2/2/2010

TESCO PRODUCTS
DIVISION
ELECTRIC
TOP DRIVE TRAINING

ECI (S)

ƒ E -- ELECTRIC
ƒ C -- COMPACT
ƒ I -- INTEGRATED

ƒ S -- SWIVEL

TOPICS WE WILL BE COVERING

ƒ LOAD
O PATH
ƒ AUXILIARY HYDRAULIC SYSTEM
ƒ ECI GEARBOX OIL LUBE CIRCUIT
ƒ ECI COOLING CIRCUIT

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ECIS 900 – ELECTRIC

- 500 Ton and 650 Ton
- 900 HP
-Standard Gear Ratio 18.61:1
-Max Drill Torque 36,700
ft/lbs.
-Max Make Up Torque 45,000
ft/lbs.
-Max Breakout Torque 56,000
ft/lbs.
-Max Speed 193 RPM.

ECIS 1350 – ELECTRIC

-500 Ton and 650 Ton

-1350 HP
-Standard Gear Ratio 18.61:1
-Max Drill Torque 58,000
ft/lbs.
-Max Make Up Torque 68,000
ft/lbs.
-Max Breakout Torque 84,000
ft/lbs.
-Max Speed 193 RPM.

TESCO

•TOP DRIVE

• SWIVEL (ECIS)

• GEARBOX

• ELECTRIC MOTORS

• AUXILIARY HYDRAULIC
FUNCTIONS (ROBOTICS)

•TOP DRIVE ELECTRICAL

PANEL “T AND A”

•LOAD PATH COMPONENTS

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LOAD PATH

LOAD PATH TOP DRIVE

TRAINING

ƒ AT THE COMPLETION OF THIS SECTION YOU

WILL BE ABLE TO :
ƒ IDENTIFY COMPONENTS
ƒ IDENTIFY COMPONENT INSPECTION
FREQUENCY
ƒ IDENTIFY LOAD PATHS
ƒ IDENTIFY AND TROUBLESHOOT PROBLEMS

LOAD PATH

ƒ LOAD PATH IS ANY PART OF THE TOP DRIVE

THAT CARRIES THE LOAD OF THE DRILL
STRING.
STRING

2 DIFFERANT LOAD PATHS

1) DRILLING
2) TRIPPING

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INSPECTION

• NDT.-- NON DESTRUCTIVE TESTING

2 TYPES THAT WE USE

• WFMPI.-- WET FLOURESENT MAGNETIC
PARTICLE INSPECTION

• MPI.– MAGNETIC PARTICLE INSPECTION

EXAMPLE

•WFMPI.-- WET
FLOURESENT MAGNETIC
PARTICLE INSPECTION

CRACKS

LOAD PATH RECOMMENDED

MINIMUM SAFETY INSPECTION
ƒ ALL THREADED CONNECTIONS ARE SUBJECT TO WET
FLUORESCENT MAGNETIC PARTICLE INSPECTION.
(WFMPI) BY A QUALIFIED INSPECTOR FOR SURFACE
DEFECTS WITH SPECIFIC ATTENTION TO THE THREAD
PROFILES OF THE BOX AND PIN CONNECTIONS EVERY
60 OPERATING DAYS (ANY PART OF AN OPERATING
DAY IS CONSIDERED ONE DAY).

ƒ *NOTE* THE ABOVE INSPECTIONS SHOULD ALSO BE

CONDUCTED AFTER EXCESSIVE ROUGH
DRILLING,EXCESSIVE JARRING OR ANY OTHER
OCCURRENCES WHICH CAN DRAMATICALLY INCREASE
FATIGUE FAILURE (AT OPERATORS DISCRETION)

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LOAD PATH NON THREADED

RECOMMENDED MINIMUM
SAFETY INSPECTION
ƒ ALL REMAINING COMPONENTS OF THE LOAD PATH ARE
SUBJECT TO MAGNETIC PARTICLE INSPECTION (MPI) BY A
QUALIFIED INSPECTOR FOR SURFACE DEFECTS EVERY 500
OPERATING DAYS (ANY PART OF AN OPERATING DAY IS
CONSIDERED ONE DAY) REMOVAL OF PAINT IS REQUIRED
FOR INSPECTION.

IDENTIFYING ECI LOAD PATH

COMPONENTS
ƒ THREADED
COMPONENTS
ƒ SWIVEL SUB ƒ NON THREADED
COMPONENTS
ƒ QUILL
ƒ LOAD NUT ASSEMBLY
ƒ MUD SAVER VALVE
(STABBING VALVE)
ƒ LOAD COLLAR
ƒ SAVER SUB
ƒ ELEVATOR LINK ASSEMBLY
(BAILS)
ƒ CROSSOVER SUB
ƒ ELEVATORS

ECIS S W IV E L B AIL

ECI
LO AD PATH S W IV E L
INSPEC TIO N FREQ UEN CY
SW IVEL SUB S W IV E L PIN
60 D AYS (W FM PI)

500 DAYS (M PI)

Q UILL
S W IV E L Q UILL
TR IPPIN G LO AD PATH

LO AD CO LLAR
D AILY (VISU AL)
LOA D C OLLA R

LO AD NU T
RE TA INER
LOA D NUT
RE TAINE R

LO AD NUT SP LIT
C O LLAR
LOA D N UT SP LIT
CO LLA R

M UD S AV E R/
ST AB B ING V A LVE
M U D S AV ER/
S TA B BIN G V ALVE
E LE V A TO R LINKS
ELE V ATO R LINK S
SA V ER S UB CHECK DIE LOCK CLAMP
BOLTS DAILY (550 ft/lbs) S A VE R S UB

E LE V ATO R
ELE V ATO R

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IDENTIFYING ECIS LOAD PATH

COMPONENTS
ƒ THREADED
COMPONENTS

ƒ QUILL
ƒ NON THREADED
ƒ
COMPONENTS
ƒ MUD SAVER VALVE
(STABBING VALVE) ƒ LOAD NUT ASSEMBLY

ƒ SAVER SUB ƒ LOAD COLLAR

ƒ CROSSOVER SUB ƒ ELEVATOR LINK ASSEMBLY

(BAILS)

ƒ ELEVATORS

ƒ SWIVEL AND SWIVEL BAIL

ECIS S W IV E L B AIL

ECI
LO AD PATH S W IV E L
INSPEC TIO N FREQ UEN CY
SW IVE L S UB S W IV E L PIN
60 D AYS (W FM PI)

500 DAYS (M PI)

Q UILL
S W IV E L Q UILL
TR IPPIN G LO AD PATH

LO AD CO LLA R
D AILY (VISU AL)
LOA D C OLLA R

LO AD NU T
RE TA INER
LOA D NUT
RE TAINE R

LO AD NUT SP LIT
C O LLAR
LOA D N UT SP LIT
CO LLA R

M UD S AV E R/
ST AB B ING V A LVE
M U D S AV ER/
S TA B BIN G V ALVE
E LE V A TO R LINKS
ELE V ATO R LINK S
SA V ER S UB CHECK DIE LOCK CLAMP
BOLTS DAILY (550 ft/lbs) S A VE R S UB

E LE V ATO R
ELE V ATO R

LOAD PATH
COMPONENTS
ECI,ECIS

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LOAD PATH
BREAKING OUT JOINTS
ƒ STABILIZE TOP DRIVE WHEN BREAKING OUT SWIVEL
CONNECTIONS (THREAD TOP DRIVE INTO HEAVY
WEIGHT PIPE OR CROSS CHAIN OFF GRABBER LEG)
ƒ **USE OF HEAT ALLOWED ONLY IF NORMAL
BREAKOUT PROCEDURES FAIL (WARM UP BOX END
QUICKLY AND EVENLY THICKEST PART TO THINNEST
PART OF BOX *APPROX. 250 DEG F/ 121 DEG C)
**** CAUTION - NEVER EXCEED 300 DEG F/ 149 DEG C
OR SEVERE DAMAGE CAN BE DONE ( THE QUILL CAN
BECOME HARD AND BRITTLE)

CHECK THREADED CONNECTIONS

SWIVEL SUB

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INTEGRATED QUILL

ECI,ECIS

INTEGRATED SWIVEL QUILL

ECI

QUILL (PIN X PIN)

ECIS

QUILL WITH INTEGRATED SWIVEL

MUD SAVER VALVE

CHECK THREADS & MATING

SURFACES & MINIMUM
DIMENSION FROM SEAL FACE
TO LOCK RING

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12.95cm MIN

1O.67cm MIN

14.29cm

13.27cm MIN 15.875cm MIN

TORQUE ALL 8 SET SCREWS TO 100 ftlb

TORQUE TO 100 MUD SAVER VALVE

ft/lbs IN 25 ft/lbs
INCREMENTS

LINE UP SERIAL # PLATE TO

SERIAL # PLATE ON ASSEMBLY
MUD SAVER ACTUATOR

MUD SAVER VALVE

QUILL

SPLINE LOCK

GAP OF ABOUT 3/8”

(1cm)

MUDSAVER VALVE

SPLINE LOCK CONNECTIONS

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MIN.
8”/20.32cm
SAVER SUB
CHECK THREADS & MATING SURFACES

CHECK LOWER THREADS DAILY

(DO NOT TURN OVER END FOR END)

CROSSOVER
SUB

SPLINE LOCK
CHECK DIE LOCK CLAMP
BOLTS DAILY (550 ft/lbs)

DIE LOCK

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LOAD PATH NON THREADED

RECOMMENDED MINIMUM
SAFETY INSPECTION
ƒ ALL REMAINING COMPONENTS OF THE LOAD PATH
ARE SUBJECT TO MAGNETIC PARTICLE INSPECTION
(MPI) BY A QUALIFIED INSPECTOR FOR SURFACE
DEFECTS EVERY 500 OPERATING DAYS (ANY PART
OF AN OPERATING DAY IS CONSIDERED ONE DAY)
REMOVAL OF PAINT IS REQUIRED FOR INSPECTION.

LOAD NUT AND LOAD COLLAR

• LOAD NUT TO LOAD COLLAR MATING SURFACES
SHOULD BE CHECKED FOR SCORING (MACHINING
IS NEEDED IF GALLING IS PRESENT)

• *CLEARANCE BETWEEN MATING SURFACES MUST BE

LESS THAN *THE
LESS* THE CLEARANCE BETWEEN THE
BOTTOM OF THE LOAD COLLAR TO THE TOP OF THE
SPRING RETAINER* (DRILL STRING LOAD WOULD
THEN BE TRANSFERRED TO THE PIPE HANDLER
FRAME)

• CHECK FOR BROKEN LOAD COLLAR STOP BOLTS AND

CONTACT BETWEEN LOAD NUT AND PIPE HANDLER
FRAME (QUILL MAY HAVE ENDPLAY)

OUTER LOAD NUT RETAINER

LOAD NUT SPLIT HALVES

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LOAD COLLAR

SPRING RETAINER

LOAD NUT

QUILL

TOP OF LOAD NUT DAMAGE FROM ROTATING WITH WEIGHT ON

BAILS, SIDE OF LOAD NUT DAMAGE FROM CONTACTING PIPE
HANDLER FRAME, CAUSED FROM ENDPLAY IN GEARBOX.

BOTTOM OF LOAD COLLAR WITH DAMAGE FROM ROTATING WITH

WEIGHT ON BAILS

CHECK THIS AREA FOR WEAR

BOTTOM OF LOAD COLLARS

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QUILL WITH DAMAGE FROM

CONTACTING LOAD COLLAR
ASSEMBLY (GEARBOX ENDPLAY)

PIPE HANDLER FRAME WITH

DAMAGE FROM CONTACTING LOAD
NUT ASSEMBLY (GEARBOX
ENDPLAY)

CHECKING CLEARANCES BETWEEN LOAD COLLAR AND LOAD NUT

LOAD COLLAR TO LOAD NUT

LOAD COLLAR TO SPRING RETAINER

LOAD COLLAR

SPRING RETAINER TOP OF LOAD NUT

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INTEGRATED SWIVEL

CHECK PINS AND PIN HOLES FOR WEAR

CHECK PIN HOLES,HOOK AREA FOR WEAR

AND BAIL FOR WARPING OR BENDING.
SWIVEL BAIL

LOAD COLLAR

CHECK FOR WEAR

CHECK FOR BROKEN BOLTS ON

(OLD STYLE)

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LOAD COLLAR

CHECKING LOAD COLLAR CHECKING LOAD COLLAR

CLEARANCE CLEARANCE
(OLD STYLE) (NEW STYLE)

1/8” GAP AT THIS POINT ON BOTH SIDES

ELEVATOR LINKS (BAILS)

117cm.

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HYDRAULIC ELEVATORS

CHECK PINS,INSERTS,AND LATCH ASSEMBLY FOR WEAR

ECI,ECIS
CHECKING THE
GEARBOX FOR ENDPLAY
(BEARING PRELOAD)
• IF NO MOVEMENT OF DIAL INDICATOR NEEDLE PRELOAD
IS PRESENT

• MOVEMENT OF DIAL INDICATOR NEEDLE ENDPLAY IS

PRESENT AND PRELOAD WILL HAVE TO BE ADJUSTED.

• CHECK BEARING RETAINER BOLTS BEFORE PROCEEDING

(ARE THE BOLTS LOOSE OR BROKEN)

• CHECK FOR ANY MOVEMENT IN THE RINGFEDER

COMPONENTS (IS THE SPRING SIEZED)

EXAMPLE
ENDPLAY 0.0” PRELOAD
UP AND DOWN MOVEMENT BEARING CRUSH

0.010” 0.005” 0.005” 0.010”

0.008”
0.008” – 0.010”
DIAL INDICATOR READING NEW SPECIFICATION

MUST REMOVE 0.016” – 0.018” SHIMS TO BE WITHIN SPECIFICATIONS

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PRELOAD IS THE AMOUNT OF

COMPRESSION BETWEEN
BEARINGS

EXAMPLE

ADD SHIMS UPPER BEARING RETAINER

REMOVE SHIMS
SHIMS

LOWER BEARING RETAINER

GEARBOX PRELOAD
SPECIFICATIONS

• 500/650 TON ECI PRELOAD

• NEW BEARINGS (.008” -.010”)

• USED BEARINGS (.000”-.005”)

GEARBOX PRELOAD
SPECIFICATIONS
• 500/650 TON ECIS PRELOAD

• NEW BEARINGS (.008” -.010”)

• USED BEARINGS (.000”-.005”)

SWIVEL PRELOAD
SPECIFICATIONS
500/650 TON ECIS PRELOAD

NEW BEARINGS (.003”)

USED BEARINGS (.0015”)

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QUILL FOR
REFERENCE
S.S. HOSE CLAMP
DUST BOOT

ECI,ECIS
GEARBOX ASSEMBLY
REFERENCE

SHIM LOCATION

LOWER QUILL COLLAR

CAP SCREW

O-RING

CAUTION** MAKE SURE RINGFEDER ASSEMBLY IS

TIGHT TO QUILL AND GEARBOX HUB

PRELOAD (END PLAY) CHECK

ECI,ECIS (TOP)

SHIM LOCATION

MAKE SURE BEARING RETAINER BOLTS ARE TIGHT (LOOSE

OR BROKEN?)

**CAUTION** IF SPRING IS SEIZED DO NOT REMOVE UPPER

QUILL COLLAR UNTILL SPRING IS FREE

COMPRESSION BOLT QUILL FOR

REFERENCE

ECI,ECIS
CAP SCREW
UPPER QUILL COLLAR

THRUST RING
THRUST RING SHIM
UPPER COMPRESSION RING
**CAUTION**
CHECK THAT
SPRING IS RINGFEDER SPRING
NOT SEIZED CAP SCREW
BEFORE LOWER COMPRESSION RING
DISASSEMBLY

CAUTION** MAKE SURE RINGFEDER ASSEMBLY IS

TIGHT TO QUILL AND GEARBOX HUB

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ECI,ECIS PRELOAD (END PLAY) CHECK

(BOTTOM)

MAKE SURE BEARING RETAINER BOLTS ARE TIGHT (LOOSE

OR BROKEN?)

SWIVEL SHIM LOCATION

ECIS

INTEGRATED SWIVEL

QUILL FOR
REFERENCE
S.S. HOSE CLAMP
DUST BOOT

ECI,ECIS

*CRITICAL* GEARBOX ASSEMBLY

REFERENCE

GREASE SHOULD BE VISIBLE AROUND LOWER

COMPRESSION RING

LOWER QUILL COLLAR

CAP SCREW

O-RING 2 OF 4 GREASE POINTS

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ECI,ECIS 2 OF 4 GREASE POINTS

*CRITICAL*

MAKE SURE GREASE TRAVELS UP GEARBOX HUB AND EXITS

AT LOWER COMPRESSION RING OF RINGFEDER ASSEMBLY

GEAR BOX HUB

GREASE POINTS ECI,ECIS

*CRITICAL*

GREASE SHOULD TRAVEL UP SPLINES AND BE

VISABLE AROUND LOWER COMPRESSION RING

NON LOAD PATH

RECOMMENDED INSPECTION

ƒ REMAINING COMPONENTS OF THE TOP DRIVE THAT

MAY BE AFFECTED BY THE LOAD PATH SHOULD BE
INSPECTED FOR ANY DEFECTS ON A REGULAR BASIS.
THIS WOULD BE UP TO THE OPERATORS DESCRETION.
THESE COMPONENTS ARE STILL SUBJECT TO THE 500
DAY INSPECTIONS

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SLEWING BEARING

• THE SLEWING BEARING IS LOCATED BETWEEN THE

MAINFRAME AND PIPE HANDLER FRAME.THE SLEWING
BEARING ALLOWS 360 DEGREES ROTATION OF THE PIPE
HANDLER FRAME INDEPENDENT OF THE MAINFRAME.THIS
ALLOWS FOR PIPE HANDLING CAPABILITY. THE EXTERNAL
RACE OF THE BEARING HAS TEETH THAT ENGAGE WITH
THE PIPE HANDLER LOCK,TO HOLD THE 2 FRAMES LOCKED
IN POSITION.

CHECK SLEWING BEARING

• CHECK MOUNTING BOLTS (LOOSE OR BROKEN)

• CHECK GEAR TEETH FOR WEAR.
• ** CAUTION**IF REPLACING SLEWING BEARING
*MEASURE INSIDE RACE THICKNESS ( 2 SIZES)
56mm REQUIRES LOCKWASHERS ON BOLTS
MOUNTING BEARING TO MAINFRAME 62mm ONLY
REQUIRES BOLTS (NO LOCKWASHERS) *LOCTITE
ON ALL BOLTS*

MAINFRAME

PIPEHANDLER
LOCK PIVOT
PIPEHANDLER
LOCK ARM
SLEWING BEARING

BEARING/PIPEHANDLER
BOLTS

BEARING/MAINFRAME
BOLTS PIPEHANDLER

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CHECKING SLEWING BEARING INSIDE RACE THICKNESS

CHECKING SLEWING BEARING INSIDE RACE THICKNESS

MOUNTING THIS BEARING TO MAIN FRAME WOULD REQUIRE

LOCKWASHERS

CHECK SLEWING BEARING TO PIPE HANDLER FRAME BOLTS

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CHECK SLEWING BEARING TO MAINFRAME BOLTS

BROKEN SLEWING BEARING BOLTS (LOAD TRANSFERRED TO PIPE

HANDLER FRAME AND BEARING INSTEAD OF QUILL)

PIPE HANDLER LOCK

(NEW STYLE)
• THE PIPE HANDLER LOCK IS A HYDRAULIC CYLINDER WITH
A GEAR SEGMENT INSTALLED ON THE END OF THE RAM, IT
IS MOUNTED VERTICALLY AND ENGAGES THE SEGMENT
WITH THE SLEWING BEARING OUTER RACE,LOCKING THE
PIPE HANDLER FRAME IN ANY 360 DEGREE POSITION TO
THE MAIN FRAME.IT MAY BE UNLOCKED TO ALLOW FOR
PIPE HANDLING CAPABILITY.

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CHECK FOR WEAR ON SLEWING

BEARING GEAR TEETH
CHECK ALL GUIDE BLOCK MOUNTING BOLTS
AND LOCKING DEVICES

NOT APPROVED LOCKING

METHOD FOR BOLTS

PIPE HANDLER LOCK ASSEMBLY

NEW STYLE

CHECK FOR WEAR ON TEETH

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OLD STYLE

PIPE HANDLER LOCK ASSEMBLY

PIPEHANDLER
LOCK ARM
PIPEHANDLER OLD STYLE
LOCK PIVOT

PIPEHANDLER
LOCK SEGMENT

PIPE HANDLER LOCK ASSEMBLY

OLD STYLE

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ECI,ECIS

TORQUE TRACK

ECI,ECIS

TORQUE BEAM
& T-BAR

ECI,ECIS

TORQUE BUSHING & EXTEND FRAME

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ECI,ECIS

TORQUE TUBE BUSHING ASSEMBLY

TORQUE TRACK ASSEMBLY

ECI,ECIS

QUILL RINGFEDER DISASSEMBLY

• REMOVE BOOT AND CHECK FOR GREASE AROUND

LOWER COMPRESSION RING ( 4 GREASE ZERKS ON THE
LOWER GEARBOX HUB SUPPLY GREASE TO THE
GEARBOX HUB AND QUILL SPLINES)

• REMOVE THE COMPRESSION BOLTS AND CHECK FOR

PROPER MACHINED ENDS,CLEAN,LUBE AND REINSTALL
BOLTS.

• TIGHTEN BOLTS DOWN EVENLY UNTIL SHIM CAN BE

REMOVED ***CAUTION IF SPRING SET STICKS DO NOT
HIT WITH HAMMER IF UPPER QUILL COLLAR IS
REMOVED.

**CAUTION** IF SPRING IS SEIZED DO NOT REMOVE UPPER

QUILL COLLAR UNTILL SPRING IS FREE

COMPRESSION BOLT QUILL FOR

REFERENCE

ECI,ECIS
CAP SCREW
UPPER QUILL COLLAR

THRUST RING
THRUST RING SHIM
UPPER COMPRESSION RING
**CAUTION**
CHECK THAT
SPRING IS RINGFEDER SPRING
NOT SEIZED CAP SCREW
BEFORE LOWER COMPRESSION RING
DISASSEMBLY

CAUTION** MAKE SURE RINGFEDER ASSEMBLY IS

TIGHT TO QUILL AND GEARBOX HUB

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BOLT GOES THROUGH

BOLT PUSHES ON UPPER
UPPER QUILL COLLAR
COMPRESSION RING
COMPRESSING SPRING

SPRING ASSEMBLY

SHIM IS INSERTED OR
REMOVED

BOLT IS THREADED THROUGH UPPER

QUILL COLLAR THRUST RING

QUILL FOR
REFERENCE
S.S. HOSE CLAMP
DUST BOOT

GEARBOX ASSEMBLY
REFERENCE

LOWER QUILL COLLAR

CAP SCREW

O-RING

UPPER COMPRESSION RING

LOWER QUILL COLLAR
THRUST RING SHIM

SPRING SET

LOWER COMPRESSION RING

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UPPER QUILL COLLAR THRUST RING

THRUST RING SHIM

UPPER QUILL COLLAR

SPECIAL GREASE FOR SPRING SET ASSEMBLY

SPRING SET

CUT LOCKWIRE

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TIGHTEN BOLTS DOWN

EVENLY (AFTER CHECKING)

REMOVE 2 PIECE SHIMS

THRUST RING SHIMS

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GAP AFTER SHIMS REMOVED

*CAUTION* DO NOT REMOVE

UPPER QUILL COLLAR IF THE
SPRING SET STICKS

UPPER QUILL COLLAR

BOLTS REMOVED

• HOOK UP NUBBIN TO TAKE LOAD OF QUILL

• REMOVE OR TIE UP RINGFEDER ASSEMBLY PIECES

(NOTE ASSEMBLY POSITION)

• LOWER QUILL ENOUGH TO REMOVE LOWER QUILL

COLLAR THEN LOWER QUILL MORE TO ALLOW
REMOVAL OF LOAD NUT SPIRALOX,2 in.SNAP RINGS
AND DOG SET SCREWS *** CAUTION DO NOT ALLOW
THE WEIGHT OF THE QUILL TO REST ON THE ROTARY
SEAL**

• LIFT OUTER LOAD NUT RETAINER UP ENOUGH TO

REMOVE SPLIT COLLAR HALVES *** CAUTION IF OUTER
LOAD NUT SEIZED BE CAREFUL NOT TO DAMAGE BY
HAMMERING

• LIFT QUILL OUT BEING CAREFUL NOT TO DAMAGE

LOAD COLLAR SEAL.

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REMOVING UPPER QUILL COLLAR BOLTS

REMOVING UPPER QUILL COLLAR

REMOVING LOWER COMPRESSION RING BOLTS

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WHEN INSTALLING INTEGRATED SWIVEL THESE PIECES MUST BE

SLID ON QUILL BEFORE INSTALLING IN GEARBOX HUB.

LIFT & TIE UP ONE PIECE RINGFEDER COMPONENTS

UPPER BEARING RETAINER

REMOVING LOWER COMPRESSION RING

LOWER QUILL COLLAR

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REMOVING LOWER QUILL COLLAR BOLTS

GREASE NIPPLES
GEARBOX HUB

QUILL
SEALANT FOR BOTTOM OF HUB

REMOVING LOWER QUILL COLLAR

ROTARY SEAL LOCATION

*CAUTION* DO NOT REST QUILL ON

ROTARY SEAL WHEN LOWERING

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LOAD COLLAR

SPRING RETAINER

LOAD NUT

QUILL

QUILL

REMOVING SPIRALOX FROM BOTTOM OF LOAD NUT

REMOVING SNAP RINGS

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REMOVING DOG SET SCREWS

DOG SET SCREW

QUILL

LIFTING OUTER LOAD NUT

SPLIT COLLAR HALVES

REMOVING SPLIT COLLAR HALVES

*NOTICE* LOAD NUT GROOVE TAPER

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CLEAN AND INSPECT:LIGHTLY LUBE (RUST INHIBITOR)

REMOVING OUTER LOAD NUT

O-RING FROM TOP OF LOAD NUT

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ROTATING QUILL TO LINE UP GEAR BOX HUB& QUILL SPLINES

QUILL SPLINES

REMOVING QUILL

TOOL JOINT
(OVER TORQUE ) (UNDERTORQUE)

• NEVER EXCEED MAXIMUM MAKE UP TORQUE OF DRILL

PIPE JOINTS

• UNDERTORQUED JOINTS CAN DO AS MUCH DAMAGE AS

JOINTS THAT ARE OVER TORQUED.

• ON TAPERED DRILL STRINGS DRILLING TORQUE SHOULD

NEVER EXCEED THE LOWEST JOINT MAKE UP TORQUE.

• MAKE SURE ALL JOINTS ARE PROPERLY LUBED.

• IF ASKED TO EXCEED TORQUE (HAVE SOMEONE SIGN OFF)

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500 DAY RECERTIFICATION

• TESCO OFFERS A COMPLETE 500 DAY INSPECTION

AND RECERTIFICATION.

• CONTACT YOUR LOCAL TESCO REPRESENTATIVE

FOR COMPLETE INFORMATION.

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 TESCO
PRODUCTS
DIVISION
ECI (S)
TOP DRIVE TRAINING

ECI (S)

ƒ E -- ELECTRIC
ƒ C -- COMPACT
ƒ I -- INTEGRATED

ƒ S -- SWIVEL

AUXILIARY
HYDRAULICS

1
 •POWER MODULE

• AC/DC
/ POWER DISTRIBUTION

• MAIN PANEL CONTROLS

• MD 500

• LAP TOP

•TOP DRIVE ELECTRICAL CABLES

AND PANEL “T AND A”

•HEAT PUMP

•MECHANICAL
MODULE

• CONTAINS MD 500
CHILLER

• CONTAINS TOP DRIVE

COOLING

• CONTAINS AUXILIARY
HYDRAULIC
COMPONENTS

TESCO

•TOP DRIVE

• SWIVEL (ECIS)

• ELECTRIC MOTORS

• GEARBOX

• AUXILIARYHYDRAULIC
FUNCTIONS (ROBOTICS)

•TOP DRIVE ELECTRICAL CABLES

AND PANEL “T AND A”

•LOAD PATH COMPONENTS

2
 •SERVICE
LOOP

• AUXILIARY
HYDRAULIC HOSES
(ROBOTICS)

•TOP DRIVE ELECTRICAL

CABLES AND PANEL “T
AND A”

•POWER CABLES

•COOLANT HOSES

AUXILIARY HYDRAULIC
TOP DRIVE TRAINING
AT THE COMPLETION OF THIS SECTION
YOU WILL BE ABLE TO :
ƒ IDENTIFY COMPONENTS
ƒ FOLLOW FLOW PATHS (SCHEMATICS)
ƒ TROUBLESHOOTING BASICS

TOP DRIVE HYDRAULICS

• LINK TILT – ALLOWS MOVEMENT OF BAILS 59”
FORWARD OR 84” BACKWARDS FROM WELL CENTER.

• LINK TILT FLOAT – RETURNS BAILS TO A NEUTRAL

POSITION UNDER TOP DRIVE.

• PIPE HANDLER LOCK – LOCKS THE PIPE HANDLER

FRAME TO THE MAIN FRAME.

• GRABBER LIFT – MOVES THE GRABBER LEG UP OR

DOWN.

• ELEVATORS – FOR PIPE HANDLING CAPABILITIES.

3
• GRABBER – CLAMPS THE DRILL STRING, FOR
MAKING OR BREAKING JOINTS,AND MAINTAINS
TOOL FACE FOR DIRECTIONAL DRILLING.

• MUDSAVER – OPERATES THE MUDSAVER VALVE OPEN

OR CLOSE.

• EXTEND – MOVES THE TOP DRIVE AWAY FROM THE

TORQUE TRACK, FOR EXTENDING OVER MOUSEHOLE
OR OUT TO THE “V” DOOR, OR RETRACTS IT BACK TO
WELL CENTER
CENTER.

• COUNTER BALANCE – WORKS LIKE A SHOCK

ABSORBER, COMPENSATES WHEN MAKING AND
BREAKING JOINTS.

• UNLOADER – DEAD ENDS THE AUXILIARY

HYDRAULIC CIRCUIT TO PRODUCE PRESSURE OR
DIRECTS OIL BACK TO TANK WHEN NO FUNCTIONS
ARE USED.

HYDRAULICS

ADVANTAGES OF USING HYDRAULICS

ƒ FLEXIBILITY
COMPONENTS CAN BE LOCATED SEPARATELY AND
CONNECTED WITH HYDRAULIC LINES.

ƒ MULTIPLICATION OF FORCES
SMALL FORCES CAN MOVE LARGE LOADS.

ƒ COMPACTNESS
HYDRAULICS CAN HANDLE MORE HORSEPOWER FOR ITS
SIZE THAN MECHANICAL OR ELECTRIC SYSTEMS.

HYDRAULICS
DISADVANTAGES OF HYDRAULICS

„ NEED FOR CLEANLINESS

DUST,DIRT,RUST,WATER,CORROSION,AIR,HEAT WILL
CAUSE DAMAGE TO THE HYDRAULIC
SYSTEM.(MAINTENANCE IS MORE CRITICAL).

„ EFFICIENCY
HYDRAULICS ARE LESS EFFICIENT THAN MECHANICAL. OR
ELECTRICAL.

„ ENVIRONMENT
HYDRAULIC OIL IS A KNOWN CONTAMINENT.
(CONTAINMENT IS REQUIRED).

4
 HYDRAULICS
THERE ARE 2 TYPES OF BASIC HYDRAULIC SYSTEMS

1 OPEN LOOP SYSTEM

OPEN LOOP FLOW PATH IS FROM THE
-- TANK
TANK-- PUMP --ACTUATOR
ACTUATOR -- BACK TO THE TANK.

2 CLOSED LOOP SYSTEM

CLOSED LOOP FLOW PATH IS FROM THE
-- PUMP --MOTOR --BACK TO THE PUMP.

THE AUXILIARY HYDRAULIC SYSTEM ON A TESCO TOP

DRIVE IS AN OPEN LOOP SYSTEM.

OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION TION

2300 PSI
2300 PSI

OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION TION

2300 PSI
2300 PSI

5
 OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION TION

2300 PSI
2300 PSI

OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION

2300 PSI
2300 PSI

OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION

2300 PSI
2300 PSI

6
 OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION

2300 PSI
2300 PSI

OPEN LOOP CIRCUIT

SPOOL SHIFTED
TO OPEN POSITION

2300 PSI
2300 PSI

BASIC CLOSED
BASIC LOOP
C LO SED CIRCUIT
CIRC U IT

CASE D RAIN LINE

FORWARD

IN PUT PV MF O U TPUT

FLO W BI-DIREC TIO N AL

HEAT E XCH ANG ER w/ BYPASS

LOW PRESSURE SIDE OF LOOP

HIGH PRESSURE SIDE OF LOOP

RES ERVO IR

7
 BASIC CLOSED
BASIC LOOP
C LO SED CIRCUIT
CIRC U IT

CASE D RAIN LINE

IN PUT PV MF O U TPUT

REVERSE

FLO W BI-DIREC TIO N AL

HEAT E XCH ANG ER w/ BYPASS

LOW PRESSURE SIDE OF LOOP

HIGH PRESSURE SIDE OF LOOP

RES ERVO IR

CHARGED SYSTEM
CHARGE RELIEF
CASE DRAIN

CHARGE
PV PF CHECK MF
VALVES
CHARGE
PUMP
CONTROL

INLET FILTER

RESERVOIR

MECHANICAL MODULE
HYDRAULIC COMPONENTS

SET @
SET @
2100 PSI
2300BAR]
[145 PSI
(158 BAR) SET @
800 PSI
HYDRAULIC
[55 BAR]
OIL TANK

8
 HYDRAULIC SYSTEM
CONTAMINATION
„ HYDRAULIC SYSTEMS MUST BE KEPT AS CLEAN AS POSSIBLE
(EXTREMELY IMPORTANT IN CLOSED LOOP SYSTEMS BECAUSE
OF CLOSE TOLERANCES IN PISTON PUMPS & MOTORS), AND
IN OPEN LOOP SYSTEMS BECAUSE OF THE SMALL PASSAGES
IN THE CONTROL VALVES.

„ CONTAMINATION MAY BE A SOLID,LIQUID,OR A GAS.

„ THE HUMAN EYE CAN SEE PARTICLES 40 MICRON IN

SIZE,PARTICLES SMALLER THAN 40 MICRON DO THE MOST
DAMAGE TO HYDRAULIC SYSTEMS.

„ KEEP YOUR SYSTEM CLEAN !!

HYDRAULIC SCHEMATIC
SYMBOLS

„ EACH COMPONENT OF A HYDRAULIC SYSTEM IS REPRESENTED BY

A INDUSTRY RECOGNIZED SYMBOL ON SCHEMATIC DRAWINGS.

711 714 713

711 714 713
2C 8C 6C

9
 OPEN LOOP MAIN
COMPONENTS & FUNCTIONS

„ HYDRAULIC TANK (RESERVOIR) - STORES OIL,HELPS COOL OIL

„ HYDRAULIC PUMP - PRODUCES FLOW.(PRESSURE

FLOW (PRESSURE IS CAUSED BY
RESISTANCE TO FLOW)

„ HYDRAULIC LINES - PASSAGE FOR OIL TO TRAVEL BETWEEN

COMPONENTS.

„ HYDRAULIC MANIFOLDS - CONTAIN PORTS USED TO MOUNT

CONTROL VALVES,FILTERS AND/ OR FITTINGS TO CONNECT
OTHER COMPONENTS.

HYDRAULIC RESERVOIR SUCTION STRAINER

(100 MESH/140 MICRON) WITH A MAGNET

HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR CAPACITY 59

GAL. (222 L) (ATF HYDRAULIC OIL)

ELECTRIC MOTOR

FLEX COUPLER

HYDRAULIC PUMP

GEAR PUMP

HP=PSI X GPM X 0.OOO7 HP=PSI X GPM/1714 X 1.2

10
OIL MUST TRAVEL AROUND THE OUTSIDE OF THE GEARS ON ALL GEAR PUMPS

TOP DRIVE HYDRAULIC QUICK COUPLER

SHOWING DIRECTION OF FLOW FROM PUMP

TOP DRIVE COOLANT QUICK COUPLER

TOP DRIVE HYDRAULIC QUICK COUPLERS

INLET

INLET

HOSE END CONNECTIONS AT TOP DRIVE

TOP DRIVE COOLANT QUICK COUPLERS

11
 HYDRAULIC HOSES

-16 = 1” - 12 = ¾”
-10 = 5/8” - 8 = ½”
-6 = 3/8” - 4 = ¼”

HYDRAULIC HOSES AND FITTINGS

HYDRAULIC LINES
– PASSAGE FOR OIL TO TRAVEL BETWEEN COMPONENTS.

CONNECTION PORTS

HYDRAULIC MANIFOLDS
– CONTAIN PORTS USED TO MOUNT CONTROL VALVES, FILTERS
AND/OR FITTINGS TO CONNECT OTHER COMPONENTS.

12
11 STATION MANIFOLD MOUNTED IN MAIN FRAME

AUXILIARY MANIFOLD LOCATION

NEW MANIFOLD
OLD MANIFOLD

ROTARY SEAL PORTING

13
 CHECKING ROTARY SEAL
BOLTS
• CHECK BOLTS THAT MOUNT ROTARY SEAL TO PIPE HANDLER
FRAME ** 3 BOLTS WITH LOCKWASHERS,RED LOCTITE,AND
LOCKWIRE** (LOOSE OR BROKEN)

• CHECK BOLTS THAT MOUNT TORQUE FLANGE TO INNER

SLEEVE ** 3 BOLTS WITH LOCKWASHERS AND BLUE LOCTITE
(LOOSE OR BROKEN)

• CHECK STOP BLOCK MOUNTING BOLTS **2 BOLTS WITH

LOCKWASHERS AND LOCKWIRE

• CHECK REMAINING ROTARY SEAL ASSEMBLY BOLTS.

CHECK BOLTS THAT HOLD STOP BRACKET TO INNER BARREL

FRAME CHECK BOLTS THAT MOUNT ROTARY SEAL TO PIPE HANDLER

ROTARY SEAL ORIENTATION

„ IF REPLACEMENT OF ROTARY SEAL IS

NECESSARY (eg. PORT TO PORT LEAKAGE) THE
ORIENTATION OF THE INNER AND OUTER
BARRELS SHOULD BE CHECKED ON THE ROTARY
SEAL BEING REPLACED, AND THE REPLACEMENT
ROTARY SEAL SHOULD BE ORIENTATED THE
SAME WAY,BEFORE INSTALLING HOSES.

14
 CHECK ORIENTATION OF INNER & OUTER BARREL, & COMPARE
TO REPLACEMENT ROTARY SEAL

ROTARY SEAL ASSEMBLY

ROTARY SEAL ASSEMBLY INSTALLED IN TOP DRIVE

„ HYDRAULIC CONTROL VALVES - CONTROL PRESSURE,DIRECTION

OF FLOW,AMOUNT OF FLOW OR,ANY COMBINATION OF THESE.

„ ACTUATORS - DO THE WORK

WORK, (eg.
(eg HYDRAULIC CYLINDERS)

„ FILTERS - REMOVE SOLID CONTAMINENTS.(RATED IN MICRONS)

„ COOLERS & RADIATORS - COOL THE OIL

„ ACUMULATORS – STORE HYDRAULIC ENERGY

„ HYDRAULIC GAUGES - TELL WHAT THE PRESSURE IS IN A

CIRCUIT.

15
 HYDRAULIC CONTROL VALVES

GRABBER LIFT CYLINDER

PISTON END OF CYLINDER

ROD END OF CYLINDER

ROD
PISTON

EXTEND CYLINDER

16
 MUDSAVER VALVE ACTUATOR

OPEN & CLOSE PORTS CONNECTIONS

OPEN
CLOSE

ROD
PISTON

HYDRAULIC FILTER

HYDRAULIC RETURN FILTER

(10 MICRON)

AUXILIARY HYDRAULIC PRESSURE GAUGE

HYDRAULIC COOLER

17
 HYDRAULIC VALVES
„ PRESSURE RELIEF VALVES
„ SEQUENCE VALVE
„ PRESSURE REDUCING VALVE
„ NEEDLE VALVE
„ FLOW CONTROL WITH A BYPASS
„ CHECK VALVE
„ PILOT TO OPEN CHECK
„ CAVITY PLUG
„ SHUTTLE VALVE
„ DIRECTIONAL CONTROL VALVE

RELIEF VALVE

1 2
Pressure Tank

„PRESSURE RELIEF VALVES

ARE USED TO LIMIT THE MAXIMUM PRESSURE DEVELOPED IN A
SYSTEM.

HYDRAULIC RESERVOIR

PRESSURE RELIEF (SKID)

18
 PRESSURE RELIEF (REMOTE)

CIRCUIT RELIEF VALVES

11 STATION MANIFOLD

SEQUENCE VALVE

Sequence Valve

SEQUENCE VALVE
ALLOWS ONE FUNCTION TO OCCUR BEFORE ANOTHER IN A
SPECIFIC ORDER.(WITHIN ONE CIRCUIT)

19
 HYDRAULIC ELEVATORS SEQUENCE VALVE

SEQUENCE VALVE

PRESSURE REDUCING VALVE

2 3

Pressure
Reducing Valve
„PRESSURE REDUCING VALVE
REDUCES THE PRESSURE IN A SECTION OF A HYDRAULIC
CIRCUIT,BELOW MAIN RELIEF PRESSURE.

20
 PRESSURE REDUCING VALVE

PRESSURE REDUCING VALVE

NEEDLE VALVES

1 2

Needle Valve

„NEEDLE VALVE/FLOW CONTROL

USED TO CONTROL FLOW (VARIABLE)

21
AUXILIARY MANIFOLD

NEEDLE VALVE

STAR VALVE

FLOW CONTROL WITH BYPASS

1 2

1 2

Flow Control Valve

with Bypass

„FLOW CONTROL WITH A BYPASS

USED TO CONTROL FLOW (VARIABLE), AND HAS A PASSAGE TO
BYPASS FLOW CONTROL

FLOW CONTROL CAN CONTROL

SPEED BUT NOT LOAD (METER IN)

LOAD

FLOW CONTROL CAN CONTROL LOAD

SPEED AND LOAD (METER OUT)

22
 12

11

10
9 1
8 2
7
6 5 4 3

LINK TILT FLOW CONTROLS

PILOT TO OPEN CHECK VALVES

2.8:1 RATIO

1
3:1 RATIO

„PILOT TO OPEN CHECK

ALLOWS FREE FLOW ONE WAY,BUT NEEDS PILOT PRESSURE TO
OPEN VALVE SO FLOW CAN GO THE OPPOSITE WAY.
(MOST HAVE A BUILT IN RATIO)

AUXILIARY MANIFOLD

PILOT TO OPEN CHECK VALVE

23
 PILOT TO OPEN CHECK VALVE(B) PORT

11 STATION MANIFOLD

SHUTTLE VALVE

Outlet

Inlet 1 Inlet 2

Shuttle Valve

SHUTTLE VALVE
HAS ONE OUTLET BUT CAN CHOOSE FROM ONE OF TWO INLETS
(WHICHEVER ONE IS HIGHER)

SHUTTLE VALVE

24
 DIRECTIONAL CONTROL VALVES
VICKERS

CONTINENTAL

ATOS

„DIRECTIONAL CONTROL VALVE

CONTROLS THE OIL FLOW PATH

LOOKING DOWN AT MANIFOLD

COIL T

A B
“A” COIL IS ON THE “A” SIDE
A B P
ATOS
“A” COIL IS ON THE “A” SIDE

A B A B

P T
A B
P T

“B” COIL IS ON THE “A” SIDE

VICKERS / CONTINENTAL
A B

“A” COIL IS ON THE “A” SIDE

B A A B

P T
A B
P T

3 POSITION VALVES SHOWN ARE ATOS D03 VALVE BLOCKS

A B

(3A)CONTINENTAL – (711)ATOS – (2C)VICKERS

P T

A B

P T (3L)CON TINENTAL– (714)ATOS – (8C)VICKERS

A B

P T (3F)CONTINENTAL – (713)ATOS – (6C)VICKERS

25
T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

26
 T A P B

T A P B

T A P B

T A P B

T A P B

T A P B

DIRECTIONAL CONTROL

„ DIRECTIONAL CONTROL VALVES ARE MOUNTED ON THE 11

STATION MANIFOLD.

„ DIRECTIONAL VALVES CONTROL THE DIRECTION OF

FLOW.
FLOW

„ VALVES ARE IDENTIFIED BY THE PORTING OF THE CENTER

ENVELOPE

„ DIRECTIONAL VALVES ARE SHIFTED BY 24 VOLT ELECTRIC

SOLENOIDS MOUNTED ON THE ENDS OF THE DIRECTIONAL
CONTROL VALVES. (MANUAL OVERIDES ON THE ENDS)

DIRECTIONAL CONTROL VALVES

11 STATION MANIFOLD

27
 CHECK VALVE

OUT
IN

IN OUT

„CHECK VALVE
USED TO CONTROL FLOW, ALLOWS FLOW IN ONE
DIRECTION, BUT BLOCKS FLOW IN THE OPPOSITE DIRECTION

CAVITY PLUG

CAVITY PLUG
BLOCKS THE FLOW OF OIL THROUGH PASSAGES.

CAVITY PLUG (A) PORT

11 STATION MANIFOLD

28
 711 714 713
711 714 713
2C 8C 6C

float directional valve

link tilt directional valve

unloader directional valve

mudsaver directional valve

pipe handler lock directional valve

grabber directional valve

extend directional valve

elevator directional valve

grabber lift directional valve

Blanking plates

11 STATION MANIFOLD

INNER BARREL PORTING

INNERCONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARYSEAL

OUTERCONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SETSEQ VALVE

OUTER12 BARREL PORTING

11

10
9 1
8 2
7
6 5 4 3

NOTES:
1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
"B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
"D" - OUTER OFF DRILLER SIDE

ROTARY SEAL ASSEMBLY INSTALLED IN TOP DRIVE

29
 AUXILIARY MANIFOLD

EXTEND FLOW CONTROLS WITH A BYPASS

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1
RM MR
SV
T2 T1
A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

REMOTE MANIFOLD AT TOP DRIVE

30
 A B
float directional valve

link tilt directional valve

unloader directional valve

mudsaver directional valve

pipe handler lock directional valve

grabber directional valve

extend directional valve

elevator directional valve

grabber lift directional valve

Blanking plates

MECHANICAL MODULE
HYDRAULIC COMPONENTS

SET @
SET @
2100 PSI
2300BAR]
[145 PSI
(158 BAR) SET @
800 PSI
HYDRAULIC
[55 BAR]
OIL TANK

WHAT DO EACH OF THE GAUGES READ?

Gauge #1______ Gauge #2________

600 psi
2100 psi
2

2000 psi

31
WHAT DO EACH OF THE GAUGES READ?

Gauge #1_____ Gauge #2_____ Gauge #3_____ Gauge #4_____

2000 psi
3

1850 psi
2100

4 1000
600 psi

2
2300psi
800 psi

HEAT GENERATION IN A
HYDRAULIC SYSTEM

„ HEAT IS GENERATED IN A HYDRAULIC SYSTEM WHENEVER OIL

DUMPS FROM A HIGHER PRESSURE TO A LOWER PRESSURE
WITHOUT PRODUCING A MECHANICAL WORK OUTPUT. e.g. 1
WHEN OIL FLOWS TO TANK THROUGH A RELIEF VALVE , 2 OIL
FLOWING THROUGH A PRESSURE REDUCING VALVE.
VALVE THE
HIGHER THE PRESSURE DROP THE MORE HEAT IS PRODUCED.

„ PRESSURE DROPS FROM ONE CYLINDER PORT TO ANOTHER

DO NOT CREATE HEAT BECAUSE THE ENERGY IS CONVERTED TO
WORK OUTPUT.

100 PSI 100 PSI

500 PSI 100 PSI

FLOW

110 PSI 100 PSI

110 PSI 110 PSI

32
 FLOW

10sqin
q x 800psi
p =8000lbs

10 gpm

FLOW

10sqin x 800psi =8000lbs

10 gpm

FLOW

10sqin x 800psi =8000lbs

.5 gpm

33
TWO MAIN TERMS IN HYDRAULICS ARE:

1) PRESSURE --- RESISTANCE TO FLOW

2) FLOW --- MOVEMENT OF LIQUID
PRESSURE = PRESSURE RESULTS WHEN THERE IS A
RESISTANCE TO FLUID FLOW, OR TO A FORCE
WHICH ATTEMPTS TO MAKE FLUID FLOW.
MEASURED IN (Pounds / Square Inch) (PSI)
FLOW = HOW MUCH OIL WILL MOVE PAST A GIVEN
POINT IN A GIVEN TIME. MEASURED IN (Gallons /
Minute or Liters / Minute)

TROUBLESHOOTING BASICS
WHAT IS THE PROBLEM ?
1) HYDRAULIC PROBLEM ?

2) ELECTRICAL PROBLEM ?

3) MECHANICAL PROBLEM ?

1) PRESSURE PROBLEM ---NO RESISTANCE TO FLOW

2) FLOW PROBLEM --- NO MOVEMENT OF LIQUID

3) MECHANICAL PROBLEM --- BINDING OR LOAD

4) ELECTRICAL PROBLEM --- NO POWER/HAS POWER

PRESSURE 2000 psi x 12.37 sq in AREA = 24,740 lbs

4570 psi WOULD BE

6” DIA NEEDED TO HOLD
THE CYLINDER FROM
28.26 sq in AREA MOVING
PISTON SIDE
4.5” DIA
q in AREA
15.89 sq
ROD SIDE
2000 psi x 28.26 sq
in AREA =
56,520 lbs

12.37 sq in AREA

28.26 sq in AREA - 15.89 sq in AREA = 12.37 sq in AREA

34
 AREAS ARE THE SAME

VOLTAGE – HOW WOULD YOU MEASURE WITHOUT A

MULTIMETER, IF THE METER READS 1200 VOLTS DC IN
THE DRILLERS PANEL IS THAT CORRECT?

PRESSURE – HOW WOULD YOU MEASURE WITHOUT A

GAUGE, IF THE GAUGE READS 10,000 psi FOR LINK TILT
FORWARD IS THAT CORRECT?

WHEN TAKING READINGS YOU NEED TO HAVE A GAUGE

OR METER AND YOU NEED TO KNOW WHAT IT SHOULD
READ!!

FUNCTION WON’T OPERATE

HUMAN ERROR?

ELECTRICAL PROBLEM? MECHANICAL PROBLEM? HYDRAULIC PROBLEM?

NO POWER LOAD HOSE PLUMBING

AUX. PUMP NOT RUNNING SEIZED COMPONENT HYDRAULIC LEAK

BAD CONNECTION ENVIRONMENT (ICE/DIRT) NO SUPPLY OF OIL TO PUMP

WIRES SHORTED/BROKEN DAMAGED COMPONENT QUICK COUPLERS

DIRECTIONAL CONTROL VALVE PUMP FAILURE DIRECTIONAL CONTROL VALVE

PLC (NO OUTPUT SIGNAL) DIRECTIONAL CONTROL VALVE PUMP FAILURE

PLC (NO INPUT SIGNAL) AUX. PUMP NOT RUNNING HYDRAULIC HOSES

SWITCH FAILURE HYDRAULIC VALVE

MOTOR FAILURE
BYPASSING!
AUX. PUMP RUNNING BACKWARDS

35
 SET @
2000 PSI

SET @ 2300 PSI

UNIT 337 AND BELOW

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI
BEFORE LATCH BEGINS TO FUNCTION GRABBER
ELEVATOR SET @
2300 PSI

UNIT 338 AND ABOVE

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

CIRCULATING

36
 ELECTRIC MOTOR

FLEX COUPLER

HYDRAULIC PUMP

GEAR PUMP

HP=PSI X GPM X 0.OOO7 HP=PSI X GPM/1714 X 1.2

ADJUSTABLE PRESSURE SWITCH

SKID PRESSURE GAUGE

SKID RELIEF

TOP DRIVE GAUGE

TOP DRIVE RELIEF

37
 GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

PIPEHANDLER LOCK

UNLOADER VALVE

PIPEHANDLER LOCK DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

PIPE HANDLER LOCK CYLINDER

38
 GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

LINK TILT AND FLOAT

UNLOADER VALVE

(SET AT 1850 PSI) (128 BAR)

FLOAT DIRECTIONAL CONTROL

VALVE

LINK TILT DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

LINK TILT FLOW CONTROLS WITH A BYPASS

39
 PORTS 5 & 6 LINK TILT

ROTARY SEAL ASSEMBLY

LINK TILT CYLINDERS

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

MUDSAVER

40
 UNLOADER VALVE

MUDSAVER DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

SHUTTLE VALVE

MUDSAVER RELIEF
(SET AT 1500 PSI) (104 BAR)

SHUTTLE VALVE MUDSAVER RELIEF

(SET AT 1500 PSI) (104 BAR)

41
 PORTS 8 & 9 MUDSAVER

ROTARY SEAL ASSEMBLY

MUDSAVER VALVE ACTUATOR

OPEN & CLOSE PORTS CONNECTIONS

OPEN
CLOSE

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

GRABBER OPEN/CLOSE

42
GRABBER INTENSIFIER APPROX 1000 PSI

6.5:1 RATIO

4800

CAUTION !!
THE GRABBER BOX SHOULD NEVER
BE CLOSED AND INTENSIFIED
WITHOUT A PIPE TO CLAMP IN
TORQUE BOX
(INJURY OR DAMAGE COULD OCCUR )

UNLOADER VALVE

PLUG
PILOT TO OPEN CHECK

2.8:1 RATIO

GRABBER OPEN/CLOSE DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

43
 PORTS 2 & 4 GRABBER OPEN/CLOSE
PORT 3 TANK

ROTARY SEAL ASSEMBLY

GRABBER SEQUENCE BLOCK LOCATION

SET PRESSURE REDUCING VALVE TO OBTAIN 4800 PSI AT THE

GRABBER CLOSE CYLINDER PORT, (PRESSURE IS READ ON GAUGE
INSTALLED IN PORT “M” OF AUXILIARY MANIFOLD) **(ADJUST
FOR DIFFERENT SIZED CONNECTIONS)**

(ADD IN)

SEQUENCE VALVE

44
 AUXILIARY MANIFOLD

GRABBER INTENSIFIER PRESSURE GAUGE

3:1 RATIO
PILOT TO OPEN CHECK VALVE

GRABBER OPEN ACCUMULATOR

(CHARGE TO 1000 PSI) (69 BAR)

GRABBER BOX CYLINDER

O C

OPEN & CLOSE PORTS

45
 C O
GRABBER CYLINDER PORTS

TORQUE BOX

GRABBER BOX

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI
BEFORE LATCH BEGINS TO FUNCTION GRABBER
ELEVATOR SET @
2300 PSI

GRABBER LIFT

UNLOADER VALVE

GRABBER LIFT DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

46
 (SET AT 600 PSI) (41 BAR)

GRABBER LIFT PRESSURE REDUCING VALVE

GRABBER LEG DOWN ACCUMULATORS

(CHARGE TO 800 PSI) (55 BAR)

PORTS 1 & 12 GRABBER LIFT

ROTARY SEAL ASSEMBLY

47
 (SET AT 3000 PSI) (207 BAR)
RELIEF VALVE

VENTED HOLE (NO PLUG)

NEW MANIFOLD

AUXILIARY MANIFOLD

(CHARGE TO 2000 PSI) ACCUMULATOR

(138 BAR)

GRABBER MEMORY PRESSURE GAUGE

RELIEF VALVE

(SET AT 3000 PSI)

(207 BAR)

NEEDLE VALVE

VENTED HOLE (NO PLUG) OLD MANIFOLD

MEMORY SECTION OF LIFT CYLINDER

GRABBER LIFT CYLINDER

WORKING SECTION OF LIFT CYLINDER

48
 GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

ELEVATOR OPEN/CLOSE

UNLOADER VALVE

(SET AT 1500 PSI) (104 BAR)

ELEVATOR OPEN/CLOSE DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

PORTS 10 & 11 ELEVATOR OPEN/CLOSE

ROTARY SEAL ASSEMBLY

49
 HYDRAULIC ELEVATORS SEQUENCE VALVE

FIELD ADJUST VALVE SO ELEVATORS CLOSE

BEFORE LATCH BEGINS TO FUNCTION

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI
BEFORE LATCH BEGINS TO FUNCTION GRABBER
ELEVATOR SET @
2300 PSI

EXTEND

UNLOADER VALVE

(SET AT 1850 PSI) (128 BAR)

EXTEND DIRECTIONAL CONTROL VALVE

11 STATION MANIFOLD

50
 EXTEND FLOW CONTROLS AND QUICK COUPLERS

EXTEND CYLINDER

GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

COUNTERBALANCE

51
 COUNTERBALANCE MANIFOLD ASSEMBLY
MOUNTED ON TOP OF GEARBOX

TORQUE BUSHING WITH COUNTER BALANCE

VENT

RELIEF VALVE

(SET AT 2000 PSI) (138 BAR)

ACCUMULATORS
(CHARGE TO 1200 PSI)
(83 BAR)

COUNTER BALANCE CYLINDERS CONNECTED TO BAIL

COUNTERBALANCE
CYLINDERS

52
 711 711 711 713 711 713 714 711 711
GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

SET @
2000 PSI

SET @ 2300 PSI

UNIT 337 AND BELOW

53
 711 711 711 713 711 713 714 711 711
GRABBER LIFT ELEVATOR EXTEND GRABBER P.H. LOCK MUDSAVER UNLOADER TILT FLOAT

a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b

P T P T P T P T P T P T P T P T P T

SET AT SET AT SET AT SET AT

1500 PSI 1500 PSI 1850 PSI 1850 PSI
2.8:1
T

P
SET AT SET AT
1850 PSI 1850 PSI

A1 P1 T1 A2 P2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10

SET AT 0-3000 PSI

1500 PSI
T3 A2 B2 GP1 P2 P3
GL
P1 P
RM MR
SV
T2 T1 T
P.H. LOCK A1 B1 SET AT GP2 SET AT
600 PSI 2000 PSI

PRECHARGE PRECHARGE
1000 PSI 800 PSI

0-5000 PSI 0-5000 PSI

EXTEND

INNER CONN. 7A 7B 1A 1B 11A 11B 10A 10B 2A 2B 4A 4B 3A 3B 5A 5B 6A 6B 8A 8B 9A 9B 12A 12B

ROTARY SEAL

OUTER CONN. 7C 7D 1D 1C 11C 11D 10C 10D 2D P 2C 4D 4C 3C 3D 5C 5D 6C 6D 8C 8D 9C 9D 12C 12D

SET SEQ. VALVE
SET TO OBTAIN
SV TO 1000 PSI
4800 PSI AT
GAUGE "M" T
(APPROX. 800 PSI) PV
P1
SET AT
2000 PSI
PRECHARGE
PRECHARGE 1200 PSI
1200 PSI T INLET

MUDSAVER VALVE
6.5:1 TILT

COUNTER BALANCE HP P
ASSEMBLY

N.C.

AUXILIARY 0-10000 PSI

MANIFOLD
N.C.

A J L
0-5000 PSI M
SET AT
3000 PSI
G DRILLERS SIDE OFF DRILLERS SIDE

B N
K

1 C 3:1
NOTES:
N.C. GRABBER LIFT 1. ROTARY SEAL CONNECTIONS: "A" - INNER DRILLER SIDE
3 E F D H "B" - INNER OFF DRILLER SIDE
"C" - OUTER DRILLER SIDE
2
"D" - OUTER OFF DRILLER SIDE
SET SO THAT PRECHARGE
ELEVATOR DOORS FULLY CLOSE 2000 PSI

ELEVATOR BEFORE LATCH BEGINS TO FUNCTION GRABBER SET @

2300 PSI

UNIT 338 AND ABOVE

54
 TESCO
PRODUCTS
DIVISION
ECI (S)
TOP DRIVE TRAINING

COOLING
SYSTEM

COOLING SYSTEM TOP DRIVE

TRAINING

ƒ AT THE COMPLETION OF THIS SECTION YOU

WILL BE ABLE TO :

ƒ IDENTIFY COMPONENTS
ƒ UNDERSTAND A BASIC REFRIDGERATION
CIRCUIT
ƒ IDENTIFY COOLING SYSTEM FLOW PATHS
ƒ IDENTIFY AND TROUBLESHOOT PROBLEMS

1
 COOLING SYSTEM
• TOP DRIVE PUMP – SUPPLIES COOLANT TO
THE TOP DRIVE FOR COOLING GEARBOX AND
MOTORS.
• DRIVE PUMP –SUPPLIES COOLANT TO THE
POWER MODULE COLD PLATES.
• CHILLER BYPASS PUMP – IS USED TO BYPASS
THE CHILLER CIRCUIT WHEN THE CHILLER IS
OUT OF SERVICE FOR REPAIR,COOLANT IS
RUN THROUGH THE MODINE INSTEAD.
• CIRCULATION PUMP – MOVES THE COOLANT
FROM THE CHILLER TANK UP TO THE CHILLER
CONDENSER COILS. (HIGH AMBIENT AND
1350)

• MODINE / AKG – RADIATORS.

• COLD PLATES – USED FOR TRANSFERRING
HEAT AWAY FROM ELECTRONIC COMPONENTS.
• KAMAN MOTOR STATORS – HAVE COOLANT
PASSING THROUGH THEM TO TRANSFER HEAT
AWAY FROM THE MOTORS,AND INTO THE
COOLANT LINES,THROUGH THE HEAT
EXCHANGER THEN RETURNING BACK TO THE
MECHANICAL MODULE.
• HEAT PUMP – COOLS OR HEATS THE POWER
MODULE CABINETS, AND CONTROLS
MOISTURE IN CABINETS. (NEWER UNITS HAVE
AN AIR CONDITIONER ONLY)
• DEHUMIDIFIER – REMOVES MOISTURE FROM
THE AIR IN THE POWER MODULE.

CHILLER
(AIR COOLED COLD GENERATOR)
– COMPRESSOR – BRINGS (LOW PRESSURE GAS IN)
AND PUMPS (HIGH PRESSURE GAS OUT) TO
CONDENSER.(R22 REFRIGERANT)

– CONDENSER – (HIGH PRESSURE GAS IN) TURNS

BACK TO (HIGH PRESSURE LIQUID OUT) WHEN IT
COOLS GOING THROUGH CONDENSER (AIR
COOLS,GOING
COOLED).

– TX VALVE – CONTROLS THE FLOW OF LIQUID

THROUGH THE EVAPORATOR,(TEMPERATURE
CONTROLLED)

– EVAPORATOR – (LOW PRESSURE LIQUID IN)

CHANGED BACK TO (LOW PRESSURE VAPOR OUT),
WHEN HEATED BY POWER MODULE COOLANT.

2
 COOLING SYSTEM DATA
•MD-500s AND CHILLER
•1 TON =12,000 BTU/HR (HEAT REMOVAL RATE)
•THE 900(2) MD-500 DRIVE REQUIRE A 10 TON CHILLER.
•THE1350(3) MD-500 DRIVE AND HIGH AMBIENT UNITS REQUIRE A
25 TON CHILLER.
•EACH MD-500 REQUIRES 15 GPM (57LPM) AND A HEAT REMOVAL
RATE OF 34,130 BTU /HR.(10kW)
•THE 900 MD-500 DRIVE COOLANT PUMP IS DRIVEN BY A 5 HP
MOTOR
•THE 1350 MD-500 DRIVE AND HIGH AMBIENT UNITS COOLANT
PUMP IS DRIVEN BY A 10 HP MOTOR
•THE 900 DRIVE USE 2 CHILLER COMPRESSORS WITH THE WATER
TEMPERATURE THERMOSTAT (WTT) SET AT
COMP#1 @70DEG.F (21.1DEG.C) 2 DEG. APART (AUTOMATIC)
• 1350 DRIVES AND HIGH AMBIENT UNITS USE 4 CHILLER
COMPRESSORS WITH THE WATER TEMPERATURE THERMOSTATS
(WTT) SET AT COMP#1 @70DEG.F (21.1DEG.C) COMP#2
@70DEG.F (21.1DEG.C) COMP#3 @72DEG.F (22.2DEG.C) COMP#4
@74DEG.F (23.3DEG.C) (MULTI STAGE SYSTEM)

COOLING SYSTEM DATA

• CHILLER BYPASS
• THE 900 MD-500 DRIVE CHILLER BYPASS PUMP IS DRIVEN BY A 5
HP MOTOR
• THE 1350 MD-500 DRIVE AND HIGH AMBIENT UNITS CHILLER
BYPASS PUMP IS DRIVEN BY A 10 HP MOTOR
• T0P DRIVE
• EACH PA44 MOTOR REQUIRES 7 GPM(26.6 LPM) OR 3.5 GPM (13.3
LPM) PER STATOR.
• THE 450 TOP DRIVE AND THE 900 TOP DRIVE COOLANT PUMP IS
DRIVEN BY A 5 HP MOTOR
• THE 1350 TOP DRIVE AND HIGH AMBIENT UNITS COOLANT PUMP
IS DRIVEN BY A 10 HP MOTOR
• FLOW SWITCHES
• THE TOP DRIVES AND MD-500 COOLANT RETURN LINES CONTAIN
FLOW SWITCHES,IF THERE IS NO FLOW THE TOP DRIVE WILL NOT
RUN (NO FLOW NO GO)

TEMPERATURE LIMITS
• 2 STATOR THERMISTOR/MOTOR- YELLOW
WARNING 266DEG.F (130 C) RED SHUTDOWN 284 DEG.F (140C)
(TOP DRIVE)

• CCB SENSOR- YELLOW WARNING 122 DEG.F(50C) RED

SHUTDOWN 131 DEG.F(55 C) (HEAT PUMP)

• PREREGULATOR SENSOR- YELLOW WARNING

122DEG.F(50C) RED SHUTDOWN 131 DEG.F(55 C) (CHILLER)

• INVERTER SENSOR- YELLOW WARNING 122 DEG.F(50C)

RED SHUTDOWN 131 DEG.F(55 C) (CHILLER)

3
 COOLING SYSTEM DATA
CONTINUED
• GOULDS PUMP MODEL # AND APPLICATIONS

• (1SVC1J6LO) – 450 HP TOP DRIVE AND DRIVE PUMPS, 900 HP

TOP DRIVE AND CHILLER BYPASS PUMPS.

• (2SVC1L6NO) – 1350 HP AND 900 HP HIGH AMBIENT PACKAGE

TOP DRIVE AND CHILLER BYPASS PUMPS.

• (3SVB1J6DO) – 900 HP DRIVE PUMP.

• (4SVB1L6DO) – 1350 HP AND 900 HP HIGH AMBIENT PACKAGE

DRIVE PUMP.

COOLING SYSTEM
ECI 900

3SV

1SV

1SV

COOLING SYSTEM
ECI 900 HIGH AMBIENT

4SV

2SV

2SV

4
 COOLING SYSTEM
ECI 1350

4SV

2SV

2SV

COOLING SYSTEM
ECI 1350 HIGH AMBIENT

4SV

2SV

2SV

5
 CHILLER TANK TOP DRIVE COOLANT TANK
145 GAL/548L 145 GAL/548L

COOLANT (UCARTHERM)
50/50 GLYCOL MIX

TOP DRIVE COOLANT PUMP CHILLER BYPASS PUMP

AND MOTOR AND MOTOR

PUMP OUTLETS

PUMP INLETS

CHILLER PUMP AND MOTOR

6
 CHILLER CIRCULATION PUMP INLET FROM RESERVOIR

CHILLER CIRCULATION PUMP

COOLANT PUMPS

SERVICE LOOP (HOSE REEL)

7
 TOP DRIVE HYDRAULIC QUICK COUPLERS

INLET

INLET

TOP DRIVE COOLANT QUICK COUPLERS

MALE COUPLER

FEMALE COUPLER

TOP DRIVE COOLANT PLUMBING

ECI 1350

COOLANT PASSAGES IN KAMAN MOTOR

8
ECI 1350

COOLING LINES OUT FROM MOTOR STATORS

CAUTION** FITTINGS OUT OF MOTOR MAY HIT QUILL IF NOT THE

CORRECT ONES

COOLING LINES INTO MOTOR STATORS

MINIMUM FLOW
3.5GPM(13.2L) /STATOR.
7GPM(26.5L) /MOTOR

THIRD MOTOR INTLET COOLING LINES ECI 1350

THIRD MOTOR OUTLET COOLING LINES

9
ECI 1350

MOTOR INLET COOLING LINES

HEAT EXCHANGER INLET FROM KAMAN MOTORS

GEARBOX OIL AND TOP DRIVE COOLANT HEAT EXCHANGER

HEAT EXCHANGER OUTLET BACK TO MECHANICAL MODULE

TO KAMAN MOTORS FROM MECHANICAL MODULE

FROM KAMAN MOTORS BACK

TO HEAT EXCHANGER

INLET FROM MECHANICAL MODULE

10
 FLOW SWITCH

OUTLET TO POWER MODULE

OUTLET TO TOP DRIVE

RETURN FROM TOP DRIVE

RETURN FROM POWER MODULE

COOLANT FILTERS
(10 MICRON)

WHEN MAKING REPAIRS

BASICTO CHILLER CIRCUIT
REFRIGERATION USE DRY N2 TO
CYCLE
PREVENT COPPER OXIDE FROM FORMING IN PIPING (BLACK)
HEATING REFRIGERANT

COOLING REFRIGERANT

HIGH PRESSURE VAPOR, HIGH PRESSURE LIQUID, LOW PRESSURE LIQUID/ VAPOUR, LOW PRESSURE VAPOUR.

11
 CHILLER CIRCUIT

LOW PRESSURE LIQUID/

VAPOUR, TURNS TO A
LOW PRESSURE VAPOUR
WHEN HEATED IN THE
EVAPORATOR WITH THE
POWER MODULE COOLANT
(LIQUID HEATED)

HIGH PRESSURE
VAPOR TURNS TO A
VAPOR,
HIGH PRESSURE
LIQUID WHEN COOLED
BY THE CONDENSOR
(AIR COOLED)

CPR

CPR

HIGH PRESSURE VAPOR, HOT GAS BYPASS HIGH PRESSURE LIQUID, LOW PRESSURE LIQUID/ VAPOUR, LOW PRESSURE VAPOUR,

DISCHARGE LINE
(GAS) (HIGH PRESSURE)

(HIGH PRESSURE CUT OUT SWITCH)

CONDENSER

CONDENSER REFRIGERANT IN
(GAS) (HIGH PRESSURE)

CONDENSER REFRIGERANT OUT

(LIQUID) (HIGH PRESSURE)

12
 HOT GAS BYPASS VALVE

LINE TO EVAPORATOR

EQUAILIZER LINE

HOT GAS BYPASS SOLENOID

PROVIDES A MEANS TO BYPASS HIGH PRESSURE REFRIDGERANT TO THE
SYSTEMS LOW PRESSURE SIDE IN ORDER TO MAINTAIN A GIVEN
MINIMUM SUCTION PRESSURE, AND TO BALANCE THE SYSTEM CAPACITY
TO THE LOAD DEMAND

LINE TO EVAPORATOR FROM HOT GAS BYPASS VALVE

COMPRESSOR HEATER

CHILLER REFRIDGERANT LEVEL GAUGE

(HIGH PRESSURE LIQUID) (R22)

13
 TX VALVE

TX VALVE BULB
OUT (B) IN

REMOTE BULB

EQUAILIZER LINE
(A)

THE THERMO EXPANSION VALVE REGULATES THE FLOW OF LIQUID REFRIDGERANT

INTO THE EVAPORATOR IN EXACT PROPORTION TO THE RATE OF EVAPORATION OF
THE LIQUID REFRIDGERANT. THE TX VALVE RESPONDS TO (A) THE TEMPERATURE OF
THE GAS REFRIDGERANT LEAVING THE EVAPORATOR AND (B) THE PRESSURE AND
THE SPRING IN THE EVAPORATOR. THIS CONTROLLED FLOW PREVENTS LIQUID
REFRIDGERANT FROM RETURNING TO THE COMPRESSOR.

P1

AS TEMPERATURE AT
BULB INCREASES THE
PRESSURE INCREASES
BULB
AT P1 AND OPENS
P2 EXPANSION VALVE.
WORKING AGAINST
OUTLET PRESSURE P2
AND SPRING P3

P3 P1 = P2 + P3
VALVE IS EQUALIZED

P1 GREATER THAN P2 + P3
VALVE WILL OPEN

P1 LESS THAN P2 + P3
VALVE WILL CLOSE

SUPERHEAT
- A VAPOR IS SUPERHEATED WHEN ITS TEMPERATURE IS HIGHER THAN THE SATURATION
TEMPERATURE CORRESPONDING TO ITS PRESSURE.

- THE AMOUNT OF SUPERHEAT EQUALS THE AMOUNT OF TEMPERATURE INCREASE ABOVE THE
SATURATION TEMPERATURE CORRESPONDING TO ITS PRESSURE.

-e.g. AN EVAPORATOR IS OPERATING WITH R22 REFRIDGERANT AND A SUCTION PRESSURE OF 69 psig.

-THE R22 SATURATION TEMPERATURE AT 69 psig IS 40 DEG.F. AS LONG AS ANY LIQUID EXISTS AT THIS
PRESSURE, THE REFRIDGERANT TEMPERATURE WILL REMAIN 40 DEG F, AS IT EVAPORATES OR BOILS OFF
IN THE EVAPORATOR.

-AS THE REFRIDGERANT MOVES ALONG IN THE COIL,, THE LIQUID

Q BOILS OFF INTO A VAPOR,, CAUSING
THE AMOUNT OF LIQUID TO DECREASE.

-ALL THE LIQUID IS FINALLY EVAPORATED BECAUSE IT HAS ABSORBED SUFFICIENT HEAT FROM THE
SURROUNDING ATMOSPHERE TO CHANGE IT TO A VAPOR.

-THE VAPOR REMAINS AT THE SAME PRESSURE 69 psig. HOWEVER ITS TEMPERATURE INCREASES DUE TO
CONTINUED ABSORBTION OF HEAT FROM THE SURROUNDING ATMOSPHERE.

-WHEN THE VAPOR REACHES THE END OF THE EVAPORATOR ITS TEMPERATURE IS 50 DEG F.

-THIS VAPOR IS NOW SUPERHEATED, AND THE AMOUNT OF SUPERHEAT IS 10 DEG F. (50 – 40 = 10).

-THE AMOUNT OF SUPERHEAT DEPENDS ON (1) THE AMOUNT OF REFRIDGERANT BEING FED TO THE
EVAPORATOR BY THE TX VALVE AND (2) THE HEAT LOAD WHICH THE EVAPORATOR IS EXPOSED TO.

14
 P1 = P2 + P3
VALVE IS EQUALIZED

59 psig = 33 DEG F.
BULB 44 DEG F.

44 DEG-
33 DEG=
11 DEG SUPERHEAT

SUPERHEAT
-THE TX VALVE CONTROLS THE AMOUNT OF REFRIDERANT THROUGH
THE EVAPORATOR.
-USING R22 REFRIDGERANT
SUPERHEAT SHOULD BE BETWEEN 12 – 17 DEG. F.

-IF THE SUPERHEAT IS BELOW 12 DEG. THE COMPRESSOR IS

RECEIVING SOME LIQUID
Q OTHER THAN JUST VAPOR THIS IS KNOWN
AS FLOODING. THE TX VALVE IS ALLOWING THE REFRIDERANT TO
PASS THROUGH THE EVAPORATOR TOO QUICKLY (OPEN TO MUCH).
THIS WILL CAUSE COMPRESSOR DAMAGE.

-IF THE SUPERHEAT IS ABOVE 17 DEG. THE COMPRESSOR IS

RECEIVING THE VAPOR WHICH HAS BEEN OVERHEATED TOO MUCH.
THE TX VALVE IS ALLOWING THE REFRIDGERANT TO PASS THROUGH
THE EVAPORAOR TOO SLOWLY. (CLOSED TO MUCH).
THIS WILL ALSO CAUSE COMPRESSOR DAMAGE.

*CHECK YOUR SUPERHEAT TO PREVENT COMPRESSOR DAMAGE*

15
EVAPORATOR REFRIGERANT IN
(LIQUID) (LOW PRESSURE)

EVAPORATOR

EVAPORATOR REFRIGERANT OUT

(VAPOR) (LOW PRESSURE)

(LOW PRESSURE CUT OUT LINE TO ADJUSTABLE SWITCH’S)

DISCHARGE LINES
(GAS) (HIGH PRESSURE)

SUCTION LINES
(GAS) (LOW PRESSURE)

16
 CHILLER COMPRESSORS AND EVAPORATORS LOCATION

COOLER

WARMER

CHILLER REFRIGERANT CAPACITY ECI 1350 OR HIGH

AMBIENT PACKAGE (30lbs)

CHILLER EVAPORATOR LOCATION

EVAPORATOR REFRIGERANT OUT

(GAS)
EVAPORATOR REFRIGERANT IN
(LIQUID)

TX VALVES

17
 ECI 900 CHILLER COMPRESSORS LOCATION

CPR VALVES PROTECT COMPRESSORS FROM OVERLOAD

WARMER

COOLER

LIQUID LINE DRIERS MAX. 1-2 DEG.BETWEEN INLET AND OUTLET

ECI 900 HIGH AMBIENT, ECI 1350

OVERHEAD CHILLER CONDENSER COILS

LIQUID LINE DRIER MAX. 1-2 DEG.BETWEEN INLET AND OUTLET

900 CHILLER

SUCTION PRESSURE SHOULD BE 60-80 PSI

DISCHARGE PRESSURE SHOULD BE 250-300 PSI (NORMAL)

18
 POWER MODULE COOLING LINES TO COLD PLATES

MINIMUM FLOW
5 GPM(19L) /COLD PLATE.
15 GPM(57L) /MD500

HEAT PUMP REFRIGERANT CAPACITY

(3.5lbs-5lbs)

FILL CONNECTIONS (HEAT PUMP)

HEAT PUMP LOCATION

19
HEAT PUMP

20
TESCO PRODUCTS
DIVISION
ELECTRIC
TOP DRIVE TRAINING

ECI (S)

ƒ E -- ELECTRIC
ƒ C -- COMPACT
ƒ I -- INTEGRATED

ƒ S -- SWIVEL

•TOP DRIVE TESCO

• SWIVEL (ECIS)

• GEARBOX

• ELECTRIC MOTORS

• AUXILIARY HYDRAULIC
FUNCTIONS (ROBOTICS)

•TOP DRIVE ELECTRICAL

PANEL “T AND A”

•LOAD PATH COMPONENTS

1
 GEARBOX
LUBRICATION
C O
CIRCUIT

GEARBOX LUBRICATION
TOP DRIVE TRAINING
AT THE COMPLETION OF THIS SECTION
YOU WILL BE ABLE TO :

ƒ IDENTIFY COMPONENTS

ƒ FOLLOW FLOW PATHS (SCHEMATICS)

ƒ TROUBLESHOOTING BASICS

**LUBRICATES IN FORWARD ONLY**

(5 psi)

(10.3 bar)

(75w90 synthetic oil)

2
 CHECK VALVES

GEARBOX OIL LEVEL

(75W90 SYNTHETIC GEAR OIL)

LUBE PUMP

RELIEF VALVE

*CAUTION* IF REPLACING GEARBOX LUBE PUMP ALWAYS CHECK

GEARBOX LUBE PRESSURE ON INITIAL ROTATION.

GEARBOX LUBE PRESSURE GAUGE

LUBE PUMP

GEARBOX OIL TEMPERATURE GAUGE

RELIEF VALVE

*CAUTION* IF REPLACING GEARBOX LUBE PUMP ALWAYS CHECK

GEARBOX LUBE PRESSURE ON INITIAL ROTATION.

3
 GEARBOX OIL AND TOP DRIVE COOLANT COOLER

GEARBOX LUBE PRESSURE GAUGE

CHECK VALVE

INLET

OUTLET

GEARBOX OIL TEMPERATURE GAUGE

GEARBOX OIL SUMP DRAIN

4
 FILTER
(10 MICRON)

GEARBOX SPRAY NOZZLE LINES

CHECK VALVE

GEARBOX SPRAY NOZZLE LINES

5
 GEARBOX SPRAY NOZZLE LINES

BEARING LUBE LINE

GEARBOX DISTRIBUTION BLOCK AND LINES

OUTLETS TO BEARINGS

OUTLET TO UPPER MOTOR SPRAY NOZZLE ON ECI 1350/HIGH

AMBIENT OR THE BEARING ON A ECI 900

6
 GEARBOX DISTRIBUTION BLOCK AND LINES

INLET TO DISTRIBUTION BLOCK

GEARBOX LUBE PRESSURE GAUGE

GEARBOX DISTRIBUTION BLOCK AND LINES ECI 900

OUTLETS TO BEARINGS

GEARBOX SPRAY NOZZLE LINES

7
 **LUBRICATES IN FORWARD AND REVERSE**

5 psi

(10.3bar)

(75w90 synthetic oil)

**SPECIAL APPLICATION**

8
TESCO PRODUCTS
DIVISION
ECI
TOP DRIVE TRAINING

ECI S

ƒ E -- ELECTRIC
ƒ C -- COMPACT
ƒ I -- INTEGRATED

ƒ S -- SWIVEL

GENERAL
MAINTENANCE
INSPECTIONS

1
 GENERAL MAINTENANCE TOP
DRIVE TRAINING
GENERAL MAINTENANCE IS THE CHECKING AND
SERVICING OF THE TOP DRIVE/MECHANICAL
SKID/POWER MODULE: DAILY, WEEKLY, MONTHLY,
SIX MONTHS, AND ANNUALY, INCLUDING:

ƒ CHECKING GAUGES
GAUGES, LEVELS,
LEVELS TEMPERATURES
TEMPERATURES, AND
FLOW METERS (IMPORTANT THAT THIS IS DONE
DAILY)

ƒ ALL FLUIDS FOR CONDITION (VISUAL, SAMPLING?)

ƒ GREASING REGULARLY (DAILY)

ƒ USING THE PROPER LUBRICANTS

Tesco Oil Applications

80W90 TS2665 205L TS10030 20L

All hydraulic unit gearboxes HS, HC, HCI, HMI.

75W90 Synthetic TS7403 205L TS9042 20L

All electric unit gearboxes EC, ECI, EMI.

15W40 TS1663 20L

All Caterpillar engines, Detroit 60 and 2000 series engines.

40W TS6246 205L TS1659 20L

All pump drives
drives, Detroit 92 series engines.
engines

HVI 68 TS8737 205L TS8736 20L

Hydraulic and electric units hydraulic systems except USA destined.

ATF TS6044 205L

Some Electric unit hydraulic systems EC, ECI, EMI.

Ucatherm TS4229 205L

All electric unit cooling systems EC, ECI, EMI.

UCATHERM CROSSOVER HEAT TRANSFERENT FLUIDS

DOWTHERM SR-1, DOWTHERM 4000, INTERCOOL OP-100, JEFFCOOLL/E-SERIES, HTF-EG

2
Daily Top Drive Service

INSPECT FOR

• Gearbox oil level - proper gearbox oil level

• Hydraulic hoses connections at top drive - leaks
• Coolant hoses at top drive - leaks

LUBRICATE WITH

• EXTEND CYLINDER GREASE NIPPLES (4) - EP2 multi-purpose grease

• Lower bearing retainer of gearbox grease ports (2) - EP2 multi-purpose grease
• Slewing bearing grease nipple (2) - EP2 multi-purpose grease
NOTE: A single point on the mainframe provides
pro ides access to
both nipples. To grease:
1. Grease the first nipple.
2. Rotate the pipe handler 180 degrees.
3. Grease the second nipple.

• Load collar grease ports (2) - EP2 multi-purpose grease

• Fluid swivel grease ports (2) - EP2 multi-purpose grease
• Link tilt cylinders (4 per side – 8 total) - EP2 multi-purpose grease
• Elevator grease ports (3) - EP2 multi-purpose grease
• Pipe handler lock (1) - EP2 multi-purpose grease
• Mud saver valve - Mystik JT6 or Metalon EP1.5
• Swivel bail hinge point ports (2) - EP2 multi-purpose grease
• Wash pipe ports (2) - EP2 multi-purpose grease
• Upper bearing retainer (1) - EP2 multi-purpose grease
• Lower bearing retainer (1) - EP2 multi-purpose grease

Weekly Top Drive Service

INSPECT FOR

• Grabber dies - excessive wear

• Auxiliary manifold - general condition
• Load collar - ensure that the load ride height on the spring is
adequate
• Mud saver valve (lower ball) - manually operate to ensure proper function
• All fasteners (nuts, bolts and lock wires) - are they in place, tight
• Top drive hydraulic connections and hoses - oil leaks
• Top drive coolant connections and hoses - coolant leaks
• Saver sub threads - excessive wear
• Connection locking clamps - proper location
• Grabber leg safety chain - broken components
• Pipe bumper/motor guard - dents or bends that may indicate bolt damage
• Counter balance system - ensure proper function and set up
• Hammer unions - integrity and tightness
• Swivel oil level - proper level

Monthly Top Drive Service

INSPECT FOR

• Gearbox oil analysis
• Hydraulic fittings
• Roto – actuator sleeve
• Grabber
• Counterbalance
• Pipe handler manifold
• Grabber open
• Grabber close pressure reducing valve
• Kaman motor termination boxes
• Sensor panel
• Solenoid junction panel
• Gearbox lubrication filter
• Quill preload
• Ringfeder protective boot
-sample for abnormalities. (water, metal particles, etc). (every 900
hours)
- tightness
- disassemble, clean, grease, coat with corrosion inhibitor – and reinstall
- check and reset grabber height
- cushion height
- nitrogen pre-charge in pipe handler manifold accumulator.
- nitrogen pre-charge
- check pressure
- moisture and bolt torque
- moisture and wire termination tightness
- moisture and wire termination tightness
- cleanliness
- proper preload
-proper lubrication
-NOTE: Once every month the ringfeder protective boot should be
removed. Grease from the bottom grease zerks of the drive hub should
travel up past the spline and exit through the ringfeder. The entire area
under the protective boot should have a grease coating. If proper
lubrication has been performed but dry spots are apparent, a more
detailed inspection is required.

LUBRICATE WITH

• Hinge pins and extend frame - spray with penetrating oil (WD 40, or spray lithium)
• Gearbox drive hub grease ports - EP2 multi-purpose grease

3
 Power Module Service Requirement
Daily Service

INSPECT FOR

• All panels and floor - coolant leaks

- moisture
• Drive components - CRITICAL: Never power up the drive components if
moisture is present !!!!!
• Indicator lights - proper function (replace if required)

Power Module Service Requirement

Weekly Service

INSPECT FOR

• System Air Exchanger air filters (bottom of the analog panel) - cleanliness (change if required)

Power Module Service Requirement

Monthly Service

INSPECT FOR

• All wire terminal screws - tightness

• Incoming and outgoing waterfall bolted connections - tightness
• Inverter motor output connections - proper position and tightness
• ER950/Inverter power connections - tightness
• Main drive component electrical connections - proper torque
• IGBT’s and related bus works - proper torque
• Cooling connectors - tightness
• All external power connections (to top drive from mechanical - these should be disassembled, sprayed with electrical
module) cleaner/moisture dispersant, and reconnected

Mechanical Module Service Requirement

Daily Service

INSPECT FOR

• Auxiliary hydraulic oil tank - oil level

• Coolant tank - coolant level
• Modine air exchanger - radiator cleanliness
• Trane chiller cooling coil - cleanliness
• All flow meters - reporting correct flow

Mechanical Module Service Requirement

Monthly Service

INSPECT FOR

• Trane chiller - freon level

• Auxiliary system pressure relief - proper setting
• Auxiliary system function light pressure switch - proper setting
• Modine thermostat switch - proper operation
• Coolant filters (2 canisters – 4 filters) - inspect and change
• Auxiliary hydraulic filter (1) - inspect and change
• Ambient cooling fluid (topdrive) - complete fluid analysis (every 900 hours)
• Chiller fluid (power module) - complete fluid analysis (every 900 hours)
• Auxiliary hydraulic fluid - complete fluid analysis (every 900 hours)

Torque System Service Requirements

Daily Service

INSPECT FOR

• All connections - soundness

• All overhead
h d equipment
i t (T-bar,
(T b ttorque beam,
b torque
t tube,
t b
torque bushing) - soundness

Torque System Service Requirements

Weekly Service

INSPECT FOR

• All bolts and ready rods - soundness

• Hang sling and hang apparatus - close visual inspection is required
• Torque bushing liner - wear
• Torque bushing clearance - amount of clearance (less than ¼ inch)

4
Service Loop
Weekly Service Requirements

INSPECT FOR

• All service loop components - damage, excessive wear

• Urethan capture blocks (at top drive and roller saddle) - hose placement
• Fluid quick couplers (auxiliary and cooling) - soundness, tightness
• bl connections
All cable ti
• (37 conductor and 18 TWP) - tightness

Service Loop
Monthly Service Requirements

INSPECT FOR

• All multi-conductor connections - open and check for moisture, dirt

- spray with electrical cleaner/moisture dispersant
• main service cable cam lock connectors - open, clean, reinstall

5
6
7
8
9
10
 6/18/2010

TESCO CORPORATE
TRAINING
AND
DEVELOPMENT

ECI Top Drives

Level I Training
Overview

Tesco Top Drive system

1
 6/18/2010

Power Module

Power Module

ƒ Houses all control and distribution power

for the Tesco top drive system.

Main Components of the Power Module

ƒ Control Panel.
ƒ MD-500.
ƒ System Controller (CCB).
ƒ PLC.
ƒ Lab View.
ƒ Motor starters.
ƒ Braking resistors.
ƒ Heat pump.
ƒ Control distribution.
ƒ Power distribution.

2
 6/18/2010

Control
P
Panel
l

MD-500

MD-500
ƒ Supplies power for
the top drive motor.
ƒ Converts both
voltage and
frequency through
PWM technology.
ƒ Works in
conjunction with the
CCB.
ƒ Designed for
Synchroness
operation.

3
 6/18/2010

System
C t ll
Controller

System Controller

System Controller is
the interface
between the MD-500
and the outside
world.
Converts speed and
torque signals to
operate the inverter.

PLC
( Programmable Logic Controller )

4
 6/18/2010

PLC
( Programmable Logic Controller )

ƒ Remote controller.
ƒ Processes
information at high
rate of speed.
ƒ Located in main
control cabinet.

PLC
( Programmable Logic Controller )

ƒ Replaces multi
conductor cables
from the Power
Module to the Drillers
Panel.
ƒ Utilizes a
communication cable
for the processing of
Inputs/Outputs rather
than 24Volt relay
logic.

Lab View

5
 6/18/2010

Lab View

ƒ Interface between
the MD-500 and the
real world.
ƒ Displays
p y status of
the MD-500 and the
top drive.
ƒ Includes
temperatures,
voltages, current,
and fault codes.

Lab View

ƒ Used as a
diagnostic tool for
the MD-500 and the
top drive.
drive
ƒ Can be used to
manipulate the
operation of the
top drive system.

Motor Starters

6
 6/18/2010

Motor Starters

ƒ Starters located
behind doors of
the starter panel.
ƒ Used for the
starting of all the
motors located in
the mechanical
module.

Braking resistors

ƒ Enabled during a fault

condition that requires a
immediate shutdown or
to control over voltage
situations during
unwind.
ƒ All voltage present on
the MD-500 and
produced from the
spinning top drive is
dissipated immediately
through the brake
resistors.

Heat Pump

7
 6/18/2010

Heat Pump
ƒ Used for the cooling
of the drive and
control cabinets.
ƒ Cools air using
glycol from the
chiller, located in
the mechanical
module, and
circulates this
cooled air through
the cabinets.

Control Distribution
24Vdc Control UPS 120Vac

UPS 120 VAC

ƒ Un-interrupted
Power Supply.
ƒ Provides back up
control power for
the System
Controller in the
event of a rig
blackout.

8
 6/18/2010

24Vdc Control

ƒ Main distribution
for robotics and
sensors.
ƒ Utilizes both 24Vdc
and 4-20mA
control systems.

Power Distribution

Power Distribution

ƒ Distributes main
power (600Vac)
through out the top
drive system.
ƒ Contains main
breakers for the
MD-500 system.
ƒ Voltage supplied
from incoming rig
power or stand
alone generator.

9
 6/18/2010

Mechanical Module

Mechanical Module

ƒ Supplies all cooling and hydraulics

p drive and the power
for the top p
module.

Main Components of the Mechanical Module

ƒ Chiller. ƒ Flow switches.

ƒ Top drive pump. ƒ Tank heater.
ƒ Drive pump. ƒ Oil level switch.
ƒ yp
Chiller by-pass pump.
p p ƒ Topp drive tempp
ƒ Auxiliary pump. switch.
ƒ Top drive cooling fan. ƒ Auxiliary pressure
switch.

10
 6/18/2010

Chiller

Chiller

ƒ Used for the cooling

of the MD-500 drive
system only.
ƒ 10 or 25ton
depending on the
amount of drives to
be cooled.

Top Drive Pump

11
 6/18/2010

Top Drive Pump

ƒ Circulates 50/50
glycol through the
top drive cooling
loop
loop.
ƒ Controlled from
the power module.

Drive Pump

Drive Pump

ƒ Supplies glycol to
the MD-500 system
only.
ƒ Must be running at
all times for the top
drive to operate.
ƒ Size of the pump
varies with the
number of drives in
the system.

12
 6/18/2010

By-pass Pump

By-pass Pump
ƒ Used as a reserve
pump for the MD-
500.
ƒ Routes glycol
through the top
drive fan via a
manifold system.
ƒ By-passes the
chiller in the case
of failure or
service.

Auxiliary Pump

13
 6/18/2010

Auxiliary Pump
ƒ Supplies all hydraulic
oil for the robotic
functions of the top
drive.
ƒ Controlled from either
the power module or
the drillers panel.
ƒ 10 HP motor coupled
to a P-30 pump
supplying 7 gpm @
2100 psi.

Top Drive Cooling Fan

Top Drive Cooling Fan

ƒ Cools glycol
returning from
the top drive.
ƒ Thermostatically
controlled.
ƒ 10 HP motor
mounted to a M-
12 Modine heat
exchanger.

14
 6/18/2010

Flow Switches

Flow Switches

ƒ Used as an
interlock for the
top drive system.
ƒ Located on the
return side of the
drive and the top
drive cooling
loops.
ƒ Wired in series.

Oil Level Switch

15
 6/18/2010

Oil Level Switch

ƒ Low oil
shutdown.
ƒ Locks out aux.
Pump in a low
oil condition.

Tank Heater

Tank Heater

ƒ Maintains operating
temperature of the
hydraulic fluid used
for the robotics
system.
ƒ Set for 30 C or 86 F.

16
 6/18/2010

Top Drive Temperature Switch

Top Drive temperature Switch

ƒ Controls the top

drive cooling fan.
ƒ Set at 32 C or 90
F
F.
ƒ Mounted on the to
drive cooling
tank.

Auxiliary
Pressure
Switch

17
 6/18/2010

Auxiliary Pressure Switch

ƒ Set at 800psi.
ƒ Indicates pressure
being produced by
the Aux.
Aux Pump
during use of the
robotics.

Service Reel

Service Reel

ƒ Holds all
electrical cables,
cooling lines,
and the
hydraulic lines
for robotics.
ƒ Commonly
called the
service loop.

18
 6/18/2010

Drillers Panel

Drillers Panel

ƒ Drillers interface with the top drive.

ƒ Provides control for all robotic,
speed, and torque functions.

Main Components of the Drillers Panel

ƒ Remote I/O (extension of main PLC).

ƒ Drive set control functions.
ƒ Draw works interlock.
ƒ Mud pump interlock.

19
 6/18/2010

Top Drive

Top Drive
ƒ Responsible for all the pipe handling
functions during the drilling
operation.
ƒ Pipe handling functions include
rotational and robotics.

Main Components of the Top Drive

ƒ Robotics.
ƒ PA44 motor.
ƒ Resolver.
ƒ Temperature sensors.
ƒ Top drive junction box.

20
 6/18/2010

Robotics
ƒ Pipe Handler lock. ƒ Mud Saver open.
ƒ Pipe Handler ƒ Mud Saver close.
unlock.
ƒ Grabber open.
ƒ Elevators open.
ƒ Grabber close.
ƒ Elevators
El t close.
l
ƒ Link Tilt forward. ƒ Grabber Lift up.
ƒ Link Tilt back. ƒ Grabber Lift down.
ƒ Extend in. ƒ Pipe Handler Rotate.
ƒ Extend out.

PA44-5W
PA44 5W
Motor

PA44-5W Motor
ƒ 450 HP
continuous.
ƒ Synchroness.
ƒ Liquid cooled.
cooled
ƒ Continuous stall
torque of 1200 lb-
ft.

21
 6/18/2010

Resolver

Resolver
ƒ Mounted on the shaft,
top side of the PA44
motor.
ƒ Determines absolute
positioning of the rotor.
ƒ Signal sent to the CCB
and used to fire the MD-
500 for Synchroness
operation.

Resolver

22
 6/18/2010

Top
p Drive
Junction
box

Temperature Sensors

Stator Temp.
ƒ Two temperature
sensors for
monitoring stator
Stator g (upper
windings ( pp
and lower).
ƒ Thermistor type
imbedded into the
stator windings.

23
 6/18/2010

THE END
For more information contact the Training and Development Department
or visit http/ngrain.com

24
 6/24/2010

TESCO CORPORATE
TRAINING
AND
DEVELOPMENT

ECI TOP DRIVES

The PA44 Motor

PA44-5W Motor

1
 6/24/2010

PA44-5W Motor
ƒ 450 HP
continuous.
ƒ Synchronous.
ƒ Liquid glycol
cooled (7
GPM).

PA44-5W Motor
ƒ Drill Mode:
• # of motors X Gear
Ratio X 1050 ft-lbs
• Connect Mode:
• # of motors X Gear
Ratio X 1250 ft-lbs
• Breakout Mode:
• # of motors X Gear
Ratio X 1539 ft-lbs Note: Connect Reverse is 80%

PA44 Motor

2
 6/24/2010

PA44 Motor

PA44 Motor
ƒ Rotor is made of
titanium.
ƒ Uses 28 permanent
magnets arranged in
14 pairs.
ƒ Set into a closed loop
system.
ƒ Magnets do not
degrade.

Resolver

3
 6/24/2010

Resolver
ƒ Mounted on the shaft, top
side of the PA44 motor.
ƒ Determines absolute
positioning of the rotor in
relation to the stator.
stator
ƒ Signal sent to the CCB
and used to fire the MD-
500 for synchronous
operation.

Resolver Signal

REFERENCE

SIN

COS

Resolver Signal
ƒ Signal is converted
by the CCB to
determine the
absolute
positioning of the
rotor.
ƒ Sine and cosine
signals are 90 deg.
apart due to the
physical location
of the windings.

4
 6/24/2010

Noisy Resolver Signal

PA44 Back EMF

MD-500 Output

5
 6/24/2010

Out of Time

In Time

Timing Adjustment
ƒ To advance or retard
the waveform, the S1
timing switch is
utilized.
ƒ In its memory
memory, it has
pre-stored locations
of the firing signal
which can be
delivered as an output
as the dipswitches
are changed.

6
 6/24/2010

Motor Terminals

Motor Terminals

Silicone and
Gasket “ALL” faces
of the junction box.

Motor Terminals
ƒ In the event that moisture
enters the Top Drive motor
junction box, the Vbus of
the relative motor can show
tracking from 300 to 500
VDC upon rotation.
t ti
ƒ As part of maintenance
ensure that the junction
box is free and clear of all
contamination and
moisture.
ƒ Bolt and set screw torques
should also be a part of the
scheduled maintenance

7
 6/24/2010

Motor Terminals

This shows the view of the

winding terminal face that
makes contact with the motor
terminal

Motor Terminals

Motor Terminals
Note : The terminal only makes contact with the internal
stator windings on the flat face of the terminal. No other
portion of the terminal makes contact. Proper tightening and
fitting of the terminal is absolutely necessary.

Only
contacting
surface

8
 6/24/2010

Motor Terminals
Torque Values

5/16 inch bolt : 150

inch/lbs

* Use three beveled washers on

the 5/16 bolt to prevent bottoming
out bolt.

Set Screw- 25 ft-lbs

Motor Terminals

ƒ Must be checked
periodically for
tightness.
ƒ If connections
loosen damage will
occur warranting
replacement of the
PA44 motor.

Temperature Sensors

9
 6/24/2010

Stator Temp.
ƒ Two temperature
sensors for
monitoring stator
windings (upper Stator
and lower).
ƒ Thermistor type
imbedded into the
Rotor : Not used
stator windings.
ƒ Rotor sensors are
capped and
“masked” with a
2.5 Kohm resistor

Stator Temp.

In summary…
ƒ The PA44 motor is a permanent magnet, brushless,
three phase, synchronous motor.

ƒ The PA44 motor is liquid cooled and must be kept below

130 degrees C to avoid magnet degradation.

ƒ The PA44 motor is designed to maintain stall torque

“indefinitely” without complications.

ƒ As part of a regular maintenance program, the motor

should be periodically checked for terminal tightness,
moisture ingress to the junction box, and timing.

10
 6/24/2010

THE END
For more information contact the Training and Development Department
or visit http/ngrain.com

11
 6/24/2010

TESCO CORPORATE
TRAINING
AND
DEVELOPMENT

ECI Top Drives

MD 500 O
MD-500 Overview
i

MD-500

1
 6/24/2010

MD-500
ƒSupplies power for the
Top Drive motor(s).
ƒAC-AC converter.
Controlling both voltage
and frequency.
ƒOperated using a
System Controller (CCB)
for running Top Drive
motor(s) in a
synchronous mode.

MD-500 Cooling

ƒLiquid cooled.
ƒEach MD-500
requires 15gpm of
cooling
li fl
flow.
ƒCooling is
interlocked with the
drive system through
flow switches.
ƒ“No Flow, No Go”

2
 6/24/2010

MD-500 Components

Input Module

Buck Module

Choke (not shown)

Inverter Module

3
 6/24/2010

Common negative
Bus

MD-500 Components

Input Module

4
 6/24/2010

Input Module
ƒThree phase full wave
bridge rectifier.
ƒ600VAC input voltage is
rectified to 830VDC.
ƒThis voltage is
automatically present
once it goes through the
bridge.
ƒThis 830VDC is called
the “Raw Bus” voltage.

Input Module

Input Topology

5
 6/24/2010

Positive of Raw
Bus

Capacitor Bank

ƒLocated behind the

Buck module.
ƒParalleled across the
“R
“Raw B
Bus”.
”
ƒReduces the ripple on
the 830Vdc from the
rectification bridge.

Capacitor Bank

6
 6/24/2010

MD-500 Components

Buck Module

Buck Module
ƒTakes “Raw Bus” voltage and
varies it from 0-780VDC.
ƒThis voltage makes up the “V
Bus” to feed the Inverter
module.
ƒVarying the voltage is possible
by the use of “IGBT’s” with an
associated blocking diode.

Buck Module

7
 6/24/2010

Buck Topology

Choke Module
ƒLocated behind the Input
Module.
ƒLarge induction coil used
to oppose the change in
current.
current
ƒHas individual input from
the Buck Module and star
connected output.
ƒUsed in conjunction with
a capacitor bank to make
an LC filter for the V-Bus.

Choke
Module

8
 6/24/2010

Choke Topology

0-780 VDC

Positive of V-
Bus

LC Filter
ƒLocated behind the
Inverter module.
ƒParalleled across the
“V-Bus”.
ƒUsed
Used in combination
with Chokes to create
an LC filter.
ƒCapacitors = C :
oppose a change in
Voltage
ƒChokes = L : oppose a
change in Current

9
 6/24/2010

Choke Module

LC Filter

Capacitor Bank

MD-500 Components

Inverter Module

Inverter Module
ƒVoltage supplied from
the “V Bus” is used to
supply a Trapezoidal
(six step) waveform to
the PA-44
PA 44 motor on the
Top Drive.
ƒProcess possible by
the use of IGBT’s
(insulated gate bi-polar
transistors).

10
 6/24/2010

Inverter
Module

Inverter Topology

Components of the MD-500

11
 6/24/2010

MD-500 Components

Input Module

Power Diodes

12
 6/24/2010

Power Diodes
ƒThree Phase Full
Wave Rectification
Bridge.
ƒTotal of three diode
packs.
ƒEach pack consists
of two back to back
diodes for a total of
six diodes.

Power Diodes

13
 6/24/2010

Power Diodes

Power Diodes

2
3

Diode

14
 6/24/2010

AC Sine Wave

Positive
VAC

0VAC

Negative
VAC

Power Diodes

+VAC

Power Diodes

-VAC

15
 6/24/2010

Power Diodes
Positive of the Negative of the
Raw Bus Raw Bus

Input (AC)
Input = 600VAC

A phase

B phase

C phase

Output (DC)

Output = 830VDC

-VDC
VDC

+VDC

16
 6/24/2010

Raw Bus

Raw Bus = 830VDC

Neg
Neg.

Raw Bus

Pos.

Capacitor
Bank

Capacitor Bank
ƒLocated behind the
Buck module.
ƒParalleled across the
“Raw Bus”.
ƒReduces the ripple
on the 830VDC from
the rectification
bridge.

17
 6/24/2010

Pre-charge cct.

Pre-charge cct.

ƒ Charges the “Raw Bus”

before main breakers can
be set.
ƒ Prevents Inrush current
to the capacitor bank
located under the Buck
module.

Pre-charge cct.

18
 6/24/2010

Pre-charge cct.

Pre-charge cct.

50VA transformer
120:600VAC

Pre-charge cct.

19
 6/24/2010

Pre-charge cct.

Precharge
Relay

Pre-charge cct.

20
 6/24/2010

High Voltage Control

HVCB ( High Voltage Control

Board)
ƒ Monitors both the “Raw
Bus” and the “V Bus” for
their respective voltages.
ƒ Controls the brake cct.
(dump cct.) in over
voltage conditions.

HVCB

21
 6/24/2010

High Voltage Control

Brake cct.

Brake cct. (Dump cct.)

ƒ Diverts all potential

stored on the MD-500 to
a grid resistor in a
shutdown or unwind
situation.

22
 6/24/2010

Brake cct.

Brake cct.

Brake Circuit

23
 6/24/2010

INTELLIGENT POWER MODULE

Brake cct.

Braking IGBT

IPM Capacitor

Blocking
diode

24
 6/24/2010

Braking resistors

ƒDischarges the “V-

Bus” when the drillers
panel is disabled or
p
during unwind.
ƒParalleled across the
“V-Bus” for
intermittent use only.

MD-500 Components

Buck Module

25
 6/24/2010

IGBT
(Insulated Gate Bi-polar Transistor)

IGBT
(Insulated Gate Bi-polar Transistor)

ƒHigh speed switching

device.
ƒHas a switching
f
frequency off 30KH
30KHz.
ƒ30,000 times per
second.
ƒ+15Vdc to turn on
and –8Vdc to force off.

IGBT
(Insulated Gate Bi-polar Transistor)

E
E C

26
 6/24/2010

IGBT
(Insulated Gate Bi-polar Transistor)

IGBT
(Insulated Gate Bi-polar Transistor)

830Vdc

15Vdc

Capacitor Bank

ƒLocated behind the

Inverter module.
ƒParalleled across
the “V-Bus”.
ƒUsed in
combination with
Chokes to create an
LC filter.

27
 6/24/2010

Capacitor
Bank

Discharge Resistor

Discharge Resistors

ƒSlowly drains the

charge off the
capacitor bank
located on the “Raw
Bus”.
ƒFully discharges
capacitors in about
5-7min.

28
 6/24/2010

Buck Module

Buck Gate driver Board

ƒ Receives a firing
g
signal from the
System controller
to gate IGBT’s.
ƒ Varies voltage
supplied from
“Raw Bus” to feed
“V Bus”.

Buck Gate Driver

ƒ Signal from system

controller comes as a
pulse. This pulse is
used to determine the
firing frequency
supplied to the
IGBT’s.
ƒ This is referred to as
PWM (Pulse Width
Modulation).

Buck Gate Driver

Flex cct’s

ƒ Signal from the

Gate Driver board
is transmitted via a
flex cct.
ƒ 15VDC is used to
turn the IGBT’s on
and –8VDC to
force them off.

29
 6/24/2010

Flex cct’s

Flex cct’s
Buck
Module
Flex cct

Driver Board Test Points

(Old Style)

30
 6/24/2010

Driver Board Test Points

(Old Style)

TP1 : Gate
TP2 : Emitter
TP3 : Collector

Driver Board Test Points

(Old Style)

1amp soldered in fuses

for the protection of the
Gate Driver board.
Checking fuse can be
performed from the
back of the board with a
multi-meter.

Buck Gate Driver Board

Buck Gate Driver

Boards can only be
identified by the
serial number.

31
 6/24/2010

Buck Gate Driver Board

The “-7” or “-4”

indicates this board
is for the Buck
Module.

*A “-5” indicates a
Inverter Gate Driver
board.

MD-500 Components

Inverter Module

32
 6/24/2010

Flex cct’s
Inverter flex cct

Inverter

Q1 Q2

Q3 Q4

Inverter

Q1 Q2

Q3 Q4

33
 6/24/2010

Inverter

Q1 Q2

Q3 Q4

Inverter

Output Waveform

34
 6/24/2010

Output Waveform

ƒVariable voltage
waveform produced by
the MD-500.
ƒWaveform can be varied
in Amplitude (Volts) and
width (Hertz).
ƒAverage similar to a
sinusoidal waveform.

System Control Module

System Control Module

ƒSystem Controller is the

interface between the MD-
500 and the outside world.
ƒConverts speed and
torque signals to operate
the inverter.

35
 6/24/2010

System Controller

Vicor power supply

ƒSupplies control
power for the CCB and
the MD-500.
ƒInput of 120Vac with
multiple outputs
(+15Vdc, -15Vdc, and
5Vdc)

VICOR Power Supply

System Controller

Commercial control board

ƒProcesses
P all
ll the
th
torque and speed
commands given to
the Top Drive.

36
 6/24/2010

CCB
( Commercial Control Board )

Common for all test JP-29

points

5Vdc Power on D1 TP-4

37
 6/24/2010

+15VDC Power on TP-75 D40

-15VDC Power on D41 TP-77

5VDC Reset Signal TP-5 D3

38
 6/24/2010

System Run D2

Sin &Cos

Resolver Input

Cos TP-26

Sin TP-27

39
 6/24/2010

Resolver +Cos TP-26

Approx. 6 Vpk-pk, 2.5 kHz

Resolver +Sin TP-27

Approx. 6 Vpk-pk, 2.5 kHz

Resolver +Iref
TP-44
* Approx 13 Vpk-pk, 2.5 kHz waveform.

40
 6/24/2010

System Control Module

VR1 Trim pot

Over voltage

41
 6/24/2010

Over Voltage
ƒ By adjusting the small set
screw on the side of the
VR1 trim pot, we set the
level of voltage at which
the unit will shutdown to ADJUSTMENT SCREW
an OV, or OverVoltage,
fault.
ƒ If the test point (TP45) is
checked while the TD is
rotating, it will shutdown to
an OV fault.

Over voltage Setting TP-45 VR-1

* 4.15VDC = 820VDC on the V-Buss

S1 Timing Switch

42
 6/24/2010

System Control Module

Buck Controller Board

ƒControls the IGBT

firing in the PreReg.
PreReg
cct.
ƒReceives voltage
command from the CCB
and compares it with
the output of the “V-
Bus”.

Buck Controller Board

Buck Controller Board

43
 6/24/2010

Buck Controller Board

D16 (red) – Pre-reg. Fault

•A Pre-Reg fault is an
indication that a fault has
occurred somewhere in the
Buck Module.
•This would most likely be
one of three things :
1. Buck Module IGBT’s
2. Buck Module Flex
Circuits
3. Buck Gate Driver Board

Buck Controller Board

D15 (green) – Power

on

Buck Controller Board

D19 (green) – Pre-Reg.

Enable

44
 6/24/2010

Housekeeping Board

Housekeeping
Board

ƒIsolation board.
board
ƒSeparates all
incoming and
outgoing signals
from the CCB.

Housekeeping Board

System Interface

45
 6/24/2010

Housekeeping Board

Housekeeping Board

Housekeeping Board

Test Points

46
 6/24/2010

Housekeeping Board

TP1 & TP3 = Com

Housekeeping Board

TP2 = 15VDC

Housekeeping Board

TP4 = 5VDC

47
 6/24/2010

Housekeeping Board

TP5 = -15VDC

Control Panel Meters

Control Switches

ƒ Switch must be left in precharge position

during running.
ƒ Precharge is disabled after either by a timer
after 2min. or the drillers panel is enabled.

48
 6/24/2010

Tracking

What is Tracking ?

ƒ Tracking is a situation
where the V-Bus gauge
follows, or “tracks”, the
Raw Bus gauge to a
certain value or matches
the full Raw Bus Value
ƒ If the gauge goes to
approximately 830 VDC,
it is called “Full tracking”.
ƒ If the gauge stops HALF TRACKING
somewhere between 250
FULL TRACKING
and 500 VDC, it is called
“Half tracking”.

Tracking

• The most likely causes :

• Half tracking:
1. Service loop ground fault
2. PA44 motor ground fault
3 Buck
3. B k Choke
Ch k ground d fault.
f lt

• Full Tracking:
1. Buck Module IGBT
2. Buck Module Flex Circuit
3. Buck Gate Driver Board

49
 6/24/2010

THE END
For more information contact the Training and Development Department
or visit http/ngrain.com

50