TDS Manual-Tesco

PU# /TD # /JOB # 500/750 TON ESI 1350 HP 250 / 500 / 750 DAY INSPECTION
SECTION 2: NON-DESTRUCTIVE TESTING AND

INSPECTION SCHEDULES
This section is an excerpt from the 500/750 Ton ESI 1350 HP Maintenance Guide (5012166).
Note: As this section was taken directly from the Maintenance Manual, any references in the sec-
tion are referring to chapters and sections within the EXI 600 Maintenance Guides, unless other-
wise indicated.
TOP DRIVE OWNER ’S GUIDELINES

The integrity, performance, and safe operation of TESCO top drives depend on sound mainte-
nance and inspection of all load path, torque arrest system, and critical components. This sec-
tion describes TESCO’s minimum recommended inspection schedule, including the following:
• recommended reporting format for third party inspections
• recommended minimum inspection frequency for each load path, torque arrest system or
critical component
• specific areas of concern for each component
Caution: In addition to the schedule suggested here, all load path,

torque arrest system, and critical components must be inspected
following rough drilling, excessive jarring, or any other exceptional
circumstance that might increase fatigue failure.
When receiving inspection reports, file them in accordance with procedures in the operating
area.
It is critical to maintain complete inspection and service records for all load path, torque arrest
system, and other critical components.
Caution: This guide addresses MPI and WFMPI testing only. This
information must be used in conjunction with a regular inspection
and maintenance program as defined in Non-Destructive Testing
and Inspection Schedules.
TESCO will not assume responsibility or liability for any component, product or material that
has been repaired, rebuilt, welded, or heat treated outside of TESCO facilities.
© 2013 TESCO CORPORATION. ALL RIGHTS RESERVEDNON-DESTRUCTIVE TESTING AND INSPECTION SCHEDULES DOC #5019533 REV 0
24
GUIDELINES FOR COMPONENT INSPECTORS

Only qualified personnel can inspect load path, torque arrest system, and critical components.
Inspectors must use only fully operational, regularly maintained testing equipment. To ensure
accurate test results, each component must be thoroughly cleaned before inspection. In some cases
removal of paint is required.
Visual and magnetic particle inspection shall be conducted in accordance with API 8B/ISO 13534.
If inspecting a TESCO load path, torque arrest system or critical component, provide the top drive
owner with the following information.
General information for each component tested:
• type of test or inspection performed (MPI, WFMPI, etc.)
• type of equipment used to perform the testing
• operating conditions
• name and type of inspecting company
• name, signature and qualification of the inspector
• date of inspection
Inspection results for each component tested:
• part description (name, size, etc.)
• serial number of the inspected part
• exact location of all points of damage (measured from a recognizable point of reference)
including the following:
• cracks
• excessive wear
• deformation
• corrosion
• erosion
• all dimensions for all cracks (length, depth, width)
• a photograph or illustration indicating all cracks or damage points
• confirmation that all indicated inspection areas have been checked
25
LOAD PATH COMPONENTS AND INSPECTION INFORMATION

This chapter contains illustrations of all components in the top drive load path. Each illustration
indicates the inspection points for the specific component. It also describes any special consider-
ations that must be addressed when inspecting the component.
It is critical that all components of the load path be subjected to periodic magnetic particle inspec-
tion (MPI) by a qualified inspector. Each piece should be inspected for surface defects according
to the schedules that follow.
Note: Any part of an operating day should be considered one day. Removal of paint might be
required for inspection.
Inspection Types
The three inspection types are outlined in Table 2-1.
Table 2-1: Inspection types
Inspection Type Description

A Visually inspect for:
• wear
• deformation
• cracks
• corrosion
• galling
• heat damage
• other irregularities
If a crack is suspected, perform local paint strip and MPI inspection. All cracked
components should be referred to TESCO Engineering for disposition.
B Perform MPI or WFMPI for cracks. All cracked components should be referred to
TESCO Engineering for disposition.
C Return to a TESCO authorized service center for complete dimensional, visual,

WFMPI/MPI inspection for recertification.
Complete part list for inspection shall refer to “1000 Day Recertification” document.
Upon completion of Type C inspection, the inspection schedule starts at zero

operating days.
D Inspect and take measurements, replace if required
26
Figure 2-1: 500 ESI Yoke and link assembly
Frequency (Operating Days) and Inspection Type*

Point Name
At 250 At 500 At 750 At 1000
1 Hook contact point A,B A,B A,B C
2 Swivel yoke A A A C
3 Swivel yoke pin holes A,B A,B A,B C
4 Yoke pins A,B A,B A,B C
5 Swivel links A A A C
6 Swivel link, yoke pin bores A,B A,B A,B C
7 Swivel link, swivel pin bores A,B A,B A,B C
8 Swivel link, pull down bores A,B A,B A,B C
*Refer to Table 2-1 on page 26 for inspection type details
27

Point Name
At 250 At 500 At 750 At 1000
28
SECTION 2: NON-DESTRUCTIVE TESTING AND

INSPECTION SCHEDULES
This section is an excerpt from the 500/750 Ton ESI 1350 HP Maintenance Guide (5012166).
Note: As this section was taken directly from the Maintenance Manual, any references in the sec-
tion are referring to chapters and sections within the EXI 600 Maintenance Guides, unless other-
wise indicated.
TOP DRIVE OWNER ’S GUIDELINES

The integrity, performance, and safe operation of TESCO top drives depend on sound mainte-
nance and inspection of all load path, torque arrest system, and critical components. This sec-
tion describes TESCO’s minimum recommended inspection schedule, including the following:
• recommended reporting format for third party inspections
• recommended minimum inspection frequency for each load path, torque arrest system or
critical component
• specific areas of concern for each component
Caution: In addition to the schedule suggested here, all load path,

torque arrest system, and critical components must be inspected
following rough drilling, excessive jarring, or any other exceptional
circumstance that might increase fatigue failure.
When receiving inspection reports, file them in accordance with procedures in the operating
area.
It is critical to maintain complete inspection and service records for all load path, torque arrest
system, and other critical components.
Caution: This guide addresses MPI and WFMPI testing only. This
information must be used in conjunction with a regular inspection
and maintenance program as defined in Non-Destructive Testing
and Inspection Schedules.
TESCO will not assume responsibility or liability for any component, product or material that
has been repaired, rebuilt, welded, or heat treated outside of TESCO facilities.
24
GUIDELINES FOR COMPONENT INSPECTORS

Only qualified personnel can inspect load path, torque arrest system, and critical components.
Inspectors must use only fully operational, regularly maintained testing equipment. To ensure
accurate test results, each component must be thoroughly cleaned before inspection. In some cases
removal of paint is required.
Visual and magnetic particle inspection shall be conducted in accordance with API 8B/ISO 13534.
If inspecting a TESCO load path, torque arrest system or critical component, provide the top drive
owner with the following information.
General information for each component tested:
• type of test or inspection performed (MPI, WFMPI, etc.)
• type of equipment used to perform the testing
• operating conditions
• name and type of inspecting company
• name, signature and qualification of the inspector
• date of inspection
Inspection results for each component tested:
• part description (name, size, etc.)
• serial number of the inspected part
• exact location of all points of damage (measured from a recognizable point of reference)
including the following:
• cracks
• excessive wear
• deformation
• corrosion
• erosion
• all dimensions for all cracks (length, depth, width)
• a photograph or illustration indicating all cracks or damage points
• confirmation that all indicated inspection areas have been checked
25
LOAD PATH COMPONENTS AND INSPECTION INFORMATION

This chapter contains illustrations of all components in the top drive load path. Each illustration
indicates the inspection points for the specific component. It also describes any special consider-
ations that must be addressed when inspecting the component.
It is critical that all components of the load path be subjected to periodic magnetic particle inspec-
to the schedules that follow.
Note: Any part of an operating day should be considered one day. Removal of paint might be
required for inspection.
Inspection Types
The three inspection types are outlined in Table 2-1.
Table 2-1: Inspection types
Inspection Type Description

A Visually inspect for:
• wear
• deformation
• cracks
• corrosion
• galling
• heat damage
• other irregularities
If a crack is suspected, perform local paint strip and MPI inspection. All cracked
components should be referred to TESCO Engineering for disposition.
B Perform MPI or WFMPI for cracks. All cracked components should be referred to
TESCO Engineering for disposition.
C Return to a TESCO authorized service center for complete dimensional, visual,

WFMPI/MPI inspection for recertification.
Complete part list for inspection shall refer to “1000 Day Recertification” document.
Upon completion of Type C inspection, the inspection schedule starts at zero

operating days.
D Inspect and take measurements, replace if required
26

Point Name
At 250 At 500 At 750 At 1000
27

Point Name
At 250 At 500 At 750 At 1000
28
Figure 2-3: 500 ESI Swivel Gearbox Housing

Point Name
At 250 At 500 At 750 At 1000
1 Swivel gearbox housing A A A C
2 Swivel gearbox pin holes A,B A,B A,B C
3 Swivel gearbox pins A,B A,B A,B C
29

Point Name
At 250 At 500 At 750 At 1000
30
Figure 2-5: Quill

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Threads on the lower gland nut and — A A A C
bore
2 Upper thrust surface — — — — C
3 Lower thrust surface — — — — C
4 Load nut grooves — A,B A,B A,B C
5 Quill pin end A,B — — — C
31

Point Name
At 250 At 500 At 750 At 1000
29

Point Name
At 250 At 500 At 750 At 1000
30
Figure 2-5: Quill

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Threads on the lower gland nut and — A A A C
bore
2 Upper thrust surface — — — — C
3 Lower thrust surface — — — — C
4 Load nut grooves — A,B A,B A,B C
5 Quill pin end A,B — — — C
31
Figure 2-6: Load nut components

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Upper load nut retainer — A,B A,B A,B C
2 Load nut split collar — A,B A,B A,B C
3 Load nut sleeve — A,B A,B A,B C
4 Lower load nut retainer — A A A C
5 Bolts — A A A Replace
6 Load nut shroud A A A C
32
Figure 2-7: Mudsaver valve and actuator

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Top box connection A,B — — — C
2 Upper valve stem hole A,B — — — C
3 Lower valve stem hole A,B — — — C
4 Lower box connection A,B — — — C
5 Length of valve body A,B — — — C
33
Figure 2-8: Saver sub

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Upper seal face A,B — — — C
2 Upper threads A,B — — — C
3 Lower seal face A,B — — — C
4 Lower threads A,B — — — C
5 Entire length of body A,B — — — C
34
Figure 2-9: 500 ESI Load Collar

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Load collar ears A A,B A,B A,B C
2 Load nut, load shoulder insert — A,B A,B A,B C
3 Bronze bushing — — — — C
4 Inner barrel — — — — C
(below the bronze bushing)
35
Figure 2-10: 750 ESI Load Collar

Point Name
Every 60 At 250 At 500 At 750 At 1000
1 Load collar ears A A,B A,B A,B C
2 Load nut, load shoulder insert — A,B A,B A,B C
3 Bronze bushings — — — — C
4 Inner barrel — — — — C
(between the bronze bushings)
36
Figure 2-11: Elevator links

Point Name
Every 250 At 1000
1 Entire length of link A,B** C
2 Top eye (load collar eye) A,B** C
3 Bottom eye (elevator eye) A,B** C
4 Length between the eyes A,B** C
**As recommended by the equipment manufacturer
37
Figure 2-12: Elevators

Point Name
At 250
1 Main hinge pin C**
2 Primary latch C**
3 Secondary latch C**
4 Elevator link ears C**
5 Elevator body C**
6 Latch pins C**
7 Elevator inserts C**
8 Insert grooves (top and bottom) C**
(Ensure the insert does not fall out)
**As recommended by the equipment manufacturer
38
THREADED CONNECTIONS
All threaded connections listed in the following table must be subjected periodically to wet fluo-
rescent magnetic particle inspection (WFMPI) by a qualified inspector. Each piece should be
inspected for surface defects. Also, an inspection of threads should be conducted in accordance
with the following schedule.
Note: Any part of an operating day should be considered one day.
Caution: All inspections listed in the following table should be per-

formed following any episode of rough drilling, excessive jarring or any
other exceptional circumstance that might increase the likelihood of
fatigue failure. Operator discretion is critical in determining when this
testing should occur.
Threaded Connection Inspection Frequency

Description Minimum Frequency* Inspection Type
Mudsaver/stabbing valve 60 operating days WFMPI
(box X box, connections)
Saver sub 60 operating days WFMPI
(pin X pin, connections) (lower threads and seal face
require daily visual inspection)
Crossover sub (if applicable) 60 operating days (lower threads WFMPI
and seal face require daily visual
inspection)
*Frequency = the number of operating days
39
TORQUE ARREST SYSTEM

All components of the torque arrest system must be subjected to periodic magnetic particle inspec-
to the following schedule.
Any part of an operating day should be considered one day. Removal of paint may be required for
inspection.
40
Figure 2-13: Non-destructive testing for the standard torque arrest system
41

Point Name At At At At
Every 30
250 500 750 1000
1 Torque bushing side plates — A A A C
2 Torque bushing front plate — A A A C
3 Extend frame — A A,B A C
4 Redi-rod nuts (torque arrest system) — A A A Replace
5 Torque beam clamp bars — A A A C
6 Torque track pins — A A A C
7 Torque track connectors — A A A C
8 Torque track — A A A C
9 Torque bushing bolts/nuts — — — — Replace
10 Extend arms — A A,B A C
11 Torque anchor beam — A A A C
12 T-bar clamp plate and bolts — A A A C
14 T-bar — A A,B A C
15 Extend frame mounts — A A A C
16 Extend frame bolts — A A A Replace
17 Torque track mounting plate on — A A,B A C
bottom section; include all bolt holes
T-bar extension (if applicable) — A A A C
18 Torque track lifting bars — B B B C
19 Sling hanging assembly B — — — —
42
PIPE HANDLER ROTATION SYSTEM INSPECTION FREQUENCY

Figure 2-14: 500/750 ESI Non-destructive inspection of PH-rotation system components
43

Point Name Every At At At At
60 250 500 750 1000
1 Quill bearing retainer — — — — C
2 Slewing gear teeth — — A — C
3 Slewing gear/gearbox bolts — — — — Replace
4 Pipe handler spool — A A A C
5 Pipe handler spool/slewing drive bolts — — — — Replace
6 Adaptor plate/load collar bolts — — — — C
7 Load collar adaptor plate — — — — C
8 Upper grabber leg mounting bolts — — — — Replace
9 Upper grabber leg — A A A C
10 Grabber mounting bolts — — — — Replace
11 Grabber — A A A C
12 Load collar spring bolts — — — — C
13 Load collar springs — — A — C
14 Pipe handler lock segment — A A,B A C
15 Pipe handler lock body & shim plates — A A A C
16 Pipe handler lock bolts — — — — Replace
17 Rotary union seals — — — — Replace
44
GEARBOX INSPECTION FREQUENCY

Figure 2-15: 500 ESI Inspection of gearbox
45
All load path equipment on the top drive must be inspected at regular intervals. The extent and
schedule of these inspections are detailed in this chapter. The most rigorous inspection must take
place every 1,000 operating days and include a complete tear down of the top drive. During this
1,000 operating day tear down, the following inspections and replacements must be done on the
gearbox components (refer to Figure 2-15):

Point Name
At 250 At 500 At 750 At 1000
1 Upper quill bearings — — — Replace
2 Lower quill bearing — — — Replace
3 Thrust bearing — — — Replace
4 Upper intermediate shaft bearing — — — Replace
5 Lower intermediate shaft bearing — — — Replace
6 Upper input pinion bearing — — — Replace
7 Lower input pinion bearing — — — Replace
8 Main motor bearings — — — Replace
9 Blower motor bearings — — — Replace
10 Bull gear — — — A,B
11 Intermediate bull gear — — — A,B
12 Intermediate pinion — — — A,B
13 Input pinion — — — A,B
14 Upper quill bearing seals — — — Replace
15 Lower quill bearing seals — — — A,B
16 Upper input pinion seal — — — Replace
17 Lower input pinion seal — — — Replace
18 Mud shield — A — A
19 All O-rings — — — Replace
20 Lubrication hoses A A A Replace
21 Auxiliary hydraulic hoses A A A Replace
22 Brake Cover — — — Replace
23 Quill Insert — A — Replace
46
Figure 2-16: 750 ESI Inspection of Gearbox
22
16
19
18 6
14
19
4
19
23
1 13 11
10 12
5
7
19
19
15
2140009.a Rev0
47

Point Name
At 250 At 500 At 750 At 1000
1 Upper quill bearings — — — Replace
2 Lower quill bearing — — — Replace
3 Thrust bearing — — — Replace
4 Upper intermediate shaft bearing — — — Replace
5 Lower intermediate shaft bearing — — — Replace
6 Upper input pinion bearing — — — Replace
7 Lower input pinion bearing — — — Replace
8 Main motor bearings — — — Replace
9 Blower motor bearings — — — Replace
10 Bull gear — — — A,B
11 Intermediate bull gear — — — A,B
12 Intermediate pinion — — — A,B
13 Input pinion — — — A,B
14 Upper quill bearing seals — — — Replace
15 Lower quill bearing seals — — — A,B
16 Upper input pinion seal — — — Replace
17 Lower input pinion seal — — — Replace
18 Mud shield — A — A
19 All O-rings — — — Replace
20 Lubrication hoses A A A Replace
21 Auxiliary hydraulic hoses A A A Replace
22 Brake Cover — — — Replace
23 Quill Insert — A — Replace
48

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PU# /TD # /JOB # 500/750 TON ESI 1350 HP 250 / 500 / 750 DAY INSPECTION

SECTION 2: NON-DESTRUCTIVE TESTING AND

TOP DRIVE OWNER ’S GUIDELINES

Caution: In addition to the schedule suggested here, all load path,

GUIDELINES FOR COMPONENT INSPECTORS

LOAD PATH COMPONENTS AND INSPECTION INFORMATION

Inspection Type Description

C Return to a TESCO authorized service center for complete dimensional, visual,

Upon completion of Type C inspection, the inspection schedule starts at zero

D Inspect and take measurements, replace if required

Figure 2-1: 500 ESI Yoke and link assembly

Frequency (Operating Days) and Inspection Type*

Figure 2-2: 750 ESI Yoke and link assembly

Frequency (Operating Days) and Inspection Type*

SECTION 2: NON-DESTRUCTIVE TESTING AND

TOP DRIVE OWNER ’S GUIDELINES

Caution: In addition to the schedule suggested here, all load path,

GUIDELINES FOR COMPONENT INSPECTORS

LOAD PATH COMPONENTS AND INSPECTION INFORMATION

Inspection Type Description

C Return to a TESCO authorized service center for complete dimensional, visual,

Upon completion of Type C inspection, the inspection schedule starts at zero

D Inspect and take measurements, replace if required

Figure 2-1: 500 ESI Yoke and link assembly

Frequency (Operating Days) and Inspection Type*

Figure 2-2: 750 ESI Yoke and link assembly

Frequency (Operating Days) and Inspection Type*

Figure 2-3: 500 ESI Swivel Gearbox Housing

Frequency (Operating Days) and Inspection Type*

Figure 2-4: 750 ESI Swivel Gearbox Housing

Frequency (Operating Days) and Inspection Type*

Figure 2-5: Quill

Frequency (Operating Days) and Inspection Type*

Figure 2-3: 500 ESI Swivel Gearbox Housing

Frequency (Operating Days) and Inspection Type*

Figure 2-4: 750 ESI Swivel Gearbox Housing

Frequency (Operating Days) and Inspection Type*

Figure 2-5: Quill

Frequency (Operating Days) and Inspection Type*

Figure 2-6: Load nut components

Frequency (Operating Days) and Inspection Type*

Figure 2-7: Mudsaver valve and actuator

Frequency (Operating Days) and Inspection Type*

Figure 2-8: Saver sub

Frequency (Operating Days) and Inspection Type*

Figure 2-9: 500 ESI Load Collar

Frequency (Operating Days) and Inspection Type*

Figure 2-10: 750 ESI Load Collar

Frequency (Operating Days) and Inspection Type*

Figure 2-11: Elevator links

Frequency (Operating Days) and Inspection Type*

Figure 2-12: Elevators

Frequency (Operating Days) and Inspection Type*

Caution: All inspections listed in the following table should be per-

Threaded Connection Inspection Frequency

TORQUE ARREST SYSTEM

Frequency (Operating Days) and Inspection Type*

PIPE HANDLER ROTATION SYSTEM INSPECTION FREQUENCY

Frequency (Operating Days) and Inspection Type*

GEARBOX INSPECTION FREQUENCY

Frequency (Operating Days) and Inspection Type*

Figure 2-16: 750 ESI Inspection of Gearbox

Frequency (Operating Days) and Inspection Type*