System Description

HMIS Top Drive System

250TON HMIS 475HP

DOCUMENT NAME: 880025 REV 2

SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER

Tesco Corporation ("TESCO") has made every effort to ensure that this document contains accurate
and current information for the TESCO top drive, however, the document is intended to be used in
conjunction with a complete training program and on-site supervision and TESCO does not
warrant or guarantee that the information contained herein is either complete or accurate in every
respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together
with its directors, officers, employees and agents from and against all liability for personal injury,
death or property damage to any person arising directly or indirectly from the use by the reader of the
information contained in the document.

Tesco Corporation © 2007

Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
Telephone: (713) 359-7000
Fax: (713) 359-7001

880025 REV 2 250TON HMIS 475HP ©TESCO CORPORATION, 2007

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REVISION INFORMATION SYSTEM DESCRIPTION

Revision Information

Version Date Description of Changes

A April 2004 Engineering review, revisions, and additions.
1 Oct 2007 Added caution symbols to all warnings and caution notes. Added more safety warnings.
Updated revision numbering to comply with new engineering numbering standards.
2 Nov 2007 New revision to remove CE-ATEX standards from manual.

©TESCO CORPORATION, 2007 250TON HMIS 475HP 880025 REV 2

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SYSTEM DESCRIPTION

TABLE OF CONTENTS
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shipping Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Drive Components ............................................................5
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Collar and Load Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter-Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Top Drive Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump Drive and Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Reservoir/Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Extend Frame and Extend Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Beam, Torque Anchor and T-bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power (Closed-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Elevators and Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Grabber Drill Pipe Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotary Table Stabilizer Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotary Hose and Standpipe Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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 SYSTEM DESCRIPTION

Other Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

ENGINEERING SIGN-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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 SYSTEM DESCRIPTION

CHAPTER 1: ABOUT THIS DOCUMENT

This document contains a description of the major components of the 250TON HMIS 475HP
Top Drive System with integrated quill.

A complete HMIS Top Drive System consists of the following:

• top drive
• power unit
• interconnecting service loop and reel
• torque arrest system
• associated buildings, containers and equipment

This document provides a brief description of each major component, as well as a list of avail-
able spares and options.
Table 1-1: Where to find more information

For information on Refer to

• installation HMIS Installation Guide
• rig up
• commissioning
• pre-operational checklists
• rig out procedures
• setting torque and speed HMIS Operations Guide
• driller's panel functions and operating descriptions
• making connections
• drilling ahead
• tripping
• freeing stuck pipe
• load path inspections HMIS Maintenance Guide
• maintenance/service schedules
• component disassembly and reassembly
TESCO manufactured parts and part numbers HMI Parts List
• electrical schematics System schematics
• hydraulic schematics
• cooling schematics
• gearbox lubrication schematics
available options and spares TESCO Representative

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ABOUT THIS DOCUMENT SYSTEM DESCRIPTION

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 SYSTEM DESCRIPTION

CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION

INTRODUCTION AND GENERAL SPECIFICATIONS

The HMIS top drive is designed for use on small drilling rigs and workover rigs. The HMIS
top drive is powered using an independent hydraulic power unit.

To create the optimum power supply system required for each of its top drives, TESCO com-
bines industry proven prime movers with its own series of hydraulic pump drives and filtration
equipment.

The HMIS top drive is powered using one of the following power unit configurations:
• 475 hp prime mover with a two-pump drive (Detroit Diesel Series 60)-most common
• 460 hp prime mover with a two-pump drive (Caterpillar 3406B)

Metric unit conversions (in brackets) have been provided for convenience only. All prod-
uct specifications use the original imperial units unless indicated otherwise.
Note: All weight values are approximate.

Table 2-1: HMIS Top Drive specifications

Specification Details
Top Drive 250TON HMIS 475HP
Rated Capacity 250 ton (226.8 metric ton)
Weight of the top drive plus: 8,900 lb. (4,037 kg)
• elevators
• elevator links
• counter balance
• swivel
Length 13 ft. 5 in. (4.089 m)
Width 33 in. (0.84 m)
Horsepower Dependent on the prime mover:
475 hp (354.2 kW)–2 pump drive
460 hp (343.0 kW)–2 pump drive

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TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION

Table 2-2: Torque Arrest System specifications

Specification Details
Weight of the following: 7,200 lb. (3265.87 kg)
• torque track
• anchor beam
• torque bushing
• extend frame
• clamps
Std Track Length 91 ft. (27.7 m); more length is available

SHIPPING CONTAINERS
The HMIS top drive is typically shipped in ocean shipping containers. Each container is 20 ft
(length) x 8 ft (width) x 8 ft 6 in. (height) (6.1 m x 2.4 m x 2.6 m).

Container 1
Approximate weight: 20,000 lb. (9071.85 kg)

Contents:
• top drive and transportation stand
• multi-conductor cable storage reels
• links
• spare parts
Note: Some countries require that spare parts be shipped separately from the original
equipment. In these cases, spare parts will be crated and shipped in a separate container.

Container 2
Approximate weight: 18,000 lb. (8164.66 kg)

Contents:
• power unit (without the hose reel skid)

Container 3
Approximate weight: 18,000 lb. (8164.66 kg)Contents:
• torque arrest system components
• one rig up basket
• hose reel skid

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

TOP DRIVE COMPONENTS

Figure 2-1: HMIS Top Drive general assembly

1. Torque Bushing 72 in.

2. Swivel Link and
Counter-Balance
3. Swivel
4. 11-Station Manifold
5. Spoon Assembly
6. Motor Manifold
7. Link Carrier Assembly
8. Gearbox and Spline Drive
Assembly
9. Load Nut and Load Collar
10.Link Tilt Cylinders
11.Mudsaver Valve
12.Grabber (with legs)
13.Elevator Link Tilt Assembly
14.Elevator
15.Torque Track Assembly

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TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION

Gearbox
• The gearbox couples one hydraulic motor to the gear train.
• The motor is a bi-directional hydraulic vane type, and it has pressure ratings of 4,000 psi
(27.6 MPa) continuous and 4,500 psi (31.0 MPa) intermittent.
• The HMIS top drive system is configured with a standard gear ratio of 2.19:1. An
optional 1.64:1 gear ratio is also available.
• The gearbox houses gear reduction and forced lubrication systems as required for the
unit.
• The integral drive hub is internally splined to accept the integrated swivel and quill.

Load Collar and Load Nut

The load collar and load nut transfer loads from the elevator links to the quill.

Mudsaver Valve
The mudsaver valve is a double-ball crank valve that acts as a mudsaver. It replaces the upper
and lower Kelly cock. The valve does not descend below the rotary table, except in emergency
situations, and it is always easily accessible. The mudsaver valve actuator can be operated
remotely from the driller’s panel.

Caution: The actuated upper ball valve is not for well control; it
functions solely as a mudsaver. The manual operating lower valve
! is for well control. Ensure that the valve selected can fit into the
existing casing.

Pipe Handling
The pipe handling abilities of the HMIS include the following:
• Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35°
forward from the vertical position and 55° backward from the vertical position.
• Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking
connections at any point in the mast. The grabber will accommodate tool joints from
2-3/8 in. to 5 in. OD.

Counter-Balance
The top drive features an automatic thread feed compensation for make up and break out oper-
ations.

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

Swivel
The HMIS top drive features a drilling swivel with an integrated one-piece quill. This configu-
ration offers the following advantages:
• no connections from the swivel bearing to the top of the mudsaver valve
• increased reliability/reduced maintenance
• decrease in the overall length and weight of the top drive
• readily available replacement parts

Top Drive Power Supplies

The top drive motor is powered by two axial piston pumps, which are located on the rear of the
prime mover. All top drive robotic functions are powered by an auxiliary hydraulic system,
which is located on the prime mover module.

Handling Frame
The top drive is shipped in its own handling frame. This frame allows you to transport and
handle the top drive by using standard rig moving equipment.

POWER UNIT
The HMIS Top Drive power unit consists of the following:
• prime mover module, which includes the pump drive and filter manifold, the oil reser-
voir and cooling system, and the auxiliary system components
• hose storage reel

Prime Mover
The prime mover is a skid-mounted diesel engine (Detroit Diesel Series 60). Prime movers are
equipped with a fuel day tank, an air starter, standard instrumentation packages, and appropri-
ate safety and emergency shutoffs.

Pump Drive and Filter Manifold

The pump drive/filter manifold is skid-mounted and includes the following equipment:
• variable displacement, bi-directional axial piston pumps (two)
• flow meters and temperature gauges
• a series of hydraulic oil filters
• hot oil shuttle (to assist with oil cooling)
• auxiliary hydraulic pump and motor

The auxiliary hydraulic equipment includes the following:

• a gear pump (2,000 psi, 7 gal/min; 13.79 MPa, 26.5 liters/minute)
• 10 hp (7.46 kW) explosion-proof electric motor
• associated filters and controls

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TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION

Hydraulic Oil Reservoir/Cooler

The hydraulic oil reservoir/cooler is skid-mounted and contains the hydraulic oil storage reser-
voir and cooling system components. All reservoirs are equipped with a level gauge, tempera-
tures gauges, and return oil filters.

Cooling System Components

The cooling system components provide cooling for hydraulic oil used by the power and aux-
iliary hydraulics systems. An air/oil heat exchanger (controlled by a thermostat) cools the
hydraulic oil before it is returned to the tank.

Figure 2-2: HMIS power unit configuration

1. Prime Mover (Detroit Diesel Series 60)

2. Air/Oil Cooler
3. Hose Reel Module
4. Auxiliary Hydraulic Pump and Motor
5. Oil Reservoir
6. Variable displacement, bi-directional axial pumps (not visible in this illustration)

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

TORQUE ARREST SYSTEM

The torque arrest system is typically shipped in the second standard sea container. It consists
of the following components:
• extend frame
• torque bushing
• extend arms
• extend hydraulic cylinders
• torque track
• T-bar
• torque beam, torque beam clamps, stabilization devices, and all required rig up items

Extend Frame and Extend Arms

The extend frame is pinned to the top drive. It allows you to extend the top drive away from
the torque track.

Torque Bushing
The torque bushing is attached to the extend frame. Ultra High Molecular Weight (UHMW)
inserts reduce friction as the top drive moves along the torque track. No lubrication is required.

Torque Track
The torque track, in conjunction with the torque beam and T-bar, transfers reactive torque to
the lower section of the derrick and the substructure.The track is suspended from the crown by
a cable hanging assembly, and is mounted with a simple clamp anchoring arrangement. Track
components can be configured to fit most mast heights.

Torque Beam, Torque Anchor and T-bar

The torque beam is mounted on the rig, typically to the lowest strongback. It is then connected
to the torque track via a T-bar. An offset torque anchor beam and post is available for use on
service rigs. This torque anchoring system compensates for the 3.5° lean of the service rig
mast.

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TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION

Figure 2-3: HMIS torque arrest system

1. “F” Clamps
2. Torque Track
3. Turnbuckles
4. “F” Clamps
5. “F” Clamp Assembly
6. Nuts, Washers and
Ready Rod
7. Torque Track
8. Final Assembly,
72 in. Torque Bushing
9. Gearbox
10.Optional Torque
Anchor Assembly
11.Mast
12.Torque Beam
Assembly
13.Torque Track

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

SERVICE LOOP
The hoses are spooled onto the hose reel prior to shipping.

Power (Closed-Loop) Hydraulic Hoses

• two 225 ft. (68.58 m) x 1-1/2 in., 5,000 psi (34.5 MPa) hoses (one supply, one return);
these supply closed-loop hydraulic oil from the pump drive module to the top drive
motor

Auxiliary Hydraulics
• one 225 ft. (68.58 m) x 3/4 in. R2, 2,000 psi (13.8 MPa) hydraulic hose; this supplies
hydraulic oil from the pump drive module to the top drive robotics system

Case Drain
• one 225 ft. (68.58 m) x 1-1/4 in. 1,625 psi (11.2 MPa) hydraulic hose; this returns auxil-
iary hydraulic oil and motor case drain flow from the top drive to the hydraulic oil reser-
voir

Control Cables
The 225 ft. control cable is spooled onto its own cable reel. The 160 ft. control cable remains
attached to the main electrical panel on the power unit and hangs from a cable hook during
storage.
• one 225 ft. (68.58 m) 37-conductor cable: this cable connects the driller's panel to the top
drive
• one 160 ft. (48.77 m) 37-conductor cable: this cable connects the driller's panel to the
main electrical panel on the power unit

DRILLER’S PANEL
The driller’s panel is a stainless steel enclosure that is mounted on the drill floor during instal-
lation procedures. It contains all controls, indicators, mounts, gauges and connectors required
to operate the top drive. There is an optional air-purge system available for the driller’s panel.
All controls are electrically activated hydraulic (24 VDC) non-earth ground.

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TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION

OPTIONS
The following options are available. For more detailed information, contact a TESCO repre-
sentative.

Elevators and Elevator Links

Elevators rated at 150 and 250 tons (136.1 and 226.8 metric tons), associated inserts for vari-
ous drill pipe sizes, and accessories are available. A variety of link lengths is also available.

Subs
A complete selection of commonly used saver, casing, cross-over and drill collar handling
subs is available. Non-standard subs can be manufactured if requested; delivery can be deter-
mined at time of order.

Grabber Drill Pipe Guides

These are used to guide the drill string into the grabber box. The drill pipe guide must match
the box of the drill pipe in use. There is a range of sizes available.

Rotary Table Stabilizer Bushings

These urethane bushings fit the standard rotary table profile and protect the table and Blowout
Preventer (BOP) from excessive wear. There is a range of sizes available.

Rotary Hose and Standpipe Extension

All equipment and accessories for these modifications are available.

Torque Arrest System

Other Available Options

• air purge system for the driller's panel and top drive junction box
• workshop/parts containers with workbench and storage cupboards
• camera system

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