Tesco HCI Operacion Guide PDF

Operations Guide
HCI(S) Top Drive System
500/650TON HCI(S) 750/1205HP
DOCUMENT NAME: 880003 REV B

OPERATIONS GUIDE COPYRIGHT AND DISCLAIMER
Tesco Corporation (“Tesco”) has made every effort to ensure that this document contains accurate and
current information 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 © 2005
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
880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

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REVISION INFORMATION OPERATIONS GUIDE
Revision Information
Version Date Description of Changes

Rev A May 2004 General Engineering review and updates for 2004
Rev B April 2005 Updates regarding the use of the grabber in the “Controlled String Back Off
Operations “ section of Chapter 8: Stuck Pipe
©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

IV
OPERATIONS GUIDE TABLE OF CONTENTS
TABLE OF CONTENTS
Chapter 1: About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: Driller’s Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Controls, Indicators and Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls and Indicators for Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls for Non-Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauges and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dual Function Remote Brake Handle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELEVATOR–CLOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GRABBER–Drawworks Interlock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3: Torque and Speed Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prime Mover Engine Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Available Torque and Quill Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Forward Rotation (PUMPS–FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reverse Rotation (PUMPS–REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BREAKOUT Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Forward Speed, Connect Mode (MODE–CONN, PUMPS–FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reverse Speed, Connect Mode (MODE–CONN, PUMPS–REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Forward or Reverse Speed, Drill Mode (MODE–DRILL, PUMPS–REV/FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PIPE HANDLER Rotation (Forward and Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to Set Forward Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust the MAX TORQUE Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust the SET TORQUE Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to Use the MAX TORQUE Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAX TORQUE Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to Set Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Set the REVERSE Speed for CONNECT Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Set the FORWARD Speed for CONNECT Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Set the PIPE HANDLER Speed (FORWARD and REVERSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to Set the Reverse Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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TABLE OF CONTENTS OPERATIONS GUIDE
Chapter 4: Other Pre-Operational Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Install the Saver Sub and Die Lock Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Orient the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Chapter 5: How to Make and Break Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Mudsaver Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pipe Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
How to Make Connections–General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
How to use the Mousehole to Connect Drill Pipe to the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . .21
How To Fully Torque a Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
How to Connect a Single Length of Drill Pipe to the Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . .23
How to Break the Top Drive/Drill Pipe Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
How to Use the Pipe Handler to Make Up Pipe Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
How to Make Up Stands in the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
How to Make Up Pipe Stands Without a Conductor Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
How to Make Up Pipe Stands in the Mousehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
How to Make Up BHA (Collars and Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
How to Connect Collars Above the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chapter 6: Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Well Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Surface Hole Drilling Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
How to Drill a Surface Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
About Connections and Surface Hole Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
About Tripping and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
About Reaming and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
How to Drill Ahead with Single Lengths of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
How to Drill Ahead with Pipe Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Mud Motors in Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
How to Adjust the Tool Face Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
How to Make and Break Connections During Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . .44
How to Maintain the Tool Face Orientation During Slide Drilling Operations . . . . . . . . . . . . . . . . .46
How to Record the Drill String Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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OPERATIONS GUIDE TABLE OF CONTENTS
Chapter 7: Tripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Well Control During Tripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
How to Remove the Mudsaver Valve Actuator During Well Control Tripping. . . . . . . . . . . . . . . . . 48
How to Trip Out Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Standard Racking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
How to Trip Out BHA (Collars and Tools). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Trip In Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
How to Trip In Tools and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
How to Trip In Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Reaming Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Use the Top Drive to Ream During Trip Out Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Use the Top Drive to Ream to Bottom During Trip In Operations . . . . . . . . . . . . . . . . . . . 59
Chapter 8: Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

How to Use the Top Drive to Free Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
How to Use the Top Drive for Jarring Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Controlled Drill String Back Off Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Uncontrolled Parting of the Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chapter 9: Run and Pull Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Prepare the Top Drive to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
How to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
How to Pull Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Chapter 10: Top Drive Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Slip and Cut Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cementing Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Slick Line Survey and Wire Line Logging Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Heavy Loads at the V-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix A: Post–Jarring Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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TABLE OF CONTENTS OPERATIONS GUIDE
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VIII
OPERATIONS GUIDE
CHAPTER 1: ABOUT THIS DOCUMENT

This Operations Guide contains information on how to use the Hydraulic Compact Integrated
(HCI(S)) top drive system to do the following:
• configure torque and speed settings
• use the driller’s panel
• make and break connections (drill pipe, top drive/swivel connection, collars, etc.)
• use the pipe handler
• drill
• trip pipe
• free stuck pipe (including jarring)
• run and pull casing
• use the top drive for special operations
Caution: This guide assumes the following: the top drive has been
installed correctly; the power system is enabled; and all required
safety checks have been performed. You will find these procedures
explained in the Installation Guide for your unit.
Table 1-1: Where to Find More Information
For information on Refer to

system components System Description
• installing the top drive Installation Guide
• rig up procedure
• commissioning
• pre-operational checklists
• rig out procedure
• load path inspections Maintenance Guide
• maintenance/service schedules
• component disassembly and reassembly
• long term storage procedures
Tesco manufactured parts and part numbers Parts List
troubleshooting Troubleshooting Guide (where available)
• electrical schematics System schematics
• hydraulic schematics
• cooling schematics
• gearbox lubrication schematics
available options and spares Tesco Representative

1
ABOUT THIS DOCUMENT OPERATIONS GUIDE

2
OPERATIONS GUIDE
CHAPTER 2: DRILLER ’S PANEL
GENERAL DESCRIPTION
The driller’s panel is a stainless steel enclosed panel that provides access to all required
switches, indicators, mounts, gauges and connectors.
The driller’s panel provides the controls, instrumentation and indicators required for safe oper-
ation of the top drive. The panel mounts at the rig floor, within convenient reach of the driller.
The driller’s panel interfaces with the main panel control system.
Table 2-1: Features of the Driller’s Panel
Controls
• robotic functions
• power unit functions
• Emergency Shut Down (E.S.D.)
Meters
• Quill RPM
• Differential motor pressure (quill torque)
Indicators
• warnings
• status
Electrical signals are transmitted from the driller’s panel to the top drive to control the follow-
ing:
• robotic functions
• forward torque limit (MAX and SET)
• range (HI/LOW)
• RPM count
• torque measurement
Electrical signals are transmitted from the driller’s panel to the power unit to control the fol-
lowing:
• auxiliary pump (on/off)
• engine speed
• Emergency Shut Down
• pump flow (rate and direction)
• reverse toque limit (break out)

3
DRILLER’S PANEL OPERATIONS GUIDE
Figure 2-1: HCI Driller’s Panel

4
OPERATIONS GUIDE DRILLER’S PANEL
CONTROLS, INDICATORS AND WARNING LIGHTS
Warning Lights
Indicator Description
CAUTION See PIPE HANDLER ‘CAUTION’ in the Controls and Indicators for
(red indicator light and push button) Robotic Functions table.
Indicator Lights
DC POWER This light, when illuminated, indicates that DC power is present at the
(green indicator light) driller’s panel.
Controls and Indicators for Robotic Functions

Unless indicated otherwise, a switch is in the ‘neutral’ position when it is in the central, verti-
cal position.
Control/Indicator Description/Function
AUX PUMP Use this switch to start or stop the auxiliary pump.
OFF/ON (switch)
ROBOTICS ‘ON’ When this light is illuminated, it indicates that a robotics function has
(yellow indicator light) been selected.
ELEVATOR Use the ELEVATOR OPEN/CLOSE switch in conjunction with the
OPEN/CLOSE SAFETY OPEN button to operate the elevators.
(switch; OPEN is spring-return to How to open the elevators:
neutral; CLOSE is maintained) 1. Turn the switch to the OPEN position and hold it there.
2. Press the SAFETY OPEN push button.
How to close the elevators:
Turn the switch to the CLOSE position, or push the brake handle.
SAFETY OPEN Use this push button in conjunction with the ELEVATOR–OPEN switch
(push button) to open the elevators.
LINK TILT Use this switch to tilt the elevator links backward and forward.
BACK/FWD Note: The links move backward and forward from the current
(switch; position is maintained) position of the pipe handler. Visually confirm the position of the pipe
handler before you operate the LINK TILT function.
FLOAT Press this button to relieve pressure in the LINK TILT cylinders. This
(push button) will return the elevator links to the neutral position (vertical below the
top drive).
EXTEND Use this switch to extend the top drive away from the torque track or
IN/OUT retract the top drive towards the torque track to its original position.
(switch; spring-return to neutral)
VALVE Use this switch to operate the actuator for the mudsaver valve. A
OPEN/CLOSE mechanical link between the actuator and the mudsaver valve opens
(switch; spring-return to neutral) and closes the valve.

5
VALVE ‘CLOSED’ When this light is illuminated, it indicates that VALVE–CLOSE has
(yellow indicator light) been selected.
GRABBER Use this switch to open and close the grabber. To achieve full clamping
OPEN/CLOSE pressure, keep the switch in the CLOSE position. When full clamping
(switch; OPEN is spring-return to pressure is achieved, you can return the switch to the neutral position
neutral; CLOSE is maintained) without losing pressure at the grabber.
GRABBER ‘CLOSED’ When this light is illuminated, it indicates that GRABBER–CLOSE has
(red indicator light) been selected at the driller’s panel.
GRABBER LIFT Use this switch to move the grabber leg up and down when you make
DOWN/UP or break connections.
(switch)
PIPE HANDLER Use this switch to lock or unlock the pipe handler. When the pipe
UNLOCK/LOCK handler is unlocked, you can rotate it to make pipe handling easier.
(switch; UNLOCK is spring-return to The quill will not rotate unless the PIPE HANDLER ‘CAUTION’ button
neutral; LOCK is maintained) is pressed.
PIPE HANDLER ‘CAUTION’ Use this button to rotate the pipe handler. Press and hold the button to
(indicator light and push button) rotate the pipe handler in forward or reverse direction. When this
button is illuminated, it indicates the pipe handler is unlocked.
Controls for Non-Robotic Functions

ENGINE The hydraulic power unit has regulators that allow you to preset two
SLOW/FAST speed ranges. The ENGINE switch allows you to manually select
(switch) either of the two preset speeds.
If you turn the switch to the neutral (centre) position, the engine will
switch speeds automatically, depending on the setting of the MODE
switch.
• If you select DRILL mode, then the fast engine speed will be applied.
• If you select CONNECT mode, then the slow engine speed will be
applied.
PUMPS Use this switch to control the quill direction (of rotation). This switch
REV/FWD (direction) changes the flow direction of fluid in the closed-loop hydraulic system,
(switch) which controls the rotational direction of the quill.
PUMPS Use this switch to control the quill speed. It works only in DRILL mode.
DECR/INCR (speed) This switch adjusts the output flow delivered by the closed-loop
(switch) hydraulic pumps.
MODE Use this switch to select the CONNECT mode or the DRILL mode.
CONN/DRILL If you select DRILL mode, the following parameters are applied:
(switch) • fast engine speed
• low/high range (whichever is selected)
• maximum torque (determined by either the SET torque relief or
MAX torque relief, whichever is selected)
If you select CONNECT mode, the following parameters are applied:
• slow engine speed
• low range
• SET torque
• preset pump output (which controls the quill RPM)

6
OPERATIONS GUIDE DRILLER’S PANEL
RANGE Use this switch to select the low or high quill speed. When you select
LOW/HIGH LOW range, fluid flow is directed to both Rineer motors. This produces
(switch) more torque.
When you select HIGH range, fluid flow is directed to one Rineer
motor. This produces higher RPM values and less torque.
MAX TORQUE Use this button to override the SET torque values set at the torque
(push button) relief valves. The maximum torque value is set at the operator’s
discretion (typically 15% greater than the SET TORQUE value).
This button is located on the side of the driller’s panel.
BREAKOUT Push this button to bypass the SET TORQUE setting for REVERSE
(push button) direction and apply the maximum system torque. This function is used
for breaking connections. The REVERSE torque setting is normally
lower than the BREAKOUT torque setting. This helps prevent
accidental break out of connections.
This button works only when the MODE switch is set to CONN, and the
PUMPS switch is set to REV.
E.S.D. PULL this button to deactivate the engine if there is an emergency.
(Emergency Shut Down push button) When you pull this button, the rig saver is tripped, and the fuel supply is
shut off.
Note: If you use the E.S.D., you must manually reset the rig saver
before restarting the prime mover.
Gauges and Displays

QUILL RPM This digital gauge displays the forward and reverse RPM for the quill.
An isolated output signal is also provided for input to a mud logger or
other data acquisition system.
QUILL TORQUE This digital gauge displays the net motor pressure, in both forward and
reverse. An isolated output signal is also provided for input to a mud
logger or other data acquisition system.
A secondary gauge for hydraulic torque pressure is also provided. This
gauge can be used in conjunction with Torque Charts to determine the
torque and RPM ranges available at a specific pump pressure.
Do not use the secondary gauge as your main source of
information. It does not account for line losses and will not provide
accurate readings in dynamic situations. Use this gauge only if the
main digital pressure gauge is not operational.
Dual Function Remote Brake Handle Control

The push button controls on the brake handle operate the ELEVATOR–CLOSE and the
GRABBER–Drawworks Interlock Override as described below.
ELEVATOR–CLOSE
To make tripping operations easier, close the elevators from a switch located on the brake han-
dle. This is a ‘spring-return’ push button that activates a timed sequence (five seconds) to
ensure that the elevators close completely. The five-second sequence activates even if the but-
ton is only briefly selected.

7
GRABBER–Drawworks Interlock Override
The interlock for the drum brake locks out the drum clutch so the driller cannot hoist while the
grabber is engaged. A red warning light located above the GRABBER switch on the driller's
panel indicates the status of the grabber. If this light is illuminated, it indicates that GRAB-
BER–CLOSE is selected. Use the push button on the brake handle to override the lockout fea-
ture.
Note: Use this override during directional drilling operations if you need to hoist
the string when the grabber is closed.
The override button operates a temporary contact. The override works only when the button is
pushed and held. When the button is released, air supply to the clutch control is interrupted,
and the override is no longer active.

8
OPERATIONS GUIDE
CHAPTER 3: TORQUE AND SPEED LIMITS
PRIME MOVER ENGINE SPEEDS

Adjust the engine speeds at the power unit before you set the torque and quill speeds for the
top drive.
Ensure that the engine is warm, then set ‘no load’ speeds as follows.
750 hp prime mover

CONNECT/LOW speed = 1100 RPM
DRILL/HIGH speed = 2100 RPM
1205 hp prime mover
CONNECT/LOW speed = 1250 RPM
DRILL/HIGH speed = 2250 RPM
Caution: Reduce the engine HIGH speed only for special drilling
activities. Consult a qualified Tesco representative before you reset
the engine HIGH speed.
Caution: Reduce the engine LOW speed only for engine cool-down.
Engine speed must be maintained to ensure the flow rate of the
charge pump remains adequate.

9
TORQUE AND SPEED LIMITS OPERATIONS GUIDE
AVAILABLE TORQUE AND QUILL SPEEDS

The torque or quill speed that is available is specific to each top drive activity. These are sum-
marized in the following table.
In this mode This torque is available This speed is available

DRILL SET TORQUE The quill RPM is determined by the
Forward or RANGE selected (HIGH or LOW) and
MAX TORQUE pump output. RPM is variable and is
(HIGH or LOW RANGE, if selected) controlled from the driller's panel.
DRILL One set value is available. The quill RPM is determined by the
Reverse (reverse pressure relief setting) RANGE selected (HIGH or LOW) and
pump output. The speed can be set to
various values.
CONNECT SET TORQUE One preset speed is available.
Forward or (minimum 17 RPM; maximum 20 RPM)
MAX TORQUE (if the MAX TORQUE
button is pressed and held during make
up operations)
CONNECT One set value is available. One preset speed is available.
Reverse (minimum 17 RPM; maximum 20 RPM)
BREAKOUT Maximum torque for the unit in LOW One preset speed
RANGE (in CONNECT MODE) is (minimum 17 RPM; maximum 20 RPM)
available.
MAX TORQUE The MAX TORQUE button applies the Dependent on the function selected.
(push button) maximum torque available when the
quill is rotating forward (CONNECT-
Forward, DRILL-Forward-LOW, DRILL-
Forward-HIGH).
Note: Intermittent maximum torque is
available regardless of whether the
MAX TORQUE switch is ON or OFF.
Torque Control
Forward Rotation (PUMPS–FWD)
Two torque settings are available for forward rotation. One is called SET TORQUE; the other
is called MAX TORQUE. Adjust these settings at two pressure relief valves located at the top
drive manifold. Adjust the torque values for SET and MAX TORQUE to match the make up
torque requirements of the drill string and the anticipated drilling conditions.
Maximum torque can be remotely selected at the driller's panel. The MAX TORQUE relief
setting can be locked with a key to prevent unauthorized adjustment.

10
OPERATIONS GUIDE TORQUE AND SPEED LIMITS
Reverse Rotation (PUMPS–REV)
One torque setting is available for reverse rotation.The torque setting for reverse rotation is
adjusted at a pressure relief valve located on the filter manifold on the power unit.
Warning! Set this torque relief valve to a value that is 50%

of the make up torque of the drill string (SET
TORQUE). This will help to prevent an
unintentional disconnection of the drill string.
BREAKOUT Torque
The BREAKOUT function is available only during CONNECT mode with the pumps in
REVERSE direction.
Breakout torque is the maximum torque that the power unit can supply. When you press the
BREAKOUT button, the torque relief is switched from the reverse pressure relief valve on the
filter manifold to the main panel relief valves. These are set to 4,500 psi.
Note: Preset speed must be a minimum of 17 RPM or a maximum of 20 RPM.
See the section on Speed Control for more information.
Speed Control
Forward Speed, Connect Mode (MODE–CONN, PUMPS–FWD)
The speed for connect mode with forward rotation is a preset value that can be adjusted at a
trim pot on the motor pot board. The trim pot is marked Connect-Forward Speed.
Reverse Speed, Connect Mode (MODE–CONN, PUMPS–REV)
The speed for connect mode with reverse rotation is preset value that can be adjusted at a com-
mon trim pot on the motor pot board. The trim pot is marked Reverse Speed.
Note: The preset speed must be a minimum of 17 RPM and a maximum of 20
RPM.
Forward or Reverse Speed, Drill Mode (MODE–DRILL, PUMPS–REV/FWD)
The speed for drill mode with forward or reverse rotation is controlled by a motorized trim pot
on the motor pot board. The operator can adjust the drilling speed from zero to the unit's max-
imum from the driller's panel as required.
PIPE HANDLER Rotation (Forward and Reverse)
The speed value for the pipe handler rotation is preset and can be adjusted at a trim pot on the
motor pot board. To ensure safe operation, the rotation speed for the pipe handler function
should not be set higher than Tesco’s recommended setting. The torque at the quill is limited
by low speed rotation and system design. The maximum torque available is not adjustable.

11
HOW TO SET FORWARD TORQUE

Set the MAX TORQUE value first when adjusting torque values. Valves are configured so that
the SET TORQUE value can never rise above the MAX TORQUE value.
Adjust the MAX TORQUE Setting

Refer to the transducer torque chart for your unit before you adjust the MAX TORQUE set-
ting. Use the torque charts for your unit to locate the appropriate values for MAX and SET
TORQUE settings.
1. At the driller’s panel, set the DRILL MAX TORQUE switch to ON.
2. Ensure that the GRABBER switch is set to OPEN.
3. Ensure that it is safe for the quill to rotate.
4. Set the ENGINE switch to SLOW.
5. Set the MODE switch to DRILL.
6. Set the RANGE switch to LOW.
7. Set the PUMPS–REV/FWD switch to FWD.
8. Use the PUMPS–DECR/INCR switch to adjust the pump flow to 25 gpm/pump.
Note: This ensures there is sufficient flow at the pump to generate adequate oil
pressure. Generally, 25 gpm/pump equates to approximately 25 RPM quill speed.
9. Set the PUMPS–REV/FWD switch to neutral (the vertical position between REV
and FWD).
10. Use the GRABBER LIFT switch to position the grabber so that it will close on the
saver sub.
11. Set the GRABBER switch to CLOSE.
Note: The system pressure will rise to the SET TORQUE value.
13. Unlock the MAX TORQUE relief valve. See Figure 3-1 on page 13.
14. Press and hold the MAX TORQUE button.
Note: This button is located on the side of the driller's panel.
15. Tighten the MAX TORQUE relief valve until the desired pressure value is
achieved.
Note: The system pressure gauge is located on the driller's panel.
16. Tighten the lock nut to secure the MAX TORQUE relief setting in place.

12
Figure 3-1: HCI SET and MAX Torque Relief Valves
“MAX Torque”
setting relief valve
“SET Torque”
setting relief valve
Adjust the SET TORQUE Setting

Refer to the torque charts for your unit before you adjust the SET TORQUE. Use the torque
charts for your unit to locate appropriate values for MAX and SET TORQUE settings.
Note: A detailed operations plan is required to ensure that the optimum setting
configuration is used.
1. At the driller’s panel, set the DRILL MAX TORQUE switch to OFF.
2. Ensure that the MAX TORQUE setting is higher than the anticipated SET
TORQUE value.
3. Set the GRABBER switch to OPEN.
6. Set the RANGE switch to LOW.
8. Use the PUMPS–DECR/INCR switch to adjust the pump flow to 25 gpm/pump.
Note: This ensures there is sufficient flow at the pump to generate adequate oil
pressure.
9. Set the PUMPS–REV/FWD switch to neutral (the vertical position between REV
and FWD).
saver sub.
Note: The system pressure will rise to the SET TORQUE value.

13
13. Tighten the SET TORQUE relief valve, located in the top drive mainframe, until
the desired torque value is achieved. See Figure 3-1 on page 13.
Note: The gauge for system pressure is located in the driller's panel.
How to Use the MAX TORQUE Function

The operator can use the MAX TORQUE button to apply maximum torque on demand when-
ever the quill is rotating in the forward direction (CONNECT–FORWARD mode, DRILL–
FORWARD mode in LOW range, and DRILL–FORWARD mode in HIGH range).
Note: The MAX TORQUE function is available on demand whether the MAX
TORQUE switch is set to ON or OFF.
MAX TORQUE Override
Set the MAX TORQUE switch to ON to override the SET TORQUE setting for DRILL–FOR-
WARD operations. This allows the MAX TORQUE value to be achieved without the operator
having to press the MAX TORQUE button. This override can be applied to either high range
or low range operations, but not both. The DRILL MAX TORQUE RANGE keyed switch is
located on the outer left side of the driller's panel, next to the MAX TORQUE button.
Note: The operator can still access maximum torque for other “quill forward”
operations on demand by pressing the MAX TORQUE button.
HOW TO SET SPEEDS

If a saver sub and die lock clamp have not been installed at this point, you can install them
now.
Set the REVERSE Speed for CONNECT Mode

1. Ensure the power unit is operational.
Note: Do not use this procedure until the power unit has been properly warmed
up.
2. Ensure the top drive is free to rotate.
3. Ensure the PIPE HANDLER is locked.
4. Set the MODE switch to CONN.
5. Set the PUMPS–REV/FWD switch to REV.
6. Note the current quill speed that is displayed at the driller's panel.
7. Locate the motor pot board at the main electrical panel of the power unit.
8. Loosen the lock nut on the trim pot labeled Connect Reverse.
9. Adjust the trim pot until the desired quill speed is achieved.
Note: 17 RPM minimum is recommended.
10. Tighten the lock nut on the trim pot.

14
Set the FORWARD Speed for CONNECT Mode

up.
2. Ensure the top drive is free to rotate.
6. Note the current quill speed displayed at the driller's panel.
8. Loosen the lock nut for the Connect Forward trim pot.
9. Adjust the trim pot until the desired quill speed is achieved.
Note: 17 RPM minimum is recommended.
10. Tighten the lock nut on the trim pot.
Set the PIPE HANDLER Speed (FORWARD and REVERSE)

up.
2. Ensure the quill is free to rotate.
Caution: Note the position of the elevator links before you operate
the pipe handler. The elevator links must be in the vertical position.
Do NOT close the grabber.
3. Set the PIPE HANDLER switch to UNLOCK.

5. Note the current quill speed displayed at the driller’s panel.
7. Loosen the lock nut for the motor pot labeled Pipe Handler.
8. Adjust the motor pot until the desired quill speed is achieved.
Note: 6 RPM is recommended.
9. Tighten the lock nut on the motor pot.

15
HOW TO SET THE REVERSE TORQUE

Ensure that a saver sub and die lock clamp have been installed before you start this procedure.
Caution: This procedure assumes you have already set the speed
setting for Connect–Reverse.
Refer to the torque charts for your unit before you adjust the reverse torque setting. The
reverse torque setting should be set to 50% of the make up (set) torque setting.
1. Ensure the relief valve for reverse torque is fully unscrewed. This valve is located
on the filter manifold of the power unit.
2. Ensure that the GRABBER switch is set to OPEN.
6. Use the PUMPS DECR/INCR switch to adjust the quill rotation to 17 RPM (±1)
7. Set the PUMPS–REV/FWD switch to neutral.
Note: Wait until the quill stops rotating.
8. Position the grabber on the saver sub.
Note: Ensure that die lock clamps have been installed (these prevent the saver sub
from disconnecting).
12. Monitor the pressure gauge at the driller's panel.
13. Adjust the relief valve at the filter manifold on the power unit to obtain the
required reverse pressure.
14. Cycle the quill rotation from forward to reverse to confirm that the desired pres-
sure value has been achieved.
15. If the reverse pressure is correct, set the PUMPS–REV/FWD switch to neutral
(the vertical position between REV and FWD).

16
OPERATIONS GUIDE
CHAPTER 4: OTHER PRE-OPERATIONAL

PROCEDURES
INSTALL THE SAVER SUB AND DIE LOCK CLAMP
Caution: If the SET or MAX TORQUE setting was increased to

connect the swivel, lower them before you perform the following
procedure.
Caution: The recommended saver sub torque for a 4-1/2 in. IF

connection is 28,000 ft·lb.

2. Position the saver sub through the grabber box.
Note: Ensure the upper pin protrudes above the grabber box.
3. Attach the saver sub by hand.
5. Apply pipe dope to the threads of the saver sub.
8. When the quill begins to rotate, use the GRABBER LIFT switch to raise the grab-
ber to join the saver sub and mudsaver valve connection.
Caution: Raise the grabber in small increments to minimize the
force on the threads.
Caution: The saver sub must be perfectly vertical and centered with
the quill. Any deviation can damage the threads on the mudsaver
valve.
9. Continue rotation until the connection is fully engaged.

10. When the desired torque is achieved, set the PUMPS–DECR/INCR switch to neu-
tral.
12. Center the die lock clamp around the quill, on top of the grabber box.
13. Loosely install the die lock bolts (8).

17
OTHER PRE-OPERATIONAL PROCEDURES OPERATIONS GUIDE
14. Raise the die lock clamp into position and hold, either manually or by using the
GRABBER LIFT function.
Note: Position the clamp so it evenly straddles the connection between the saver
sub and the mud valve.
15. Apply anti-seize compound to all cap screws and tighten them all evenly.
Note: Monitor the end gaps to ensure that the clamp is installed evenly.
16. Torque all 7/8 in. Grade 8 fasteners to 550 ft·lb.
Note: For more information, refer to the appendix titled ‘Torque Specifications
for High Strength Fasteners’ in the Maintenance Guide for your unit.
17. Use the GRABBER LIFT switch to lower the grabber.
18. Seat the dies.
Note: To seat the dies, strike the back side of each half of the clamp as hard as
possible with a sledge hammer.
19. When the dies seat properly, torque all bolts to 550 ft·lbs.
ORIENT THE PIPE HANDLER

Take the following precautions before you operate the pipe handler function:
• Ensure the elevators and elevator links are hanging vertically.
• If the top drive is connected to the drill string, ensure that it is safe to rotate the string.
1. Ensure that the pipe handler is not holding any reactive torque from the drill
string. Do this by setting the GRABBER switch to OPEN and setting the
PUMPS–REV/FWD switch to neutral.
2. Ensure the PUMPS–REV/FWD switch is set to neutral.
Note: This switch must be set to neutral for at least five seconds before the pipe
handler will unlock.
Caution: The grabber should close on the saver sub. Do not close
the grabber on the threads of the saver sub.

Note: The PIPE HANDLER CAUTION light illuminates on the driller’s panel.
5. Use the PUMPS–REV/FWD switch to select the direction of rotation for the pipe
handler.
Note: The pipe handler will not rotate until you press the PIPE HANDLER CAU-
TION button.
6. Press and hold the PIPE HANDLER CAUTION button to rotate the pipe handler.
7. Release the PIPE HANDLER CAUTION button when you achieve the desired
orientation.
9. Set the PIPE HANDLER switch to LOCK.
Caution: Visually inspect the locking mechanism on the pipe han-
dler to ensure that the lock is fully engaged.
10. Open the grabber, if required, and continue operations.

18
OPERATIONS GUIDE
CHAPTER 5: HOW TO MAKE AND BREAK

CONNECTIONS
WARNINGS
Mudsaver Valve
When you operate the mudsaver valve, the valve switch applies pressure to the actuator. If the
quill rotates with pressure applied, seal damage can result. Because of this, a mudsaver inter-
lock stops the quill rotation for five seconds while the valve operates.
Pipe Slips
Danger! Always exercise caution when you set and

remove pipe slips. If you set the slips when the
rotary table is locked, this might trap torque in the
drill string. When you remove the slips, any
trapped torque might release and turn the drill
string. Hoist the drill string free of the slips before
you remove the slips.

19
HOW TO MAKE AND BREAK CONNECTIONS OPERATIONS GUIDE
HOW TO MAKE CONNECTIONS–GENERAL

Do the following before you begin this procedure:
• Ensure the torque and speed settings are appropriate for the drill string and drilling con-
ditions.
• Ensure that the thread on the saver sub matches the thread on the drill string.
• Properly apply pipe dope to all threaded connections.
Caution: When you connect the top drive to a single length of drill
pipe, position the grabber so that it closes on the drill pipe tool
joint. When you make up the top drive and additional connections
simultaneously, position the break-out tongs on the drill pipe tool
joint located in the slips.
Figure 5-1: Correct Tong Position to Make a Connection
Correct tong position for:

top drive connection only
top drive and pipe/pipe connection

Note: The top drive turns at the pre-selected RPM for CONNECT mode with for-
ward rotation.
3. Apply a back-out tong to the underside of the lower connection of the single or
stand of pipe.
Note: If you make up the top drive and lower connection at the same time, apply
the back-out tong below the lower connection. If you make up a top drive connec-
tion only, apply the break-out tong to the single length of pipe. In this case you can
use the grabber instead of a break-out tong.
4. Slowly lower the top drive to the connection.
5. Ensure that the box connection enters into the drill pipe guide.
6. Monitor the weight indicator gauge.

20
OPERATIONS GUIDE HOW TO MAKE AND BREAK CONNECTIONS
7. Continue to lower the top drive until the weight indicator begins to fluctuate.
Caution: Ensure that the Vernier dampening valve (located on the
weight indicator) is open.
8. Lead the top drive into the connection.

Note: Lower the top drive in small increments as the connection rotates in. Keep a
small amount of weight on the connection (i.e. the weight indicator should register
only a small amount of weight). This prevents the top drive from “lifting” the
stand or single of drill pipe and damaging the threaded connections.
9. Continue forward rotation until the connection is fully engaged.
Note: The top drive stalls when it reaches the preset SET torque. The forward
rotation speed then drops to zero.
10. Monitor the digital pressure display on the driller’s panel.
11. When the torque matches the required make up torque value, set the PUMPS–
REV/FWD switch to neutral.
12. Wait until the differential pressure value decreases to zero.
13. Remove the back-up tong, or open the grabber (if used).
How to use the Mousehole to Connect Drill Pipe to the Top

Drive
Use this procedure when you drill with single lengths of pipe.
1. Put a single length of pipe in the mousehole.
2. Apply pipe dope to the box connection on the drill pipe.
3. Turn the EXTEND switch to OUT.
4. Extend the top drive until it is situated directly over the mousehole.
5. Lower the top drive until the elevator and elevator links are near the rig floor.

21
Figure 5-2: Correct Position for Elevator Links and Elevator
6. Set the LINK TILT switch to BACK.

7. Move the elevator links and elevators backward and out of the way of the connec-
tion.
8. Lower the top drive until the saver sub is within a foot of the pipe connection.
11. Slowly lower the top drive to engage the connection between the saver sub and the
drill pipe.
Note: If the pipe starts to spin in the mousehole, set the PUMPS–REV/FWD
switch to neutral. Adjust the weight on the connection to prevent spinning, then
set the PUMPS–REV/FWD switch to FWD.
13. When the connection is fully engaged, set the PUMPS–REV/FWD switch to neu-
tral.

22
How To Fully Torque a Connection

4. When the torque value matches the value required to fully torque the connection
to specification, set the PUMPS–REV/FWD switch to neutral.
How to Connect a Single Length of Drill Pipe to the Drill String

1. Hoist the single length of pipe out of the mousehole without torquing the connec-
tion.
2. Set the EXTEND switch to IN.
3. Retract the extend arms until the top drive is positioned over hole center.
4. Place break-out tongs on the tool joint of the drill pipe that is held by the rig slips.
5. Apply pipe dope to the tool joint box.
6. Lower the top drive to stab the drill pipe into the tool joint box of the drill pipe
held in the rig slips.
10. Monitor the differential pressure gauge.
11. When the torque reaches the required torque value to make up the current connec-
tion, set the PUMPS–REV/FWD switch to neutral.

23
Figure 5-3: Connect a Single Length of Pipe to the Drill String
HOW TO BREAK THE TOP DRIVE/DRILL PIPE CONNECTION

Use this procedure to disengage the connection between the top drive and the drill pipe.
1. Position the grabber so that it will close on the box of the drill pipe.
Caution: Ensure that the grabber will not close on any part of the
saver sub or the hard band of the drill pipe.

Danger! This is an important safety step.

Note: The differential pressure gauge will rise to the ‘reverse relief’ pressure.
6. Push and hold the BREAKOUT button.
7. When the connection breaks, do the following:
• Immediately release the BREAKOUT button.
• Quickly set the PUMPS–REV/FWD switch to neutral.
10. Lead the top drive out of the connection.

24
11. When connection is disengaged, hoist the top drive clear of the rig floor.
Figure 5-4: Break the Top Drive/Drill Pipe Connection
Close the grabber on the box of

the drill pipe. Use connect-
reverse operations and the
BREAKOUT button to break the
connection.

25
HOW TO USE THE PIPE HANDLER TO MAKE UP PIPE STANDS
How to Make Up Stands in the Rotary Table

Figure 5-5: Make Up Stands in the Rotary Table
1. Pick up a single length of pipe from the mousehole.

2. Lower the pipe through the rotary table.
3. Pick up the second length of pipe from the mousehole.
4. Connect the two lengths of pipe.
5. Lower the connected lengths of pipe through the rotary table.
The following procedure assumes that you are making up stands of pipe where there is 60 ft. of
available depth below the rotary table. This is usually possible if conductor pipe is complete.
If no conductor pipe is drilled, refer to “How to Make Up Pipe Stands Without a Conductor
Pipe” on page 28.
Note: Use the floor tugger to make up stands of pipe more efficiently. Use the
floor tugger to place single lengths of pipe in the mousehole while you use the top
drive to make connections in the rotary table.
1. Use the floor tugger to lower a single length of pipe into the mousehole.
2. Lower the top drive.
3. Use the LINK TILT switch to tilt the elevator forward over the mousehole.
Caution: Do not use the EXTEND function to move the top drive
over the mousehole or the travelling blocks might strike the racking
platform if you hoist the top drive.
4. Position the elevator on the pipe single.

5. Set the ELEVATOR switch to CLOSE.

26
6. Hoist the top drive and the pipe out of the mousehole.
7. Press the FLOAT button. This allows the elevator to come to the vertical position
over hole center.
8. Lower the pipe through the rotary table to the required connection height.
9. Set the slips.
10. Set the ELEVATOR switch to OPEN. Push and hold the SAFETY OPEN button.
11. Use the LINK TILT switch to tilt the elevator back slightly.
Note: This prevents the elevator from hitting the tool joint as the top drive is
raised.
12. Hoist the top drive until the elevator is clear of the pipe.
13. Set the LINK TILT switch to FORWARD.
14. Position the elevator over the mousehole.
15. Lower the top drive and close the elevator on the second length of drill pipe now
located in the mousehole.
Note: The tugger operator should have place the pipe in the mousehole while the
top drive operator was making the connection at the rotary table.
16. Hoist the top drive until the bottom of the second length of pipe is above the pipe
in the rotary table.
17. Press the FLOAT button. This allows the elevator to come to hole center.
18. Lower the top drive and stab the pipe in the rotary table.
19. Attach the pipe spinner to the upper length of pipe, or rotate the connection by
using chain tongs.
20. Spin the upper pipe until the connection is fully engaged but not tight.
21. Remove the pipe spinner, then use rig tongs to torque the connection to specifica-
tion.
22. Hoist the top drive and the double length of pipe.
23. Remove the slips.
Note: If you are making up double lengths of pipe only, proceed to “Standard
Racking Procedure” on page 52.
24. Lower the top drive and the double length of pipe into the rotary table to the
required connection height.
25. Set the slips.

27
How to Make Up Pipe Stands Without a Conductor Pipe

If no conductor pipe is in place, make up triple stands of pipe by modifying the previous pro-
cedure as follows:
1. Connect the first two single lengths of pipe as described in the previous proce-
dure, then continue to the following steps.
2. Hoist the double stand of pipe until it is above the drill floor.
3. Use the floor tugger to place a single length of pipe into the rotary table.
4. Set the slips.
5. Lower the top drive and the double length of pipe to stab the pipe single in the
rotary table.
6. Connect the pipe double and pipe single by using the pipe spinner and rig tongs.
7. Use the rig tongs to torque the connection.
8. Proceed with racking as described in “Standard Racking Procedure” on page 52.
How to Make Up Pipe Stands in the Mousehole

It is more difficult and less efficient to make up stands of pipe in the mousehole than when you
use the rotary table. Use the following procedure when the rotary table is unavailable.
Figure 5-6: Make Up Pipe Stands in the Mousehole
1. Use the top drive to pick up a single length of pipe from the mousehole.
2. Use the tugger to insert a second length of pipe into the mousehole.
3. Connect the first length of pipe to the second length of pipe that is in the mousehole.
4. Hoist the connected double length of pipe.
5. Use the tugger to put the third length of pipe into the mousehole.Lower the top drive
and connect the double length of pipe to the third pipe that is in the mousehole.

28
1. Use the floor tugger to lower a single length of pipe into the mousehole.
2. Lower the top drive.
3. Use the LINK TILT switch to tilt the elevator forward over the mousehole.
Warning! Do not use the EXTEND function to move the top
drive over the mousehole. If you hoist the top
drive while it is extended, it might collide with the
racking platform.
4. Position the elevator on the single length of pipe.

6. Hoist the pipe out of the mousehole.
7. Use the floor tugger to lower the second length of pipe into the mousehole.
8. Lower the top drive and pipe and stab the second length of pipe that is in the
mousehole.
Caution: Release all the weight off the elevator to reduce the fric-
tion between the pipe and the elevator.
9. Attach chain tongs to the upper and lower lengths of pipe.

Caution: You cannot use most pipe spinners when you make con-
nections at the mousehole.
10. Ensure the connection is fully engaged but not tightened.

11. Use the rig tongs to torque the pipe connection to the required specification.
12. Hoist the double length of pipe out of the mousehole.
Warning! Adjust the LINK TILT position as required to
avoid hitting the racking platform while you hoist
the top drive. The same caution applies when
you use the EXTEND function.
13. Use the floor tugger to lower the third length of pipe into the mousehole.
14. Lower the top drive and double length of pipe to stab the third pipe that is in the
mousehole.
Warning! Adjust the LINK TILT position to avoid hitting the
racking platform while you make this connection.
15. Release all the weight off the elevator to reduce the friction between the pipe and
the elevator.
16. Attach chain tongs to the double and single lengths of pipe.
17. Ensure the connection is fully engaged but not tightened.
18. Use the rig tongs to torque the pipe connection to the required specification.

29
19. Hoist the completed triple stand of pipe until the bottom of the stand is above the
floor racking area.
Warning! Use caution when the pipe stand clears the
mousehole; the stand will tend to swing to the
vertical position. Move the elevator links and
elevator to hole centre to avoid hitting the
racking platform when you hoist the top drive.
20. Follow the “Standard Racking Procedure” on page 52.

21. Lower the top drive and proceed with making up the next stand of pipe.

30
HOW TO MAKE UP BHA (COLLARS AND TOOLS)

Use the pipe handler to help make up the Bottom Hole Assembly (BHA), collars, and tools.
The rate of rotation for the pipe handler is set when torque and speed settings are established.
When the LINK TILT function is used to move collars, remember the link tilt cylinders have
limitations. If the elevator links are extended over the mousehole and connected to a collar,
they might return to hole center when the top drive is raised. If this occurs, hydraulic oil will
be directed over the safety relief valve.
Caution: If pick-up elevators are used for the collars, disconnect

the elevator ‘open’ and ‘close’ hydraulic hoses.
Figure 5-7: Connect Collars
1. Pick up the first collar from the mousehole.

2. Lower the collar into the rotary table.
3. Disconnect the pick-up sub from the collar.
4. Pick up a second collar from the mousehole.
5. Hoist the second collar out of the mousehole.
6. Lower the top drive and connect the collars.
1. Use the floor tugger to put a collar in the mousehole.

2. Ensure that a pick-up sub is installed on the collar.
Note: Use chain tongs to install the pick-up sub.
Warning! Torque the connection between the pick-up sub

and the collar to prevent it from unscrewing.

31
3. Raise the grabber box to its maximum height.

5. Position the elevators over the mousehole.
6. Lower the top drive and position the elevator on the pick-up sub.
8. Hoist the top drive until the collar is clear of the mousehole.
9. Press the FLOAT button. This allows the elevator to return to a vertical position
over hole center.
10. Lower the top drive until the collar is correctly positioned in the rotary table.
11. Set the slips and attach a safety clamp.
12. Use the rig tongs to loosen the connection between the pick-up sub and the collar.
13. Once this connection is loosened, use the chain tongs to unscrew the connection
completely.
14. Hoist the top drive and the pick-up sub.
15. Use the floor tugger to place a second collar in the mousehole.
17. Position the elevator over the mousehole.
18. Lower the top drive and the pick-up sub, and stab the second collar that is in the
mousehole.
19. Use the chain tongs to connect the pick-up sub and the collar.
Caution: Torque the connection between the pick-up sub and the
collar to prevent it from unscrewing.
20. Hoist the top drive until the collar is clear of the mousehole.
21. Press the FLOAT button. This allows the elevator to move to the vertical position.
22. Lower the top drive to stab the collar that is in the rotary table.
Caution: The elevator links must hang vertically over the connec-
tion point.
23. Position the grabber so that it will close on the saver sub, then set the GRABBER
switch to CLOSE.
24. Set the PIPE HANDLER switch to UNLOCK. This allows the pipe handler to
rotate and make up the connection.
26. Push and hold the PIPE HANDLER CAUTION button. The pipe handler begins
to rotate at the preset speed.

32
27. While holding the PIPE HANDLER CAUTION button, lower the top drive to
engage the connection.
Note: Carefully calibrate top drive weight on the connection to prevent the collar
from spinning in the elevator. Balance the top drive by raising and lowering it in
small increments.
Caution: You must use the grabber override button on the brake
handle to hoist the top drive when the grabber is closed.
28. Rotate the connection until it is fully engaged but not tightened.
29. Release the PIPE HANDLER CAUTION button.
31. Attach rig tongs to the collars.
32. Torque the connection to the required specification.
33. Remove the safety clamp.
34. Hoist the top drive and remove the slips. This suspends the collars from the eleva-
tor of the top drive.
35. Lower the collars through the rotary table to the desired connection height.
37. Use the rig tongs to disconnect the pick-up sub from the top collar.
38. Repeat steps 19. to 37. to connect the third collar.
39. When all required collars are made up, do the following:
a. Set the PIPE HANDLER switch to LOCK.
b. Set the GRABBER switch to OPEN.
c. Visually inspect the pipe handler to confirm that it is locked.
How to Connect Collars Above the Rotary Table

1. Follow steps 1. to 37. of “How to Make Up BHA (Collars and Tools)” on page 31
to connect the first two collars in the rotary table.
Note: When these steps are complete, ensure that:
• there are two collars in the rotary table (one low in the table, the second above),
• the top collar is connected to a pick-up sub, and
• both collars are suspended from the top drive elevator.
3. Hoist the top drive and remove the slips. This suspends the collars from the top
drive elevator.
4. Hoist the top drive and collars above the rotary table.
Note: Use the floor tugger to place a third collar in the rotary table. Use the slips
and a safety clamp to secure the collar in place.
5. Lower the top drive to stab the connection in the rotary table.
Caution: The elevator links must hang vertically over the connec-
tion point.

33
6. Position the grabber so that it will close on the saver sub, then set the GRABBER
switch to CLOSE.
7. Set the PIPE HANDLER switch to UNLOCK. This will allow the pipe handler to
rotate and make up the connection.
9. Push and hold the PIPE HANDLER CAUTION button. The pipe handler will
begin to rotate at the preset speed.
10. While holding the PIPE HANDLER CAUTION button, lower the top drive to
engage the connection.
Note: Carefully calibrate top drive weight on the connection to prevent the collar
from spinning in the elevator. Balance the top drive by raising and lowering it in
small increments.
Caution: You must use the grabber override button on the brake
handle to hoist the top drive when the grabber is closed.
11. Rotate the connection until it is fully engaged but not tightened.
12. Release the PIPE HANDLER CAUTION button.
14. Attach rig tongs to the collars.
15. Torque the connection to the required specification for the drill collar.
17. Hoist the top drive to clear the collars from the rotary table.
18. Rack the collars according to the “Standard Racking Procedure” on page 52.
19. When all required collars are picked up, do the following:
a. Set the PIPE HANDLER switch to LOCK.
b. Set the GRABBER switch to OPEN.
c. Visually inspect the pipe handler to confirm that it is locked.

34
OPERATIONS GUIDE
CHAPTER 6: DRILLING OPERATIONS
WELL CONTROL
As the owner/operator of a top drive, you must establish guidelines and procedures for all pos-
sible well control situations. These guidelines and procedures should reflect industry standard
practice for your operating location and conditions.
In most cases, the addition of a top drive will not significantly change the established proce-
dures for well control. Whenever possible, use the same well control procedures established
prior to the addition of a top drive.
All personnel must be trained to adhere to safe operating practices and should be periodically
tested to verify their skill level.
Review safety procedures before each drilling operation.
SURFACE HOLE DRILLING OPERATIONS

The following procedure applies when you drill a surface hole with drill collars, by using
either a single joint of drill pipe (as a working pipe single) or drillable pick-up subs.
Use only drillable pick-up subs for tripping operations. A drillable pick-up sub has a 5ft.
length of tube on which the elevators can slide up and down. The threaded connections at the
top of the drillable pick-up sub are the same as those on the saver sub, while those at the bot-
tom of the drillable pick-up sub are the same as those on the drill collars. This allows the drill-
able pick-up sub to be threaded into drill collars and used as a pick-up sub for racking
operations. A drillable pick-up sub allows you to ream and back-ream during tripping opera-
tions, if required.

35
DRILLING OPERATIONS OPERATIONS GUIDE
How to Drill a Surface Hole

1. Use the appropriate rig equipment and safe working procedures to position a col-
lar in the mousehole.
2. Use chain tongs to install a drillable pick-up sub on the collar.
Caution: Torque the connection between the drillable pick-up sub
and the collar to prevent it from unscrewing.
3. Lower the top drive to position the elevator at the pick-up sub.
5. Hoist the top drive until the drillable pick-up sub and collar clear the mousehole.
6. Press the FLOAT button. This will bring the elevator to the vertical position.
Note: Ensure there is adequate clearance for the racking platform.
7. Install the bit sub and drill bit, and apply the appropriate torque.
8. Hoist the collar out of the bit-breaker and lower it through the rotary table.
9. When the bit reaches the bottom of the hole, hoist it 1-2 ft. off the bottom and set
the slips.
10. Lower the top drive with the elevator closed. Allow the elevator to slide down the
drillable pick-up sub. Guide the drillable pick-up sub through the pipe guide.
13. Slowly lower the top drive to engage the connection between the saver sub and the
drillable pick-up sub.
Warning! Ensure the rotary table is locked.

15. When the connection is fully engaged, set the PUMPS–REV/FWD switch to neu-
tral.
16. Use the GRABBER LIFT switch to position the grabber on the box connection of
the drillable pick-up sub.
18. Set the PUMPS–REV/FWD switch to FWD (the MODE switch should still be set
to CONN).
19. When the torque reaches the desired torque value, turn the PUMPS–REV/FWD
switch to neutral.
21. Hoist the top drive and remove the slips.
22. Set the mudsaver VALVE switch to OPEN.
23. Start the rig mud pump.
24. Begin drilling.

36
OPERATIONS GUIDE DRILLING OPERATIONS
About Connections and Surface Hole Operations

Make connections as you would normally. Leave the drillable pick-up sub on the top drive.
Refer to “How to Make Up BHA (Collars and Tools)” on page 31.
About Tripping and Surface Hole Operations

Trip drill pipe in and out of the hole as you would normally, but use a drillable pick-up sub on
the top of each stand instead of a standard pick-up sub.
About Reaming and Surface Hole Operations

Refer to “Reaming Operations” on page 57.
HOW TO DRILL AHEAD WITH SINGLE LENGTHS OF PIPE

Drilling operations proceed more efficiently when you use the tugger to place single lengths of
pipe in the mousehole while the top drive makes connections and drills.
This procedure assumes that the top drive is at floor level and connected to the drill string.
Figure 6-1: Drill Ahead with Single Lengths of Pipe
1. Break out the connection between the top drive and the drill
pipe.
2. Pick up a single length of pipe from the mousehole.
3. Connect the pipe to the top drive and the drill string.
4. Remove the slips and drill ahead.

37
1. Raise the bit 1-2 ft. off the bottom of the hole.
3. Allow the reactive torque to release.
Caution: As the torque releases, the drill string may rotate slightly.
Wait until the rotation ceases before you continue.
4. Set the slips.

5. Shut off the rig mud pump.
6. Monitor the standpipe pressure gauge and wait for the mud pump pressure to
decrease to zero.
7. Set the mudsaver VALVE switch to CLOSE.
Warning! Do not close the grabber on the saver sub or the
hard band of the drill pipe.

Note: The top drive torque will increase to the preset value.
12. Press and hold the BREAKOUT button.
Note: Torque increases until it reaches the maximum value available for breakout
torque for the unit.
13. When the quill rotates 1/2 turn, release the BREAKOUT button.
14. Immediately set the GRABBER switch to OPEN.
Note: This allows you to raise the top drive in small increments and minimizes the
load on the threads as the connection unscrews. The counter-balance system also
assists with thread disengagement.
15. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging the pipe threads, do not let the weight of the top drive
rest on the connection while it unscrews.
16. When the connection unscrews completely, set the PUMPS–REV/FWD switch to
neutral.
17. Hoist the top drive until the elevator clears the drill string stump in the rotary
table.
18. Set the ELEVATOR switch to OPEN, then push and hold the elevator SAFETY
OPEN button.
19. Use the LINK TILT switch to move the elevator forward so that it is above the
mousehole.
20. Lower the top drive until the elevator reaches the drill pipe in the mousehole.
21. Position the elevator on the drill pipe, then set the ELEVATOR switch to CLOSE.
22. Hoist the top drive until the single length of pipe is above the drill pipe stump in
the rotary table.

38
23. Press the FLOAT button to bring the elevator to the vertical position.
Caution: Rig floor personnel should stabilize the lower end of the
drill pipe.
24. Lower the top drive and stab the drill pipe connection.
25. Position a back-up tong on the box connection of the stump.
28. Lower the top drive further until the pipe makes contact with the saver sub.
29. Use the LINK TILT function to guide the pipe through the drill pipe guide.
30. Lead the top drive into the connection until the pipe/pipe and pipe/saver sub con-
nections are fully engaged but not tightened.
Note: When both connections are fully engaged, the break-out tongs will tighten
and the top drive will stall.
31. Wait until the torque increases to the required make up torque for the connection.
33. Remove the break-out tong.
34. Set the ELEVATOR switch to OPEN, and press and hold the ELEVATOR
SAFETY OPEN button.
35. Set the LINK TILT switch to BACK. This moves the elevator away from the drill
string and avoids unnecessary wear of the elevator inserts.
36. Set the VALVE switch to OPEN.
37. If required, start the rig mud pump.
38. Hoist the top drive and drill string.
42. Use the PUMPS–DECR/INCR switch to increase the RPM to the desired drilling
speed.
43. Commence drilling.

39
HOW TO DRILL AHEAD WITH PIPE STANDS

This procedure assumes that the top drive is at floor level and connected to the drill string.
Figure 6-2: Drill Ahead with Pipe Stands
1. Break out the connection between the top drive and the drill pipe.
2. Pick up a stand of pipe from the racking platform.
3. Connect the stand of pipe to the top drive and the drill string.
4. Remove the slips and drill ahead.
1. Raise the bit 1-2 ft. off the bottom of the hole.
3. Allow the reactive torque to release.
Caution: As the torque releases, the drill string may rotate slightly.
Wait until the rotation ceases before you continue.
4. Set the slips.

decrease to zero.
Warning! Do not close the grabber on the saver sub or the
hard band of the drill pipe.

40

Note: The top drive torque will increase to the preset value.
Note: Torque increases until it reaches the maximum value available for breakout
torque for the unit.
13. When the quill rotates 1/2 turn, release the BREAKOUT button.
Note: This allows you to raise the top drive in small increments and minimizes the
load on the threads as the connection unscrews. The counter-balance system also
assists with thread disengagement.
Note: To avoid damaging the pipe threads, do not let the weight of the top drive
rest on the connection while it unscrews.
16. When the connection unscrews completely, set the PUMPS–REV/FWD switch to
neutral.
17. Hoist the top drive until the elevator clears the drill string stump in the rotary
table.
18. Set the ELEVATOR switch to OPEN, then push and hold the ELEVATOR
SAFETY OPEN button.
19. Use the LINK TILT switch to move the elevator forward so that it is past the
stump.
20. Hoist the top drive to the racking platform.
21. Position the elevator to capture the top tool joint of the next stand of pipe.
23. Ensure that rig floor personnel are ready to assist in guiding the stand out of its
racking position.
24. When the stand is picked up, press the FLOAT button.
25. Hoist the top drive slowly, allowing the rig floor personnel to guide the bottom of
the stand to a vertical position.
26. Hoist the top drive until the bottom pin of the stand clears the stump.
27. Lower the top drive and stab the drill pipe connection into the stump.
28. Position a back-up tong on the box connection of the stump.
29. Lower the top drive further until the pipe makes contact with the saver sub.
32. Use the LINK TILT function to guide the pipe through the drill pipe guide.
and the top drive will stall.
34. Wait until the torque increases to the required make up torque for the connection.

41

37. Set the ELEVATOR switch to OPEN, and press and hold the ELEVATOR
SAFETY OPEN button.
38. Set the LINK TILT switch to BACK. This moves the elevator away from the drill
string and avoids unnecessary wear of the elevator inserts.
40. If required, start the rig mud pump.
45. Use the PUMPS–DECR/INCR switch to increase the RPM to the desired drilling
speed.
SLIDE DRILLING OPERATIONS
Introduction
In slide drilling operations, power to the bit is supplied using downhole mud motors. As a
result, the drill string does not rotate during drilling operations. This procedure addresses how
to make and break connections during slide drilling operations.
Caution: During slide drilling operations, ensure the grabber

remains closed on the saver sub. Once the grabber is fully closed,
return the GRABBER switch to the neutral position to avoid over-
heating the auxiliary hydraulic system.
During extended periods of slide drilling, set the GRABBER switch to CLOSE, then back to
neutral, once every hour. This helps to maintain full pressure in the grabber–close hydraulic
circuit.
Mud Motors in Slide Drilling Operations

When you drill with a downhole mud motor, ensure the top drive drill–forward torque setting
is greater than the maximum torque output of the mud motor.
1. Trip in the drill pipe and mud motor until the mud motor reaches the bottom of the
hole. Refer to “Tripping Operations” on page 47.
2. Connect the top drive to the drill string by lowering the top drive until the drill
pipe makes contact with the saver sub.
Note: Use the LINK TILT feature to guide the drill pipe into the drill pipe guide.
3. Use the GRABBER LIFT switch to position the grabber on the box of the drill
pipe.

42

7. Lead the top drive into the connection until the pipe/saver sub connection is fully
engaged but not tightened.
8. Wait until the torque increases to the required value for the current thread and con-
nection type.
9. As soon as the torque reaches the required value to make up the connection, set
the PUMPS–REV/FWD switch to neutral.
11. Use the GRABBER LIFT switch to reposition the grabber on the saver sub.
17. Start drilling by lowering the top drive.
You might have to adjust the orientation of the tool face to drill in the required direction when
you drill with a mud motor. Refer to the next section, “How to Adjust the Tool Face Orienta-
tion”.

43
How to Adjust the Tool Face Orientation

This procedure assumes the following:
• the top drive is above the drill floor
• the top drive is connected to the drill string
• the top drive is ready to proceed with drilling
• the grabber is closed on the saver sub
3. Use the PUMPS–DECR/INCR switch to decrease the quill speed to zero, then
slowly increase the speed until you observe a deflection of the grabber box.
4. When you observe deflection of the grabber box, set the GRABBER switch to
OPEN.
Note: If the torque in the drill string matches the torque of the top drive, you can
open the grabber with no rotation (static).
5. Reorient the tool face by doing one of the following:
a. To turn the drill string clockwise, use the PUMPS–DECR/INCR switch to
increase the torque slowly. Increasing the torque allows the top drive to over-
come the reactive torque of the downhole motor. When this happens, the drill
string slowly turns clockwise.
Note: When you achieve the required toolface orientation, slowly decrease
the torque until the quill stalls, then close the grabber.
b. To turn the drill string counter-clockwise, use the PUMPS–DECR/INCR
switch to decrease the torque slowly. Decreasing the torque allows the down-
hole motor to overcome the torque of the top drive, and the drill string turns
slowly counter-clockwise.
Note: When you achieve the required toolface orientation, slowly increase the
torque until the quill stalls, then close the grabber.
How to Make and Break Connections During Slide Drilling

Operations
1. Set the slips.
Caution: Ensure the rotary table is locked.

3. Use the GRABBER LIFT switch to reposition the grabber on the box of the drill
pipe.
decrease to zero.

44
9. Set the PUMPS–REV/FWD to REV.

Note: The top drive torque increases to the preset value.
Note: Torque increases until it reaches the maximum break out torque value for
your top drive unit.
11. When the saver sub/pipe connection breaks and rotates 1/2 turn, release the
BREAKOUT button.
Note: This allows you to raise the top drive in small increments as the connection
unscrews.
Note: To avoid damaging the pipe threads, do not allow the weight of the top
drive to sit on the connection while it unscrews.
14. When the connection completely unscrews, set the PUMPS–REV/FWD switch to
neutral.
15. Hoist the top drive high enough to allow the elevator to pass over the stump.
16. Use the top drive elevator to pick up the required drill pipe.
Note: You may slide drill with either single lengths of pipe or stands of pipe.
Refer to “How to Drill Ahead with Single Lengths of Pipe” on page 37 and “How
to Drill Ahead with Pipe Stands” on page 40 for more information.
17. Hoist the top drive until the bottom pin of the pipe stand clears the stump.
18. Press the FLOAT button.The elevator and pipe stand will move to hole center.
19. Position the break-out tong on the box connection of the stump.
20. Lower the top drive until the drill pipe makes contact with the saver sub.
Note: Use the LINK TILT function to guide the drill pipe into the drill pipe guide.
and the top drive will stall. It is also possible that the top drive will torque into the
locked rotary table.
24. Wait until the DELVERED TORQUE gauge increases to required value for the
connection type.
25. As soon as the torque reaches the required value to make up connections, set the
PUMPS–REV/FWD to neutral.
27. Use the GRABBER LIFT switch to reposition the grabber on the saver sub (the
grabber should be open).
29. Set the mudsaver VALVE switch to open.
31. Hoist the top drive and drill pipe.

45

Danger! Exercise caution when removing the slips. Stored
drill string torque may spin the slips when the drill
string is hoisted.
How to Maintain the Tool Face Orientation During Slide Drilling

Operations
It is essential to maintain the tool orientation during slide drilling, as it determines the drilling
direction. To maintain tool orientation while making or breaking connections, the drill string
must be locked in the rotary table with the slips, as described in “How to Make and Break
Connections During Slide Drilling Operations” on page 44.
Caution: The rotary table must remain locked during this proce-
dure.
Tesco recommends that you mark the position of the drill string so you can monitor whether or
not some of the stored torque in the drill string is released when you make a connection.
In some instances it might be necessary to remove the slips while the grabber is still open. In
this case, the top drive must absorb the torque in the drill string. Use the following procedure
to allow the top drive to safely absorb the torque in the drill string.
3. Use the PUMPS–DECR/INCR switch to decrease the quill torque to zero.
4. Use the PUMPS–DECR/INCR switch to increase the quill torque slowly until the
torque at the top drive matches the torque in the drill string. Refer to the following
procedure, “How to Record the Drill String Torque”, for more information.
5. When the torque reaches the required value, hoist the top drive and remove the
slips.
How to Record the Drill String Torque

This procedure assumes you are currently drilling with a mud motor, and the bit is currently on
the bottom of the wellbore.
1. Close the grabber on the saver sub.
4. Use the PUMPS–DECR/INCR switch to decrease the quill torque to zero.
5. Use the PUMPS–DECR/INCR switch to increase the torque gradually.
6. When you observe deflection of the grabber box towards the driller's side (clock-
wise), record the torque value.
7. Re-check the drill string torque periodically during downhole motor operations.

46
OPERATIONS GUIDE
CHAPTER 7: TRIPPING OPERATIONS

• Trip Out: the act of removing the drill string from the wellbore.
• Trip In: the act of inserting the drill string into the wellbore.
WELL CONTROL DURING TRIPPING OPERATIONS

As the owner/operator of a top drive, you must establish guidelines and procedures for all pos-
sible well control situations. These guidelines and procedures should reflect industry standard
practice for your operating location and conditions.
In most cases, the addition of a top drive will not significantly change the established well con-
trol procedures. Whenever possible, use the same well control procedures established prior to
the addition of a top drive.
All personnel must be trained to adhere to safe operating practices and should be periodically
tested to verify their skill level.
Safety procedures should be reviewed before each operation.
Caution: If the top drive is connected to the drill string when the
drill string is off the bottom of the hole, the following equipment is
required:
· additional saver sub
· spare double-ball mudsaver valve
· strip kit (tools required to remove mudsaver actuator)
If you plan to connect the top drive to the drill string when it is off the bottom of the hole,
Tesco recommends that you remove the actuator and service the entire assembly on a regular
basis. Refer to the following procedure for information on how to remove the actuator.

47
TRIPPING OPERATIONS OPERATIONS GUIDE
How to Remove the Mudsaver Valve Actuator During Well

Control Tripping
Danger! The removal of the actuator off of the double ball

valve is relatively simple and quick, however,
there are a few steps that must be followed in
sequence for reasons of safety.
1. Set the slips.

2. Shut off the mud pump.
3. Use the valve wrench that is provided to close the manual ball valve. This ball
valve is located below the actuator. See Figure 7-1 on page 49.
4. Set the mudsaver VALVE switch (driller’s panel) to OPEN. This will open the
actuated mudsaver valve.
Note: Visually verify that there is no pressure in the standpipe at this point.
5. Remove the upper die-lock clamp from the mudsaver valve.
6. Remove the lower die-lock clamp from the mudsaver valve.
bottom of the mudsaver valve.
8. Set the GRABBER switch (driller’s panel) to CLOSE. The grabber should close
on the mudsaver valve.
9. Break out the mudsaver valve from the top drive.
a. Set the MODE switch to CONN.
b. Set the PUMPS–REV/FWD switch to REV.
c. Push and hold the BREAKOUT button. Release the BREAKOUT button
when the quill has rotated 1/2 turn.
Note: Hoist the top drive in small increments as the connection unscrews. This
will keep the weight of the top drive off the connection.
11. Hoist the top drive until the grabber is positioned approximately 1 in. from the
actuator.
Caution: Do not hoist any higher, or the grabber will hit the actua-
tor. This can damage the actuator.
12. Use the GRABBER LIFT switch to lift the grabber until the actuator rests on the
grabber.
13. Remove the two worm ring clamps from the actuator.
14. Remove the two snap rings and the two hex drives. Use a slide hammer to remove
these items. See Figure 7-2 on page 50.
15. Remove the four upper lock pin assemblies.
Note: The lock pin assemblies consist of a setscrew, a spring and a lock pin.
16. Remove the four lower lock pin assemblies if they are present.
17. Install two lifting eyes in the upper lock pin holes at 180°. Attach a tugger or other
lifting device to the lifting eyes.

48
OPERATIONS GUIDE TRIPPING OPERATIONS
18. Hoist the top drive slowly. The actuator should slide off of the mudsaver valve.
Use the tugger or lifting device to remove the actuator from the grabber after the
actuator is released from the mudsaver valve.
19. You may install an inside Blow Out Preventer or other device to control the well
pressure at this stage.
20. You may use the top drive to make up the connection.
21. After the connection is secure, use the mudsaver valve wrench to open the manual
ball valve slowly.
22. You can now insert the drill string into the wellbore. Use the procedure described
in “How to Trip In Drill Pipe” on page 56.
Figure 7-1: Remove the Mudsaver Valve Actuator for Well Control
1. Quill
2. Upper Die-Lock Clamp
3. Actuator
4. Manual Ball Valve
5. Mudsaver Wrench
6. Mudsaver Valve
7. Lower Die-Lock Clamp
8. Saver Sub
9. Grabber

49
Figure 7-2: Remove the Actuator from the Mudsaver Valve
1. Pin
2. Spring
3. Set Screw
4. Hex Drive Shaft

50
TRIP OUT OPERATIONS

Before you begin trip out operations, observe all required operating conventions. These would
include procedures such as ‘circulating the hole’, ‘pumping a pill’, etc.
How to Trip Out Drill Pipe

Figure 7-3: Trip Out Drill Pipe
1. Break out the connection between the top drive and the drill pipe (if
required).
2. Hoist the top drive with the drill pipe in the elevators.
3. Break the drill pipe connection. Rack the stand.
4. Lower the top drive to pick up the next stand of drill pipe.
Caution: Ensure that the pipe handler is oriented such that you can
tilt the links toward the derrickman when you are ready to rack the
drill pipe.
1. Shut off the rig mud pumps.

2. Monitor the standpipe gauge to ensure that mud pump pressure decreases to zero.
3. Set the VALVE switch to CLOSE.
4. Hoist the top drive.
5. Set the slips.
Note: Ensure the stored torque in the drill string has dissipated before the slips are
set.
6. Position the elevator on the drill pipe using the LINK TILT function.

51
8. Use the GRABBER LIFT switch to position the grabber on the tool joint of the
drill pipe.
Note: The top drive torque will increase to the preset torque value for reverse
rotation.
Note: The top drive torque will increase to the break out torque value for the unit.
13. When the connection loosens and the quill rotates 1/2 turn, release the BREAK-
OUT button.
Note: This will allow you to raise the top drive in small increments as the connec-
tion unscrews.
Note: To avoid damaging the pipe threads, do not allow the weight of the top
drive to sit on the connection while it unscrews.
16. When the top drive clears the connection, set the PUMPS–REV/FWD switch to
neutral.
17. Hoist the top drive and drill pipe.
19. Hoist the top drive to lift the drill pipe (single, double or stand) above the rotary
table.
20. Set the slips.
21. Use tongs to break the stump connection, then unscrew the connection by using
chain tongs or a pipe spinner.
22. Hoist the drill pipe clear of the stump.
23. Proceed with the standard racking procedure. See “Standard Racking Procedure”
on page 52.
24. Lower the top drive and grab the drill string stump with the elevator.
25. Repeat steps 17. to 24. to trip out the rest of the drill string.
Standard Racking Procedure

1. Hoist the drill pipe (single, double or triple stand) until the bottom is above the
floor racking area.
Note: Elevator links will have to be set to vertical/hole center to avoid hitting the
racking board.
2. Set the TILT switch to FWD.
3. Allow the rig floor personnel to push the bottom of the stand into place on the
racking floor.
4. Set the stand down in the racking area.
5. Position the tip of the stand where the derrickman can easily reach and take con-
trol of it.

52
6. Wait until the stand is secured and the derrickman is ready to take control of the
stand.
7. Push and hold the ELEVATOR SAFETY OPEN.
8. Set the SAFETY switch to OPEN.
9. Press the FLOAT button.
10. Lower the top drive to receive the next section of pipe.
Caution: In cold weather operations mud can freeze within the com-
ponents. To prevent freezing, air blow the top drive, kelly hose and
stand pipe back to tank after pulling 4-5 stands of free pipe and
when stopping for a flow check. If the mud valve is to be closed for
any length of time in extreme weather conditions, the same proce-
dures apply.
How to Trip Out BHA (Collars and Tools)

This procedure assumes that all drill pipe has been removed from the wellbore and that the
first collar is above the rotary table.
Note: Ensure that the pipe handler is oriented such that you can tilt the links
toward the derrickman when the collars are ready to be racked.
Figure 7-4: Trip Out Collars
1. Install a pick-up sub in the top collar and torque it to specification.

2. Latch the pick-up sub in the elevator and hoist the top drive. Break the
connection between the collar segments at the floor.
3. Rack the stand of collars.
4. Lower the top drive to the rig floor. Repeat this procedure for the next
stand of collars.
1. Set the slips.

53
2. Attach a safety clamp.

3. Ensure that the elevator and elevator links are hanging vertically.
6. Press and hold the PIPE HANDLER CAUTION button.
Note: The pipe handler will begin to rotate at the preset speed.
7. Position the pipe handler so that you can use the LINK TILT feature to assist in
racking the collars.
8. When the pipe handler is in the proper position, release the PIPE HANDLER
CAUTION button.
Caution: Visually verify that the pipe handler lock engages fully.
11. Use the LINK TILT feature to position the top drive elevator to accept a pick-up
sub.
13. Hoist the top drive to position the pick-up sub above the collar.
14. Push the FLOAT button. This allows the elevator and pick-up sub to 'float' to hole
center.
15. Lower the top drive to stab the pick-up sub into the top collar.
16. Use chain tongs to fully engage the connection between the pick-up sub and the
collar.
Caution: Torque the connection to prevent it from unscrewing.

18. Hoist the top drive and remove the slips.
19. Hoist the top drive until the required number of collars are above the rotary table.
21. Use rig tongs to break the connection between the collar segments.
22. When the connection is loosened, use the pipe handler, rotary table or chain tongs
to fully unscrew the connection.
23. Hoist the collar(s).
24. Allow rig floor personnel to position the bottom of the collar for racking.
25. Use the LINK TILT feature to tilt the collar(s) toward the derrickman.
Note: You can also use the EXTEND function.
26. When the derrickman has control of the collar(s), set the ELEVATOR switch to
OPEN, and push and hold the ELEVATOR SAFETY OPEN button.
27. Release the collar(s) and the pick-up sub.
Note: The pick-up sub will remain on the collar(s) to facilitate ‘trip in’ operations.
28. Repeat this procedure for each collar or stand of collars.

54
TRIP IN OPERATIONS
How to Trip In Tools and Collars

Figure 7-5: Trip in Tools and Collars
1. Pick up a stand of collars from the racking board. A pick-up sub should already be
attached to the collar.
2. Connect the tools or collars at the rig floor.
3. Lower the stand of collars through the rotary table and set the slips. Attach a safety
clamp.
4. Remove the pick-up sub from the collar and set it to the side.
5. Hoist the top drive to the racking board and pick up the next stand of collars.
1. Use the top drive to lower the first section (bit and tools) into the rotary table.
Note: If acceptable, the floor tugger may also be used to perform this step.
2. Set the slips and, if applicable, attach a safety clamp.
3. Use the rig tongs to break out the joint of the pick-up sub.
4. Set the ELEVATOR switch to OPEN, and push and hold the ELEVATOR
SAFETY OPEN button.
6. Use the chain tongs to unscrew the pick-up sub.
7. Use the floor tugger to remove the pick-up sub.
8. Set the LINK TILT switch to FWD.
9. Use the EXTEND function, if necessary, to accept the first collar from the derrick-
man.
10. Position the elevator on the collar of the pick-up sub.
11. Set the ELEVATOR button to CLOSE.

55
12. Hoist the top drive and the stand of collars/tools from the racking area.
13. Press the FLOAT button. This will bring elevator and elevator links to the vertical
position.
Caution: If you used the EXTEND function, bring the top drive to the
IN position.
14. Allow rig personnel to hold the bottom of the stand and carefully move it to hole
center.
15. Lower the top drive and stab the lower connection.
16. Use the pipe handler, chain tongs or spinning chain to connect the collar to the
stump.
17. Use rig tongs to torque the connection to specification.
19. Hoist the top drive and the drill string.
21. Lower the stand of collars/tools through the rotary table to the appropriate height
for the next connection.
22. Set the slips and install a safety clamp.
23. Use the rig tongs to break out the pick-up sub.
24. Use the chain tongs to unscrew the pick-up sub from the top collar.
25. Use the LINK TILT switch to bring the elevator forward and position the pick-up
sub where it you can remove it from the rig floor by using the floor tugger.
26. Set the ELEVATOR switch to OPEN, and push and hold the ELEVATOR
SAFETY OPEN button.
27. Hoist the top drive and pick up the next collar or stand of collars.
28. Repeat this procedure for all collars.
Note: When all collars have been tripped in, the pipe handler must be oriented to
pick up drill pipe.
How to Trip In Drill Pipe

1. Ensure that the elevator and elevator links are hanging vertically.
4. Press and hold the PIPE HANDLER CAUTION button.
Note: The pipe handler will begin to rotate at the preset speed.
5. Position the pipe handler so that you can use the LINK TILT feature to pick up
drill pipe.
6. When the pipe handler is in the proper position, release the PIPE HANDLER
CAUTION button.

56

Caution: Visually confirm that the pipe handler lock engages fully.

10. Use the LINK TILT switch to tilt the links forward to accept the first drill pipe or
stand of drill pipe from the derrickman.
11. Position the elevator on the drill pipe.
13. Hoist the top drive and drill pipe off the racking area.
14. Press the FLOAT button to bring the elevator and elevator links to hole center.
15. Allow rig personnel to hold the bottom of the pipe and move it into position.
16. Lower the top drive and stab the connection.
17. Connect the drill pipe using the chain tongs, spinning chain, or pipe spinner.
18. Use rig tongs to torque the connection to specification.
19. Hoist the top drive and the drill pipe.
21. Lower the top drive and drill string.
22. Lower the stand of drill pipe through the rotary table to the appropriate height for
the next connection.
23. Set the slips.
24. Repeat this procedure for all single lengths or stands of drill pipe that you trip in to
the wellbore.
REAMING OPERATIONS
How to Use the Top Drive to Ream During Trip Out Operations
• Ream: to enlarge the diameter of a wellbore.
Reaming is performed whenever a tight spot is encountered during trip out operations. This
most commonly occurs when a collar encounters an obstruction or a narrowing in the open
hole.
If you use the top drive to perform tripping operations, the drill pipe and bottom hole assembly
(BHA–tools and collars) will be suspended from the top drive elevator. In order to ream, the
top drive must be connected to the drill string and the tight section must be worked until the
drill string can pass freely. To continue tripping operations after the obstruction is cleared, the
top drive must be disconnected and the drill string suspended from the elevator.
Use the following procedure if you encounter a tight spot while tripping out (the weight indi-
cator displays more than the weight of the drill string), or if the drill string is stuck:

57
1. Lower the top drive and the drill string.

Note: Ensure that the uppermost drill pipe connection is in position to connect to
the top drive.
2. Set the slips.
3. Lower the top drive until the saver sub contacts the drill pipe.
the drill pipe.
Note: Ensure the grabber closes on the box connection of the drill pipe.
6. Set the MODE switch to CONNECT.
8. Lower the top drive into the connection.
Note: Do not allow the top drive weight to sit on the threaded connection.
9. Fully engage the connection between the saver sub and the drill pipe.
10. When the torque reaches the required torque for the connection, set the PUMPS–
13. Start the mud pumps.
16. Set speed and torque to the required values.
Note: Recommended speed is 30-40 RPM.
17. Hoist the top drive until the tight spot is encountered.
18. Raise and lower the top drive several times (or until the hole is clean) while circu-
lating the mud.
Note: It is advisable to trip out one or two stands with the top drive connected to
the drill string.
19. When reaming operations are complete, set the PUMPS–REV/FWD switch to
select neutral.
20. Hoist top drive to the proper position for disconnecting it from the drill pipe.
21. Set the slips.
22. Turn off the rig mud pumps.
24. Disconnect the drill pipe from the top drive. See “How to Break the Top Drive/
Drill Pipe Connection” on page 24 for more information.
25. Continue with standard procedures for trip out operations.

58
How to Use the Top Drive to Ream to Bottom During Trip In

Operations
Ream: to enlarge the diameter of a wellbore.
Reaming to bottom is performed whenever a tight spot is encountered during trip in opera-
tions.
If you use the top drive for tripping operations, the drill pipe or BHA (tools and collars) will be
suspended from the top drive elevator. In order to ream ahead, the top drive must be connected
to the drill string and the tight section must be worked until the drill string can pass freely. To
continue tripping operations after the obstruction is cleared, the top drive must be discon-
nected and the drill string suspended from the elevator.
Use the following procedure if you encounter a tight spot during trip in operations (weight
comes off the weight indicator).
1. Hoist the top drive to lift the bottom hole assembly (BHA) above the tight spot.
Note: Ensure that the uppermost drill pipe connection is in position to connect to
the top drive.
2. Set the slips.
3. Lower the top drive until the saver sub contacts the drill pipe.
the drill pipe.
8. Rotate the top drive into the connection.
Note: Do not allow the top drive weight to sit on the threaded connection.
9. Fully engage the connection between the saver sub and the drill pipe.
10. When the torque reaches the required torque for the connection, set the PUMPS–
13. Start the mud pumps.
16. Set the speed and torque to the required values for drilling operations.
17. Lower the top drive until the tight spot is encountered.
18. Raise and lower the top drive several times (or until the hole is clean) while circu-
lating the mud.
Note: It is advisable to trip in one or two stands with the top drive connected to
the drill string.
19. When reaming is complete, set the PUMPS–REV/FWD switch to neutral.

59
20. Hoist or lower the top drive to the proper position for disconnecting it from the
drill pipe.
21. Set the slips.
22. Turn off the mud pumps.
24. Disconnect the drill pipe from the top drive. See “How to Break the Top Drive/
Drill Pipe Connection” on page 24 for additional information.
25. Continue with standard procedures for trip in operations.

60
OPERATIONS GUIDE
CHAPTER 8: STUCK PIPE

Tesco top drives allow you to maintain mud circulation and torque on the drill pipe while you
pull or jar stuck drill pipe, unlike conventional Kelly systems.
HOW TO USE THE TOP DRIVE TO FREE STUCK PIPE

1. Connect the top drive to the drill string.
2. If possible, maintain mud pump flow.
4. Set speed to the required value.
6. Raise and lower the top drive to work the drill string up and down.
7. Continue to raise and lower the top drive and drill string until a free point is estab-
lished.
8. When the drill string begins to rotate, raise and lower the top drive in the free
point area in small increments.
9. Gradually increase the travel distance until the obstruction is cleared.

61
STUCK PIPE OPERATIONS GUIDE
HOW TO USE THE TOP DRIVE FOR JARRING OPERATIONS

If you cannot free the drill pipe by using the top drive as described in the previous procedure,
you might have to initiate ‘jarring’ operations.
Tesco recommends that you do not jar the drill string while the drill pipe is suspended from the
elevator. If access to the drill pipe is absolutely necessary (for wire line or logging, for exam-
ple), then ensure that the elevator is closed and the elevator hydraulic hoses are removed.
Note: You can apply torque when working or jarring pipe, if necessary.
Warning! Always exercise extreme care when you ‘jar’ with

torque in the drill string. Monitor the torque
bushing and travel assembly carefully for the
duration of the jarring operation.
1. Ensure that the top drive is connected to the drill string.

2. Maintain mud pump flow if possible.
3. Close the elevator on the drill pipe.
5. Set the speed to the required value.
7. Initiate jarring operations; use the top drive to hoist and lower the drill string.
8. When the string begins to rotate, raise and lower the top drive in the free point
area in small increments.
9. Gradually increase the travel distance until the obstruction is cleared.
Warning! To help ensure the functional integrity of the top
drive, perform a ‘post jarring check’ after any
jarring operation. Refer to ‘Appendix 1: Post
Jarring Checklist’.
Warning! If jarring operations exceed eight hours, or if

jarring is extremely rough, a complete load path
inspection must be performed at the first
available opportunity.

62
OPERATIONS GUIDE STUCK PIPE
CONTROLLED DRILL STRING BACK OFF OPERATIONS

In some cases it is necessary to separate the stuck portion of the drill string from the free
length (to ‘back off’ the drill string). This is best accomplished by applying reverse torque to
the connection immediately above the stuck point, and then deploying an explosive charge at
the connection.
The decision to back off a drill string has significant financial and operational implica-
tions. Back off of a drill string should never be authorized or undertaken until all inter-
ested parties have agreed to the procedure.
1. Set the DRILL torque for reverse rotation to 70% of the make up torque.
Note: See “How to Set the Reverse Torque” on page 16 for more information.
2. Position wireline tools and the charge device at the connection where you want
the drill string to disconnect.
5. Work the drill pipe up and down and slowly increase the quill speed in very small
increments.
Note: Use the PUMPS–DECR/INCR switch to adjust the pump flow so that it just
holds the torque steady.
Caution: Excessive RPM or torque will force oil over the relief valve,
and this could result in excessive heat. Always monitor the temper-
ature of the case drain for overheating.
Note: If you need to increase the torque in stages, use the PUMPS–DECR/INCR
switch, and increase the torque slowly. Monitor the differential pressure gauge at
the driller’s panel.
6. When the correct amount of torque has been put into the drill string (indicated
when the correct torque value appears on the torque gauge and the pipe stops turn-
ing), then close the grabber.
8. Reposition the blocks.
Caution: The blocks should be positioned to achieve neutral weight
at the connection to be shot. This means that the weight indicator
reading should equal the weight of the free portion of drill pipe.

63
STUCK PIPE OPERATIONS GUIDE
Figure 8-1: Neutral Weight at the Connection
Total weight of pipe downhole = 125,000 lb The weight indicator will

Weight of pipe below the stuck point = 65,000 lb display 60,000 lb when the
first free connection is at
Total weight of the free pipe = 60,000 lb
neutral.
9. When neutral weight is established, fire the explosive charge.

10. Monitor the weight indicator and string rotation.
When the drill pipe is free, the drill string should rotate freely. If the pipe has
parted at the correct location, the weight indicator reading should not change sig-
nificantly.
Caution: If the weight indicator falls, this may indicate that the drill
pipe has parted above the expected connection. If this occurs, do
not hoist. It might be possible to re-establish the connection. Evalu-
ate the situation before proceeding.
11. Ensure that the drill string is free by doing the following:
• confirm free rotation of pipe
• hoist carefully to confirm that the rotating pipe is not stuck
12. Open the grabber.
13. Trip out the first stand of pipe from the hole while it is connected to the top drive.
14. When first stand is racked, break the top drive connection.
15. Continue with normal tripping operations.
UNCONTROLLED PARTING OF THE DRILL STRING

Warning! If the drill string parts in an uncontrolled manner
at any time, a post jarring inspection MUST be
performed before drilling operations commence.
Refer to “Appendix A: Post–Jarring Checklist”.

64
OPERATIONS GUIDE
CHAPTER 9: RUN AND PULL CASING

There are advantages to using the Tesco top drive to run casing:
• You can connect fill-up tools directly to the top drive to provide fill-up capability while
you run the casing.
• You can use LINK TILT and EXTEND functions to assist rig personnel in handling and
stabbing the casing.
Figure 9-1: Pick Up Casing
1. Floor slip elevators

2. Working platform
(optional)
3. Sling
4. Casing Running
elevators
5. Pick-up elevators

65
RUN AND PULL CASING OPERATIONS GUIDE
PREPARE THE TOP DRIVE TO RUN CASING

1. If required, orient the pipe handler so that the elevator links can be tilted toward
the V-door.
2. Remove the hydraulic elevator from the elevator links.
3. If required, remove the elevator links.
Note: Longer elevator links are often required when you run casing. Use the floor
tugger to attach the longer links.
Caution: If you use elevator links longer than 12 ft., do not use the
LINK TILT function. Consult a Tesco representative if you must use
links longer than 12 ft.
4. Pick up the casing running elevators.

5. If casing fill-up apparatus is required, use the grabber and the top drive to connect
it to the top drive saver sub.
6. If you are using the top drive to bring casing up the V door and onto the rig floor,
use a set of pick-up elevators and slings:
• Attach the ‘pick-up elevator’ slings such that the single-joint pick-up elevators
hang approximately 3–4 ft. below the main elevator.
• Attach the ‘pick-up elevator’ slings to the pick-up elevators.
7. Ensure that a working platform and floor elevators are installed and operational if
required.
Warning! Use a crane or a “tail-in” line to assist in lifting
large diameter, heavy weight casing from the V-
door to the rig floor. If you do not take this
precaution, the weight of the casing will pull the
top drive away from the torque track. This can
damage the EXTEND components of the torque
arrest system.

66
OPERATIONS GUIDE RUN AND PULL CASING
HOW TO RUN CASING

Figure 9-2: Run Casing
1. Use the pick-up elevators to lower the first joint of casing through the floor slip elevators.
2. Close the slips. Fill up the casing, if required at this point.
3. Use the pick-up elevators to pick up the next joint of casing. Use casing tongs to make up
the connection between the two joints of casing.
4. When the connection is complete, release the pick-up elevators and attach running ele-
vators.
5. Open the floor slip elevators and lower the casing.
1. Attach the pick-up elevators to the first joint of casing.

Note: If required, use the EXTEND and LINK TILT functions to extend the reach.
Caution: Whenever possible, use the EXTEND and LINK TILT func-
tions to reduce the stress on the torque track.
Figure 9-3: Reduce the Stress on the Torque Track
Incorrect Good Better

67
2. Ensure that floor personnel are ready to control the bottom of the casing joint.
3. Slowly hoist the top drive to move the casing to the drill floor.
Warning! The weight of the casing tends to pull the top
drive away from the torque track. This strains the
stabilization devices for the torque track.
Warning! If the top drive is extended toward the casing

when you hoist, it could collide with the racking
platform.
4. Hoist the casing until it is above the rig floor.

5. Lower the casing into the wellbore to the desired connection height.
6. Set the slips onto the casing.
8. Unlatch the pick-up elevators.
9. If required, lower the top drive to stab the fill-up tool into the casing stump.
10. Fill the casing as required.
11. Repeat Steps 1.–4. for the second joint of casing, then continue with the following
steps.
12. Lower the second joint of casing until its pin end enters the box end of the casing
in the slips.
Note: You can also use the LINK TILT and EXTEND functions to assist in align-
ing the casing joints.
13. Use casing tongs to make up the casing connection.
14. After the connection is made up securely, remove the pick-up elevators.
15. Latch the casing running elevators onto the top joint of casing.
17. Hoist the casing.
19. Lower the casing into the wellbore to the desired connection height.
21. Set the slips on the casing.
22. Unlatch the casing running elevators.
23. If required, lower the top drive the stab the fill-up tool into the casing stump.
24. Fill the casing as required.
25. Repeat this procedure as required for all joints of casing.

68
OPERATIONS GUIDE RUN AND PULL CASING
HOW TO PULL CASING

1. Attach casing running elevators to the top joint of casing.
3. Hoist the top drive until the entire joint of casing is above the rig floor.
4. Set the slips.
5. Unlatch the running elevators from the casing.
6. Attach the pick-up elevators to the casing.
7. Use casing tongs to break and unscrew the casing connection.
8. Hoist the top drive and the casing joint.
9. Use the EXTEND and LINK TILT functions to move the casing toward the
V-door.
10. Ensure that rig personnel are in place to guide the bottom of the casing joint.
11. Lower the top drive slowly and allow floor personnel to control the bottom of the
casing.
12. When the casing is secured in the V-door, unlatch the pick-up elevators.
13. Repeat this procedure for all casing joints.
Caution: When you reach the last few lengths of casing, you might
need to use a safety clamp to ensure the casing does not slide
through the slips.

69

70
OPERATIONS GUIDE
CHAPTER 10: TOP DRIVE CONSIDERATIONS
SLIP AND CUT OPERATIONS

You can maintain mud circulation while performing slip and cut operations.
Caution: Never suspend the weight of the top drive from the torque
tube during slip and cut operations. Instead, rest part of the weight
of the top drive on a single length of drill pipe secured in the rotary
table, and suspend the remainder of the weight from the block
sling.
1. Obtain and install a new block sling.

Figure 10-1: Block Sling
Block sling
Link Tilt
backwards
Drill pipe
Note: Size this block sling so that it will support the top drive, swivel and blocks
close to the rig floor.
2. Connect the top drive to a single length of drill pipe.
3. Raise the top drive and connect the block sling.
4. Use the blocks to lower the top drive and single length of pipe.

71
TOP DRIVE CONSIDERATIONS OPERATIONS GUIDE
5. Lower the pipe through the rotary table.

Note: To lower the top drive to the rig floor, tilt the links as far back as possible.
Maintain enough clearance so that you can remove the front cover of the draw-
works for servicing.
6. When the block sling is almost tight, stop lowering the top drive.
Note: Balance the weight of the top drive between the block hanging sling and the
pipe in the slips.
7. Set the slips.
CEMENTING OPERATIONS
Do not run cement through the top drive unless it is absolutely necessary. Cement causes wear
and, if allowed to harden, will irreparably damage the top drive.
If you suspend a cement head from the top drive elevator ensure the following conditions
exist:
• The elevator links are long enough to accommodate the cement head.
• The elevator hydraulic hoses are disconnected.
Note: Disconnect the hydraulic hose when the cement head is in position and the eleva-
tors are closed.
When you use a flow-through cement head, some cement might enter the quill and mud valve.
After you complete cementing operations, Tesco advises that you flush the quill, mudsaver
valve and lower Kelly valve thoroughly. Operate the mudsaver and Kelly valves to ensure they
work properly.
Danger! Failure to perform these operational checks can

compromise rig safety!

72
OPERATIONS GUIDE TOP DRIVE CONSIDERATIONS
SLICK LINE SURVEY AND WIRE LINE LOGGING OPERATIONS

Several issues must be addressed when you use a top drive for slick line or wire line opera-
tions.
When you use a turn-down sheave, use the following conventions:

• Orient the elevator links so they are parallel to the direction of line travel.
• Remove the elevator hydraulic hoses when you suspend the turn-down sheave from the
elevator. This prevents accidental opening of the elevator.
Elevator Links
Elevator
Correct Incorrect
Tesco's wire line/slick line guide attaches to the front of the grabber. The guide leads the wire
line/slick line from the front of the top drive to the center of the hole. Guide rollers prevent the
line from running over sharp corners that can cause damage.
If you use the wire line/slick line guide, place the grabber leg in the fully ‘up’ position, if pos-
sible.
Grabber Leg
Grabber Box
Guide Roller

73
TOP DRIVE CONSIDERATIONS OPERATIONS GUIDE
HEAVY LOADS AT THE V-DOOR

This procedure describes how you can use the top drive to pick up heavy loads from the V-
door.
Warning! The extend frame and EXTEND function allow

you to handle drilling tools, pick up casing, and
rack drill pipe and collars. They are for
convenience only and are not designed to pick-
up heavy loads while extended.
Warning! You can use the top drive to pick up heavy loads
from the V-door, if you use the following
procedure. Care, attention and common sense
must be used in addition to this procedure.
1. Connect the elevators links on the top drive to the load you want to pick up. Use
slings that are strong enough to support the load.
2. Connect a rig winch to the load you want to pick up.
3. Hoist the top drive with the extend frame completely retracted until the slings are
tight and the top drive is beginning to pick up the load.
4. At this point, hold the EXTEND switch at the IN position to maintain pressure on
the extend cylinders. This will prevent the extend frame from “opening up” while
the load is lifted. The force of gravity, combined with the load and the angle at
which it is being lifted, will tend to pull the extend frame open.
5. If the load is too heavy, and holding the EXTEND switch in the IN position is not
sufficient to keep the extend frame retracted, pick up the load with the rig winch.
This will create less pull on the extend frame and allow it to stay retracted. The
top drive, with the extend frame retracted, can be hoisted vertically with no
chance of the torque bushing binding on the torque track.
6. Continue to hoist the load until it is at the level required.
Warning! The extend frame must remain retracted at all
times when you are hoisting any heavy load. If it
is allowed to extend, the torque bushing can
bind on the torque track and damage the extend
frame and extend cylinders. For this reason,
always use a rig winch to help lift the load. If
done carefully, most normal drilling equipment
can be lifted using the above procedure.
Warning! For extremely heavy loads, Tesco recommends

that you either use additional winches to assist
in the lift or use cranes to position the equipment
on the drill floor instead of picking them up with
the top drive. You can avoid damage to the top
drive and unnecessary repair time with proper
planning and preparation.

74
OPERATIONS GUIDE LIST OF FIGURES
LIST OF FIGURES
Figure 2-1: HCI Driller’s Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3-1: HCI SET and MAX Torque Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 5-1: Correct Tong Position to Make a Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 5-2: Correct Position for Elevator Links and Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 5-3: Connect a Single Length of Pipe to the Drill String. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 5-4: Break the Top Drive/Drill Pipe Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 5-5: Make Up Stands in the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 5-6: Make Up Pipe Stands in the Mousehole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 5-7: Connect Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 6-1: Drill Ahead with Single Lengths of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 6-2: Drill Ahead with Pipe Stands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 7-1: Remove the Mudsaver Valve Actuator for Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 7-2: Remove the Actuator from the Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 7-3: Trip Out Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 7-4: Trip Out Collars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 7-5: Trip in Tools and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 8-1: Neutral Weight at the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 9-1: Pick Up Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 9-2: Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 9-3: Reduce the Stress on the Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 10-1: Block Sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

75
LIST OF FIGURES OPERATIONS GUIDE

76
OPERATIONS GUIDE INDEX
INDEX
A pre-operational procedures, 20
about the top drive, 1
AUX PUMP switch, 5 D
die lock clamp installation, 17
B DRILL mode speed control, 11
BHA drill pipe
make up, 31 connect to the drill string, 23
trip in, 55 connect to the top drive at the mousehole, 21
trip out, 53 make connections, general, 20
brake handle, 7 make up stands, 26
elevator-close, 7 make up triples, 28
BREAKOUT push button, 7 driller’s panel
BREAKOUT torque control, 11 controls, 5
features, 3
gauges, 7
C
general description, 3
cautions
indicators, 5
collars, 31, 32
non-robotic functions, 6
elevator links, 32
robotic functions, 5
EXTEND function, 26
warning lights, 5
grabber override, 33
making or breaking connections, 19
mudsaver valve, 19 E
pick-up elevators, 31 E.S.D. push button, 7
pick-up sub, 31, 32 ELEVATOR switch, 5
pipe handler, 18 ELEVATOR-CLOSE
saver sub torque, 17 brake handle, 7
SET and MAX torque, 17 engine speeds, 9
slips, 19 cautions, 9
trapped torque, 19 ENGINE switch, 6
Vernier dampening valve, 21 engine torque and speed, 10
collars and tools EXTEND function
make up, 31 cautions, 26
CONNECT mode, 11 EXTEND switch, 5
set forward speed, 15
set reverse speed, 14 F
speed control, 11 FLOAT push button, 5
connections
break connection to top drive, 24
G
cautions, 19
gauges on the driller’s panel, 7
connect collars above the rotary table, 33
GRABBER ’CLOSED’ light, 6
connect pipe single to drill sting, 23
GRABBER LIFT switch, 6
general overview, 20
GRABBER switch, 6
how to connect drill pipe at the mousehole, 21
GRABBER-Drawworks override, 8
how to fully torque, 23
make up BHA (collars and tools), 31
make up pipe stands, 26, 28 I
make up triples, 28 information, where to find more, 1
mousehole, 21

77
INDEX OPERATIONS GUIDE
L PUMPS-FWD control, 10
LINK TILT switch, 5 PUMPS-REV control, 11
M Q
make connections QUILL RPM gauge, 7
general, 20 QUILL TORQUE gauge, 7
precautions, 20
MAX torque R
how to adjust, 12 RANGE switch, 7
how to use, 14 remote brake handle, 7
MAX torque override, 14 reverse torque, setting, 16
MAX TORQUE push button, 7 robotic functions
MODE switch, 6 controls and indicators, 5
mousehole ROBOTICS ’ON’ light, 5
make up stands, 28 rotary table
use to make connections, 21 connect collars, 33
mudsaver valve make up pipe stands, 26
cautions, 19
S
N SAFETY OPEN push button, 5
non-robotic functions, 6 saver sub installation, 17
SET torque, 13
O speed
override set forward speed, CONNECT mode, 15
ELEVATOR-CLOSE, 7 set PIPE HANDLER speeds, 15
GRABBER-Drawworks, 8 set reverse speed, CONNECT mode, 14
speed available, 10
speed control, 11
P
forward or reverse rotation drill mode, 11
pipe
forward rotation connect mode, 11
break connection with top drive, 24
pipe handler, 11
connect to drill string, 23
reverse rotation connect mode, 11
make up triples, 28
speed, setting, 14
pipe handler
orientation before operation, 18
precautions, 18 T
use to make up pipe stands, 26 TILT switch, 5
PIPE HANDLER ’CAUTION’ light and push button, torque
6 adjust MAX torque, 12
PIPE HANDLER speed control, 11 adjust SET torque, 13
PIPE HANDLER switch, 6 how to set reverse torque, 16
PIPE HANDLER, set speed, 15 MAX torque function, 14
pipe stands MAX torque override, 14
make up in mousehole, 28 set for forward rotation, 12
make up in rotary table, 26 trapped in drill string, 19
make up with pipe handler, 26 torque available, 10
pre-operational procedures torque control, 10
install the die lock clamp, 17 breakout, 11
install the saver sub, 17 forward rotation, 10
orient the pipe handler, 18 reverse rotation, 11
prime mover engine speeds, 9 torquing connections, 23
PUMPS DECR/INCR switch, 6
PUMPS REV/FWD switch, 6

78
OPERATIONS GUIDE INDEX
V
VALVE ’CLOSED’ light, 6
VALVE switch, 5

79
INDEX OPERATIONS GUIDE

80
OPERATIONS GUIDE POST–JARRING CHECKLIST
APPENDIX A: POST–JARRING CHECKLIST
Unit #: Date: Operating Days:

(total towards 500 Day Inspection)
Tesco recommends that you use this checklist for the safety of all personnel who work with the top drive
and for the top drive’s continued operation.
After continuous jarring, or severe surface jarring, check components as indicated below:
Equipment Requirement OK Needs Repair

Load Path Inspect all connections including swivel
(mag particle or black light)
Check for quill endplay
Check the preload assembly (remove the protective boot)
Check the clearance between the load collar and the load nut
Elevators Check bolts on ram brackets
Check insert bolts
Check latch pin
Pipe handler Check all Grabber bolts
Check Grabber die holders
Check bolts and pins on lock
Check manifold and intensifier ram for tightness
Check for broken load collar lift springs
Check bolts in bail retainer ears
Check bolts on link tilt cylinder and clamps
Check all hoses
Mainframe Check preload on bearings
Check anchor bolts on roto seal
Check dowel pins into gear box
Check directional valves and mount
Check bolts on offset ears, extend arm, etc.
Torque Tubes Check hanging assembly
Check clevis’ and swivel joint
Check joints on tubes
Check all stabilization
Check all safety pins
Check clamps on anchor beam and in derrick
Check T-bar bolts
Check extend frame and torque bushing
Hose Saddle Check cable capture clamp, slings, safety pins, clevis
Comments:
Company Rep: Top Drive Supervisor:

A-1
POST–JARRING CHECKLIST OPERATIONS GUIDE

A-2

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Operations Guide

HCI(S) Top Drive System

500/650TON HCI(S) 750/1205HP

DOCUMENT NAME: 880003 REV B

Tesco Corporation © 2005

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

Version Date Description of Changes

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

Chapter 2: Driller’s Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 3: Torque and Speed Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

Chapter 4: Other Pre-Operational Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 5: How to Make and Break Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 6: Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

Chapter 7: Tripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Chapter 8: Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chapter 9: Run and Pull Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Chapter 10: Top Drive Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Appendix A: Post–Jarring Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

This page has been left blank intentionally.

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

CHAPTER 1: ABOUT THIS DOCUMENT

Table 1-1: Where to Find More Information

For information on Refer to

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

This page has been left blank intentionally.

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

CHAPTER 2: DRILLER ’S PANEL

Table 2-1: Features of the Driller’s Panel

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

Figure 2-1: HCI Driller’s Panel

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

CONTROLS, INDICATORS AND WARNING LIGHTS

Controls and Indicators for Robotic Functions

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

Controls for Non-Robotic Functions

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

Gauges and Displays

Dual Function Remote Brake Handle Control

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

GRABBER–Drawworks Interlock Override

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

CHAPTER 3: TORQUE AND SPEED LIMITS

PRIME MOVER ENGINE SPEEDS

750 hp prime mover

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005

AVAILABLE TORQUE AND QUILL SPEEDS

In this mode This torque is available This speed is available

Forward Rotation (PUMPS–FWD)

©TESCO CORPORATION, 2005 500/650TON HCI(S) 750/1205HP 880003 REV B

Reverse Rotation (PUMPS–REV)

Warning! Set this torque relief valve to a value that is 50%

Forward Speed, Connect Mode (MODE–CONN, PUMPS–FWD)

Reverse Speed, Connect Mode (MODE–CONN, PUMPS–REV)

Forward or Reverse Speed, Drill Mode (MODE–DRILL, PUMPS–REV/FWD)

PIPE HANDLER Rotation (Forward and Reverse)

880003 REV B 500/650TON HCI(S) 750/1205HP ©TESCO CORPORATION, 2005