EMI 400 Installation Guide

Installation Guide
EMI400 Top Drive System
250TON EMI 400HP 50Hz
DOCUMENT NAME: 1270411 REV 3

INSTALLATION GUIDE COPYRIGHT AND DISCLAIMER
Tesco Corporation (“TESCO”) has made every effort to ensure that this document contains accurate
and current documentation 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.
This equipment was filled at the factory with TESCO ULTREX™ brand fluids and greases. To ensure
maximum performance and to avoid cross-contamination, we strongly recommend the continued
usage of TESCO ULTREX™ lubricants, unless otherwise specified.
TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.
© 2014 Tesco Corporation. All rights reserved.
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
www.tescoparts.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
After Market Sales and Service Contact

Toll Free North America: 1-877-TESCO-77
International: 713-359-7295
CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

INTL: 713-359-7295 I WWW.TESCOPARTS.COM
REVISION INFORMATION INSTALLATION GUIDE
Revision Information
Version Date ECN Description of Changes

Rev 0 May 2010 127-0245 Initial release of document
Rev 1 May 2012 097-0214 Removed references to ‘cat line tugger with rope’ and replaced with ‘tugger
line with steel cable’, according to safety incident reported in RES-0422
Rev 2 Mar 2013 157-0032 Updated Safety Instructions section; added “Appendix D: Torque Standards
for High Strength Fasteners”; updated “Appendix C: Sling Load Ratings”
Rev 3 Apr 2014 157-0048 Updated the Safety Instructions section with DROPS information and
added DROPS poster. Added text and image indicating the HPU power
source must be in a non-hazardous area.

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INSTALLATION GUIDE TABLE OF CONTENTS
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 2: PRE-INSTALLATION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rig Installation and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power/Service Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Power Requirements (Rig AC Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Inspection (Pre-installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHAPTER 3: RIG UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Equipment Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Optimal Placement of the Power Module and Auxiliary Hydraulic Power Unit (HPU) . . . . . . . . . . . 9
How to Place the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Optimal Placement of the Service Loop Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Optimal Placement of the Cable/Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to Install the Cable Roller Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How to Install the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to Install the Service Loop: Option 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to Install the Service Loop: Option 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Before Installing the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque Arrest System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Torque Arrest System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to Determine the Torque Track Configuration (where an application drawing is not supplied) . . . . . . . . . . . . 22
Sample Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
How to Install the EMI400 Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Extend Arm Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
How to Set the Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Driller's Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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TABLE OF CONTENTS INSTALLATION GUIDE
How to Install the Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Safety Air Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
How to Install the Drawworks Interlock and Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Mud Pump Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
CHAPTER 4: SYSTEM INSPECTION AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Inspection-General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Supply Power and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
System Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Table of Circuit Breakers and Main Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Support Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
How to Start the Generator (if supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Preliminary Checks and ESD Shutdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
How to Apply 600 VAC Transformer Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Up the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
How to Check Phase Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
How to Check the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
How to Test the E.S.D. on the Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Final Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
How to Reset the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
About Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
How to Modify Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHAPTER 5: RIG OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Remove the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Remove the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Remove the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Disconnect the Power and Auxiliary Hydraulic Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
APPENDIX A: PRE-INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
APPENDIX B: VISUAL INSPECTION CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
APPENDIX C: SLING LOAD RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Capacity Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Basket Hitch Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Choker Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
APPENDIX D: TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS . . . . . . . . . . . . .65

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INSTALLATION GUIDE TABLE OF CONTENTS
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
APPENDIX E: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION . . . . . . . . . . . . . . . . 69
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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TABLE OF CONTENTS INSTALLATION GUIDE
This page has been left blank intentionally.

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INSTALLATION GUIDE LIST OF FIGURES
LIST OF FIGURES
Figure 2-1: Hydraulic power unit in hazardous area, power source in non-hazardous area . . . . . . . . . . 4
Figure 2-2: Hydraulic power unit and power source in non-hazardous area. . . . . . . . . . . . . . . . . . . . . . 4
Figure 2-3: Power connection with rig AC bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2-4: Power connection with integrated generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3-1: EMI 400 optimal equipment placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 3-2: EMI 400 hose saddle placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3-3: Service loop installation (option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 3-4: EMI 400 roller saddle cable capture clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3-5: Service loop installation (option 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 3-6: Cable/hose saddle clamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3-7: Front and end views of saddle, hose, and service loop . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3-8: EMI 400 cable/hose saddle capture clamp configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 3-9: Hoisting the hose saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3-10: Positioning the hose saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3-11: Torque arrest system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 3-12: Fastener tightening for torque track flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 3-13: Torque arrest system - permanent installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 3-14: Link locks in locked and unlocked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 3-15: EMI Top Drive capture clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 3-16: Counter-balance system interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 3-17: EMI counter-balance cushion height; yoke and split block interface . . . . . . . . . . . . . . . . 34
Figure 3-18: Drawworks override installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 4-1: Recommended supply power and grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 4-2: Change phase rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 5-1: Setting the swivel link locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 5-2: Spooling the service loop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 5-3: Spooling the service loop 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure C-1: Basket hitch capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure C-2: Choker capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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LIST OF FIGURES INSTALLATION GUIDE

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INSTALLATION GUIDE LIST OF TABLES
LIST OF TABLES
Table 1-1: Where to find more information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Table B-1: Top drive inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table B-2: Power module inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table B-3: Auxiliary hydraulic power unit inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table B-4: Cable reel/service loop inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table B-5: Driller’s panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table C-1: Capacity Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table D-1: Standard torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table D-2: Special fastener torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table D-3: Spiralock fastener torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table D-4: B7 Stud torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Table D-5: Thread engagements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table E-1: Hand signals for boom operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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LIST OF TABLES INSTALLATION GUIDE

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INSTALLATION GUIDE
SAFETY INSTRUCTIONS
Warning! Before operating or servicing this top drive system,

always read and follow all safety instructions such
as the warnings and cautions mentioned below and
! throughout the manual.
Top Drive System users risk injury to themselves and to others if the top drive is used
improperly and/or safety precautions are not followed. TESCO advises personnel who
work with or near the equipment to always wear proper personal protective equipment
(PPE). Proper PPE consists of, but is not limited to, the following:
• hearing protection (ear defenders)
• hard hat
• safety glasses
• steel toe shoes
• fall protection when working above 6.5 ft (2 m), or the minimum height
requirement as directed by local jurisdiction.
Important! Tools and portable equipment used at height shall be

adequately secured to either the user or the workplace.
! Ensure that personnel adhere to all safety warnings
and protocols. Work should be planned to minimize or
eliminate the risk of dropped objects.

TESCO's Dropped Object Prevention Program fully
supports the industry-wide Dropped Objects Preven-
tion Scheme (DROPS), which focuses on preventing
dropped objects from occurring on the job site. TESCO
encourages all rig personnel to adhere to the DROPS
best practice guidelines (www.dropsonline.org).
Caution: This equipment is designed and certified for use in a

hazardous environment. When maintenance requires replacement
! of parts, only identical parts can be used. Using alternate, non-identi-
cal parts as a substitution may void compliance and certification.
Caution: Always perform the correct lock-out procedures as recom-

mended by the Safety or Loss Prevention department before imple-
! menting maintenance.

INTL: 713-359-7295 XI WWW.TESCOPARTS.COM
SAFETY INSTRUCTIONS INSTALLATION GUIDE
Caution: Never attempt to perform services procedures or repairs

when equipment is operating.
!
Caution: Only authorized personnel can install and operate the top
! drive system.
Caution: Only trained personnel must perform inspections and

! related activities.
Caution: Safe access must be provided to all areas where adjust-

! ments and maintenance are necessary.
Caution: This equipment can generate noise up to 90 decibels.

Hearing protection suitable for this noise level must be worn when
! operating this equipment.
Caution: The top drive will be energized automatically if the stored

torque in the drill string rotates the top drive backwards more than 5
rpm - even if the QUILL switch is set to neutral. This is to prevent an
! uncontrollable backspin even if the stored torque in the drill string
is instantly released.
Warning! Electrical voltages of different potentials are used

throughout the TESCO top drive components (600
VAC, 208 VAC, 120 VAC, 840 VDC, 5-24 VDC). It is
imperative that only qualified personnel install,
! maintain and/or troubleshoot the electrical
systems. A severe hazard exists to personnel not
accustomed to, or familiar with, electrical hazards
and procedures.
Warning! There are high voltage capacitors installed in the

ACS800 drive module. It is imperative that at least 5
minutes elapse, after power to the drive has been
! turned off, before any testing or repairs be
undertaken at the module. The capacitors require
time to ‘drain’ their stored electrical energy.
Warning! Accumulators used in the auxiliary hydraulic

system are under pressure from gas. Release this
! pressure before any maintenance is done on the
auxiliary hydraulic system.

INTL: 713-359-7295 XII WWW.TESCOPARTS.COM
INSTALLATION GUIDE SAFETY INSTRUCTIONS

INTL: 713-359-7295 XIII WWW.TESCOPARTS.COM
SAFETY INSTRUCTIONS INSTALLATION GUIDE

INTL: 713-359-7295 XIV WWW.TESCOPARTS.COM
INSTALLATION GUIDE
CHAPTER 1: ABOUT THIS DOCUMENT

This document contains information on how to install the 250TON EMI 400HP 50Hz top
drive, power module, auxiliary hydraulic power unit, torque arrest system, and service loop.
The installation sequence described in this document can be altered to accommodate current
rig activity. The procedures described in this document provide instructions on how to do the
following:
• perform a pre-installation assessment and equipment check
• place equipment
• install the service loop and connect services
• install the torque arrest system
• install the counter-balance system
• install the top drive
• connect the driller’s panel and safety interlocks
• perform a system inspection and commission the unit
• rig out
Metric unit conversions (in parentheses) have been provided for convenience only. All
product specifications use the original Imperial units unless indicated otherwise.
Note: All weight values are approximate.
Table 1-1: Where to find more information
For information on Refer to

system components System Description
• setting torque and speed Operations Guide
• driller's panel functions and operating descriptions
• making connections
• drilling ahead
• tripping
• freeing stuck pipe
• load path inspections Maintenance Guide
• maintenance/service schedules
• component disassembly and reassembly
TESCO manufactured parts and part numbers Parts List
• electrical schematics System schematics
• hydraulic schematics
• gearbox lubrication schematics
available options and spares TESCO Representative

INTL: 713-359-7295 1 WWW.TESCOPARTS.COM
CHAPTER 1: ABOUT THIS DOCUMENT INSTALLATION GUIDE

INSTALLATION GUIDE
CHAPTER 2: PRE-INSTALLATION ACTIVITIES
RIG INSTALLATION AND MEASUREMENT

To ensure that top drive installation progresses smoothly, complete a detailed rig measurement
package before ordering equipment. Rig measurement packages are available from TESCO.
Accurate rig measurement helps do the following:

• Determine an equipment placement plan
• Determine the best method for installing the top drive
• Identify specialized equipment requirements, including the following:
• torque track hanging pad eye
• components and subs (top drive to drill string)
• cable lengths and specific accessories
• air/electric safety interlocks
• torque arrest system components
• roller saddle or cable/hose saddle mounting requirements
• mud hose extension and connection
• standpipe extension
Ask a qualified TESCO representative to complete the rig measurement package. This will help
to ensure that the equipment will fit properly within the rig’s configuration.
POWER/SERVICE CONNECTION REQUIREMENTS

Discuss the following items with a qualified TESCO representative before requesting
shipment of the top drive system:
• size and output of all generators
• type and model of the distribution/SCR systems
The top drive system requires a 600 VAC, 50 Hz power supply. If the top drive unit is equipped
with an integrated generator, then the connection requirements for fuel and air should be
considered.
The following figures illustrate the connection considerations to address before the top drive
system arrives on location.

CHAPTER 2: PRE-INSTALLATION ACTIVITIES INSTALLATION GUIDE
Figure 2-1: Hydraulic power unit in hazardous area, power source in non-hazardous area
Figure 2-2: Hydraulic power unit and power source in non-hazardous area
Caution: Hydraulic power unit power cabling must be connected to

! a power source that is located in a non-hazardous zone area.

INSTALLATION GUIDE CHAPTER 2: PRE-INSTALLATION ACTIVITIES
Figure 2-3: Power connection with rig AC bus
Figure 2-4: Power connection with integrated generator

Main Power Requirements (Rig AC Bus)

1. Determine a location for the power and mechanical modules.
Note: If the rig configuration has not been finalized, then select two possible loca-
tions for the power module.
2. Determine where the main disconnect breaker panel will be located.
Note: The best location provides room for service personnel and some shelter
from the weather.
3. Determine the distance from the AC-Bus to the breaker panel.
4. Determine the distance from the breaker to the power module.
5. Determine if any special equipment is required. Examples: penetration or plug boards.
Note: This equipment is required if the three-phase power cables must pass
through walls on their way from the main breaker to the power module.
6. Determine if cable tray or suitable space is available to accommodate three-phase
power cables (from the breaker to the power module).
Note: If adequate space is not available, determine what materials would be
required to protect the cables from the breaker to the power module.
7. If the customer is providing the main power supply (interconnection package),
consult TESCO.
Fuel Considerations
If the top drive unit is equipped with an integrated generator, then the connection requirements
for fuel and air should be considered.
1. Determine the location and type of the fuel supply.
Note: The fuel connector line should be 1 in (2.5cm) minimum, and it should be
able to supply enough fuel for the power unit’s maximum consumption. The fuel
return line should also be 1 in (2.5 cm) minimum.
2. For the Detroit Diesel 635 hp (474 kW) Genset, maximum consumption is 22.8
gallons per hour (86 liters per hour).
3. Determine the required length of the fuel line. Determine the route it will take
from the fuel supply to the power unit.
Note: Avoid routing the fuel line where it might become damaged or pinched.
4. Verify the quality of the fuel supply.
Note: Poor fuel quality might require special treatment. For example, fuel line
heaters might be required in areas where diesel fuel contains high levels of paraf-
fin.

INSTALLATION GUIDE CHAPTER 2: PRE-INSTALLATION ACTIVITIES
Air Considerations
If the top drive unit is equipped with an integrated generator, then the connection requirements
for fuel and air should be considered.
1. Determine if the air supply is adequate.
Note: 100 psi (689 kPa) minimum with a 1 in (2.5 cm) supply line.
2. Verify the quality of the air supply.
Note: If the humidity in the area is high, then a moisture trap might be required to
remove moisture from the starter’s air supply.
3. Determine the required length and route of the air supply line.
Note: Avoid routing the line where it might become damaged or pinched. Placing
the air receiver close to the power unit might help it start more easily.
EQUIPMENT INSPECTION (PRE-INSTALLATION)

TESCO inspects all top drive equipment before shipping, however, some damage might occur
while equipment is in transit.
It is important to identify any shipping damage as quickly as possible. This allows for any
necessary repairs to be made, ordering of equipment replacements, and optimizing system
readiness.
As part of a pre-installation equipment inspection, do the following:

• Check all shipping containers for damage. External damage may indicate damage to con-
tents.
• Visually inspect all principle components for damage or missing parts.
• If the top drive system is shipped with fluid levels at full, check the fluid levels. Low
fluid levels may indicate a leak in the hydraulic, cooling, or lubrication system.
A sample equipment checklist is included in “Appendix A: Pre-Installation Checklist”.


INSTALLATION GUIDE
CHAPTER 3: RIG UP PROCEDURE
EQUIPMENT PLACEMENT
Optimal Placement of the Power Module and Auxiliary

Hydraulic Power Unit (HPU)
Placement of the power and mechanical modules is similar regardless of whether the power is
supplied by the rig or by an independent generator. The following diagram shows the optimal
placement of the power module and auxiliary hydraulic power unit. This placement is
considered ideal for the following reasons:
• The distance from the main disconnect breaker to the power module is short.
• The placement allows straight-line access from the cable reel to the cable/hose saddle.
• The power module is in the aft position (closest to the generators).
• The service loop cable connections are outboard of the rig.
Note: Excess service loop cable can be easily secured on the roof of the power module
when it is in this position.
• There is easy access to the power module waterfall.
• The auxiliary hydraulic power unit is placed close to the power unit and the connections
of the auxiliary hydraulic hose are easily accessible.
Caution: Hydraulic power unit power cabling must be connected to

! a power source that is located in a non-hazardous zone area.

CHAPTER 3: RIG UP PROCEDURE INSTALLATION GUIDE
Figure 3-1: EMI 400 optimal equipment placement
Although the location of the power module depends on the rig configuration, the factors listed
above should be considered when placing equipment.
How to Place the Power Module

1. Ensure the ground surface is level; remove any major obstructions.
2. Install rig matting or another secure material under the equipment location.
Note: Ensure the rig matting extends far enough beyond the equipment to provide
a walkway for outside service activity.
3. Using a crane or loader, place the power module on the rig matting.
4. Move the auxiliary hydraulic power unit to a location within 30 ft (9.1 m) of the
power module.
5. Connect the following cords from the auxiliary hydraulic power unit to the incom-
ing cable panel on the power module:
• one power cable
• one sensor cable
6. Connect the auxiliary hydraulic power module to the hose reel motor, using the
auxiliary hydraulics jumper hoses.

INSTALLATION GUIDE CHAPTER 3: RIG UP PROCEDURE
Optimal Placement of the Service Loop Reel

The service loop reel acts as a spooling and storage device for electrical cables and auxiliary
hydraulic hoses; it is not required during top drive operations. After the hoses and cables are
moved onto the saddle and connected to the power unit and top drive, the hose reel can be
moved from the installation location to any convenient storage area.
“Figure 3-1: EMI 400 optimal equipment placement” shows the optimal location for the hose
reel during installation of the service loop. This position is considered optimal for the
following reasons:
• There is a clear view of the cable/hose saddle.
• There is straight-line access from the hose reel to the cable/hose saddle.
Although the placement indicated on the illustration is considered optimal, placement of the
reel is determined by the available space on site. Always ensure that the selected path is free of
sharp edges and corners that can damage the service loop.
Optimal Placement of the Cable/Hose Saddle

The following illustration shows the optimal placement of the cable/hose saddle. This placement
is considered ideal because the cable/hose saddle is situated as follows:
• High enough to prevent cables from landing on the rig floor when top drive is lowered:
• If the mast height is 100 to 125 ft (30.5 to 38.1 m), it is 55 to 65 ft (16.8 to 19.8 m)
above the rig floor.
• If the mast height is 130 to 145 ft (39.6 to 44.2 m), it is 75 to 85 ft (22.9 to 25.9 m)
above the rig floor.
• Low enough to allow the top drive to reach the rig floor without straining or damaging
cables.
• Where there is straight-line cable access from the power unit.
Note: This position is a low activity area for overhead equipment. Accidental damage to
cables is less likely to occur when the roller saddle is placed here.

Figure 3-2: EMI 400 hose saddle placement
Although the arrangement shown here is considered optimal, placement of the cable roller
saddle is determined by several factors:
• mast height
• strongback location and type
• length of traveling equipment (drill string, compensator, blocks, and swivel)
• available cable length (maximum service loop length is 225 ft (68.6 m) unless otherwise
requested)
• power module location
How to Install the Cable Roller Saddle

1. Use a crane or other available lifting equipment to move the cable roller saddle to
the rig floor.
2. Use a steel cable tugger to hoist the roller saddle to a predetermined location on
the mast.
3. Mount the cable roller saddle to the strongback.
Note: The strongback type determines which mounting hardware should
be used. Discuss mounting requirements during the rig measurement and
pre-installation analysis.

HOW TO INSTALL THE SERVICE LOOP

There are typically two options to installing the service loop:
• Option 1: The service loop needs to be strung through the mast structure. A roller saddle
should be used as the service loops are typically ‘pulled’ over the roller saddle and
through the mast structure.
• Option 2: The service loop is hung outside the mast structure and does not have to pass
through the mast structure. The service loop is clamped to a cable/hose saddle and
hoisted up beside the mast.
How to Install the Service Loop: Option 1

Use this procedure to string the service loop through the mast structure by using a roller saddle.
Figure 3-3: Service loop installation (option 1)

1. Use a crane or other available lifting equipment to move the cable roller saddle to
the rig floor.
2. Use a steel cable tugger to hoist the roller saddle to a predetermined location on
the mast.
3. Mount the cable roller saddle to the strongback.
Note: The strongback type determines which mounting hardware should be used.
Discuss mounting requirements during the rig measurement and pre-installation
analysis.
4. Place the reel in a location where there is a clear view of the roller saddle.
5. Connect the auxiliary hydraulic power unit to the storage reel using the 35 ft (10.7 m)
extension hoses.
Note: To unreel the hoses when the auxiliary hydraulic system is not available,
manually unreel the hoses by connecting the two quick couplers closest to the
hose reel motor. This allows oil to free-flow through the motor, hoses, and quick
couplers. If using this technique, the motor free-wheels (no reel brake is avail-
able).
6. Ensure the auxiliary pump is operational.
Note: If the unit is connected to an independent generator, ensure the fuel and air
supply lines are connected.
Note: When connecting to the main electrical power, ensure that 600 VAC power
is established with correct phase rotation and that electrical power is available for
the hydraulic pump at the auxiliary hydraulic power unit.
7. Bundle the ends of all the cables and hoses together in a soft sling.
8. On the rig floor, thread the steel cable tugger through the snatch block.
9. Attach the sling to the steel cable tugger.
Note: Verify that the slings are long enough to pass over the roller saddle and
extend to the service reel. If adequate sling length is not available, see “How to
Install the Service Loop: Option 2” on page 16.
10. Thread the slings over the roller saddle.
11. Attach the sling to the soft sling on the service loop.
12. Use the steel cable tugger to begin spooling out the service loop.
Note: Use the hydraulic reel controls to hold back or feed the line as required.
13. Spool out the correct length of service loop (enough to reach from the reel side of
the roller saddle to the rig floor plus 2 ft (0.61 m)), then install the mast cable cap-
ture clamp as follows:
a. Use slings to attach the back plate of the capture clamp to the mast.
b. Position the urethane inserts on the back plate.
c. Position the cables and plates as indicated in Figure 3-4 on page 15.
d. Tighten all bolts to prevent cables and hoses from slipping, then install the
cotter pins in the bolts.

Figure 3-4: EMI 400 roller saddle cable capture clamp
1. Power cord
2. Spare
3. Power cord
4. Power cord
5. GND cable
6. Blower motor cable
7. Spare
8. Sensor cable
9. Auxiliary Hydraulic
Return
10.Auxiliary Hydraulic 
Pressure
11.Robotics Cable
12.Spare
Caution: Ensure that all the cables and hoses bend gently and
evenly as they rise up off the ground and go up the derrick. This
ensures the cables are of even length on the rig floor once the ser-
! vice loop is in place. The auxiliary and coolant hoses are longer
because they must reach the opposite side of the top drive, how-
ever, they must all make the same even, gentle bend at the ground.
14. Pull the remaining portion of the service loop over the roller saddle and down to
the rig floor.
15. Use slings to secure the mast cable capture clamp assembly to the mast approxi-
mately 2 ft (0.61 m) below the roller saddle on the reel side.
16. Connect the service loop cables and hoses at the top drive, the power module and
the auxiliary hydraulic power unit.
Note: The auxiliary supply/return quick couplers are located on the auxiliary
hydraulic power unit. The power, sensor, robotics and ground cables are con-
nected to the appropriate receptacles in the supply waterfall of the power module.
These cables and hoses cannot be connected until the top drive is mounted to the
torque track. The cable to the driller’s panel cannot be connected until the driller’s
panel is mounted on the drill floor.

How to Install the Service Loop: Option 2
Figure 3-5: Service loop installation (option 2)
Use this option when the service loop does not need to be strung through the mast structure.
1. Place the reel in a location where there is a clear view of the roller saddle
2. Ensure that the auxiliary hydraulic fluid lines are connected to the hose reel control.
Note: To unreel the hoses when the auxiliary hydraulic system is not available,
manually unreel the hoses by connecting the two quick couplers closest to the
hose reel motor. This allows oil to free-flow through the motor, hoses, and quick
couplers. If using this technique, the motor free-wheels (no reel brake is avail-
able).
3. Use a soft sling to bundle the end of the service loop.
4. Attach the bundled end to the steel cable of the floor tugger or loader.
5. Use the hose reel and steel cable tugger to lay out the length the of service loop
that will travel with the top drive.
6. Measure the length of the service loop, starting at the hose or cable ends. Keep the
service loop tidy, and ensure the ends of all hydraulic hoses and cables are as even
with each other as possible.
7. When the correct length has been spooled off the reel, insert the hoses and cable in
the cable/hose saddle capture clamp.

Figure 3-6: Cable/hose saddle clamping location
1 - Cable and hose ends

2 - Hose saddle
When the hose saddle is in place, the hoses to the top drive should reach the rig floor,
and approximately 3 ft of hose should be lying on the floor.
Figure 3-7: Front and end views of saddle, hose, and service loop

Figure 3-8: EMI 400 cable/hose saddle capture clamp configuration
1. Hydraulic return hose

2. Hydraulic pressure hose
3. Cord “T”
4. Cord “A”
5. Phase 1 power cable
8. Ground cable
9. Blower motor power cable
8. Connect the hose saddle to the steel cable of the floor tugger or crane.
Caution: Ensure that all the cables and hoses bend gently and
evenly as they rise up off the ground and go up the derrick. This
ensures that cables are of even length on the rig floor once the
! service loop is in place. The auxiliary and coolant hoses are longer
because they must reach the opposite side of the top drive, how-
ever, they must all make the same even, gentle bend at the ground.
9. Hoist the saddle and hoses into position below the racking platform.
Note: Hoist the saddle slightly higher than its final position.

Figure 3-9: Hoisting the hose saddle
Figure 3-10: Positioning the hose saddle

10. Install the hanging sling for the hose saddle at the racking platform.
Note: Attach the hanging sling to the pad eye with a shackle, or wrap it around a
suitable beam.
11. Use a shackle to attach the hose saddle to the hanging sling.
Note: The hose saddle sling must be strong enough to hold loads of more than
2,000 lb (907.2 kg).
12. Use the steel cable floor tugger or crane to lower the saddle until the weight trans-
fers to the hanging sling.
13. Install a back-up safety sling around the hose saddle.
Caution: This back-up sling is considered critical safety equip-

! ment.
14. Lower the crane or steel cable floor tugger.

15. Attach the crane or steel cable floor tugger to the sling at the free end of the service
loop.
16. Hoist the free end of the service loop to the rig floor and secure it in place until it
can be connected to the top drive and driller’s panel.
TORQUE ARREST SYSTEM
Before Installing the Torque Arrest System

Install a hanging pad eye in the crown before installing the torque arrest system. This pad eye
must be designed and installed to support the hanging weight of the entire torque assembly
(safe working load of 15,000 lb. (6804 kg) plus the recommended safety factor for overhead
equipment).
The pad eye is typically placed 22.5 in (57.15 cm) back from the crown cluster center. It is
easiest to install the pad eye when the mast is down. Discuss installation procedures with a
TESCO representative as part of pre-installation activities.

Danger! Design and installation of the pad eye should

meet or exceed all safety specifications for the
! operating area and operating conditions.
A variety of stabilization devices can be used to hold the torque arrest system in place during
operations. It is easiest to install the stabilization systems before raising the mast.
Torque Arrest System Components

A standard torque arrest system includes the torque beam, T-bar, and the following torque
track sections (typical). The number of torque track sections depends on the free working
height of the mast and is shown on the application drawing supplied with the top drive system:
• one adjustable hanging sling
• one cable clamp mount and cable capture clamp
• one 18.5 ft (5.6 m) reversible, bolted, bottom torque track section
• five 18.5 ft (5.6 m) standard torque track sections
• one 10 ft (3.1 m) torque track section
Obtain additional length by lengthening the top section hanging sling. Purchase additional
torque track sections to accommodate larger masts.
The following two sections of torque track are also included:

• one 1.3 ft (0.4 m) deflector section (bull nose)
Caution: Never subject these sections to torque. Mount them

! below the torque beam only.
The deflector section is always mounted at the bottom. Its tapered design assists in mounting
the torque bushing onto the torque track.
Torque Arrest System Configuration

The following must be determined before configuring the torque track:
• Height of the hanging pad eye for the torque track, measured from the rig floor (A)
• Position (height above rig floor) where the torque beam and T-bar will be mounted (B)
• Length of the hanging assembly for the torque track, including hanging swivel, nut, and
shackles (2.5 ft (0.8 m) minimum to 15 ft (4.6 m) maximum)
Note: Shorter configurations are safer and more practical.
Note: Correct calculations will help ensure that the torque bushing will not come off
of the torque tube when the blocks are fully hoisted to the crown.
• The location of any upper strongback that may interfere with the vertical hanging of the
torque track
Note: If the torque track is to remain in the mast during rig moves, match the torque
track connections to the mast connections wherever possible.

Figure 3-11: Torque arrest system configuration
How to Determine the Torque Track Configuration (where an application drawing is not supplied)
Sketch and calculate the following on paper before connecting sections of torque track.
1. Place the bottom of the deflector section 7 to 8 ft (2.1 to 2.4 m) above the drill floor (C).
2. Place the bottom bolted section of torque track above the deflector section.
Note: Ensure that a suitable strongback for mounting the torque beam and T-bar
is available somewhere along the length of the bolted section of torque track.
Remember that the bolted section is reversible.
3. Stack the track sections (18.5, 5, and 10 ft sections) until they are 5 to 15 ft (1.5 to 4.6 m)
from the pad eye.
4. Determine the length of hanging assembly required.
Note: Ensure that the length of hanging assembly is incorporated into the calcula-
tion.
5. Calculate the height of the torque bushing to ensure that it will not come off the
top end of the torque track when it is in the uppermost position.
Sample Calculation
If the mast height is 102 ft (31.1 m):

1. 102 ft less 7 ft (height above the rig floor for the deflector section) = 95 ft (29.0 m)
2. 95 ft less 2.5 ft (minimum hang sling length) = 92.5 ft (28.2 m)
3. 92.5 ft divided by 18.5 = five full length tubes; this does not include the deflector
section.
Torque beam desired height = 11 ft (3.4 m)

The rig up would be as follows:
Track Part Qty Length (ft) Total Length (ft)

Hanging Track 1 18.5 18.5
Standard Tracks 2 37 (18.5 x 2) 55.5
10 ft section 1 10 65.5
5 ft section 1 5 70.5
Bolted* section 1 18.5 89
Deflector 1 1.3 90.3
Hanging Assembly 1 Set to 3 feet 90.3
* The bolted track section would be run with the bolt section down, below the
standard track sections and 10 ft (3 m) and 5 ft (1.5 m) sections. The deflector
track section would be mounted below the bolted section.
How to Install the Torque Arrest System

Use this procedure to install the torque arrest track system. Refer to Figure 3-13 on page 27.
1. Ensure the hanging pad-eye for the torque track is installed in the crown.
Note: Normal placement for a standard track is 22.5 in (0.57 m) back from the
crown cluster center.
2. Assemble the torque beam, T-bar, and T-bar clamp.
Warning! Assemble the above with the T-bar at mid-length.
This balances the assembly during lifting. The
! assembly should not be fully torqued, but it
should hold the T-bar securely in place.
3. Use the steel cable tugger to move the torque beam onto the drill floor and up to
the lowest, most practical strongback beam.
Note: Install the torque beam low in the mast. Attach it to a large beam anywhere
between 10 ft (3 m) and 16 ft (4.9 m) above the drill floor. If installing it any
higher, additional stabilization might be required below the torque beam. TESCO
can supply additional stabilization, if required.
4. Use four clamps to mount the torque beam to the selected supporting beam.
Note: On a permanent installation, weld the anchor beam clamp onto the mast.
5. Slide the T-bar to the most rearward position.
Note: Always mount the T-bar on top of the torque beam. If possible, mount it so
the T-bar sits approximately 1/8 inch above the T-bar clamp so that the torque
hanging assembly carries the total weight of the torque track.
6. Use the calculation method described in “How to Determine the Torque Track
Configuration (where an application drawing is not supplied)” on page 22 to cal-
culate the required torque track section configuration.
Note: When the torque track is suspended, the bottom of the deflector section
should be 7 to 8 ft (2.1 to 2.4m) off the floor.
7. Set and secure the calculated pinned insert location (if used), or adjust the hanging
assembly to the appropriate length.
Note: Use a soft sling to hold the sling in place so that it will be easily accessible
when the torque track is lifted to the hanging pad eye.

8. Use the steel cable rig floor tuggers to hoist the first track section up to the floor.
Note: On most rigs, two full-length sections of torque track can be assembled on
the ground before being lifted to the rig floor. If the rig is very small, the torque
track lengths should be brought to the rig floor one at a time.\
Note: As the first section is installed, make up additional sections on the ground.
9. Lower the first track section through the rotary table or mousehole.
Note: If the rotary table is too small to permit the torque track to pass through, use
an alternate location on the rig floor. If no alternate location exists, mate the sec-
tions above the rig floor.
10. Lower the blocks and install two handling slings on the torque track.
Note: Thread the slings through the block becket and attach them to the top track
using the handling assembly for the torque track.
Caution: Attach the top section of track such that the top portion of
track extends above the blocks. This allows the hanging assembly
! to reach the pad eye without crowning out the blocks.
11. Place a ratchet strap around the top of the blocks and thread it around the torque track.
12. Use the ratchet strap to pull the blocks and track together.
Note: This immobilizes the track section and keeps it hanging vertically as it trav-
els up the mast.
13. Hoist the blocks until they support the weight of the torque track.
14. Remove the steel cable floor tugger.
15. Hoist the blocks until the bottom of the first section is 8 ft (2.4 m) above the drill floor.
16. Connect the steel cable floor tugger to the second section of torque track and hoist
it to the rig floor.
17. Lower the second section of track through the rotary table or into the mousehole
until it reaches the appropriate level for connecting to the upper section (which is
currently suspended from the blocks).
18. Install all the studs and lower nuts before connecting the sections.
Note: The studs cannot be installed after the track sections are connected.
19. Lower the blocks and upper section of track and connect the two sections. Bolt the
sections together, ensuring a flush connection.
Note: Coat all bolts with an anti-seize compound before installation.
20. At the two lower-most sections of the torque track, including the deflector,
install connector guards as per guidelines in safety bulletin SB017. Torque
the bolts 3/4 in-10UNC Grade 8 Spiralock fasteners between 388 to 423 ft-lb.
Working from the middle outwards, use a criss-cross tightening pattern to
ensure even clamping, as shown in Figure 3-12.

Figure 3-12: Fastener tightening for torque track flange
21. Repeat steps 16.–20. until all sections are connected and supported by the blocks.
Note: The last section that is installed is typically composed of the reversible
bolted section, the deflector section and, if required, the two-foot track section.
22. Use a ratchet strap to secure the extend arms of the torque bushing in place.
23. Attach a steel cable tugger to the torque bushing and move the bushing onto the
drill floor.
Note: Ensure that the extend frame is down.
24. Position the torque bushing over hole center.
25. Use the blocks to lower the assembled torque track and stab it through the torque
bushing.
26. When the torque bushing is in position, pin it in place.
Note: Ensure that the top drive pin ends are at least 8 ft (2.4 m) above the drill
floor. If the torque bushing is too tight to move freely along the torque track,
adjust the torque bushing by adding additional shim packs. To ensure a proper fit,
periodically check the bushing during the first few days of operation.
27. After the torque bushing is installed, raise the blocks to the crown.
28. Connect the hanging assembly of the torque track to the pad eye.
29. When the hanging assembly is connected to the pad eye, lower the blocks until the
weight of the track is transferred to the pad eye.
Note: Do not remove the handling assembly yet. Use the blocks to raise and lower
the torque track while making the fine adjustments required to connect the T-bar
to the bolted section.
30. Connect the T-bar to the bolted section of the torque track.
Caution: When connecting the bolted section of the torque track,

! suspend the full weight of the torque track from the pad eye.

Note: If the T-bar and bolted sections are not vertically aligned, then use the
blocks to hoist the track. While the track weight is suspended from the blocks,
adjust the hanging swivel as required. Up to 2 in (5.1 cm) of adjustment is avail-
able in the hanging assembly and the lock nut.
31. When all T-bar fastening bolts are tight, move the T-bar to the correct position in
the T-bar seat and tighten the clamp to hold it in position.
Note: Hang the center of the torque track vertically, 22.5 in (0.57 m) back from
the hole center.
32. Tighten the lock nut on the hanging assembly.
33. Remove the handling assembly at the crown and lower the blocks.
34. Install stabilization systems.
Note: These are most easily installed when the mast is down, but can also be
installed during rig-up.
35. Attach the stabilization devices to the torque track as shown in the following illus-
trations.

Figure 3-13: Torque arrest system - permanent installation
1 Torque track 7 Extend arms

2 3-way stabilizer 8 T-Bar
3 “F” clamp 9 T-Bar bolts
4 Nuts, washers, and Redi-rod 10 Torque anchor beam
5 Extend frame 11 Torque track (bolted section)
6 Torque bushing 12 Torque anchor beam clamps
If the rig set-up requires a customized stabilization installation, contact TESCO.

TOP DRIVE
How to Install the EMI400 Top Drive
Caution: Before moving the top drive onto the rig floor, ensure the
swivel yoke link with integral counter-balance is installed in the
! top drive and is securely supported by the top drive travel stand.
Caution: Always attach the hoisting line to the top drive travel
stand and not to any part of the top drive when the top drive is
! installed in the travel stand.
1. Using blocks or a crane, move the top drive to the rig floor.
Note: If using the block, attach a hold-back line from the travel stand of the top
drive to a loader or steel cable tugger. Use the line to prevent the top drive from
swinging when it is lifted off the rig floor.
2. Position the top drive over the hole center.
3. Lower the blocks and remove the lifting sling.
4. Lower the blocks further and install the top drive yoke into the block hook or
becket.
5. Raise the blocks to support weight of the top drive.
! Caution: Do not lift the top drive off the floor.
6. Remove the pins on the travel stand of the top drive (three or four in total, depend-
ing on the unit type).
Caution: Ensure the link locks are set so that the top drive will not
! tilt forward. See Figure 3-14.

Figure 3-14: Link locks in locked and unlocked position
Link locks in locked position Link locks in unlocked position
7. Lift the top drive until it is clear of the travel stand.

8. Use the steel cable floor tugger to remove the travel stand from the rig floor.
9. Apply a thin film of an anti-seize grease to all pins.
10. Use the blocks to position the top drive so that it can be joined to the extend frame.
Note: Align the ears on the top drive with the extend frame and extend arms and
pin them in place.
11. Remove the pin that is holding the torque bushing in place on the torque track.
Note: The weight of the top drive and torque bushing are now suspended from the
blocks.
12. Remove the link locks so that the links can swivel freely.
13. Lower the top drive to the rig floor.
14. Check if the top drive hangs vertical. If not, refer to the “Extend Arm Adjustment
Procedure” on page 31.
15. Reposition the T-bar so the top drive sits over the hole center, and secure it in
place (if required).
16. Tighten the T-bar connection to secure it in place.
17. Locate the service loop. It should have been installed before this point. If the ser-
vice loop has not been installed, see “How to Install the Service Loop: Option 1”
on page 13.

18. Connect the following hoses and cables for the service loop to the top drive:
• supply and return hoses for the auxiliary hydraulic system
• one sensor cable
• one robotics cable
• one blower motor and heater cable
• one ground cable
• 3 IC #313 cables
Figure 3-15: EMI Top Drive capture clamp
1. Blower Motor Power

2. Ground
3. Power Phase 3
4. Power Phase 2
5. Power Phase 1
6. Cord “A” (robotics cable)
7. Cord “T” (sensor cable)
8. Hydraulic Pressure
9. Hydraulic Return
19. When all service loop hoses and cable are attached, check the loop position.
• The loop should be off the floor.
• There should not be any snagging/interference.
20. Re-check all hose connections.
21. Ensure that all required valves are open.
22. When the top drive and driller’s panel are connected, continue with additional 
set-up procedures, or begin rig commissioning.
Note: The counter-balance cushion height can be set after all support systems are
running. The cushion height must be set before any drilling operations start. See
“How to Set the Counter-Balance Cushion Height” on page 32.

Extend Arm Adjustment Procedure

The aim of this procedure is to ensure that the top drive hangs vertical and is aligned with the
hole center. Firstly, adjust the extend arms to ensure the top drive is vertical. Secondly, adjust
the torque track to align the top drive with the hole center.
1. Start with the extend frame retracted in and a joint in the rotary table.
2. Move the grabber box up to the point where the bottom end of the saver sub is
protruding through the grabber box.
3. Lower the top drive so that it is just above the joint in the rotary table
(2 to 6 in (5.1 to 15.2 cm)).
4. Place a level on the top drive upper grabber leg to determine how the extend arms
(extend or retract) will have to be adjusted. The top drive should hang vertically;
if adjustment is required, loosen the jam nuts on the extend arm clevises.
5. Remove the upper extend arm pins and unbolt the split flanges in the extend arms.
Warning! Use a cat line to support the top drive so it does

not tilt forward and to enable easy access and
! adjustment.
6. Adjust the arms appropriately by adding or removing shims. This is a trial and
error process that requires guesswork. Ensure the extend arms are equal length by
ensuring the same amount of shims are installed in both extend arms.
7. Tighten the split flange bolts and re-pin the extend arms to the torque bushing.
8. Visually inspect the level. If satisfactory, as judged by the level, continue to the
next step. If the top drive is not satisfactorily level, repeat steps 4. through 8. until
the top drive is vertical (this is a trial and error process and may take 3 to 4 adjust-
ments before the top drive is vertical).
9. Torque the jam nuts appropriately (2,300 ft·lb (311 daN·m) dry, 1,725 ft·lb
(233 daN·m) lubed) with a wrench and ensure the retaining cap screws are
installed on the lower extend arm pins.
10. Visually inspect the alignment of the saver sub with the joint in the rotary table. If
they are not aligned, adjust the torque track by adjusting the T-bar in the T-bar
clamp.
Note: The torque track stabilizers must be adjusted accordingly to ensure the
torque track hangs parallel to hole center.

COUNTER-BALANCE SYSTEM
Figure 3-16: Counter-balance system interface
1. Accumulators: 
N2-Nitrogen and Oil
2. Counter-balance cylinder
3. Needle Valve
4. Auxiliary system quick-coupler
How to Set the Counter-Balance Cushion Height

The following conditions must exist before the following portion of the counter-balance
installation can be completed.
• The top drive must be installed.
• The hydraulic circuit must be connected.
• The driller’s panel must be operational.
• The top drive must be positioned at the racking platform.
1. Connect the hose quick-coupler for the elevator to the charge fitting for the
counter-balance system.
2. Shut off the auxiliary pump.
3. Set the ELEVATOR switch (at the driller’s panel) to ‘CLOSE’.
4. Open the needle valve on the counter-balance manifold.
Note: This relieves all pressure on the counter-balance system.
5. Check the nitrogen pressure, and adjust if required.
Note: The nitrogen pressure must be 1,250 psi (8,618 kPa).
6. Ensure the counter-balance relief valve is set at 2,000 psi (13,790 kPa).
7. Close the needle valve on the counter-balance manifold.
8. Start the auxiliary pump.

9. Set the ELEVATOR switch (driller’s panel) to ‘OPEN’, and push and hold the
ELEVATOR SAFETY–OPEN button.
Note: This will send 1,500 psi (10,342 kPa) hydraulic pressure to the needle valve
on the counter-balance manifold.
10. Slowly open the needle valve and allow the hydraulic oil to charge the 
counter-balance system.
11. Monitor the counter-balance cushion by watching the gap that develops between
the swivel bail and the block hook.
12. Continue to charge the system until the gap is 1.5 to 2 in (3.8 to 5.1 cm).
13. Close the needle valve.
Note: This will allow the oil pressure in the auxiliary system to decrease.
15. Set the ELEVATOR switch to ‘OPEN’, then to ‘CLOSE’. This will relieve any
pressure in the system.
16. Remove the elevator hydraulic hose from the counter-balance manifold.
Caution: If disconnecting a quick coupler while there is pressure in

! the system, it will be extremely difficult to reconnect the coupler.

Figure 3-17: EMI counter-balance cushion height; yoke and split block interface

DRILLER'S PANEL
How to Install the Driller’s Panel

The location selected for the driller’s panel should be as follows:
• within reach of the driller
• where there is an unobstructed view of the rig floor
• in a safe position
The bottom of the driller’s panel is equipped with a four-bolt mounting plate. Use this to attach
the control panel to a custom-built pedestal or existing framework. Some on-site fabrication of
a mounting site might be required.
1. Locate the position for the driller’s panel.
2. Fabricate a mounting location if required.
3. Drill bolt holes in the mounting location.
Note: A second mounting plate is provided to use as a template.
Caution: To avoid damaging components, avoid mounting the

! driller's panel in a location that is exposed to vibration.
4. Install a 4-twisted-pair control cable from the driller's panel to the power module.
5. Mount the brake handle control box to the brake handle.
6. Connect the brake handle control box to the driller’s panel.
Note: The driller’s panel has three labeled extension cords with military connec-
tors. Use the correct cord (use cord F).

SAFETY AIR INTERLOCKS

For detailed information about safety interlocks, refer to the schematics for the unit and/or
contact a qualified TESCO representative.
How to Install the Drawworks Interlock and Override

The drum clutch interlock stops the air supply to the drum clutch so that the driller cannot
hoist the top drive while the grabber is closed. Use the push button on the brake handle to
override this lockout feature. The drawworks interlock override cannot be installed until the
driller’s panel is in place.
Figure 3-18: Drawworks override installation
1.Supply air 7. Driller’s panel

2.Air/Electric solenoid valve 8. GRABBER switch
3.Air line 9. Elevator button
4.Drum clutch valve 10.Grabber override button
5.Air line 11.Control box for the brake handle
6.Drawworks
1. Shut off the air supply from the compressor to the drum clutch control.
Note: Use an isolator valve if necessary.
2. Disconnect the hose for the drum clutch air supply from the control valve.
3. Connect the air supply hose to an air/electric solenoid valve.
Note: If two air supply hoses are present, connect each hose to an air/electric sole-
noid valve (one for low clutch and one for high clutch).
4. Connect the air supply hose from the air/electric solenoid valve to the drum clutch
air control valve.

5. Connect an electric cable from the air/electric solenoid valve to the extension cord
at the driller’s panel. The cord is labeled “Cord C”.
Note: If two air/electric solenoid valves are required, use a splitter to establish a
connection from both valves to the driller’s panel.
6. Ensure the control box for the brake handle is connected to the driller’s panel.
Mud Pump Interlock

The mud pump air interlock is designed to disallow operation of the mud pump unless the
mudsaver valve is open.
Caution: Before attempting to install this safety interlock, discuss

equipment requirements and operational considerations with a
! qualified TESCO representative.


INSTALLATION GUIDE
CHAPTER 4: SYSTEM INSPECTION AND START UP
INSPECTION-GENERAL NOTES
When the installation procedures are complete, perform a visual inspection of the complete
system.
Caution: Perform visual inspections before applying power to the

! system.
Inspection checklists for the following are included in “Appendix B: Visual Inspection
Checklists”.
• top drive
• power module
• auxiliary hydraulic power unit
• control cables
• power cables
• cable/hose reel
• driller’s panel

CHAPTER 4: SYSTEM INSPECTION AND START UP INSTALLATION GUIDE
WARNINGS
Electrical
If client-supplied power is not 600VAC, 50Hz, discuss necessary system changes with a
qualified TESCO representative.
Danger! Electrical voltages of different potentials are used

throughout the TESCO top drive components
(600VAC, 208VAC, 120VAC, 840VDC, 5–24VDC).
ONLY qualified personnel should install, maintain,
and/or troubleshoot the electrical systems. A
! severe safety hazard exists for personnel not
accustomed to, or familiar with, electrical hazards
and procedures.
Danger! There are high voltage capacitors installed in the

Drive power module. Wait at least five minutes
after disengaging power to the drive before
performing any testing or repairs in the module.
! The capacitors require time to drain their stored
electrical energy.
Supply Power and Grounding
Grounding methodology has always been a challenge because of differing interpretations of

the rules and understanding of intent. On-site conditions such as add-on buildings fed from a
common power source or a separate power source and/or power sources not requiring a neutral
conductor all have specific grounding criteria that must be met. TESCO strives to maintain a
safe “standard” method of grounding so that its implementation becomes familiar to all
personnel installing these systems.
The following is TESCO’s recommended grounding method when a ground fault detection
system is not incorporated into the service supply.
TESCO incorporates a “single point” ground system when we provide the power source to
TESCO loads and/or add-on loads. Furthermore, when an “isolated” system (a power system
that is not conductively connected to the distribution system, as in the case of separate
generator but most commonly a transformer), is incorporated into our system of power supply,
it is intended that all ground paths be connected to the common ground electrode/s.

INSTALLATION GUIDE CHAPTER 4: SYSTEM INSPECTION AND START UP
Figure 4-1: Recommended supply power and grounding
• It is imperative that the grounding methodology

shown be adhered to when using a designated
generator as the main power service supply for
the TESCO top drive system.
• Since the separate generator supplying power to
the TESCO equipment does not incorporate a
ground fault detection system (and whether the
rig employs a ground fault detection system or
not) it is required that the generator system neu-
tral be grounded at one point only via the main
ground bus and ground rods.
• When two or more power systems are
employed, a “common system grounding con-
ductor” shall be installed unless separate
grounding is supplied for each such system, in
which case the grounding for the individual sys-
tems shall be interconnected.
• Therefore, a separate ground cable must be
installed between the rig’s ground grid and the
generator ground grid.
• Due to this “link”, the ground rods at the gener-
ator may be eliminated, but TESCO recom-
mends that they remain.

Other
• Close the main breakers MB2 and MB4 to turn the hydraulic tank heater on. When the
temperature reaches 50ºF (10ºC), the heating circuit will be shut off automatically.
• Ensure that all electrical components are free of frost and condensation before system
start up. Do this by opening all cabinet doors inside the power module and heating the
building to at least 50o F (10C) for eight hours. 208V power is required to operate the
building HVAC unit.
• Install a saver sub in the grabber on the top drive before testing for hydraulic leaks or
operating any robotics function.
Caution: The hydraulic pump cannot be started if the Emergency

Shut Down (E.S.D.) is activated (either of two red buttons: one on
! the driller’s panel and one on the door of the main panel control
system).
• Before starting any pumps, ensure that all appropriate valves on the tanks and pumps are
open.
SYSTEM START UP
After completing all visual inspections, begin the system start up process. This section provides
instructions on how to do the following:
• power up support systems
• power up the drive system
• test the robotics functions and operations of the top drive
Danger! The information presented in this section is a

guide ONLY. It is not intended to replace complete
! training on the use of high voltage equipment.
Note: Refer to the electrical schematics supplied with the unit.
Table of Circuit Breakers and Main Breakers

Refer to the electrical schematics for the unit to confirm breaker details.
CB (Circuit Breakers)
Breaker Type and Number Function
CB1 (inside the power module main panel) Building lights
CB2 (in 120/208V distribution panel) 120V control power
CB3 Power module building receptacle
CB4 24 DC power supply
CB9 Motor heater
CB12/14/16 Power module building HVAC
MB (Main Breakers)
Breaker Type and Number Function
Drive main fusible disconnect Drive system power
MB2 Distribution panel power
MB3 (in 600V distribution panel) Spare
MB4 (in 600V distribution panel) 15kVA 600:208/120V transformer

Support Systems
How to Start the Generator (if supplied)

1. Ensure that all fuel and air connections are secure.
2. Ensure that the following are set to ‘OFF’.
• main service interface breaker
• all main drive breakers in the power module building
• all switches
3. Check all oil and coolant levels. Ensure the generator battery is above 22 volt.
4. Ensure that the following are clear of any obstructions or protective packing mate-
rial:
• radiator
• air intakes
• exhaust
5. Ensure all cabling and controls are in good operating condition (no noticeable
damage).
6. Engage the air starter for one short burst without starting the engine.
Note: This ensures the engine is free to roll over.
7. Set the controls to Start, and start the engine.
8. When the engine is running, check the oil pressure and rpm.
Caution: Ensure the oil pressure and rpm are within normal operat-
! ing parameters.
9. Allow the engine to warm up.

Note: The warm up time required varies depending on the ambient operating tem-
perature.
10. Increase the rpm to the rated speed (1,800 rpm).
11. Engage the disconnect breaker for the main generator.
Note: This applies only if the generator has its own service disconnect breaker
and the system also incorporates a TESCO specified main service disconnect (see
step 13.).
12. Adjust the generator controls for frequency and voltage (600 VAC and 50 Hz).
13. Switch the main service disconnect breaker to ‘ON’ (if applicable). This is the
TESCO specified main service disconnect that feeds the power module building.

Top Drive
Preliminary Checks and ESD Shutdown Test

1. Ensure all breakers in the power module are set to ‘OFF’.
2. Ensure that 600VAC power is present at the main service interface breaker.
3. Verify that the Emergency Shut Down cable is connected.
4. Verify that the Emergency Shut Down (E.S.D.) push button is pulled out (this is
the operational position). This button is located next to the entrance door of the
power module.
5. Switch the main service interface breaker to ‘ON’.
6. Ensure that 600 VAC power is present on the outgoing cables to the power module.
Note: Check this on the terminal lugs in the Interface Breaker cabinet under the
interface breaker.
7. Ensure that the ‘SERVICE BREAKER CLOSED’ indicator light for rig power is
illuminated.
Note: The light is located on the door of the main panel in the power module
building.
8. Push the E.S.D.push button to test the Emergency Shut Down circuit.
! Caution: This should trip the main service interface breaker.
9. Reset the E.S.D. push button and repeat steps 5.through 7.
How to Apply 600 VAC Transformer Power
Use this procedure to provide power for the lighting, receptacles, and controls (120/208V
and 15/24VDC). The top drive start up procedure is the same whether a generator supplied
by TESCO or rig power is used.
1. Ensure that ALL breakers and switches for the power module are set to ‘OFF’.
2. Switch the main breaker MB3 that is feeding the 9 KVA transformer to the ‘ON’
position.
Note: This breaker energizes the transformer that provides power to the power
module lighting, receptacles, and controls. Refer to the electrical schematics for
the unit for more detailed information.
3. Inside the 120/208V distribution panel, switch the following circuit breakers to
the ‘ON’ position:
• Motor controls (turn the heater on only if the temperature is below 32ºF (0ºC)
• 120VAC and 15/24VDC control power
• Lights and receptacles
• HVAC
4. Set the light switch to the ‘ON’ position.
Note: This switch is located on the wall of the power module.
5. Turn the DC power switch to ‘ON’. The white ‘DC POWER AVAILABLE’ light
should illuminate.
Note: The DC power breaker is located inside the door of the main panel in the
power module.
6. Proceed to the following section, “Power Up the Drive System”.

Power Up the Drive System

1. Verify that the E.S.D. on the driller’s panel is not activated.
2. Close the main fusible disconnect on the drive panel to power up the drive system.
3. On the left side of driller’s panel, turn the ENABLE switch to ‘OFF’.
4. Press the RESET button on the left side of driller’s panel to clear any trips and
warning in the drive system.
5. Ensure that the green ‘READY’ light on driller’s panel illuminates.
6. Verify that the ENCODER switch inside the power module main panel is at
‘NORMAL’ position.
7. Proceed to the following section, “How to Check Phase Rotation”.
How to Check Phase Rotation

Use this procedure to ensure that the phase rotation is correct, and that all pumps, fans and
motors turn in the proper direction. Do not use pump motors to check phase rotation.
1. Switch motor starters 2M and 3M to ‘ON’.
2. Make sure all switches on the driller’s panel are set to neutral position.
3. Turn the ENABLE switch to ‘ON’.
4. Set the ‘Set Speed’ and ‘Set Torque’ to zero using the SPEED DECR and
TORQUE DECR switch.
5. Turn the QUILL switch to either ‘REV’ or ‘FWD’ to activate the fans for the
drive system and top drive.
6. Ensure that the top drive is not rotating.
7. Perform a visual check to ensure that the fan for the OEM drive rotates clockwise.
8. Ensure that the blower motor for the top drive rotates counter-clockwise when
viewed from above.
9. Turn the QUILL switch back to neutral position.
10. If the direction of the fan is incorrect, do the following:
a. Shut off the main fusible disconnect and shut off the power at the main
service breaker.
b. At the power module (service supply waterfall), remove the feed cable(s)
from phase A and B.
c. Install the phase A cable(s) into the phase B input(s).
d. Install the phase B cable(s) into the phase A input(s).
e. Retest to verify the fan is rotating in the correct direction (steps 1.to 9.)
f. Retag the cabling to the current (correct) configuration.

Figure 4-2: Change phase rotation
11. Proceed to the following section, “How to Check the Hydraulic System”.
How to Check the Hydraulic System

1. Install a saver sub in the grabber on the top drive.
Caution: Never close the grabber unless there is a saver sub or

tool joint for it to close on. Closing the grabber when it is empty
! severely damages the grabber cylinder.
Caution: Install a saver sub to prevent the piston on the grabber

cylinder from making contact with the gland nut on the grabber
! cylinder body. When this happens, the gland nut is pushed out of
the cylinder body.
2. In the 600V distribution panel, set the starter 3M for the auxiliary pump to ‘ON’.
3. Set the switch on the driller’s panel for the auxiliary pump to ‘ON’.
Note: The green light should illuminate.
4. Check and record the circulating pressure (it should be 400 to 600 psi (2,757 to
4,137 kPa) at normal operating temperature).
5. Inspect the lines for leaks.
7. Check the auxiliary tank level and fill it, if required.
Note: Oil from the top drive hydraulic lines returns to the tank when the system is
idle. This might cause tanks to appear over-full. Check the fluid levels before
starting the system and when the system is running.

How to Test the E.S.D. on the Driller’s Panel
When activated, the E.S.D. on the driller’s panel will trip off the main contactor for the drive
system and turn off the auxiliary hydraulic pump.
1. Set the ENABLE switch on the driller’s panel to the ‘OFF’ position.
2. Verify the main fusible disconnect and the hydraulic pump are set to ‘ON’.
3. Press the E.S.D. button on the driller’s panel.
4. Verify that the main contactor has been tripped off.
5. Verify that the hydraulic pump has been turned off.
6. To reset the E.S.D., pull the button to the ‘UP’ position.
Final Start Up
When all critical systems are started and operating properly, start the top drive.
Before proceeding, confirm that all the following systems are operating correctly:
• cooling fans for drive and the top drive
After confirming that all systems are operating correctly, perform the following steps:
1. Ensure that the Drive Data Manager indicates ‘Drive healthy’ status.
Note: The green HEALTHY indicator illuminates.
2. Check the indicators on the driller’s panel. The following lights should be on:
• Ready
• Module On
• System Temperature
3. At the driller’s panel, set the ENABLE switch to ‘ON’.
4. Check the rotation and torque (at low settings) to confirm proper operation.
How to Reset the Drive

Use the following procedure if the Drive System trips “offline” because an internal protection
system has been activated. This procedure assumes that the system has sustained no damage
and that supply power of 600 VAC is present.
1. Set all switches on the driller’s panel to the neutral position.
2. Turn the ENABLE switch on the driller’s panel to the ‘OFF’ position (disable).
3. Ensure the following:
• The communication between PLC and drive works properly
• There are no loose wires for the encoder
• The fans for the top drive and drive system work properly
• The SYSTEM TEMP light is on and continuously illuminates
4. Check the fault information in Drive Data Manager.

5. Press the RESET button on the driller’s panel to reset faults after the faulty condi-
tions have been removed.
a. Check and record any faults that might be present.
b. If no faults are present, proceed to the next step.
6. Return to the driller’s panel and turn the ENABLE switch to the ‘ON’ position.
The green READY light will illuminate.
7. Continue with regular operations.
8. Continue to determine why the unit tripped offline. Make note of all relevant drill-
ing conditions that existed before the breakers tripped.
Drive Parameters
About Drive Parameters
The following drive parameters (torque and speed settings) can be modified from the
driller’s panel:
• Drill Forward – Torque and Speed
• Drill Reverse – Torque and Speed
• Connect Forward – Torque and Speed
• Connect Reverse – Torque and Speed
• Breakout – Speed
Set the drive parameters (torque and speed) to minimize the possibility of injury to personnel
and damage to drilling equipment. For example, limit the torque setting for Drill–Forward
mode to prevent the drill string twisting off while drilling. Set the speed and torque for
Connect mode to promote proper make up of tool joints and to prevent damage to threads and
seal faces caused by over-torquing.
Limit the rotation speed and torque of the pipe handler to ensure the pipe handler rotates at a
safe speed and stops rotating when it achieves the pre-set torque.
The drive system will not surpass the programmed torque and speed settings during operation.
To change the settings, use the following procedure. The steps required to set or adjust a
setting are the same for all functions.
How to Modify Drive Parameters

1. At the driller’s panel, turn 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. Set the MODE switch to ‘DRILL’.
2. Set the QUILL switch to ‘FWD’.
3. Use the TORQUE switch to increase or decrease the SET TORQUE
reading on the digital gauge on the driller’s panel.
Drill Forward Set this limit at 2,000 ft·lb (271.2 daN·m) less than the lowest connected
Torque joint torque setting (see Connect–Forward Torque). Consult with the Rig
Manager or Oil Company Representative to determine the proper setting.
If using a downhole mud motor, the torque set limit must be higher than
the maximum output of the mud motor. Refer to ‘Mud Motors in Slide
Drilling Operations’ within the Operations Guide for the unit.
1. Set the MODE switch to ‘DRILL’.
2. Set the QUILL switch to ‘REV’.
Drill Reverse 3. Use the SPEED switch to increase or decrease the SET SPEED reading on
Speed and the digital gauge on the driller’s panel. TESCO recommends 10 rpm or less.
Torque 4. Use the TORQUE switch to increase or decrease the SET TORQUE
reading on the digital gauge on the driller’s panel. TESCO recommends
8,000 ft·lb (1,085 daN·m) or less, depending on drill string configuration.
1. Set the MODE switch to ‘CONN’.
Connect
3. Use the SPEED switch to increase or decrease the SET SPEED reading on
Forward
the digital gauge on the driller’s panel. TESCO recommends 15 rpm or less.
Speed and
Torque
reading on the digital gauge on the driller’s panel. Use the torque require-
ments for the drill string connections to determine this setting.
Connect
3. Use the SPEED switch to increase or decrease the SET SPEED reading on
Reverse
the digital gauge on the driller’s panel. TESCO recommends 15 rpm or less.
Speed and
Torque
8,000 ft·lb (1,085 daN·m) or less.
Pipe Handler 3. Push and hold the PIPE HANDLER ROTATE button.
Forward 4. Use the SPEED switch to increase or decrease the SET SPEED reading
Speed and on the digital gauge on the driller’s panel. TESCO recommends 5 rpm.
5,000 ft·lb (679 daN·m) or less.
Pipe Handler 3. Push and hold the PIPE HANDLER ROTATE button.
Reverse 4. Use the SPEED switch to increase or decrease the SET SPEED reading
Speed and on the digital gauge on the driller’s panel. TESCO recommends 5 rpm.
5,000 ft·lb (679 daN·m) or less.
5. Release the DRIVE SET keyed switch.

6. Remove the key.
7. Set the ENABLE switch to ‘ON’.


INSTALLATION GUIDE
CHAPTER 5: RIG OUT PROCEDURE

The top drive rig-out (removal) procedure is divided into the following separate activities:
• remove the top drive
• remove the torque arrest system
• remove the service loop
• prepare the power module and auxiliary hydraulic power unit.
When the rig-out procedures are complete, store all equipment in shipping containers. For more
information on long term storage, please consult the Maintenance Guide for the unit type.
REMOVE THE TOP DRIVE

1. Move the top drive travel stand to the rig floor.
2. Locate a pin position on the torque track and pin the torque bushing to the torque track.
Note: This pin connection holds the torque bushing in place when it is discon-
nected from the top drive.
3. Set the swivel link locks.
Figure 5-1: Setting the swivel link locks
Link locks in locked Link locks in

position unlocked position
4. Disconnect the top drive from the extend frame.

CHAPTER 5: RIG OUT PROCEDURE INSTALLATION GUIDE
5. Hoist the top drive.

6. Position the top drive travel stand over the hole center.
7. Lower the top drive into the travel stand and pin it in place.
8. Disconnect all service loop items from the top drive.
9. Remove the top drive from the rig floor.
Caution: Connect the hoisting cable to the top drive travel stand
! and not to any part of the top drive or yoke.
REMOVE THE TORQUE ARREST SYSTEM

This procedure assumes that the top drive is disconnected from the swivel and removed from
the rig floor.
Note: If there are plans to reinstall the top drive into the existing mast, leave the torque
track stabilization equipment in place. If there are no plans to reinstall the top drive,
remove the stabilization equipment when lowering the mast.
1. Connect the steel cable tugger to the torque bushing and extend frame. Take the
weight of the load with the steel cable tugger.
Note: The bushing will be pinned near the bottom of the torque track.
2. Remove the pin and carefully lower the torque bushing off the bottom of the
torque track and onto the rig floor.
3. Use the steel cable tugger to move the bushing out the V-door.
4. Run two torque track handling slings through the becket of the blocks.
5. Attach the pick-up pin of the torque track to the slings.
6. Raise the blocks to the crown.
7. Connect the torque track to the blocks by placing the pick-up pin of the torque
track through the hole in the torque track. Then, attach the slings to both sides of
the pick-up pin.
8. With the slings and pick-up pin in position, hoist the blocks to transfer the weight
of the torque track from the torque track hanging assembly to the block slings.
9. Unbolt the T-bar from the torque track.
10. Loosen the T-bar clamp.
11. Slide the T-bar to its most rearward position.
Note: This prevents the T-bar from obstructing the torque track during
disassembly.
12. Re-tighten two bolts on the T-bar clamp.
13. Disconnect the hanging assembly from the pad eye in the crown.
14. Use the blocks to lower the torque track through the rotary table until the first
flanged connection is at working height.

INSTALLATION GUIDE CHAPTER 5: RIG OUT PROCEDURE
15. Use a 4-3/4 ton (4.3 metric tonne) shackle through the stabilizer attachment bar
(on the back of the torque track) to attach the steel cable rig tugger to the bottom
section of track. This will hold it in place while it is unbolted.
Caution: If a wellhead is not installed, ensure that the casing bowl

! is covered to prevent objects from falling into the hole.
16. Hoist the remaining track (suspended from the blocks) 10-15 ft above the rig floor.
17. Use the steel cable rig tugger (already attached) to lift the bottom section of track
out of the rotary table and off the rig floor.
18. Repeat steps 14.-17. for each section of torque track.
19. Remove the handling slings from the blocks and hoist the blocks clear of the rig
floor.
20. Connect the steel cable tugger line to the T-bar/torque anchor beam.
21. Loosen and remove the anchor beam clamps.
22. Use the steel cable tugger to lower the T-bar/torque anchor beam and move it off
the rig floor.
REMOVE THE SERVICE LOOP

Use the following procedure if the service loop is not strung through the mast and hangs off
from a cable/hose saddle.
1. Position the cable storage reel in a convenient location for spooling.
Note: There should be straight-line access from the reel to the cable/hose saddle.
2. Disconnect all service cables and hoses from the plug board on the power unit and
auxiliary hydraulic power unit.
3. Move the disconnected ends to the storage reel.
Note: Clean and protect cable and hose ends.
4. Attach the steel cable tugger line to the cable/hose saddle.
5. Disconnect the cable/hose saddle from the mast.
6. Connect the hydraulic control lines from the auxiliary hydraulic power unit to the
storage reel.
7. Begin to spool the cables and hoses onto the reel.
8. When all the slack is taken up, lower the cable/hose saddle while continuing
to spool.
9. Stop spooling when the cable/hose saddle reaches the storage reel.
10. Mark the location of the cable/hose saddle on the hoses with tape or paint.
11. Remove the cable/hose saddle from the service loop.
12. Spool the remainder of the service loop onto the storage reel.

Use the following procedure if the service loop is strung through the mast and over a roller
saddle.
1. Use a soft sling to bundle all service loop cables and hoses that are at the rig floor.
2. Connect the sling to the steel cable floor tugger.
3. Remove any service loop stabilization slings that are currently installed.
4. Position the cable storage reel in a convenient location for spooling.
Note: Position the cable reel so that there is straight-line access from the reel to
the cable roller saddle.
5. Connect the hydraulic control lines from the auxiliary hydraulic power unit to the
cable storage reel.
6. Disconnect all service loop cables and hoses from the plugboards on the power
module and auxiliary hydraulic power unit.
7. Move the ends of the disconnected cables and hoses to the storage reel.
Note: Clean and protect all cable and hose ends.
Caution: Use the cable storage reel for all main power cables,
! hydraulic hoses, and multi-conductor cables.
8. Hoist the steel cable floor tugger to take the weight from the cable capture
clamp on the roller saddle.
Figure 5-2: Spooling the service loop 1

INSTALLATION GUIDE CHAPTER 5: RIG OUT PROCEDURE
9. Remove the slings that hold the capture clamp in place in the mast.
Note: Do not disassemble or loosen the capture clamp. Lower it to the ground
with the remainder of the service loop.
10. Place the ends of the service loop cables and hoses on the reel.
11. Begin to spool the hoses and cables at the reel.
12. When all slack is taken up, lower the steel cable floor tugger while continuing to
spool.
13. When the capture clamp reaches the reel, stop spooling and lowering.
14. Use tape or paint to mark all cables to indicate the position of the capture clamp.
Note: When the top drive is reinstalled, use these markings to position and con-
nect the capture clamp before drawing the service loop up into the mast.
15. Remove the capture clamp.
16. Spool the remainder of the hose onto the storage reel.
Note: The sling arrangement may need to be reconfigured so that all cable can be
spooled onto the reel.
Figure 5-3: Spooling the service loop 2
17. Remove the cable roller saddle from the mast.

18. Disconnect the gauge cable from the driller’s panel and power module.
19. Remove the interlocks from the drawworks and mud pumps (if required).
20. Remove the driller’s panel from the rig floor.
Note: To prevent damage to switches and meters, ensure the panel is wrapped or
boxed prior to storage.

DISCONNECT THE POWER AND AUXILIARY HYDRAULIC

POWER UNIT
1. Lock out the main breaker.
2. Disconnect the power to the power module.
3. Bundle all power cables.
Note: Clean and protect all connectors.
4. Remove the Emergency Shut Down cable from the power module.
5. Remove and manually spool the hydraulic hoses that are connected to the cable
storage reel.
6. Disconnect the auxiliary hydraulic power unit from the power unit.

INSTALLATION GUIDE APPENDIX A: PRE-INSTALLATION CHECKLIST
APPENDIX A: PRE-INSTALLATION CHECKLIST

Before beginning installation procedures, use the following checklist to check for any damage
to equipment that may have occurred during shipment.
Component Description Date Initials

Containers Containers 1, 2, and 3 and 4 (if required)
Top Drive Travel stand
Top drive guard
Pipe Handler
Gearbox
Gearbox oil level
Top Drive cables and hoses
Auxiliary system
(10-Station Manifold and solenoids)
Encoder
Mudsaver valve
Link Tilt cylinders
Power Module Drive Data Manager
Dynamic braking unit and braking resistors
15kVA, 600: 120/208V transformer
HVAC unit
600V distribution panel
120/208V distribution panel
Auxiliary Pump, and sensor wiring
hydraulic unit
Systems fittings and hoses
Auxiliary pump and motor
Filter housings
Pump quick connect fittings
Hydraulic reservoir
Service Loop Roller saddle and capture clamp
Urethane inserts
Hose reel
Hose reel control
Slings, shackles, and safety pins

APPENDIX A: PRE-INSTALLATION CHECKLIST INSTALLATION GUIDE
Component Description Date Initials

Hoses Hose reel
1×225 ft auxiliary return hose
1×225 ft auxiliary supply hose
2×35 ft auxiliary jumper hoses
Main Power 1×4/0 ground cable, 225 ft long
Cables
1×225 ft #14.7C motor blower cable
3×313 MCM 225 ft cables
Other Cables 1×225 ft 37-conductor robotics control cable
1×225 ft motor sensor feedback cable
1×150 ft 4TWP driller’s panel instrumentation
Cable B
1×150 ft 18/4 emergency shutdown cable
(if required)
2×8 ft 18/4 mud pump interlock cable
2×8 ft 18/4 drawworks interlock cable
2×8 ft 18/4 splitter box cable
1×29 ft #14.7C pump skid power cable
1×29 ft #18.4 pump skid sensor cable
Driller’s Panel Instrumentation
Switches
Connectors
Internal wiring
Auxiliary Hoses 1×225 ft auxiliary return hose (1-1/4 in)
1×225 ft auxiliary supply hose (3/4 in)
2×10 ft auxiliary jumper hoses (1 in - R2)
Torque Arrest Extend frame
System
Torque bushing
Torque beam and T-bar
Torque track
Hanging sling assembly
Accessories Main service interface breaker
(if purchased)
Crimping tool (if required)
Counter-balance system
Elevators
Elevator inserts
Elevator links
Saver subs

INSTALLATION GUIDE
APPENDIX B: VISUAL INSPECTION CHECKLISTS

Use this checklist to ensure that all relevant installation activities are complete and to inspect
for damage to equipment that may have occurred during the installation process.
Note: This checklist should be used after installation procedures are complete but before
starting the system.
Danger! Before proceeding with the checklists ensure that

! all power to the top drive is shut off and locked out.
Danger! Only qualified electrical personnel should check

electrical equipment.
!
IMPORTANT: This equipment was filled at the factory with TESCO
ULTREX™ brand fluids and greases. To ensure maximum performance
and to avoid cross-contamination, we strongly recommend the contin-
ued usage of TESCO ULTREX lubricants, unless otherwise specified.
Table B-1: Top drive inspection list

Component Activity Steps
Sensors and Inspect the sensors and wiring. 1. Open the motor junction box. Open the sensor/
Wiring robotics panel.
2. Inspect the wiring to the following:
• Encoder
• RTDs
• Pressure switch
Note: Look for damage to wiring and ensure
all the connections are tight.
3. Replace the desiccant pack if necessary.
Motor Cabling Check the motor cabling. 1. Remove the access covers on the junction boxes.
2. Check wiring to the drive motor.
3. Check for cable discoloration (as a result of
heat damage).
4. Ensure that motor lugs and other terminations
are tight.
5. Ensure the junction box gaskets are in good
condition and will seal properly.
6. Restore the access covers to their original
position on the junction box.

APPENDIX B: VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE
Table B-1: Top drive inspection list

Robotics Inspect the listed components. 1. 10-Station manifold
2. Solenoids and wiring
3. Auxiliary hydraulic hosing
4. 37C control cable
5. All fittings (for tightness and correct engagement)
Gearbox Inspect the listed items. 1. Check for leaks.
2. Check the oil level.
Top Drive Hoses Check the auxiliary hydraulic 1. Inspect all hoses including service loop.
hoses and gearbox lubrication 2. Tighten the fittings as necessary.
hoses.
Lubrication Ensure lubrication is adequate. 1. Grease all lubrication points.
2. Check and verify the slew drive is properly greased.
IMPORTANT: This equipment was filled at the
factory with TESCO ULTREX brand fluids and
greases. To ensure maximum performance and
to avoid cross-contamination, we strongly
recommend the continued usage of TESCO
ULTREX lubricants, unless otherwise specified.
Quill Inspect the listed components. 1. Quill
2. Load nut and locking pins
3. Mudsaver
4. Load collar stops (set)
5. Saver sub
6. Locking clamps
Grabber Inspect the listed components. 1. The safety chain is installed.
2. All drilled bolts are safety wired.
3. Hoses are installed and routed correctly.
Extend Frame Inspect all pins and bolts. 1. Check for missing fasteners.
Mount 2. Check the ears on the extend frame for damage.
Table B-2: Power module inspection list

Wiring Check all power module wiring. 1. Check connections for damage or decay.
Tighten if required.
Note: Ensure that connections are properly
torqued.
2. Check the AC feed connections.
3. Check the switch and breaker wiring.
Breakers Check that the trip voltage is set 1. Verify the breaker UV trip voltage.
correctly for all main breakers. 2. Verify the breaker current trip level.
Plugboard Check all connections. Check the motor leads from the drive to the
(Waterfall) plugboard.

INSTALLATION GUIDE APPENDIX B: VISUAL INSPECTION CHECKLISTS
Table B-3: Auxiliary hydraulic power unit inspection list

Wiring Systems Check all electrical wiring to the Check the following cord ends for condition and
Auxiliary Hydraulic Power Unit cleanliness:
• power cables
Fluid Systems Check hydraulic systems 1. Check the following for condition, cleanliness,
and tightness:
• auxiliary hydraulics system fittings
2. Ensure tank drain valve is closed.
3. Check hydraulic fluid level in reservoir.
Mechanical Check the mechanical Check for proper rotation of the pump motor.
components of the module
Valves Inspect Ensure all valves are set to the correct position.
Return Filters Inspect Ensure all filters are in place.
Table B-4: Cable reel/service loop inspection list

Reel Lock Inspect Ensure the reel lock is locked into position.
Service Loop Inspect Ensure all wear points are protected and secure.
Protection
Service Loop Inspect cables and hoses. Inspect cables and hoses for the following:
• cuts
• abrasions
• signs of stretching
Service Loop Inspect connectors and fittings. 1. Inspect connectors for damage to the pins.
Terminations 2. Ensure that all pin connectors are correctly
seated.
3. Check the threads on all brass fittings.
4. Ensure that all connectors are clean and free of
moisture.
Table B-5: Driller’s panel

Driller’s Panel Inspect panel and connectors. 1. Inspect all switches.
2. Ensure all switches are in the neutral position.
3. Inspect all instrumentation.
4. Inspect all connectors.
5. Ensure that all the cords are operational.

APPENDIX B: VISUAL INSPECTION CHECKLISTS INSTALLATION GUIDE

INSTALLATION GUIDE APPENDIX C: SLING LOAD RATINGS
APPENDIX C: SLING LOAD RATINGS

Rated capacities are based on a design factor of 5/1.
Danger! Do not exceed rated capacities.

!
Capacity Ratings
Table C-1: Capacity Ratings
Safety Factor = 5
Sling Single Single Choker Single Basket
2-leg Bridle Hitch
Diameter (in) Vertical Hitch Hitch Hitch
Tons Tons 60° 45° 30°

Inches Tons
See Figure C-2 See Figure C-1 Tons Tons Tons
3/8 1.4 1.1 2.9 2.5 2.0 1.4
7/16 1.9 1.4 3.9 3.4 2.7 1.9
1/2 2.5 1.9 5.1 4.4 3.6 2.5
9/16 3.2 2.4 6.4 5.5 4.5 3.2
5/8 3.9 2.9 7.8 6.8 5.5 3.9
3/4 5.6 4.1 11.2 9.7 7.9 5.6
7/8 7.6 5.6 15.2 13.0 11.0 7.6
1 9.8 7.2 20.0 17.0 14.0 9.8
1-1/8 12.0 9.1 24.0 21.0 17.0 12.0
1-1/4 15.0 11.0 30.0 26.0 21.0 15.0
1-3/8 18.0 13.0 36.0 31.0 25.0 18.0
1-1/2 21.0 16.0 42.0 37.0 30.0 21.0
Note: The values in this table are based on TESCO standard slings (XIPS 6 x 19 (IWRC) wire rope up
to 1 inch diameter and 6 x 37 (IWRC) for 1-1/8 to 1-1/2 inch diameters).

APPENDIX C: SLING LOAD RATINGS INSTALLATION GUIDE
Basket Hitch Capacity

A basket hitch has twice the capacity of a single leg only if D/d ratio is 25/1 and the legs are
vertical.
Figure C-1: Basket hitch capacity
Choker Capacity
The values in Table C-1 are valid only if the angle of the choker hitch is 120° or greater.
Figure C-2: Choker capacity

INSTALLATION GUIDE
APPENDIX D: TORQUE STANDARDS FOR

HIGH STRENGTH FASTENERS
The following information originated from the Standards document STD0015.
PURPOSE
This standard should be used as a guideline for all fasteners used in production where the
torque values are not specified on the engineering documentation and drawings. All TESCO
standards on fasteners should be adhered to, as non-conformance can lead to the following:
• low quality products
• rework cost
• warranty claims
• late delivery
• customer dissatisfaction
• lower production
STANDARDS
1. All capscrews, bolts and nuts have to be Grade 8 or equivalent unless noted other-
wise (U.N.O.).
2. Fasteners must be torqued in accordance with Table D-1, Table D-2, and Table D-
4 U.N.O. Torques should be applied smoothly and with a calibrated wrench.
3. Multiple fastener arrays must be made up evenly using an appropriate torque
sequence to minimize distortion. Fasteners shall be tightened using intermediate
torque settings of 40% and 75% of values in the tables. All fasteners must be
made up snug prior to starting the tightening sequence.
4. Fastener torques for bolting dissimilar materials must be based on the torque
requirements for the lower strength material U.N.O.
5. Fasteners and holes should be free of burrs or damage. Damaged threads must be
repaired using the appropriate tooling to ensure a free and smooth assembly.
6. When thread locking compound is used, holes and fasteners should be cleaned
(free of oil or grease) and the compound should be applied in conformance with
manufacturer’s recommendations.
7. Allowable bolt tension and torque based on bolt thread engagement must be in
accordance with Table D-5 U.N.O.
8. Special fasteners must be installed and torqued in accordance with Table D-2.

APPENDIX D: TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS INSTALLATION GUIDE
9. When threadlock is used, fasteners must be torqued in accordance with Table D-1,
Table D-2 and Table D-4, using the ‘Lubricated’ Torque data U.N.O.
10. For torque values for B7 studs with 2H nuts, see Table D-4.
11. Lubricated fasteners must have oil or thread locking compound applied to the
threads only.
12. Where metals with strongly varying electromotive properties are bolted together,
such as steel and aluminum, thread locking compounds should be applied to limit
the effects of galvanic corrosion.
13. A minimum of two full threads should project above any nut or locknut installed
on a stud or as part of a bolted connection. Additional length is allowed to install
safety pins or cotter pins to prevent fasteners from falling into overhead equip-
ment.
TABLES
Table D-1: Standard torques
Material Aluminum (ft-lb) Mild Steel (ft-lb) High Strength Steel (ft-lb)
Size Dry Lubricated Dry Lubricated Dry Lubricated
1/4 in-20 UNC 9 7 10 8 12 9
5/16 in-18 UNC 16 12 19 15 25 19
3/8 in-16 UNC 33 25 40 30 45 34
7/16 in-14 UNC 47 36 57 43 70 53
1/2 in-13 UNC 86 64 100 75 110 83
9/16 in-12 UNC 118 88 141 106 160 120
5/8 in-11 UNC 163 122 195 146 220 165
3/4 in-10 UNC 278 209 333 250 400 300
7/8 in-9 UNC 436 327 523 393 645 484
1 in-8 UNC 667 500 800 600 970 728
1-1/8 in-7 UNC 950 713 1142 856 1370 1028
1-1/4 in-7 UNC 1317 988 1575 1181 1900 1425
1-1/2 in-6 UNC 2283 1713 2742 2056 3200 2400
Recommended torques are based on bolt tensions of approximately 80% of the yield strength and
a minimum of one bolt diameter class 2B thread engagement in the material, or bolt head bearing
pressures, whichever is less.
Table D-2: Special fastener torques

Minimum Mild Steel (ft-lb) High Strength Steel (ft-lb)
Fastener Description Engagement Dry Lubricated Dry Lubricated
UNBRAKO 5/16 in-18 UNRC 3/8 in 27 20 35 26
Special fasteners shall be used only in critical locations or special applications. Thread engagement is
based on the minimum class 2B tapped threads in mild steel capable of developing bolt tension 80% of
bolt yield. When using hardened steel washers on mild steel, use torque values for high strength steel.

INSTALLATION GUIDE APPENDIX D: TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS
Table D-3: Spiralock fastener torques

Stud Size Dry (ft-lb) Lubricated (ft-lb)
.20 k Factor .15 k Factor
Min. Max. Min. Max.
1/4 in – 20 UNC 13 14 10 11
5/16 in – 18 UNC 27 29 20 22
3/8 in – 16 UNC 48 52 36 39
1/2 in – 13 UNC 117 128 88 96
9/16 in – 12 UNC 169 184 127 138
5/8 in – 11 UNC 233 254 175 191
3/4 in – 10 UNC 414 452 310 339
7/8 in – 9 UNC 667 728 500 546
1 in – 8 UNC 999 1090 750 818
1-1/8 in –7 UNC 1416 1545 1062 1159
Recommended torques are based on bolt tensions of approximately 75% of stud yield strength; SAE
J995 Grade 8; 120 ksi, Proof Load Stress.
Table D-4: B7 Stud torques

Stud Size Dry (ft-lb) Lubricated (ft-lb)
1/2 in-3 UNC 85 64
5/8 in-11 UNC 175 131
3/4 in-10 UNC 300 225
7/8 in-9 UNC 450 338
1 in-8 UNC 680 510
1-1/8 in-7 UNC 880 660
1-1/4 in-7 UNC 1260 945
1-3/8 in-6 UNC 1700 1275
1-1/2 in-8 UN 2300 1725
Recommended torques are based on bolt tensions of
approximately 75% of stud yield strength.

APPENDIX D: TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS INSTALLATION GUIDE
Table D-5: Thread engagements

Material Aluminum Mild Steel High Strength Steel
Engagement* % of Full Torque % of Full Torque % of Full Torque
100% 100% 100% 100%
90% 100% 100% 100%
80% 100% 100% 100%
70% 100% 100% 100%
60% 90% 100% 100%
50% 70% 100% 100%
40% 60% 75% 100%
30% 45% 60% 75%
20% 30% 40% 55%
* Engagement as a percentage of the bolt diameter
Values represent the percentage of torque from Table D-1. Engagement does
not include chamfer or incomplete threads. Engagements of less than one bolt
diameter in tapped holes shall not be used without the engineer’s approval.

INSTALLATION GUIDE
APPENDIX E: HAND SIGNALS FOR BOOM

EQUIPMENT OPERATION
The following chart contains examples of typical signals used by the signalman during boom
equipment operations. If the project requires special signals, agree on what they will be before
beginning operations.
Boom operators will not respond to unclear signals.
Designate one signalman before operation begins. The boom operator accepts signals only
from the designated signalman.
Table E-1: Hand signals for boom operation
This Signal Means This
Use Load Line

Tap fist on head, then use regular signals.
Use Whip Line

Tab elbow with one hand, then use regular
signals.
Raise Load

APPENDIX E: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE
Lower Load
Raise Load Slowly
Lower Load Slowly
Raise Boom
Lower Boom
Raise Boom and Lower Load

Extend thumb upward and flex fingers in and out
as long as load movement is required.

INSTALLATION GUIDE APPENDIX E: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION
Lower Boom and Raise Load

Extend thumb downward and flex fingers in and
out as long as load movement is required.
Swing
Extend arm. Use forefinger to indicate direction of
swing.
Stop
Extend forearm and hand in horizontal position.
Make a slicing motion.
Dog Everything
Emergency Stop
Travel (Both Tracks)

Use both fists to make a circular motion to indicate
the direction of travel (forward or backward).
Travel (One Track)

Raise fist to indicate which side of the track to
lock. Move the other fist in a circular motion to
indicate the direction of travel (forward or
backward)

APPENDIX E: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION INSTALLATION GUIDE
Open Clamshell Bucket
Close Clamshell Bucket
Move Carriage In
Move Carriage Out

INSTALLATION GUIDE INDEX
INDEX
Numerics equipment
600 VAC power, 40 cable roller saddle, 11
600V power, 42 inspecting, 7
600VAC inspecting for damage, 7
applying power, 44 placement procedure, 10
spotting, 9
equipment placement
A
service loop reel, 11
air considerations, 7
ESD See Emergency Shut Down
air intakes, 43
ESD test
air starter, 43
top drive, 44
auxiliary hydraulic power unit, 51
exhaust, 43
disconnecting, 56
auxiliary pump, 46
F
final start up, 47
B
fuel considerations, 6
battery, 43
blocks, 29
G
generator, 43
C
starting, 43
cable roller saddle
optimal placement, 11
placement factors, 12 H
placement procedure, 12 high strength fasteners, torque standards, 65
coolant levels, 43 hose reel, 39
counter balance system hydraulic system
installation, 32 checking, 46
D I
damage inspecting equipment
pre-installation inspection, 7 pre-installation, 7
danger inspection
electrical warnings, 40 general notes, 39
driller's control panel, 42, 55 installation
driller’s panel pre-installation measurement, 3
installation, 35 rig measurement, 3
drive module, 42, 44 installing drawworks interlock and override, 36
drive parameters
connect reverse, 49 M
drill forward torque, 49 main panel control system, 42
modifying, 48 measurement
set connect forward, 49 rig, 3
set drill reverse speed and torque, 49 mud pump interlock, 37
E P
electrical phase rotation
warnings, 40 checking, 45
Emergency Shut Down, 42 power

INDEX INSTALLATION GUIDE
checklist, 5 installation, 20
connection requirements, 3 removing, 51, 52
supplying to equipment, 44 torque track, 23
power module, 51 torque bushing, 29
disconnecting, 56 torque track
placement procedure, 10 mounting, 23
pre-installation transformer power
inspection, 7 applying, 44
main power connection requirements, 3
main power requirements checklist, 5 W
measurement, 3 warnings
before start up, 40
R condensation, 42
radiator, 43 electrical, 40
rig out, 51 other, 42
disconnect auxiliary hydraulic power unit, 56
disconnect power module, 56
rig up
equipment spotting, 9
S
safety air interlocks
installation, 36
saver sub, 42
service loop, 51
installation option 1, 13
installation option 2, 16
removing, 53
service loop reel
optimal placement, 11
speed
set connect forward, 49
set connect reverse, 49
set drill reverse, 49
start up
final phase, 47
support systems
start up, 43
T
top drive
preliminary checks and ESD test, 44
starting, 44
torque
set connect forward, 49
set connect reverse, 49
set drill forward, 49
set drill reverse, 49
torque arrest system
before installing, 20
components, 21
configuration sample calculation, 22
determine the configuration, 21

INSTALLATION GUIDE
ENGINEERING SIGN-OFF
This sign-off sheet indicates that this document has been approved for release by the 
Engineering Department at TESCO.
Document Complete By Signature Date Signed
Edward Chan May 30, 2014
Document Reviewed/Approved Date Signed
ENGIN
AL E
N N M E L AX
ER
KE
OFESSIO
ALBERTA
PR
9 June 2014
Member# M51185
TESCO Corp. permit to practice# P06505

ENGINEERING SIGN-OFF INSTALLATION GUIDE


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Installation Guide

EMI400 Top Drive System

250TON EMI 400HP 50Hz

DOCUMENT NAME: 1270411 REV 3

TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.

© 2014 Tesco Corporation. All rights reserved.

After Market Sales and Service Contact

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

Version Date ECN Description of Changes

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2: PRE-INSTALLATION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 3: RIG UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

How to Install the Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

CHAPTER 4: SYSTEM INSPECTION AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

CHAPTER 5: RIG OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

APPENDIX A: PRE-INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

APPENDIX B: VISUAL INSPECTION CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

APPENDIX C: SLING LOAD RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

APPENDIX D: TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS . . . . . . . . . . . . .65

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

APPENDIX E: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION . . . . . . . . . . . . . . . . 69

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

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CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

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CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

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CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

Warning! Before operating or servicing this top drive system,

Important! Tools and portable equipment used at height shall be

Caution: This equipment is designed and certified for use in a

Caution: Always perform the correct lock-out procedures as recom-

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

Caution: Never attempt to perform services procedures or repairs

Caution: Only trained personnel must perform inspections and

Caution: Safe access must be provided to all areas where adjust-

Caution: This equipment can generate noise up to 90 decibels.

Caution: The top drive will be energized automatically if the stored

Warning! Electrical voltages of different potentials are used

Warning! There are high voltage capacitors installed in the

Warning! Accumulators used in the auxiliary hydraulic

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

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CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CHAPTER 1: ABOUT THIS DOCUMENT

For information on Refer to

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

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CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

CHAPTER 2: PRE-INSTALLATION ACTIVITIES

RIG INSTALLATION AND MEASUREMENT

Accurate rig measurement helps do the following:

POWER/SERVICE CONNECTION REQUIREMENTS

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

Caution: Hydraulic power unit power cabling must be connected to

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM

Figure 2-3: Power connection with rig AC bus

Figure 2-4: Power connection with integrated generator

CONTACT: 1-877-TESCO-77 250TON EMI 400HP 50HZ WWW.TESCOCORP.COM