HXI PLC Operations Manual

Operations Guide
250 HXI 700 Top Drive System
PLC System
250TON HXI 700HP with D4P-700 Power Unit
DOCUMENT NAME: 1570014 REV 0

OPERATIONS GUIDE 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 © 2008
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
1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

I
REVISION INFORMATION OPERATIONS GUIDE
Revision Information
Version Date Description of Changes

Rev 0 July 2008 First release of document
©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

II
OPERATIONS GUIDE TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 2: CONTROL INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Controls, Indicators, and Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Indicator Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls and Indicators for Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls for Top Drive Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gauges and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dual Function Remote Brake Handle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELEVATOR–CLOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GRABBER–Drawworks Interlock Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Robotic Function Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELEVATOR Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LINK TILT Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EXTEND Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VALVE Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
GRABBER Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PIPE HANDLER Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Unit Main Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PLC Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auxiliary HPU Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

III
TABLE OF CONTENTS OPERATIONS GUIDE
CHAPTER 3: TORQUE AND SPEED LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
LOCAL Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
REMOTE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Available Torque and Quill Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
About Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Forward Rotation Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reverse Rotation Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BREAKOUT Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Quill Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Forward Speed, Connect Mode (MODE: CONN + QUILL:FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Reverse Speed, Connect Mode (MODE: CONN + QUILL:REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Forward or Reverse Speed, Drill Mode (MODE: DRILL LO or DRILL HI; QUILL: FWD or REV) . . . . . . . . . . . . . . . . . . . . 24
How to Set Forward Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Adjust the MAX TORQUE Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Adjust the SET TORQUE Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
How to Use the MAX TORQUE Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
MAX TORQUE Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to Set the Reverse Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
How to Set Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Connect Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Drill Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
CHAPTER 4: OTHER PRE-OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . .29

Install the Saver Sub and Die Lock Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Orienting the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Setting the Grabber Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Setting the Grabber Closing Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
CHAPTER 5: MAKING/BREAKING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mudsaver Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Pipe Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
How to Make Connections–General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
How to Use the Mousehole to Connect Drill Pipe to the Top Drive. . . . . . . . . . . . . . . . . . . . . . . . .35
Pipe Handler Orientation–Grabber to V-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to Fully Torque a Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
How to Connect a Single Length of Drill Pipe to the Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . .37
How to Break the Top Drive/Drill Pipe Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
How to Use the Top Drive to Make Up Pipe Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

IV
OPERATIONS GUIDE TABLE OF CONTENTS
How to Make Up Stands in the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

How to Make Up Pipe Stands Without a Conductor Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
How to Make Up Pipe Stands in the Mousehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
How to Make Up BHA (Collars and Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
How to Connect Collars Above the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHAPTER 6: DRILLING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Surface Hole Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
How to Drill a Surface Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
About Connections and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
About Tripping and Surface Hole Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
About Reaming and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
How to Drill Ahead with Single Lengths of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
How to Drill Ahead with Pipe Stands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Mud Motors in Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Adjust the Tool Face Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
How to Make and Break Connections During Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . 59
How to Maintain the Tool Face Orientation During Slide Drilling Operations . . . . . . . . . . . . . . . . . 60
How to Record the Drill String Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CHAPTER 7: TRIPPING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Well Control During Tripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
How to Remove the Mudsaver Valve Actuator During Well Control Tripping. . . . . . . . . . . . . . . . . 64
Trip Out Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
How to Trip Out Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Standard Racking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
How to Trip Out BHA (Collars and Tools). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Trip In Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
How to Trip in Tools and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
How to Trip In Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reaming Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
How to Use the Top Drive to Ream During Trip Out Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 75
How to Use the Top Drive to Ream to Bottom During Trip In Operations . . . . . . . . . . . . . . . . . . . 76
CHAPTER 8: STUCK PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

How to Use the Top Drive to Free Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
How to Use the Top Drive for Jarring Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Controlled Drill String Back Off Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Uncontrolled Parting of the Drill String. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

V
TABLE OF CONTENTS OPERATIONS GUIDE
CHAPTER 9: RUN AND PULL CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Prepare the Top Drive to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
How to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
How to Pull Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
CHAPTER 10: TOP DRIVE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Slip and Cut Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Cementing Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Slickline Survey and Wireline Logging Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Heavy Loads at the V-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
APPENDIX A: POST JARRING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

VI
OPERATIONS GUIDE
SAFETY INSTRUCTIONS
Warning! Before operating or servicing this top drive

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

before implementing maintenance.
Caution: Only authorized personnel can operate the top drive

! system.

VII
SAFETY INSTRUCTIONS OPERATIONS GUIDE
This page has been left blank intentionally.

VIII
OPERATIONS GUIDE LIST OF FIGURES
LIST OF FIGURES
Figure 2-1: 250 HXI 700 driller’s panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2-2: Engine interface panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 2-3: Caterpillar C18 engine control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 2-4: Power unit main panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 2-5: PLC panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 2-6: Auxiliary HPU panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3-1: HXI torque curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 3-2: HXI SET and MAX torque relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 4-1: Grabber intensifier manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 5-1: Correct tong position to make a connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 5-2: Correct position for elevator links and elevator . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 5-3: Connect a single length of pipe to the drill string . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 5-4: Break the top drive/drill pipe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 5-5: Make up stands in the rotary table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 5-6: Make up pipe stands in the mousehole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 5-7: Connect collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 6-1: Drill ahead with single lengths of pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 6-2: Drill ahead with pipe stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 7-1: Remove the mudsaver valve actuator for well control . . . . . . . . . . . . . . . . . . . . 65
Figure 7-2: Remove the actuator from the mudsaver valve . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 7-3: Trip out drill pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 7-4: Trip out collars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 7-5: Trip in tools and collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 8-1: Neutral weight at the connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 9-1: Pick up casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 9-2: Run casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 9-3: Reduce the stress on the torque track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 10-1: Block sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

IX
LIST OF FIGURES OPERATIONS GUIDE

X
OPERATIONS GUIDE
CHAPTER 1: ABOUT THIS DOCUMENT

This Operations Guide contains information on how to use the 250 HXI 700 Top Drive
System. It includes information on:
• configuring torque and speed settings
• using the driller’s panel
• making and breaking connections (drill pipe, collars, etc.)
• using the pipe handler
• drilling
• tripping pipe
• freeing stuck pipe (including jarring)
• running and pulling casing
• using the top drive for special operations
Caution: This guide assumes the following: the top drive has
been installed correctly; the power system is enabled; and all
! required safety checks have been performed. These procedures
are explained in the Installation Guide for the unit.
Table 1-1: Where to find more information
For information on Refer to

system components System Description
• installing the top drive Installation Guide
• rig up procedure
• commissioning
• pre-operational checklists
• rig out procedure
• load path inspections Maintenance Guide
• maintenance/service schedules
• component disassembly and reassembly
• long term storage procedures
TESCO manufactured parts and part numbers Parts List
troubleshooting Troubleshooting Guide (where available)
• electrical schematics System schematics
• hydraulic schematics
• cooling schematics
• gearbox lubrication schematics
available options and spares TESCO representative

1
ABOUT THIS DOCUMENT OPERATIONS GUIDE

2
OPERATIONS GUIDE
CHAPTER 2: CONTROL INTERFACES
DRILLER’S PANEL
Warning! Ensure all switches are set to the neutral position

in the event of a power failure and/or before
! starting the auxiliary pump.
General Description
The driller’s panel is a stainless steel enclosed panel that provides access to all required
switches, indicators, mounts, gauges and connectors.
The driller’s panel provides the controls, instrumentation and indicators required for safe
operation of the top drive. The panel mounts on the rig floor, within convenient reach of the
driller.
The driller’s panel interfaces with the PLC located in the PLC panel on the power unit.
Table 2-1: Features of the driller’s panel
Controls for:
• top drive robotic functions
• top drive rotation
• Emergency Shut Down (E.S.D.)
Meters providing:
• top drive delivered speed
• top drive delivered torque in ft-lbs
• differential motor pressure (quill torque)
• closed-loop hydraulic fluid temperature
Indicators
• warnings
• status

3
CONTROL INTERFACES OPERATIONS GUIDE
Figure 2-1: 250 HXI 700 driller’s panel

4
OPERATIONS GUIDE CONTROL INTERFACES
Controls, Indicators, and Warning Lights
Warning Lights
WARNING When illuminated, this light warns the driller that an alarm has been
(red indicator light) activated. An indicator light on the PLC panel will identify the source
of the alarm.
Indicator Lights
Indicator Description
READY When illuminated, this light indicates that the TD CRTL switch is set to
(green indicator light) ‘RUN’ and the driller’s panel is enabled.
Controls and Indicators for Robotic Functions

Unless indicated otherwise, a switch is in the ‘neutral’ position when it is in the central,
vertical position.
Control/Indicator Description/Function
TD CTRL Use this switch to enable or disable the driller’s panel and to set quill
SET/OFF/RUN switch speed limits.
• ‘SET’ allows the set-up of quill speed limits.
• ‘OFF’ disables the driller’s panel.
• ‘RUN’ activates the driller’s panel.
AUXILIARY PUMP Use this switch to remotely start or stop one or both primary and
ON/OFF switch secondary auxiliary hydraulic pumps.
Note: The auxiliary pump switches on the auxiliary pump panel must
(both functions are be set to ‘AUTO’ to be able to start the pumps from this switch.
spring return to neutral)
AUXILIARY PUMP ON When illuminated, this light indicates that at least one auxiliary pump
Indicator light (green) is running.
PIPE HANDLER Use this switch to lock or unlock the pipe handler rotation function.
UNLOCK/LOCK switch • ‘UNLOCK’ unlocks the pipe handler function. The pipe handler will
now be free to rotate.
(UNLOCK is spring return • ‘LOCK’ locks the pipe handler rotation function. The pipe handler
to neutral; LOCK is latched) will be unable to rotate.
• ‘NEUTRAL’ hydraulically maintains the lock cylinder in its cur-
rent position.
PIPE HANDLER Use this switch to rotate the pipe handler forward or reverse.
REV/FWD switch • ‘REV’ rotates the pipe handler anti-clockwise when viewed from
the top of the top drive.
(both functions are • ‘FWD’ rotates the pipe handler clockwise when viewed from the
spring return to neutral) top of the top drive.
• In both cases, the pipe handler must be unlocked for it to rotate.
PIPE HANDLER When illuminated, this light indicates that the pipe handler lock is in the
CAUTION indicator light (yellow) ‘UNLOCK’ position.

5
ELEVATOR Use this switch to open or close the elevators. The OPEN function
OPEN/CLOSE switch must be used in conjunction with the SAFETY OPEN push button.
(OPEN is spring return to How to open the elevators:

neutral; CLOSE is latched) 1. Turn the switch to the ‘OPEN’ position and hold it there.
2. Push the SAFETY OPEN push button.
How to close the elevators:

1. Turn the switch to the ‘CLOSE’ position. While the switch is
latched in the ‘CLOSE’ position, there will be hydraulic pressure
on the elevator open/close cylinder. If the switch is returned to
the neutral position, the cylinder will be hydraulically locked in the
current position.
Note: TESCO recommends that the switch remains in the
‘CLOSE’ position while there is drill pipe in the elevators.
ELEVATOR Use this switch in conjunction with the ELEVATOR–OPEN switch to
SAFETY OPEN push button open the elevators.
TILT Use this switch to tilt the elevator links backward or forward.
BACK/FWD switch • ‘BACK’ tilts the elevators backward (i.e., away from the well center
and toward the grabber leg).
(both functions are • ‘FWD’ tilts the elevators forward (i.e., away from the well center
spring return to neutral) and away from the grabber leg).
• ‘NEUTRAL’ hydraulically locks the link tilt cylinders in the
current position.
Note: The links move backward and forward from the current position
of the pipe handler. Visually confirm the position of the pipe handler
before operating the LINK TILT function.
TILT This button will relieve the pressure in the link tilt cylinders, allowing the
FLOAT push button elevator links to return to the neutral position (i.e., vertically below the
top drive).
EXTEND Use this switch to extend the top drive away from or retract it towards
IN/OUT switch the torque track.
• ‘OUT’ extends the top drive away from the torque track.
(both functions are • ‘IN’ retracts the top drive towards the torque track.
spring return to neutral) • ‘NEUTRAL’ hydraulically locks the extend cylinders in the
current position.
VALVE Use this switch to operate the actuator on the mudsaver valve to open
OPEN/CLOSE switch or close the valve.
• ‘OPEN’ opens the mudsaver valve.
(both functions are • ‘CLOSE’ closes the mudsaver valve.
spring return to neutral)
Note: The top drive should not rotate while the opening or closing of
the valve is in the progress.
VALVE When illuminated, this light indicates that ‘VALVE–CLOSE’ has been
CLOSED indicator light (yellow) selected.
GRABBER Use this switch to open and close the grabber.
OPEN/CLOSE switch • ‘OPEN’ opens the grabber.
• ‘CLOSE’ closes the grabber.
(OPEN is spring return to
neutral; CLOSE is latched) If the switch is returned to the neutral position, the grabber cylinder is
locked hydraulically to maintain the grabber clamping force.

6
GRABBER When illuminated, this light indicates that ‘GRABBER–CLOSED’ has
CLOSED indicator light (red) been selected.
GRABBER LIFT Use this switch to lift or lower the grabber leg and align the grabber
UP/DOWN switch with the pipe connection.
• ‘UP’ lifts the grabber leg.
(both functions are • ‘DOWN’ lowers the grabber leg.
spring return to neutral) • ‘NEUTRAL’ hydraulically locks the circuit.
COLD CLIMATE Push this button in to activate the cold climate function. The function
PUSH/PULL button allows for the auxiliary fluid to circulate through the 12-station auxiliary
manifold on the top drive and heat up any parts that is in contact with
(this switch is located on the the hydraulic fluid. The auxiliary hydraulic fluid is heated by a heater in
left side of the driller’s panel)
the auxiliary hydraulic fluid reservoir.
The same function also allows for the circulation of the closed-loop
hydraulic fluid (see “Controls for Top Drive Rotation” on page 7).
Controls for Top Drive Rotation

MODE Use this switch to select the drill mode to be applied.
CONN/DRILL LO/DRILL HI switch • ‘CONN’ selects the connect mode typically used to make-up or
break connections. The following parameters are applied in this
(three-position latched) mode:
• Maximum make-up torque of 29,000 ft-lbs (also see
forward torque settings).
• Quill speed set to a constant 17 rpm.
• Forward or Reverse quill rotation.
• ‘DRILL LO’ selects the low speed drilling mode typically used
in low speed–high torque drilling applications. The following
drilling parameters are applied in this mode:
• Selectable quill rpm from 0 to 100 rpm.
• Continuous quill torque of 24,000 ft-lbs.
• Forward or Reverse quill rotation.
• ‘DRILL HI’ selects the high speed drilling mode typically used
in high speed–low torque drilling applications. The following
parameters are applied in this mode:
• Selectable quill rpm from 0 to 200 rpm.
• Continuous quill torque of 12,000 ft-lbs.
• Forward and Reverse quill rotation.
SPEED Use this switch to adjust the quill rpm.
DECR/INCR switch • ‘DECR’ reduces the quill rpm.
• ‘INCR’ increases the quill rpm.
(both functions are
spring return to neutral) When using this switch, note the following:
• This switch increases or decreases the displacement of the main
hydraulic pumps on the power unit, thereby increasing or
decreasing the closed-loop flow. This results in a corresponding
increase or decrease in the quill rpm.
• The last set speed is registered by the PLC so that when quill
rotation is resumed, it will rotate at the last set speed. To cancel
the last registered speed, set the QUILL switch to neutral and
toggle the SPEED switch once to either ‘DECR’ or ‘INCR’.

7
QUILL Use this switch to select the direction of the quill rotation.
REV/FWD switch • ‘REV’ selects quill rotation in reverse (i.e., anti-clockwise when
viewed from the top of the top drive).
(three-position latched) • ‘FWD’ selects quill rotation in the forward direction (i.e., clockwise
when viewed from the top of the top drive).
• ‘NEUTRAL’ stops quill rotation.
When using this switch, note the following:

• If this switch is set to ‘FWD’ or ‘REV’ to continue quill rotation, the
quill rotates at the last set speed unless the speed register has
been canceled. To cancel the last registered speed, set the QUILL
switch to neutral and toggle the SPEED switch once to either
‘DECR’ or ‘INCR’.
BREAKOUT Push this button to obtain maximum breakout torque during breaking of
Push button connections.
When using this button, note the following:

• This function is available only when the MODE switch is set to
‘CONN’ and the QUILL switch is set to ‘REV’.
• This function overrides the reverse torque setting by bypassing
the reverse flow relief valve on the power unit.
MAX TORQUE Push this button to override the SET torque limit and obtain MAX
Push button torque (see “About Torque Control” on page 23 in Chapter 3 of the
Operations Guide).
(this switch is located on the
This function is available in CONN, DRILL LO and DRILL HI mode as
long as the QUILL switch is set to ‘FWD’. It is not available during
reverse rotation of the quill.
DRILL MAX TORQUE Use this switch to override the SET torque limit and obtain maximum
LOW/OFF/HIGH torque only in the selected drill mode. It omits the use of the MAX
torque push button.
(three-position latched switch) • ‘LOW’ overrides the SET torque limit only in DRILL LO mode.
• ‘OFF’ disables this switch. To obtain maximum torque, use the
(this switch is located on the MAX push button.
• ‘HIGH’ overrides the SET torque limit only in DRILL HI mode.
COLD CLIMATE Push this button in to activate the cold climate function. This function
Push/Pull button allows for the closed-loop hydraulic fluid to circulate through the motor
manifold and heat up any parts that is in contact with the hydraulic
(this switch is located on the fluid. The hydraulic fluid is heated by a heater in the closed-loop
hydraulic fluid reservoir.
The same function is also allowed for the circulation of the auxiliary
hydraulic fluid (see “Controls and Indicators for Robotic Functions” on
page 5).
E.S.D. (Emergency Shut Down) PULL this button to deactivate the engine if there is an emergency.
Pull button When pulling this button, the rig saver is tripped, and the fuel supply is
shut off.
Note: If using the E.S.D., the rig saver must manually reset before
restarting the prime mover.

8
Gauges and Displays

Indicator Description
DELIVERED SPEED (RPM) This digital gauge displays the forward and reverse quill speed in
revolutions per minute (rpm).
DELIVERED TORQUE (FT-LB) This digital gauge displays the torque delivered by the top drive quill.
This is a calculated value based on the differential pressure between
the inlet and outlet of the top drive main hydraulic motor in forward or
reverse rotation. The differential pressure is measured by a pressure
transducer.
PRESSURE DIFFERENTIAL (PSI) This digital gauge displays the differential pressure between the inlet
and outlet of the top drive main hydraulic motor in forward or reverse
rotation. The differential pressure is measured by a pressure
transducer and is displayed in psi. This differential pressure can be
used in conjunction with Torque Charts to determine the actual torque
delivered by the quill.
LOOP TEMPERATURE (ºF) This digital gauge displays the closed-loop hydraulic fluid temperature.
DUAL FUNCTION REMOTE BRAKE HANDLE CONTROL

The push button controls on the brake handle operate the ELEVATOR–CLOSE and the
GRABBER–Drawworks Interlock Override as described below.
ELEVATOR–CLOSE
To make tripping operations easier, close the elevators from a switch located on the brake
handle. This is a ‘spring-return’ push button that activates a timed sequence five seconds) to
ensure that the elevators close completely. The five-second sequence activates even if the
button is only briefly selected.
GRABBER–Drawworks Interlock Override

The interlock for the drum brake locks out the drum clutch so the driller cannot hoist while
the grabber is engaged. A red warning light located above the GRABBER switch on the
driller’s panel indicates the status of the grabber. If this light is illuminated, it indicates that
‘GRABBER–CLOSE’ is selected. Use the push button on the brake handle to override the
lockout feature.
Note: If required, use this override during directional drilling operations to hoist the string
when the grabber is closed.
The override button operates a temporary contact. The override works only when the button is
pushed and held. When the button is released, air supply to the clutch control is interrupted
and the override is no longer active.

9
ROBOTIC FUNCTION DESCRIPTIONS

The following convention is used to describe switch functions: SWITCHNAME–SETTING
Examples:
• ELEVATOR–OPEN
• VALVE–CLOSE
• GRABBER–OPEN
• MODE–DRILL
The auxiliary hydraulic pump starts automatically once a robotic function is activated.
The driller, however, has the option to manually start the auxiliary pumps from the
driller’s panel or auxiliary HPU panel.
ELEVATOR Function
The hydraulic elevators attach to the end of the elevator links. They clamp around and
manipulate drill pipe, collars, drilling tools and casing.
Safety features for the elevators include a double-action OPEN switch. The three-position
ELEVATOR switch on the driller’s panel works in conjunction with the elevator SAFETY
OPEN push button. To open the elevators, turn the ELEVATOR switch to ‘OPEN’ and press
the SAFETY OPEN push button at the same time; this prevents accidental opening of the ele-
vators. Operating either switch by itself will not energize the elevator solenoid. Additionally,
the switch and the push button are ‘spring-return to neutral’, ensuring that both have to be
manually selected each time ‘ELEVATOR–OPEN’ is required.
Another safety feature for the elevators is ensuring that the elevators fully close and latch.
When selecting ‘ELEVATOR–CLOSE’ at the driller’s panel, pressure to the close circuit
remains high for enough time to positively engage the latch.
The driller can also use the CLOSE button on the brake handle to close the elevators. This
allows the driller to close the elevators (and lower or raise the drawworks) by using one hand,
and leaves the other hand free to operate other drilling controls.
LINK TILT Function

The LINK TILT function allows the operator to move the elevator links (with the attached ele-
vators) to a position forward or back of hole center (the links move up to 35° forward and up to
55° back of hole center). Use the LINK TILT function to manipulate pipe stands when tripping
pipe, running casing, and making up pipe stands. Use the LINK TILT function in conjunction
with other functions to rack back pipe stands, make up pipe stands in the mouse hole, and
retrieve pipe stands for reconnection.
Use the LINK TILT–BACK function to move the links and elevators out of the way and lower
the top drive closer to the rig floor, or to reposition the links to an angle back of hole center.
Use the LINK TILT–FWD function to move the links and elevators away from hole center and
toward the V-door.
The FLOAT function returns the links to hole center. Pushing the FLOAT button on the
driller’s panel relieves the pressure in the LINK TILT cylinders and the links return to a
vertical position below the top drive.

10
EXTEND Function
Use the EXTEND function to handle stands of drill pipe during tripping, or to handle rig tools
when the top drive is not over hole center. The EXTEND function moves the entire top drive
away from the torque track to a maximum distance of 54 in (1.4 m).
The EXTEND switch on the driller’s panel is ‘spring-return to neutral’, which means it must
be held in the desired position to activate the function. This allows the operator to stop the top
drive at any point along its travel path by releasing the switch. Operators can also ‘jog’ (move
in small increments) the top drive along its travel path by momentarily selecting ‘EXTEND–
IN’ or ‘EXTEND–OUT’.
Use the EXTEND–OUT function to move the top drive away from the torque track and
towards the V-door. This enables the operator to handle stands of drill pipe more effectively
when additional distance from hole center is desired. Combine this function with the LINK
TILT–FWD function to achieve maximum extension of the top drive.
Use EXTEND–IN to move the top drive towards its original position over hole center.
VALVE Function
The VALVE function operates the mud valve actuator, which opens and closes the mudsaver
section of the mud valve. The mud valve is a double-ball valve. The lower ball is used for well
control and the upper ball is used as a mudsaver.
The mud pump(s) must be deactivated when making or breaking pipe joints. Use the VALVE
function to close the mudsaver valve to prevent gravity loss of drilling fluid that is trapped in
the swivel, quill and hose.
When ‘VALVE–CLOSE’ is selected at the driller’s panel, electrical controls stop the quill
rotation. The valve closes and a five-second timer activates. After the timer expires, restart
the quill rotation by setting the QUILL switch to neutral, then to ‘FWD’ or ‘REV’.
Note: When the mud pump interlock is properly installed it will prevent the mud pump
from starting if the valve is closed.
When ‘VALVE–CLOSE’ is selected, a yellow warning light illuminates on the driller’s panel
and remains lit until ‘VALVE–OPEN’ is selected.
GRABBER Function
The grabber is a hydraulically operated device used to clamp onto and hold pipe. It is located
at the bottom of the grabber leg of the top drive. The grabber is used as break-out tongs for
making or breaking pipe stand joints to or from the top drive.
The GRABBER–OPEN switch on the driller’s panel is ‘spring-return to neutral’, and it

requires only momentary functioning to begin the OPEN sequence. The GRABBER–CLOSE
switch is ‘maintained’, which means that it maintains power to CLOSE hydraulic directional
valves until the operator manually turns the switch to the neutral position.

11
The red GRABBER ‘CLOSED’ warning light on the driller’s panel illuminates when the
‘GRABBER–CLOSE’ function is selected.
TESCO recommends installing safety interlocks to prevent the operator from hoisting the
drawworks when the grabber is closed (unless the operator presses an override button on the
brake handle).
PIPE HANDLER Function

The pipe handler section of the top drive is located from the slewing bearing down, and is
designed to rotate independently of the swivel gearbox of the top drive. The pipe handler
allows the operator to handle pipe stands and downhole tools easily and conveniently.
The pipe handler section is locked to the swivel gearbox of the top drive at the slewing bear-
ing. The PIPE HANDLER switch on the driller’s panel must be set to ‘UNLOCK’ before the
pipe handler can be rotated. The pipe handler is independently driven by a hydraulic motor and
does not utilize the primary drive system.
The direction of rotation for the pipe handler is determined by the PIPE HANDLER REV/
FWD switch. 360° rotation is available. Release the REV/FWD switch to stop rotation. The
pipe handler rotates at approximately 4 rpm, but may be adjusted using the flow control valves
next to the hydraulic motor.
A red CAUTION light illuminates at the driller’s panel when the pipe handler is unlocked.
Warning! No person should be within the radius of link

movement whenever the PIPE HANDLER
! FWD/REV switch is operated.

12
ENGINE INTERFACE PANEL
General Description
The engine interface panel is located on the power unit at the prime mover. The purpose of the
panel is to interface the PLC with the engine controls. The panel front cover contains a digital
display and a two-position latched switch.
Figure 2-2: Engine interface panel
1. Messenger Display
2. Speed Control Switch
Controls and Indicators

Control/Indicator Description
LOCAL/REMOTE Use this switch to select remote or local engine control.
• 'LOCAL' disables engine speed control by the PLC. Engine
(two-position latched switch) speed can only be adjusted from the throttle switch on the engine
control panel (see “Engine Control Panel” on page 14).
• 'REMOTE' enables engine speed control by the PLC.
MESSENGER DISPLAY Various engine parameters and self diagnostic codes can be displayed
on the messenger display. Refer to the Caterpillar C18 engine
Operations and Maintenance Manual for a complete description of all
the parameters and diagnostic codes that can be displayed and how to
select the display.

13
ENGINE CONTROL PANEL
General Description
The engine control panel is located on the power unit at the prime mover. This panel displays
the status of important engine parameters and should to be checked regularly to ensure engine
health. The panel also contains several engine controls. Refer to the Caterpillar C18 engine
Operations and Maintenance Manual for a complete description of the indicators, gauges and
switches.
Figure 2-3: Caterpillar C18 engine control panel

14
POWER UNIT MAIN PANEL
General Description
The main panel is located on the power unit and contains the 480V, 120V and 24V distribution
centers. Various circuit breakers are located on the door of the panel.
Figure 2-4: Power unit main panel

15

MB1 - COOLING FANS Use this switch to disconnect power to the cooling fan motor.
ON/OFF switch • OFF - cooling fan motor is disconnected from electrical power.
• ON - cooling fan motor is connected to electrical power.
Note: This switch only disconnects the cooling fan motor from
electrical power during maintenance. It is not used to turn the fan on
or off (see COOLING FAN - HAND/OFF/AUTO switch). This switch
must be set to 'ON' to start the power unit.
MB2 - BUILDING HEATER Use this switch to disconnect power to a building heater if a building
ON/OFF switch heater is installed (optional). Use this switch to disconnect power to an
optional workshop.
MB3-WORKSHOP POWER Use this switch to disconnect power to an optional workshop.
ON/OFF switch
MB4-ENGINE HEATER Use this switch to turn the power to the engine heater ‘ON’ or ‘OFF’.
ON/OFF switch
Note: The engine heater does not have a thermostat that will turn the
heater on or off. Once ‘ON’ is selected, the heater will be working.
Caution: The heater must be switched off once the

! engine is running.
MB5-TANK HEATER Use this switch to disconnect power to the heater in the closed-loop
ON/OFF switch hydraulic fluid reservoir.
Note: The tank heater contains a thermostat that will turn the heater
‘ON’ or ‘OFF’ at a pre-set temperature.
MB6-480-120/208V XFMR Use this switch to turn power to the 480 to 120V transformer ‘ON’ or
ON/OFF switch ‘OFF’. This switch must be set to 'ON' to start the power unit.
CB1-120VAC CONTROL Use this switch to turn power to the 120V control circuitry ‘ON’ or
ON/OFF switch ‘OFF’. This switch must be set to 'ON' to start the power unit.
CB2-LIGHTS Use this switch to disconnect power to the 'LIGHTS' receptacles on the
ON/OFF switch side of the main panel.
CB3-RECEPTACLES Use this switch to disconnect power to the 'RECEPTACLES'
ON/OFF switch receptacles on the side of the main panel.
COOLING FAN Use this switch to select the control method to start/stop the cooler fan
HAND/OFF/AUTO switch motor.
• 'HAND' manually starts the cooler fan, disregarding the tem-
(3-position latched switch) perature of the hydraulic fluid in the closed-loop hydraulic fluid
reservoir.
• 'OFF' turns off all control methods to start the fan.
• 'AUTO' switches the start/stop control of the cooler fan to the PLC.
The PLC will start or stop the fan at a factory set temperature.
24VDC CONTROL POWER When illuminated, this light indicates that the 24VDC control power is
Indicator light (Green) switched to ‘ON’.
COOLING FAN When illuminated, this light indicates that the cooler fan has been
Indicator light (Green) switched to ‘ON’ manually or by the PLC.

16
PLC PANEL
General Description
The Programmable Logic Controller (PLC) panel is located on the power unit. It contains the
PLC that controls all the functions of the top drive system. Various alarm indicator lights are
located on the door of the PLC panel. Once the PLC detects that an alarm condition is reached
in a particular sub-system, it will shut down the entire system and illuminates the particular
alarm indicator light. These lights can then be used to troubleshoot the system.
Figure 2-5: PLC panel

17

24 VDC POWER When illuminated, this light indicates that the 24 VDC power to the
Indicator light (Green) PLC is ‘ON’.
MAIN TANK TEMPERATURE When illuminated, this light indicates that the hydraulic fluid in the
ALARM closed-loop hydraulic fluid reservoir has reached the factory set
Indicator light (Red) shut-down temperature of 165ºF (74ºC). This means the closed-loop
hydraulic fluid is too hot to operate.
LOOP TEMPERATURE ALARM When illuminated, this light indicates that the hydraulic fluid circulating
Indicator light (Red) in the closed-loop circuit has reached the factory set shut-down
temperature of 190ºF (88ºC). The temperature transducer providing
the loop temperature to the PLC is located on the reverse filter
manifold.
AUXILIARY TANK When illuminated, this light indicates that the hydraulic fluid in the
TEMPERATURE ALARM auxiliary hydraulic fluid reservoir, located on the auxiliary HPU, has
Indicator light (Red) reached the factory set shut-down temperature of 190ºF (88ºC).
MAIN TANK LEVEL ALARM When illuminated, this light indicates that the hydraulic fluid in the
Indicator light (Red) closed-loop hydraulic fluid reservoir has reached the low shut-down
level.
AUX TANK LEVEL ALARM When illuminated, this light indicates that the hydraulic fluid in the
Indicator light (Red) auxiliary hydraulic fluid reservoir has reached the low shut-down level.
MAIN PUMP DRIVE When illuminated, this light indicates that the temperature of the
TEMPERATURE ALARM pump drive lubrication oil has reached the factory set shut-down
Indicator light (Red) temperature of 220ºF (104ºC).
AUX PUMP PRESSURE ALARM When illuminated, this light indicates that the pressure in the auxiliary
Indicator light (Red) system is lower than a preset factory value.

18
AUXILIARY HPU PANEL
General Description
The auxiliary HPU panel is located on the auxiliary power unit. The auxiliary power unit is
mounted on the hose reel skid of the D4P-700 power module. The auxiliary HPU panel
essentially contains the breakers, pump control switches and pump status indicator lights.
Figure 2-6: Auxiliary HPU panel

19

MB8-480:120VAC XFMR Use this breaker to turn power to the 480-120V control transformer
ON/OFF breaker ‘ON’ or ’OFF’. This switch must be set to 'ON' to start the power unit.
MB7-AUX HPU SUPPLY Use this breaker to turn power ‘ON’ or ‘OFF’ to the auxiliary HPU
ON/OFF breaker panel.
MB9-AUX TANK HEATER Use this breaker to disconnect power to the heater in the auxiliary
ON/OFF breaker hydraulic fluid reservoir.
Note: The tank heater contains a thermostat that will turn the heater
‘ON’ or ‘OFF’ at a pre-set temperature.
PRIMARY PUMP CONTROL Use this switch to select the control method to start/stop the primary
HAND/OFF/AUTO auxiliary pump motor.
• 'HAND' manually starts the primary pump motor.
(three-position latched switch) • 'OFF' turns off all control methods to start the primary pump.
• 'AUTO' switches the start/stop control of the primary pump to the
PLC. The PLC will start or stop the primary pump whenever a
robotic function is activated from the driller’s panel. In this mode,
the auxiliary pumps can also be started remotely from the driller’s
panel.
SECONDARY PUMP CONTROL Use this switch to select the control method to start/stop the secondary
HAND/OFF/AUTO auxiliary pump motor.
• 'HAND' manually starts the secondary pump motor.
(three-position latched switch) • 'OFF' turns off all control methods to start the secondary pump.
• 'AUTO' switches the start/stop control of the secondary pump to
the PLC. The PLC will start or stop the secondary pump whenever
a robotic function is activated from the driller’s panel. In this mode,
the auxiliary pumps can also be started remotely from the driller's
panel.
Note: If a high auxiliary flow is required, both the primary and

secondary pumps can be started simultaneously by selecting 'AUTO'
on both pump control switches.
PRIMARY PUMP ON When illuminated, this light indicates that the primary pump is running.
Indicator light (red)
SECONDARY PUMP ON When illuminated, this light indicates that the secondary pump is
Indicator light (red) running.

20
OPERATIONS GUIDE
CHAPTER 3: TORQUE AND SPEED LIMITS

OVERVIEW
The torque that the top drive can develop is related to the rotational speed of the quill.
The relationship between quill rotational speed and maximum drilling torque is nonlinear,
as seen in Figure 3-1.
Figure 3-1: HXI torque curve

21
TORQUE AND SPEED LIMITS OPERATIONS GUIDE
ENGINE SPEED
Engine speed can be adjusted in two modes: LOCAL and REMOTE. These modes are selected
at a switch located on the engine interface panel (see “Engine Interface Panel” on page 13).
LOCAL Mode
In LOCAL mode, the engine speed can be adjusted by a toggle switch on the Engine Control
Panel (see Operations and Maintenance Manual for the Caterpillar C18 engine). In this mode,
any engine speed is available up to 1,900 rpm. This mode is typically selected during mainte-
nance or troubleshooting.
REMOTE Mode
In REMOTE mode, the engine speed is adjusted by the PLC and depends on the function that
is selected. In any drill mode, once the QUILL switch is set to either ‘FWD’ or ‘REV’ to start
quill rotation, the engine speed will increase from idle to a preset value (approximately 1,800
rpm). This value is set at the optimum running speed of the engine. For most of the selected
drilling parameters, the engine will run at this constant speed.
The engine will automatically go to idle speed (800 rpm) after the QUILL switch is set to
neutral for five minutes.
AVAILABLE TORQUE AND QUILL SPEEDS

The torque or quill speed that is available is specific to each top drive activity. These are
summarized in the following table.
In this mode This torque is available This speed is available

DRILL LO Forward SET TORQUE or MAX TORQUE 0 to 100 rpm
DRILL LO Reverse One set value is available 0 to 100 rpm
(reverse pressure relief setting)
DRILL HI Forward SET TORQUE or MAX TORQUE 0 to 200 rpm
DRILL HI Reverse One set value is available 0 to 200 rpm
(reverse pressure relief setting)
CONNECT Forward SET TORQUE or MAX TORQUE Quill speed is set to 17 rpm
(if the MAX TORQUE button is pressed
and held during make up operations)
CONNECT Reverse One set value is available Quill speed is set to 17 rpm
BREAKOUT CONNECT- Maximum torque for the unit (in Quill speed is set to 17 rpm
REVERSE only CONNECT MODE-REV) is available

22
OPERATIONS GUIDE TORQUE AND SPEED LIMITS
MAX TORQUE The MAX TORQUE button applies Dependent on the function selected
(push button) the maximum torque available when
the quill is rotating forward (CONN,
DRILL LO and DRILL HI)
Note: Intermittent maximum torque is

available regardless of whether the
MAX TORQUE switch is ‘ON’ or ‘OFF’
About Torque Control
Forward Rotation Torque Control
In the forward rotational direction on hydraulic top drives, torque control is achieved by open-
ing a poppet valve in the motor manifold. The motor manifold is located on the top drive. The
torque delivered by the hydraulic motor is directly proportional to the differential pressure
between the inlet and outlet of the motor. Once the pressure at the inlet of the motor reaches a
certain set value, hydraulic fluid is released from a relief valve. The released hydraulic fluid
then allows a poppet valve in the motor manifold to open, which in turn allows the closed-
loop hydraulic fluid to circulate through the motor manifold rather than through the motor. At
this point, the motor will stall. The value at which this relief valve is set at is the so-called
SET torque value. A second relief valve in the closed-loop system controls the torque of the
motor in a similar manner, except that this relief valve is typically set to a higher value than
the SET torque value. This value is called the MAX torque setting. To achieve MAX torque
from the top drive, press the MAX TORQUE push button on the driller’s panel. By pushing
this button, the SET torque relief valve is isolated from the closed-loop circuit and therefore
will not open when the SET torque value is reached. The pressure in the loop will then have to
reach the MAX torque value before the motor will stall. Both the SET torque and MAX
torque relief valves are located on the top drive motor manifold (see “How to Set Forward
Torque” on page 25).
Reverse Rotation Torque Control
Torque control in the reverse direction is achieved in a slightly different manner. A relief
valve in the return line is set to a pressure that will provide the required reverse torque. If the
top drive is rotated in the reverse direction, the return line actually becomes the forward line.
Therefore, once the pressure in the return line increases to the set pressure, it relieves the
hydraulic fluid from the closed-loop and causes the motor to stall. This relief valve is located
in the hot oil shuttle relief (HOSR) and reverse relief manifold on the power unit.
Warning! Set this torque relief valve to a value that is

50% of the make up torque of the drill string
! (SET TORQUE). This will help to prevent an
unintentional disconnection of the drill string.
BREAKOUT Torque
The BREAKOUT function is available only during CONNECT mode with the quill in
REVERSE direction.

23
Breakout torque is the maximum torque that the power unit can supply. If the BREAKOUT
button on the driller’s panel is pushed, the reverse relief valve on the HOSR manifold is iso-
lated from the closed-loop pressure. This will allow the pumps to supply maximum pressure
to the top drive.
Note: The preset speed is 17 rpm. See “Quill Speed Control” on page 24 for more
information.
Quill Speed Control
Forward Speed, Connect Mode (MODE: CONN + QUILL:FWD)
The speed for CONNECT mode with forward rotation is a preset value in the PLC code.
Note: The preset speed is 17 rpm.
Reverse Speed, Connect Mode (MODE: CONN + QUILL:REV)
The speed for CONNECT mode with reverse rotation is a preset value in the PLC code.
Note: The preset speed is 17 rpm.
Forward or Reverse Speed, Drill Mode (MODE: DRILL LO or DRILL HI; QUILL: FWD or REV)
The speed for DRILL mode with forward or reverse rotation is achieved by adjusting the
pump displacement and/or engine speed. Based on the quill speed selected on the driller’s
panel, the PLC will increase the displacement of the pumps until the displacement
reaches 100%.

24
HOW TO SET FORWARD TORQUE

Set the MAX TORQUE value first when adjusting torque values. Valves are configured so that
the SET TORQUE value can never rise above the MAX TORQUE value.
Adjust the MAX TORQUE Setting

Refer to the transducer torque chart for the unit before adjusting the MAX TORQUE setting.
Use the torque charts for the unit to locate the appropriate values for MAX and SET TORQUE
settings.
1. At the motor manifold of the top drive, ensure both MAX and SET TORQUE
relief valves are fully unscrewed.
Figure 3-2: HXI SET and MAX torque relief valves
2. Ensure that the GRABBER switch is set to ‘OPEN’.

3. Ensure that it is safe for the quill to rotate.
4. Set the MODE switch to ‘DRILL LO’.
5. Set the QUILL–REV/FWD switch to ‘FWD’.
6. Use the SPEED–DECR/INCR switch to adjust the pump flow to 25 gpm/
pump.
Note: This ensures that there is sufficient flow at the pump to generate
adequate oil pressure. Generally, 25 gpm/pump equates to approximately
40 rpm quill speed.
7. Set the QUILL–REV/FWD switch to neutral (the vertical position between
‘REV’ and ‘FWD’).

25
8. Use the GRABBER LIFT switch on the driller’s panel to position the grabber
to close on the saver sub.
9. Set the GRABBER switch to ‘CLOSE’.
10. Ensure the pipe handler is locked.
Note: The system pressure will rise to the SET TORQUE value.
12. Press and hold the MAX TORQUE button.
Note: This button is located on the side of the driller’s panel.
13. Slowly turn the MAX TORQUE relief valve adjustment screw in until the
desired differential pressure value is achieved.
Note: The differential pressure gauge is located on the driller’s panel.
14. Tighten the lock nut to secure the MAX TORQUE relief setting in place.
Adjust the SET TORQUE Setting

Refer to the torque charts for the unit before adjusting the SET TORQUE. Use the torque
charts for the unit to locate appropriate values for MAX and SET TORQUE settings.
Note: A detailed operations plan is required to ensure that the optimum setting
configuration is used.
1. At the motor manifold of the top drive, ensure that the SET TORQUE relieve
valve is fully unscrewed.
2. Ensure that the MAX TORQUE setting is higher than the anticipated SET
TORQUE value.
3. Set the GRABBER switch to ‘OPEN’.
4. Ensure that it is safe for the quill to rotate.
7. Use the SPEED–DECR/INCR switch to adjust the pump flow to 25 gpm/
pump.
Note: This ensures there is sufficient flow at the pump to generate ade-
quate oil pressure. Generally, 25 gpm/pump equates to approximately
40 rpm quill speed.
8. Set the QUILL–REV/FWD switch to neutral (the vertical position between
‘REV’ and ‘FWD’).
9. Ensure the grabber is positioned to close on the saver hub.
Note: The system pressure will rise to the SET TORQUE value.
13. Slowly turn the SET TORQUE relief valve adjustment screw in until the
desired torque value is achieved.
Note: The gauge for differential pressure is located on the driller’s panel.
14. Tighten the lock nut to secure the SET TORQUE relief setting in place.

26
How to Use the MAX TORQUE Function

The operator can use the MAX TORQUE button to apply maximum torque on demand
whenever the quill is rotating in the forward direction (CONN–FWD; DRILL LO–FWD;
and DRILL HI–FWD mode).
Note: The MAX TORQUE function is available on demand whether the MAX TORQUE
switch is set to ON or OFF.
MAX TORQUE Override
Set the MAX TORQUE switch to ‘ON’ to override the SET TORQUE setting for DRILL–
FORWARD operations. This allows the MAX TORQUE value to be achieved without the
operator having to press the MAX TORQUE button. This override can be applied to either
DRILL LO or DRILL HI mode, but not both. The DRILL MAX TORQUE switch is located
on the outer left side of the driller’s panel, next to the MAX TORQUE button.
Note: The operator can still access maximum torque for other “quill forward” operations
on demand by pressing the MAX TORQUE button.
HOW TO SET THE REVERSE TORQUE

Ensure that a saver sub and die lock clamp have been installed before starting this procedure.
Refer to the torque charts for the unit before adjusting the reverse torque setting. The reverse
torque setting should be set to 50% of the make up (set) torque setting.
1. Ensure the relief valve for reverse torque is fully unscrewed. This valve is
located on the HOSR manifold.
2. Ensure that the GRABBER switch is set to ‘OPEN’.
3. Position the grabber on the saver sub.
Note: Ensure that die lock clamps have been installed (these prevent
the saver sub from disconnecting).
6. Set the QUILL–REV/FWD switch to ‘REV’.
7. Monitor the differential pressure gauge at the driller’s panel.
8. Adjust the relief valve at the filter manifold on the power unit to obtain the
required reverse pressure.
9. Cycle the quill rotation from forward to reverse to confirm that the desired
pressure value has been achieved.
10. If the reverse pressure is correct, set the QUILL–REV/FWD switch to neutral
(the vertical position between ‘REV’ and ‘FWD’).

27
HOW TO SET SPEEDS
Connect Mode
Quill speed for CONNECT mode is factory set at 17 rpm and cannot be adjusted. A revised
PLC code is required to change the connect speed in forward and reverse.
Drill Mode
Although the full range of quill speeds are available in DRILL LO (0 to 100 rpm) and DRILL
HI (0 to 200 rpm), the driller may want to set a maximum quill speed. To set the maximum
quill speed for the DRILL LO mode, use the following steps.
1. Set the TD CTRL switch to ‘OFF’. This switch is located on the side of the
driller’s panel.
2. Ensure the QUILL switch is set to neutral.
4. Set the QUILL switch to ‘FWD’.
5. On the TD CTRL switch, select and hold ‘SET’.
Note: The quill will not rotate.
6. Toggle the SPEED switch towards ‘INCR’ until the desired maximum speed
is displayed on the DELIVERED SPEED gauge.
7. Release the TD CTRL switch.
8. The maximum speed for DRILL LO mode in the FWD direction is now set.
9. Set the QUILL switch to ‘REV’.
10. On the TD CTRL switch, select and hold ‘SET’.
11. Toggle the SPEED switch towards ‘INCR’ until the desired maximum speed
is displayed on the DELIVERED SPEED gauge.
12. Release the TD CTRL switch.
13. The maximum speed for DRILL LO mode in the REV direction is now set.
14. Set the QUILL switch to neutral.
15. Set the TD CTRL switch to ‘RUN’. This will enable the driller’s panel.
16. The system is now ready to commence drilling.
Use the same procedure to set the maximum speed for DRILL HI mode, except set the MODE
switch to ‘DRILL HI’.

28
OPERATIONS GUIDE
CHAPTER 4: OTHER PRE-OPERATIONAL

PROCEDURES
INSTALL THE SAVER SUB AND DIE LOCK CLAMP
Caution: The recommended saver sub torque for a 4-1/2 in.

! (11.4 cm) IF (NC50) connection is 28,000 ft-lb (37,968 N-m).
Caution: The recommended saver sub torque for a 4 in. (10 cm)
! FH (NC40) connection is 18,000 ft-lb (24,408 N-m).
Caution: The recommended saver sub torque for a 3-1/2 in. (8.9 cm)
! IF (NC38) connection is 16,000 ft-lb (21,696 N-m).
1. Ensure the PIPE HANDLER switch is set to locked.

2. Position the saver sub through the grabber box.
Note: Ensure the upper pin protrudes above the grabber box.
3. Apply pipe dope to the threads of the saver sub.
4. Attach the saver sub by hand.
Note: Tighten as much as possible.
6. Set the MODE switch to ‘CONN’.
8. Continue rotation until the connection is fully engaged.
9. When desired torque is achieved, set the QUILL–FWD/REV switch to neutral.
11. Center the die lock clamp around the quill, on top of the grabber box.
12. Loosely install the die lock bolts (8).
13. Raise the die lock clamp into position and hold, either manually or by using
the GRABBER LIFT function.
Note: Position the clamp so it evenly straddles the connection between
the saver sub and the mud valve.

29
OTHER PRE-OPERATIONAL PROCEDURES OPERATIONS GUIDE
14. Apply anti-seize compound to all cap screws and tighten them all evenly.
Note: Monitor the end gaps to ensure that the clamp is installed evenly.
15. Torque all 7/8 in. Grade 8 fasteners to 550 ft-lb (746 N-m).
Note: For more information, refer to the appendix titled “Torque Specifica-
tions for High Strength Fasteners” in the Maintenance Guide for the unit.
16. Use the GRABBER LIFT switch to lower the grabber.
17. Seat the dies.
Note: To seat the dies, strike the back side of each half of the clamp as
hard as possible with a sledge hammer.
18. When the dies seat properly, torque all bolts to 550 ft-lb (746 N-m).
ORIENTING THE PIPE HANDLER

Take these precautions before operating the pipe handler:
• Ensure that the links and elevators are hanging vertically.
• Ensure that the pipe handler is holding no reactive torque from the drill string. This can
be done by setting the GRABBER switch to ‘OPEN’.
1. Ensure the GRABBER OPEN/CLOSE switch is set to ‘OPEN’.
2. Using the PIPE HANDLER UNLOCK/LOCK switch, select ‘UNLOCK’.
Note: The PIPE HANDLER CAUTION light will illuminate.
3. Select PIPE HANDLER ‘FWD/REV’ (depending on desired rotation).
4. When the desired position is reached, release the PIPE HANDLER FWD/REV
switch to neutral.
5. Using the PIPE HANDLER UNLOCK/LOCK switch, select ‘LOCK’.
6. If the PIPE HANDLER CAUTION light remains illuminated, the lock has not
engaged. Using the REV/FWD switch, rotate the pipe handler slightly until the
CAUTION light turns off. This indicates the pipe handler is locked.
SETTING THE GRABBER HEIGHT

The grabber must close on the box connection of the drill string, just below the saver sub. The
grabber height can be adjusted from the driller’s panel. To adjust the height, use the following
procedure:
1. Determine if the grabber needs to move up or down to align with the connection
of the drill string.
2. On the driller’s panel, select ‘OPEN’ on the GRABBER switch.
Note: The auxiliary hydraulic pump will start automatically if it is not
running at this time.
3. On the driller’s panel, select ‘UP’ or ‘DOWN’ on the GRABBER LIFT switch
and hold it there.
4. Release the GRABBER LIFT switch as soon as the grabber reaches the correct
height.
5. The grabber height is now set.
30
OPERATIONS GUIDE OTHER PRE-OPERATIONAL PROCEDURES
SETTING THE GRABBER CLOSING PRESSURE

The grabber hydraulic circuit incorporates a hydraulic oil pressure boosting device (intensi-
fier), which allows the grabber to operate at much higher hydraulic pressure than the rest of the
auxiliary hydraulic system. This results in much higher grabber clamping forces, very useful
when using larger drill pipe sizes.
In some cases, when drilling with small pipe sizes, it may be necessary to reduce the grabber
clamping force to avoid damaging the tool joints. This can be achieved by reducing the grab-
ber closing hydraulic oil pressure. Follow the procedure below to adjust the grabber closing
pressure:
1. Set the grabber switch to ‘OPEN’.
2. Using the GRABBER LIFT switch, position the grabber to close around the
saver sub, or other suitable tubular which can withstand high clamping force.
3. Using the GRABBER OPEN/CLOSE switch, select ‘CLOSE’.
4. Read the grabber high pressure oil gauge located on the grabber intensifier
manifold. The highest possible pressure is approximately 5,000 psi (34.5 MPa).
5. Adjust the pressure reducing valve using an allen key.
Note: Clockwise rotation = increase; counter-clockwise rotation = decrease.
6. Monitor gauge pressure until the pressure reading is at the appropriate level,
as described in Table 4-1 for corresponging drill pipe size.
7. Using the GRABBER OPEN/CLOSE switch, select ‘OPEN’, then ‘CLOSE’,
and confirm gauge pressure. Re-adjust if necessary.
Note: The oil pressure intensifier counterbalance valve is factory preset and should not
be adjusted.
Figure 4-1: Grabber intensifier manifold

31
OTHER PRE-OPERATIONAL PROCEDURES OPERATIONS GUIDE
Table 4-1: Correct pressure for different drill pipe sizes
Drill Pipe Size Type of Connection Grabber Closing Pressure (psi)

3 1/2” NC38 (3 1/2 IF) 2,500 to 3,000
3 1/2” NC40 (4 FH) 3,000 to 3,500
4” NC40 (4 FH) 3,000 to 3,500
4” NC46 (4 IF) 3,500 to 4,000
4 1/2” NC46 (4 IF) & NC50 (4 1/4 IF) 4,000 to 4,500
5” and larger NC50 (4 1/2 IF) or larger 4,500 to 5,000 max

32
OPERATIONS GUIDE
CHAPTER 5: MAKING/BREAKING CONNECTIONS
WARNINGS
Mudsaver Valve
When operating the mudsaver valve, the valve switch applies pressure to the actuator. If the
quill rotates with pressure applied, seal damage can result. Because of this, a mudsaver
interlock stops the quill rotation for five seconds while the valve operates.
Pipe Slips
Danger! Always use caution when setting and removing

pipe slips. If the slips are set when the rotary table
is locked, this might trap torque in the drill string.
! When removing the slips, any trapped torque
might release and turn the drill string. Hoist the
drill string free of the slips before removing the
slips.

33
MAKING/BREAKING CONNECTIONS OPERATIONS GUIDE
HOW TO MAKE CONNECTIONS–GENERAL

Do the following before beginning this procedure:
• Ensure that the torque and speed settings are appropriate for the drill string and
drilling conditions.
• Ensure that the thread on the saver sub matches the thread on the drill string.
• Properly apply pipe dope to all threaded connections.
Caution: When connecting the top drive to a single length of drill

pipe, position the grabber so that it closes on the drill pipe tool
joint. When making up the top drive and additional connections
! simultaneously, position the break-out tongs on the drill pipe tool
joint located in the slips.
Figure 5-1: Correct tong position to make a connection
Correct tong position for:
top drive connection only
top drive and pipe/pipe connection

34
OPERATIONS GUIDE MAKING/BREAKING CONNECTIONS

Note: The top drive turns at the pre-selected rpm for CONNECT mode with
forward rotation.
3. Apply a back-up tong to tool joint in the slips.
Note: If making up the top drive and lowering the connection at the same
time, apply the back-up tong below the lower connection. If making up a top
drive connection only, apply the back-up tong to the single length of pipe. In
this case use the grabber instead of a back-up tong.
4. Slowly lower the top drive to the connection.
5. Ensure that the box connection enters into the drill pipe guide.
6. Monitor the weight indicator gauge.
7. Continue to lower the top drive until the weight indicator begins to fluctuate.
Caution: Ensure that the Vernier dampening valve (located on

! the weight indicator) is open.
8. Lead the top drive into the connection.

Note: Lower the top drive in small increments as the connection rotates in.
Keep a small amount of weight on the connection (i.e., the weight indicator
should register only a small amount of weight). This prevents the top drive
from “lifting” the stand or single section of drill pipe and damaging the
threaded connections.
9. Continue forward rotation until the connection is fully engaged.
Note: The top drive stalls when it reaches the preset SET torque. The forward
rotation speed then drops to zero.
10. Monitor the digital pressure display on the driller’s panel.
11. When the torque matches the required make up torque value, set the
QUILL–REV/FWD switch to neutral.
12. Wait until the differential pressure value decreases to zero.
13. Remove the back-up tong, or open the grabber (if used).
How to Use the Mousehole to Connect Drill Pipe to the Top Drive
Pipe Handler Orientation–Grabber to V-door
Use this procedure when drilling with single lengths of pipe.

Note: This procedure applies when making connections when the mousehole is not offset.
Caution: Ensure that the tilt links are close to hole center when
! hoisting pipe out of the mousehole with the pipe handler in this
orientation. This will prevent the links from hitting the torque track.
1. Put a single length of pipe in the mousehole.

2. Apply pipe dope to the box connection on the drill pipe.
3. Using the EXTEND switch, select ‘OUT’ and hold until the top drive is situated
directly over the mousehole.
4. Lower the top drive until the elevator and elevator links are near the rig floor.

35
Figure 5-2: Correct position for elevator links and elevator
5. Set the LINK TILT switch to ‘BACK’.

6. Move the elevator links and elevators backward and out of the way of the
connection.
7. Lower the top drive until the saver sub is within a foot of the pipe connection.
8. Using the MODE switch, select ‘CONN’.
9. Using the QUILL-REV/FWD switch, select ‘FWD’.
10. Slowly lower the top drive to engage the connection between the saver sub and
the drill pipe.
Note: If the pipe starts to spin in the mousehole, set the QUILL–REV/FWD
switch to neutral. Adjust the weight on the connection to prevent spinning,
then set the QUILL–REV/FWD switch to ‘FWD’.
12. When the connection is fully engaged, set the QUILL–REV/FWD switch to
neutral.

36
How to Fully Torque a Connection

3. Set the QUILL switch to ‘FWD’.
4. When the torque value on the DELIVERED TORQUE gauge matches the value
required to fully torque the connection to specification, set the QUILL switch to
neutral.
How to Connect a Single Length of Drill Pipe to the Drill String

1. Hoist the single length of pipe out of the mousehole without torquing the
connection.
2. Set the EXTEND switch to ‘IN’.
3. Retract the extend arms until the top drive is positioned over hole center.
4. Place back-up tongs on the tool joint of the drill pipe that is held by the rig slips.
5. Apply pipe dope to the tool joint box.
6. Lower the top drive to stab the drill pipe into the tool joint box of the drill pipe
held in the rig slips.
10. Monitor the differential pressure gauge or DELIVERED TORQUE gauge.
11. When the torque reaches the required torque value to make up the current
connection, set the QUILL–REV/FWD switch to neutral.

37
Figure 5-3: Connect a single length of pipe to the drill string
HOW TO BREAK THE TOP DRIVE/DRILL PIPE CONNECTION

Use this procedure to disengage the connection between the top drive and the drill pipe.
1. Position the grabber so that it will close on the box of the drill pipe.
Caution: Ensure that the grabber will not close on any part of
! the saver sub or the hard band of the drill pipe.
! Danger! This is an important safety step.

38

5. Set the QUILL-REV/FWD switch to ‘REV’.
Note: The differential pressure gauge will rise to the ‘reverse relief’ pressure.
6. Push and hold the BREAKOUT button.
7. When connection breaks, do the following:
• Immediately release the BREAKOUT button.
• Quickly set the QUILL–REV/FWD switch to neutral.
10. Lead the top drive out of the connection.
11. When connection is disengaged, hoist the top drive clear of the floor.
Figure 5-4: Break the top drive/drill pipe connection

39
HOW TO USE THE TOP DRIVE TO MAKE UP PIPE STANDS
How to Make Up Stands in the Rotary Table
Figure 5-5: Make up stands in the rotary table
The following procedure assumes that stands of pipe are made where there is 60 ft. (18.3 m) of
available depth below the rotary table. This is usually possible if conductor pipe is complete.
If no conductor pipe is drilled, refer to “How to Make Up Pipe Stands Without a Conductor
Pipe” on page 41.
Note: Use the floor tugger to make up stands of pipe more efficiently. Use the floor tugger
to place single lengths of pipe in the mousehole while using the top drive to make connec-
tions in the rotary table.
1. Use the floor tugger to lower a single length of pipe into the mousehole.
2. Lower the top drive.
3. Use the LINK TILT switch to tilt the elevator forward over the mousehole.
Caution: Do not use the EXTEND function to move the top drive
!
over the mousehole or the travelling blocks might strike the
racking platform when hoisting the top drive.

40
4. Position the elevator on the pipe single and set the ELEVATOR switch to
‘CLOSE’.
5. Hoist the top drive and the pipe out of the mousehole.
6. Press the FLOAT button. This allows the elevator to come to the vertical position
over hole center.
7. Lower the pipe through the rotary table to the required connection height.
8. Set the slips.
9. Set the ELEVATOR switch to ‘OPEN’. Push and hold the SAFETY OPEN button.
10. Use the LINK TILT switch to tilt the elevator back slightly.
Note: This prevents the elevator from hitting the tool joint as the top drive
is raised.
11. Hoist the top drive until the elevator is clear of the pipe.
12. Set the LINK TILT switch to ‘FORWARD’.
13. Position the elevator over the mousehole.
14. Lower the top drive and close the elevator on the second length of drill pipe now
located in the mousehole.
Note: The tugger operator should have placed the pipe in the mousehole
while the top drive operator was making the connection at the rotary table.
15. Hoist the top drive until the bottom of the second length of pipe is above the pipe
in the rotary table.
16. Press the FLOAT button. This allows the elevator to come to hole center.
17. Lower the top drive and stab the pipe in the rotary table.
18. Attach the pipe spinner to the upper length of pipe, or rotate the connection by
using chain tongs.
19. Spin the upper pipe until the connection is fully engaged but not tight.
20. Remove the pipe spinner, then use rig tongs to torque the connection to
specification.
21. Hoist the top drive and the double length of pipe.
22. Remove the slips.
Note: If making up double lengths of pipe only, proceed to “Standard Racking
Procedure” on page 69.
23. Lower the top drive and the double length of pipe into the rotary table to the
required connection height.
24. Set the slips.
How to Make Up Pipe Stands Without a Conductor Pipe

If no conductor pipe is in place, make up triple stands of pipe by modifying the previous
procedure as follows:
1. Connect the first two single lengths of pipe as described in the previous
procedure, then continue to the following steps.
2. Hoist the double stand of pipe until it is above the drill floor.
3. Use the floor tugger to place a single length of pipe into the rotary table.

41
4. Set the slips.

5. Lower the top drive and the double length of pipe to stab the pipe single in the
rotary table.
6. Connect the pipe double and pipe single by using the pipe spinner and rig tongs.
7. Use the rig tongs to torque the connection.
8. Proceed with racking as described in “Standard Racking Procedure” on page 69.
How to Make Up Pipe Stands in the Mousehole

It is more difficult and less efficient to make up stands of pipe in the mousehole than using the
rotary table. Use the following procedure when the rotary table is unavailable.
Figure 5-6: Make up pipe stands in the mousehole
1. Use the floor tugger to lower a single length of pipe into the mousehole.
2. Lower the top drive.
3. Use the LINK TILT switch to tilt the elevator forward over the mousehole.

42
Warning! Do not use the EXTEND function to move the top

drive over the mousehole. If the top drive is
! being hoisted while it is extended, it might
collide with the racking platform.
4. Position the elevator on the single length of pipe and set the ELEVATOR
switch to ‘CLOSE’.
5. Hoist the pipe out of the mousehole.
6. Use the floor tugger to lower the second length of pipe into the mousehole.
7. Lower the top drive and pipe and stab the second length of pipe that is in the
mousehole, and attach chain tongs to the upper and lower lengths of pipe.
Caution: Release all the weight off the elevator to reduce the
! friction between the pipe and the elevator.
Caution: Most pipe spinners cannot be used when making

! connections at the mousehole.
8. Ensure the connection is fully engaged but not tightened.

9. Use the rig tongs to torque the pipe connection to the required specification.
10. Hoist the double length of pipe out of the mousehole.
Warning! Adjust the LINK TILT position as required to

avoid hitting the racking platform while hoisting
! the top drive. The same caution applies when
using the EXTEND function.
11. Use the floor tugger to lower the third length of pipe into the mousehole.
12. Lower the top drive and double length of pipe to stab the third pipe that is in
the mousehole.
Warning! Adjust the LINK TILT position to avoid hitting the

! racking platform while making this connection.
13. Release all the weight off the elevator to reduce the friction between the pipe
and the elevator.
14. Attach chain tongs to the double and single lengths of pipe.
15. Ensure the connection is fully engaged but not tightened.
16. Use the rig tongs to torque the pipe connection to the required specification.
17. Hoist the completed triple stand of pipe until the bottom of the stand is above
the floor racking area.
Warning! Use caution when the pipe stand clears the

mousehole; the stand will tend to swing to the
vertical position. Move the elevator links and
! elevator to hole center to avoid hitting the
racking platform when hoisting the top drive.
18. Follow the “Standard Racking Procedure” on page 69.

19. Lower the top drive and proceed with making up the next stand of pipe.
43
HOW TO MAKE UP BHA (COLLARS AND TOOLS)

Use the pipe handler to help make up the Bottom Hole Assembly (BHA), collars, and tools.
When the LINK TILT function is used to move collars, remember that the link tilt cylinders
have limitations. If the elevator links are extended over the mousehole and connected to a
collar, they might return to hole center when the top drive is raised. If this occurs, hydraulic
oil will be directed over the safety relief valve.
Caution: If pick-up elevators are used for the collars, disconnect

! the elevator ‘open’ and ‘close’ hydraulic hoses.
Figure 5-7: Connect collars

44
1. Use the floor tugger to put a collar in the mousehole.

2. Ensure that a pick-up sub is installed on the collar.
Note: Use chain tongs to install the pick-up sub.
Warning! Torque the connection between the pick-up sub

! and the collar to prevent it from unscrewing.
3. Ensure the grabber is positioned immediately below the saver sub.

5. Position the elevators over the mousehole.
6. Lower the top drive and position the elevator on the pick-up sub.
7. Set the ELEVATOR switch to ‘CLOSE’.
8. Hoist the top drive until the collar is clear of the mousehole.
9. Press the FLOAT button. This allows the elevator to return to a vertical position
over hole center.
10. Lower the top drive until the collar is correctly positioned in the rotary table.
11. Set the slips and attach a safety clamp.
12. Use the rig tongs to loosen the connection between the pick-up sub and the collar.
13. Once this connection is loosened, use the chain tongs to unscrew the connection
completely.
14. Hoist the top drive and the pick-up sub.
15. Use the floor tugger to place a second collar in the mousehole.
17. Position the elevator over the mousehole.
18. Lower the top drive and the pick-up sub, and stab the second collar that is in the
mousehole.
19. Use the chain tongs to connect the pick-up sub and the collar.
20. Hoist the top drive until the collar is clear of the mousehole.
21. Press the FLOAT button. This allows the elevator to move to the vertical position.
22. Lower the top drive to stab the collar that is in the rotary table.
Caution: The elevator links must hang vertically over the

! connection point.
23. Lower the top drive to position the grabber so that it will close on the pick-up sub,
then set the GRABBER switch to ‘CLOSE’.
24. Set the PIPE HANDLER switch to ‘UNLOCK’. This allows the pipe handler to
rotate and make up the connection.
25. Set the PIPE HANDLER switch to ‘FWD’ and hold the switch at ‘FWD’ position.
The pipe handler begins to rotate at the preset speed.

45
26. While holding the PIPE HANDLER switch to ‘FWD’, lower the top drive to
engage the connection.
Note: Carefully calibrate top drive weight on the connection to prevent the
collar from spinning in the elevator. Balance the top drive by raising and
lowering it in small increments.
Caution: The GRABBER OVERRIDE button on the brake handle

! must be used to hoist the top drive when the grabber is closed.
27. Rotate the connection until it is fully engaged but not tightened.
28. Release the PIPE HANDLER FWD switch.
29. Attach rig tongs to the collars.
30. Torque the connection to the required specification.
31. Remove the safety clamp.
32. Hoist the top drive and remove the slips. This suspends the collars from the
elevator of the top drive.
33. Lower the collars through the rotary table to the desired connection height.
35. Use the rig tongs to disconnect the pick-up sub from the top collar.
36. Repeat steps 19 to 35 to connect the third collar.
37. When all required collars are made up, do the following:
a. Set the PIPE HANDLER switch to ‘LOCK’.
b. Set the GRABBER switch to ‘OPEN’.
How to Connect Collars Above the Rotary Table

1. Follow steps 1 to 37 of “How to Make Up BHA (Collars and Tools)” on page 44
to connect the first two collars in the rotary table.
Note: When these steps are complete, ensure that:
• there are two collars in the rotary table (one low in the table, the second
above),
• the top collar is connected to a pick-up sub, and
• both collars are suspended from the top drive elevator
3. Hoist the top drive and remove the slips. This suspends the collars from the top
drive elevator.
4. Hoist the top drive and collars above the rotary table.
Note: Use the floor tugger to place a third collar in the rotary table. Use the
slips and a safety clamp to secure the collar in place.
5. Lower the top drive to stab the connection in the rotary table.
Caution: The elevator links must hang vertically over the

! connection point.

46
6. Lower the top drive to position the grabber so that it will close on the pick-up sub,
then set the GRABBER switch to ‘CLOSE’.
7. Set the PIPE HANDLER switch to ‘UNLOCK’. This will allow the pipe handler
to rotate and make up the connection.
8. Set the PIPE HANDLER switch to ‘FWD’ and hold it at ‘FWD’ position. The
pipe handler will begin to rotate at the preset speed.
9. While holding the PIPE HANDLER FWD switch, lower the top drive to engage
the connection.
Note: Carefully calibrate top drive weight on the connection to prevent the
collar from spinning in the elevator. Balance the top drive by raising and low-
ering it in small increments.
Caution: The GRABBER OVERRIDE button on the brake handle

! must be used to hoist the top drive when the grabber is closed.
10. Rotate the connection until it is fully engaged but not tightened.
11. Attach rig tongs to the collars.
12. Torque the connection to the required specification for the drill collar.
14. Hoist the top drive to clear the collars from the rotary table.
15. Rack the collars according to the “Standard Racking Procedure” on page 69.
16. When all required collars are picked up, do the following:
a. Set the PIPE HANDLER switch to ‘LOCK’.
b. Set the GRABBER switch to ‘OPEN’.

47

48
OPERATIONS GUIDE
CHAPTER 6: DRILLING OPERATIONS
WELL CONTROL
As the owner/operator of a top drive, it is important to establish guidelines and procedures
for all possible well control situations. These guidelines and procedures should reflect
industry standard practice for operating location and conditions.
In most cases, the addition of a top drive will not significantly change the established proce-
dures for well control. Whenever possible, use the same well control procedures established
prior to the addition of a top drive.
All personnel must be trained to adhere to safe operating practices and should be periodically
tested to verify their skill level.
Review safety procedures before each drilling operation.
SURFACE HOLE DRILLING OPERATIONS

The following procedure applies when drilling a surface hole with drill collars, by using either
a single joint of drill pipe (as a working pipe single) or drillable pick-up subs.
Use only drillable pick-up subs for tripping operations. A drillable pick-up sub has a 5 ft.
(1.5 m) length of tube on which the elevators can slide up and down. The threaded connec-
tions at the top of the drillable pick-up sub are the same as those on the saver sub, while those
at the bottom of the drillable pick-up sub are the same as those on the drill collars. This
allows the drillable pick-up sub to be threaded into drill collars and used as a pick-up sub for
racking operations. A drillable pick-up sub allows for the ability to ream and back-ream dur-
ing tripping operations, if required.
How to Drill a Surface Hole

1. Use the appropriate rig equipment and safe working procedures to position a
collar in the mousehole.
2. Use chain tongs to install a drillable pick-up sub on the collar.
Caution: Torque the connection between the drillable pick-up sub

! and the collar to prevent it from unscrewing.
3. Lower the top drive to position the elevator at the pick-up sub.
5. Hoist the top drive until the drillable pick-up sub and collar clear the mousehole.
49
DRILLING OPERATIONS OPERATIONS GUIDE
6. Press the FLOAT button. This will bring the elevator to the vertical position.
Note: Ensure there is adequate clearance for the racking platform.
7. Install the bit sub and drill bit, and apply the appropriate torque.
8. Hoist the collar out of the bit-breaker and lower it through the rotary table.
9. When the bit reaches the bottom of the hole, hoist it 1 to 2 ft. (30 to 60 cm) off
the bottom and set the slips.
10. Lower the top drive with the elevator closed. Allow the elevator to slide down
the drillable pick-up sub. Guide the drillable pick-up sub through the pipe guide.
13. Slowly lower the top drive to engage the connection between the saver sub
and the drillable pick-up sub.
! Warning! Ensure the rotary table is locked.

15. When the connection is fully engaged, set the QUILL–REV/FWD switch to
neutral.
16. Ensure the grabber is positioned over the box connection of the drillable
pick-up sub.
18. Set the QUILL–REV/FWD switch to ‘FWD’ (the MODE switch should still be
set to ‘CONN’).
19. When the torque reaches the desired torque value, turn the QUILL–REV/FWD
switch to neutral.
21. Hoist the top drive and remove the slips.
22. Set the mudsaver VALVE switch to ‘OPEN’.
23. Set the MODE switch to ‘DRILL LO’ or ‘DRILL HI’.
24. Start the rig mud pump.
25. Begin drilling.
About Connections and Surface Hole Operations

Make connections as they would normally be done. Leave the drillable pick-up sub on the top
drive. Refer to “How to Make Up BHA (Collars and Tools)” on page 44.
About Tripping and Surface Hole Operations

Trip drill pipe in and out of the hole as they would normally be done, but use a drillable
pick-up sub on the top of each stand instead of a standard pick-up sub.
About Reaming and Surface Hole Operations

Refer to “Reaming Operations” on page 75.

50
OPERATIONS GUIDE DRILLING OPERATIONS
HOW TO DRILL AHEAD WITH SINGLE LENGTHS OF PIPE

Drilling operations proceed more efficiently when the tugger is used to place single lengths
of pipe in the mousehole while the top drive makes connections and drills.
This procedure assumes that the top drive is at floor level and connected to the drill string.
Figure 6-1: Drill ahead with single lengths of pipe
1. Raise the bit 1 to 2 ft. (30 to 60 cm) off the bottom of the hole.
2. Set the QUILL–REV/FWD switch to neutral.
3. Allow the reactive torque to release.
Caution: As the torque releases, the drill string may rotate slightly.
! Wait until the rotation ceases before continuing.
4. Set the slips.

51
5. Shut off the rig mud pump.

6. Monitor the standpipe pressure gauge and wait for the mud pump pressure to
decrease to zero.
7. Set the mudsaver VALVE switch to ‘CLOSE’.
Warning! Do not close the grabber on the saver sub or the

! hard band of the drill pipe.

Note: The top drive torque will increase to the preset value.
12. Press and hold the BREAKOUT button.
Note: Torque increases until it reaches the maximum value available for
breakout torque for the unit.
13. When the quill rotates 1/2 turn, release the BREAKOUT button.
14. Immediately set the GRABBER switch to ‘OPEN’.
Note: This allows the top drive to be raised in small increments and
minimizes the load on the threads as the connection unscrews. The
counter-balance system also assists with thread disengagement.
15. Lead the top drive out of the drill pipe connection.
Note: To avoid damaging the pipe threads, do not let the weight of the top
drive rest on the connection while it unscrews.
16. When the connection unscrews completely, set the QUILL–REV/FWD switch
to neutral.
17. Hoist the top drive until the elevator clears the drill string stump in the rotary
table.
18. Set the ELEVATOR switch to ‘OPEN’, then push and hold the elevator SAFETY
OPEN button.
19. Use the LINK TILT switch to move the elevator forward so that it is above the
mousehole.
20. Lower the top drive until the elevator reaches the drill pipe in the mousehole.
21. Position the elevator on the drill pipe, then set the ELEVATOR switch to
‘CLOSE’.
22. Hoist the top drive until the single length of pipe is above the drill pipe stump in
the rotary table.
23. Press the FLOAT button to bring the elevator to the vertical position.
.
Caution: Rig floor personnel should stabilize the lower end of

! the drill pipe.
24. Lower the top drive and stab the drill pipe connection.
25. Position a back-up tong on the box connection of the stump.

52

28. Lower the top drive further until the pipe makes contact with the saver sub.
29. Use the LINK TILT function to guide the pipe through the drill pipe guide.
30. Lead the top drive into the connection until the pipe/pipe and pipe/saver sub
connections are fully engaged but not tightened.
Note: When both connections are fully engaged, the back-up tongs will tighten
and the top drive will stall.
31. Wait until the torque increases to the required make up torque for the connection.
33. Remove the back-up tong.
34. Set the ELEVATOR switch to ‘OPEN’, and press and hold the ELEVATOR
SAFETY OPEN button.
35. Set the LINK TILT switch to ‘BACK’. This moves the elevator away from the
drill string and avoids unnecessary wear of the elevator inserts. Avoid contacting
the elevator to the torque track.
36. Set the VALVE switch to ‘OPEN’.
37. If required, start the rig mud pump.
38. Hoist the top drive and drill string.
42. Use the SPEED–DECR/INCR switch to increase the rpm to the desired drilling
speed.
43. Commence drilling.

53
HOW TO DRILL AHEAD WITH PIPE STANDS

This procedure assumes that the top drive is at floor level and connected to the drill string.
Figure 6-2: Drill ahead with pipe stands

54
1. Raise the bit 1 to 2 ft. (30 to 60 cm) off the bottom of the hole.
3. Allow the reactive torque to release.
Caution: As the torque releases, the drill string may rotate

! slightly. Wait until the rotation ceases before continuing.
4. Set the slips.

decrease to zero.
Warning! Do not close the grabber on the saver sub or the

! hard band of the drill pipe.

Note: The top drive torque will increase to the preset value.
Note: Torque increases until it reaches the maximum value available for
breakout torque for the unit.
13. When the quill rotates 1/2 turn, release the BREAKOUT button.
Note: This allows the top drive to be raised in small increments and
minimizes the load on the threads as the connection unscrews. The
counter-balance system also assists with thread disengagement.
Note: To avoid damaging the pipe threads, do not let the weight of the top
drive rest on the connection while it unscrews.
16. When the connection unscrews completely, set the QUILL–REV/FWD
switch to neutral.
17. Hoist the top drive until the elevator clears the drill string stump in the rotary
table.
18. Set the ELEVATOR switch to ‘OPEN’, then push and hold the ELEVATOR
SAFETY OPEN button.
19. Use the LINK TILT switch to move the elevator forward so that it is past the
stump.
20. Hoist the top drive to the racking platform.
21. Position the elevator to capture the top tool joint of the next stand of pipe.
23. Ensure that rig floor personnel are ready to assist in guiding the stand out of its
racking position.

55
24. When the stand is picked up, press the FLOAT button.
25. Hoist the top drive slowly, allowing the rig floor personnel to guide the bottom
of the stand to a vertical position.
26. Hoist the top drive until the bottom pin of the stand clears the stump.
27. Lower the top drive and stab the drill pipe connection into the stump.
28. Position a back-up tong on the box connection of the stump.
29. Lower the top drive further until the pipe makes contact with the saver sub.
30. Use the LINK TILT function to guide the pipe through the drill pipe guide.
Note: When both connections are fully engaged, the back-up tongs will
tighten and the top drive will stall.
34. Wait until the torque increases to the required make up torque for the connection.
37. Set the ELEVATOR switch to ‘OPEN’, and press and hold the ELEVATOR
SAFETY OPEN button.
38. Set the LINK TILT switch to ‘BACK’. This moves the elevator away from the
drill string and avoids unnecessary wear of the elevator inserts. Avoid contacting
the elevator to the torque track.
39. Set the VALVE switch to ‘OPEN’.
40. If required, start the rig mud pump.
45. Use the SPEED–DECR/INCR switch to increase the rpm to the desired drilling
speed.

56
SLIDE DRILLING OPERATIONS

Introduction
In slide drilling operations, power to the bit is supplied using downhole mud motors. As a
result, the drill string does not rotate during drilling operations. This procedure addresses
how to make and break connections during slide drilling operations.
Caution: During slide drilling operations, ensure the grabber
! remains closed on the saver sub. Once the grabber is fully closed,
return the GRABBER switch to the neutral position.
During extended periods of slide drilling, set the GRABBER switch to ‘CLOSE’, then back to
neutral, once every hour. This helps to maintain full pressure in the grabber–close hydraulic
circuit.
Mud Motors in Slide Drilling Operations

When drilling with a downhole mud motor, ensure the top drive drill–forward torque setting is
greater than the maximum torque output of the mud motor.
1. Trip in the drill pipe and mud motor until the mud motor reaches the bottom of the
hole. Refer to “Tripping Operations” on page 63.
2. Connect the top drive to the drill string by lowering the top drive until the drill
pipe makes contact with the saver sub.
Note: Use the LINK TILT feature to guide the drill pipe into the drill
pipe guide.
3. Position the grabber to close on the box of the drill pipe.
7. Lead the top drive into the connection until the pipe/saver sub connection is fully
engaged but not tightened.
8. Wait until the torque increases to the required value for the current thread and
connection type.
9. As soon as the torque reaches the required value to make up the connection, set
the QUILL–REV/FWD switch to neutral.
11. Reposition the grabber to close on the saver sub.
12. Set the GRABBER switch to ‘CLOSE’ and set the VALVE switch to ‘OPEN’.
16. Start drilling by lowering the top drive.
Note: Ensure the QUILL switch remains in neutral.

57
When drilling with a mud motor, the orientation of the tool face might need to be adjusted to
drill in the required direction. Refer to the next section, “How to Adjust the Tool Face Orien-
tation”.
How to Adjust the Tool Face Orientation

This procedure assumes the following:
• the top drive is above the drill floor
• the top drive is connected to the drill string
• the top drive is ready to proceed with drilling
• the grabber is closed on the saver sub
1. Cancel the speed register by setting the MODE switch to neutral and toggle the
SPEED switch once to either ‘INCR’ or ‘DECR’.
4. Use the SPEED–DECR/INCR switch to decrease the quill speed to zero, then
slowly increase the speed until a deflection of the grabber box is observed.
5. When observing a deflection of the grabber box, set the GRABBER switch
to ‘OPEN’.
Note: If the torque in the drill string matches the torque of the top drive,
open the grabber with no rotation (static).
6. Reorient the tool face by doing one of the following:
a. To turn the drill string clockwise, use the SPEED–DECR/INCR switch to
increase the torque slowly (Note: This only applies when pump displacement
is very low and the closed-loop flow has just overcome pump and motor
leakage). Increasing the torque allows the top drive to overcome the reactive
torque of the downhole motor. When this happens, the drill string slowly
turns clockwise.
Note: When the required tool face orientation is achieved, slowly
decrease the torque using the SPEED-DECR/INCR function until the
quill stalls, then close the grabber.
b. To turn the drill string counter-clockwise, use the SPEED–DECR/INCR
switch to decrease the torque slowly. Decreasing the torque allows the down-
hole motor to overcome the torque of the top drive, and the drill string turns
slowly counter-clockwise.
Note: When the required tool face orientation is achieved, slowly
increase the torque using the SPEED-DECR/INCR function until the
quill stalls, then close the grabber.

58
How to Make and Break Connections During Slide Drilling

Operations
1. Set the slips.
! Caution: Ensure the rotary table is locked.

3. Reposition the grabber to close on the box of the drill pipe.
decrease to zero.
9. Set the QUILL–REV/FWD to ‘REV’.
Note: The top drive torque increases to the preset value.
Note: Torque increases until it reaches the maximum break out torque value
for the top drive unit.
11. When the saver sub/pipe connection breaks and rotates 1/2 turn, release the
BREAKOUT button.
Note: This allows the top drive to be raised in small increments as the
connection unscrews.
Note: To avoid damaging the pipe threads, do not allow the weight of the top
drive to sit on the connection while it unscrews.
14. When the connection completely unscrews, set the QUILL–REV/FWD switch
to neutral.
15. Hoist the top drive high enough to allow the elevator to pass over the stump.
16. Use the top drive elevator to pick up the required drill pipe.
Note: Slide drill with either single lengths of pipe or stands of pipe. Refer to
“How to Drill Ahead with Single Lengths of Pipe” on page 51 and “How to
Drill Ahead with Pipe Stands” on page 54 for more information.
17. Hoist the top drive until the bottom pin of the pipe stand clears the stump.
18. Press the FLOAT button. The elevator and pipe stand will move to hole center.
19. Position the back-up tong on the box connection of the stump.
20. Lower the top drive until the drill pipe makes contact with the saver sub.
Note: Use the LINK TILT function to guide the drill pipe into the drill
pipe guide.

59
Note: When both connections are fully engaged, the back-up tongs will
tighten and the top drive will stall. It is also possible that the top drive will
torque into the locked rotary table.
24. Wait until the DELIVERED TORQUE gauge increases to required value for the
connection type.
25. As soon as the torque reaches the required value to make up connections, set the
27. Reposition the grabber to close on the saver sub.
31. Hoist the top drive and drill pipe.
Danger! Exercise caution when removing the slips. Stored

drill string torque may spin the slips when the drill
! string is hoisted.
How to Maintain the Tool Face Orientation During Slide Drilling

Operations
It is essential to maintain the tool orientation during slide drilling, as it determines the drilling
direction. To maintain tool orientation while making or breaking connections, the drill string
must be locked in the rotary table with the slips, as described in “How to Make and Break
Connections During Slide Drilling Operations” on page 59.
Caution: The rotary table must remain locked during this

! procedure.
TESCO recommends marking the position of the drill string to monitor whether or not some of
the stored torque in the drill string is released when making a connection.
In some instances it might be necessary to remove the slips while the grabber is still open. In
this case, the top drive must absorb the torque in the drill string. Use the following procedure
to allow the top drive to safely absorb the torque in the drill string.
3. Use the SPEED–DECR/INCR switch to decrease the quill speed to zero.
4. Use the SPEED–DECR/INCR switch to increase the quill torque slowly until the
torque at the top drive matches the torque in the drill string (Note: This only
applies when the pump displacement is very low and the closed-loop flow has just
overcome pump and motor leakage). Refer to the following procedure, “How to
Record the Drill String Torque”, for more information.
5. When the torque reaches the required value, hoist the top drive and remove
the slips.
60
How to Record the Drill String Torque

This procedure assumes that a mud motor is currently used for drilling, and the bit is currently
on the bottom of the wellbore.
1. Close the grabber on the saver sub.
4. Use the SPEED–DECR/INCR switch to decrease the quill torque to zero.
5. Use the SPEED–DECR/INCR switch to increase the torque gradually.
6. When observing deflection of the grabber box towards the driller’s side
(clockwise), record the torque value or differential pressure.
7. Re-check the drill string torque periodically during downhole motor operations.

61

62
OPERATIONS GUIDE
CHAPTER 7: TRIPPING OPERATIONS

• Trip Out: the act of removing the drill string from the wellbore.
• Trip In: the act of inserting the drill string into the wellbore.
WELL CONTROL DURING TRIPPING OPERATIONS

As the owner/operator of a top drive, it is important to establish guidelines and procedures
for all possible well control situations. These guidelines and procedures should reflect
industry standard practice for operating location and conditions.
In most cases, the addition of a top drive will not significantly change the established well
control procedures. Whenever possible, use the same well control procedures established
prior to the addition of a top drive.
All personnel must be trained to adhere to safe operating practices and should be periodically
tested to verify their skill level.
Safety procedures should be reviewed before each operation.
Caution: If the top drive is connected to the drill string when the
drill string is off the bottom of the hole, the following equipment
is required:
! · additional saver sub
· spare double-ball mudsaver valve
· strip kit (tools required to remove mudsaver actuator)
If planning to connect the top drive to the drill string when it is off the bottom of the hole,
TESCO recommends removing the actuator and servicing the entire assembly on a regular
basis. Refer to the following procedure for information on how to remove the actuator.

63
TRIPPING OPERATIONS OPERATIONS GUIDE
How to Remove the Mudsaver Valve Actuator During Well

Control Tripping
Danger! The removal of the actuator off of the double ball

valve is relatively simple and quick, however,
! there are a few steps that must be followed in
sequence for reasons of safety.
1. Set the slips.

2. Shut off the mud pump.
3. Use the valve wrench that is provided to close the manual ball valve. This ball
valve is located below the actuator. See Figure 7-1 on page 65.
4. Set the mudsaver VALVE switch (driller’s panel) to ‘OPEN’. This will open the
actuated mudsaver valve.
Note: Visually verify that there is no pressure in the standpipe at this point.
5. Raise the upper spline lock above the mudsaver valve connection. Use a setscrew
to hold the spline lock onto the quill.
6. Remove the lower die-lock clamp from the mudsaver valve.
7. Use the grabber lift needle valve to position the grabber so that it will close on the
bottom of the mudsaver valve.
8. Set the GRABBER switch (driller’s panel) to ‘CLOSE’. The grabber should close
on the mudsaver valve.
9. Break out the mudsaver valve from the top drive.
a. Set the MODE switch to ‘CONN’.
b. Set the QUILL–REV/FWD switch to ‘REV’.
c. Push and hold the BREAKOUT button. Release the BREAKOUT button
when the quill has rotated 1/2 turn.
Note: Hoist the top drive in small increments as the connection unscrews.
This will keep the weight of the top drive off the connection.
11. Hoist the top drive until the grabber is positioned approximately 1 in. (2.5 cm)
from the actuator.
Caution: Do not hoist any higher, or the grabber will hit the
! actuator. This can damage the actuator.
12. Use the GRABBER LIFT switch to lift the grabber until the actuator rests on
the grabber.
Note: Blocking may be required between the grabber and actuator.
13. Remove the two worm ring clamps from the actuator.
14. Remove the two snap rings and the two hex drives. Use a slide hammer to remove
these items. See Figure 7-2 on page 66.
15. Remove the four upper lock pin assemblies.
Note: The lock pin assemblies consist of a setscrew, a spring and a lock pin.
16. Remove the four lower lock pin assemblies if they are present.

64
OPERATIONS GUIDE TRIPPING OPERATIONS
17. Install two lifting eyes in the upper lock pin holes at 180°. Attach a tugger or other
lifting device to the lifting eyes.
18. Hoist the top drive slowly. The actuator should slide off of the mudsaver valve.
Use the tugger or lifting device to remove the actuator from the grabber after the
actuator is released from the mudsaver valve.
19. An inside Blow Out Preventer or other device may be installed to control the well
pressure at this stage.
20. The top drive may be used to make up the connection.
21. After the connection is secure, use the mudsaver valve wrench to open the manual
ball valve slowly.
22. Insert the drill string into the wellbore. Use the procedure described in “How to
Trip In Drill Pipe” on page 74.
Figure 7-1: Remove the mudsaver valve actuator for well control

65
Figure 7-2: Remove the actuator from the mudsaver valve
1. Pin 3. Set Screw

2. Spring 4. Hex Drive Shaft

66
TRIP OUT OPERATIONS

Before beginning trip out operations, observe all required operating conventions. These would
include procedures such as ‘circulating the hole,’ ‘pumping a pill,’ etc.
How to Trip Out Drill Pipe
Figure 7-3: Trip out drill pipe

67
Caution: Ensure that the pipe handler is oriented such that the
! links can be tilted toward the derrickman when the drill pipe is
ready to be racked.
1. Shut off the rig mud pumps.

2. Monitor the standpipe gauge to ensure that mud pump pressure decreases to zero.
3. Set the VALVE switch to ‘CLOSE’.
4. Hoist the top drive.
5. Set the slips.
Note: Ensure that the stored torque in the drill string has dissipated before
the slips are set.
6. Position the grabber on the drill pipe using the LINK TILT function.
8. Position the grabber on the tool joint of the drill pipe.
Note: The top drive torque will increase to the preset torque value for
reverse rotation.
Note: The top drive torque will increase to the break out torque value for
the unit.
13. When the connection loosens and the quill rotates 1/2 turn, release the
BREAKOUT button.
Note: This will allow for the ability to raise the top drive in small increments
as the connection unscrews.
Note: To avoid damaging the pipe threads, do not allow the weight of the
top drive to sit on the connection while it unscrews.
16. When the top drive clears the connection, set the QUILL–REV/FWD switch
to neutral.
17. Hoist the top drive and drill pipe.
19. Hoist the top drive until a single, double or drill pipe stand is above the rotary
table.
20. Set the slips.
21. Use tongs to break the stump connection, then unscrew the connection by using
chain tongs or a pipe spinner.
22. Hoist the drill pipe clear of the stump.
23. Proceed with the standard racking procedure. See “Standard Racking Procedure”
on page 69.
24. Lower the top drive and grab the drill string stump with the elevator.
25. Repeat steps 17 to 24 to trip out the rest of the drill string.

68
Standard Racking Procedure

1. Hoist the drill pipe (single, double or triple stand) until the bottom is above the
floor racking area.
Note: Elevator links will have to be set to vertical/hole center to avoid hitting
the racking board.
2. Set the TILT switch to ‘FWD’.
3. Allow the rig floor personnel to push the bottom of the stand into place on the
racking floor.
4. Set the stand down in the racking area.
5. Position the tip of the stand where the derrickman can easily reach and take
control of it.
6. Wait until the stand is secured and the derrickman is ready to take control of
the stand.
7. Push and hold the ELEVATOR SAFETY ‘OPEN’.
8. Set the ELEVATOR switch to ‘OPEN’.
9. Press the FLOAT button.
10. Lower the top drive to receive the next section of pipe.
Caution: In cold weather operations mud can freeze within the

components. To prevent freezing, air blow the top drive, kelly
hose and stand pipe back to tank after pulling 4 to 5 stands of
! free pipe and when stopping for a flow check. If the mud valve is
to be closed for any length of time in extreme weather conditions,
the same procedures apply.
How to Trip Out BHA (Collars and Tools)

This procedure assumes that all drill pipe has been removed from the wellbore and that the
first collar is above the rotary table.
Note: Ensure that the pipe handler is oriented such that the links can be tilted toward the
derrickman when the collars are ready to be racked.

69
Figure 7-4: Trip out collars

70
1. Set the slips.

2. Attach a safety clamp.
3. Ensure that the elevator and elevator links are hanging vertically.
4. Set the PIPE HANDLER switch to ‘UNLOCK’.
5. Set and hold the PIPE HANDLER switch at ‘FWD’ position.
Note: The pipe handler will begin to rotate at the preset speed.
6. Position the pipe handler so that the LINK TILT feature can be used to assist in
racking the collars.
7. When the pipe handler is in the proper position, release the PIPE HANDLER
switch from FWD to neutral position.
8. Set the PIPE HANDLER switch to ‘LOCK’.
9. Use the LINK TILT feature to position the top drive elevator to accept a
pick-up sub.
11. Hoist the top drive to position the pick-up sub above the collar.
12. Push the FLOAT button. This allows the elevator and pick-up sub to ‘float’ to
hole center.
13. Lower the top drive to stab the pick-up sub into the top collar.
14. Use chain tongs to fully engage the connection between the pick-up sub and
the collar.
! Caution: Torque the connection to prevent it from unscrewing.

16. Hoist the top drive and remove the slips.
17. Hoist the top drive until the required number of collars are above the rotary table.
19. Use rig tongs to break the connection between the collar segments.
20. When the connection is loosened, use the pipe handler, rotary table or chain tongs
to fully unscrew the connection.
21. Hoist the collar(s).
22. Allow rig floor personnel to position the bottom of the collar for racking.
23. Use the LINK TILT feature to tilt the collar(s) toward the derrickman.
Note: The EXTEND function can also be used to tilt the collar.
24. When the derrickman has control of the collar(s), set the ELEVATOR switch to
‘OPEN’, and push and hold the ELEVATOR SAFETY OPEN button.
25. Push the FLOAT button to allow the elevator and elevator links to “float”
to hole center.
Note: The pick-up sub will remain on the collar(s) to facilitate ‘trip in’
operations.
26. Repeat this procedure for each collar or stand of collars.

71
TRIP IN OPERATIONS
How to Trip in Tools and Collars
Figure 7-5: Trip in tools and collars

72
1. Use the top drive to lower the first section (bit and tools) into the rotary table.
Note: If acceptable, the floor tugger may also be used to perform this step.
2. Set the slips and, if applicable, attach a safety clamp.
3. Use the rig tongs to break out the joint of the pick-up sub.
4. Use the chain tongs to unscrew the pick-up sub.
5. Use the floor tugger to remove the pick-up sub.
6. Set the ELEVATOR switch to ‘OPEN’, and push and hold the ELEVATOR
SAFETY OPEN button.
8. Set the LINK TILT switch to ‘FWD’.
9. Use the EXTEND function, if necessary, to accept the first collar from the
derrickman.
10. Position the elevator on the collar of the pick-up sub.
11. Set the ELEVATOR button to ‘CLOSE’.
12. Hoist the top drive and the stand of collars/tools from the racking area.
13. Press the FLOAT button. This will bring elevator and elevator links to the
vertical position.
Caution: If using the EXTEND function, bring the top drive to

! the IN position.
14. Allow rig personnel to hold the bottom of the stand and carefully move it to
hole center.
15. Lower the top drive and stab the lower connection.
16. Use the pipe handler, chain tongs or spinning chain to connect the collar to the
stump.
17. Use rig tongs to torque the connection to specification.
19. Hoist the top drive and the drill string.
21. Lower the stand of collars/tools through the rotary table to the appropriate
height for the next connection.
22. Set the slips and install a safety clamp.
23. Use the rig tongs to break out the pick-up sub.
24. Use the chain tongs to unscrew the pick-up sub from the top collar.
25. Use the LINK TILT switch to bring the elevator forward and position the pick-up
sub where it can be removed from the rig floor by using the floor tugger.
26. Set the ELEVATOR switch to ‘OPEN’, and push and hold the ELEVATOR
SAFETY OPEN button.
27. Hoist the top drive and pick up the next collar or stand of collars.
28. Repeat this procedure for all collars.
Note: When all collars have been tripped in, the pipe handler must be oriented
to pick up drill pipe.

73
How to Trip In Drill Pipe

1. Ensure that the elevator and elevator links are hanging vertically.
2. Set the PIPE HANDLER switch to ‘UNLOCK’.
3. Set and hold the PIPE HANDLER switch to ‘FWD’.
Note: The pipe handler will begin to rotate at the preset speed.
4. When the pipe handler is in the proper position, release the PIPE HANDLER
switch from ‘FWD’ to neutral position.
5. Set the PIPE HANDLER switch to ‘LOCK’
7. Use the LINK TILT switch to tilt the links forward to accept the first drill pipe or
stand of drill pipe from the derrickman.
8. Position the elevator on the drill pipe.
10. Hoist the top drive and drill pipe off the racking area.
11. Press the FLOAT button to bring the elevator and elevator links to hole center.
12. Allow rig personnel to hold the bottom of the pipe and move it into position.
13. Lower the top drive and stab the connection.
14. Connect the drill pipe using the chain tongs, spinning chain, or pipe spinner.
15. Use rig tongs to torque the connection to specification.
16. Hoist the top drive and the drill pipe.
18. Lower the top drive and drill string.
19. Lower the stand of drill pipe through the rotary table to the appropriate height for
the next connection.
20. Set the slips.
21. Set ELEVATOR switch to ‘OPEN’.
22. Repeat this procedure for all single lengths or stands of drill pipe that are tripped
in to the wellbore.

74
REAMING OPERATIONS
How to Use the Top Drive to Ream During Trip Out Operations
• Ream: to enlarge the diameter of a wellbore.
Reaming is performed whenever a tight spot is encountered during trip out operations. This
most commonly occurs when a collar encounters an obstruction or a narrowing in the open
hole.
If using the top drive to perform tripping operations, the drill pipe and bottom hole assembly
(BHA–tools and collars) will be suspended from the top drive elevator. In order to ream, the
top drive must be connected to the drill string and the tight section must be worked until the
drill string can pass freely. To continue tripping operations after the obstruction is cleared,
the top drive must be disconnected and the drill string suspended from the elevator.
Use the following procedure if encountering a tight spot while tripping out (the weight
indicator displays more than the weight of the drill string), or if the drill string is stuck:
1. Lower the top drive and the drill string.
Note: Ensure that the uppermost drill pipe connection is in position to
connect to the top drive.
2. Set the slips.
3. Lower the top drive until the saver sub contacts the drill pipe.
4. Position the grabber to close on the box connection of the drill pipe.
Note: Ensure the grabber closes on the box connection of the drill pipe.
8. Lower the top drive into the connection.
Note: Do not allow the top drive weight to sit on the threaded connection.
9. Fully engage the connection between the saver sub and the drill pipe.
10. When the torque reaches the required torque for the connection, set the
13. Start the mud pumps.
16. Set the speed to the required values.
Note: Recommended speed is 30 to 40 rpm.
17. Hoist the top drive until the tight spot is encountered.

75
18. Raise and lower the top drive several times (or until the hole is clean) while
circulating the mud.
Note: It is advisable to trip out one or two stands with the top drive connected
to the drill string.
19. When reaming operations are complete, set the QUILL–REV/FWD switch to
select neutral.
20. Hoist the top drive to the proper position for disconnecting it from the drill pipe.
21. Set the slips.
22. Turn off the rig mud pumps.
24. Disconnect the drill pipe from the top drive. See “How to Break the Top Drive/
Drill Pipe Connection” on page 38 for more information.
25. Continue with standard procedures for trip out operations.
How to Use the Top Drive to Ream to Bottom During Trip In

Operations
• Ream: to enlarge the diameter of a wellbore.
Reaming to bottom is performed whenever a tight spot is encountered during trip in

operations.
If using the top drive for tripping operations, the drill pipe or BHA (tools and collars) will be
suspended from the top drive elevator. In order to ream ahead, the top drive must be connected
to the drill string and the tight section must be worked until the drill string can pass freely. To
continue tripping operations after the obstruction is cleared, the top drive must be discon-
nected and the drill string suspended from the elevator.
Use the following procedure if encountering a tight spot during trip in operations (weight
comes off the weight indicator).
1. Hoist the top drive to lift the bottom hole assembly (BHA) above the tight spot.
Note: Ensure that the uppermost drill pipe connection is in position to connect
to the top drive.
2. Set the slips.
3. Lower the top drive until the saver sub contacts the drill pipe.
4. Position the grabber to close on the box connection of the drill pipe.
8. Rotate the top drive into the connection.
Note: Do not allow the top drive weight to sit on the threaded connection.
9. Fully engage the connection between the saver sub and the drill pipe.
10. When the required torque for the connection is attained, set the QUILL–REV/
FWD switch to neutral.

76

13. Start the mud pumps.
16. Set the speed to the required values for drilling operations.
17. Lower the top drive until the tight spot is encountered.
18. Raise and lower the top drive several times (or until the hole is clean) while
circulating the mud.
Note: It is advisable to trip in one or two stands with the top drive connected
to the drill string.
19. When reaming is complete, set the QUILL–REV/FWD switch to neutral.
20. Hoist or lower the top drive to the proper position for disconnecting it from the
drill pipe.
21. Set the slips.
22. Turn off the mud pumps.
24. Disconnect the drill pipe from the top drive. See “How to Break the Top Drive/
Drill Pipe Connection” on page 38 for additional information.
25. Continue with standard procedures for trip in operations.

77

78
OPERATIONS GUIDE
CHAPTER 8: STUCK PIPE

Unlike conventional kelly systems, TESCO top drives can maintain mud circulation and
torque on the drill pipe while pulling or jarring stuck drill pipe.
HOW TO USE THE TOP DRIVE TO FREE STUCK PIPE

1. Connect the top drive to the drill string.
2. If possible, maintain mud pump flow.
4. Set speed to the required value.
6. Raise and lower the top drive to work the drill string up and down.
7. Continue to raise and lower the top drive and drill string until a free point is
established.
8. When the drill string begins to rotate, raise and lower the top drive in the free
point area in small increments.
9. Gradually increase the travel distance until the obstruction is cleared.

79
STUCK PIPE OPERATIONS GUIDE
HOW TO USE THE TOP DRIVE FOR JARRING OPERATIONS

If the drill pipe cannot be freed by using the top drive as described in the previous procedure,
it might be necessary to initiate ‘jarring’ operations.
TESCO recommends not jarring the drill string while the drill pipe is suspended from the
elevator. If access to the drill pipe is absolutely necessary (e.g., for wireline or logging),
then ensure that the elevator is closed and the elevator hydraulic hoses are removed.
Note: Torque can be applied when working or jarring pipe, if necessary.
Warning! Always exercise extreme care when ‘jarring’

with torque in the drill string. Monitor the torque
! bushing and travel assembly carefully for the
duration of the jarring operation.
1. Ensure that the top drive is connected to the drill string.

2. Maintain mud pump flow if possible.
3. Close the elevator on the drill pipe.
5. Set the speed to the required value.
7. Initiate jarring operations; use the top drive to hoist and lower the drill string.
8. When the string begins to rotate, raise and lower the top drive in the free point
area in small increments.
9. Gradually increase the travel distance until the obstruction is cleared.
Warning! To help ensure the functional integrity of the

top drive, perform a ‘post jarring check’ after
! any jarring operation. Refer to “Appendix A:
Post Jarring Checklist”.
Warning! If jarring operations exceed eight hours, or if

jarring is extremely rough, a complete load
! path inspection must be performed at the first
available opportunity.

80
OPERATIONS GUIDE STUCK PIPE
CONTROLLED DRILL STRING BACK OFF OPERATIONS

In some cases it is necessary to separate the stuck portion of the drill string from the free
length (to ‘back off’ the drill string). This is best accomplished by applying reverse torque to
the connection immediately above the stuck point, and then deploying an explosive charge at
the connection.
The decision to back off a drill string has significant financial and operational
implications. Back off of a drill string should never be authorized or undertaken
until all interested parties have agreed to the procedure.
1. Set the DRILL torque for reverse rotation to 70% of the make up torque.
Note: See “How to Set the Reverse Torque” on page 27 for more information.
2. Position wireline tools and the charge device at the connection where the drill
string is to be disconnected.
5. Work the drill pipe up and down and slowly increase the quill speed in very small
increments.
Note: Use the SPEED–DECR/INCR switch to adjust the pump flow so that it
just holds the torque steady.
Caution: Excessive rpm or torque will force oil over the relief
! valve, and this could result in excessive heat. Always monitor

the temperature of the closed-loop for overheating.
Note: If it is necessary need to increase the torque in stages, use the SPEED–
DECR/INCR switch, and increase the torque slowly. Monitor the differential
pressure gauge at the driller’s panel.
6. When the correct amount of torque has been put into the drill string (indicated
when the correct torque value appears on the torque gauge and the pipe stops
turning), then close the grabber.
8. Reposition the blocks.
Caution: The blocks should be positioned to achieve neutral

weight at the connection to be shot. This means that the weight
! indicator reading should equal the weight of the free portion of
drill pipe.

81
STUCK PIPE OPERATIONS GUIDE
Figure 8-1: Neutral weight at the connection
Total weight of pipe downhole = 125,000 lb The weight indicator will display
Weight of pipe below the stuck point = 65,000 lb 60,000 lb when the first free
connection is at neutral.
Total weight of the free pipe = 60,000 lb
9. When neutral weight is established, fire the explosive charge.

10. Monitor the weight indicator and string rotation.
When the drill pipe is free, the drill string should rotate freely. If the pipe has
parted at the correct location, the weight indicator reading should not change
significantly.
Caution: If the weight indicator falls, this may indicate that the
drill pipe has parted above the expected connection. If this
! occurs, do not hoist. It might be possible to re-establish the
connection. Evaluate the situation before proceeding.
11. Ensure that the drill string is free by doing the following:
• confirm free rotation of pipe
• hoist carefully to confirm that the rotating pipe is not stuck (using override)
12. Open the grabber.
13. Trip out the first stand of pipe from the hole while it is connected to the top drive.
14. When first stand is racked, break the top drive connection.
15. Continue with normal tripping operations.
UNCONTROLLED PARTING OF THE DRILL STRING

Warning! If the drill string parts in an uncontrolled manner
at any time, a post jarring inspection MUST be
! performed before drilling operations commence.
Refer to “Appendix A: Post Jarring Checklist”.

82
OPERATIONS GUIDE
CHAPTER 9: RUN AND PULL CASING

There are advantages to using the TESCO top drive to run casing:
• Connect fill-up tools directly to the top drive and provide fill-up capability while running
the casing.
• Use the LINK TILT and EXTEND functions to assist rig personnel in handling and
stabbing the casing.
Figure 9-1: Pick up casing
1. Floor slip elevators

2. Working platform
(optional)
3. Sling
4. Casing Running
elevators
5. Pick-up elevators

83
RUN AND PULL CASING OPERATIONS GUIDE
PREPARE THE TOP DRIVE TO RUN CASING

1. If required, orient the pipe handler so that the elevator links can be tilted toward
the V-door.
2. Remove the hydraulic elevator from the elevator links.
3. If required, remove the elevator links.
Note: Longer elevator links are often required when running casing.
Use the floor tugger to attach the longer links.
Caution: If using elevator links longer than 12 ft. (3.7 m), do not
! use the LINK TILT function. Consult a TESCO representative if it

is necessary to use links longer than 12 ft (3.7 m).
4. Pick up the casing running elevators.

5. If casing fill-up apparatus is required, use the grabber and the top drive to connect
it to the top drive saver sub.
6. If the top drive is used to bring casing up the V-door and onto the rig floor, use a
set of pick-up elevators and slings:
• Attach the ‘pick-up elevator’ slings such that the single-joint pick-up elevators
hang approximately 3 to 4 ft. (0.9 to 1.2 m) below the main elevator.
• Attach the ‘pick-up elevator’ slings to the pick-up elevators.
7. Ensure that a working platform and floor elevators are installed and operational
if required.
Warning! Use a crane or a “tail-in” line to assist in lifting

large diameter, heavy weight casing from the
V-door to the rig floor. If this precaution is not
taken, the weight of the casing will pull the top
! drive away from the torque track. This can
damage the EXTEND components of the
torque arrest system.

84
OPERATIONS GUIDE RUN AND PULL CASING
HOW TO RUN CASING
Figure 9-2: Run casing
1. Attach the pick-up elevators to the first joint of casing.

Note: If required, use the EXTEND and LINK TILT functions to extend
the reach.
Caution: Whenever possible, use the EXTEND and LINK TILT

! functions to reduce the stress on the torque track.

85
Figure 9-3: Reduce the stress on the torque track
Incorrect Good Better
2. Ensure that floor personnel are ready to control the bottom of the casing joint.
3. Slowly hoist the top drive to move the casing to the drill floor.
Warning! The weight of the casing tends to pull the top

drive away from the torque track. This strains the
! stabilization devices for the torque track.
Warning! If the top drive extends out when it is being

! hoisted, it could collide with the racking platform.
4. Hoist the casing until it is above the rig floor.

5. Lower the casing into the wellbore to the desired connection height.
6. Set the slips onto the casing.
8. Unlatch the pick-up elevators.
9. If required, lower the top drive to stab the fill-up tool into the casing stump.
10. Fill the casing as required.
11. Repeat Steps 1 to 4 for the second joint of casing, then continue with the
following steps.
12. Lower the second joint of casing until its pin end enters the box end of the
casing in the slips.
Note: The LINK TILT and EXTEND functions can also be used to assist
in aligning the casing joints.
13. Use casing tongs to make up the casing connection.
14. After the connection is made up securely, remove the pick-up elevators.
15. Latch the casing running elevators onto the top joint of casing.

86
OPERATIONS GUIDE RUN AND PULL CASING

17. Hoist the casing.
19. Lower the casing into the wellbore to the desired connection height.
21. Set the slips on the casing.
22. Unlatch the casing running elevators.
23. If required, lower the top drive to stab the fill-up tool into the casing stump.
24. Fill the casing as required.
25. Repeat this procedure as required for all joints of casing.
HOW TO PULL CASING

1. Attach casing running elevators to the top joint of casing.
3. Hoist the top drive until the entire joint of casing is above the rig floor.
4. Set the slips.
5. Unlatch the running elevators from the casing.
6. Attach the pick-up elevators to the casing.
7. Use casing tongs to break and unscrew the casing connection.
8. Hoist the top drive and the casing joint.
9. Use the EXTEND and LINK TILT functions to move the casing toward the
V-door.
10. Ensure that rig personnel are in place to guide the bottom of the casing joint.
11. Lower the top drive slowly and allow floor personnel to control the bottom of
the casing.
12. When the casing is secured in the V-door, unlatch the pick-up elevators.
13. Repeat this procedure for all casing joints.
Caution: When reaching the last few lengths of casing, it might
! be necessary to use a safety clamp to ensure the casing does not

slide through the slips.

87

88
OPERATIONS GUIDE
CHAPTER 10: TOP DRIVE CONSIDERATIONS
SLIP AND CUT OPERATIONS

Mud circulation can be maintained while performing slip and cut operations.
Caution: Never suspend the weight of the top drive from the
torque tube during slip and cut operations. Instead, rest part of
! the weight of the top drive on a single length of drill pipe

secured in the rotary table, and suspend the remainder of the
weight from the block sling.
Figure 10-1: Block sling

89
TOP DRIVE CONSIDERATIONS OPERATIONS GUIDE
1. Obtain and install a new block sling

Note: Size this block sling so that it will support the top drive, swivel and
blocks close to the rig floor.
2. Connect the top drive to a single length of drill pipe.
3. Raise the top drive and connect the block sling.
4. Use the blocks to lower the top drive and the single length of pipe.
5. Lower the pipe through the rotary table.
Note: To lower the top drive to the rig floor, tilt the links as far back as pos-
sible. Maintain enough clearance so that the front cover of the drawworks
can be removed for servicing.
6. When the block sling is almost tight, stop lowering the top drive.
Note: Balance the weight of the top drive between the block hanging sling
and the pipe in the slips.
7. Set the slips.
CEMENTING OPERATIONS
Do not run cement through the top drive unless it is absolutely necessary. Cement causes wear
and, if allowed to harden, will irreparably damage the top drive.
If suspending a cement head from the top drive elevator ensure the following conditions exist:
• The elevator links are long enough to accommodate the cement head.
• The elevator hydraulic hoses are disconnected.
Note: Disconnect the hydraulic hose when the cement head is in position and the
elevators are closed.
When using a flow-through cement head, some cement might enter the quill and mud valve.
After completing cementing operations, TESCO advises flushing the quill, mudsaver valve
and lower kelly valve thoroughly. Operate the mudsaver and kelly valves to ensure they work
properly.
Danger! Failure to perform these operational checks can

! compromise rig safety!
SLICKLINE SURVEY AND WIRELINE LOGGING OPERATIONS

Several issues must be addressed when using a top drive for slickline or wireline operations.
When using a turn-down sheave, use the following conventions:

• Orient the elevator links so they are parallel to the direction of line travel.
• Remove the elevator hydraulic hoses when suspending the turn-down sheave from the
elevator. This prevents accidental opening of the elevator.

90
OPERATIONS GUIDE TOP DRIVE CONSIDERATIONS
Elevator Links
Elevator
Correct Incorrect
TESCO’s wireline/slickline guide attaches to the front of the grabber. The guide leads the
wireline/slickline from the front of the top drive to the center of the hole. Guide rollers prevent
the line from running over sharp corners that can cause damage.
If using the wireline/slickline guide, place the grabber leg in the fully ‘up’ position, if possible.
Grabber Leg
Grabber Box
Guide Roller

91
TOP DRIVE CONSIDERATIONS OPERATIONS GUIDE
HEAVY LOADS AT THE V-DOOR

This procedure describes how to pick up heavy loads from the V-door using the top drive.
Warning! The extend frame and EXTEND function handle

drilling tools, pick up casing, and rack drill pipe
and collars. They are for convenience only and
! are not designed to pick-up heavy loads while
extended.
Warning! Exercise care, attention and common sense when

applying the following procedure to pick up
! heavy loads from the V-door using the top drive.
1. Connect the elevator links on the top drive to the load that is to be picked up. Use slings
that are strong enough to support the load.
2. Connect a rig winch to the load that is to be picked up.
3. Hoist the top drive with the extend frame completely retracted until the slings are tight
and the top drive is beginning to pick up the load.
4. At this point, hold the EXTEND switch at the ‘IN’ position to maintain pressure on the
extend cylinders. This will prevent the extend frame from “opening up” while the load
is lifted. The force of gravity, combined with the load and the angle at which it is being
lifted, will tend to pull the extend frame open.
5. If the load is too heavy, and holding the EXTEND switch in the ‘IN’ position is not
sufficient to keep the extend frame retracted, pick up the load with the rig winch. This
will create less pull on the extend frame and allow it to stay retracted. The top drive,
with the extend frame retracted, can be hoisted vertically with no chance of the torque
bushing binding on the torque track.
6. Continue to hoist the load until it is at the level required.
Warning! The extend frame must remain retracted at all

times when hoisting any heavy load. If it is
allowed to extend, the torque bushing can bind
on the torque track and damage the extend frame
! and extend cylinders. For this reason, always
use a rig winch to help lift the load. If done
carefully, most normal drilling equipment can be
lifted using the above procedure.
Warning! For extremely heavy loads, TESCO recommends

using additional winches to assist in the lift or
cranes to position the equipment on the drill floor
! instead of picking them up with the top drive.
Avoid damage to the top drive and unnecessary
repair time with proper planning and preparation.

92
OPERATIONS GUIDE POST JARRING CHECKLIST
APPENDIX A: POST JARRING CHECKLIST

93
POST JARRING CHECKLIST OPERATIONS GUIDE

94
OPERATIONS GUIDE INDEX
INDEX
A connect to the drill string, 37

about the top drive, 1 connect to the top drive at the mousehole, 35
AUX PUMP switch, 5 make connections, general, 34
make up triples, 41
driller’s panel
B
controls, 4
BHA
features, 3
make up, 44
gauges, 9
trip in, 72
general description, 3
trip out, 69
indicators, 4
brake handle, 10
non-robotic functions, 7
elevator-close, 10
robotic functions, 5
BREAKOUT torque control, 23
switch naming convention, 10
warning lights, 4
C
cautions
E
collars, 45
ELEVATOR function description, 10
elevator links, 45
ELEVATOR-CLOSE
EXTEND function, 40
brake handle, 10
grabber override, 46
ELEVATOR-SAFETY-OPEN, 10
making or breaking connections, 33
engine speeds, 22
mudsaver valve, 33
engine torque and speed, 22
pick-up elevators, 44
EXTEND function
pick-up sub, 45
cautions, 40
saver sub torque, 29
description, 11
slips, 33
trapped torque, 33
Vernier dampening valve, 35 F
collars and tools FLOAT push button, 5
make up, 44 function descriptions
CONNECT mode, 24 ELEVATOR, 10
speed control, 24 EXTEND, 11
connections GRABBER, 12
break connection to top drive, 38 PIPE HANDLER, 12
cautions, 33 TILT, 11
connect collars above the rotary table, 46 VALVE, 12
connect pipe single to drill sting, 37
general overview, 34 G
how to connect drill pipe at the mousehole, 35 gauges on the driller’s panel, 9
how to fully torque, 37 GRABBER function description, 12
make up BHA (collars and tools), 44 GRABBER-Drawworks override, 10
make up pipe stands, 42
make up triples, 41
I
mousehole, 35
information, where to find more, 1
pre-operational procedures, 34
L
D
LINK TILT switch, 5
die lock clamp installation, 29
DRILL mode speed control, 24
drill pipe

95
INDEX OPERATIONS GUIDE
M S
make connections saver sub installation, 29
general, 34 SET torque, 26
precautions, 34 speed available, 22
MAX torque speed control, 24
how to adjust, 25 forward or reverse rotation drill mode, 24
how to use, 27 forward rotation connect mode, 24
MAX torque override, 27 reverse rotation connect mode, 24
MODE switch, 7 speed, setting, 28
mousehole
make up stands, 42 T
use to make connections, 35 TILT function description, 11
mudsaver valve torque
cautions, 33 adjust MAX torque, 25
adjust SET torque, 26
N how to set reverse torque, 27
naming conventions for switch settings, 10 MAX torque function, 27
non-robotic functions, 7 MAX torque override, 27
set for forward rotation, 25
O trapped in drill string, 33
override torque available, 22
ELEVATOR-CLOSE, 10 torque control, 23
GRABBER-Drawworks, 10 breakout, 23
forward rotation, 23
torquing connections, 37
P
pipe
break connection with top drive, 38 V
connect to drill string, 37 VALVE function description, 12
make up triples, 41
pipe handler
function description, 12
pipe stands
make up in mousehole, 42
make up in rotary table, 40
pipe stands, how to make up, 40
pre-operational procedures
install the die lock clamp, 29
install the saver sub, 29
prime mover engine speeds, 22
PUMPS-FWD control, 23
Q
QUILL RPM gauge, 9
R
remote brake handle, 10
reverse torque, setting, 27
robotic functions
controls and indicators, 5
ROBOTICS ’ON’ light, 5
rotary table
connect collars, 46
make up pipe stands, 40

96

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Operations Guide

250 HXI 700 Top Drive System

250TON HXI 700HP with D4P-700 Power Unit

DOCUMENT NAME: 1570014 REV 0

Tesco Corporation © 2008

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

Version Date Description of Changes

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

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

CHAPTER 2: CONTROL INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

CHAPTER 3: TORQUE AND SPEED LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

CHAPTER 4: OTHER PRE-OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . .29

CHAPTER 5: MAKING/BREAKING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

How to Make Up Stands in the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

CHAPTER 6: DRILLING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

CHAPTER 7: TRIPPING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

CHAPTER 8: STUCK PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

CHAPTER 9: RUN AND PULL CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

CHAPTER 10: TOP DRIVE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

APPENDIX A: POST JARRING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

Warning! Before operating or servicing this top drive

Caution: Always perform the correct lock-out procedures as

! recommended by the Safety or Loss Prevention department

Caution: Only authorized personnel can operate the top drive

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

This page has been left blank intentionally.

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

This page has been left blank intentionally.

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

CHAPTER 1: ABOUT THIS DOCUMENT

Table 1-1: Where to find more information

For information on Refer to

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

This page has been left blank intentionally.

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

CHAPTER 2: CONTROL INTERFACES

Warning! Ensure all switches are set to the neutral position

Table 2-1: Features of the driller’s panel

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

Figure 2-1: 250 HXI 700 driller’s panel

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

Controls, Indicators, and Warning Lights

Controls and Indicators for Robotic Functions

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

(OPEN is spring return to How to open the elevators:

How to close the elevators:

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

Controls for Top Drive Rotation

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

When using this switch, note the following:

When using this button, note the following:

©TESCO CORPORATION, 2008 250TON HXI 700HP 1570014 REV 0

Gauges and Displays

DUAL FUNCTION REMOTE BRAKE HANDLE CONTROL

GRABBER–Drawworks Interlock Override

1570014 REV 0 250TON HXI 700HP ©TESCO CORPORATION, 2008

ROBOTIC FUNCTION DESCRIPTIONS

LINK TILT Function