note: Hoist the saddle slightly higher than its final position.
8. Install the hanging sling for the hose saddle at the racking platform.
Note: Attach the hanging sling to the pad eye with a shackle, or wrap it around a
suitable beam.
9. Use a shackle to attach the hose saddle to the hanging sling.
Note: The hose saddle sling must be strong enough to hold loads of more than
2,000 lbs (907.2 kg).
10. Use the floor tugger or crane to lower the saddle until the weight transfers to the
hanging sling.
Figure 3-4: Hoisting the Hose Saddle
Figure 3-5: Positioning the Hose Saddle
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11. Install a back-up safety sling around the hose saddle.
Caution: This back-up sling is considered critical safety equip-
ment.
12. Lower the crane or floor tugger cable.
13. Attach the crane or floor tugger cable to the sling at the free end of the service
loop.
14. Hoist the free end of the service loop to the rig floor and secure it in place until it
can be connected to the top drive and driller's panel.
15. Bring the 160 ft. (48.8 m) 37C control cable, connected to the main panel on the
power unit, to the drill floor.
TORQUE ARREST SYSTEM
Before You Install the Torque Arrest System
Install a hanging pad eye in the crown before you install the torque arrest system. This pad eye
must be designed and installed to support the hanging weight of the entire torque assembly
(safe working load of 5,000 lb. (2,268 kg) plus the recommended safety factor for overhead
equipment).
The pad eye is typically placed 18 in. (45.72 cm) back from the crown cluster centre. It is 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.
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.
RIG UP PROCEDURE INSTALLATION GUIDE
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Torque Arrest System Components
A standard torque arrest system includes the torque beam, T-bar, and the following torque
track sections:
one adjustable hanging sling
one cable clamp mount and cable capture clamp
one 18.5 ft. (5.6m) reversible, bolted, bottom torque track section
three 18.5 ft. (5.6m) standard torque track sections
one 10 ft. (3.1m) torque track section
one 5 ft. (1.5m) torque track section
The total length of the torque track sections is 91 ft. (27.7m). Obtain additional length by
lengthening the top section hanging sling. Purchase additional torque track sections to accom-
modate larger masts.
One 1.3 ft. (.4m) deflector section (bull nose) of torque track is included.
Caution: Never subject the deflector section to torque. Mount it
below the torque beam only.
The deflector section is always mounted at the bottom. Its tapered design assists in mounting
the torque bushing onto the torque track.
Torque Arrest System Configuration
You must know the following before you can determine the torque track configuration:
height of the hanging pad eye for the torque track, measured from the rig floor (A)
position (height above rig floor) where the torque beam and T-bar will be mounted (B)
length of the hanging assembly for the torque track, including hanging swivel, nut, and
shackles (2.5 ft. minimum (.8m) to 15 ft. (4.6) maximum)
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
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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 7 ft.-8 ft. (2.1m-2.4m) above the drill
floor (C).
2. Place the bottom bolted section of torque track above the deflector section.
Note: Ensure that a suitable strongback for mounting the torque beam and T-bar is
available somewhere along the length of the bolted section of torque track.
Remember that the bolted section is reversible.
3. Stack the track sections (18.5 ft., 5 ft. and 10 ft. sections) until you reach 5 ft.-15
ft. (1.5 m-4.6 m) from the pad eye.
4. Determine the length of hanging assembly required.
Note: Ensure that the length of hanging assembly is incorporated into the calcula-
tion.
5. Calculate the height of the torque bushing to ensure that it will not come off the
top end of the torque track when it is in the uppermost position.
Figure 3-6: Torque Arrest System Configuration
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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.
1. Ensure the hanging pad-eye for the torque track is installed in the crown.
Note: Normal placement for a standard track is 18 in. back from the crown cluster
centre.
2. Assemble the torque beam, T-bar, and T-bar clamp.
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 10 ft. and 16 ft. above the drill floor. If you install it any higher, you
might require additional stabilization below the torque beam. Tesco can supply
additional stabilization, if required.
4. Use four clamps to mount the torque beam to the selected supporting beam.
5. Slide the T-bar to the most rearward position.
6. Use the calculation method described in How to Determine the Torque Track
Configuration on page 15 to calculate the required torque track section configu-
ration.
Note: When the torque track is suspended, the bottom of the deflector section
should be 7 ft.-8 ft. off the floor.
7. When the torque track section rig-up is determined, set and secure the calculated
hanging sling length.
Caution: Torque sling bolt clamps to 230 ftlbs.
Note: When you tighten the sling clamp bolts, ensure that the sling is compressed
evenly along its length. It will take several repetitions to ensure that the clamping
force is distributed evenly across all of the cable clamps.
8. Fasten the hanging sling plate to the top section of torque track.
Note: Use a soft sling to hold the sling in place so that it will be easily accessible
when the torque track is lifted to the hanging pad eye.
9. 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.
10. 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.
11. Lower the first track section through the rotary table or mousehole.
12. 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.
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13. Place a ratchet strap around the top of the blocks and thread it around the torque
track.
14. Use the ratchet strap to pull the blocks and track together.
Note: This immobilizes the track section and keeps it hanging vertically as it trav-
els up the mast.
15. Hoist the blocks until they support the weight of the torque track.
16. Remove the floor tugger.
17. Hoist the blocks until the bottom of the first section is 8 ft. above the drill floor.
18. Connect the floor tugger to the second section of torque track and hoist it to the rig
floor.
19. 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).
Note: If the rotary table is too small to permit the torque track to pass through, use
an alternate location on the rig floor. If no alternate location exists, mate the sec-
tions above the rig floor.
20. Use chains to secure the second section in place, or place a strong bar through the
back strap of the torque track.
21. 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.
22. Torque the bolts to 350 ftlbs.
23. Repeat steps 18.22. 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.
24. Use a ratchet strap to secure the extend arms of the torque bushing in place.
25. Attach a tugger to the torque bushing and move the bushing onto the drill floor.
Note: Ensure that the extend frame is down.
26. Position the torque bushing over hole centre.
27. Use the blocks to lower the assembled torque track and stab it through the torque
bushing.
28. 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.
29. After the torque bushing is installed, raise the blocks to the crown.
30. Connect the hanging assembly of the torque track to the pad eye.
31. 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.
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32. 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.
33. When all T-bar fastening bolts are tight, move the T-bar to the correct position in
the T-bar seat and tighten the clamp to hold it in position.
Note: Hang the centre of the torque track vertically,18 in. back from the hole cen-
tre.
34. Tighten the lock nut on the hanging assembly.
35. Remove the handling assembly at the crown and lower the blocks.
Caution: Before you move the top drive onto the rig floor, ensure
the following is in place:
the swivel yoke link (with an integral counter-balance) is installed
in the block becket
the accumulators are facing the torque track
the gauge, coupler and valve are facing the drillers side
36. Install stabilization systems.
Note: Three sets are usually installed: one at the top strongback, one at the rack-
ing platform, and one between the racking platform and the torque beam. These
are most easily installed when the mast is down, but can also be installed during
rig-up.
37. Attach the stabilization devices to the torque track as shown in the illustrations
starting on the following page.
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If your rig set-up requires a customized stabilization installation, contact Tesco.
Figure 3-7: F-Clamp and Turnbuckle Assembly
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TOP DRIVE
How to Install the HMIS Top Drive
Before you move the top drive onto the rig floor, ensure the following conditions exist:
You have installed the swivel yoke link (with integral counter-balance) in the becket of
the block.
The accumulators are facing the torque track, and the gauge, coupler and valve face the
drillers side.
1. Using blocks or a crane, move the top drive to the rig floor.
Note: If using the block, attach a hold-back line from the handling frame of the
top drive to a loader or cat line tugger. Use the line to prevent the top drive from
swinging when it is lifted off the rig floor.
2. Position the top drive over the hole center.
3. Lower the blocks.
4. Connect the links of the swivel yoke to the swivel on the top drive.
Note: The grease zerks (on the pins of the yoke link) must face the load.
5. Raise the blocks to support weight of the top drive.
Caution: Do not lift the top drive off the floor.
6. Remove the pins on the handling frame of the top drive (three or four in total,
depending on the unit type).
7. Lift the top drive until it is clear of the handling frame.
8. Use the floor tugger to remove the handling frame from the rig floor.
9. Use the blocks to position the top drive so that it can be joined to the extend
frame.
Note: Align the ears on the top drive with the arms on the extend frame and pin
them in place.
10. Remove the pin that is holding the torque bushing in place on the torque track.
Note: The weight of the top drive and torque bushing are now suspended from the
blocks.
11. Lower the top drive to the rig floor.
12. Reposition the T-bar so the top drive sits over the hole center, and secure it in
place (if required).
13. Tighten the T-bar connection to secure it in place.
14. Locate the service loop. If the service loop has not been installed, see Figure 3-2
on page 9.
15. Connect the following hoses and cables for the service loop to the top drive:
supply and return hoses for the closed-loop hydraulic system
supply hose for the auxiliary hydraulic system
return hose for the case drain and auxiliary hydraulics system
37C control cable, 225 ft.
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16. When all service loop hoses and cable are attached, check the loop position.
The loop should be off the floor.
There should not be any snagging/interference.
17. Re-check all hose connections.
18. Ensure that all required valves are open.
four at the top drive: 2 on the hoses, 2 on the top drive
five at the hose reel: 2 on the reel, 2 on the hoses, 1 on the auxiliary line
19. When the top drive and driller's panel are connected, continue with additional set-
up procedures, or begin commissioning.
COUNTER-BALANCE SYSTEM
How to Set the Counter-Balance Cushion Height
The following conditions must exist before the following portion of the counter-balance instal-
lation can be completed:
The top drive must be installed.
The hydraulic circuit must be connected.
The drillers panel must be operational.
1. Connect the hydraulic hose for the Elevator-Open circuit to the valve assembly on
the counter-balance coupler. This is located next to the swivel link on the drillers
side.
2. Shut off the auxiliary pump.
3. At the drillers panel, turn the ELEVATOR switch to CLOSE.
Figure 3-8: Counter-Balance System Interface
1. Accumulators:
N2-Nitrogen and Oil
2. Counter-balance cylinder
3. Needle Valve
4. Auxiliary system quick-
coupler
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4. Open the needle valve on the counter-balance charge hose.
Note: This relieves all pressure on the counter-balance system.
5. Check the nitrogen pressure in the counter-balance accumulators.
Note: The accumulators must be charged to 800 psi.
6. Close the needle valve on the counter-balance manifold.
7. Start the auxiliary pump.
8. Open the elevators. At the drillers panel, push and hold the ELEVATOR
SAFETY OPEN button, and turn the ELEVATOR switch to OPEN.
9. Open the needle valve and monitor the connection between the upper link and the
yoke.
10. Continue to increase pressure to the counter-balance system until the counter-bal-
ance cylinders lift the yoke pins to the central position in the link becket.
11. Close the needle valve.
12. At the driller's panel, turn the AUX PUMP switch to OFF.
13. At the driller's panel, cycle the ELEVATOR switch to OPEN, then to CLOSE.
Note: This relieves any pressure in the system.
14. Remove the charge hose for the elevator from the counter-balance manifold.
15. Reconnect the hydraulic hose for the elevator to the quick-connect coupler on the
elevator.
16. Lower the top drive.
Figure 3-9: HMIS Counter-Balance Cushion Height
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DRILLER'S PANEL
How to Install the Drillers Panel
The drillers panel cannot be connected to the top drive until the hose saddle and service loop
have been installed.
The location you select for the drillers 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.
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 drillers panel.
6. Connect the second 37C control cable coming from the power unit to the drillers
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 connec-
tors. Use the correct cord (cord F).
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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.
1. Shut off the air supply from the compressor to the drum clutch control.
Note: Use an isolator valve if necessary.
2. Disconnect the hose for the drum clutch air supply from the control valve.
3. Connect the air supply hose to an C-cord solenoid valve.
Note: If two air supply hoses are present, connect each hose to an air/electric sole-
noid valve (one for low clutch and one for high clutch).
4. Connect the air supply from the air/electric solenoid valve to the drum clutch air
control valve.
5. Connect an electric cable from the air/electric solenoid valve to the extension cord
at the driller's panel. The cord is labeled 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.
Figure 3-10: Drawworks Override Installation
1.Supply air
2.Air/Electric solenoid valve
3.Air line
4.Drum clutch valve
5.Air line
6.Drawworks
7. Drillers panel
8. Grabber Open/Close switch
9. Elevator button
10.Grabber override button
11.Control box for the brake handle
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About the Mud Pump Interlock
The mud pump air interlock is designed to disallow operation of the mud pump unless the
mudsaver valve is open.
Before you attempt to install this safety interlock, discuss equipment requirements and opera-
tional considerations with a qualified Tesco representative.
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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
drillers 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.
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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:
Danger! Only qualified electrical personnel should test the
power supply and AC power circuits.
3. Ensure that all cables from the following items to the electrical cabinet on the
power unit are in place and correctly connected:
motor for the fan
motor for the auxiliary pump
skid transformer on the power unit
4. Set the breaker labeled TRANSFORMER to ON. This will activate the power
supply.
5. Set the breaker labeled LIGHT to ON (if applicable).
6. Find the breaker labeled 120V FOR 24V POWER SUPPLY. Switch the 24V
breaker to ON.
7. Set the breaker labeled ENGINE HEATER to ON, then check the operation of the
heater.
Note: If ambient temperatures are below 32 Fahrenheit (0 Celsius), run the
engine heater for four hours before you start the prime mover.
Normal
480 VAC
100 amp recommended
(60 amp minimum)
60 Hz
Optional
380 VAC
100 amp recommended
(60 amp minimum)
50 Hz
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8. Set the breaker labeled COOLING FAN to ON.
9. Use the cooling fan on/off switch to activate the fan briefly. Check the fan for
proper rotation.
Note: If the cooling fan does not rotate in the required direction, then the incom-
ing phases of the power supply must be switched. First, SHUT OFF THE MAIN
POWER SUPPLY, then switch two of the incoming power phases at the incoming
fuses of the main panel.
Caution: If you switch the phases, ensure the incoming power
cables are correctly labeled.
10. Check the oil level in the hydraulic oil storage tank.
11. Ensure that any required hydraulic oil valves are in the open position.
12. Briefly activate the auxiliary pump (use the AUX PUMP switch).
13. Listen for correct operation.
Note: If the pump does not operate properly, check for correct rotation of the
pump. Monitor the motor-to-pump coupler to confirm the direction of rotation.
14. Ensure that the lines for the auxiliary supply and case drain return are connected
to the top drive.
Note: If you connect the auxiliary supply and return lines to the top drive, you can
test the system by connecting the supply and return jumpers to the hose reel.
15. Set the auxiliary pump 3-position switch to HAND; this will turn the auxiliary
pump ON.
16. Ensure that the flow meter near the cooler is registering flow.
17. When electrical power connection has been confirmed, continue with the proce-
dure for starting the prime mover.
Prime Mover
Before You Start the Prime Mover
1. Ensure the supply lines for the air and rig fuel are connected to the prime mover.
2. Check the oil level for the engine.
3. Check the oil level for the pump drive.
4. Check the coolant level.
Caution: Only check the coolant level when the engine is cold.
5. Ensure that the valves on the suction line from the hydraulic oil tank to the charge
pumps are open.
6. Connect the supply and return hoses for the closed-loop system to the top drive.
Caution: Ensure that all isolation valves are open.
7. Use the KILL/E.S.D. (Emergency Shut Down) button at the drillers panel to test
the operation of the rig savers.
Caution: After you test the rig savers, reset them to the fully open
position.
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How to Start the Engine
1. At the drillers 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.
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 Mainte-
nance Guide and the Troubleshooting Guide for your unit for infor-
mation on charge pressure.
2. Check the closed-loop system for leaks.
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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 drillers 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 (approxi-
mately 2100 rpm).
5. Set the MODE switch to CONN.
Note: The idle speed of the engine should decrease.
6. Set the PUMPSREV/FWD switch to FWD.
Caution: The MODE switch must be set to CONN.
Note: The quill should begin rotating at 17-20 rpm.
7. Use the remote pressure gauge at the drillers 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 PUMPSREV/FWD switch to neutral, then check the quill
for obstruction. If no obstruction is observed, ensure all valves are in the proper
position.
Note: In cold weather, the oil will be more viscous, which might cause the loop
pressure to rise above normal.
8. The top drive should now be rotating at Connect-Forward speed. Go to the power
unit.
9. Check the flow meters for the closed loop (2).
Note: All values on the meters should be within 5% of each other.
10. Ensure that the reservoir level for the hydraulic oil remains adequate.
11. Return to the drillers panel.
12. Set the PUMPSREV/FWD switch to neutral.
13. Set the MODE switch to DRILL (low speed).
14. Set the PUMPSDECR/INCR switch to DECR and hold this position for ten sec-
onds.
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 PUMPSREV/FWD switch to FWD.
16. Use the PUMPSDECR/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 PUMPSREV/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.
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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 (>190F)(>88C)
high tank temperature shutdown (>165F)(>74C)
20. Verify that the automatic cooling fan is functioning properly.
Top Drive Robotic Functions
Test the robotic functions for the top drive before you start drilling operations.
1. Start the auxiliary pump at the power unit.
2. Check the meter for the return flow.
Note: The return flow should be approximately 6 gpm.
3. Make a note of the circulating pressure.
Note: Circulating pressure is valuable information for troubleshooting.
4. Go to the drillers panel.
5. Use the AUX PUMP switch to select OFF, then select ON.
Note: Confirm that the control for the auxiliary pump at the drillers panel is func-
tioning properly.
6. Use the controls at the drillers panel to test all robotic functions for correct opera-
tion.
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CHAPTER 5: RIG OUT PROCEDURE
The top drive rig-out (removal) procedure is divided into the following separate activities:
remove the top drive
remove the torque arrest system
remove the service loop
remove the power unit
When the rig-out procedures are complete, store all equipment in shipping containers. For
more information on long term storage, please consult the Maintenance Guide for your unit
type.
REMOVE THE TOP DRIVE
1. Move the top drive handling frame to the rig floor.
2. Locate a pin position on the torque track and pin the torque bushing to the torque
track.
Note: This pin connection holds the torque bushing in place when it is discon-
nected from the top drive.
3. 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 (if applicable).
8. Disconnect all service loop items from the top drive.
9. Remove the top drive from the rig floor.
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.
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1. Connect the tugger to the torque bushing and extend frame. Take the weight of the
load with the tugger.
Note: The bushing will be pinned near the bottom of the torque track.
2. Remove the pin and carefully lower the torque bushing off the bottom of the
torque track and onto the rig floor.
3. Use the tugger to move the bushing out the V-door.
4. Run two torque track handling slings through the becket of the blocks.
5. Attach the pick-up pin of the torque track to the slings.
6. Raise the blocks to the crown.
7. Connect the torque track to the blocks by placing the pick-up pin of the torque
track through the hole in the torque track. Then, attach the slings to both sides of
the pick-up pin.
8. With the slings and pick-up pin in position, hoist the blocks to transfer the weight
of the torque track from the torque track hanging assembly to the block slings.
9. Unbolt the T-bar from the torque track.
10. Loosen the T-bar clamp.
11. Slide the T-bar to its most rearward position.
Note: This prevents the T-bar from obstructing the torque track during
disassembly.
12. Re-tighten two bolts on the T-bar clamp.
13. Disconnect the hanging assembly from the pad eye in the crown.
14. Use the blocks to lower the torque track through the rotary table until the first
flanged connection is at working height.
15. Use a 4-3/4 ton shackle through the stabilizer attachment bar (on the back of the
torque track) to attach the rig tugger to the bottom section of track. This will hold
it in place while it is unbolted.
Caution: If a wellhead is not installed, ensure that the casing bowl is
covered to prevent objects from falling into the hole.
16. Hoist the remaining track (suspended from the blocks) 10-15 ft. above the rig
floor.
17. Use the rig tugger (already attached) to lift the bottom section of track out of the
rotary table and off the rig floor.
18. Repeat steps 14-17 for each section of torque track.
19. Remove the handling slings from the blocks and hoist the blocks clear of the rig
floor.
20. Connect the tugger line to the T-bar/torque anchor beam.
21. Loosen and remove the anchor beam clamps.
22. Use the tugger to lower the T-bar/torque anchor beam and move it off the rig floor.
INSTALLATION GUIDE RIG OUT PROCEDURE
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
35
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 posi-
tion the capture clamp before you install the hanging saddle in the mast.
10. Continue to spool the service loop onto the hose reel.
Note: Ensure that the ends of all cables and hoses are clean and properly pro-
tected.
Caution: Do not store multi-conductor cables on the hose reel.
11. Disconnect the control cable from the drillers panel and spool it onto a separate
reel.
12. Disconnect the second control cable from the drillers 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 drillers panel.
Figure 5-1: Service Loop Removal
RIG OUT PROCEDURE INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
36
14. Remove the drillers panel from the rig floor.
Note: Wrap or box the drillers panel before putting it into storage. This will help
prevent damage to switches and meters.
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 man-
ifold/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.
INSTALLATION GUIDE LIST OF FIGURES
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
37
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: HMIS Optimal Equipment Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3-2: HMIS Hose Saddle Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 3-3: HMIS Hose Saddle Capture Clamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 3-4: Hoisting the Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3-5: Positioning the Hose Saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3-6: Torque Arrest System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3-7: F-Clamp and Turnbuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3-8: Counter-Balance System Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 3-9: HMIS Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 3-10: Drawworks Override Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 5-1: Service Loop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LIST OF FIGURES INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
38
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INSTALLATION GUIDE LIST OF TABLES
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
39
LIST OF TABLES
Table 1-1: Where to Find More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Table 3-1: HMIS - Cable and Hoses for 460 and 475 HP Prime Movers . . . . . . . . . . . . . . . . . . . .11
Table B-1: Maximum Safe Working Loads (Pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Table B-2: Rope Diameter Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Table C-1: Hand Signals for Boom Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
LIST OF TABLES INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
40
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INSTALLATION GUIDE INDEX
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
41
INDEX
B
blocks, 20
C
counter balance system
installation, 21
D
damage
pre-installation inspection, 6
drillers panel
installation, 23
E
equipment
hose saddle, 8
inspecting, 6
inspecting for damage, 6
placement during rig up, 7
placement of power unit, 8
spotting, 7
H
hose reel, 27
hose saddle
installation, 9
optimal placement, 8
placement factors, 9
I
inspecting equipment
pre-installation, 6
inspection
general notes, 27
installation
hose hanging saddle, 9
pre-installation measurement, 3
rig measurement, 3
service loop, 9
top drive, 20
M
measurement
rig, 3
mechanical module
placement during rig up, 7
mud pump interlock, 25
P
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
R
rig out, 33
rig up
equipment spotting, 7
S
safety air interlocks
installation, 24
saver sub, 27
service loop, 33
calculate length, 9
installation, 9
removing, 35
T
top drive installation, 20
torque arrest system
before you install, 13
components, 14
determine the configuration, 14
installation, 13
removing, 33
torque track, 16
torque bushing, 20
torque track
mounting, 16
W
warnings
before start up, 27
INDEX INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
42
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INSTALLATION GUIDE PRE-INSTALLATION CHECKLIST
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
A-1
APPENDIX A: PRE-INSTALLATION CHECKLIST
Use the following checklist before beginning installation procedures.
Component Description Date Initials
Containers Containers 1, 2, and 3
Top Drive Transportation stand
Main Frame
Gearbox
Gearbox oil level
Rineer/manifold
Top Drive hoses
Auxiliary system (11-Station Manifold and
solenoids)
Mudsaver valve
Link Tilt cylinders
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
Service Loop Hose hanging saddle
Urethane inserts
Hose reel
Hose reel control
Slings, shackles, and safety pins
PRE-INSTALLATION CHECKLIST INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
A-2
Drillers 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
(750 hp)
2 x 225 ft. 5,000 psi hose (2 in.)
2 x 15 ft. 5,000 psi hose (2 in.)
Main Fluid Hoses
(1205 hp)
4 x 225 ft. 5,000 psi hose (2 in.)
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
Component Description Date Initials
INSTALLATION GUIDE SLING LOAD RATINGS
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
B-1
APPENDIX B: 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 B-1: Maximum Safe Working Loads (Pounds)
Safety Factor = 5
Rope
Diameter
Single
Vertical
Hitch
Single
Choker
Hitch
Single
Basket
Hitch
(vertical
legs)
2-leg Bridle Hitch and Single Basket
Hitch with legs included
60 in. 45 in. 30 in.
3/16 600 450 1,200 1,050 850 600
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
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
9,500 7,100 19,000 16,500 13,400 9,500
7/8 12,800 9,600 25,600 22,200 18,100 12,800
1 16,700 12,500 33,400 28,900 23,600 16,700
1 1/8 21,200 15,900 42,400 36,700 30,000 21,200
1 26,200 19,700 52,400 45,400 37,000 26,200
1 3/8 32,400 24,300 64,800 56,100 45,800 32,400
1 38,400 28,800 76,800 66,500 54,300 38,400
1 5/8 45,200 33,900 90,400 78,300 63,900 45,200
1 52,000 39,000 104,000 90,000 73,500 52,000
1 7/8 60,800 45,600 121,600 105,300 86,000 60,800
2 67,600 50,700 135,200 117,100 95,600 67,600
2 84,000 63,000 168,000 145,500 118,800 84,000
2 104,000 78,000 208,000 180,100 147,000 104,000
2 122,000 91,500 244,000 211,300 172,500 122,000
SLING LOAD RATINGS INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
B-2
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 B-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%
INSTALLATION GUIDE HAND SIGNALS FOR BOOM EQUIPMENT OPERATION
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
C-1
APPENDIX C: 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 C-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
HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
C-2
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.
Table C-1: Hand Signals for Boom Operation
This Signal Means This
INSTALLATION GUIDE HAND SIGNALS FOR BOOM EQUIPMENT OPERATION
880026 REV A 250TON HMIS 475HP TESCO CORPORATION, 2004
C-3
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
Table C-1: Hand Signals for Boom Operation
This Signal Means This
HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE
TESCO CORPORATION, 2004 250TON HMIS 475HP 880026 REV A
C-4
Move Carriage In
Move Carriage Out
Table C-1: Hand Signals for Boom Operation
This Signal Means This