ECI Basic Overview

TESCO
CORPORATION
Copyright 2011 Tesco Corporation

ECI Top Drives
Level I Training
Overview

Tesco Top Drive
system

Power Module

Power Module
Houses all control
and distribution
power for the Tesco
Top Drive system.

Main Components
of the Power Module
 TVSS.
 Control Panel.
 MD-500.
 System Control Module.
 PLC.
 Lab View.
 Motor starters.
 Braking resistors.
 Heat pump.
 Dehumidifier.
 Control distribution.
 Power distribution.
TVSS
 The TVSS, or
Transient Voltage
Surge Suppressor,
reduces incoming
power issues such as
spikes or surges.
 The TVSS is designed

to fail before any
damage can be
sustained by the
MD500 Drive system.
TVSS

Control
Panel

Control Panel Meters
 The Raw Bus and V Bus
meters are “Line Voltage
Meters”. They are not step
down meters and as such
have the actual voltage shown
present at the back terminals.
 Caution must be exercised

when checking these meters
as potentially harmful voltages
are present between 0 – 850
VDC ( they are rated for 0 to
1000 VDC)
MD-500

MD-500
 Supplies power for the

Top Drive motor.
 Converts both voltage
and frequency through
PWM technology.
 Works in conjunction
with the CCB (SCM).
 Designed for
synchronous operation.

System Control Module
( Commercial Control Board )

System Control Module
( Commercial Control Board )
 The System Control

Module is the interface
between the MD-500
and the outside world.
 Converts speed and

torque signals to
operate the inverter.

PLC
( Programmable Logic Controller )

PLC

PLC
 Remote controller.
 Processes information
at high rate of speed.
 Located in main control
cabinet.

PLC
 Replaces multi conductor

cables from the Power
Module to the Drillers
Panel.
 Utilizes a communication
cable for the processing of
Inputs/Outputs rather than
24Volt relay logic.

Lab View

Lab View
 Interface between the
MD-500 and the real
world.
 Displays status of the
MD-500 and the Top
Drive.
 Includes temperatures,
voltages, current, and
fault codes.

Lab View
 Used as a diagnostic
tool for the MD-500
and the Top Drive.
 Can be used to
manipulate the
operation of the Top
Drive system.

Motor Starters
 Starters located
behind doors of the
starter panel.
 Used for the starting
of all the motors and
the setting of their
respective overloads
located on the
mechanical module.

Braking resistors
 Enabled during a fault
condition that requires an
immediate shutdown or
to control over voltage
situations during unwind.
 All voltage present on the

MD-500 and produced
from the spinning Top
Drive is dissipated
immediately through the
brake resistors.

Heat Pump

Heat Pump
 Used for the cooling of

the Drive and control
cabinets.
 Cools air using glycol
from the chiller, located
in the mechanical
module, and circulates
this cooled air through
the cabinets.

Dehumidifier
 The Building
Dehumidifier maintains
the humidity in the
power module at
approximately 30%. The
Dehumidifier is a
complete external unit,
it is not tied into the
control system.

Control Distribution
24VDC Control UPS 120VAC

UPS 120 VAC
 Un-interrupted Power
Supply.
 Provides back up
control power for the
System Controller in
the event of a rig
blackout.

24VDC Control
 Main distribution for
robotics and sensors.
 Utilizes both 24VDC and
4-20 mA control
systems.
 Each terminal strip has
its own designation.
They are labeled MPA,
MPB, MPT, etc. as per
the actual Tesco
electrical schematic.
Power Distribution

Power Distribution
 Distributes main power

(600VAC) through out the
Top Drive system.
 Contains main breakers
for the MD-500 system.
 Voltage supplied from
incoming rig power or
stand alone generator.

PA44-5W Motor

PA44-5W Motor
 450 HP continuous.
 Synchronous.
 Liquid cooled.
 Continuous stall
torque of 1250 lb-ft.
in Connect mode.

Resolver

Resolver
 Mounted on the shaft, top side
of the PA44 motor.
 Determines absolute
positioning of the rotor in
relation to the stator.
 Signal sent to the CCB and
used to fire the MD-500 for
synchronous operation.
 Acts as bearing retainer for
upper motor bearing (old
style).
 Newer Resolvers come as 2
piece components so the
bearing retainer stays in
position while the Resolver is
replaced.
Resolver

Mechanical Module

Mechanical Module
 Supplies all cooling and hydraulics for

the Top Drive and the power module.

Main Components
of the Mechanical Module
 Chiller.  Flow switches.

 Top Drive pump.  Tank heater.
 Drive pump.  Oil level switch.
 Chiller by-pass pump.  Top drive temp switch.
 Auxiliary pump.  Auxiliary pressure
 Top drive cooling fan. switch.

Chiller

Chiller
 Used for the cooling of

the MD-500 drive system
only. When not
cooling, the
 10 or 25ton depending on
suction and
the amount of drives to discharge lines
be cooled. should be
 Set within 5 degrees of equal.
the Heat Pump setting to
prevent condensation.

Top Drive Pump

Top Drive Pump
 Circulates 50/50 glycol

through the Top Drive
cooling loop.
 Controlled from the
power module.
 Top Drive Motors need
7 GPM (3.5 per stator)
each.

Drive Pump

Drive Pump
 Supplies glycol to the

MD-500 system only.
 Must be running at all
times for the Top Drive
to operate.
 Each MD-500 Drive
requires 15 GPM.

By-pass Pump

By-pass Pump
 Used as a reserve
pump for the MD-500.
 Routes glycol through
the Top Drive fan via
an adjustable
manifold system.
 By-passes the chiller
in the case of failure
or service.

COOLING SYSTEM
ECI 900
3SV
1SV
1SV

Auxiliary Pump

Auxiliary Pump
 Supplies all hydraulic oil

for the robotic functions
of the Top Drive.
 Controlled from either
the power module or
the drillers panel.
 10 HP motor coupled to
a P-30 pump supplying
7 GPM @ 2300 psi.

SET @
2000 PSI
SET @ 2300 PSI
UNIT 337 AND BELOW Copyright 2011 Tesco Corporation

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT
a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b
P T P T P T P T P T P T P T P T P T
SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T
P
SET AT SET AT
1850 PSI 1850 PSI
A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10
SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI
PRECHARGE PRECHARGE
1000 PSI 800 PSI
0-5000 PSI 0-5000 PSI

EXTEND
INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B
ROTARY SEAL
OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET
MUDSAVER VALVE
6.5:1 TILT
COUNTER BALANCE HP P
ASSEMBLY
N.C.
AUXILIARY 0-10000 PSI

MANIFOLD
N.C.
A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE
B N
K
1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
PRECHARGE "D" - OUTER OFF DRILLER SIDE
SET SO THAT
ELEVATOR DOORS FULLY CLOSE 2000 PSI
BEFORE LATCH BEGINS TO FUNCTION GRABBER
ELEVATOR SET @
2300 PSI
UNIT 338 AND ABOVE

Top Drive Cooling Fan

Top Drive Cooling Fan
 Cools glycol returning

from the Top Drive.
 Thermostatically or
“hand” controlled.
 10 HP 600 VAC motor
is mounted to an M-12
Modine heat
exchanger.

Flow Switches

Flow Switches
 Used as an interlock
for the Top Drive
system.
 Located on the return
side of the Drive and
the Top Drive cooling
loops.
 Wired in series.
 “No Flow, No Go”

Oil Level Switch

Oil Level Switch
 Low oil shutdown.

 Locks out aux.
Pump in a low oil
condition and when
the Drillers panel
ESD is depressed.

Tank Heater

Tank Heater
 Maintains operating
temperature of the
hydraulic fluid used for
the robotics system.
 Set for 30 C or 86 F.

Top Drive Temperature
Switch

Top Drive Temperature
Switch
 Controls the Top Drive

cooling fan.
 Set at 32 C or 90 F.
 Mounted on the Top
Drive cooling tank.

Aux. Pressure Switch

Aux. Pressure Switch
 Set at 800psi.
 Indicates pressure, by way of
an amber light on the Drillers
Panel, being produced by the
Aux. Pump during use of the
robotics.
 Normal circulating Pressure
should be approximately 300-
400 psi.

Service Reel

Service Reel
 Holds all electrical

cables, cooling lines,
and the hydraulic lines
for robotics.
 Commonly called the
service loop.

Drillers Panel

Drillers Panel
 Drillers interface with the Top Drive.

 Provides control for all robotic, speed, and
torque functions.
 Displays Set and Delivered speeds and
torques.
 Different coloured lights provide warnings
and status indication.

Main Components
of the Drillers Panel
 Remote I/O (extension of main PLC).

 Drive set control functions.
 Set and Delivered Meters
 Draw works interlock.
 Mud pump interlock.

Top Drive

Top Drive
 Responsible for all the pipe handling

functions during the drilling operation.
 Pipe handling functions include
rotational and robotics.

Main Components
of the Top Drive
 Robotics.
 PA44 motor.
 Resolver.
 Temperature sensors.
 Top Drive junction box.

Robotics
 Pipe Handler lock.  Mud Saver open.
 Pipe Handler unlock.  Mud Saver close.
 Elevators open.  Grabber open.
 Elevators close.  Grabber close.
 Link Tilt forward.  Grabber Lift up.
 Link Tilt back.  Grabber Lift down.
 Extend in.  Pipe Handler Rotate.
 Extend out.

Top Drive
Junction
Box

Temperature Sensors

Stator Temperature
 Two temperature sensors
for monitoring stator
windings (upper and Stator
lower).
 Thermistor type imbedded
into the stator windings
(cannot be field replaced).
 All rotor sensors are Rotor : Not Used
removed and capped. The
signal is “masked” with a
2.5 KΩ resistor.

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TESCO

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 The TVSS is designed

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Caution must be exercised

Copyright 2011 Tesco Corporation

 Supplies power for the

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 The System Control

 Converts speed and

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Replaces multi conductor

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 All voltage present on the

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Used for the cooling of

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

24VDC Control UPS 120VAC

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Distributes main power

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Supplies all cooling and hydraulics for

Copyright 2011 Tesco Corporation

 Chiller.  Flow switches.

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Used for the cooling of

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Circulates 50/50 glycol

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Supplies glycol to the

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Supplies all hydraulic oil

Copyright 2011 Tesco Corporation

SET @ 2300 PSI