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Operations Guide

900 ECI(S) Top Drive


MD500 Model

DOCUMENT NAME: TDO900ECIBAS00

COPYRIGHT AND DISCLAIMER

Tesco Corporation ("Tesco") has made every effort to ensure that this
document contains all of the information necessary to operate an ECI 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 2003

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

III

TABLE OF CONTENTS

Table of Contents
Section 1: About This Document .......................................... 1
Other Information on ECI Top Drives..........................................1

Section 2: Driller's Panel ........................................................ 3


System Description ........................................................................3
Controls, Indicators, and Warning Lights ...................................6
Warning Lights .............................................................................6
Robotic Functions and Associated Indicators.............................6
Drive Controls and Associated Indicators...................................7
Quill/Rotation Controls.................................................................8
Meters ..........................................................................................8
Function Descriptions (Robotics and ESD)................................9
Elevators ......................................................................................9
Tilt - Backward/Forward/Float .....................................................9
Extend - In/Out...........................................................................10
Valve...........................................................................................10
Grabber ......................................................................................11
Pipe Handler ..............................................................................11
Emergency Shut Down (ESD) ..................................................12
ESD on the Driller's Panel........................................................................................................... 12
ESD on the Main Panel Control System.................................................................................... 12

Torque and Quill Speed Controls...............................................13


Drill Forward...............................................................................13
Torque .......................................................................................................................................... 13
Speed ........................................................................................................................................... 13

Drill Reverse...............................................................................13
Torque .......................................................................................................................................... 13
Speed ........................................................................................................................................... 14

Connect Forward .......................................................................14


Torque .......................................................................................................................................... 14
Speed ........................................................................................................................................... 14
900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 1: ABOUT THIS DOCUMENT

Connect Reverse.......................................................................14
Torque .......................................................................................................................................... 14
Speed ........................................................................................................................................... 14

Breakout Button .........................................................................14


Dual Function Remote Brake Handle Control ..........................15
Elevator-Close.............................................................................................................................. 15
Grabber/Drawworks Interlock Override...................................................................................... 15

Calibrating Drillers Panel Meters...............................................16


Calibrating a Meter ....................................................................16
Meter Settings............................................................................17
Meter Settings............................................................................18
Set RPM....................................................................................................................................... 18
Delivered RPM............................................................................................................................. 18
Set Torque.................................................................................................................................... 18
Delivered Torque ......................................................................................................................... 18

Section 3: Setting Torque and Speed Limits ..................... 19


Motor Maximum Capacity............................................................19
Quill Torque and RPM Chart.....................................................20
Setting the Drive Parameters ......................................................20
Modifying Any Drive Parameter ................................................21

Section 4: Other Pre-operational Procedures.................... 23


Installing the Saver Sub and Die Lock Clamp ..........................23
Orienting the Pipe Handler..........................................................24

Section 5: Making/Breaking Connections .......................... 25


Important Cautions.......................................................................25
Making Connections ....................................................................25
Making Mousehole Connections...............................................27
Making a Connection (Pipe Handler Orientation Grabber to V-door).................................. 27
Making a Connection (Pipe Handler Orientation Grabber to Drawworks) .......................... 29
How To Completely Torque a Connection ................................................................................ 30
How to Connect a Single to the Drill String................................................................................ 30

Breaking the Top Drive/Drill Pipe Connection ..........................32


900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

VI

TABLE OF CONTENTS

Making up Stands with Pipe Handler.........................................33


Making up Stands in the Rotary Table......................................33
Making Up Stands in the Mousehole ........................................37
Making up BHA (Collars and Tools)...........................................40

Section 6: Drilling Ahead ..................................................... 45


Well Control While Drilling ..........................................................45
Drilling Surface Hole ....................................................................45
Drilling.........................................................................................46
Making Connections ..................................................................47
Tripping ......................................................................................47
Reaming.....................................................................................47
Drilling Ahead with Singles .........................................................48
Drilling Ahead with Stands..........................................................51
Slide Drilling ..................................................................................54
Introduction.................................................................................54
Drilling Using a Mud Motor ........................................................54
Adjusting the Tool Face Orientation..........................................55
Making/Breaking Connections while Slide Drilling....................56
Maintaining Tool Orientation While
Making/Breaking Connections ..................................................58
Recording the Drill String Torque..............................................59
Combination Drilling ....................................................................60

Section 7: Tripping................................................................ 61
Well Control While Tripping ........................................................61
Tripping Out...................................................................................62
Tripping Out Drill Pipe................................................................62
Standard Racking Procedure ..................................................................................................... 64

Tripping Out BHA (Collars and Tools) ......................................65


Tripping In (Tools, Collars, and Drill Pipe) ................................67
Tools and Collars .......................................................................67
Tripping In Drill Pipe...................................................................69
900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

VII

SECTION 1: ABOUT THIS DOCUMENT

Reaming .........................................................................................70

Section 8: Freeing Stuck Pipe.............................................. 73


Freeing Stuck Pipe Using a Top Drive.......................................73
Jarring ............................................................................................74
Controlled Drill String Back-off ..................................................75

Section 9: Running and Pulling Casing.............................. 77


Preparing the Top Drive to Run Casing ....................................77
Running Casing ............................................................................78
Pulling Casing ...............................................................................80

Section 10: Top Drive Considerations ................................ 81


While Performing Slip and Cut Operations...............................81
While Cementing...........................................................................82
During Slick Line Survey and Wire Line Logging....................82

List of Illustrations ................................................................ 85


Index ....................................................................................... 87
Appendix 1: Post Jarring Checklist........................................ i

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

VIII

SECTION 1: ABOUT THIS DOCUMENT

Section 1: About This Document


This Operations Guide contains information on using the top drive system. It
includes procedures for the following:
setting torque and speeds with PLC control
using the drillers panel
making and breaking connections (drill pipe, top drive/swivel,
collars etc.)
using the pipe handler
drilling
tripping
freeing stuck pipe (including jarring)
running and pulling casing
performing special operations
Critical: This guide assumes that the top drive is properly installed, the
power system is enabled, and all required safety checks are complete.
These procedures are detailed in the 900 ECI (MD500) Installation
Guide.

Other Information on ECI Top Drives


For information on

Refer to

system components

ECI(S) (MD 500 Model) System Description

installing

ECI(S) (MD 500 Model) Installation Guide

rigging up
commissioning
pre-operational checklists
load path inspections

ECI(S) (MD 500 Model) Maintenance Guide

maintenance/service schedules
disassembly
storage procedures
Tesco manufactured parts and part
numbers

ECI(S) (MD 500 Model) Parts List

electrical schematics

ECI(S) (MD 500 Model) System Schematics

hydraulic schematics
cooling schematics
available options and spares

Tesco Representative

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Section 2: Driller's Panel


System Description
Refer to the illustrations on the following pages.
The drillers panel is a stainless steel enclosure that provides access to all
required switches, indicators, mounts, meters and connectors.
The panel provides the controls, instrumentation and indicators required for
safe operation of the top drive. The control panel mounts at the drillers
console on the drill floor within convenient reach of the driller.
ECI drillers panel provides controls for the following:
robotic functions
drive functions
Emergency Shut Down (ESD)
ECI drillers panel provides meters that display the following drive
information:
set speed
delivered speed
set torque
delivered torque
ECI drillers panel provides indicators for the following:
warnings
status
The drillers panel interfaces with the main panel control system.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Illustration 1: ECI Drillers Panel

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Illustration 2: ECI Main Panel

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Controls, Indicators, and Warning Lights


Warning Lights
System Temp.
(red indicator light)

The system temperature light illuminates as a


warning prior to shutdown when over-heating
occurs. The light illuminates when any of the five
monitored drive system components exceeds
normal operating temperature: motor stators, rotor,
pre-regulator, inverter and system controller.
If this light illuminates, consult the LabVIEW
software to determine the location of overheating. If
you cannot fix the heating problem, the drive system
automatically shuts down.

Robotic Functions and Associated Indicators


AUXILIARY PUMP
Off/On
(switch)

This switch turns the auxiliary pump on or off. You


can also stop or start the pump from the power
module building.

ON
(green indicator light)

If illuminated, this signals that the auxiliary hydraulic


pump starter is energized.

ROBOTICS ON
(yellow indicator light)

If illuminated, this indicates that a robotics function is


currently selected and the auxiliary system is
pressured above 800 psi.

ELEVATOR
Close/Open
(switch, spring-return
Open, maintained
Close)

To operate the elevators, use the Open/Close


switch in conjunction with the Safety Open button.
To open the elevators:
1. Turn the Close/Open switch to the Open position
and hold.

Safety Open
(button, spring-return)

TILT
Back/Fwd.
(switch, maintained)

Float
(button, spring-return)

EXTEND
In/Out
(switch, spring return)

2. Press and hold the Safety Open button.


To close the elevators:
Turn the Close/Open switch to the Close position.
Note: You can also close the Elevators remotely
from the Brake Handle.
This switch tilts the elevator links backward and
forward.
Note: The links move backward and forward from
the current orientation of the pipe handler. Take
note of the pipe handler position before operating
the tilt function.
Press the Float button to relieve pressure in the tilt
cylinders. When the pressure is relieved, the links
return to the neutral position (vertical below the top
drive). The Float circuit remains energized until
either Link Tilt/Forward or Link Tilt/Backward is
selected.
This switch extends the top drive away from the
torque track or retracts the top drive to its original
position.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

VALVE
Close/Open
(switch, spring-return)

This switch operates the mudsaver valve actuator.


A mechanical link between the actuator and the
mud valve opens/closes the valve.

(yellow indicator light)

If illuminated, this light signals that the Mudsaver


Valve-Close is selected. This light indicates only that
the electrical signal has been sent, it does not
indicate that the valve has functioned.

GRABBER
Close/Open
(switch, spring-return
Open, maintained
Close)

This switch opens and closes the Grabber. To


achieve full clamping pressure, keep the Grabber
switch in the Close position. Once intensification is
complete, you can return the switch to neutral with
no loss of pressure.
Note: The Grabber override button is mounted on
the Brake Handle and is used only when the
Grabber is closed and hoisting the drawworks is
required (e.g. during directional drilling).

CLOSED
(red indicator light)

If illuminated, this light signals that Grabber-Close is


selected.

Grabber Lift
Up/Down

Use this switch to move the Grabber leg up and


down when making or breaking connections.

PIPE HANDLER
Rotate Push Button
(push and hold)

Use this push-button in conjunction with QuillForward/Reverse to rotate the pipe handler in
forward or reverse.

Caution
(red indicator light)

Illuminates when the pipe handler is unlocked.

Unlock/Lock
(switch, spring-return
Unlock, maintained
Lock)

This switch locks or unlocks the pipe handler. When


unlocked, the pipe handler rotates to facilitate pipe
handling.

Drive Controls and Associated Indicators


Ready
(green indicator light)

If illuminated, this light indicates that there are no


drive system faults, and the unit is ready for
operation.

ESD

Pushing this button trips the main breakers (A & B)


supplying power to the MD500 Drive system. It also
shuts off the auxiliary pump. Rotation stops but the
drive may require up to 5 minutes to dissipate
voltage.
There is a separate ESD push-button on the power
module building.

(Emergency Shut Down)

(push-button)

MODULE "ON"
(green indicator light)

If illuminated, this light indicates that the MD500


module drive system is energized.

Enable Off/On
(switch)

Setting this switch to On readies the drive to accept


rotational commands.

Reset
(button, spring return)

This button resets the Kaman drive system


controller (reboots). It only functions if the Enable
switch is set to Off.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Drive Set
(keyed switch, springreturn)

This switch is used to set the Speed and Torque


limits for rotational functions. It only functions if the
Enable switch is set to Off. Refer to Torque and
Quill Speed Controls on page 13 for more details.

Quill/Rotation Controls
QUILL
Reverse/Forward
(switch, maintained)

Use this switch to select a direction (forward or


reverse) for the top drive quill rotation.

SPEED
Decrease/Increase
(switch, spring-return)
TORQUE
Decrease/Increase
(switch, spring-return)

This switch increases or decreases the quill speed.


See Torque and Quill Speed Controls on page 13
for more information.
This switch increases or decreases the torque
output of the drive. See Torque and Quill Speed
Controls on page 13 for more information.

BREAKOUT
(button, spring-return)

This button applies breakout torque (it only works in


Connect mode in Reverse). Push and hold the
button to achieve full breakout torque.

MODE
Mode
(switch)

This switch allows you to select the Connection


mode or Drill mode.

Meters
Set Speed
(meter)

This meter displays the rotating speed as selected


by the driller. Can be set between 0-193 rpm for
18.61:1 gear ratio, and 0-246 rpm for 14.45:1 gear
ratio. This speed is set using the Speed switch. See
Torque and Quill Speed Controls on page 13 for
more information.

Delivered Speed
(meter)

This meter displays the actual quill speed of the top


drive.

Set Torque
(meter)

This meter displays torque as selected by the driller.


This is expressed in ftlb. See Torque and Quill
Speed Controls on page 13 for more information.

Delivered Torque
(meter)

This meter displays the actual torque produced at


the quill. This is expressed in ftlb.

It is possible to calibrate torque meters to display DNm, although this is


rarely required. For additional information, contact a qualified Tesco
representative.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Function Descriptions (Robotics and ESD)


To operate most ECI robotics functions you must manually start the auxiliary
hydraulic pump. The exceptions are the Grabber and Mudsaver Valve
functions. If you select either of these functions, the pump starts
automatically.

Elevators
The hydraulic elevators attach to the end of the Elevator links. They clamp
around and handle drill pipe, collars, drilling tools and casing.
Safety features include a double-action open switch function. The 3-position
Elevator switch on the drillers panel works in conjunction with the elevator
Safety Open push-button. You must turn the Elevator switch to Open and
press the Safety Open push-button at the same time to open the elevators; this
prevents accidental opening of the elevators. Operating either switch by itself
will not energize the elevator solenoid.
It is essential that when Elevator-Close is selected, the elevators fully close
and latch. When you select Elevator-Close, pressure to the close circuit
remains high for enough time to positively engage the latch.
For convenience, the operator can remotely close the elevators from the
drillers brake handle. This option allows the driller to close the elevators and
lower or raise the drawworks using one hand, leaving the other hand free to
operate other drilling controls.

Tilt - Backward/Forward/Float
The Tilt function allows the operator to move the Elevator links, with the
attached elevators, to a position forward or back of hole center. This function
is useful when handling pipe stands during tripping, running casing, and
making up stands. Links move 55 back and 35 forward of hole center.
Use the Tilt-Back function to move the links and elevators out of the way and
lower the top drive closer to the rig floor, or to re-position the links to an
angle back of hole center. Selecting Tilt-Forward moves the links and
attached elevators away from hole center toward the V-door. Using this
option with other functions allows the operator to easily rack back tripped
drill pipe stands, make up stands in the mouse hole, or retrieve stands for
reconnection.
The Float function returns the links to hole center. Pressure in the Tilt
cylinders is relieved and the links return to a vertical position below the top
drive.
900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

SECTION 2: DRILLER'S PANEL

Extend - In/Out
Use the Extend feature to efficiently handle stands of drill pipe during
tripping, or to handle rig tools while not oriented over hole center. Operating
this function moves the entire top drive out from the torque track, to a
maximum distance of 54.
Extend-In and Extend-Out switches are 'spring return to neutral', and must be
held in the desired selection. This allows the operator to stop the top drive at
any increment along its travel distance by simply releasing the switch.
Operators can also jog the top drive through its travel distance by
momentarily selecting the In or Out function.
Selecting Extend-Out moves the top drive away from the torque track
towards the V-door. This re-orientation of the top drive enables the driller to
more effectively handle stands of drill pipe where additional distance from
hole center is desired (additional to that achieved using Tilt-Forward).
Extend-In returns the top drive back to its original position over hole center.
As previously mentioned, any increment of the total distance can be
achieved.

Valve
The Valve function operates the mud valve actuator, which opens and closes
the mudsaver section of the mud valve. The mud valve is a double-ball valve.
The lower ball is used for well control and the upper is used as a mudsaver.
When making connections or tripping in or out of the hole, it is necessary to
deactivate the mud pump(s) to make or break pipe joints. Close the mudsaver
valve to prevent gravity loss of drilling fluid trapped in the swivel, quill and
hose.
When Valve-Close is selected, electrical controls stop quill rotation. After the
valve closes and the five second timer expires, you can restart rotation by
selecting Quill-Neutral, then Quill Forward or Reverse.
Note: When properly installed, the mud pump interlock prevents the
mud pump from starting if the valve is closed.

When Valve-Close is selected, a yellow warning light illuminates on the


drillers panel and remains lit until you select Valve-Open.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

10

SECTION 2: DRILLER'S PANEL

Grabber
The Grabber is a hydraulically operated pipe-clamping device located at the
bottom of the Grabber leg of the top drive. The Grabber is used as back up
tongs for making/breaking pipe stand joints to/from the top drive.
The Grabber-Open switch is a 'spring return' type and requires only
momentary functioning to begin the open sequence. The Grabber-Close
switch is a 'maintained type. It maintains power to the appropriate hydraulic
directional valves until the neutral position is selected.
A red warning light on the drillers panel illuminates when Grabber-Close is
selected.
Tesco recommends installing safety interlocks that prevent the operator from
hoisting the drawworks when the Grabber is closed (unless the operator
presses an override button). Another PLC-programmed interlock prevents the
Grabber from closing if the quill speed is higher than 2 rpm.

Pipe Handler
The top drive is designed with a Pipe Handler section. Located from the
slewing bearing down, this section is designed to rotate independently of the
top drive main frame and provides unique options for handling pipe stands,
casing and downhole tools.
The Pipe Handler section is locked to the top drive main frame at the slewing
bearing. To access the Pipe Handler rotation feature, ensure the Pipe Handler
section is unlocked. The Kaman drive system drives the Pipe Handler.
Selecting Pipe Handler-Unlock (in conjunction with the Grabber Close and
Pipe Handler Rotate push-button) allows Pipe Handler rotation using the
Kaman drive controls. Selecting Pipe Handler-Lock allows the Kaman drive
controls to rotate the quill in forward or reverse in Connect mode. Controls
are available when lock-pin engagement is verified.
Exercise caution when rotating the top drive Pipe Handler section. When you
set the Pipe Handler to Unlock or switch from Unlock to Neutral, a red
Caution light illuminates at the drillers panel and remains lit until you select
Pipe Handler-Lock.
Selecting Quill-Forward or Reverse and pushing/holding the Pipe Handler
Rotate push-button allows 360 rotation. Releasing the push-button stops
rotation. The pipe handler rotates from 1 rpm to 14 rpm. Tesco recommends
5 rpm.
If Pipe Handler-Lock is selected but fails to fully engage, the Caution light
remains lit and control priority remains with the Pipe Handler controls.
Reselect Pipe Handler-Lock to engage the function.
900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

11

SECTION 2: DRILLER'S PANEL

Emergency Shut Down (ESD)


There are two ESD circuits, each with its own specific function.
ESD on the Driller's Panel
Pushing this ESD trips the main circuit breakers A and B (located in the
power module), which supply 600 VAC to the MD500 Drive power module.
This effectively removes all high voltage power from the Kaman drive. The
quill stops rotating. This ESD also deactivates the auxiliary hydraulic pump.
The overall result is that in the event an emergency shut down is required, all
devices that operate or rotate at the drill floor become inactive.
Resetting the Driller's Panel ESD

When the ESD switch is reset (pulled back out), the driller has the option of
starting the auxiliary pump from the drillers panel, however, you cannot
reestablish drive system power from the drillers panel. To restart the Kaman
drive, follow standard start-up procedures.
ESD on the Main Panel Control System
This ESD switch (located on the power module door) cuts all power to the
Tesco Power Module unit. This ESD switch is interlocked to trip the main
service supply breaker.
Resetting the Main Panel Control System ESD

To restore power, reset the ESD switch (pull it back out), then reset and
activate the main breaker.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

12

SECTION 2: DRILLER'S PANEL

Torque and Quill Speed Controls


Available torque or quill speed is specific to each top drive activity. They are
summarized in the table below.
In this mode

This torque is available

This speed is available

Drill Forward

0 100% of the maximum


preset*

0 rpm maximum rpm

Drill Reverse

0 100% of the maximum


preset*

0 - 28 rpm (18.61:1 gear ratio)


0 - 35 rpm (14.45:1 gear ratio)

Connect Forward

0 100% of the maximum


preset*

0 rpm maximum rpm

Connect Reverse

0 100% of the maximum


preset*

0 - 28 rpm (18.61:1 gear ratio)


0 - 35 rpm (14.45:1 gear ratio)

* Refer to Setting the Drive Parameters on page 20.

Drill Forward
Torque
Drillers panel controls allow the operator to select the top drive forward quill
torque to suit various tool joints.
The driller selects from 0 100% of the maximum preset torque limit. Preset
this maximum limit at the drillers panel before operating the unit (see Setting
the Drive Parameters on page 20).
Speed
The full range of quill speed is available in drill-forward mode.
Note: Quill speed ranges from 0-195 rpm for 18.61:1 gear ratio and
0-246 rpm for 14.45:1 gear ratio.

Drill Reverse
Torque
Set drill reverse torque limit at the drillers panel. Preset this limit before
operating the unit (see Setting the Drive Parameters on page 20). 0-100% of
this preset limit is available from the drillers panel during reverse drilling
operations.

900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE


TDO900ECIBAS00
TESCO CORPORATION, 2003

13

SECTION 2: DRILLER'S PANEL

Speed
Preset a single drill reverse speed limit at the drillers panel before operating
the unit (see Setting the Drive Parameters on page 20). This is the only speed
setting available from the drillers panel during reverse drilling operations.
Available speed in reverse is 0 28 rpm (18.61:1 gear ratio) and 0-35 rpm
(14.45:1 gear ratio).

Connect Forward
Torque
Preset the maximum connect torque limit at the drillers panel before
operating the unit (see Setting the Drive Parameters on page 20). The driller
selects a setting from 0 100% of the maximum preset torque limit.
Speed
Set a single make-up quill speed limit at the drillers panel before operating
the unit (see Setting the Drive Parameters on page 20). This is the only quill
speed available from the drillers panel during make-up operations.

Connect Reverse
Torque
Preset a connect-reverse torque upper limit at the drillers panel before
operating the unit (see Setting the Drive Parameters on page 20). This is the
only connect reverse torque setting available from the drillers panel, unless
the Breakout button is pressed.
Speed
Set a single connect reverse speed limit at the drillers panel before operating
the unit (see Setting the Drive Parameters on page 20). This is the only
connect reverse quill speed available from the drillers panel unless the
Breakout button is pressed.

Breakout Button
Press and hold this button to apply maximum reverse torque to the pipe. The
torque ramps up from zero to the maximum torque over a period of ten
seconds, then holds this maximum torque for three seconds. After the three
second hold time, the system ramps down the applied torque to zero (in two
seconds) and goes into a temporary shutdown state for ten seconds. The
temporary shutdown prevents damage to drive components.
900 ECI(S) TOP DRIVE MD500 MODEL OPERATIONS GUIDE
TDO900ECIBAS00
TESCO CORPORATION, 2003

14

SECTION 2: DRILLER'S PANEL

At the end of the shutdown period, the system returns to ready mode, unless
you select Connect-Reverse. If you select Connect-Reverse, return the Quill
switch to Neutral and wait for the ready light to illuminate.
If the pipe joint breaks before reaching maximum torque, the top drive rotates
at the preset Breakout speed. When you release the Breakout button, the top
drive rotates at Connect-Reverse speed, if this is selected. The system
remains in a ready state and no temporary shut down occurs.

Dual Function Remote Brake Handle Control


The brake handle push-button controls operate the Elevator-Close and the
Grabber/Drawworks Interlock Override as described below.
Elevator-Close
For ease of tripping, operate the elevators from a switch located on the brake
handle. This is a spring-return push-button switch that activates a five second
timed sequence to ensure that the elevators close completely. The five second
sequence activates even if the switch is only briefly selected.
Grabber/Drawworks Interlock Override
The drum clutch interlock locks out the drum clutch so the driller cannot hoist
while the Grabber is engaged. A red warning light positioned above the
Grabber switch on the drillers panel indicates the status of the Grabber. If
illuminated, this light indicates that Grabber-Close is selected. Use the pushbutton on the brake handle to override the lockout feature.
Note: This override is important in several circumstances (for example, when
hoisting the string with the Grabber closed during directional drilling).

The override button operates a temporary contact that either controls an air
valve that allows air back to the drum clutch or triggers a PLC signal that
interrupts the drawworks controls. The override works only when the button
is pushed and held. When the button is released, air supply to the clutch
control or the PLC interlock with the drawworks control is once again
interrupted and the override is no longer active.

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SECTION 2: DRILLER'S PANEL

Calibrating Drillers Panel Meters


The drillers panel contains four display meters:
set RPM
delivered RPM
set torque
delivered torque
Calibrate all meters before every job using the following procedure.
Recommended settings appear in the tables that follow the procedure.
Although values are different for each meter type, you can calibrate all meters
using the same procedure.
Each meter has five calibration buttons located immediately below the
display.

Calibrating a Meter
1.

If necessary, stop quill rotation at the top drive.

2.

Push the Menu button.


The first input signal displays.

3.

Push the Tare button to scroll through the input signal options.

4.

From the available options, select 4-20.

5.

Press the Menu button.


Note: This stores the selected input signal option and displays the first

decimal places option.


6.

Push the Tare button to scroll through the decimal places options.
Select decimal place options as follows:
For Set and Delivered Speed, select the decimal place at the
extreme right (i.e. to display whole numbers).
For Set and Delivered Torque, set the decimal place one place
from the right (i.e. to display one decimal place).
Note: Both Torque displays now give values in thousands of ftlb,
such that a reading of 20.3 means 20,300 ftlb.

7.

When the desired decimal places option appears, press the Menu
button.
Note: This stores the selected decimal places option and displays the
first scaling option.

8.

Push the Tare button to scroll through the scaling options (Live or Int).

9.

Select Int.

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SECTION 2: DRILLER'S PANEL

10. Press the Menu button.


Note: This stores the selected scaling option and displays the first RD1
(low setting) option. The meter display flashes "0400".
11. Push the Tare button.
The first digit flashes, indicating you can set it.
12. Press the Max button to change the flashing number.
Note: Continue pressing the Max button until the desired number
appears.
13. Repeat the previous two steps for the second, third and fourth digits.
14. When the desired RD1 numbers appears, press the Menu button.
Note: This stores the selected RD1 numbers and displays the first RD2
(high setting) option. The meter display flashes 2000.
15. Push the Tare button to select the first digit. The first digit flashes,
indicating you can set it.
16. Press the Max button to change the flashing number.
Note: Continue pressing the Max button until the desired number
appears.
17. Repeat the previous two steps for the second, third and fourth digits.
18. When the desired RD2 numbers appear, press the Menu button.
Note: This stores the selected RD2 numbers.
19. Push the Tare button to zero the meter.
Important: Ensure the quill is motionless during this step.

Meter Settings
Note: To display the highest recorded value from gauge memory, push
the Max button. The value appears. If desired, push the Reset button to
remove the maximum value from memory.
Note: You may adjust delivered torque and delivered speed for your
particular top drive unit. Small changes to RD1 and RD2 may be
required. For additional information on fine-tuning these settings, please
contact a qualified Tesco representative.

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SECTION 2: DRILLER'S PANEL

Meter Settings
These are the recommend settings for each of the drillers panel gauges.
Set RPM
Signal
Decimal Point
Scaling Option
RD1 (18.61:1 ratio)
RD2 (18.61:1 ratio)
RD1 (14.45:1 ratio)
RD2 (14.45:1 ratio)

4 20 mA (4 mA is 0 rpm, 20 mA is 193 rpm)


FFFF.
Int.
-0193
0193
-0246
0246

Delivered RPM
Signal
Decimal Point
Scaling Option
RD1 (18.61:1 ratio)
RD2 (18.61:1 ratio)
RD1 (14.45:1 ratio)
RD2 (14.45:1 ratio)

4 20 mA (12 mA is 0 rpm, 20 mA is 193 rpm)


FFFF.
Int.
-0193
0193
-0246
0246

Set Torque
Signal
Decimal Point
Scaling Option
RD1 (18.61:1 ratio)
RD2 (18.61:1 ratio)
RD1 (14.45:1 ratio)
RD2 (14.45:1 ratio)

4 20 mA (4 mA is 0, 20 mA is 69,200 ftlb)
FF.FF
Int.
0
46,500
0
36,125

Delivered Torque
Signal

4 20 mA (4 mA is 0, 20 mA is 86,500 ftlb)

Decimal Point
Scaling Option
RD1 (18.61:1 ratio)
RD2 (18.61:1 ratio)
RD1 (14.45:1 ratio)
RD2 (14.45:1 ratio)

FF.FF
Int.
0
57,600
0
44,750

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SECTION 3: SETTING TORQUE AND SPEED LIMITS

Section 3: Setting Torque and Speed


Limits
The speed and torque of the top drive work in conjunction. Without sufficient
speed, you may not reach required torque values. Similarly, with insufficient
torque, you may not reach desired speeds.
The drive produces a motor speed and torque that is proportional to a variable
voltage input to the system controller. The system controller accepts one
input for speed and one input for torque. Therefore, the control circuitry and
strategy for each rotational function must be determined before the inputs are
sent to the system controller. Each rotational requirement is different so each
final voltage input is different.
As an example, the operator may need to drill forward at 150 rpm but would
never consider making up a connection at 150 rpm, although the transition
from drill forward to connect forward is made simply by the operator turning
one switch. Therefore, the control behind the scenes must be in place to
differentiate and limit the inputs.
During the units commissioning stage, specific values of desired speed and
torque are selected for each rotational function and preset as defaults. On
site, making final adjustments required to meet specific drilling requirements
is recommended, and is easily done at the drillers panel.

Motor Maximum Capacity


The motor shaft is connected to the gearbox with a gear ratio of 18.61:1 or
14.45:1 that produces rotation of the quill. The drill pipe is attached to the
quill (via the saver sub).
In forward, the motor achieves 3600 rpm. In reverse, the motor achieves 513
rpm. Each is reflective of a 10 VDC input to the system controller.
The Kaman motor can continuously produce 1050 ftlb of torque, in drill
forward or reverse. In makeup, the motor produces 1250 ftlb of torque. This
torque holds for 5 seconds, after which it falls back to 1050 ftlb, which is
then maintained. In breakout, the motor produces 1539 ftlb of torque for a
maximum of 3 seconds, after which it ramps down to zero.

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SECTION 3: SETTING TORQUE AND SPEED LIMITS

Quill Torque and RPM Chart


18.61:1Ratio
Makeup Torque = 1250 ftlbs x 18.61:1x 2 = 46,525 ftlbs
Drill Torque = 1050 ftlbs x 18.61:1x 2 = 39,081 ftlbs
Breakout Torque= 1539 ftlbs x 18.61:1x 2 = 57,282 ftlbs
Forward RPM = 3600 18.61:1 = 193.4
Reverse RPM = 513 18.61:1 = 27.6
14.45:1Ratio
Makeup Torque = 1250 ftlbs x 14.45:1x 2 = 36,125 ftlbs
Drill Torque = 1050 ftlbs x 14.45:1 x 2 = 30,345 ftlbs
Breakout Torque= 1539 ftlbs x 14.45:1 x 2 = 44,477 ftlbs
Forward RPM = 3600 14.45:1 = 249.1
Reverse RPM = 513 14.45:1 = 35.5

Setting the Drive Parameters


You can modify these drive parameters (torque and speed settings) from the
drillers panel:
Drill Forward Torque
Drill Reverse Torque and Speed
Connect Forward Torque and Speed
Connect Reverse Torque and Speed
Breakout Speed
Pipe Handler Forward Torque and Speed
Pipe Handler Reverse Torque and Speed
Setting drive parameters (torque and speed) minimizes the possibility of
injury and damage to drilling equipment. For example, limiting drill forward
torque guards against twisting off the drill string while drilling. Setting
connection speed and torque allows for proper make up of tool joints and
guards against damage to threads and seal faces caused by over-torquing.
Limiting pipe handler rotation speed and torque ensures the pipe handler
rotates at a safe speed and stops rotating when it achieves pre-set torque.
The drive system will not surpass the programmed torque and speed settings,
however, you can change settings using the following procedure.
Use the same steps to set or adjust a setting for all functions.

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SECTION 3: SETTING TORQUE AND SPEED LIMITS

Modifying Any Drive Parameter


1.

At the drillers panel, set the Enable switch to off.

2.

Insert the key into the Drive Set keyed switch.

3.

Turn and hold the key in the Set position.

4.

Select and set the required function using the following table:

To set this

Perform these steps


1. Using the Mode switch, select Drill.
2. Using the Quill switch, select Forward.

Drill Forward
Torque

3. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Set this limit at 2,000 ftlb less than the lowest connected joint
torque setting (see Connect Forward Torque).
Consult with the Rig Manager or Oil Company Representative to
determine the proper setting.
Important: If using a downhole mud motor, the torque set limit must be
higher than the maximum output of the mud motor. See Drilling Using a
Mud Motor on page 54.
1. Using the Mode switch, select Drill.
2. Using the Quill switch, select Reverse.

Drill Reverse
Speed and
Torque

3. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 10 RPM or less.
4. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Tesco recommends 10,000 ftlb or less, depending on drill string
configuration.
1. Using the Mode switch, select Connect.
2. Using the Quill switch, select Forward.

Connect
Forward
Speed and
Torque

3. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 15 RPM or less.
4. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Determine this setting using the torque requirements for the drill
string connections.
1. Using the Mode switch, select Connect.
2. Using the Quill switch, select Reverse.

Connect
Reverse
Speed and
Torque

3. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 15 rpm or less.
4. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Tesco recommends 8000 ftlb or less.

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SECTION 3: SETTING TORQUE AND SPEED LIMITS

To set this

Perform these steps


1. Using the Mode switch, select Connect.
2. Using the Quill switch, select the Neutral position.

Breakout
Speed

3. Push and hold the Breakout button.


4. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 6 rpm.
1. Using the Mode switch, select Connect.
2. Using the Quill switch, select Forward.

Pipe Handler
Forward
Speed and
Torque

3. Push and hold the Pipe Handler Rotate button.


4. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 5 rpm.
5. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Tesco recommends 5000 ftlb or less.
1. Using the Mode switch, select Connect.
2. Using the Quill switch, select Reverse.

Pipe Handler
Reverse
Speed and
Torque

3. Push and hold the Pipe Handler Rotate button.


4. Using the Speed switch, increase or decrease the Set Speed reading on
the digital gauge on the drillers panel.
Note: Tesco recommends 5 rpm.
5. Using the Torque switch, increase or decrease the Set Torque reading
on the digital gauge on the drillers panel.
Note: Tesco recommends 5000 ftlb or less.

5.

Release the Drive Set keyed switch.

6.

Remove the key.

7.

Push and hold the RESET button for 5 seconds.

8.

Set the Enable switch to On.


Important: System controller memory maintains settings only if 24
VDC is maintained to the system controller. You must re-enter all
preset values whenever the UPS is deactivated (during rig moves,
repairs, maintenance etc.).

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SECTION 4: OTHER PRE-OPERATIONAL PROCEDURES

Section 4: Other Pre-operational


Procedures
Installing the Saver Sub and Die Lock Clamp
1.

Set the Pipe Handler switch to Lock.

2.

Stab the saver sub through the Grabber box.


Note: Ensure the upper pin protrudes above the Grabber box.

3.

Dope the saver sub threads.

4.

Attach the saver sub by hand.


Note: Tighten as far as possible.

5.

Set the Grabber switch to Close.

6.

Use the Torque switch to reduce the torque to approximately 30% of


the required make-up torque.

7.

Set the Mode switch to Connect.

8.

Set the Quill switch to Forward.

9.

Continue rotation until the connection shoulders up.

10. Using the Torque switch, increase the torque to the required make-up
torque.
11. When desired torque is achieved, set the Quill switch to Neutral.
12. Using the Grabber switch, select Open.
13. Place the die lock clamp on top of the Grabber box.
14. Loosely install the die lock bolts (8).
15. Raise the die lock clamp into position and hold, either manually or by
using Grabber-Lift.
Note: Position the clamp so it evenly straddles the saver sub/mud valve
connection.
16. Evenly tighten all cap screws.
Note: Monitor the end gaps to ensure that the clamp is installed evenly.
17. Torque all 7/8" Grade 8 fasteners to 550 ftlb.
18. Seat the dies.
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SECTION 4: OTHER PRE-OPERATIONAL PROCEDURES

Note: To seat the dies, strike the back side of each half of the clamp as
hard as possible, using a sledge hammer.

19. When the dies seat properly, torque all bolts to 550 ftlb.

Orienting the Pipe Handler


Take the following precautions before you operate the pipe handler:
Ensure the links and elevators hang vertically.
If the top drive is connected to the drill string, ensure that it is safe
to rotate the string.
Ensure that the pipe handler is holding no reactive torque from the
drill string. You can do this by setting the Grabber switch to
Open and setting the Quill switch to Neutral.
1.

Ensure the Quill switch is set to Neutral.

2.

Set the Grabber switch to Close.


Note: The Grabber should close on the saver sub. Do not close on the
saver sub threads.

3.

Using the Pipe Handler switch, select Unlock.


Note: The Pipe Handler Caution light illuminates.

4.

Using the Quill switch, select the direction of rotation for the pipe
handler.
Note: The pipe handler will not rotate until the Pipe Handler Rotate
button is pressed.

5.

Press and hold the Pipe Handler Rotate button to rotate the pipe
handler in the desired direction.

6.

Release the Pipe Handler Rotate button when you achieve the desired
orientation.

7.

Set the Quill switch to Neutral.

8.

Set the Pipe Handler switch to Lock.


Important: Before proceeding, inspect the pipe handler lock to ensure
that the lock is fully engaged.

9.

Open the Grabber, if required, and continue operations.

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SECTION 5: MAKING/BREAKING CONNECTIONS

Section 5: Making/Breaking Connections


Important Cautions
When making or breaking any connection, you must open or close the
mudsaver valve. Always stop quill rotation before you function the valve.
When you function the valve, the valve switch applies hydraulic pressure to
the actuator. If the quill rotates with pressure applied, seal damage may result.
If you function the valve switch while the quill is rotating, an interlock in the
PLC program prevents damage to the actuator seals as follows:
The PLC program stops quill rotation.
It allows the mudsaver valve to complete its timed circuit.
When the circuit completes, you can continue operating by
functioning the Quill direction switch to Neutral, then to the
desired direction.
Important: Always exercise caution when setting and removing pipe

slips. Setting slips when the rotary table is locked may trap torque in
the drill string. When you remove the slips this trapped torque may
release and turn the drill string.
Hoist the pipe free of the slips before you manually remove them.

Making Connections
Do the following before you begin this procedure:
Ensure that proper torque and speed settings are pre-set into the
drive system.
Ensure that the top drive saver sub thread matches the drill string
thread.
Properly dope all connections.
Important: When connecting the top drive to a drill pipe single,

position the Grabber so it closes on the drill pipe tool joint. When
making up the top drive and additional connections simultaneously,
position the back-up tongs on the drill pipe tool joint located in the
slips.

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SECTION 5: MAKING/BREAKING CONNECTIONS

Illustration 3: Tong Position for Making Connection

Grabber location

back-up tong location


rig slips

1.

Set the Mode switch to Connect.

2.

Set the Quill switch to Forward.


Note: The top drive turns at the pre-selected rpm for
Connect/Forward.

3.

Using the Torque switch, set torque to 30% of the pre-set value.

4.

Slowly lower the top drive to the connection.

5.

Ensure that the box connection enters into the Grabber guide.

6.

Monitor the weight indicator gauge.

7.

Continue lowering the top drive until the weight indicator begins to
fluctuate.
Critical: Ensure that the Vernier dampening valve (on the weight

indicator) is open.
8.

Lead the top drive into the connection.


Note: As the connection rotates in, lower the top drive in small
increments. Keep a small amount of weight on the connection (i.e.
weight should come off the weight indicator). This prevents the top
drive from "lifting" the stand or single and damaging the threaded
connections.

9.

Continue rotating until the connection is complete.


Note: The top drive stalls when it reaches the pre-set make up torque.
The top drive rotating speed then drops to zero.

10. Using the Torque switch, increase to the pre-determined torque


required for the current connection and thread type.
11. Monitor the Delivered Torque gauge.
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SECTION 5: MAKING/BREAKING CONNECTIONS

12. When delivered torque reaches desired make up torque, set the Quill
switch to Neutral.
13. Allow the delivered torque to fall to zero.
14. Remove the back-up tong.

Making Mousehole Connections


Making a Connection
(Pipe Handler Orientation Grabber to V-door)
Use this procedure when drilling with singles.
Note: This procedure applies to making connections when the

mousehole is not offset.


Critical: When first hoisting out of the mousehole with the Pipe

Handler in this orientation, ensure that the Tilt links are close to hole
center to avoid hitting the torque track.
1.

Ensure the single length of pipe is situated in the mousehole.

2.

Properly dope the drill pipe box connection.

3.

Using the Extend switch, select Out.

4.

Extend the top drive until it is situated directly over the mousehole.

5.

Lower the top drive until it is near the rig floor.

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SECTION 5: MAKING/BREAKING CONNECTIONS

Illustration 4: Link/Elevator Position for Making Mousehole


Connections

6.

Set the Tilt switch to Back.

7.

Move the links and elevators back and out of the way of the connection.

8.

Lower the top drive until the saver sub is within a foot of the pipe
connection.

9.

Set the Mode switch to Connect.

10. Set the Quill switch to Forward.


11. Using the Torque switch, set torque to 30% of the pre-set value.
Note: To avoid cross-threading, properly align the top drive and the
single length of pipe.
12. Slowly lower the top drive to engage the saver sub/pipe connection.
13. Lead the top drive into the connection.
Note: If the pipe starts to spin in the mousehole, set the Quill switch to
Neutral. Close the Grabber on the drill pipe tool joint then set the Quill
switch to Forward.
14. When the connection shoulders up, set the Quill switch to Neutral
(open the Grabber if required).
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SECTION 5: MAKING/BREAKING CONNECTIONS

15. Complete the connection as described in one of the following


procedures:
How To Completely Torque a Connection on page 30
How to Connect a Single to the Drill String on page 30
Making a Connection
(Pipe Handler Orientation Grabber to Drawworks)
Use this procedure if connecting the occasional individual single from the
mousehole to the drill string.
Critical: When first hoisting out of the mousehole with the Pipe

Handler in this orientation, ensure that the Tilt links are close to the
drill pipe to avoid hitting the monkey board.
1.

Ensure the single length of pipe is situated in the mousehole.

2.

Properly dope the drill pipe box connection.

3.

Using the Extend switch, select Out.

4.

Extend the top drive until it is situated directly over the mousehole.

5.

Lower the top drive until it is near the rig floor.

Illustration 5: Link/Elevator Position for Making Connections Grabber


to Drawworks

6.

Set the Tilt switch to Back.

7.

Move the links and elevators back and out of the way of the connection.

8.

Lower the top drive until the saver sub is within a foot of the pipe
connection.
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SECTION 5: MAKING/BREAKING CONNECTIONS

9.

Set the Mode switch to Connect.

10. Set the Quill switch to Forward.


11. Using the Torque switch, set torque to 30% of pre-set torque value.
Note: To avoid cross-threading, properly align the top drive and the
single length of pipe.
12. Slowly lower the top drive to engage the saver sub/pipe connection.
13. Lead the top drive into the connection.
Note: If the pipe starts to spin in the mousehole, set the Quill switch to
Neutral. Close the Grabber on the drill pipe tool joint, then set the Quill
switch to Forward.
14. When the connection shoulders up, set the Quill switch to Neutral (and
open the Grabber if required).
15. Complete the connection using one of the following procedures:
How To Completely Torque a Connection on page 30.
How to Connect a Single to the Drill String on page 30.
How To Completely Torque a Connection
1.

Set the Grabber switch to Close.

2.

Set the Mode switch to Connect.

3.

Set the Quill switch to Forward.

4.

Using the Torque switch, increase the set torque to the value required
for the connection and thread type.

5.

When delivered torque reaches the desired torque value, set the Quill
switch to Neutral.

6.

Using the Grabber switch, select Open.

How to Connect a Single to the Drill String


1.

Hoist the single out of the mousehole.

2.

Using the Extend switch, select In.

3.

Retract the extend arms until the top drive is positioned over hole center.

4.

Place back-up tongs on the tool joint of the drill pipe held in the rig
slips.

5.

Dope 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.

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SECTION 5: MAKING/BREAKING CONNECTIONS

7.

Using the Torque switch, set the torque to 40 - 50% of the pre-set
value.

8.

Set the Mode switch to Connect.

9.

Set the Quill switch to Forward.

Illustration 6: Connecting a Single to the Drill String

10. Lead the top drive into the connection.


11. When the connection shoulders up, use the Torque switch to set to the
desired connection torque.
12. Observe the delivered torque gauge.
13. When delivered torque reaches the desired torque value, set the Quill
switch to Neutral.

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SECTION 5: MAKING/BREAKING CONNECTIONS

Breaking the Top Drive/Drill Pipe Connection


1.

Position the Grabber to close on the box of the drill pipe.


Critical: Ensure that the Grabber will not close on any part of the saver

sub or the hard band of the drill pipe.


2.

Set the Grabber switch to Close.

3.

Set the Mode switch to Connect.

4.

Using the Quill switch, select Reverse.

5.

Wait until the delivered torque meter indicates that delivered torque has
increased to the preset value.

6.

Push and hold the Breakout button.

7.

When the connection breaks, do the following:


release the Breakout button immediately
quickly set the Quill switch to Neutral

8.

Using the Grabber switch, select Open.

9.

Using the Quill switch, select Reverse.

10. Lead the top drive out of the connection.


11. When connection is undone, hoist the top drive clear of the floor.
Illustration 7: Breaking the Top Drive/Drill Pipe Connection

Close the grabber on the


box of the drill pipe.
Use Connect-Reverse
and the breakout button to
break the connection.

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SECTION 5: MAKING/BREAKING CONNECTIONS

Making up Stands with Pipe Handler


Making up Stands in the Rotary Table
The following procedure assumes that you are making up stands 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 the end of this procedure for special
notes.
Note: Making up stands proceeds more efficiently if the tugger is used
to place singles in the mousehole while the top drive makes connections
in the rotary table.

1.

Using the floor tugger, lower a single into the mousehole.

2.

Lower the top drive.

3.

Using the Link Tilt switch, tilt elevators Forward over the mousehole.
Note: Do not use the extend function to move the top drive over the
mousehole.

4.

Position the elevators on the single.

5.

Using the Elevator switch, select Close.

6.

Hoist the single out of the mousehole.

7.

Press the Float button and allow the elevators to come to the vertical
position (over hole center).

8.

Lower the single through the rotary table to required connection height.

9.

Set the slips.

10. Using the Elevator switch, select Open.


11. Using the Link Tilt switch, tilt the elevators back slightly.
Note: This prevents the elevators from hitting the tool joint as the top
drive is raised.
12. Hoist the top drive until the elevators clear the single.
13. Using the Link Tilt switch, select Forward.
14. Position the elevators over the mousehole.
15. Lower the top drive and close the elevators on the second single.
16. Hoist the top drive until the bottom of the second single is above the
single in the rotary table.
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17. Press the Float button and allow the elevators to come to hole center.
18. Lower the top drive and stab the single in the rotary table.
19. Attach the pipe spinner to the upper single, or rotate by hand with chain
tongs.
20. Spin the upper pipe until the connection shoulders up.
21. Remove the spinner and torque the connection using rig tongs.
22. Hoist the top drive and double.
23. Remove the slips.
Note: If you are making up doubles, go to Step 27.
Illustration 8: Making Stands in the Rotary Table

1. Pick up single from mousehole.


2. Lower the single through the rotary table.
3. Pick up the second single from the mousehole.
4. Connect the singles.
5. Lower the connected drill pipe through the rotary table.

24. Lower the top drive and double into the rotary table to required
connection height.
25. Set the slips.
26. Repeat Step 10 - 22 to connect the third single.
27. Hoist the completed stand until the bottom is above the floor racking
area.
28. Allow a roughneck to push the bottom of the stand into place on the
racking floor.
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29. Lower the top drive to set the bottom of the stand in the racking area.
30. Using the Link Tilt switch, select Forward.
31. Position the top of the stand where the derrickman can easily reach and
take control of it.
32. Wait until the stand is secured and the derrickman is ready to take
control of the stand.
33. Using the Elevator switch, select Open, and push/hold the Elevator
Safety button to release the stand.
34. Press the Float button.
35. Lower the top drive and proceed with making up the next stand.
Making Up Triples Without a Conductor Pipe

If no conductor pipe is in place, make up triples by modifying the procedure


above as follows:
1.

Connect the first two singles as described in the previous procedure,


then continue to the following steps.

2.

Hoist the double stand until it is above the drill floor.

3.

Using the floor tugger, place a single into the rotary table.

4.

Set the slips.

5.

Lower the top drive and double to stab the single in the rotary table.

6.

Connect the double and single using the pipe spinner and rig tongs.

7.

Proceed with racking as described in the procedure above.

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Illustration 9: Connecting Above the Rotary Table

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Making Up Stands in the Mousehole


Making up stands using the mousehole is more difficult and less efficient
than using the rotary table. Use the following procedure when the rotary table
is unavailable.
Illustration 10: Making Stands in the Mousehole

1. Pick up single from the mousehole.


2. Hoist the single out of the mousehole and place second single using the tugger.
3. Connect to the second single.
4. Hoist the connected singles.
5. Place third single in the mousehole and lower top drive to make connection.

1.

Using the floor tugger, lower a single into the mousehole.

2.

Lower the top drive.

3.

Using the Link Tilt switch, tilt elevators Forward over the mousehole.
Important: It is not advisable to use the extend function to move the

top drive over the mousehole. Raising the top drive while extended
may result in a collision with the monkey board.
4.

Position the elevators on the single.

5.

Using the Elevator switch, select Close.

6.

Hoist the single out of the mousehole.

7.

Using the floor tugger, lower the second single into the mousehole.

8.

Lower the top drive and single and stab the single in the mousehole.
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Note: Slack all the weight off the single to reduce the friction between

the pipe and elevators.


9.

Attach chain tongs to the upper and lower singles.


Note: You cannot use most pipe spinners when making connections at
the mousehole.

10. Shoulder up the connection.


11. Using rig tongs, torque the pipe to the required specification.
12. Hoist the double out of the mousehole.
Note: Adjust the Link Tilt position as required to avoid hitting the
monkey board while hoisting. The same caution applies when using the
Extend function.
13. Using the floor tugger, lower the third single into the mousehole.
14. Lower the top drive and drill pipe to stab the single in the mousehole.
Note: Fine-tune the Link Tilt position to avoid the monkey board while
making this connection.
15. Slack all the weight off the double to reduce the friction between the
pipe and elevators.
16. Attach chain tongs to the double and single.
17. Shoulder up the connection.
18. Using rig tongs, torque the pipe to the required specification.
19. Hoist the completed stand until the bottom is above the floor racking
area.
Note: Set bails and elevators to vertical/hole center to avoid hitting the
monkey board.
Caution: Use caution when the stand clears the mousehole. The stand

swings to hole center.


20. Allow a roughneck to push the bottom of the stand into place on the
racking floor.
21. Set the stand down in the racking area.
22. Using the Link Tilt switch, select Forward.
23. Position the top of the stand where the derrickman can easily reach and
take control of it.
24. Wait until the stand is secured and the derrickman is ready to take
control of the stand.
25. Using the Elevator switch, select Open, then push and hold the
Elevator Safety button to release the stand.
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26. Press the Float button.


27. Lower the top drive and proceed with making up the next stand.

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Making up BHA (Collars and Tools)


If required, use the pipe handler to assist in making up the BHA, collars, and
tools. The rate of pipe handler rotation is determined when setting torque and
speed settings.
Illustration 11: Connecting Collars

1. Pick up the first collar from the mousehole.


2. Lower into the rotary table.
3. Disconnect pick-up sub from the collar, link tilt to the mousehole
to pick up second collar.
4. Hoist the second collar out of the mousehole then lower to connect.

1.

Using the floor tugger, position a collar in the mousehole.

2.

Ensure that a pick-up sub is installed on the collar.


Note: The pick-up sub is installed using chain tongs.
Important: Torque the pick-up sub/collar connection to prevent it from

backing out.
3.

Raise the Grabber box.

4.

Using the Link Tilt switch, select Forward.

5.

Position the elevators over the mousehole.

6.

Lower the top drive to properly position the elevators on the pick-up
sub.

7.

Using the Elevator switch, select Close.

8.

Hoist the top drive until the collar is clear of the mousehole.

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9.

Press the Float button to bring the elevators to vertical.

10. Lower the top drive until the collar is properly positioned in the rotary
table.
11. Set the slips and attach a dog collar.
12. Using the rig tongs, break out the pick-up sub from the collar.
13. Once this connection is broken, unscrew using chain tongs.
14. Hoist the top drive and pick up the sub.
Note: Place a second collar in the mousehole using the floor tugger.
15. Using the Tilt switch, select Forward.
16. Position the elevators over the mousehole.
17. Lower the top drive and pick-up sub and stab the second collar.
18. Connect the pick-up sub and collar using chain tongs.
Important: Torque the pick-up sub/collar connection to prevent it from

backing out.
19. Hoist the top drive until the collar is clear of the mousehole.
20. Press the Float button to bring the elevators to vertical.
21. Lower the top drive to stab the collar in the rotary table.
Critical: The elevator links must hang vertically over the connection

point.
22. Close the Grabber on the saver sub.
23. Using the Pipe Handler switch, select Unlock. This allows the pipe
handler to rotate and make up the connection.
24. Using the Quill switch, select Forward.
25. Push and hold the Pipe Handler Rotate button. The pipe handler
begins to rotate at the pre-selected speed.
26. While holding the Pipe Handler Rotate 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 elevators. Balance the top drive by
raising and lowering it in small increments.
Important: In order to hoist the top drive when the Grabber is closed,
you must use the Grabber Override button on the brake handle.
27. Rotate the connection until it shoulders up.
28. Release the Pipe Handler Rotate button.
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29. Using the Quill switch, select Neutral.


30. Attach rig tongs to the collars.
31. Torque the connection to specification.
32. Remove the dog collar.
33. Hoist the top drive and remove the slips. This suspends the collars from
the top drive elevators.
34. Lower the collars through the rotary table to the desired connection
height.
35. Set the slips and attach a dog collar.
36. Using the rig tongs, break out the pick-up sub from the top collar.
37. Repeat Steps 15-33 to connect the third collar.
38. When all required collars are picked-up, do the following:
a.

Using the Pipe Handler switch, select Lock.

b.

Using the Grabber switch, select Open.

c.

Confirm the pipe handler is locked (visually inspect).

Connecting Collars Above the Rotary Table

1.

Using Steps 1 -29 in Making up BHA (Collars and Tools), 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 elevators.

2.

Remove the dog collar.

3.

Hoist the top drive and remove the slips. This suspends the collars from
the top drive elevators.

4.

Hoist the top drive and collars above the rotary table.
Note: Place a third collar in the rotary table using the floor tugger.
Secure the collar using slips and a dog collar.

5.

Lower the top drive to stab the connection in the rotary table (i.e. collar,
BHA etc.)
Critical: The elevator links must hang vertically over the connection

point.

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Illustration 12: Connecting Collars Above the Rotary Table

6.

Close the Grabber on the saver sub.

7.

Using the Pipe Handler switch, select Unlock. This allows the pipe
handler to rotate and make up the connection.

8.

Using the Quill switch, select Forward.

9.

Push and hold the Pipe Handler Rotate button. The pipe handler
begins to rotate at the pre-selected speed.

10. While pushing the Pipe Handler Rotate 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 elevators. Balance the top drive by
raising and lowering it in small increments.
Important: To hoist the top drive when the Grabber is closed, use the

Grabber override button on the brake handle.


11. Rotate the connection until it shoulders up.
12. Release the Pipe Handler Rotate button.
13. Using the Quill switch, select Neutral.
14. Attach rig tongs to the collars.
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15. Torque the connection to drill collar specifications.


16. Remove the dog collar.
17. Hoist the top drive and remove the slips.
18. Rack the collars using the procedure detailed in Making up Stands with
Pipe Handler on page 33.
19. When all required collars are picked-up, do the following:
a.

Using the Pipe Handler switch, select Lock.

b.

Using the Grabber switch, select Open.

c.

Confirm the pipe handler is locked (visually inspect).

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SECTION 6: DRILLING AHEAD

Section 6: Drilling Ahead


Well Control While Drilling
As the owner/operator of a top drive, you must establish guidelines and
procedures for all possible 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
established well control 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 practice and should
be periodically tested to verify skill level.
Review safety procedures before each operation.

Drilling Surface Hole


This procedure applies to drilling a surface hole with drill collars, using either
a single joint of drill pipe (as a working single) or drillable pick-up subs.
For tripping, use only drillable pick-up subs. A drillable pick-up sub has a 5
length of tube for the Elevators to slide up and down on. The threaded
connections at the top are the same as those on the saver sub, while those at
the bottom are the same as those on the drill collars. This allows the drillable
pick-up sub to be threaded into drill collars and used as a pick-up sub for
racking back. Using a drillable pick-up sub allows for reaming and backreaming when tripping, as necessary.

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Drilling
1.

Using the appropriate rig equipment and safe working procedures,


position a collar in the mousehole.

2.

Install a drillable pick-up sub on the collar.


Note: The drillable pick-up sub is installed using chain tongs.
Important: Torque the drillable pick-up sub/collar connection to

prevent it from backing out.


3.

Lower the top drive to properly position the elevators at the pick-up sub.

4.

Using the Elevator switch, select Close.

5.

Hoist the top drive until the drillable pick-up sub and collar clear the
mousehole.

6.

Press the Float button to bring the elevators to vertical.


Note: Ensure adequate monkey-board clearance.

7.

Install the bit sub and bit, and apply appropriate torque.

8.

Hoist out of the bit breaker and lower through the rotary table.

9.

When the bit reaches hole bottom, pick up 1-2 feet off bottom and set
the slips.

10. Leave the Elevators closed and allow the Elevators to slide down the
drillable pick-up sub.
11. Stab into the threads via the pipe guide and saver sub.
12. Using the Grabber switch, select Close.
13. Using the Torque switch, increase torque to 30% of the maximum
connect value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
14. Slowly lower the top drive to engage the saver sub/drillable pick-up sub
connection.
15. Lead the top drive into the connection.
16. Using the Torque switch, increase to the predetermined torque required
for the current thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
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17. When the connection fully torques, set the Quill switch to neutral.
18. Hoist the top drive and remove the slips.
19. Using the Mudsaver Valve switch, select Open.
20. Start the rig mud pump.
21. Begin drilling.

Making Connections
Make connections in normal fashion. Leave the drillable pick-up sub on the
top drive. Refer to Making up BHA (Collars and Tools) on page 40.

Tripping
Trip in the normal fashion, but use a drillable pick-up sub on the top of each
stand rather than a standard pick-up sub.

Reaming
Refer to Reaming on page 70.

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Drilling Ahead with Singles


Drilling proceeds more efficiently when you use the tugger to place singles 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.
Illustration 13: Drilling Ahead with Singles

1. Break out the top drive/drill pipe connection.


2. Pick up single from the mousehole.
3. Connect the single to the top drive and drill string
4. Remove slips and drill ahead.

1.

Raise the bit 1-2 off bottom.

2.

Using the Quill switch, select Neutral.

3.

Allow the reactive torque to release.


Caution: As the torque releases, the drill string may rotate slightly. Do

not proceed until rotation ceases.


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 fall to zero.

7.

Using the Valve switch, select Close.

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8.

Using the Grabber switch, close the Grabber on the drill pipe box.
Note: Do not close the Grabber on the saver sub or the drill pipe hard
band.

9.

Using the Mode switch, select Connect.

10. Using the Quill switch, select Reverse.


11. The top drive torque ramps up to the preset value.
12. Press and hold the Breakout button.
Note: Torque drops to zero, then ramps up until it breaks the connection
(maximum of 57,600 ftlb for 18.61:1 gear ratio, 44,750 ftlb for 14.45:1
gear ratio).
13. When the quill rotates 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
minimize thread loading as the connection unscrews. The
counterbalance system also assists with thread disengagement.
15. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging pipe threads, do not let the top drive weight
rest on the connection while unscrewing.
16. When the connection unscrews completely, set the Quill switch to
Neutral.
17. Using the Elevator switch, select Open, then push and hold the
Elevator Safety button.
18. Hoist the top drive to allow the elevators to clear the stump.
19. Use the Link Tilt function to maneuver the elevators past the stump.
20. Using the Link Tilt switch, position the elevators over the mousehole.
21. Lower the top drive until the elevators reach the drill pipe in the
mousehole.
22. Position the elevators on the drill pipe and select Elevator-Close.
23. Hoist the top drive until the single is above the drill pipe in the rotary
table.
24. Press the Float button to bring elevators to the vertical position.
Note: Floor hand should stabilize the lower end of the drill pipe.
25. Lower the top drive and stab the drill pipe connection.
26. Using the Mode switch, select Connect.
27. Using the Quill switch, select Forward.
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28. Using the Torque switch, increase torque to 30-40% of the maximum
connect value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
29. Position the back-up tong on the box connection of the stump.
30. Lower the top drive until the single makes contact with the saver sub.
Note: Use the Link Tilt function to guide the single into the drill pipe
guide.
31. Lead the top drive into the connection until the pipe/pipe and pipe/quill
connections shoulder up.
Note: When both connections shoulder up, the back-up tongs tighten
and the top drive stalls.
32. Using the Torque switch, increase torque to the make-up value required
for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
33. Wait until the delivered torque increases to the required value.
34. Using the Quill switch, select Neutral.
Note: Reactive torque ramps down in approximately two seconds.
35. Remove the back-up tong.
36. Using the Valve switch, select Open.
37. If required, start the rigs mud pump.
38. Hoist the top drive and drill pipe.
39. Remove the slips.
Note: Ensure the elevators are open and tilted away from the spinning
drill pipe. This prevents wear on the elevator inserts.
40. Using the Mode switch, select Drill.
41. Using the Quill switch, select Forward.
42. Using the Speed switch, set the desired drilling rpm.
43. Using the Torque switch, increase torque to desired drilling torque
value for the thread and connection type.
Note: Drilling torque maximum value is determined prior to job start
and entered at the drillers panel using the procedure defined in Setting
the Drive Parameters on page 20. Preset value for maximum drilling
torque value must be less than maximum connection torque.
44. Commence drilling.
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SECTION 6: DRILLING AHEAD

Drilling Ahead with Stands


This procedure assumes that the top drive is at floor level and connected to
the drill string.
Illustration 14: Drilling Ahead with Stands

1. Break out the top drive/drill pipe connection.


2. Pick up stand from the racking board.
3. Connect the stand to the top drive and drill string
4. Remove slips and drill ahead.

1.

Raise the bit 1-2 off bottom.

2.

Using the Quill switch, select Neutral.

3.

Allow the reactive torque to release.


Caution: As the torque is released, the drill string may rotate slightly.

Do not proceed until rotation ceases.


4.

Set the slips.

5.

Shut off the rig mud pump.

6.

Monitor the standpipe pressure gauge and wait for mud pump pressure
to fall to zero.

7.

Using the Valve switch, select Close.

8.

Using the Grabber switch, close the Grabber on the drill pipe box.
Note: Do not close the Grabber on the saver sub or the drill pipe hard
band.
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9.

Using the Mode switch, select Connect.

10. Using the Quill switch, select Reverse.


The top drive torque ramps up to the preset value.
11. When the top drive torque reaches the preset value, press and hold the
Breakout button.
Note: Torque drops to zero, then ramps up until it breaks the connection
(maximum of 57,600 ftlb for 18.61:1 gear ratio, 44,750 ftlb for 14.45:1
gear ratio).
12. When the quill rotates turn, release the Breakout button.
13. Immediately set the Grabber switch to Open.
Note: This allows you to raise the top drive in small increments as the
connection unscrews.
14. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging pipe threads, do not let the top drive weight
rest on the connection while unscrewing.
15. When the connection completely unscrews, use the Quill switch to
select Neutral.
16. Hoist the top drive high enough to allow the elevators to pass over the
stump.
17. Press the Elevator Safety Open button and, using the Elevator switch,
select Open.
18. Use the Link Tilt function to maneuver the elevators past the stump.
19. Using the Link Tilt switch, select Forward.
20. Hoist the top drive to the monkey board.
21. Position the elevators to capture the top tool joint of the stand.
22. Using the Elevators switch, select Close.
23. Ensure that 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 floor personnel to guide the bottom
of the stand to the vertical position.
26. Hoist the top drive until the bottom pin of the stand is clear of the stump.
27. Lower the top drive and stab the drill pipe connection.
28. Using the Mode switch, select Connect.
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29. Using the Quill switch, select Forward.


30. Using the Torque switch, increase torque to 30-40% of the maximum
connect value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
31. Position the back-up tong on the box connection of the stump.
32. Lower the top drive until the stand makes contact with the saver sub.
Note: Use the Tilt function to guide the stand into the drill pipe guide.
33. Lead the top drive into the connection until the pipe/pipe and pipe/quill
connections shoulder up.
Note: When both connections shoulder up, the back-up tongs tightens
and the top drive stalls.
34. Using the Torque switch, increase torque to the make-up value required
for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page20.
35. Wait until the delivered torque increases to the required value.
36. Using the Quill switch, select Neutral.
Note: Reactive torque ramps down in approximately two seconds.
37. Remove the back-up tong.
38. Using the Valve switch, select Open.
39. If required, start the rig mud pump.
40. Hoist the top drive and drill pipe.
41. Remove the slips.
Note: Ensure the elevators are open and tilted away from the spinning
drill pipe. This prevents wear on the elevator inserts.
42. Using the Mode switch, select Drill.
43. Using the Quill switch, select Forward.
44. Use the Speed switch to set desired drilling rpm.
45. Using the Torque switch, increase torque to desired drilling torque
value for the thread and connection type.
Note: Drilling torque maximum value is determined prior to job start
and entered at the drillers panel using the procedure defined in Setting
the Drive Parameters on page 20. Preset value for maximum drilling
torque value must be less than maximum connection torque.
46. Commence drilling.
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Slide Drilling
Introduction
In slide drilling operations, power to the bit is supplied using downhole mud
motors. As a result, the drill string does not rotate while drilling. This
procedure addresses making and breaking connections during slide drilling.
Note: During slide drilling operations, the Grabber should always
remain closed on the saver sub. Once the Grabber is fully closed, return
the Grabber switch to the Neutral position, to avoid overheating 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 circuit.

Drilling Using a Mud Motor


When drilling with a downhole mud motor, ensure the top drive Drill
Forward torque setting is greater than the maximum torque output of the mud
motor. See also Combination Drilling on page 60 for more information.
1.

Trip in the drill pipe and mud motor until the mud motor reaches the
bottom of the hole. Refer to Section 7: Tripping starting on page 61.

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.

Using the Grabber Lift switch, position the Grabber on the drill pipe
box.

4.

Using the Grabber switch, select Close.

5.

Using the Mode switch, select Connect.

6.

Using the Quill switch, select Forward.

7.

Lead the top drive into the connection until the pipe/quill connection
shoulders up.

8.

Using the Torque switch, increase torque to the maximum connect


value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.

9.

Wait until the delivered torque increases to required value.

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10. Using the Quill switch, select Neutral (center position).


11. Using the Grabber switch, select Open.
12. Using the Grabber Lift switch, reposition the Grabber on the saver sub.
13. Using the Grabber switch, select Close.
14. Using the Valve switch, select Open.
15. Start the rig mud pump.
16. Hoist the top drive and drill pipe.
17. Remove the slips.
18. Start drilling by lowering the top drive.
When drilling with a mud motor, it might be necessary to adjust the
orientation of the tool face to drill in the required direction. Refer to the next
section, Adjusting the Tool Face Orientation.

Adjusting the Tool Face Orientation


This procedure assumes that the top drive is above the drill floor, connected
to the drill string, and is ready to proceed with drilling. It also assumes the
Grabber is closed on the saver sub.
Before opening the Grabber, syncronize the top drive and mud motor torques
as follows:
1.

Using the Mode switch, select Drill.

2.

Using the Quill switch, select Forward.

3.

Using the Speed switch, set the speed to 2 rpm.

4.

Using the Torque switch, gradually increase the torque while


monitoring output on the delivered torque meter.

5.

When you observe deflection of the Grabber box, open the Grabber.
Note: If the torques match, you can open the Grabber with no rotation
(static).

6.

Reorient the tool face by doing one of the following:


a.

To turn the drill string clockwise, use the Torque switch to slowly
increase the torque. Selecting Torque-Increase allows the top
drive to overcome the reactive torque of the downhole motor.
When this happens, the drill string slowly turns to the right.
When you achieve the proper toolface orientation, slowly
decrease torque until the quill stalls, then close the Grabber.

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b.

7.

To turn the drill string counter-clockwise, use the Torque switch


to slowly decrease the torque. Selecting Torque-Decrease allows
the downhole motor to overcome the torque requested by the
driller, and the drill string turns slowly to the left.
When you achieve the proper toolface orientation, slowly
increase torque until the quill stalls, then close the Grabber.

Commence drilling.

Making/Breaking Connections while Slide Drilling


1.

Set the slips.


Critical: Ensure the rotary table is locked.

2.

Using the Grabber switch, select Open.

3.

Using the Grabber Lift switch, reposition the Grabber on the box of the
drill pipe.

4.

Using the Grabber switch, select Close.

5.

Shut off the rig mud pump.

6.

Monitor the standpipe pressure gauge and wait for the mud pump
pressure to fall to zero.

7.

Using the Valve switch, select Close.

8.

Using the Mode switch, select Connect.

9.

Using the Quill switch, select Reverse.

10. The top drive torque ramps up to the preset value.


11. Press and hold the Breakout button.
Note: Torque drops to zero, then ramps up until it breaks the connection
(maximum of 57,600 ftlb for 18.61:1 gear ratio, 44,750 ftlb for 14.45:1
gear ratio).
12. When the quill/pipe connection breaks and rotates turn, release the
Breakout button.
13. Immediately set the Grabber switch to Open.
Note: This allows you to raise the top drive in small increments as the
connection unscrews.
14. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging pipe threads, do not allow the top drive to sit
on the connection while unscrewing.
15. When the connection completely unscrews, use the Quill switch to
select Neutral.
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16. Hoist the top drive high enough to allow the elevators to pass over the
stump.
17. Pick up the required drill pipe.
Note: You may slide drill with either singles or stands. Please refer to
Drilling Ahead with Singles on page 48 and Drilling Ahead with Stands
on page 51 for information on picking up pipe.
18. Hoist the top drive until the bottom pin of the stand is clear of the stump.
19. Lower the top drive and stab the drill pipe connection.
20. Using the Mode switch, select Connect.
21. Using the Quill switch, select Forward.
22. Using the Torque switch, increase torque to 30-40% of the maximum
connect value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page20.
23. Position the back-up tong on the box connection of the stump.
24. Lower the top drive until the single makes contact with the saver sub.
Note: Use the Link Tilt feature to guide the single into the drill pipe
guide.
25. Lead the top drive into the connection until the pipe/pipe and pipe/quill
connections shoulder up.
Note: When both connections shoulder up, the back-up tongs tighten
and the top drive stalls. It is also possible that the top drive will torque
into the locked rotary table.
26. Using the Torque switch, increase torque to the maximum connect
value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.
27. Wait until the delivered torque increases to required value.
28. Using the Quill switch, select Neutral.
29. Remove the back-up tong.
30. Using the Grabber Lift switch, reposition the Grabber on the saver sub
(the Grabber should be open at this point).
31. Using the Grabber switch, select Close.
32. Using the Valve switch, select Open.
33. Start the rig mud pump.
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34. Hoist the top drive and drill pipe.


35. Remove the slips.
Critical: Exercise caution when removing the slips. Stored drill string

torque may spin the slips when the drill string is hoisted.
36. Commence drilling.

Maintaining Tool Orientation While Making/Breaking


Connections
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 Making/Breaking Connections while Slide
Drilling on page 56.
Important: The rotary table must remain locked during this procedure.

It is recommended that you mark the position of the drill string so you can
monitor if 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 take up
the drill string torque:
1.

Using the Mode switch, select Drill.

2.

Using the Quill switch, select Forward.

3.

Using the Speed switch, set speed to 4-5 rpm.

4.

Using the Torque switch, set the torque value equal to the string torque.
Refer to Recording the Drill String Torque for information on how to
determine the drill string torque.

5.

When the delivered torque reaches the required value, hoist the top drive
and remove the slips.

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SECTION 6: DRILLING AHEAD

Recording the Drill String Torque


This procedure assumes you are currently drilling with a mud motor, and the
bit is currently on bottom.
1.

Close the Grabber on the saver sub.

2.

Using the Mode switch, select Drill.

3.

Using the Quill switch, select Forward.

4.

Using the Speed switch, set the speed to 2 rpm.

5.

Using the Torque switch, gradually increase the torque while


monitoring output on the delivered torque meter.

6.

When you observe deflection of the Grabber box towards the drillers
side, record the torque value.

7.

Re-check the drill string torque periodically during downhole motor


operations.

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SECTION 6: DRILLING AHEAD

Combination Drilling
Combination drilling refers to the practice of slowly rotating the top drive in
Forward while drilling with a downhole mud motor. This practice, if used,
usually occurs after the angle is built and it is only necessary to maintain the
achieved angle.
Critical: It is essential to use the following guideline if you are drilling

using this method.


The Set torque output reading on the drillers panel must AT ALL TIMES
be 20% higher than the maximum torque output of the downhole motor in
use.
Explanation

Failure to maintain the top drive torque setting at a sufficient level to


counteract the downhole motor torque can force the top drive into a partial or
continuous state of unwind. If the top drive torque is set too low, the
downhole motor can apply reactive torque to the top drive and cause it to turn
in Reverse. The power generated by the top drive turning in reverse is
dissipated by the controlled unwind program called regen-mode. Extended
use of this mode while still supplying power to the mud motor will eventually
create a situation where the resistive brake may overheat and/or an
overvoltage condition can disable the drive.
Critical: Under these conditions, the shutdown of the MD-500 drive

causes a complete uncontrolled unwind of the top drive, which can


cause severe damage to the MD-500 drive system.

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SECTION 7: TRIPPING

Section 7: Tripping
Well Control While Tripping
As the owner/operator of a top drive, you must establish guidelines and
procedures for all possible 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
established well control 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 practice and should
be periodically tested to verify skill level.
Review safety procedures before each operation.
Critical: If the top drive is connected to the drill string off bottom, the

following equipment is required:


an 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 off bottom, Tesco
recommends removing the actuator and servicing the entire assembly
on a regular basis.

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SECTION 7: TRIPPING

Tripping Out
Before tripping out, observe all required operating conventions. These would
include procedures such as circulating the hole, pumping a pill etc.

Tripping Out Drill Pipe


Note: Ensure that the pipe handler is properly oriented to allow you to
Link Tilt toward the derrickman when the single, double, or triple is
ready for racking.
Illustration 15: Tripping Out Drill Pipe

1. Break out the top drive/drill pipe connection (if required).


2. With drill pipe in elevators, hoist the top drive. Break the drill pipe connection.
3. Rack the stand.
4. Lower the top drive to pick up the next stand of drill pipe.

1.

Power down the rig mud pump.

2.

Check the standpipe gauge to ensure that the mud pump pressure is
zero.

3.

Using the Valve switch, select Close.

4.

Hoist the top drive high enough to allow the elevators to close on the
drill pipe, above the slips (with slips in the set position).

5.

Set the slips.

6.

Position the elevators on the drill pipe.

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7.

Using the Elevator switch, select Close.

8.

Using the Grabber Lift switch, position the Grabber on the tool joint of
the drill pipe.

9.

Using the Grabber switch, select Close.

10. Using the Mode switch, select Connect.


11. Using the Quill switch, select Reverse. The top drive torque ramps up
to the preset value.
12. Press and hold the Breakout button.
Note: Torque drops to zero, then ramps up until it breaks the connection
(maximum of 57,600 ftlb for 18.61:1 gear ratio, and 44,750 ftlb for
14.45:1 gear ratio).
13. When the quill rotates 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 as the
connection unscrews.
15. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging pipe threads, do not allow the top drive
weight to rest on the connection while unscrewing.
16. When the connection unscrews completely, use the Quill switch to
select Neutral.
17. Hoist the top drive and drill pipe.
18. Pull the slips.
19. Hoist the top drive to lift the single, double or triple above the rotary
table.
20. Set the slips.
21. Break the stump connection using tongs, then spin out using chain tongs
or the pipe spinner.
22. Hoist the single, double, or triple clear of the stump.
23. Proceed with standard racking procedure.
24. Repeat Steps 6 - 23 for all drill pipe.

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SECTION 7: TRIPPING

Standard Racking Procedure


1.

Hoist the single, double or triple until the bottom is above the floor
racking area.
Note: Set links and elevators to vertical/hole center to avoid hitting the
monkey board.

2.

Using the Tilt switch, select Forward.

3.

Allow the roughneck 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 top of the stand where the derrickman can easily reach and
take control of it.

6.

Wait until the stand is secured and the derrickman is ready to take
control of the stand.

7.

Open the elevators. (Press the Safety Open push-button and turn the
Elevator switch to Open.)

8.

Press the Float button.

9.

Lower the top drive to receive the next stand.


Critical: When you close the mudsaver valve for extended periods
during cold weather operations, drilling mud may freeze in the top
drive, Kelly hose, and standpipe. To prevent this from happening,
connect an air hose to the saver sub on the top drive. Blow the drilling
mud from the top drive, Kelly hose and standpipe back to the mud tank.
Periodically check this equipment to ensure it is free of ice.

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SECTION 7: TRIPPING

Tripping Out BHA (Collars and Tools)


This procedure assumes that all drill pipe is tripped out and that the first collar
is above the rotary table.
Note: Ensure that the pipe handler is properly oriented to allow you to
Link Tilt toward the derrickman when the collars are ready for racking.
Caution: Never rotate the top drive quill with weight suspended in the

elevators.
Illustration 16: Tripping Out Collars

1. Install a pick-up sub in the top collar and torque to specification.


2. Latch the pick-up sub in the elevators and hoist. Break the collar/collar
connection at the at the floor.
3. Rack the stand of collars.
4. Lower to floor. Pick up the next stand of collars (pick-up sub installed).

1.

Set the slips.

2.

Attach a dog collar.

3.

Ensure that the elevators and elevator links hang vertically.

4.

Using the Pipe Handler switch, select Unlock.

5.

Using the Quill switch, select Forward.

6.

Press and hold the Pipe Handler Rotate button.


Note: The pipe handler begins to rotate at the preset speed.

7.

Position the pipe handler so that the link tilt feature can be used to assist
in racking the collars.

8.

When the pipe handler is in the proper position, release the Pipe
Handler Rotate button.
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9.

Using the Quill switch, select Neutral.

10. Using the Pipe Handler switch, select Lock.


Important: Check to ensure that the pipe handler lock engages fully.

11. Position the top drive elevators to accept a pick-up sub.


12. Using the Elevator switch, select Close.
13. Hoist the top drive to position the pick-up sub above the collar.
14. Lower the top drive to stab the pick-up sub into the top collar.
15. Using chain tongs, rotate in the sub/collar connection.
Note: Torque the connection to prevent back-out.
16. Remove the dog collar.
17. Hoist the top drive and remove the slips.
18. Hoist the top drive until the required collars are above the rotary table.
19. Set the slips and apply a dog collar.
20. Break the connection using the rig tongs.
21. When the connection is broken, unscrew using the pipe spinner, rotary
table, or chain tongs.
22. Hoist the collar(s).
23. Allow rig floor personnel to position the bottom of the collar for
racking.
24. Using the Link Tilt feature, tilt the collar(s) toward the derrickman.
Note: You can also use the Extend function.
25. When the collar(s) are in control of the derrickman, open the elevators.
(Press the Safety Open push-button and turn the Elevator switch to
Open.)
26. Release the collar(s) and pick-up sub.
Note: The pick-up sub remains on the stand of collars to facilitate
tripping in.
27. Repeat this procedure for each collar or stand of collars.

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SECTION 7: TRIPPING

Tripping In (Tools, Collars, and Drill Pipe)


Tools and Collars
Caution: Never rotate the top drive quill with weight suspended in the

elevators.
Illustration 17: Tripping in Collars

1. Pick up a stand of collars and pick-up sub at the racking board.


2. Connect to the tools or collar at the drill floor.
3. Lower the stand of collars through the rotary table, set slips,
and install the dog collar.
4. Remove the pick-up sub and place to side.
5. Raise top drive to the racking board to pick up the next stand.

1.

Using the top drive, lower the first section (bit and tools) into the rotary
table.

2.

Set the slips and, if applicable, apply the dog collar.

3.

Using the rig tongs, break out the pick-up sub joint.

4.

Open the elevators. (Press the Safety Open push-button and turn the
Elevator switch to Open.)

5.

Hoist the top drive to the monkey board.

6.

Use the chain tongs to unscrew the pick-up sub.

7.

Using the tugger line, remove the pick-up sub.

8.

Using the Tilt switch, select Forward.

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9.

Using the Extend function, if required, accept the first collar from the
derrickman.

10. Position the elevators on the top collar pick-up sub.


11. Using the Elevator switch, select Close.
12. Press the Float button to bring the elevators and elevator links to the
vertical position.
Note: If Extend was used, bring the top drive back to the In position.
13. Hoist the top drive and stand over the rotary table.
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. Connect the collar and stump using the pipe handler, chain tongs or pipe
spinner.
17. Using rig tongs, torque the connection to specification.
18. Remove the dog collar.
19. Hoist the top drive and drill string.
20. Remove the slips.
21. Lower the top drive and drill string.
22. Lower the stand of collars/tools through the rotary table to the
appropriate height for the next connection.
23. Set slips and install a dog collar.
24. Break out the pick-up sub using the rig tongs.
25. Using chain tongs, spin the pick-up sub from the top collar.
26. Screw a nubbin into the pick-up sub.
27. Using Tilt functions, remove the pick-up sub and position it where it
can be removed from the rig floor using the floor tugger.
28. Hoist the top drive to pick up the next collar, or stand of collars.
29. Repeat this procedure for all collars.
Note: When all collars are tripped in, orient the pipe handler to pick up
drill pipe.

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SECTION 7: TRIPPING

Tripping In Drill Pipe


1.

Ensure that the elevators and elevator links hang vertically.

2.

Using the Pipe Handler switch, select Unlock.

3.

Using the Quill switch, select Forward.

4.

Press and hold the Pipe Handler Rotate button.


The pipe handler begins to rotate at the preset speed.

5.

Position the pipe handler so that the Link Tilt feature can be used to pick
up drill pipe.

6.

When the pipe handler is in the proper position, release the Pipe
Handler Rotate button.

7.

Using the Quill switch, select Neutral.

8.

Using the Pipe Handler switch, select Lock.


Important: Check to ensure that the pipe handler lock engages fully.

9.

Hoist the top drive to the monkey board.

10. Use the Link Tilt function to accept the first stand of drill pipe from the
derrickman.
11. Position the elevators on the drill pipe.
12. Using the Elevator switch, select Close.
13. Press the Float button to bring the elevators and elevator links to the
vertical position.
14. Hoist the top drive and stand over the rotary table.
15. Allow rig personnel to hold back the bottom of the stand and move it
into position.
16. Lower the top drive and stab the connection.
17. Connect the drill pipe using the chain tongs or pipe spinner.
18. Using rig tongs, torque the connection to specification.
19. Hoist the top drive and drill pipe.
20. Remove the slips.
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 for all stands of drill pipe.
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SECTION 7: TRIPPING

Reaming
Reaming is performed under the following circumstances:
when a tight spot is encountered while tripping in or out
when cleaning to bottom
when enlarging an under-gauge hole
If tripping using the top drive, suspend the drill pipe and BHA (tools and
collars) from the top drive elevators. To ream, connect the top drive to the
drill string and work the tight section until the string passes freely. When the
obstruction is cleared, disconnect the top drive and suspend the drill string
from the elevators to continue tripping.
Use this procedure if a tight spot is encountered while tripping out (weight
indicator reads more than drill string weight), or if the drill string is stuck.
1.

Lower the top drive and drill string.


Note: Ensure that the uppermost drill pipe connection is in position to
connect to the top drive.

2.

Set the slips.

3.

Using the Mode switch, select Connect.

4.

Using the Quill switch, select Forward.

5.

Using the Torque switch, increase torque to 30-40% of the maximum


connect value required for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.

6.

Lower the top drive until the saver sub contacts the drill pipe.

7.

Lower the top drive into the connection.


Note: Do not allow the top drive weight to rest on the threaded
connection.

8.

Shoulder up the top drive/drill pipe connection.

9.

Position the Grabber so it closes on the drill pipe tool joint, and select
Grabber-Close.

10. Using the Torque switch, increase torque to the make-up value required
for the thread and connection type.
Note: Torque value is determined prior to job start and entered at the
drillers panel using the procedure defined in Setting the Drive
Parameters on page 20.

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11. When the delivered torque reaches the desired maximum, set the Quill
switch to Neutral.
Note: Reactive torque automatically ramps down, in approximately 2
seconds.
12. Using the Valve switch, select Open.
13. Start the mud pumps.
14. Open the elevators. (Press the Safety Open push-button and function
the Elevator switch to Open.)
15. Using the Mode switch, select Drill.
16. Using the Quill switch, select Forward.
17. Set speed and torque to required values.
Note: Determine torque and speed values prior to job start. Enter them
at the drillers panel using the procedure defined in Setting the Drive
Parameters on page 20. Typically, torque is set to 80% of make-up
torque.
18. Hoist the top drive until the tight spot is encountered.
19. While circulating, raise and lower the top drive several times (or until
the hole is clean).
Note: It is advisable to trip out one or two stands with the top drive
connected to the drill string (see Drilling Ahead with Stands on page 51
for more information).
20. When reaming is complete, use the Quill switch to select Neutral.
21. Hoist or lower the top drive to the proper position for disconnecting
from the drill pipe.
22. Set the slips.
23. Turn off the mud pumps.
24. Ensure the standpipe (mud pump) pressure drops to zero.
25. Using the Valve switch, select Close.
26. Use the Tilt function to position the elevators on the drill pipe.
27. Using the Elevator switch, select Close.
Important: Obtain visual confirmation that the elevators are closed.

28. Press the Float button to bring elevators to the vertical position.
29. Disconnect the drill pipe from the top drive. See Breaking the Top
Drive/Drill Pipe Connection on page 32 for more information.
30. Continue with standard procedure for tripping (in or out).
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SECTION 8: FREEING STUCK PIPE

Section 8: Freeing Stuck Pipe


Unlike conventional Kelly systems, top drives allow you to maintain
circulation and torque on the drill pipe while pulling or jarring stuck drill
pipe.

Freeing Stuck Pipe Using a Top Drive


1.

Connect the top drive to the drill string.

2.

If possible, maintain pump flow.

3.

Using the Mode switch, select Drill.

4.

Set speed and torque to required values.


Note: Determine torque and speed values prior to job start. Enter them
at the drillers panel using the procedure defined in Setting the Drive
Parameters on page 20. Typically, torque is set to 80% of make-up
torque.

5.

Using the Quill switch, select Forward.

6.

Raise and lower the top drive, working the drill string up and down.

7.

Continue raising and lowering until a free point is established.

8.

When the string begins to rotate, raise and lower the top drive in the free
point area in small increments.
Critical: When jarring with torque in the drill string, pay special

attention to the condition of the torque bushing and torque tube.


9.

Gradually increase the travel distance until the obstruction clears.

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SECTION 8: FREEING STUCK PIPE

Jarring
If you cannot free the drill pipe using the top drive, jarring may be required.
Jarring while the drill pipe is suspended from the elevators is not
recommended. If access to the drill pipe is absolutely necessary (for wireline
or logging, for example) elevators must be closed, and the elevator hydraulic
hoses disconnected.
Important: If required, apply torque when working or jarring pipe

(when the drill string is connected to the top drive).


1.

Ensure that the top drive is connected to the drill string.

2.

Ensure that the elevators are closed on the drill pipe.


Important: Visually confirm that the elevators are closed.

3.

If possible, maintain pump flow.

4.

Using the Mode switch, select Drill.

5.

Set speed and torque to required values.


Note: Determine torque and speed values prior to job start. Enter them
at the drillers panel using the procedure defined in Setting the Drive
Parameters on page 20. Typically, torque is set to 80% of make-up
torque.

6.

Using the Quill switch, select Forward.

7.

Initiate jarring using 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.


Critical: Always perform a post jarring check of the top drive following

any jarring operation. See Appendix 1: Post Jarring Checklist.


Critical: If jarring duration exceeds eight hours, or if jarring is

extremely rough, perform a complete load path inspection at the first


available opportunity.

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SECTION 8: FREEING STUCK PIPE

Controlled Drill String Back-off


In some cases it is necessary to separate the stuck portion of the drill string
from the free length. This is best accomplished by applying reverse torque to
the connection immediately above the stuck point and deploying an explosive
charge at the connection.
The decision to back-off the drill string has significant financial and
operational implications. Never authorize or undertake back-off operations
until all interested parties have agreed.
1.

Set the Drill Reverse torque to 70% of the make-up torque.


Note: Torque value is determined prior to job start and entered at the

drillers panel using the procedure defined in Setting the Drive


Parameters on page 20.
2.

Position wireline tools and charge at the connection where the back-off
should occur.

3.

Using the Mode switch, select Drill.

4.

Using the Quill switch, select Reverse.

5.

Work reverse torque into the string by raising and lowering the top drive
in small increments.
Note: Torque is assumed to be full when the pipe will not rotate any
further. If torque needs to be stepped up in stages, adjust the
Drill-Reverse setting as you work torque into the string. See Setting the
Drive Parameters on page 20. If you require a specific number of turns,
increase the torque setting until you reach the required value.

6.

When you achieve the desired reverse torque or number of turns,


reposition the blocks.
Critical: Position the blocks 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.

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SECTION 8: FREEING STUCK PIPE

Illustration 18: Neutral Weight at Connection

Total weight of pipe downhole = 125,000 lb


Weight of pipe below stuck point = 65,000 lb
Total weight of free pipe = 60,000 lb

Weight Indicator will read


60,000 lb when first
free connection is at neutral.

7.

Establish neutral weight, then fire the explosive charge.

8.

Monitor the weight indicator and string rotation.


Note: When the pipe is free, the drill string should rotate freely (in
reverse). If the pipe has parted at the correct location, the weight
indicator reading will not change significantly.
Important: If the weight indicator falls, this may indicate that the pipe

has parted above the expected connection. If this occurs, do not hoist.
It may be possible to reestablish the connection. Evaluate the situation
before proceeding.
9.

To ensure the drill string is free, do the following:


a.

Confirm free rotation of pipe in reverse.

b.

Hoist carefully to confirm rotating pipe is not stuck.

10. Using the Quill switch, select Neutral.


11. Trip the first stand of pipe out of the hole while connected to the top
drive.
12. Break the top drive from the stand at the monkey board.
13. Rack back this stand using normal tripping procedures.
14. Continue with normal tripping operations.

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SECTION 9: RUNNING AND PULLING CASING

Section 9: Running and Pulling Casing


Illustration 19: Picking Up Casing

Running Slip Elevators

Sling

Working Platform
Pick-up Elevators
Floor Slip Elevators

Using a top drive to run casing offers the following advantages:


Fill-up tools can be connected directly to the top drive to provide
fill-up capability while running.
The Link Tilt and Extend functions can be used to assist in
handling and stabbing casing.

Preparing 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 elevators from the elevator links.

3.

If required, remove the elevator links.


Note: Longer elevator links are often required when running casing.
Attach these using the floor tugger.
Critical: When using elevator links longer than 12 ft., do not use the

Tilt function.
4.

Pick up the running elevators.


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SECTION 9: RUNNING AND PULLING CASING

5.

If a casing fill-up apparatus is required, connect it to the top drive saver


sub using the Grabber and top drive.

6.

If 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 pickup elevators hang approximately 3-4 feet below the main
elevators.
Attach the pick-up elevator slings to the pick-up elevators.

7.

Ensure that a working platform and floor elevators are installed and
operational.

Running 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
reach.
Important: Whenever possible, use the elevators and Link Tilt to

reduce the stress on the torque tube.

DD

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.
Important: Exercise caution when moving casing. The weight of the

casing tends to pull the top drive away from the torque track. The strain
is then transmitted to torque track stabilization.
Also, if the top drive is extended toward the casing during hoisting, it
may collide with the monkey board.
4.

Hoist the casing until it is above the working platform.

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SECTION 9: RUNNING AND PULLING CASING

Illustration 20: Running Casing

1. Using the pick-up elevators, lower the first joint of casing through the floor slip
2. Close slips. Fill up the casing, if required.
3. Pick up the next joint of casing using the pick-up elevators, then
connect using casing tongs.
4. Connect casing, release the pick-up elevators, and attach the running elevators.
5. Open the floor slips and lower the casing.

5.

Lower the casing through the working platform, floor elevators and
rotary table.

6.

Lower to the proper connection height.

7.

Latch the floor elevators on the casing.

8.

If required, lower the top drive to stab the fill-up tool into the casing
stump.

9.

Fill casing as required.

10. Repeat Steps 1-4 for the second joint of casing.


11. Lower the second joint of casing to stab the stump connection.
Note: You can also use the Link Tilt and Extend functions to assist in
stabbing.
12. Make the casing connection using casing tongs.
13. If required, lower the top drive to stab the fill-up tool into the casing
stump.
14. Fill casing as required.
15. Latch the running elevators onto the top joint of casing.
16. Hoist the casing.
17. Unlatch the floor elevators.
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SECTION 9: RUNNING AND PULLING CASING

18. Lower the casing through the working platform, floor elevators and
rotary table.
19. Lower to proper connection height.
20. Unlatch the pick-up elevators.
21. Latch the floor elevators on the casing.
22. Unlatch the running elevators.
23. Repeat Steps 11 - 22 for all joints of casing.

Pulling Casing
If required, bring the first joint of casing above the rotary table. Specialized
tools are required for this operation.
1.

Attach running elevators to the top joint of casing.

2.

Unlatch the floor elevators.

3.

Hoist the top drive until the entire joint of casing is above the working
platform.

4.

Latch the floor elevators.

5.

Unlatch the running elevators from the casing.

6.

Attach the pick-up elevators to the casing.

7.

Break and unscrew the casing connection using casing tongs.

8.

Hoist the top drive and 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. Slowly lower the top drive allowing 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 steps 1-12 for all casing joints.

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SECTION 10: TOP DRIVE CONSIDERATIONS

Section 10: Top Drive Considerations


While Performing Slip and Cut Operations
Critical: Never suspend the weight of the top drive by the torque tube

during slip and cut operations. Instead, rest part of the weight on a
single of drill pipe secured in the rotary table and suspend the
remainder from the block sling.
Note: You can maintain circulation while
performing slip and cut operations.

1.

Obtain and install a new block sling.


Note: Size this block sling to support the top
drive, swivel and blocks close to the rig
floor.

2.

Connect the top drive to a single of drill pipe.

3.

Raise the top drive and connect the block


sling to the travelling block.

Block Sling

Links Tilted to Back


Drill Pipe

4.

Lower the top drive and single, using the


blocks.

5.

Lower the single 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 the drawworks front cover
can be removed and service can be performed.

6.

When the block sling is nearly tight, stop lowering the top drive.

7.

Set the slips.


Note: Try to balance the weight between the block hanging sling and
the top drive/drill pipe connection.

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SECTION 10: TOP DRIVE CONSIDERATIONS

While Cementing
Do not cement through the top drive unless it is absolutely necessary. Cement
causes wear and, if allowed to harden, irreparably damages the top drive.
If you suspend a cement head from the top drive elevators, ensure the
following:
The elevator links are long enough to accommodate the cement
head.
The elevator hydraulic hoses are disconnected.
Note: Do this when the cement head is in position and the
elevators are closed.
When using a flow-through cement head, some amount of cement may enter
the quill and mud valve. After completing cementing operations, it is
advisable to flush the quill, mudsaver valve and lower Kelly valve.
Operate the mudsaver and Kelly valves to ensure they work properly.
Critical: Failure to perform these checks may compromise rig safety.

During Slick Line Survey and Wire Line


Logging
Several issues result when using a top drive for slick line or wire line
operations.
When a turn down sheave is used, use the following conventions:
Orient the elevator links so they are parallel to the direction of line
travel.
When suspending the turn down sheave from the elevators,
remove the elevator hydraulic hoses. This prevents accidental
opening of the elevators.

Grabber Leg
Grabber Box

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Guide Roller

SECTION 10: TOP DRIVE CONSIDERATIONS

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 hole
center. Guide rollers prevent the line from running over sharp corners that
may cause damage.
If the wire line/slick line guide is used, place the Grabber in the full up
position, if possible.

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LIST OF ILLUSTRATIONS

List of Illustrations
Illustration 1: ECI Drillers Panel....................................................................................... 4
Illustration 2: ECI Main Panel ........................................................................................... 5
Illustration 3: Tong Position for Making Connection...................................................... 26
Illustration 4: Link/Elevator Position for Making Mousehole Connections ................... 28
Illustration 5: Link/Elevator Position for Making
Connections Grabber to Drawworks .......................................................................... 29
Illustration 6: Connecting a Single to the Drill String ..................................................... 31
Illustration 7: Breaking the Top Drive/Drill Pipe Connection......................................... 32
Illustration 8: Making Stands in the Rotary Table.......................................................... 34
Illustration 9: Connecting Above the Rotary Table........................................................ 36
Illustration 10: Making Stands in the Mousehole........................................................... 37
Illustration 11: Connecting Collars ................................................................................. 40
Illustration 12: Connecting Collars Above the Rotary Table......................................... 43
Illustration 13: Drilling Ahead with Singles..................................................................... 48
Illustration 14: Drilling Ahead with Stands ..................................................................... 51
Illustration 15: Tripping Out Drill Pipe............................................................................. 62
Illustration 16: Tripping Out Collars................................................................................ 65
Illustration 17: Tripping in Collars................................................................................... 67
Illustration 18: Neutral Weight at Connection ................................................................ 76
Illustration 19: Picking Up Casing .................................................................................. 77
Illustration 20: Running Casing ...................................................................................... 79

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INDEX

Index
A
Auxiliary Pump Indicator Light, 6
Auxiliary Pump Off/On, 6

B
backreaming, 45
BHA, 40, 42, 47, 65, 70
Brake Handle, 15
breaking mousehole connections, 27
Breakout, 8, 15

Enable, 7
ESD, 7, 12
Driller's Control Panel, 12
Main Panel Control System, 12
Reset, 12
Extend, 10
Extend In/Out, 6

F
fill-up tools, 77
Float, 6, 9
floor elevators, 78
flow-through cement head, 82

calibrating meters, 16
casing, 1, 77, 78, 79, 80
cement, 82
circulating the hole, 62
Connect Forward, 13, 14
Connect Reverse, 13, 14

Grabber, 11, 15, 24, 30, 32, 41, 43, 49, 55,
56, 57
Grabber Indicator Light, 7
Grabber Open/Close, 7
Grabber/Drawworks interlock override, 15

D
delivered speed, 17
Delivered Speed Meter, 8
delivered torque, 17
Delivered Torque Meter, 8
double ball mud saver valve, 61
downhole mud motors, 54
drill collars, 45
Drill Forward, 13
Drill Reverse, 13
drill string motors
limiting Top Drive torque, 60
drill string torque, 58
drillable pick-up sub, 45
driller's control panel, 1, 26
Driller's Control Panel, 3, 19
Drive Set, 8

E
ECI Installation Guide, 1
ECI Maintenance Guide, 1
Elevator Close, 15
Elevator Open/Close, 6
Elevator Safety Open, 6
Elevators, 9, 45
Emergency Shut Down. See ESD

I
interlocks, 11

J
jarring, 1, 73, 74

K
Kaman motor, 19
Kelly valve, 82

L
link tilt. See Tilt

M
Making Connections, 25
making mousehole connections, 27
meters - calibrating, 16
Mode Conn/Drill, 8
Module ON, 7
mousehole, 46
Mousehole Connections, 27
mud saver valve, 82
Mud valve. See Mudsaver valve
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INDEX

Mudsaver valve, 10

P
pick-up elevator, 78
Pipe Handler, 11, 33
Pipe Handler Lock, 11
Pipe Handler Reverse/Forward, 7
Pipe Handler Rotation, 11
Pipe Handler Unlock/Lock, 7

Q
Quill Reverse/Forward, 8

R
Ready, 7
ream, 70
reaming, 45
Remote Brake Handle. See Brake Handle
Reset, 7
Robotics ON, 6

S
saver sub, 24, 25, 28, 29, 30, 32, 41, 43, 45,
46, 49, 51, 54, 55, 57, 61, 70, 78
Set Speed Meter, 8
Set Torque Meter, 8
slide drilling, 54
Speed Decrease/Increase, 8

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speed limits
setting, 19
standpipe gauge, 62
strip kit, 61
stuck drill pipe, 73
System Temperature, 6

T
Tilt, 9
Tilt Back/Fwd, 6
Torque Decrease/ Increase, 8
torque limits
setting, 19
torque tube, 81
turn down sheave, 82

U
undergauge hole, 70

V
Valve, 10
Valve Close/Open, 7
Vernier dampening valve, 26

W
weight indicator, 26, 70
well control, 45, 61

APPENDIX 1: POST JARRING CHECKLIST

Appendix 1: Post Jarring Checklist


After continuous jarring, or severe surface jarring, perform a thorough inspection.
If damage is suspected, remove the unit from service until proper maintenance
and testing can be conducted.
Equipment

Requirement

OK

Load Path

Inspect all connections including swivel


(mag particle or black light)

Elevators

Check bolts on ram brackets

Needs
Repair

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.

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APPENDIX 1: POST JARRING CHECKLIST

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

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