System Description

250 HXI 750 Top Drive System

250TON HXI 750HP

DOCUMENT NAME: 1570000 REV 0

SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER

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

Tesco Corporation © 2007

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

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REVISION INFORMATION SYSTEM DESCRIPTION

Revision Information

Version Date Description of Changes

Rev 0 November 2007 First release of document

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SYSTEM DESCRIPTION

TABLE OF CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

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

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

Introduction and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shipping Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Collar and Load Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter-Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Top Drive Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump Drive and Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Reservoir/Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Extend Frame and Extend Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Beam and T-bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power (Closed-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Elevators and Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grabber Drill Pipe Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rotary Table Stabilizer Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Rotary Hose and Standpipe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Other Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

ENGINEERING SIGN-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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SAFETY INSTRUCTIONS

Warning! Before starting to work with this top drive system,

always read and follow all safety instructions
! such as the warnings and cautions mentioned
below and throughout the manual.

Top Drive System users risk injury to themselves and to others if the top drive is used improp-
erly and/or safety precautions are not followed. TESCO advises personnel who work with or
near the equipment to always wear proper personal protective equipment (PPE). Proper PPE
consists of, but is not limited to, the following:
• hearing protection (ear defenders)
• hard hat
• safety glasses
• steel toe shoes
• fall protection when working above 6.5 ft (2 m), or the minimum height requirement as
directed by local jurisdiction.
Caution: Always perform the correct lock-out procedures as recom-
! mended by your Safety or Loss Prevention department
before implementing maintenance.

! Caution: Only authorized personnel can operate the top drive system.

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CHAPTER 1: ABOUT THIS DOCUMENT

This document contains a description of the major components of the 250TON HXI 750HP
System.

A complete 250 HXI 750 Top Drive System consists of the following:
• top drive
• hydraulic power unit
• interconnecting service loop and reel
• torque arrest system
• associated buildings, containers and equipment

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

For information on Refer to

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

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CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION

INTRODUCTION AND GENERAL SPECIFICATIONS

The 250 HXI 750 Top Drive System is designed for use on land-based drilling rigs and work-
over rigs. The top drive is powered using an independent hydraulic power unit.

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

The 250 HXI 750 Top Drive is powered using a 750 hp prime mover with a four-pump drive
(Detroit Diesel 12V-2000).

Metric unit conversions (in brackets) have been provided for convenience only. All prod-
uct specifications use the original imperial units unless indicated otherwise.
Note: All weight values are approximate.
Table 2-1: 250 HXI 750 Top Drive Specifications

Specification Details
Top Drive 250TON HXI 750HP
Rated Capacity 250 ton (226.8 metric ton)
Weight of the top drive plus: 14,000 lb (6350 kg)
• elevators
• elevator links
• yoke + links
Length (with 9 ft (2.7 m) links) 17 ft. 6 in. (5.33 m)
Width 47 in. (1.2 m)
Horsepower 750 hp (560 kW) 4 pump drive

Table 2-2: Torque Arrest System Specifications

Specification Details
Weight of the following: 8,400 lb (3810 kg)
• torque track
• anchor beam
• torque bushing
• extend frame
• clamps
Std Track Length 92 ft (28 m); more length is available

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SHIPPING CONTAINERS
The 250 HXI 750 Top Drive is typically shipped in ocean shipping containers. Each container
is 20 ft (length) × 8 ft (width) × 8 ft 6 in. (height) (6.1 m × 2.4 m × 2.6 m).

Container 1
Approximate weight: 24,000 lb (10 900 kg)

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

Container 2
Approximate weight: 28,000 lb (12 700 kg)

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

Container 3
Approximate weight: 20,000 lb (9070 kg)

Contents:
• torque arrest system components
• one rig up basket
• hose reel skid

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TOP DRIVE COMPONENTS

Figure 2-1: 250 HXI 750 Top Drive General Assembly

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Gearbox
• the gearbox is an integrated gearbox and swivel containing the main swivel bearing and
gear train to drive the quill.
• single reduction helical gears (2.28:1) are utilized for high capacity, extended service
life, and maximum efficiency.
• the gear train is driven with a single bi-directional, hydraulic vane type motor. It has a
pressure rating of 4500 psi (31 Mpa) continuous, and 5000 psi (34.5 Mpa) intermittent.
• the gearbox is flooded with oil for maximum gear and bearing lubrication and reliability.

Load Collar and Load Nut

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

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

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

Pipe Handling
The pipe handling abilities of the 250 HXI 750 Top Drive include the following:
• Pipe Handler Rotation: The HXI pipe handler rotate mechanism, powered by a single
hydraulic motor, provides 360° rotation and can be locked into any orientation. You can
use this feature to resolve grabber torque when making or breaking connections.
• Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35°
forward from the vertical position and 55° backward from the vertical position.
• Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking
connections at any point in the mast. The grabber will accommodate tool joints from
3-1/8 in. to 8-3/4 in. OD.
Note: For tool joints smaller than 4-3/4 in. OD, non-standard dies or a shim kit
must be installed. Grabber intensifier pressures must also be adjusted when
smaller OD pipe is used.

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

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Top Drive Power

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

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

POWER UNIT
The 250 HXI 750 Top Drive power unit consists of the following:
• prime mover module, which includes the pump drive and filter manifold, the oil reser-
voir and cooling system, and the auxiliary system components
• hose storage reel

Prime Mover
The prime mover is a skid-mounted diesel engine (Detroit Diesel 12V-2000). Prime movers
are equipped with a fuel day tank, an air starter, standard instrumentation packages, and appro-
priate safety and emergency shutoffs.

Pump Drive and Filter Manifold

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

The auxiliary hydraulic equipment includes the following:

• a gear pump (2000 psi, 7 gal/min; 13.79 MPa, 26.5 liters/minute)
• 10 hp (7.46 kW) explosion-proof electric motor
• associated filters and controls

Hydraulic Oil Reservoir/Cooler

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

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Cooling System Components

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

Figure 2-2: 250 HXI 750 Power Unit Configuration

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

TORQUE ARREST SYSTEM

The torque arrest system consists of the following components:
• torque bushing
• extend frame
• extend arms
• extend hydraulic cylinders
• torque track
• T-bar
• torque beam, torque beam clamps, stabilization devices, and all required rig up items

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

Extend Frame and Extend Arms

The extend frame is pinned to the top drive. It allows you to extend the top drive away from
the torque track, enabling improved pipe handling.

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

Torque Beam and T-bar

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

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Figure 2-3: HXI Torque Arrest System

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SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION

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

Power (Closed-Loop) Hydraulic Hoses

• two 225 ft (68.58 m) × 2 in. (5.1 cm), 5000 psi (34.5 MPa) hoses (one supply, one
return); these supply closed-loop hydraulic oil from the pump drive module to the top
drive motor.

Auxiliary Hydraulics
• one 225 ft (68.58 m) × 3/4 in. (1.9 cm) R2, 2000 psi (13.8 MPa) hydraulic hose; this sup-
plies hydraulic oil from the pump drive module to the top drive robotics system.

Case Drain
• one 225 ft (68.58 m) x 1-1/4 in. (3.2 cm), 1625 psi (11.2 MPa) hydraulic hose; this
returns auxiliary hydraulic oil and motor case drain flow from the top drive to the
hydraulic oil reservoir.

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

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

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Figure 2-4: Driller’s Panel

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

Elevators and Elevator Links

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

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

Grabber Drill Pipe Guides

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

Rotary Table Stabilizer Bushings

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

Rotary Hose and Standpipe Extension

All equipment and accessories for these modifications are available.

Torque Arrest System

Optional equipment for non-standard and large mast torque arrest systems is available.

Other Available Options

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

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ENGINEERING SIGN-OFF
This sign-off sheet indicates that this document has been approved for release by the
Engineering Department at TESCO.

Document Completed By Signature Date Signed

Edward Chan Nov 12, 2007

Document Reviewed/Approved Date Signed

Nov 13, 2007

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