Bulletin 20900e

TOP DRIVES CASING DRILLING® AZIMUTH TUBULAR SERVICES­™

¸
TESCO

Top Drive
Rig Floor
Safety
Orientation
Doghouse
Manual

Better Ways to The Bottom™

Top Drive Rig Floor Safety Orientation Doghouse Manual
www.tescocorp.com Page 
 ¸
TESCO
Better Ways to The Bottom™

TESCO CORPORATION
WELL SITE OPERATIONS
6204-BURBANK ROAD S.E.
CALGARY, ALBERTA
CANADA T2H 2C2

Phone: 403 720 2858

Fax: 403 203 2295
Web:www.tescocorp.com
email: topdrives@tescocorp.com

Top Drive Rig Floor

Safety Orientation
Printed in Canada / Dec. 2002 TC120
©Tesco Corporation

Page  Top Drive Rig Floor Safety Orientation Doghouse Manual

Table of
Contents
Introduction 4
CHAPTER 1
RIGGING UP THE EQUIPMENT
Torque System 4
Power Module 5
Service Loop 6
Top Drive 6
CHAPTER 2
COMPONENT IDENTIFICATION
Top Drive 7
CHAPTER 3
Safety Interlocks 8
CHAPTER 4
CONTROLS AND ROBOTICS
Clearance and Visibility 10
Extend 10
Link Tilt 10
Grabber 10
Grabber Lift 10
Pipe Handler 10 Disclaimer 17
Elevators 11
Mud Saver Valve and Actuator 11
Top Drive Rig Floor Safety Orientation Doghouse Manual
CHAPTER 5
MAKING CONNECTIONS
Safety 12
Breaking Out 12
Making Up Singles 12
Making Up Doubles 12
Making Up Triples 13
CHAPTER 6
OPERATIONS
Drilling 13
Tripping 14
Cold Climate 14
Reaming 15
Working Tight Hole 15
Jarring 16
Running Casing 16
Cementing 16
CHAPTER 7
TOP DRIVE CONSIDERATIONS
Slip and Cut Drilling Line 17
Maintenance 17
Page 

INTRODUCTION Rigging up the
FOR DRILLERS
This manual is intended to provide basic information
only, and does not constitute
a comprehensive guide to
the functioning or operation
of a Tesco Top Drive. It is to
be used only in conjunction
with the orientation and on
site supervision provided by
Tesco personnel. The Tesco
Top Drive Technician must
be notified of any concerns
or incidents involving
Tesco equipment and its
operation.
Chapter 1
Equipment
The Torque System:
After measuring the rig and determining the torque
system configuration, the top drive technician will require
the help of a select number of crewmembers. As a
driller, it’s up to you to choose workers who are confident
working at heights and follow instructions well. A well
thought out pre-job meeting and the right people can
make rigging up the top drive much easier and safer.
The torque system includes the following:
1. Torque Track
2. Torque Anchor Beam
3. T-Bar
In the next few pages we will describe the parts of the
torque system, what they do and some effective ways
of installing them.

OTHER THAN AS Torque Track:

DESCRIBED IN THE The torque track consists of varying lengths of track.
PRECEDING PARAGRAPH, Each section is designed to fit another by lining up the
TESCO CORPORATION, ITS flanges and tightening the bolts. The length of the track
AFFILIATED COMPANIES depends on the size of the rig mast but in all cases the
AND EMPLOYEES ASSUME NO RESPONSIBILITY bottom of the track, called the deflector section, should
FOR USE OF THE be between 7 and 8 feet from the floor. The track is hung
INFORMATION CONTAINED by attaching an adjustable hanging cluster to a pad
eye that has been welded to the crown’s beams. The
IN THIS MANUAL.
bottom of the track is secured to the derrick by bolting
on the T-bar and fastening it in to the torque anchor
At Tesco, we put a lot of effort beam. Using turnbuckles we can center the track
into developing ways to make and provide rigidity along the length of the derrick. The
drilling a well more efficient. turnbuckles are attached to the torque track and derrick
Training the operators to run using clamps or by welding in pad eyes on the derrick
the equipment in the most beams prior to rig up.
effective manner makes the job
easier by reducing downtime In some cases our technicians may pre-assemble the
and safer by eliminating the torque track on the ground and hoist up to 2 sections
risk of injury to workers. at once. When hoisting the torque track, good
communication and the use of a hold back line are
required.
This manual will provide you
with information to present Once the first section of track has been lifted to the drill
to your crew during a pre-job floor with the tugger line, it is then lowered through the
safety meeting or whenever rotary table so that the top of the track can be attached
you need to reinforce what you already know. to the traveling block. After raising the track above the
floor with the blocks, the rest of the track sections can
be hoisted to the floor and placed in the rotary table
individually and bolted into the previous sections.

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When the torque track is fastened together in the length T-Bar:
required to allow the top drive to travel between the The T-bar is a solid steel arm that bolts on to the torque
highest and lowest points in the derrick, it then needs track at it’s lowest point and takes the drilling torque from
to be secured to the crown. This is done by attaching the top drive and transfers it through the anchor beam
the hanging cluster at the top of the track to a welded-on and across the derrick.
pad eye with a shackle.
Next we need to position the torque track so that we The T-bar can be installed
can fasten the t-bar to it and make sure that the torque in the torque anchor as
anchor beam will accept it as well. soon as the beam is
secured to the derrick.
Once the torque track is in place the turnbuckles need to
be attached to it and secured in predetermined locations The T-bar can also be
on the derrick strongbacks. Using these adjustable, bolted on to the torque
locking turnbuckles we can center the track and help track just before the track
provide rigidity along the length of it. is hung from the crown when the bolt pattern section of
track is at a comfortable height.
When the torque system is installed it should be straight
and at the proper distance from well center and the rig When the T-bar is attached to the torque track and the
floor. track is hanging from the pad eye at the crown, the
T-bar should be just slightly higher than the anchor.
Torque Anchor Beam: This way, when the anchor clamp is tightened down it
The torque anchor beam will pull the track into tension.
accepts the torque directly
from the quill and transfers it to After all the main components of the torque system are
the derrick. On some rigs we installed the turnbuckles can be adjusted to straighten
can weld the anchor in place, the track.
on others we need to install
the beam using clamps. The Note: All shackles, turnbuckles, and similar items should
beam is usually attached to be secured with cotter pins or safety wires, to prevent
the lowest strongback where accidental loosening.
the energy can be displaced
across the widest point of the The Power Module:
derrick. Periodic inspection The Tesco hydraulic
of the welds or the clamps top drive comes with
tightness must be performed a building containing
to prevent any movement of a prime mover that
the torque track. drives a series of
variable displacement,
Position the hoisting sling and tugger line on the center bi-directional hydraulic
of the load. Carefully raise the anchor beam to the pumps. These pumps
appropriate strongback. send hydraulic flow
through a closed loop,
The top drive technician will need assistance to position high-pressure system
the anchor beam on the strongback and hold it in place to the top drive motor(s), which provide quill rotation
until the clamps can be secured. before returning to the skid to be filtered. Additional
gear pumps send hydraulic flow through an auxiliary
Safety - Make sure all workers are connected to an system to the top drive, operating the various robotic
approved fall arrest system. functions as well as circulate oil through a filtration
and cooling system before returning to the reservoir.
The power module also contains an electrical panel,
which accepts a 480 or 600 volt AC input from the rig’s

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 

generators and converts it to other voltages that operate Before the top drive is raised
the electrical components of the top drive system. When to the rig floor, the torque
spotting the power module, it must be lifted using proper bushing and extend frame
hoisting techniques and placed in an ideal position for need to be installed onto the
the service loop to reach the derrick. If the service reel torque track and pinned in
is not attached to the power module skid, then it should place.
be placed on rig matting with the power module and
connected to the auxiliary hydraulic system. With the top drive stand
positioned over hole center
The Service Loop: and secured to the derrick
The service loop sends and receives electrical legs using chains and
communication from the power unit and the driller’s boomers, the swivel can
panel as well as hydraulic flow to and from the top drive. now be properly doped and
It is critical that these lines not be damaged due to threaded into the quill with a
improper lifting or obstructions in the derrick. Once the chain tong.
service loop has been installed, observe its movement
along the entire travel of the top drive. On top drives equipped
with an integrated swivel,
The service loop should make no contact with any the swivel bail or yoke is
part of the rig. directly installed into the
becket or block hook.
Using a soft hoisting sling and the floor tugger, the
operator will raise the service loop into the derrick while Now the top drive can be lifted from the transport stand
the top drive technician reels out enough slack to install by raising the blocks and the transport stand removed
the lines into the hose saddle and capture clamp. from the rig floor.

Once the hose saddle position has been determined it is Using the blocks, line-up the pin holes between the
then attached to the derrick. The rig design and top drive extend frame and the top drive and insert the drive pins
model will determine where the saddle is located. and keepers.

A safety sling should always be installed around the With the weight of the top drive hanging on the overhead
hose saddle and hoses, and then attached to either a blocks and swivel, remove the torque bushing pin.
welded in pad eye or a suitable beam. Safety slings
should also be installed between the hose ends and The top drive technician will connect the service loop to
the top drive. the top drive and install the driller’s panel.

With the power unit now running and the service loop
The Top Drive: and drillers panel connected to the top drive, we can now
The top drive is a heavy, unbalanced load and should make up the swivel to the specified torque. To do this
be carefully handled to prevent injury or equipment the off-drillers side tongs must be raised to the required
damage. The top drive technician should always be height to bite against the swivel or cross over and back
present to oversee any loading or unloading of Tesco up slings attached to a suitable point on the derrick.
equipment.
It is critical that the bottom of the top drive be
Once the top drive arrives on location, it should be secured with a cross chain on the grabber leg or
placed on the catwalk so that it can be hoisted to the a joint of heavy weight drill pipe connected to the
rig floor using 2 point, load rated slings attached to the saver sub and set in the slips - or both. Torque
blocks. A hold back line should be used to prevent the should always be applied to the swivel connection
top drive from shifting once it is lifted. in ‘drill mode’ and only the required personnel to do
the job should remain on the rig floor.

Page  Top Drive Rig Floor Safety Orientation Doghouse Manual

Chapter 2
Component Identification
Top Drive:

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 

Chapter 3
The Rosemount Gauge receives a milliamp signal
The Drillers Panel from a pressure transducer located on the top drive.
Description:
The drillers panel
is a stainless
steel enclosure
equipped with all
of the controls,
indicator lights,
mounts, gauges
and connectors
required to
operate the top
drive from the
driller’s position.
All of the controls
are 24 volts DC
electric over hydraulic. The two main cables to the panel
The transducer measures the differential between the
are 37 pin conductor cables with each wire serving a
high and low pressure sides of the top drive hydraulic
specific function. One 37-pin cable connects the power
motor(s). This measurement gives you the most
module to the driller’s panel and the other connects the
accurate torque reading while drilling, when the hydraulic
top drive with the driller’s panel. The four smaller cables
oil in the loop is in a high flow state.
are 4 or 5 pin Amphenol connectors which control input
to the safety interlocks, overrides and digital gauges for
The Hydraulic Pressure Gauge is used primarily to set
quill torque and RPM.
the torque reliefs, which control the amount of torque

that can be applied to the quill. This gauge is also very
Positioning: accurate when making and breaking connections, when
When deciding where the hydraulic oil in the loop is in a semi-static condition
to mount the driller’s and pressure losses are at a minimum.
panel it is important
that your view of the
rig floor from the
Indicator Lights:
There are indicator lights installed in the driller’s panel
driller’s position is not
reminding you that a function is, or has been performed.
obstructed and that you
The response to an illuminated indicator light should
can reach the controls
be:
well enough to operate
the drawworks and top drive simultaneously. All of the
Stop - Why it is illuminated and how will it effect
cables to the panel should be routed in such a manner
further operations?
that moving parts will not damage them and they should
be elevated from the floor.
There are indicator lights for the following:
DC Power This green light should be illuminated at all
Instrument Gauges: times, indicating that the power supply to the driller’s
There are two digital gauges on the driller’s panel, panel is on.
the RPM Gauge that meters quill rotation and the
Rosemount Gauge, which reads quill torque. Separate Grabber When the grabber is closed, the light will come
from the driller’s panel is the Hydraulic Pressure on and will not go off until ‘grabber open’ is selected.
Gauge, which reads the closed loop pressure in psi.
The RPM Gauge gives an exact reading of the quill Valve When the mud saver valve is closed, the light will
speed. come on will not go out until ‘valve open’ is selected.

Page  Top Drive Rig Floor Safety Orientation Doghouse Manual

Auxiliary Pump This amber light will illuminate if the Mud Saver Valve When the valve is switched to
auxiliary pump is already running and then a robotic close an interlock exactly like the
function is selected. This indicates that the hydraulic drawworks one is energized to cut off
pressure needed to operate the robotics has been the air supply to the mud pump clutch
delivered. If you notice that the light is on, check to see controls. This prevents accidentally
if any switches have been left in the energized state. starting of the mud pump and dead-
When the pump is left pressured-up, the oil return is ending pump flow against the mud
restricted and the oil must pass over a relief. When this saver valve.
occurs, the hydraulic oil will quickly become very hot and
the pump may eventually fail. Connection Mode/Forward To
make a connection, the driller’s panel
If a robotic function is selected and this light does must be switched to ‘connection’
not come on, the function has not occurred. mode. When in this mode, several
preset functions occur and the
Pipe Handler Unlock When the pipe handler is drawworks interlock is part of those functions. Once
unlocked, a proximity switch located on the top drive will the tool joint has been made up to specified torque, it
activate a light on the drillers panel, indicating the locking would be possible to leave the top drive in ‘forward’ and
assembly has been disabled. There is also an interlock hoist the drillstring to remove the slips. The drillstring
associated with this circuit that will be described in the would then turn and the slip handles could injure the
following section. (Tesco Model HCI only) floorhands trying to remove them. The interlock cuts
off the air supply to the hoisting clutch, preventing this
Safety Interlocks: from happening. Once the slips have been removed,
An interlock is a term used to describe an electrical do not switch to ‘forward’ until ‘drill’ mode has been
input from one function that prevents the use of another selected.
by cutting off the flow of electrical current. Interlocks
are used on the top drive to minimize the possibility Pipe Handler The improper use of the pipe handler can
of an unsafe condition. The following describes which have serious consequences, but with safety interlocks
functions have interlocks, how they work and why: and proper training we can minimize the risk of any
incidents. When the pipe handler “unlock” is actuated,
Grabber When the grabber is switched to the closed a proximity switch locks out the quill rotation unless the
position, a signal is sent to the drawworks interlock pipe handler caution (rotate) button is pushed and held
installed in the rig’s drawworks console. This device is while in ‘connection forward or reverse’.
a solenoid actuated air valve, which closes and cuts off (Tesco Top Drive Model HCI, ECI &EMI only)
the air supply to the hoisting clutch controls. This will
prevent the accidental lifting of the blocks when the top
drive quill is not connected to the tool joint against which
grabber has been closed (i.e. after a connection has
been broken). The grabber is not designed to accept
any significant amount of load; this could result in pulling
the grabber components from the top drive. Override
– In order to hold toolface while directional drilling, the
grabber will remain closed on the top tool joint. If the
drillstring needs to be worked while holding toolface, the
grabber close interlock must be overridden. To do this,
push and hold the red button, located on the brake
handle control box and hoist simultaneously.

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 

Chapter 4
Controls and Robotics hydraulic gauge to bleed off below 1000psi before
selecting grabber ‘open’.

Clearance and Visibility: Allow 5 seconds for the grabber to fully open before
The top drive takes up much more space on the rig floor switching the grabber to neutral.
than a kelly would, so this work area must be kept clear
of obstacles that may interfere with the movement of the Grabber Lift (Tesco Top Drive Model HMI, not
top drive and that of the personnel. When the top drive equipped): A hydraulic cylinder, located in the grabber
is moving through the derrick, you must be aware of it’s leg, raises and lowers the grabber to the required
position at all times. Because you are not always able height for backing-up the
to see the top drive, the other members of your crew tool joint. Always position
must also watch and be aware of the top drive’s position the grabber at the top tool
and movement at all times. joint before raising the top
drive from the floor level.
Note: If you are unsure about any situation, stop If for any reason, such as
and ask for help. This will save more time in the end having to begin a trip before
and reduce the likelihood of an incident occurring. the stand has been drilled,
you can simply close the
Robotic Functions: grabber to break-out of the
Extend This feature allows the top drive to reach stand at the monkeyboard
forward over the mouse hole, giving it the ability to height without having to
make up stands in the mouse hole for drilling as well guess whether or not the
as aiding the process of handling tools to and from the grabber is in the correct
v-door. Note: An optional extend alarm is available position.
if requested. This device provides an alarm if the top
drive is extended. Pipe Handler In order to turn the elevators in the
direction needed for a certain operation, the pipe handler
Note: If you leave the top drive extended out while will have to be used. To perform this, proper operation
hoisting with blocks, the top drive could make is critical for worker and equipment safety.
contact with the monkey board.
The following steps must be followed before
Link Tilt Commonly known as ‘the bails’, the links can unlocking the pipe handler:
be tilted to move the elevators up to 35 degrees forward • All personnel must clear the area of the top drive,
and 55 degrees back from vertical, extending the reach elevators, and links.
of the top drive to perform many tasks associated with • Link tilt vertical (if possible, latch the elevators on
pipe handling. the pipe).
• Pumps to ‘neutral’.
Grabber The grabber acts like a back-up tong and • Pipe handler ‘unlock’ and return to neutral.
closes onto a tool joint to arrest the reactive torque when • Grabber ‘close’ (on the saver sub).
making up or breaking out a connection. • Pumps ‘forward’ or ‘reverse’.
• Push ‘pipe handler – caution’ button (rotate)
Rule of thumb: Allow 10 seconds for the grabber to
close before applying torque. The pipe handler section of the top drive will now rotate
When breaking out, close the grabber and leave the up to 360 degrees at 4 RPM. Once the orientation of
switch in the ‘close’ position until the connection breaks. the pipe handler is correct, these steps must be
Then open it while reversing out of the thread box. This followed to disengage pipe handler rotation.
way, you can hoist out of the tool joint once completely • Release ‘rotate or caution’ button.
un-threaded without the interlock disabling the hoisting • Pumps to neutral.
clutch. For making-up a joint, leave the grabber switch • Grabber ‘open’.
in the ‘close’ position until the specified torque is reached • Pipe handler ‘lock’ and return to neutral - a visual
and the top drive stalls. Return the ‘pumps’ switch
from forward to neutral and allow the pressure on the
Page 10 Top Drive Rig Floor Safety Orientation Doghouse Manual
confirmation is critical to ensure the locking
mechanism has fully engaged the lock ring gear.
The top drive can now return to normal operation.

Hydraulic Elevators The Tesco top drive comes

equipped with automatic elevators, which eliminate the
need to have a person manually operate them. This gives
the ability to
open and close
the elevators on
extremely tall
stands of BHA
and reduces
worker exposure
to additional
h a z a r d s
associated with
manual operation of the elevators. The 3-position switch
must be turned to ‘open’ and a safety push button held
at the same time with no load in the elevators for them
to open. This way, selecting the wrong switch cannot
accidentally open the elevators. The elevators can be
closed by either switching to ‘close’ on the drillers panel
or by pushing the close button located on the brake
handle control box. When closing the elevators, visually
confirm the latch has closed.

Mud Saver Valve and Actuator Tesco top drives

incorporate a double ball mud saver valve with a remote
actuator to act as both a mud
saver and as an emergency
blow out prevention valve.
The actuator is designed to
allow you to open or close
the mud saver valve at any
point in the derrick. It is
critical that the actuator
is never functioned while
the quill is rotating; this will damage the internal
components and lead to failure of the actuator. When
you select valve ‘close’ the actuator will close with up
to 5000 psi of hydrostatic well bore pressure against it.
Once you have selected valve ‘open’ the actuator will
open and cannot be closed again for 7 seconds. This
prevents the accidental re-closure of the valve once the
mud pumps have been started.

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 11

Chapter 5
Making Connections “working single” remains on the top drive.

Note: Make sure that all connections are properly

Safety: doped.
Making connections with a Tesco top drive greatly
reduces time and manpower needed to get back to
bottom and drilling ahead. We can add pipe to the Making Up Singles:
drillstring in single joints and double or triple stands. Extend out and stab into the mousehole single. Latch
When making a connection, many tasks are being the rig tong on to mousehole single and rotate the quill
performed by the top drive and it is critical that all forward to shoulder up the connection.
personnel are aware of pinch point locations and
stand clear of the top drive. All connection torque Important – Do not torque the connection in the
values must be agreed upon by the customer prior to mousehole with the top drive.
drilling, and a connection worksheet signed. The Tesco
technician sets the torque parameters and these cannot Carefully retract the top drive into the torque track while
be exceeded. hoisting out of mousehole. Position the new single above
hole center and slowly lower it into the stump. Latch
Breaking Out: the rig tong on the stump and rotate the quill forward to
The top drive can be drilled down to floor height by make up the connection to the specified torque. The
opening the elevators and selecting link tilt ‘back’. To torque value will be read on both the hydraulic pressure
make a connection, rotation is stopped, the mud pumps gauge and the Rosemount gauge.
are turned off, the slips set, and drillers panel set to
‘connection’ mode. Similar procedures are used for an ‘off-bottom
connection’, but extra care must be taken when hoisting
Know the weight of the top drive and overhead to retract the top drive and avoid contact with the
hoisting equipment. This amount should be read on monkey-board.
the weight indicator gauge when the slips are set.
If you have less than the weight of the top drive on Making Up Doubles:
the weight indicator, the counter balance system Using the floor tugger, install one single in the mousehole
will not be able to lift the top drive out of the thread and another single on the v-door left connected to the
box and thread damage will occur. If you have tugger. Extend top drive over the mousehole and link
more than the weight of the top drive reading on the tilt forward so that the elevators can close on the v-
weight indicator, the threads will be damaged and door single. Hoist the v-door single above the rig floor
the top drive could bounce out of the threads and and stab it into the mousehole single. Shoulder up the
also damage the seal face. connection by using either a chain tong or by carefully
guiding the top of the new stand into the top drive with the
Once the mud pump SPM and standpipe pressure link tilt function and rotate the quill until both connections
gauge read zero, it is safe to close the mud saver valve. have shouldered up. Use the rig tongs to back up the
Switch the grabber to ‘close’, wait for the dies to set, single in the mousehole while making up a connection
and then select ‘reverse’. The connection will not break with the top drive.
until the ‘break out’ button is pushed and held. Once
the connection has broken, the break out button can be Important - Do not torque connection in the
released and the grabber opened. Continue reversing mousehole with the top drive.
until the connection is completely unthreaded and the
counter balance system has gently lifted the top drive Now, carefully retract top drive into the torque track
saver sub out of the thread box. while hoisting out of the mousehole. Ensure top drive
and blocks are clear of monkey-board. Position the
If preferred, connections can be made ‘off bottom’ by new stand above hole center and slowly lower it into the
hoisting one single through the table, before setting stump. Latch the rig tong on to the stump and rotate
the slips. The rig tongs must be used to break the the quill forward and make up both connections to the
connection instead of the top drive. In this method a specified torque.

Page 12 Top Drive Rig Floor Safety Orientation Doghouse Manual


Note: If the rig floor is too large to pickup singles from
the v-door with the link tilt and extend, it is still possible
to make double (or triple) connection. Make a single
connection as described above. Raise the top drive and
joint of pipe. Place another joint of pipe in the mousehole
and make up as per ‘off-bottom’ connection. Repeat if
a ‘triple’ is required.
Although it is possible to make up triple stands in the
mouse hole with the top drive, it may be more efficient
to make up stands in advance and leave them racked
in the derrick if drilling with triple stands is required.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Chapter 6
Operations
Drilling:
When drilling ahead with a top drive, adhere to the same
safety and operating practices and procedures as with
conventional rotary drilling.
Rotating Once you have made a connection and the
slips have cleared the table, select ‘valve open’ and start
up the mud pump, then select ‘drill’ mode immediately.
The preset functions in connection mode will be disabled
and now you can manipulate the quill RPM by selecting
‘forward’ and ‘increasing or decreasing’ the pumps.
Slide Drilling In order to hold toolface while sliding,
you must close the grabber on the saver sub, allow the
grabber cylinder to pressure-up, and then switch the
‘pumps – forward/reverse’, to neutral. The grabber light
will remain on.
When sliding, the grabber is closed and the hoisting
clutch interlock is activated. In order to work the
drillstring you must push and hold the ‘override’ button
on the brake handle control box while hoisting. This
allows the drawworks drum clutch to engage.
When running a mud motor, keep accurate records of
the reactive torque (motor pressure) in the string. At
any given time, you may need to orient the toolface of
the downhole motor. To do this the grabber will need to
be opened; if you do not track downhole torque history,
turning the string in small increments will be impossible.
Assuming that you know the amount of torque present,
follow these steps to orient the toolface:
1. Select ‘drill forward’.
2. Decrease the pumps so that x psi (the pressure equal
to the reactive torque) is present on the hydraulic
pressure gauge.
3. Select ‘grabber open’.
4. If the value of x provides enough torque, the string
should not turn.
Turn the string to the right by selecting:
5. ‘Increase pumps’ until the pipe turns very slowly
and under control.
6. When you have achieved the new orientation,
quickly close the grabber.
Page 13
The amount of loop pressure needed to hold the
drillstring when the grabber is opened will change as
depth, and angle of build increase. This is why you
should record a downhole torque history, because the
x value will be easier to predict.
Turn the string to the left by decreasing loop pressure
(‘decrease pumps’), and, if there is not much reactive
torque present, select ‘reverse’ until positioning is
complete, then close the grabber.
Note: The maximum reverse torque is set to prevent
the string unscrewing. Do not engage the ‘breakout’
function or the drillstring could come apart.
Tripping:
The Tesco top drive reduces the amount of time and
work involved in tripping and reaming by giving you the
ability to thread into the drillstring at any point in the
derrick. This is useful when encountering hole problems
while tripping (for instance, pulling tight, bridging off or
when a kick is evident). In short, any time when the
need to pump fluid into the well exists, it can be done
without having to position the drillstring at floor level in
order to install the kelly.
Tripping pipe with a top drive is similar to conventional
methods, with the exception that the robotic functions
ease pipe-handling procedures. At no time is it
necessary for the rig crew to position the elevators or
open and close them. The link tilt function can push
the stand of pipe to be racked to the worker, both on
the rig floor and to the derrickhand. When running in
the hole, the derrickhand does not need to lean out to
throw the stand in the elevators; he can simply ease
the stand into the elevators, which are extended toward
him. Once the stand is placed in the elevators, they
can be closed hydraulically. After the stand is racked
in the derrick or added to the string the links should be
returned to the vertical hanging position by selecting
the ‘float’ function.
Important – The links and elevators should never
be manually operated by a worker. Connection mode keeps the prime mover at an idle when
Cold Climate:
When the hydraulic top drive is working in a freezing
environment, the oil quickly becomes thick and this will
reduce its effectiveness. While drilling, the heat from
the top drive motor(s) warms the oil enough so that this
is not a concern, but whenever the quill is not rotating,
such as when you are slide drilling or tripping, the cold
Page 14
climate function should be used. To activate cold
climate follow these steps:
1. Push in the cold climate button (on the left side of
the drillers panel).
2. Select engine speed ‘slow’.
3. ‘Drill’ mode.
4. ‘Forward’ pumps.
5. ‘Increase or decrease’ pumps, to maintain 700psi
on the hydraulic pressure gauge.
When the cold climate button is pushed in it de-energizes
the circuit to the top drive speed control valve and allows
the flow of loop oil to pass through the motor manifold
and circulates the closed loop system without turning
the quill.
Selecting engine speed slow brings the prime mover
to idle speed for cold climate operation. This saves
overall wear and tear on the engine when it has a low
load on it.
Drill mode allows you to control the hydraulic pumps
internal swash plates, which command the amount of
oil flow to maintain 700psi.
Forward pumps directs the oil flow in such a way that it
passes through the maximum amount of filtration before
going through the pumps again.
Follow these steps in order to properly disengage the
cold climate function:
1. ‘Neutral’ pumps.
2. ‘Connection’ mode.
3. ‘Neutral’ engine speed.
4. Pull out the cold climate button.
By selecting neutral pumps, the flow of hydraulic oil is
stopped.
Important: Never push out the cold climate button
without the preceding 3 steps.
the engine speed is switched to neutral.
After pulling out the cold climate button the top drive can
now return to normal operation.
Tip: If the top drive will rotate and everything else is
operating normally, double check that the cold climate
button has not been accidentally operated.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Reaming:
Back reaming out of the hole is one of the greatest
features the Tesco top drive provides. These steps
should be followed before commencing:
Note – Reaming is to commence only at operator’s
discretion and until the driller is experienced with
this operation, the Tesco technician should be
alerted.
1. Ensure the correct saver sub is installed on the top
drive and keep it properly doped while reaming or
back-reaming.
2. Connect the top drive to the drillstring.
3. Open the mud saver valve.
4. Start the mud pumps and establish circulation.
5. Remove the slips.
6. Select ‘drill’ mode.
7. Pumps ‘forward’ Set quill speed to 30-40 RPM.
8. Hoist the drill string and close the elevators on 12. Ream through the obstruction until the string is
the stand.
9. Work the drill string until free of obstruction.
When you are ready to rack the stand in the derrick, the
procedure is as follows:
1. Stop rotation.
2. Stop the mud pumps.
3. Set the slips.
4. Break out the lowest connection with the rig tongs.
5. Hoist stand out of the stump and allow the pipe to thresholds.
drain.
6. Close the mud saver valve.
7. Lower the stand to approximately 2 inches above pipe using the top drive. With the top drive, the ability to
the rotary table.
8. Ensure the grabber is in position at the top tool
joint.
9. Close the grabber and break out the top drive.
10. Once the top drive is unscrewed from the pipe, open
the grabber and the stand will rest on the floor.
11. Hoist the top drive until the elevators pick up the
stand.
12. Link tilt forward until the derrickhand has control of
the stand and it has been placed in the birdbath.
13. Open the elevators.
14. Link tilt back to vertical.
15. Lower the top drive to the floor and continue back
reaming if necessary.
Top Drive Rig Floor Safety Orientation Doghouse Manual
If an obstruction is encountered when tripping in the hole,
or if for any reason it is necessary to establish circulation,
i.e. well control, the top drive can be connected to the
drillstring quickly by following these steps:
1. If an obstruction is encountered, hoist until the
drillstring is free, and a connection is at floor level.
2. Set the slips.
3. Lower the top drive and guide the top tool joint into
the grabber. Set backup tongs on tool joint at floor
level.
4. Select ‘connection’ mode.
5. Rotate the top drive into the top tool joint and
shoulder it up.
6. Make up the connection to the specified torque.
7. Open the mud saver valve.
8. Remove the tongs and the slips.
9. Start the mud pumps and establish circulation.
10. Select ‘drill’ mode.
11. Set quill speed to 30-40 RPM.
free.
13. Lower top drive to the floor and disconnect the topdrive
– see, break out connection procedures.
Working Tight Hole:
It is important to know that when torque is applied
to the drillstring you cannot pull up to the maximum
force that the pipe is rated for. The top drive
technician will provide information on specific
classes of tubulars and their torsion/tension
In tight hole situations, it will be necessary to free the
maintain mud pump flow, raise and lower the drillstring
and hold torque all at the same time is possible. It is
recommended that when working tight hole, some torque
can be applied to the drillstring.
This is best done by selecting:
1. ‘Drill’ mode
2. ‘Decrease’ pumps
3. ‘Forward’ pumps
4. Slowly ‘Increase’ pumps
Page 15
By decreasing forward pump pressure, there will not be Logging:
enough hydraulic flow to rotate the pipe. Now, slowly When using the hydraulic elevators to support a wire line
‘increase’ the pumps until the pipe begins to rotate. sheave, disconnect the hydraulic hoses at the elevator
Maintain enough pressure on the hydraulic gauge to quick connects to reduce the chances of accidental
hold drillstring in torsion without reaching the torque opening.
relief setting on the top drive. When maintaining static
torque over extended time periods, it is recommended Note: The hoses should also be disconnected to
to increase the pumps to a value less than the torque prevent accidental opening in any other operation where
relief setting and allow the pumps to control the desired the elevators support a load other than the drillstring
torque. If the top drive torque relief is activated, the (for example, when a set of secondary elevators are
hydraulic oil passing through the relief over time, will supported from a nubbin in the hydraulic elevators).
create excessive heat. The hot oil may, in turn, activate
a power unit shut down, resulting in an untimely torque
Running Casing:
release of the drill string.
Using the top drive for
running casing offers
The power module is equipped with numerous safety
some advantages over
shutdowns. When the hydraulic oil reaches the high
conventional methods.
oil temperature shutdown setting, the prime mover
At the customer ’s
will shut down. This should be avoided, especially in
request, Tesco can
situations where hole problems are encountered.
provide a crossover sub
to connect the quill to the
Continue working the drillstring while maintaining torque
casing, eliminating the
with the top drive until a free point is established. When
need to rig-up chiksans
the pipe begins to rotate at this torque setting keep
and fill up hoses. The
raising and lowering pipe in the free point increasing the
top drive also provides
travel distance until the obstruction is cleared.
pipe handling functions
to make handling casing much simpler and safer.
Jarring:
If jarring is required, the torque applied to the drillstring
Cementing:
will need to be released. By slowly decreasing the quill
Unless it is absolutely necessary, never attempt to
torque shown on the hydraulic gauge, the reactive torque
cement through the top drive. With the exception of this
in the string will overcome the quill torque and the pipe
rule, cementing with a top drive is similar to conventional
will, in a controlled manner, rotate in reverse until torsion
methods.
is released. Once this is done, set the slips in order to
break out the top drive.

Tesco does not recommend jarring with the

drillstring connected to the quill. The drillstring
should be suspended from the elevators before
jarring commences.

Disconnect hydraulic hoses at the elevator quick
connects to reduce the chances of elevators opening
accidentally.

After any jarring is done the top drive technician will need
the time to perform a visual inspection of the top drive
components and fill out a ‘Post Jarring Checklist’. In the
event of excessive jarring a load path inspection may
need to be performed at the earliest convenience.

Page 16 Top Drive Rig Floor Safety Orientation Doghouse Manual

Chapter 7
Top Drive Disclaimer
Considerations This manual is intended to provide basic information
only, and does not constitute a comprehensive
Slip and Cut Drilling Line: guide to the functioning or operation of a Tesco
Some daily rig operations change when a rig is fitted Top Drive. It is to be used only in conjunction with
with a top drive. Some simple procedures that your the orientation and on site supervision provided by
crew has performed regularly will need to be adjusted Tesco personnel. The Tesco Top Drive Technician
to consider top drive issues. must be notified of any concerns or incidents
involving Tesco equipment and its operation.
To slip and cut drilling line, obviously the weight of the
top drive cannot hang from the same line as the blocks OTHER THANAS DESCRIBED IN THE PRECEDING
alone did. The top drive technician will assist you in PARAGRAPH, TESCO CORPORATION, ITS
determining the length of a block-hanging sling to be
AFFILIATED COMPANIES AND EMPLOYEES
installed in the derrick to a suitable beam so that the top
ASSUME NO RESPONSIBILITY FOR USE OF THE
drive is positioned at floor level. If your rig is already
fitted with a block-hanging sling, the sling and the eye on INFORMATION CONTAINED IN THIS MANUAL.
the blocks should be rated to support the weight of the
top drive as well as the traveling block. The top drive
will have to be connected to the drillstring and set in the Tesco Corporation (“Tesco”) has made every effort
slips as low as the block-hanging sling will allow, to help to ensure that this manual describes the basic
distribute the additional weight of the top drive. knowledge needed to provide a quick reference for
top drive operators.
Note – When performing a slip and cut with a top
drive it is possible to pump fluid into the well if
necessary.
This manual is to be used in conjunction
Important – The blocks should never be hung from with an orientation and on site
a floor tugger. supervision.
Top Drive Maintenance:
The regular daily maintenance and inspections on the
top drive do not have to interfere with rig operations. In
order to keep the top drive running safely and efficiently,
up to 15 minutes every tour must be available to service
the equipment. The top drive technician’s knowledge of
drilling allows him to choose a ‘window of opportunity’
to do this when the top drive is accessible from a ladder
on the rig floor, while minimizing the impact on the
customer’s operation.

If any service or repairs need to be done on the top

drive, all of the drawworks controls and the driller’s
panel must be locked out and tagged to ensure the
safety of the personnel.

Important – The top drive technician must be notified

of any concerns or incidents involving Tesco
equipment.

Top Drive Rig Floor Safety Orientation Doghouse Manual Page 17

Page 18 Top Drive Rig Floor Safety Orientation Doghouse Manual
Page 19 Top Drive Rig Floor Safety Orientation Doghouse Manual
 Due to ongoing product development, all specifications are subject to change without notice.
Printed in Canada / October 2006 / TC

Better Ways to The Bottom™ ¸

TESCO
Corporate Headquarters World Wide Operations
6204 - 6A Street S.E. 11330 Brittmoore Park Drive
Calgary, Alberta, Canada T2H 2B7 Houston, Texas, USA 77041
Page 20 Tel: 403 692-5700 • Fax: 403 692-5710 Tel:
Top Drive Rig Floor 713 849-5900
Safety • Fax:
Orientation 713 849-0075
Doghouse Manual