401_20900e - dog house manual oct 06

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Top Drive Rig Floor Safety Orientation Doghouse Manual

Bulletin 20900e

TOP DRIVES CASING DRILLING® AZIMUTH TUBULAR SERVICES ™

Better Ways to The Bottom™

www.tescocorp.com

Top Drive Rig Floor

Safety OrientationDoghouse

Manual

TESCO

Top Drive Rig Floor Safety Orientation Doghouse ManualPage �

Top Drive Rig Floor Safety Orientation

TESCO CORPORATIONWELL SITE OPERATIONS

6204-BURBANK ROAD S.E.CALGARY, ALBERTACANADA T2H 2C2

Phone: 403 720 2858Fax: 403 203 2295

Web:www.tescocorp.comemail: [email protected]

Printed in Canada / Dec. 2002 TC120©Tesco Corporation

Better Ways to The Bottom™TESCO

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Table of ConTenTs

C H a P T e R 5MaKInG ConneCTIons

Safety 12BreakingOut 12MakingUpSingles 12MakingUpDoubles 12MakingUpTriples 13

C H a P T e R 6oPeRaTIons

Drilling 13Tripping 14ColdClimate 14Reaming 15WorkingTightHole 15Jarring 16RunningCasing 16Cementing 16

CHaPTeR 7ToP DRIVe ConsIDeRaTIons

SlipandCutDrillingLine 17Maintenance 17

Disclaimer 17

Introduction 4

C H a P T e R 1RIGGInG UP THe eQUIPMenT

TorqueSystem 4PowerModule 5ServiceLoop 6TopDrive 6

C H a P T e R 2CoMPonenT IDenTIfICaTIon

TopDrive 7

C H a P T e R 3

SafetyInterlocks 8

C H a P T e R 4ConTRols anD RoboTICs

ClearanceandVisibility 10Extend 10LinkTilt 10Grabber 10GrabberLift 10PipeHandler 10Elevators 11MudSaverValveandActuator 11


InTRoDUCTIon foR DRIlleRsThismanualisintendedtoprovidebasicinformation

only,anddoesnotconstitutea comprehensive guide tothefunctioningoroperationofaTescoTopDrive.Itistobeusedonlyinconjunctionwith the orientation and onsitesupervisionprovidedbyTescopersonnel.TheTescoTop DriveTechnician mustbe notified of any concerns or inc iden ts invo lv ingTesco equipment and itsoperation.

O T H E R T H A N A SD E S C R I B E D I N T H EPRECEDINGPARAGRAPH,TESCOCORPORATION,ITSAFFILIATED COMPANIES

ANDEMPLOYEESASSUMENORESPONSIBILITYF O R U S E O F T H EINFORMATIONCONTAINEDINTHISMANUAL.

AtTesco,weputalotofeffortintodevelopingwaystomakedrilling a well more efficient. Training theoperators to runthe equipment in the mosteffectivemannermakesthejobeasierby reducingdowntimeand safer by eliminating theriskofinjurytoworkers.

Thismanualwillprovideyouwithinformationtopresenttoyourcrewduringapre-jobsafetymeetingorwheneveryouneedtoreinforcewhatyoualreadyknow.

Chapter1RIGGInG UP THe eQUIPMenTThe Torque system:After measuring the rig and determining the torquesystem configuration, the top drive technician will require the help of a select number of crewmembers. As adriller, it’s up to you to choose workers who are confident workingatheightsandfollowinstructionswell.Awellthoughtoutpre-jobmeetingandtherightpeoplecanmakeriggingupthetopdrivemucheasierandsafer.Thetorquesystemincludesthefollowing:

1. TorqueTrack2. TorqueAnchorBeam3. T-Bar

Inthenextfewpageswewilldescribethepartsofthetorquesystem,whattheydoandsomeeffectivewaysofinstallingthem.

Torque Track:Thetorque trackconsistsofvaryinglengthsoftrack.Each section is designed to fit another by lining up the flanges and tightening the bolts. The length of the track dependsonthesizeoftherigmastbutinallcasesthebottomofthetrack,calledthedeflector section,shouldbe between 7 and 8 feet from the floor. The track is hung byattachinganadjustablehanging cluster toapadeyethathasbeenweldedtothecrown’sbeams.ThebottomofthetrackissecuredtothederrickbyboltingontheT-barandfasteningitintothetorque anchor beam. Using turnbuckles we can center the trackandproviderigidityalongthelengthofthederrick.Theturnbucklesareattachedtothetorquetrackandderrickusingclampsorbyweldinginpadeyesonthederrickbeamspriortorigup.

Insomecasesourtechniciansmaypre-assemblethetorquetrackonthegroundandhoistupto2sectionsat once. When hoisting the torque track, goodcommunication and the use of a hold back line arerequired.

Once the first section of track has been lifted to the drill floor with the tugger line, it is then lowered through the rotarytablesothatthetopofthetrackcanbeattachedtothetravelingblock.Afterraisingthetrackabovethefloor with the blocks, the rest of the track sections can be hoisted to the floor and placed in the rotary table individuallyandboltedintotheprevioussections.

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Whenthetorquetrackisfastenedtogetherinthelengthrequired to allow the top drive to travel between thehighestandlowestpointsinthederrick,itthenneedstobesecuredtothecrown.Thisisdonebyattachingthehangingclusteratthetopofthetracktoawelded-onpadeyewithashackle.Nextweneedtoposition thetorquetracksothatwecanfastenthet-bartoitandmakesurethatthetorqueanchorbeamwillacceptitaswell.

Oncethetorquetrackisinplacetheturnbucklesneedtobeattachedtoitandsecuredinpredeterminedlocationson the derrick strongbacks. Using these adjustable,lockingturnbuckleswecancenter thetrackandhelpproviderigidityalongthelengthofit.

Whenthetorquesystemisinstalleditshouldbestraightandattheproperdistancefromwellcenterandtherigfloor.

Torque anchor beam:The torque anchor beamaccepts the torque directlyfromthequillandtransfersittothederrick.Onsomerigswecanweldtheanchorinplace,on others we need to installthebeamusingclamps.Thebeam is usually attached tothe loweststrongbackwheretheenergycanbedisplacedacrossthewidestpointofthederrick. Periodic inspectionof the welds or the clampstightnessmustbeperformedto prevent any movement ofthetorquetrack.

Positionthehoistingslingandtuggerlineonthecenterof the load. Carefully raise the anchor beam to theappropriatestrongback.Thetopdrivetechnicianwillneedassistancetopositiontheanchorbeamonthestrongbackandholditinplaceuntiltheclampscanbesecured.Safety - Make sure all workers are connected to an approved fall arrest system.

T-bar:TheT-barisasolidsteelarmthatboltsontothetorquetrackatit’slowestpointandtakesthedrillingtorquefromthetopdriveandtransfersitthroughtheanchorbeamandacrossthederrick.

TheT-barcanbeinstalledin the torque anchor assoon as the beam issecuredtothederrick.

The T-bar can also bebolted on to the torquetrackjustbeforethetrack

ishungfromthecrownwhentheboltpatternsectionoftrackisatacomfortableheight.

WhentheT-barisattachedtothetorquetrackandthetrackishangingfromthepadeyeatthecrown,theT-barshouldbejustslightlyhigherthantheanchor.Thisway,whentheanchorclampistighteneddownitwillpullthetrackintotension.

Afterallthemaincomponentsofthetorquesystemareinstalledtheturnbucklescanbeadjustedtostraightenthetrack.

Note:Allshackles,turnbuckles,andsimilaritemsshouldbesecuredwithcotterpinsorsafetywires,topreventaccidentalloosening.

The Power Module:The Tesco hydraulictop drive comes witha building containinga prime mover thatdrives a series ofvariabledisplacement,bi-directionalhydraulicpumps.Thesepumpssend hydraulic flowthroughaclosed loop,high-pressuresystem

to the topdrivemotor(s),whichprovidequill rotationbefore returning to the skid to be filtered. Additional gear pumps send hydraulic flow through an auxiliarysystemtothetopdrive,operatingthevariousroboticfunctions as well as circulate oil through a filtration andcooling systembefore returning to the reservoir.Thepower modulealsocontainsanelectricalpanel,whichacceptsa480or600voltACinputfromtherig’s


generatorsandconvertsittoothervoltagesthatoperatetheelectricalcomponentsofthetopdrivesystem.Whenspottingthepowermodule,itmustbeliftedusingproperhoistingtechniquesandplacedinanidealpositionfortheservicelooptoreachthederrick.Iftheservicereelisnotattachedtothepowermoduleskid,thenitshouldbeplacedon rigmattingwith thepowermoduleandconnectedtotheauxiliaryhydraulicsystem.

The service loop:The service loop sends and receives electricalcommunication from the power unit and the driller’spanel as well as hydraulic flow to and from the top drive. It is critical that these lines not be damaged due toimproperliftingorobstructionsinthederrick.Oncetheserviceloophasbeeninstalled,observeitsmovementalongtheentiretravelofthetopdrive.

The service loop should make no contact with any part of the rig.

Usingasoft hoisting sling and the floor tugger, the operatorwillraisetheserviceloopintothederrickwhilethetopdrivetechnicianreelsoutenoughslacktoinstallthelinesintothehosesaddleandcapture clamp.

Oncethehose saddlepositionhasbeendetermineditisthenattachedtothederrick.Therigdesignandtopdrivemodelwilldeterminewherethesaddleislocated.Asafety slingshouldalwaysbeinstalledaroundthehosesaddleandhoses,andthenattachedtoeitheraweldedinpadeyeorasuitablebeam.Safetyslingsshouldalsobe installedbetween thehoseendsandthetopdrive.

The Top Drive:Thetopdriveisaheavy,unbalancedloadandshouldbe carefully handled to prevent injury or equipmentdamage. The topdrive technicianshouldalwaysbepresenttooverseeanyloadingorunloadingofTescoequipment.

Once the top drive arrives on location, it should beplacedonthecatwalksothatitcanbehoistedtotherig floor using 2 point, load rated slings attached to the blocks.Aholdbacklineshouldbeusedtopreventthetopdrivefromshiftingonceitislifted.

Beforethetopdriveisraisedto the rig floor, the torque bushing and extend frameneedtobeinstalledontothetorque track and pinned inplace.

With the top drive standpositionedoverholecenterand secured to the derricklegs using chains andboomers, the swivel cannowbeproperlydopedandthreadedintothequillwithachaintong.

On top drives equipped with an integrated swivel, the swivel bail or yoke is directly installed into the

becket or block hook.

Nowthetopdrivecanbeliftedfromthetransportstandbyraisingtheblocksandthetransportstandremovedfrom the rig floor.Using the blocks, line-up the pin holes between theextendframeandthetopdriveandinsertthedrivepinsandkeepers.

Withtheweightofthetopdrivehangingontheoverheadblocksandswivel,removethetorquebushingpin.Thetopdrivetechnicianwillconnecttheservicelooptothetopdriveandinstallthedriller’s panel.Withthepowerunitnowrunningandtheserviceloopanddrillerspanelconnectedtothetopdrive,wecannowmake up the swivel to the specified torque. To do this theoff-drillerssidetongsmustberaisedtotherequiredheighttobiteagainsttheswivelorcrossoverandbackupslingsattachedtoasuitablepointonthederrick.

It is critical that the bottom of the top drive be secured with a cross chain on the grabber leg or a joint of heavy weight drill pipe connected to the saver sub and set in the slips - or both. Torque should always be applied to the swivel connection in ‘drill mode’ and only the required personnel to do the job should remain on the rig floor.

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Chapter2Component IdentificationTop Drive:


The Rosemount Gauge receives a milliamp signalfromapressure transducer locatedon the topdrive.

Thetransducermeasuresthedifferentialbetweenthehighandlowpressuresidesofthetopdrivehydraulicmotor(s). This measurement gives you the mostaccuratetorquereadingwhiledrilling,whenthehydraulicoil in the loop is in a high flow state.

The Hydraulic Pressure Gaugeisusedprimarilytosetthetorquereliefs,whichcontroltheamountoftorquethatcanbeappliedtothequill.Thisgaugeisalsoveryaccuratewhenmakingandbreakingconnections,whenthehydraulicoilintheloopisinasemi-staticconditionandpressurelossesareataminimum.

Indicator lights:Thereareindicatorlightsinstalledinthedriller’spanelremindingyouthatafunctionis,orhasbeenperformed.The response toan illuminated indicator light shouldbe:

Stop - Why it is illuminated and how will it effect further operations?

Thereareindicatorlightsforthefollowing:DC Power Thisgreenlightshouldbeilluminatedatalltimes, indicating that thepowersupply to thedriller’spanelison.

Grabber Whenthegrabberisclosed,thelightwillcomeonandwillnotgooffuntil‘grabberopen’isselected.

Valve Whenthemudsavervalveisclosed,thelightwillcomeonwillnotgooutuntil‘valveopen’isselected.

Chapter3The Drillers PanelDescription:Thedrillers paneli s a s ta in lesssteel enclosureequipped with allof the controls,indicator lights,mounts, gaugesand connectorsr e q u i r e d t ooperate the topdr ive from thedriller’s position.Allofthecontrolsare 24 volts DCelectricoverhydraulic.Thetwomaincablestothepanelare37pinconductorcableswitheachwireservingaspecific function. One 37-pin cable connects the power moduletothedriller’spanelandtheotherconnectsthetopdrivewiththedriller’spanel.Thefoursmallercablesare4or5pinAmphenolconnectorswhichcontrolinputtothesafetyinterlocks,overridesanddigitalgaugesforquilltorqueandRPM. Positioning:

When deciding whereto mount the driller’spanel it is importantthat your view of ther ig f loor f rom thedriller’sposition isnotobstructedandthatyoucanreachthecontrolswellenoughtooperate

thedrawworksandtopdrivesimultaneously.Allofthecablestothepanelshouldberoutedinsuchamannerthatmovingpartswillnotdamagethemandtheyshouldbe elevated from the floor.

Instrument Gauges:There are two digital gauges on the driller’s panel,the RPM Gauge that meters quill rotation and theRosemount Gauge,whichreadsquilltorque.Separatefrom the driller’s panel is the Hydraulic Pressure Gauge,whichreadstheclosedlooppressureinpsi.The RPM Gauge givesanexact readingof thequillspeed.

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auxiliary Pump Thisamberlightwillilluminateiftheauxiliary pump is already runningand thena roboticfunctionisselected.Thisindicatesthatthehydraulicpressure needed to operate the robotics has beendelivered.Ifyounoticethatthelightison,checktoseeifanyswitcheshavebeenleft intheenergizedstate.When thepump is leftpressured-up, theoil return isrestrictedandtheoilmustpassoverarelief.Whenthisoccurs,thehydraulicoilwillquicklybecomeveryhotandthepumpmayeventuallyfail.

If a robotic function is selected and this light does not come on, the function has not occurred.

Pipe Handler Unlock When the pipe handler isunlocked,aproximityswitchlocatedonthetopdrivewillactivatealightonthedrillerspanel,indicatingthelockingassemblyhasbeendisabled.Thereisalsoaninterlockassociatedwiththiscircuitthatwillbedescribedinthefollowingsection.(Tesco Model HCI only)

safety Interlocks:An interlock is a term used to describe an electricalinputfromonefunctionthatpreventstheuseofanotherby cutting off the flow of electrical current. Interlocks are used on the top drive to minimize the possibilityofanunsafecondition.Thefollowingdescribeswhichfunctionshaveinterlocks,howtheyworkandwhy:

Grabber Whenthegrabberisswitchedtotheclosedposition, a signal is sent to the drawworks interlockinstalledintherig’sdrawworksconsole.Thisdeviceisasolenoidactuatedairvalve,whichclosesandcutsofftheairsupplytothehoistingclutchcontrols.Thiswillpreventtheaccidentalliftingoftheblockswhenthetopdrivequillisnotconnectedtothetooljointagainstwhichgrabberhasbeenclosed (i.e.afteraconnectionhasbeenbroken).Thegrabberisnotdesignedtoacceptany significant amount of load; this could result in pulling thegrabbercomponentsfromthetopdrive.Override – Inordertoholdtoolfacewhiledirectionaldrilling,thegrabberwillremainclosedonthetoptooljoint.Ifthedrillstringneedstobeworkedwhileholdingtoolface,thegrabbercloseinterlockmustbeoverridden.Todothis,push and hold the red button,locatedonthebrakehandlecontrolboxandhoistsimultaneously.

Mud saver Valve When the valve is switched toclose an interlock exactly like thedrawworksoneisenergizedtocutofftheairsupplytothemudpumpclutchcontrols.Thispreventsaccidentallystartingofthemudpumpanddead-ending pump flow against the mud savervalve.

Connection Mode/forward Tomakeaconnection,thedriller’spanelmust be switched to ‘connection’mode.Wheninthismode,severalpreset functions occur and the

drawworks interlock ispartof those functions. Oncethe tool joint has been made up to specified torque, it wouldbepossibletoleavethetopdrivein‘forward’andhoist thedrillstringtoremovetheslips.Thedrillstringwould then turnand thesliphandlescould injure thefloorhands trying to remove them. The interlock cuts offtheairsupplytothehoistingclutch,preventingthisfromhappening.Once the slips have been removed, do not switch to ‘forward’ until ‘drill’ mode has been selected.

Pipe Handler Theimproperuseofthepipehandlercanhaveseriousconsequences,butwithsafetyinterlocksand proper training we can minimize the risk of anyincidents.Whenthepipehandler“unlock”isactuated,aproximityswitchlocksoutthequillrotationunlessthepipehandlercaution(rotate)buttonispushedandheldwhilein‘connectionforwardorreverse’.(Tesco Top Drive Model HCI, ECI &EMI only)

Top Drive Rig Floor Safety Orientation Doghouse ManualPage �0

Chapter4hydraulic gauge to bleed off below 1000psi beforeselectinggrabber‘open’.

Allow 5 seconds for the grabber to fully open before switching the grabber to neutral.

Grabber lift (Tesco Top Drive Model HMI, notequipped):Ahydrauliccylinder,locatedinthegrabberleg, raises and lowers the grabber to the required

height for backing-up thetooljoint.Alwayspositionthegrabberatthetoptooljointbeforeraisingthetopdrive from the floor level. If foranyreason,suchashavingtobeginatripbeforethestandhasbeendrilled,you can simply close thegrabbertobreak-outofthestandatthemonkeyboardheight without having toguess whether or not thegrabber is in the correctposition.

Pipe Handler Inorder to turn theelevators in thedirectionneededforacertainoperation,thepipehandlerwillhavetobeused.Toperformthis,properoperationiscriticalforworkerandequipmentsafety.

The following steps must be followed before unlocking the pipe handler:•Allpersonnelmustcleartheareaofthetopdrive, elevators,andlinks.•Linktiltvertical(ifpossible,latchtheelevatorson thepipe).•Pumpsto‘neutral’.•Pipehandler‘unlock’andreturntoneutral.•Grabber‘close’(onthesaversub).•Pumps‘forward’or‘reverse’.•Push‘pipehandler–caution’button(rotate)

Thepipehandlersectionofthetopdrivewillnowrotateupto360degreesat4RPM.Once the orientation of the pipe handler is correct, these steps must be followed to disengage pipe handler rotation.•Release‘rotateorcaution’button.•Pumpstoneutral.•Grabber‘open’.•Pipehandler ‘lock’and return toneutral -a visual

Controls and RoboticsClearance and Visibility:The top drive takes up much more space on the rig floor thanakellywould,sothisworkareamustbekeptclearofobstaclesthatmayinterferewiththemovementofthetopdriveandthatofthepersonnel.Whenthetopdriveismovingthroughthederrick,youmustbeawareofit’spositionatalltimes.Becauseyouarenotalwaysabletoseethetopdrive,theothermembersofyourcrewmustalsowatchandbeawareofthetopdrive’spositionandmovementatalltimes.

Note:If you are unsure about any situation, stop and ask for help. This will save more time in the end and reduce the likelihood of an incident occurring.

Robotic functions:extend This feature allows the top drive to reachforward over the mouse hole, giving it the ability tomakeupstandsinthemouseholefordrillingaswellasaidingtheprocessofhandlingtoolstoandfromthev-door. Note: Anoptional extendalarm isavailableifrequested.Thisdeviceprovidesanalarmifthetopdriveisextended.

Note: If you leave the top drive extended out while hoisting with blocks, the top drive could make contact with the monkey board.

link Tilt Commonlyknownas‘thebails’,thelinkscanbetiltedtomovetheelevatorsupto35degreesforwardand55degreesbackfromvertical,extendingthereachofthetopdrivetoperformmanytasksassociatedwithpipehandling.

Grabber Thegrabberactslikeaback-uptongandclosesontoatooljointtoarrestthereactivetorquewhenmakinguporbreakingoutaconnection.

Rule of thumb: Allow 10 seconds for the grabber to close before applying torque.Whenbreakingout, close thegrabberand leave theswitchinthe‘close’positionuntiltheconnectionbreaks.Thenopenitwhilereversingoutofthethreadbox.Thisway,youcanhoistoutofthetooljointoncecompletelyun-threadedwithouttheinterlockdisablingthehoistingclutch.Formaking-upajoint,leavethegrabberswitchin the ‘close’ position until the specified torque is reached and the top drive stalls. Return the ‘pumps’ switchfromforwardtoneutralandallowthepressureonthe

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confirmation is critical to ensure the locking mechanism has fully engaged the lock ring gear. Thetopdrivecannowreturntonormaloperation.

Hydraulic elevators TheTesco top drive comesequippedwithautomaticelevators,whicheliminatetheneedtohaveapersonmanuallyoperatethem.Thisgives

the abi l i ty toopen and closetheelevatorsonextremely tallstands of BHAand reducesworkerexposureto add i t iona lh a z a r d sassociated with

manualoperationoftheelevators.The3-positionswitchmustbeturnedto‘open’andasafetypushbuttonheldatthesametimewithnoloadintheelevatorsforthemtoopen.Thisway,selectingthewrongswitchcannotaccidentallyopentheelevators.Theelevatorscanbeclosedbyeitherswitchingto‘close’onthedrillerspanelor by pushing the close button located on the brakehandlecontrolbox.Whenclosingtheelevators,visuallyconfirm the latch has closed.

Mud saver Valve and actuator Tesco top drivesincorporateadoubleballmudsavervalvewitharemote

actuatortoactasbothamudsaverandasanemergencyblowoutpreventionvalve.Theactuatorisdesignedtoallowyoutoopenorclosethemudsavervalveatanypoint in the derrick. It is critical that the actuator is never functioned while

the quill is rotating; this will damage the internal componentsandleadtofailureoftheactuator.Whenyouselectvalve‘close’theactuatorwillclosewithupto5000psiofhydrostaticwellborepressureagainstit.Onceyouhaveselectedvalve‘open’theactuatorwillopenandcannotbeclosedagainfor7seconds.Thispreventstheaccidentalre-closureofthevalveoncethemudpumpshavebeenstarted.

Top Drive Rig Floor Safety Orientation Doghouse ManualPage ��

Chapter5“workingsingle”remainsonthetopdrive.

Note: Make sure that all connections are properly doped.

Making Up singles:Extendoutandstabintothemouseholesingle.Latchtherigtongontomouseholesingleandrotatethequillforwardtoshoulderuptheconnection.

Important –Do not torque the connection in the mousehole with the top drive.

Carefullyretractthetopdriveintothetorquetrackwhilehoistingoutofmousehole.Positionthenewsingleaboveholecenterandslowlylowerit intothestump.Latchtherigtongonthestumpandrotatethequillforwardtomake up the connection to the specified torque. The torquevaluewillbereadonboththehydraulicpressuregaugeandtheRosemountgauge.

Similar procedures are used for an ‘off-bottomconnection’,butextracaremustbetakenwhenhoistingto retract the top drive and avoid contact with themonkey-board.

Making Up Doubles:Using the floor tugger, install one single in the mousehole andanothersingleonthev-doorleftconnectedtothetugger.Extendtopdriveoverthemouseholeandlinktilt forward so that the elevators can close on the v-door single. Hoist the v-door single above the rig floor andstabitintothemouseholesingle.Shoulderuptheconnectionbyusingeitherachaintongorbycarefullyguidingthetopofthenewstandintothetopdrivewiththelinktiltfunctionandrotatethequilluntilbothconnectionshaveshoulderedup.Usetherigtongstobackupthesingleinthemouseholewhilemakingupaconnectionwiththetopdrive.

Important - Do not torque connection in the mousehole with the top drive.

Now, carefully retract top drive into the torque trackwhilehoistingoutofthemousehole.Ensuretopdriveand blocks are clear of monkey-board. Position thenewstandaboveholecenterandslowlyloweritintothestump.Latchtherigtongontothestumpandrotatethequillforwardandmakeupbothconnectionstothespecified torque.

Making Connectionssafety:Making connections with a Tesco top drive greatlyreduces time and manpower needed to get back tobottom and drilling ahead. We can add pipe to thedrillstring in single joints anddoubleor triple stands.When making a connection, many tasks are beingperformedby the topdriveand it is critical that all personnel are aware of pinch point locations and stand clear of the top drive. All connection torquevaluesmustbeagreeduponbythecustomerpriortodrilling,andaconnectionworksheetsigned.TheTescotechniciansetsthetorqueparametersandthesecannotbeexceeded.

breaking out:The top drive can be drilled down to floor height by openingtheelevatorsandselectinglinktilt‘back’.Tomakeaconnection,rotationisstopped,themudpumpsare turnedoff, the slips set, anddrillerspanel set to‘connection’mode.

Know the weight of the top drive and overhead hoisting equipment. This amount should be read on the weight indicator gauge when the slips are set. If you have less than the weight of the top drive on the weight indicator, the counter balance system will not be able to lift the top drive out of the thread box and thread damage will occur. If you have more than the weight of the top drive reading on the weight indicator, the threads will be damaged and the top drive could bounce out of the threads and also damage the seal face.

Once the mud pump SPM and standpipe pressuregaugereadzero,itissafetoclosethemudsavervalve.Switchthegrabberto ‘close’,wait for thediestoset,andthenselect‘reverse’.Theconnectionwillnotbreakuntilthe‘breakout’buttonispushedandheld.Oncetheconnectionhasbroken,thebreakoutbuttoncanbereleasedandthegrabberopened.Continuereversinguntiltheconnectioniscompletelyunthreadedandthecounterbalancesystemhasgentlyliftedthetopdrivesaversuboutofthethreadbox.

Ifpreferred,connectionscanbemade‘offbottom’byhoisting one single through the table, before settingthe slips. The rig tongs must be used to break theconnectioninsteadofthetopdrive.Inthismethoda

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Note: If the rig floor is too large to pickup singles from thev-doorwiththelinktiltandextend,itisstillpossibletomakedouble(ortriple)connection.Makeasingleconnectionasdescribedabove.Raisethetopdriveandjointofpipe.Placeanotherjointofpipeinthemouseholeandmakeupasper‘off-bottom’connection.Repeatifa‘triple’isrequired.

Althoughitispossibletomakeuptriplestandsinthemouse hole with the top drive, it may be more efficient tomakeupstandsinadvanceandleavethemrackedinthederrickifdrillingwithtriplestandsisrequired.

Chapter6OperationsDrilling:Whendrillingaheadwithatopdrive,adheretothesamesafetyandoperatingpracticesandproceduresaswithconventionalrotarydrilling.

Rotating Onceyouhavemadeaconnectionandtheslipshaveclearedthetable,select‘valveopen’andstartupthemudpump,thenselect‘drill’modeimmediately.ThepresetfunctionsinconnectionmodewillbedisabledandnowyoucanmanipulatethequillRPMbyselecting‘forward’and‘increasingordecreasing’thepumps.slide DrillingInordertoholdtoolfacewhilesliding,youmustclosethegrabberonthesaversub,allowthegrabber cylinder topressure-up,and thenswitch the‘pumps–forward/reverse’,toneutral.Thegrabberlightwillremainon.

Whensliding, thegrabber is closedand thehoistingclutch interlock is activated. In order to work thedrillstringyoumustpushandholdthe‘override’buttonon thebrakehandlecontrolboxwhilehoisting. Thisallowsthedrawworksdrumclutchtoengage.

Whenrunningamudmotor,keepaccuraterecordsofthereactivetorque(motorpressure) in thestring. Atanygiventime,youmayneedtoorientthetoolfaceofthedownholemotor.Todothisthegrabberwillneedtobe opened; if you do not track downhole torque history, turningthestringinsmallincrementswillbeimpossible.Assumingthatyouknowtheamountoftorquepresent,followthesestepstoorientthetoolface:

1. Select‘drillforward’.2. Decreasethepumpssothatxpsi(thepressureequal

tothereactivetorque)ispresentonthehydraulicpressuregauge.

3. Select‘grabberopen’.4. Ifthevalueofxprovidesenoughtorque,thestring shouldnotturn.

Turnthestringtotherightbyselecting:

5. ‘Increasepumps’untilthepipeturnsveryslowly andundercontrol.6. Whenyouhaveachievedtheneworientation, quicklyclosethegrabber.


The amount of loop pressure needed to hold thedrillstringwhenthegrabber isopenedwillchangeasdepth, andangleof build increase. This iswhyyoushouldrecordadownholetorquehistory,becausethexvaluewillbeeasiertopredict.

Turnthestringtotheleftbydecreasinglooppressure(‘decreasepumps’),and,ifthereisnotmuchreactivetorque present, select ‘reverse’ until positioning iscomplete,thenclosethegrabber.

Note:Themaximumreversetorqueissettopreventthestringunscrewing. Donotengage the ‘breakout’functionorthedrillstringcouldcomeapart.

Tripping: TheTesco topdrivereduces theamountof timeandworkinvolvedintrippingandreamingbygivingyoutheability to thread into thedrillstringatanypoint in thederrick.Thisisusefulwhenencounteringholeproblemswhiletripping(forinstance,pullingtight,bridgingofforwhenakick isevident). Inshort,any timewhentheneed to pump fluid into the well exists, it can be done without having to position the drillstring at floor level in ordertoinstallthekelly.

Trippingpipewithatopdriveissimilartoconventionalmethods,withtheexceptionthattheroboticfunctionsease pipe-handling procedures. At no time is itnecessaryfortherigcrewtopositiontheelevatorsoropenandclosethem. The link tilt functioncanpushthestandofpipetoberackedtotheworker,bothonthe rig floor and to the derrickhand. When running in thehole,thederrickhanddoesnotneedtoleanouttothrow the stand in the elevators; he can simply ease thestandintotheelevators,whichareextendedtowardhim. Once thestand isplaced in theelevators, theycanbeclosedhydraulically.Afterthestandisrackedinthederrickoraddedtothestringthelinksshouldbereturned to thevertical hangingpositionby selectingthe ‘float’ function.Important – The links and elevators should never be manually operated by a worker. Cold Climate: Whenthehydraulic topdrive isworking ina freezingenvironment,theoilquicklybecomesthickandthiswillreduceitseffectiveness.Whiledrilling,theheatfromthetopdrivemotor(s)warmstheoilenoughsothatthisisnotaconcern,butwheneverthequillisnotrotating,suchaswhenyouareslidedrillingortripping,thecold

climate function should be used. To activate coldclimatefollowthesesteps:1. Pushinthecoldclimatebutton(ontheleftsideof thedrillerspanel).2. Selectenginespeed‘slow’.3. ‘Drill’mode.4. ‘Forward’pumps.5. ‘Increaseordecrease’pumps,tomaintain700psi onthehydraulicpressuregauge.Whenthecoldclimatebuttonispushedinitde-energizesthecircuittothetopdrivespeedcontrolvalveandallowsthe flow of loop oil to pass through the motor manifold andcirculatestheclosedloopsystemwithoutturningthequill.

Selectingenginespeedslowbrings theprimemoverto idle speed for cold climate operation. This savesoverallwearandtearontheenginewhenithasalowloadonit.

Drillmodeallowsyou tocontrol thehydraulicpumpsinternalswashplates,whichcommandtheamountofoil flow to maintain 700psi.

Forward pumps directs the oil flow in such a way that it passes through the maximum amount of filtration before goingthroughthepumpsagain.

Followthesestepsinordertoproperlydisengagethecoldclimatefunction:

1. ‘Neutral’pumps.2. ‘Connection’mode.3. ‘Neutral’enginespeed.4. Pulloutthecoldclimatebutton.

By selecting neutral pumps, the flow of hydraulic oil is stopped.

Important: never push out the cold climate button without the preceding 3 steps.Connectionmodekeepstheprimemoveratanidlewhentheenginespeedisswitchedtoneutral.

Afterpullingoutthecoldclimatebuttonthetopdrivecannowreturntonormaloperation.

Tip: If thetopdrivewill rotateandeverythingelse isoperatingnormally,doublecheckthatthecoldclimatebuttonhasnotbeenaccidentallyoperated.

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Reaming:BackreamingoutoftheholeisoneofthegreatestfeaturestheTescotopdriveprovides.Thesestepsshouldbefollowedbeforecommencing:

Note – Reaming is to commence only at operator’s discretion and until the driller is experienced with this operation, the Tesco technician should be alerted.

1. Ensurethecorrectsaversubisinstalledonthetopdriveandkeepitproperlydopedwhilereamingorback-reaming.

2. Connectthetopdrivetothedrillstring.3. Openthemudsavervalve.4. Startthemudpumpsandestablishcirculation.5. Removetheslips.6. Select‘drill’mode.7. Pumps‘forward’Set quill speed to 30-40 RPM.8. Hoistthedrillstringandclosetheelevatorson

thestand.9. Workthedrillstringuntilfreeofobstruction.Whenyouarereadytorackthestandinthederrick,theprocedureisasfollows:

1. Stoprotation.2. Stopthemudpumps.3. Settheslips.4. Breakoutthelowestconnectionwiththerigtongs.5. Hoiststandoutofthestumpandallowthepipeto

drain.6. Closethemudsavervalve.7. Lowerthestandtoapproximately2inchesabove

therotarytable.8. Ensure the grabber is in position at the top tool

joint.9. Closethegrabberandbreakoutthetopdrive.10.Oncethetopdriveisunscrewedfromthepipe,open

the grabber and the stand will rest on the floor.11.Hoist the topdriveuntil theelevatorspickup the

stand.12.Linktiltforwarduntilthederrickhandhascontrolof

thestandandithasbeenplacedinthebirdbath.13.Opentheelevators.14.Linktiltbacktovertical.15. Lower the top drive to the floor and continue back

reamingifnecessary.

Ifanobstructionisencounteredwhentrippinginthehole,orifforanyreasonitisnecessarytoestablishcirculation,i.e.wellcontrol,thetopdrivecanbeconnectedtothedrillstringquicklybyfollowingthesesteps:1. Ifanobstructionisencountered,hoistuntilthe

drillstring is free, and a connection is at floor level.2. Settheslips.3. Lowerthetopdriveandguidethetoptooljointinto

the grabber. Set backup tongs on tool joint at floor level.

4. Select‘connection’mode.5. Rotate the top drive into the top tool joint and

shoulderitup.6. Make up the connection to the specified torque.7. Openthemudsavervalve.8. Removethetongsandtheslips.9. Startthemudpumpsandestablishcirculation.10.Select‘drill’mode.11.Setquillspeedto30-40RPM.12.Ream through the obstruction until the string is

free.13. Lower top drive to the floor and disconnect the topdrive

–see,break out connection procedures.

Working Tight Hole:It is important to know that when torque is applied to the drillstring you cannot pull up to the maximum force that the pipe is rated for. The top drive technician will provide information on specific classes of tubulars and their torsion/tension thresholds.

Intightholesituations,itwillbenecessarytofreethepipeusingthetopdrive.Withthetopdrive,theabilitytomaintain mud pump flow, raise and lower the drillstring andholdtorqueallatthesametimeispossible.Itisrecommendedthatwhenworkingtighthole,sometorquecanbeappliedtothedrillstring.

Thisisbestdonebyselecting:

1. ‘Drill’mode2. ‘Decrease’pumps3. ‘forward’pumps4.Slowly‘Increase’pumps


Bydecreasingforwardpumppressure,therewillnotbeenough hydraulic flow to rotate the pipe. Now, slowly ‘increase’ the pumps until the pipe begins to rotate.Maintainenoughpressureon thehydraulicgauge tohold drillstring in torsion without reaching the torquereliefsettingonthetopdrive.Whenmaintainingstatictorqueoverextendedtimeperiods,itisrecommendedtoincreasethepumpstoavaluelessthanthetorquereliefsettingandallowthepumpstocontrolthedesiredtorque. If the topdrive torque relief isactivated, thehydraulicoilpassing through the reliefover time,willcreateexcessiveheat.Thehotoilmay,inturn,activateapowerunitshutdown,resultinginanuntimelytorquereleaseofthedrillstring.

The power module is equipped with numerous safety shutdowns. When the hydraulic oil reaches the high oil temperature shutdown setting, the prime mover will shut down. This should be avoided, especially in situations where hole problems are encountered.

Continueworkingthedrillstringwhilemaintainingtorquewiththetopdriveuntilafreepointisestablished.Whenthe pipe begins to rotate at this torque setting keepraisingandloweringpipeinthefreepointincreasingthetraveldistanceuntiltheobstructioniscleared.

Jarring:Ifjarringisrequired,thetorqueappliedtothedrillstringwillneedtobereleased.Byslowlydecreasingthequilltorqueshownonthehydraulicgauge,thereactivetorqueinthestringwillovercomethequilltorqueandthepipewill,inacontrolledmanner,rotateinreverseuntiltorsionisreleased.Oncethisisdone,settheslipsinordertobreakoutthetopdrive.

Tesco does not recommend jarring with the drillstring connected to the quill. The drillstring should be suspended from the elevators before jarring commences.Disconnect hydraulic hoses at the elevator quickconnectstoreducethechancesofelevatorsopeningaccidentally.

Afteranyjarringisdonethetopdrivetechnicianwillneedthetimetoperformavisualinspectionofthetopdrivecomponents and fill out a ‘Post Jarring Checklist’. In the eventofexcessivejarringaload path inspectionmayneedtobeperformedattheearliestconvenience.

logging:Whenusingthehydraulicelevatorstosupportawirelinesheave,disconnectthehydraulichosesattheelevatorquick connects to reduce the chances of accidentalopening.

Note: The hoses should also be disconnected topreventaccidentalopeninginanyotheroperationwheretheelevatorssupporta loadother than thedrillstring(forexample,whenasetof secondaryelevatorsaresupportedfromanubbininthehydraulicelevators).

Running Casing:Using the topdrive forrunning casing offerssomeadvantagesoverconventional methods.A t the cus tomer ’srequest, Tesco canprovideacrossoversubtoconnectthequilltothecasing, eliminating theneedtorig-upchiksansand fill up hoses. The topdrivealsoprovidespipehandlingfunctions

tomakehandlingcasingmuchsimplerandsafer.

Cementing:Unless it is absolutely necessary, never attempt tocementthroughthetopdrive.Withtheexceptionofthisrule,cementingwithatopdriveissimilartoconventionalmethods.

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Chapter7Top DriveConsiderationsslip and Cut Drilling line:Some daily rig operations change when a rig is fitted witha topdrive. Somesimpleprocedures that yourcrewhasperformedregularlywillneedtobeadjustedtoconsidertopdriveissues.

Toslipandcutdrillingline,obviouslytheweightofthetopdrivecannothangfromthesamelineastheblocksalonedid. The topdrive technicianwillassistyou indetermining the lengthofablock-hangingsling tobeinstalledinthederricktoasuitablebeamsothatthetopdrive is positioned at floor level. If your rig is already fitted with a block-hanging sling, the sling and the eye on theblocksshouldberatedtosupporttheweightofthetopdriveaswellasthetravelingblock.Thetopdrivewillhavetobeconnectedtothedrillstringandsetintheslipsaslowastheblock-hangingslingwillallow,tohelpdistributetheadditionalweightofthetopdrive.

Note – When performing a slip and cut with a top drive it is possible to pump fluid into the well if necessary.

Important – The blocks should never be hung from a floor tugger.

Top Drive Maintenance:Theregulardailymaintenanceandinspectionsonthetopdrivedonothavetointerferewithrigoperations.Inorder to keep the top drive running safely and efficiently, upto15minuteseverytourmustbeavailabletoservicetheequipment.Thetopdrivetechnician’sknowledgeofdrillingallowshimtochoosea‘windowofopportunity’todothiswhenthetopdriveisaccessiblefromaladderon the rig floor, while minimizing the impact on the customer’soperation.

If any service or repairs need to be done on the top drive, all of the drawworks controls and the driller’s panel must be locked out and tagged to ensure the safety of the personnel.

Important – The top drive technician must be notified of any concerns or incidents involving Tesco equipment.

DisclaimerThismanualisintendedtoprovidebasicinformationonly, and does not constitute a comprehensiveguide to the functioning or operation of aTescoTopDrive.ItistobeusedonlyinconjunctionwiththeorientationandonsitesupervisionprovidedbyTescopersonnel.TheTescoTopDriveTechnicianmust be notified of any concerns or incidentsinvolvingTescoequipmentanditsoperation.

OTHERTHANASDESCRIBEDINTHEPRECEDINGPARAGRAPH, TESCO CORPORATION, ITSAFFILIATED COMPANIESAND EMPLOYEESASSUMENORESPONSIBILITYFORUSEOFTHEINFORMATIONCONTAINEDINTHISMANUAL.

TescoCorporation(“Tesco”)hasmadeeveryeffortto ensure that this manual describes the basicknowledgeneededtoprovideaquickreferencefortopdriveoperators.

This manual is to be used in conjunction with an or ientat ion and on si te supervision.

Top Drive Rig Floor Safety Orientation Doghouse ManualPage �0

Better Ways to The Bottom™

Corporate Headquarters6204-6AStreetS.E.

Calgary,Alberta,CanadaT2H2B7Tel:403692-5700•Fax:403692-5710

World Wide operations11330BrittmooreParkDriveHouston,Texas,USA77041

Tel:713849-5900•Fax:713849-0075

PrintedinC

anada/October2006/TC

Due to ongoing product developm

ent, all specifications are subject to change without notice.

TESCO