Tesco Top Drive Operations Guide Rev1

Operations Guide
EMI 400 Top Drive System
250TON EMI 400HP 50Hz
DOCUMENT NAME: 1270412 REV 1

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.
This equipment was filled at the factory with TESCO ULTREX™ brand fluids and greases. To ensure
maximum performance and to avoid cross-contamination, we strongly recommend the continued
usage of TESCO ULTREX™ lubricants, unless otherwise specified.
TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.
© 2010 Tesco Corporation. All rights reserved.
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
www.tescoparts.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
After Market Sales and Service Contact

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

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

Rev 0 May 2010 127-0245 Initial release of document
Rev 1 Mar 2013 157-0036 Updated the Safety Instructions section; updated torque, speed and drive
information

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OPERATIONS GUIDE TABLE OF CONTENTS
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IX
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Warnings and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHAPTER 2: DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitoring the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Up the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
START/STOP and RESET the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Run with Encoder/Encoderless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CHAPTER 3: DRILLER’S PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Controls, Indicators, and Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Controls and Indicators for Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Controls for Quill/Rotation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Robotic and E.S.D. Function Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ELEVATOR Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TILT Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EXTEND Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
VALVE Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GRABBER Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PIPE HANDLER Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Emergency Shut Down (E.S.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
E.S.D. on the Driller's Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
E.S.D. on the Main Panel Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reset E.S.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Controls for Torque and Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

DRILL Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DRILL Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CONNECT Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CONNECT Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BREAKOUT Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Dual Function Remote Brake Handle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ELEVATOR–CLOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
GRABBER–Drawworks Interlock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
How to Calibrate the Meters on the Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
How to Calibrate a Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Meter Setting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Meter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
SET SPEED (rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DELIVERED SPEED (rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
SET TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DELIVERED TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
CHAPTER 4: TORQUE AND SPEED LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Motor Maximum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
How to Set or Change Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Setting Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Connect-Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Connect-Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Drill-Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Drill-Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Pipe Handler Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Pipe Handler Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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CHAPTER 5: OTHER PRE-OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 35

How to Install the Saver Sub and Die Lock Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to Orient the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
How to Set the Grabber Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CHAPTER 6: MAKING/BREAKING CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pipe Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
How to Make Connections–General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
How to Use the Mousehole to Connect Drill Pipe to the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . 42
Pipe Handler Orientation–Grabber to V-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
How to Fully Torque a Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
How to Connect a Single Length of Drill Pipe to the Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
How to Break the Top Drive/Drill Pipe Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
How to Use the Pipe Handler to Make Up Pipe Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
How to Make Up Stands in the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
How to Make Up Pipe Stands Without a Conductor Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
How to Make Up Pipe Stands in the Mousehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
How to Make Up BHA (Collars and Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
How to Connect Collars Above the Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CHAPTER 7: DRILLING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Surface Hole Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
How to Drill a Surface Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
About Connections and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
About Tripping and Surface Hole Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
About Reaming and Surface Hole Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Drill Ahead with Single Lengths of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
How to Drill Ahead with Pipe Stands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Mud Motors in Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
How to Adjust the Tool Face Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
How to Make and Break Connections During Slide Drilling Operations . . . . . . . . . . . . . . . . . . . . . 65
How to Maintain the Tool Face Orientation During Slide Drilling Operations . . . . . . . . . . . . . . . . . 67
How to Record the Drill String Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Combination Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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CHAPTER 8: TRIPPING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Well Control During Tripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
How to Remove the Mudsaver Valve Actuator During Well Control Tripping . . . . . . . . . . . . . . . . .70
Trip Out Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
How to Trip Out Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Standard Racking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
How to Trip Out BHA (Collars and Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Trip In Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
How to Trip in Tools and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
How to Trip In Drill Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Reaming Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
How to Use the Top Drive to Ream During Trip Out Operations . . . . . . . . . . . . . . . . . . . . . . . . . .81
How to Use the Top Drive to Ream to Bottom During Trip In Operations. . . . . . . . . . . . . . . . . . . .82
CHAPTER 9: STUCK PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

How to Use the Top Drive to Free Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
How to Use the Top Drive for Jarring Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Controlled Drill String Back Off Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Uncontrolled Parting of the Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
CHAPTER 10: RUN AND PULL CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Prepare the Top Drive to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
How to Run Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
How to Pull Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
CHAPTER 11: TOP DRIVE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Slip and Cut Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Cementing Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Slickline Survey and Wireline Logging Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Heavy Loads at the V-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
APPENDIX A: POST JARRING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

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OPERATIONS GUIDE LIST OF FIGURES
LIST OF FIGURES
Figure 2-1:ACS800 Drive Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2-2:Panel operation mode keys and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2-3:Actual signal display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2-4:View full name of signals and view/reset history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2-5:Display and reset an active fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2-6:Drive signal descriptions, 01.01 to 01.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2-7:Drive signal descriptions, 01.23 to 01.45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 3-1:EMI 400 driller’s control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 3-2:Example of a meter on the driller’s panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 5-1:Grabber lift needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 6-1:Correct tong position to make a connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 6-2:Correct position for elevator links and elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 6-3:Connect a single length of pipe to the drill string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 6-4:Break the top drive/drill pipe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 6-5:Make up stands in the rotary table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 6-6:Make up pipe stands in the mousehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 6-7:Connect collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 7-1:Drill ahead with single lengths of pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 7-2:Drill ahead with pipe stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 8-1:Remove the mudsaver valve actuator for well control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 8-2:Remove the actuator from the mudsaver valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 8-3:Trip out drill pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 8-4:Trip out collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 8-5:Trip in tools and collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 9-1:Neutral weight at the connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 10-1:Pick up casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 10-2:Run casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 10-3:Reduce the stress on the torque track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 11-1:Block sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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LIST OF FIGURES OPERATIONS GUIDE
This page has been left blank intentionally.

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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: This equipment is designed and certified for use in a

hazardous environment. When maintenance requires replacement
! of parts, only identical parts can be used. Using alternate, non-iden-
tical parts as a substitution may void compliance and certification.
Caution: Always perform the correct lock-out procedures as
! recommended by the Safety or Loss Prevention department

before implementing maintenance.
Caution: Never attempt to perform services procedures or repairs
! when equipment is operating.
Caution: Only authorized personnel can install and operate the top
! drive system.

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SAFETY INSTRUCTIONS OPERATIONS GUIDE
Caution: Only trained personnel must perform inspections and

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

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

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

torque in the drill string rotates the top drive backwards more than
! 5 rpm - even if the QUILL switch is set to neutral. This is to prevent

an uncontrollable backspin even if the stored torque in the drill
string is instantly released.
Warning! Electrical voltages of different potentials are used

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

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

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

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OPERATIONS GUIDE
CHAPTER 1: ABOUT THIS DOCUMENT

This Operations Guide contains information on how to use the 250TON EMI 400HP 50Hz
Top Drive System. It includes information on:
• powering up the top drive
• starting, stopping, and resetting the top drive
• configuring torque and speed settings
• using the driller’s panel
• making and breaking connections (drill pipe, top drive/swivel connection, collars, etc.)
• 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

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CHAPTER 1: ABOUT THIS DOCUMENT OPERATIONS GUIDE
Warnings and Notices
Warning! Electrical voltages of different potentials are

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

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

OPERATIONS GUIDE
CHAPTER 2: DRIVE SYSTEM
SYSTEM DESCRIPTION
The TESCO EMI 400 top drives use a Ward Leonard electric motor and an ABB ACS800
variable frequency drive (VFD). The system voltage is 600VAC (50Hz) and can be supplied
by a self-contained generator or directly from the rig’s AC bus.
The motor is rated for 400hp (298kW) with 150% overload capability for 60 seconds. The
maximum speed of the motor is 2,340 rpm. The motor can produce 1,840 ft·lb torque
continuously within the 0 to 1,150 rpm nominal speed range. RTDs are embedded in the
motor’s stator windings to monitor motor temperature.
The ABB ACS800 electric drive is a modular solution with two modules (one rectifier and one
inverter module) required to run a 400hp top drive. Its continuous power rating is 560Kw with
560A continuous current and 840A peak current.
The EMI 400 uses a closed loop control scheme with variable torque limits. The top drive
motor is driven by the ACS800 VFD, which in turn is controlled by the main PLC via
PROFIBUS serial communication. The PLC issues START/STOP commands, speed
reference, and torque limits to the VFD. which then drives the motor accordingly. The PLC
receives feedback from the motor encoder as well as torque feedback from the VFD. The PLC
also controls the auxiliary robotics functions of the top drive.
Drive Control Panel

The Drive Control Panel is a small keypad location on the front door of the main VFD breaker
cabinet. It provides a visual user interface for setting and displaying drive parameters,
monitoring drive status, and indicating warnings and faults.
Important: Only qualified TESCO personnel certified by ABB should
!
attempt to change or modify drive parameters. Incorrect drive program-
ming may result in equipment damage or injury to personnel. As a pre-
caution, the drive parameters are password protected to prevent
unauthorized access.

CHAPTER 2: DRIVE SYSTEM OPERATIONS GUIDE
Figure 2-1: ACS800 Drive Control Panel

OPERATIONS GUIDE CHAPTER 2: DRIVE SYSTEM
Figure 2-2: Panel operation mode keys and displays

Figure 2-3: Actual signal display mode

Figure 2-4: View full name of signals and view/reset history

Figure 2-5: Display and reset an active fault

Monitoring the Drive

The Drive Control Panel allows the user to display the operational status of the drive. The
following images list and describe the actual signals available for monitoring.
Figure 2-6: Drive signal descriptions, 01.01 to 01.22

Figure 2-7: Drive signal descriptions, 01.23 to 01.45

POWER UP THE TOP DRIVE

The main power supply of the EMI 400 top drive is 600VAC. The system also contains
120VAC and 24/15 VDC control voltages. The power distribution system of the EMI 400
mainly consists of a 600VAC distribution panel, a 15KVA transformer (600: 208/120V), and a
208/120V distribution panel.
To power up EMI 400 top drive:

1. Connect the power supply cables, motor cables, and ground cables correctly to the
plugboard of power module building.
2. In the 600V distribution panel:
• Close main breaker MB4 for hydraulic tank heater
• Close main breaker MB3 for 120/208V distribution
3. In the 208/120V distribution panel:
• Close breaker CB1 for building lighting
• Close breaker CB2 for 120V control power supply
• Close breaker CB3 for building receptacle
• Close breaker CB4 for 15/24VDC power supply
• Close breaker CB9 for motor heater
• Close breaker CB12/14/16 for building HVAC
4. Inside the main panel:
• Close breaker CB1 for 24VDC power supply
• Close fuse F7,F8, F9, F10 of 24VDC supply for PLC and driller’s panel
5. On VFD panel, to close main breaker MB1 for drive system:
• Close the main fusible disconnect
START/STOP AND RESET THE TOP DRIVE

When the EMI 400 top drive is powered up and if there is no fault in the drive system, the top
drive is in READY status. The top drive will start and rotate if the START command and a
non-zero speed reference are present.
START/STOP
START/STOP commands sent to the drive are generated from the QUILL switch on the
driller’s panel (see Driller’s Panel). When the drive is ready, turn the switch away from neutral
position, either to ‘FWD’ or ‘REV’, to start the drive. The drive stops once the switch is turned
back to neutral position.
If the Set Speed (see Driller’s Panel) is not zero, depending on the load, the top drive may start
rotating once it is started. Increase the Set Torque by turning the TORQUE switch to ‘INCR’ if
the top drive is not rotating. Use the SPEED switch to increase or decrease the speed.

RESET
When the drive is faulty, the TRIPPED indicator on the Drive Data Manager will flash. Press
the RESET button on the left side of driller’s panel to reset trips after the faulty conditions
have been removed. Use this button to clear any warnings or trips that may occur after power
up.
Run with Encoder/Encoderless

The EMI 400 top drive is equipped and intended to operate with an encoder to achieve high
dynamic performance, however, to allow continuous operation in the case of a broken encoder
or loss of encoder wire, the EMI 400 can operate without an encoder.
Without an encoder, the drive’s dynamic performance is limited to operation at nominal speed.
If it operates at low speed, the output torque of the motor may not be stable. It is strongly
recommended that the damaged encoder be replaced as soon as possible. Operating the drive
without an encoder at low speed with high torque is not recommended. The minimum motor
frequency for operating in the encoderless vector mode is approximately 3Hz.

OPERATIONS GUIDE
CHAPTER 3: DRILLER ’S PANEL
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 at the rig floor, within convenient reach of the
driller.
The driller’s panel interfaces with the main panel control system.
Table 3-1: Features of the 250TON EMI 400HP 50Hz driller’s panel
Controls
• robotic functions
• drive functions
• Emergency Shut Down (E.S.D.)
Meters
• SET speed
• DELIVERED speed
• SET torque
• DELIVERED torque
Indicators
• warnings
• status

CHAPTER 3: DRILLER’S PANEL OPERATIONS GUIDE
Figure 3-1: EMI 400 driller’s control panel

OPERATIONS GUIDE CHAPTER 3: DRILLER’S PANEL
CONTROLS, INDICATORS, AND WARNING LIGHTS
Warning Lights
Indicator Description
SYSTEM TEMP. The System Temperature light illuminates under normal conditions. It
(green indicator light) will flash 3 times per second if the temperature of the motor windings
exceeds 311ºF (155ºC). The top drive will shut down if the temperature
exceeds 347ºF (175ºC).
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
AUXILIARY PUMP Use this switch to start or stop the auxiliary pump.
OFF/ON (switch)
ROBOTICS ‘ON’ When this light is illuminated, it indicates that a robotics function has
(yellow indicator light) been selected.
ELEVATOR Use the ELEVATOR switch in conjunction with the SAFETY OPEN
OPEN/CLOSE button to operate the elevators.
(switch; OPEN is spring-return to How to open the elevators:
neutral; CLOSE is maintained) 1. Turn the switch to the ‘OPEN’ position and hold it there.
2. Press the SAFETY OPEN push button.
How to close the elevators:
Turn the switch to the ‘CLOSE’ position, or push the CLOSE button
on the brake handle.
SAFETY OPEN Use this push button in conjunction with the ELEVATOR switch in the
(push button) ‘OPEN’ position to open the elevators.
TILT Use this switch to tilt the elevator links backward and forward.
BACK/FWD
(switch; position is maintained)
FLOAT Press this button to relieve pressure in the TILT cylinders. This will return
(push button) the elevator links to the neutral position (vertical below the top drive).
EXTEND Use this switch to extend the top drive away from the torque track or
IN/OUT retract the top drive towards the torque track to its original position.
(switch; spring-return to neutral)
VALVE Use this switch to operate the actuator for the mudsaver valve. A
OPEN/CLOSE mechanical link between the actuator and the mudsaver valve opens
(switch; spring-return to neutral) and closes the valve.
VALVE ‘CLOSED’ When this light is illuminated, it indicates that ‘CLOSE’ has been
(yellow indicator light) selected on the VALVE.
GRABBER Use this switch to open and close the grabber. To achieve full clamping
OPEN/CLOSE pressure, keep the switch in the ‘CLOSE’ position.
(switch; OPEN is spring-return to
neutral; CLOSE is maintained)

GRABBER ‘CLOSED’ When this light is illuminated, it indicates that ‘CLOSE’ has been
(red indicator light) selected on the GRABBER switch.
PIPE HANDLER Use this switch to rotate the pipe handler in reverse or forward.
REV/FWD
(switch; spring return to neutral)
PIPE HANDLER This switch is used to turn the pipe handler on or off. When turned on,
ON/OFF the pipe handler can be rotated to facilitate pipe handling.
(switch)
PIPE HANDLER ‘ON’ Illuminates when the pipe handler is turned on.
red indicator light
Drive Controls and Indicators

READY When this light is illuminated, it indicates that there are no drive system
(green indicator light) faults, and the unit is ready for operation.
E.S.D. Push this button to trip the main breaker that supplies power to the
(Emergency Shut Down push button) drive system. This button will also deactivate the auxiliary pump.
NOTE: Rotation stops when this button is pushed, but the
drive system might require up to five minutes to dissipate
voltage.
There is a separate E.S.D. push button on the power module building.
MODULE ‘ON’ When this light is illuminated, it indicates that the main breaker MB1
(green indicator light) (which energizes the drive system) is turned on.
ENABLE Turn this switch to ‘ON’ to prepare the drive to accept rotational
OFF/ON commands. This switch is located on the left side of the driller’s panel.
(switch)
RESET Push this button to reset the faults of the drive system. This button is
(button; spring-return) located on the left side of the driller’s panel.
DRIVE SET Use this switch to set the speed and torque limits for rotational
OFF/ON functions. It works only if the ENABLE switch is set to ‘OFF’. See
(keyed switch; spring-return) “Controls for Torque and Speed” on page 21 for more information.
This switch is located on the left side of the driller’s panel.

Controls for Quill/Rotation Functions

QUILL Use this switch to select the direction of rotation for the top drive quill.
REV/FWD
(switch; maintained position)
SPEED Use this switch to increase or decrease the quill speed. See “Controls
DECR/INCR for Torque and Speed” on page 21 for more information.
(switch; spring-return)
TORQUE Use this switch to increase or decrease the torque output limit of the
DECR/INCR drive. See “Controls for Torque and Speed” on page 21 for more
(switch; spring-return) information.
BREAKOUT Push this button to apply maximum reverse torque of the drive
(push button; spring-return) and initiate the use of the torque boost motor.(Only functional in
Connect - REV mode.)
MODE Use this switch to select the CONNECTION mode or the DRILL mode.
CONN/DRILL
(switch)
Meters
Indicator Description
SET SPEED This meter displays the desired rotating speed selected by the driller.
Use the SPEED switch to set the value between 0 to 200 rpm.
DELIVERED SPEED This meter displays the actual quill speed of the top drive.
SET TORQUE This meter displays the max. torque setting selected by the driller.
The value is expressed in ft·lb. See “Controls for Torque and
Speed” on page 21 for more information.
DELIVERED TORQUE This meter displays the actual torque delivered by the top drive.
The value is expressed in ft-lb.
It is possible to calibrate the torque meters to display DNm, although this is rarely required.
For more information, contact a qualified TESCO representative.

ROBOTIC AND E.S.D. 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 must be manually started to operate most robotics functions.
The exceptions are the GRABBER and VALVE functions. If either of these functions is
selected, the auxiliary hydraulic pump starts automatically.
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 3-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 elevators. 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.
TILT Function
The TILT function allows the operator to move the elevator links (with the attached
elevators) to a position forward or back of hole center (the links move up to 55° forward
and up to 35° back of hole center). Use the TILT function to manipulate pipe stands when
tripping pipe, running casing, and making up pipe stands. Use the 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 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 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. When pushing the FLOAT button on
the driller’s panel, this relieves the pressure in the TILT cylinders and the links return to a
vertical position below the top drive.
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 more handle stands of drill pipe more
effectively when additional distance from hole center is desired. Combine this function
with the TILT–FORWARD 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 selecting VALVE–CLOSE at the driller’s panel, electrical controls stop the quill
rotation. The valve closes and an eight-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 selecting VALVE–CLOSE, 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 the CLOSE
hydraulic directional valves until the operator manually turns the switch to the neutral
position.
The red GRABBER ‘CLOSED’ warning light on the driller’s panel illuminates when
selecting the GRABBER–CLOSE function.
TESCO recommends installing safety interlocks that prevent the operator from hoisting the
drawworks when the grabber is closed (unless the operator presses an override button on
the brake handle). A separate PLC-programmed interlock prevents the grabber from
closing if the quill speed is greater than 5 rpm.
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
bearing. The PIPE HANDLER switch on the driller’s panel must be set to ‘UNLOCK’
before the ROTATE function can be accessed. The pipe handler is independently driven by
two hydraulic motors and does not utilize the electric drive system.
Use the PIPE HANDLER–ON function in conjunction with the GRABBER–CLOSE

function and the PIPE HANDLER REV/FWD switch to rotate the pipe handler. The
direction of rotation for the pipe handler is determined by the QUILL switch. 360° reverse
or forward rotation is available. The pipe handler rotates at one speed: 3 rpm.
A red CAUTION light illuminates at the driller’s panel when selecting PIPE HANDLER–ON.
This light remains lit until PIPE HANDLER–OFF is selected.

Emergency Shut Down (E.S.D.)

There are two E.S.D. circuits, each with its own specific function.
E.S.D. on the Driller's Panel
Push the E.S.D. button on the driller’s panel to trip the main circuit breaker (the breaker
supplies 600 VAC to the ACS800 drive and is located in the power module building). This
removes all high voltage power from the drive. The quill stops rotating. This E.S.D. also
deactivates the auxiliary hydraulic pump. All devices that operate or rotate at the drill floor
become inactive.
When resetting the E.S.D. switch (i.e., switch is pulled out), the auxiliary pump can be
activated from the driller’s panel, however, power for the drive system cannot be activated
from the driller’s panel. Follow standard start-up procedures to restart the drive.
E.S.D. on the Main Panel Control System
Push the E.S.D. button on the door of the power module main panel to cut all power to the
TESCO power module. This E.S.D. switch is interlocked to trip the breaker for the main
service power supply.
Reset E.S.D
The E.S.D. button has spring-return. Reset and activate the main breaker to restore power
to the power module.
CONTROLS FOR TORQUE AND SPEED

The torque and quill speed that is available is specific to each top drive activity. They are
summarized in the following table.
Table 3-2: Available torque and quill speed
Mode Available Torque Available Speed
DRILL (FWD) 0 to 100% of the maximum preset value* 0 rpm to maximum rpm
DRILL (REV) 0 to 100% of the maximum preset value* 0 to 28 rpm
CONNECT (FWD) 0 to 100% of the maximum preset value* 0 rpm to maximum rpm
CONNECT (REV) 0 to 100% of the maximum preset value* 0 to 28 rpm
* Refer to “How to Set or Change Drive Parameters” on page 30.
The operator uses the driller’s panel to access the torque and speed functions, and to set the
torque and speed limits.

DRILL Forward
DRILL Forward mode is achieved by turning the MODE switch to ‘DRILL’, and the
QUILL switch to ‘FWD’.
Torque
Controls on the driller’s panel allow the operator to increase or decrease the quill torque to
suit various tool joints as required during drilling operations. The operator can select from 0 to
100% of the maximum preset torque limit. Preset the maximum torque limit at the driller’s
panel before operating the unit (see “How to Set or Change Drive Parameters” on page 30).
Speed
Controls on the driller’s panel allow the operator to increase or decrease the quill speed as
required during drilling operations. The full range of the quill speed is available in DRILL
Forward mode. Quill speed ranges from 0 to 200 rpm.
DRILL Reverse
DRILL Reverse mode is achieved by turning the MODE switch to ‘DRILL’, and the
QUILL switch to ‘REV’.
Torque
Controls on the driller’s panel allow the operator to increase or decrease the quill torque as
required during reverse drilling operations. The operator can select from 0 to 100% of the
maximum preset torque limit. Preset the maximum limit at the driller’s panel before
operating the unit (see “How to Set or Change Drive Parameters” on page 30).
Speed
Only one speed is available during reverse drilling operations. The operator presets the
DRILL Reverse speed limit at the driller’s panel before operating the unit (see “How to Set
or Change Drive Parameters” on page 30). The available set speed in DRILL Reverse mode
is 0 to 30 rpm.

CONNECT Forward
CONNECT Forward mode is achieved by setting the MODE switch to ‘CONN’, and the
QUILL switch to ‘FWD’.
Torque
Controls on the driller’s panel allow the operator to increase or decrease the quill torque to
suit various tool joints as required when making connections. The operator can select from 0
to 100% of the maximum preset torque limit. Preset the maximum connect torque limit at the
driller’s panel before operating the unit (see “How to Set or Change Drive Parameters” on
page 30).
Speed
Only one speed is available in CONNECT Forward mode. The operator presets the
CONNECT Forward speed limit at the driller’s panel before operating the unit (see “How
to Set or Change Drive Parameters” on page 30).
CONNECT Reverse
Torque
Only one torque setting is available in CONNECT Reverse mode (unless the operator
presses the BREAKOUT button). The operator presets the torque limit at the driller’s panel
before operating the unit.
Speed
Only one speed setting is available in CONNECT Reverse mode (unless the operator
presses the BREAKOUT button). The operator sets the CONNECT Reverse speed limit at
the driller’s panel before operating the unit (see “How to Set or Change Drive Parameters”
on page 30).
BREAKOUT Button
Press and hold the BREAKOUT button to apply maximum reverse torque to the pipe joint.
The torque increases from preset Connect-Reverse torque to the maximum available
torque.
If the pipe joint breaks before the top drive reaches maximum torque, the top drive rotates
at the preset BREAKOUT speed. When releasing the BREAKOUT button, the top drive
rotates at the preset CONNECT Reverse speed, if this is selected. The system remains in a
‘ready’ state and no temporary shut down occurs.

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 (eight seconds)
to ensure that the elevators close completely. The eight-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: Use this override during directional drilling operations if hoisting the string when
the grabber is closed.
The override button operates a temporary contact that either a) controls an air valve that
allows air back to the drum clutch or b) triggers a PLC signal that interrupts the drawworks
controls. The override works only when the button is pushed and held. When the button is
released, air supply to the clutch control or the PLC interlock with the drawworks control is
once again interrupted and the override is no longer active.

HOW TO CALIBRATE THE METERS ON THE DRILLER ’S PANEL

The driller’s panel contains four display meters:
• SET rpm
• DELIVERED rpm
• SET TORQUE
• DELIVERED TORQUE
Figure 3-2: Example of a meter on the driller’s panel
The meter uses a four-digit LED display.

The meter has two modes: Run Mode and
Configuration Mode. Push the MENU button to
access the configuration mode.
Use the following procedure to calibrate all meters before every job. Recommended
settings appear in the tables that follow the procedure.
Although the values are different for each type of meter, all meters can be calibrated using
the same procedure.
How to Calibrate a Meter

1. If necessary, stop quill rotation at the top drive.
2. Open the driller’s panel and access the meter.
3. Press the MENU button. The meter displays the first input signal option.
4. Press the TARE button to scroll through the available options for input signals.
5. From the available options, select ‘4-20’.
6. Press the MENU button to save the signal option selected.
The meters displays ‘dEC.P’ momentarily, then displays the last saved decimal
point location.
7. Press the TARE button to select the decimal place option required.
• On the SET and DELIVERED SPEED meters, select the decimal place at the
extreme right (FFFF.). This will display the speed as a whole number.
• On the SET and DELIVERED TORQUE meters, set the decimal place one place
from the right (FFF.F). This will display one decimal place.
Note: Both TORQUE meters now display values in thousands of ft·lb, such
that a reading of 20.3 means 20,300 ft·lb.
8. Press the MENU button on each meter to save the decimal place option selected.
The meter displays ‘ScAL’ momentarily, then displays the last saved setting for
the scaling method.

9. Press the TARE button to view the available scaling options (‘LivE’ or ‘int’).
10. Select ‘int’.
11. Press the MAX button.
The meter momentarily flashes ‘rd1’, then displays the low setting option. The
meter display flashes ‘0400’.
12. Press the TARE button. The first digit flashes, indicating it can be set.
13. Press the MAX button to change the flashing number.
14. Repeat the previous two steps for the second, third, and fourth digit.
15. Press the MENU button to store the low setting value.
The meter momentarily flashes ‘rd2’, then displays the high setting option. The
meter display flashes ‘2000’.
16. Press the TARE button to select the first digit. The first digit flashes, indicating it
can be set.
17. Press the MAX button to change the flashing number.
18. Repeat the previous two steps for the second, third and fourth digits.
19. Press the MENU button to save the high setting value.
20. Press the TARE button to zero the meter. Scaling is now complete.
! Caution: Ensure the quill is motionless during this step.
Meter Setting Notes
Press the MAX button to display the highest recorded value from gauge memory. The value
appears. Push the RESET button to remove the maximum value from memory, if required.
DELIVERED TORQUE and DELIVERED SPEED settings may be adjusted for a

particular top drive unit. Small changes to rd1 and rd2 settings may be required. For more
information on how to calibrate these settings for specific needs, contact a qualified
TESCO representative.

Meter Settings
The following tables show the recommended settings for each of the meters on the driller’s
panel.
SET SPEED (rpm)
Meter Option Settings

Signal 4-12 mA (4 mA is -200 rpm; 12 mA is 0 rpm)
12-20mA (12 mA is 0 rpm; 20 mA is 200 rpm)
Decimal Point FFFF.
Scaling Option int
rd1 0000
rd2 200
DELIVERED SPEED (rpm)

Signal 4-12 mA (4 mA is -200 rpm; 12 mA is 0 rpm)
12-20mA (12 mA is 0 rpm; 20 mA is 200 rpm)
Decimal Point FFFF.
Scaling Option int
rd1 -0200
rd2 -0200
SET TORQUE

Signal 4–20 mA (4 mA is 0; 20 mA is 32,000 ft·lb)
Decimal Point FFF.F
Scaling Option int
rd1 0000
rd2 0320
DELIVERED TORQUE

Signal 4-20 mA (4 mA is 0; 20 mA is 32,000 ft·lb)
Decimal Point FFF.F
Scaling Option int
rd1 0000
rd2 032.0


OPERATIONS GUIDE
CHAPTER 4: TORQUE AND SPEED LIMITS
OVERVIEW
The speed and torque of the top drive work in conjunction. Without sufficient speed, the
required torque may not be reached. Similarly, without sufficient torque, the required speed
may not be achieved.
For example, the operator might need to drill forward at 150 rpm but would never consider
making a connection at 150 rpm. The only difference between the two operations is the
position of the MODE switch at the driller’s panel. Therefore, the control “behind the
scenes” must be in place to differentiate and limit the signal inputs.
During the unit’s commissioning stage specific values of desired speed and torque are
selected for each rotational function and preset as defaults. On site, “fine tuning” to meet
specific drilling requirements is recommended and is easily done from the driller’s panel.
MOTOR MAXIMUM CAPACITY

The EMI 400 top drive uses a Ward Leonard electric motor and most have a gearbox ratio of
10.96:1. The nominal speed of the electric motor is 1,150 rpm and maximum speed is 2,340
rpm, which is equivalent to nominal and maximum quill speed of approximately 100 rpm and
213 rpm respectively. The motor can produce continuously 1,840 ft-lb nominal torque or
20,166 ft-lb quill torque. Based on this value, the maximum quill torque for drill forward or
reverse is set to 20,166 ft-lb via PLC logic. The motor has 150% overload capability for 60
seconds and can provide 30,249 ft-lb quill torque. In breakout operation, the maximum torque
is set to 30,249 ft-lb, according to the overload capability of the motor.
Note: The top drive is capable of producing 20,166 ft-lb torque continuously only if it
operates in speeds ranging from 0-100 rpm. When operating at a speed higher than 100
rpm, the torque will drop below nominal value and the achievable torque is speed depen-
dent. The higher the speed, the lower the torque that the motor can produce. At 200 rpm,
the achievable torque is approximately 11,000 ft-lb. These values are based on the load
curve provided by the motor vendor.
Note: These values are based on 10.96:1 gear ratio. A 12.47:1 gear ratio will produce
more torque and less speed. Different motors will have different nominal speed and torque
values. Contact TESCO for more information if required.

CHAPTER 4: TORQUE AND SPEED LIMITS OPERATIONS GUIDE
DRIVE PARAMETERS
Overview
The following drive parameters (torque and speed settings) can be set at the driller’s panel:
• DRILL Forward - Torque
• DRILL Reverse - Torque and Speed
• CONNECT Forward - Torque and Speed
• CONNECT Reverse - Torque and Speed
• BREAKOUT - Speed
Set the drive parameters for torque and speed to minimize the possibility of injury to
personnel and damage to drilling equipment.
For example, limit the torque setting for the DRILL Forward function to help prevent the
drill string from twisting off during drilling operations. Limit the speed and torque settings
for the CONNECT function to promote the proper make up of tool joints and guard against
damage to threads and seal faces caused by over-torquing.
The drive system will not surpass the programmed torque and speed settings, however, the
following procedure can be used to change the settings if required.
Use the same steps to set or change a setting for all functions.
How to Set or Change Drive Parameters

This procedure can only be performed if the drive system is disabled.
Danger! Release all torque in the drill before disabling

the drive system or damage to the electrical
! components might occur.
1. At the driller’s panel, turn the ENABLE switch to ‘OFF’.

2. Insert the key into the DRIVE SET keyed switch.
3. Turn and hold the key in the ‘SET’ position.
4. Use the procedures in the following table to set the required parameter(s):

OPERATIONS GUIDE CHAPTER 4: TORQUE AND SPEED LIMITS
Table 4-1: How to set or change drive parameters

To set this parameter Perform these steps
DRILL Forward 1. Set the MODE switch to ‘DRILL’.
Torque 2. Set the QUILL switch to ‘FWD’.
3. Use the TORQUE switch to increase or decrease the SET TORQUE value on
the digital gauge on the driller's panel.
Note: Set this limit at 2,000 ft·lb less than the lowest connected joint torque
setting (see CONNECT Forward Torque). Consult the Rig Manager or Oil
Company Representative to determine the proper setting.
Important: If using a downhole mud motor, the torque set limit must be
higher than the maximum output of the mud motor.
DRILL-Reverse 1. Set the MODE switch to ‘DRILL’.
Speed and Torque 2. Set the QUILL switch to ‘REV’.
3. Use the SPEED switch to increase or decrease the SET SPEED value on the
digital gauge on the driller's panel.
Note: TESCO recommends 10 rpm or less.
Note: TESCO recommends 10,000 ft·lb or less, depending on the drill string
configuration.
CONNECT-Forward 1. Set the MODE switch to ‘CONN’.
Speed and Torque 2. Set the QUILL switch to ‘FWD’.
Note: Use the torque requirements for the drill string connections to
determine this setting.
CONNECT-Reverse 1. Set the MODE switch to ‘CONN’.
Speed and Torque 2. Set the QUILL switch to ‘REV’.
Note: TESCO recommends 8,000 ft·lb or less.
BREAKOUT Speed Breakout speed is set to 7 rpm by PLC Logic and is not adjustable.
5. Release the DRIVE SET keyed switch.

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

SETTING TORQUE LIMITS

In order not to exceed the torque limits of the pipe and threaded connections being used, the
operator presets torque limits before operations begin. Failure to limit torque may result in
damaged pipe and/or connections. Once set, these limits will not be exceeded by the Top Drive
during operations.
EMI 400 top drive can produce 20,166 ft-lb of nominal torque continuously, with 1.5 times
overload capability. Therefore the torque limits should be set based on the ability of the motor
and the drill pipe being used.
During breakout operations, the torque will ramp up to maximum 30,249 ft-lb. This is the limit
for breakout and is not adjustable.
If Connect-Forward/Reverse is selected, the drive will apply torque to the preset value for
Connect-Forward/Reverse. For safety, the torque limit for Connect-Reverse is normally set
very low to prevent accidental back-off.
Drill-Forward torque limit should be preset to remain within the limitations of the drill pipe
being used. During operations, the full range of torque (from zero to the preset limit) is
available to the operator. For safety, Drill-Reverse torque is normally set very low, to prevent
accidental back-off. If required, higher values can be preset. During operations, the full range
of torque (from zero to the preset limit) is available to the operator. This feature allows fully-
controlled back-off, if required.
Note: When operating at a speed higher than 100 rpm, the top drive will produce less
torque than nominal value.
Breakout
There is no need to set a torque limit for Breakout as the torque applied by the drive system
is preprogrammed and unadjustable.
The breakout torque is pre-programmed to 30,249 ft·lb which is the full overload capacity
of the motor. It is typically 150% of nominal torque value
The Set Torque meter is the third one down on the set of four digital meter displays on the
right side of the driller’s panel.
Note: For convenience, speed and torque limit settings can be done in sequence; that is, the
operator can set the speed and then set the torque before proceeding to the next rotational
function.

OPERATIONS GUIDE CHAPTER 4: TORQUE AND SPEED LIMITS
Connect-Forward
It is recommended that the Connect-Forward torque limit be set to comply with the drill
pipe connection specifications. Maximum achievable value is 26,216 ft·lb. It is typically
130% of nominal torque value.
1. Ensure that the top drive quill is not rotating.
2. Turn the ENABLE switch to ‘OFF’.
3. Insert the key into the DRIVE SET switch, turn clockwise and hold.
4. Select the MODE switch to ‘CONN’.
5. Select the QUILL switch to ‘FWD’.
6. View the SET TORQUE meter and adjust displayed value to desired value using
the TORQUE switch.
7. Release the DRIVE SET switch. The Connect-Forward torque limit is now set.
Connect-Reverse
It is recommended that the Connect-Reverse torque limit be set at approximately 5,000 to
8,000 ft·lb.
4. Select the MODE switch to ‘CONN’.
5. Select the QUILL switch to ‘REV’.
the TORQUE switch.
7. Release the DRIVE SET switch. The Connect-Reverse torque limit is now set.
Drill-Forward
The unit has the capacity to drill in forward at a maximum quill speed of 200 rpm.
4. Select the MODE switch to ‘DRILL’.
5. Select the QUILL switch to ‘FWD’.
the SPEED switch.
7. Release the DRIVE SET switch. The Drill-Forward torque limit is now set.

Drill-Reverse
It is recommended that the Drill-Reverse torque limit be set at approximately 5,000 to 8,000
ft·lb.
3. Insert the key into the DRIVE SET switch, and turn clockwise and hold.
4. Select the MODE switch to ‘DRILL’.
5. Select the QUILL switch to ‘REV’.
6. View SET TORQUE meter and adjust displayed value to desired value using the
TORQUE INCREASE/DECREASE switch.
7. Release the DRIVE SET switch. The Drill Reverse torque limit is now set.
PIPE HANDLER SETTINGS
Pipe Handler Speed
Warning! No person should be within the radius of link

movement when operating the PIPE HANDLER
! FWD/REV switch.
The pipe handler rotates at one speed: 3 rpm, in both directions. This speed is
fixed and cannot be adjusted.

OPERATIONS GUIDE
CHAPTER 5: OTHER PRE-OPERATIONAL

PROCEDURES
HOW TO INSTALL THE SAVER SUB AND DIE LOCK CLAMP
1. Ensure the PIPE HANDLER ON/OFF switch is set to ‘OFF’.
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.
5. Set the GRABBER switch to ‘CLOSE’.
6. Use the TORQUE switch to reduce the torque to approximately 30% of the
required make up torque.
7. Set the MODE switch to ‘CONN’.
8. Set the QUILL switch to ‘FWD’.
9. Continue rotation until the connection is fully engaged.
10. Use the TORQUE switch to increase the torque to the torque required to make up
the connection.
11. When desired torque is achieved, set the QUILL switch to neutral.
12. Set the GRABBER switch to ‘OPEN’.
13. Place the die lock clamp on top of the grabber box.
14. Loosely install the die lock bolts (8).
15. 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.
16. 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.
17. Torque all 7/8 in. Grade 8 fasteners to 550 ft·lb.
Note: For more information, refer to the appendix titled “Torque Specifications for
High Strength Fasteners” in the Maintenance Guide for the unit.
18. Seat the dies.
Note: To seat the dies, strike the back side of each half of the clamp as hard as
possible with a sledgehammer.
19. When the dies seat properly, torque all bolts to 550 ft·lb.

CHAPTER 5: OTHER PRE-OPERATIONAL PROCEDURES OPERATIONS GUIDE
HOW TO ORIENT 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’.
Danger! Ensure that the top drive is extended out from the
! torque track by at least 6 in. (15.2 cm).
1. Ensure the GRABBER switch is set to ‘OPEN’.

2. Using the PIPE HANDLER ON/OFF switch, select ‘ON’.
Note: The PIPE HANDLER ON light illuminates.
3. Set the PIPE HANDLER FWD/REV switch to ‘FWD’ or ‘REV’ (depending on
desired rotation).
4. When the desired position is reached, set the PIPE HANDLER FWD/REV switch
to neutral.
Note: Due to the configuration, the pipe handler is automatically locked in posi-
tion when it is stopped.
5. Set the PIPE HANDLER ON/OFF switch to ‘OFF’.
6. The PIPE HANDLER ON light will go out.
HOW TO SET THE GRABBER HEIGHT

The grabber height cannot be adjusted from the driller’s panel, therefore it has to be pre-set
to close on the box connection of the drill pipe just below the saver sub. Follow this
procedure to pre-set the grabber-height.
1. Turn the auxiliary pump on.
3. Open grabber lift drain needle valve to lower the grabber to the lowest possible
position.
Note: Monitor the safety chain on the grabber leg to ensure it does not over extend
as it is lowered.
4. Open the grabber lift needle valve to lift the grabber.
5. When the grabber reaches the correct height (just below the lower sealing face of
the saver sub so the grabber closes on the box connection of the drill pipe) close
the grabber lift needle valve.
7. Turn off the auxiliary pump.

OPERATIONS GUIDE CHAPTER 5: OTHER PRE-OPERATIONAL PROCEDURES
Figure 5-1: Grabber lift needle valve
1. Grabber lift needle valve

2. Grabber lift drain needle valve

CHAPTER 5: OTHER PRE-OPERATIONAL PROCEDURES OPERATIONS GUIDE

OPERATIONS GUIDE
CHAPTER 6: 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.
If operating the mudsaver VALVE switch while the quill is rotating, an interlock in the PLC
program prevents damage to the actuator seals as follows:
• The PLC program stops quill rotation.
• The PLC allows the mudsaver valve to complete its timed circuit.
When the circuit is complete, the top drive will restart automatically.
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.
Warning! The user must be certain that the operator is

able to ensure, from the control station, that no
personnel is working in the danger zone areas. It
is the responsibility of the user to conduct a risk
! assessment in accordance with the EN 1050
safety of machinery standard when the
equipment is installed.

CHAPTER 6: MAKING/BREAKING CONNECTIONS OPERATIONS GUIDE
HOW TO MAKE CONNECTIONS–GENERAL

Do the following before beginning this procedure:
• Ensure that correct torque and speed settings are pre-set into the drive system.
• Ensure 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 6-1: Correct tong position to make a connection
Keep the grabber position just below

the saver sub seal to prevent grabber
die damage from hard band
Top drive and pipe/pipe connection

OPERATIONS GUIDE CHAPTER 6: MAKING/BREAKING CONNECTIONS

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

! weight indicator) is open.

Note: Feather 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 reg-
ister 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. Use the TORQUE switch to increase the torque setting to the torque required for
the current connection and thread type.
11. Monitor the DELIVERED TORQUE gauge.
12. When the DELIVERED TORQUE gauge displays the desired make up torque
value, set the QUILL switch to neutral.
13. Wait until the DELIVERED TORQUE gauge value decreases to zero.
14. 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. Set the EXTEND switch to ‘OUT’.
4. Extend the top drive until it is situated directly over the mousehole.
5. Feather the top drive until the elevator and elevator links are near the rig floor.
Figure 6-2: Correct position for elevator links and elevator

6. Using the TILT switch, select ‘BACK’.

7. Move the elevator links and elevators backward and out of the way of the connection.
8. Feather the top drive until the saver sub is within a foot (30 cm) of the pipe con-
nection.
9. Using the MODE switch, select ‘CONN’.
10. Using the QUILL switch, select ‘FWD’.
11. Using the TORQUE switch, set torque to 30% of required torque.
Note: Ensure the top drive and the single length of pipe are aligned, to avoid
cross-threading.
12. Feather 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 switch to neutral.
Close the grabber on the tool joint of the drill pipe, then set the QUILL switch to
‘FWD’.
Caution: Do not use the top drive to fully torque the connection
! in the mousehole.
14. When the connection is fully engaged (shoulders up), set the QUILL switch to
neutral.
15. Complete the connection as described in one of the following procedures:
• “How to Fully Torque a Connection” on page 43.
• “How to Connect a Single Length of Drill Pipe to the Drill String” on page 44.
How to Fully Torque a Connection

4. Make up recommended torque value required for the current connection and
thread type.
5. When the torque value 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 connec-
tion.
2. Set the EXTEND switch to ‘IN’.
3. Retract the extend arms until the top drive is positioned over hole center.
4. Place break-out tongs on the tool joint of the drill pipe that is held by the rig slips.
Note: Do not use the rotary table lock.
5. Apply pipe dope to the tool joint box.
6. Feather the top drive to stab the drill pipe into the tool joint box of the drill pipe
held in the rig slips.
10. When the connection fully engages, use the TORQUE switch to set the make up
torque required for the current connection and thread type.
11. Monitor the DELIVERED TORQUE gauge. When the torque reaches the required
torque value to make up the current connection, set the QUILL switch to neutral.
Figure 6-3: Connect a single length of pipe to the drill string

HOW TO BREAK THE TOP DRIVE/DRILL PIPE CONNECTION

1. Ensure the piper handler is locked (i.e., the PIPE HANDLER ON/OFF switch is
set to ‘OFF’).
Danger! This is an important safety step.

!
2. Position the grabber so that it will to 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.

5. Set the QUILL switch to ‘REV’. Wait until the DELIVERED TORQUE meter
indicates that delivered torque has increased to the preset value.
6. Push and hold the BREAKOUT button.
7. When the connection breaks, do the following:
• Release the BREAKOUT button.
• Set the QUILL switch to neutral.
9. Set the QUILL switch to ‘REV.
10. Feather the top drive out of the connection.
11. When the connection is disengaged, hoist the top drive clear of the floor.
Figure 6-4: Break the top drive/drill pipe connection
1. Quill
2. Mud saver valve
3. Saver sub
4. Grabber
5. Box connection on drill
pipe
Close the grabber on the box of

the drill pipe. Use connect-
reverse operations and the
BREAKOUT button to break the
connection.

HOW TO USE THE PIPE HANDLER TO MAKE UP PIPE STANDS
How to Make Up Stands in the Rotary Table

Figure 6-5: Make up stands in the rotary table
1. Pick up a single length of pipe from the mousehole.

2. Lower the pipe through the rotary table.
3. Pick up the second length of pipe from the mousehole.
4. Connect the two lengths of pipe.
5. Lower the connected lengths of pipe through the rotary table.
The following procedure assumes that stands of pipe are being made up where there is 60 ft
(18.3 m) of available depth below the rotary table. This is usually possible if the conductor
pipe is set.
If no conductor pipe is drilled, refer to “How to Make Up Pipe Stands Without a Conductor
Pipe” on page 48.
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. Feather the top drive.
3. Use the 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 traveling blocks might strike the racking
! platform if the top drive is being hoisted.
4. Position the elevator on the pipe single.

5. Set the ELEVATOR switch to ‘CLOSE’.

6. Hoist the top drive and the pipe out of the mousehole.
7. Press the TILT FLOAT button. This allows the elevator to come to the vertical
position over hole center.
8. Lower the pipe through the rotary table to the required connection height.
9. Set the slips.
10. Set the ELEVATOR switch to ‘OPEN’. Push and hold the ELEVATOR SAFETY
OPEN button.
11. Use the TILT switch to tilt the elevator back slightly.
Note: This prevents the elevator from hitting the tool joint as the top drive is
raised.
12. Hoist the top drive until the elevator is clear of the pipe.
13. Set the TILT switch to ‘FWD’.
14. Position the elevator over the mousehole.
15. Feather 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.
16. Hoist the top drive until the bottom of the second length of pipe is above the pipe
in the rotary table.
17. Press the TILT FLOAT button. This allows the elevator to come to hole center.
18. Feather the top drive and stab the pipe in the rotary table.
19. Attach the pipe spinner to the upper length of pipe, or rotate the connection by
using chain tongs.
20. Spin the upper pipe until the connection is fully engaged but not tight.
21. Remove the pipe spinner, then use rig tongs to torque the connection to specifica-
tion.
22. Hoist the top drive and the double length of pipe.
23. Remove the slips.
Note: If making up double lengths of pipe only, proceed to “Standard Racking
Procedure” on page 75.
24. Feather the top drive and the double length of pipe into the rotary table to the
required connection height.
25. 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 proce-
dure, 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.
4. Set the slips.
5. Feather 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 75.
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 when
using the rotary table. Use the following procedure when the rotary table is unavailable.
Figure 6-6: Make up pipe stands in the mousehole
1. Use the top drive to pick up a single length of pipe from the mousehole.
2. Use the tugger to insert a second length of pipe into the mousehole.
3. Connect the first length of pipe to the second length of pipe that is in the mousehole.
4. Hoist the connected double length of pipe.
5. Use the tugger to put the third length of pipe into the mousehole. Feather the top drive
and connect the double length of pipe to the third pipe that is in the mousehole.

1. Use the floor tugger to lower a single length of pipe into the mousehole.
2. Feather the top drive.
3. Use the TILT switch to tilt the elevator forward over the mousehole.
Warning! Do not use the EXTEND function to move the top

drive over the mousehole. Hoisting the top drive
! while it is extended may cause it to collide with
the racking platform.
4. Position the elevator on the single length of pipe.

6. Hoist the pipe out of the mousehole.
7. Use the floor tugger to lower the second length of pipe into the mousehole.
8. Feather the top drive and pipe and stab the second length of pipe that is in the
mousehole.
Caution: Release all the weight off the elevator to reduce the
! friction between the pipe and the elevator.
9. Attach chain tongs to the upper and lower lengths of pipe.
Caution: Most pipe spinners cannot be used when making

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

11. Use the rig tongs to torque the pipe connection to the required specification.
12. Hoist the double length of pipe out of the mousehole.
Warning! Adjust the TILT position as required to avoid

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

! racking platform while making this connection.
15. Release all the weight off the elevator to reduce the friction between the pipe and
the elevator.
16. Attach chain tongs to the double and single lengths of pipe.
17. Ensure the connection is fully engaged but not tightened.
18. Use the rig tongs to torque the pipe connection to the required specification.
19. 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.
20. Follow the “Standard Racking Procedure” on page 75.

21. Feather the top drive and proceed with making up the next stand of pipe.

HOW TO MAKE UP BHA (COLLARS AND TOOLS)

When the 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 6-7: Connect collars
1. Pick up the first collar from the mousehole.

2. Lower the collar into the rotary table.
3. Disconnect the pick-up sub from the collar.
4. Pick up a second collar from the mousehole.
5. Hoist the second collar out of the mousehole.
6. Feather the top drive and connect the collars.
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! Use rig tongs to torque the connection between

the pick-up sub and the collar to prevent it from
! unscrewing.
3. Raise the grabber box to its maximum height; see procedure on “How to Set the
Grabber Height” on page 36.


5. Position the elevators over the mousehole.
6. Feather the top drive and position the elevator on the pick-up sub.
7. Set the ELEVATOR OPEN/CLOSE switch to ‘CLOSE’.
8. Hoist the top drive until the collar is clear of the mousehole.
9. Press the TILT FLOAT button. This allows the elevator to return to a vertical posi-
tion over hole center.
10. Feather 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. Feather 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 TILT FLOAT button. This allows the elevator to move to the vertical
position.
22. Feather 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. Attach rig tongs to the collars.

24. Torque the connection to the required specification.
25. Remove the safety clamp.
26. Hoist the top drive and remove the slips. This suspends the collars from the eleva-
tor of the top drive.
27. Lower the collars through the rotary table to the desired connection height.
29. Use the rig tongs to disconnect the pick-up sub from the top collar.
30. Repeat steps 19. to 23. to connect the third collar.

How to Connect Collars Above the Rotary Table

1. Follow steps 1. to 18. of “How to Make Up BHA (Collars and Tools)” on page 51
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
• 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 elevators to place a third collar in the rotary table. Use the slips and
a safety clamp to secure the collar in place.
5. Feather the top drive to stab the connection in the rotary table.
Caution: The elevator links must hang vertically over the

! connection point.
6. Attach rig tongs to the collars.

7. Torque the connection to the required specification for the drill collar.
9. Hoist the top drive to clear the collars from the rotary table.
10. Rack the collars according to the “Standard Racking Procedure” on page 75.


OPERATIONS GUIDE
CHAPTER 7: DRILLING OPERATIONS
WELL CONTROL
Top drive owners and operators must establish guidelines and procedures for all possible
well control situations. These guidelines and procedures should reflect industry standard
practice for the operating location and conditions.
In most cases, the addition of a top drive will not significantly change the established
procedures 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 5ft (1.5
m) length of tube on which the elevators can slide up and down. The threaded connections
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 provides the ability to ream and back-ream
during tripping operations, if required.

CHAPTER 7: DRILLING OPERATIONS OPERATIONS GUIDE
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.
6. Press the TILT 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 (0.3 to 0.6 m) 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.
14. Lead the top drive into the connection.

15. When the connection is fully engaged, set the QUILL switch to neutral.
17. Set the QUILL switch to ‘FWD’ (the MODE switch should still be set to ‘CONN’).
18. When the torque reaches the desired torque value, turn the QUILL switch to neutral.
20. Hoist the top drive and remove the slips.
21. Set the mudsaver VALVE switch to ‘OPEN’.
22. Start the rig mud pump.
23. Begin drilling.
About Connections and Surface Hole Operations

Make connections as per normal procedure. Leave the drillable pick-up sub on the top
drive. Refer to “How to Make Up BHA (Collars and Tools)” on page 51.

OPERATIONS GUIDE CHAPTER 7: DRILLING OPERATIONS
About Tripping and Surface Hole Operations

Trip drill pipe in and out of the hole as per normal procedure, 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 81.
HOW TO DRILL AHEAD WITH SINGLE LENGTHS OF PIPE

Drilling operations proceed more efficiently when using the tugger 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 7-1: Drill ahead with single lengths of pipe
1. Break out the connection between the top drive and the drill pipe.
2. Pick up a single length of pipe from the mousehole.
3. Connect the pipe to the top drive and the drill string.
4. Remove the slips and drill ahead.
1. Raise the bit 1 to 2 ft (0.3 to 0.6 m) off the bottom of the hole.
2. Set the QUILL 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.

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’.
8. Position the grabber so that it will close on the box of the drill pipe.
Warning! Do not close the grabber on the saver sub or the

! hard band of the drill pipe.

11. Set the QUILL switch to ‘REV’.
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 connection breaks, release the BREAKOUT button. The top drive will
rotate at the preset speed.
14. When the quill rotates 1/2 turn, release the BREAKOUT button.
15. 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.
16. 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.
17. When the connection unscrews completely, set the QUILL switch to neutral.
18. Hoist the top drive until the elevator clears the drill string stump in the rotary table.
19. Set the ELEVATOR switch to ‘OPEN’, then push and hold the ELEVATOR
SAFETY OPEN button.
20. Use the TILT switch to move the elevator forward so that it is above the mouse-
hole.
21. Lower the top drive until the elevator reaches the drill pipe in the mousehole.
22. Position the elevator on the drill pipe, then set the ELEVATOR switch to ‘CLOSE’.
23. Hoist the top drive until the single length of pipe is above the drill pipe stump in
the rotary table.
24. Press the TILT FLOAT button to bring the elevator to the vertical position.

Caution: Rig floor personnel should stabilize the lower end of the
! drill pipe.
25. Lower the top drive and stab the drill pipe connection.
26. Position a back-up tong on the box connection of the stump.
29. Use the TORQUE switch to increase torque to 30 to 40% of the maximum con-
nect value required for the thread and connection type.
Note: Torque values are set prior to start of the drilling operation and these values
are entered at the driller’s panel using the procedure defined in “How to Set or
Change Drive Parameters” on page 30.
30. Lower the top drive further until the pipe makes contact with the saver sub.
31. Use the TILT function to guide the pipe through the drill pipe guide.
32. Lead the top drive into the connection until the pipe/pipe and pipe/saver sub con-
nections are fully engaged but not tightened.
Note: When both connections are fully engaged, the break-out tongs will tighten
and the top drive will stall.
33. Use the TORQUE switch to increase the torque value to the make up value
required for the thread and connection type.
34. Wait until the torque increases to the required make up torque for the connection.
36. Remove the break-out tong.
37. Set the ELEVATOR switch to ‘OPEN’, and press and hold the ELEVATOR
SAFETY OPEN button.
38. Set the TILT switch to ‘BACK’. This moves the elevator away from the drill
string and avoids unnecessary wear of the elevator inserts.
40. If required, start the rig mud pump.
41. Hoist the top drive and drill string.
43. Set the MODE switch to ‘DRILL’.
45. Use the SPEED switch to set the required drilling rpm.
46. Use the TORQUE switch to increase the torque to the desired drilling torque value
for the thread and connection type.
Note: Torque values are set prior to start of the drilling operation and these val-
ues are entered at the driller’s panel using the procedure defined in “How to Set
or Change Drive Parameters” on page 30. The preset value for the maximum
drilling torque must be less than the maximum torque value for the connection
type.
47. Commence drilling.

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 7-2: Drill ahead with pipe stands
1. Break out the connection between the top drive and the drill pipe.
2. Pick up a stand of pipe from the racking platform.
3. Connect the stand of pipe to the top drive and the drill string.
4. Remove the slips and drill ahead.
1. Raise the bit 1 to 2 ft (0.3 to 0.6 m) 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.
8. Position the grabber so that it will close on the box of the drill pipe.
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. Torque increases until it reaches the max-
imum value available for breakout torque for the unit.
13. When the connection breaks, release the BREAKOUT button. The top drive will
rotate at the preset speed.
14. 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.
17. When the connection unscrews completely, set the QUILL switch to neutral.
18. Hoist the top drive until the elevator clears the drill string stump in the rotary table.
19. Set the ELEVATOR switch to ‘OPEN’, then push and hold the ELEVATOR
SAFETY OPEN button.
20. Use the TILT switch to move the elevator forward so that it is past the stump.
21. Hoist the top drive to the racking platform.
22. Position the elevator to capture the top tool joint of the next stand of pipe.
24. Ensure that rig floor personnel are ready to assist in guiding the stand out of its
racking position.
25. When the stand is picked up, press the TILT FLOAT button.
26. Hoist the top drive slowly, allowing the rig floor personnel to guide the bottom of
the stand to a vertical position.
27. Hoist the top drive until the bottom pin of the stand clears the stump.
28. Lower the top drive and stab the drill pipe connection into the stump.
29. Position a back-up tong on the box connection of the stump.
30. Lower the top drive further until the pipe makes contact with the saver sub.


Note: Torque values are set prior to start of the drilling operation and these values
are entered at the driller’s panel using the procedure defined in “How to Set or
34. Use the TILT function to guide the pipe through the drill pipe guide.
and the top drive will stall.
36. Use the TORQUE switch to increase the torque value to the make up value
37. Wait until the torque increases to the required make up torque for the connection.
40. Set the ELEVATOR switch to ‘OPEN’, and press and hold the ELEVATOR
SAFETY OPEN button.
41. Set the TILT switch to ‘BACK’. This moves the elevator away from the drill
string and avoids unnecessary wear of the elevator inserts.
43. If required, start the rig mud pump.
48. Use the SPEED switch to set the required drilling rpm.
49. Use the TORQUE switch to increase the torque to the desired drilling torque value
for the thread and connection type.
or Change Drive Parameters” on page 30. The preset value for the maximum
drilling torque must be less than the maximum torque value for the connection
type.

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 to
avoid overheating the auxiliary hydraulic system.
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. See also
“Combination Drilling Operations” on page 68 for more information.
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 69.
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 TILT feature to guide the drill pipe into the drill pipe guide.
6. Lead the top drive into the connection until the pipe/saver sub connection is fully
engaged but not tightened.
7. Use the TORQUE switch to increase torque to the maximum ‘connect’ value
or Change Drive Parameters” on page 30.
8. Wait until the torque increases to the required value for the current thread and con-
nection type.
9. As soon as the torque reaches the required value to make up the connection, set
the QUILL switch to neutral.
12. Set the VALVE switch to ‘OPEN’.


16. Start drilling by lowering the top drive.
The orientation of the tool face may need to be adjusted to drill in the required direction
when drilling with a mud motor. Refer to the next section, “How to Adjust the Tool Face
Orientation”.
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
3. Use the SPEED switch to set the speed to 2 rpm.
4. Use the TORQUE switch to increase the torque gradually. Monitor the output on
the DELIVERED TORQUE meter.
5. When observing 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, the
grabber can be opened with no rotation (static).
6. Reorient the tool face by doing one of the following:
a. To turn the drill string clockwise, use the TORQUE switch to increase the
torque slowly. 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 until the quill stalls, then close the grabber.
b. To turn the drill string counter-clockwise, use the TORQUE switch to
decrease the torque slowly. Decreasing the torque allows the downhole 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 until the quill stalls, then close the grabber.

How to Make and Break Connections During Slide Drilling

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

!
decrease to zero.
8. Set the QUILL 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.
10. 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 con-
nection 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.
13. When the connection completely unscrews, set the QUILL switch to neutral.
14. Hoist the top drive high enough to allow the elevator to pass over the stump.
15. 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 57 and “How to Drill
Ahead with Pipe Stands” on page 60 for more information.
16. Hoist the top drive until the bottom pin of the pipe stand clears the stump.
17. Press the TILT FLOAT button. The elevator and pipe stand will move to hole center.
18. Position the break-out tong on the box connection of the stump.
19. Lower the top drive until the drill pipe makes contact with the saver sub.
Note: Use the TILT function to guide the drill pipe into the drill pipe guide.

or Change Drive Parameters” on page 30.
and the top drive will stall. It is also possible that the top drive will torque into the
locked rotary table.
24. Use the TORQUE switch to increase the torque to the maximum connect value
25. Wait until the DELIVERED TORQUE gauge increases to required value for the
connection type.
26. As soon as the torque reaches the required value to make up connections, set the
QUILL switch to neutral.
28. Use the grabber lift needle valve to reposition the grabber on the saver sub (the
grabber should be open). Set the GRABBER switch to ‘CLOSE’.
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 65.
Caution: The rotary table must remain locked during this

! procedure.
TESCO recommends marking the position of the drill string in order 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 switch to set the quill speed to 4 to 5 rpm.
4. Use the TORQUE switch to set the torque value of the top drive to match the
torque in the drill string. 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.
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 switch to set the speed to 2 rpm.
5. Use the TORQUE switch to increase the torque gradually. Monitor the DELV-
ERED TORQUE meter.
6. When observing deflection of the grabber box towards the driller’s side (clockwise),
record the torque value.
7. Re-check the drill string torque periodically during downhole motor operations.

COMBINATION DRILLING OPERATIONS

Summary
Combination drilling refers to the practice of rotating the top drive slowly in forward
rotation while drilling with a downhole mud motor. This practice, if used, usually occurs
after the angle is built and it is only necessary to maintain the achieved angle.
Caution: It is essential to use the following guideline if this

! method of drilling is used.
The SET torque output reading on the driller’s panel must AT ALL TIMES be 20% higher
than the maximum torque output of the downhole motor in use.
Explanation
Failure to maintain the top drive torque setting at a sufficient level to counteract the
downhole motor torque can force the top drive into a partial or continuous state of unwind.
If the top drive torque is set too low, the downhole motor can apply reactive torque to the
top drive and cause it to rotate in reverse (counter-clockwise). The power generated by the
top drive rotating in reverse is dissipated by the controlled unwind program called ‘regen-
mode’. Extended use of this mode while power is still applied to the mud motor will
eventually create a situation where the resistive brake might overheat and/or an overvoltage
condition occurs that can disable the drive.
Danger! If the drive shuts down under these conditions, a

complete uncontrolled unwind of the top drive
! can occur. This event can cause severe damage
to the drive system.

OPERATIONS GUIDE
CHAPTER 8: 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

Top drive owners and operators must establish guidelines and procedures for all possible
well control situations. These guidelines and procedures should reflect industry standard
practice for the current 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 connecting 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.

CHAPTER 8: 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 8-1 on page 71.
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. Lift the upper spline-lock clamp from the mudsaver valve and secure with set-
screws.
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 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 needle valve to lift the grabber until the actuator rests on the
grabber.
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 8-2 on page 72.
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.

OPERATIONS GUIDE CHAPTER 8: 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 can 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. The drill string can now be inserted into the wellbore. Use the procedure
described in “How to Trip In Drill Pipe” on page 80.
Figure 8-1: Remove the mudsaver valve actuator for well control
1. Quill
2. Upper Die-Lock Clamp
3. Actuator
4. Manual Ball Valve
5. Mudsaver Wrench
6. Mudsaver Valve
7. Lower Die-Lock Clamp
8. Saver Sub
9. Grabber

Figure 8-2: Remove the actuator from the mudsaver valve
1. Pin
2. Spring
3. Set Screw
4. Hex Drive Shaft

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 8-3: Trip out drill pipe
1. Break out the connection between the top drive and the drill pipe (if required).
2. Hoist the top drive with the drill pipe in the elevators.
3. Break the drill pipe connection. Rack the stand.
4. Lower the top drive to pick up the next stand of drill pipe.

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

2. Monitor the standpipe gauge to ensure that mud pump pressure decreases to zero.
4. Hoist the top drive.
5. Set the slips.
Note: Ensure the stored torque in the drill string has dissipated before the slips are
set.
6. Position the elevator on the drill pipe using the TILT function.
8. Hoist or lower the top drive until the grabber is positioned 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 the top drive to be raised in small increments as the connec-
tion 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 switch to neutral.
17. Hoist the top drive and drill pipe.
19. Hoist the top drive to lift the drill pipe (single, double or stand) 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 75.
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.

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.
3. Allow rig floor personnel to push the bottom of the stand into place on the rack-
ing 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 con-
trol 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 button.
8. Set the ELEVATOR switch to ‘OPEN’.
9. Press the TILT 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 racking the collars.
Figure 8-4: Trip out collars
1. Install a pick-up sub in the top collar and torque it to specification.

2. Latch the pick-up sub in the elevator and hoist the top drive. Break the connection
between the collar segments at the floor.
3. Rack the stand of collars.
4. Lower the top drive to the rig floor. Repeat this procedure for the next stand of collars.

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 OFF/ON switch to ‘ON’.
5. Set and hold the PIPE HANDLER REV/FWD switch at ‘FWD’ position.
Note: The pipe handler will begin to rotate at the preset speed.
6. Position the pipe handler so that the TILT feature can be used to assist in racking
the collars.
7. When the pipe handler is in the proper position, set the PIPE HANDLER REV/
FWD switch from ‘FWD’ to neutral position.
8. Set the PIPE HANDLER OFF/ON switch to ‘OFF’.
9. Use the 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 TILT 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 TILT feature to tilt the collar(s) toward the derrickman.
Note: The EXTEND function can also be used to tilt the collar(s).
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. Release the collar(s) and the pick-up sub.
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.

TRIP IN OPERATIONS
How to Trip in Tools and Collars

Figure 8-5: Trip in tools and collars
1. Pick up a stand of collars from the racking board. A pick-up sub should already be attached to the collar.
2. Connect the tools or collars at the rig floor.
3. Lower the stand of collars through the rotary table and set the slips. Attach a safety clamp.
4. Remove the pick-up sub from the collar and set it to the side.
5. Hoist the top drive to the racking board and pick up the next stand of collars.

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. Set the ELEVATOR switch to ‘OPEN’, and push and hold the ELEVATOR
SAFETY OPEN button.
6. Use the chain tongs to unscrew the pick-up sub.
7. Use the floor tugger to remove the pick-up sub.
9. Use the EXTEND function, if necessary, to accept the first collar from the derrick-
man.
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 TILT FLOAT button. This will bring elevator and elevator links to the
vertical position.
Caution: If the EXTEND function was used, 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 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.

How to Trip In Drill Pipe

1. Ensure that the elevator and elevator links are hanging vertically.
2. Set the PIPE HANDLER OFF/ON switch to ‘ON’.
3. Set and hold the PIPE HANDLER REV/FWD 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, set the PIPE HANDLER REV/
FWD switch from ‘FWD’ to neutral position.
5. Set the PIPE HANDLER OFF/ON switch to ‘OFF’.
7. Use the 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 TILT FLOAT button to bring the elevator and elevator links to hole cen-
ter.
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
into the wellbore.

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.
Note: Ensure the grabber closes on the box connection of the drill pipe.
7. Use the TORQUE switch to increase the torque to 30 to 40% of the maximum
connect values required for the thread and connection type.
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. Use the TORQUE switch to increase the torque to the make up value required for
the thread and connection type.
11. When the torque reaches the required torque for the connection, set the QUILL
switch to neutral.
14. Start the mud pumps.
17. Set speed and torque to the required values.
18. Hoist the top drive until the tight spot is encountered.

19. Raise and lower the top drive several times (or until the hole is clean) while circu-
lating the mud.
Note: It is advisable to trip out one or two stands with the top drive connected to
the drill string.
20. When reaming operations are complete, set the QUILL switch to select neutral.
21. Hoist top drive to the proper position for disconnecting it from the drill pipe.
22. Set the slips.
23. Turn off the rig mud pumps.
25. Disconnect the drill pipe from the top drive. See “How to Break the Top Drive/
Drill Pipe Connection” on page 45 for more information.
26. 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 disconnected 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.
7. Rotate the top drive into the connection.
Note: Do not allow the top drive weight to sit on the threaded connection.
8. Fully engage the connection between the saver sub and the drill pipe.
9. Use the TORQUE switch to increase the torque to the value required to make up
the thread and connection type.
10. When the torque reaches the required torque for the connection, set the QUILL
switch to neutral.


13. Start the mud pumps.
16. Set the speed and torque 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 circu-
lating 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 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 45 for additional information.
25. Continue with standard procedures for trip in operations.


OPERATIONS GUIDE
CHAPTER 9: STUCK PIPE

Unlike conventional Kelly systems, TESCO top drives help 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.
5. Set the torque to the required value.
Note: Drill torque is typically 80% of the make up torque. Refer to “How to Set or
7. Raise and lower the top drive to work the drill string up and down.
8. Continue to raise and lower the top drive and drill string until a free point is
established.
9. When the drill string begins to rotate, raise and lower the top drive in the free
point area in small increments.
Warning! When jarring with torque in the drill string,

carefully monitor the condition of the torque
! bushing and torque tube.
10. Gradually increase the travel distance until the obstruction is cleared.

CHAPTER 9: 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, ‘jarring’ operations may need to be initiated.
Caution: 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 (for wireline or logging, for example), 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.
Note: Recommended speed is 30 to 40 rpm.
6. Set the torque to the required value.
Note: Drill torque is typically 80% of the make up torque. Refer to “How to Set or
8. Initiate jarring operations; use the top drive to hoist and lower the drill string.
9. When the string begins to rotate, raise and lower the top drive in the free point
area in small increments.
10. 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.

OPERATIONS GUIDE CHAPTER 9: 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.
Warning! 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 appropriate for the pipe and conditions.
Consult rig management.
Note: See “How to Set or Change Drive Parameters” on page 30 for more
information.
2. Position wireline tools and the charge device at the connection where the drill
string is to disconnect.
5. Work the drill pipe up and down and slowly increase the quill speed in very small
increments.
Note: Torque is assumed to be at its limit when the pipe will not rotate any further.
If there is a need to increase the torque in stages, adjust the drill-reverse torque set-
ting when increasing the torque in the drill string. If a specific number of rotations
of the drill pipe is required, increase the torque until the required number of rota-
tions is achieved.
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.

CHAPTER 9: STUCK PIPE OPERATIONS GUIDE
Figure 9-1: Neutral weight at the connection
Total weight of pipe downhole = 125,000 lb The weight indicator will

Weight of pipe below the stuck point = 65,000 lb display 60,000 lb when the
first free connection is at
Total weight of the free pipe = 60,000 lb
neutral.
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. Open the grabber.

12. 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)
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”.

OPERATIONS GUIDE
CHAPTER 10: RUN AND PULL CASING

There are advantages to using the TESCO top drive to run casing:
• Connecting fill-up tools directly to the top drive to provide fill-up capability while
running the casing.
• Using TILT and EXTEND functions to assist rig personnel in handling and stabbing
the casing.
Figure 10-1: Pick up casing
1. Floor slip elevators

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

CHAPTER 10: 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 using

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 being 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. Not taking this
precaution could result in the weight of the
! casing pulling the top drive away from the
torque track and damaging the EXTEND
components of the torque arrest system.

OPERATIONS GUIDE CHAPTER 10: RUN AND PULL CASING
HOW TO RUN CASING

Figure 10-2: Run casing
1. Use the pick-up elevators to lower the first joint of casing through the floor slip elevators.
2. Close the slips. Fill up the casing, if required at this point.
3. Use the pick-up elevators to pick up the next joint of casing. Use casing tongs to make up the 
connection between the two joints of casing.
4. When the connection is complete, release the pick-up elevators and attach running elevators.
5. Open the floor slip elevators and lower the casing.
1. Attach the pick-up elevators to the first joint of casing.

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

! to reduce the stress on the torque track.

Figure 10-3: 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 is extended toward the casing

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 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.
17. Hoist the casing.

OPERATIONS GUIDE CHAPTER 10: RUN AND PULL 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 the 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 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 may be

necessary to use a safety clamp to ensure the casing does not
! slide through the slips.


OPERATIONS GUIDE
CHAPTER 11: 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.
1. Obtain and install a new block sling.

Figure 11-1: Block sling
1. Block sling
2. Link tilt backwards
3. Drill pipe stump
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.

CHAPTER 11: TOP DRIVE CONSIDERATIONS OPERATIONS GUIDE
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 possible.
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 recommends 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!

OPERATIONS GUIDE CHAPTER 11: TOP DRIVE CONSIDERATIONS
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.
Elevator Links
Elevator
Correct Incorrect
The TESCO 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
HEAVY LOADS AT THE V-DOOR

This procedure describes how the top drive can be used to pick up heavy loads from the V-
door.
Warning! The extend frame and EXTEND functions 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 being picked up.
Use slings that are strong enough to support the load.
2. Connect a rig winch to the load that is being 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.

OPERATIONS GUIDE CHAPTER 11: TOP DRIVE CONSIDERATIONS
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 either additional winches to assist in the
lift or use cranes to position the equipment on
the drill floor instead of picking them up with the
! top drive. Damage to the top drive and
unnecessary repair time can be avoided with
proper planning and preparation.


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

APPENDIX A: POST JARRING CHECKLIST OPERATIONS GUIDE

OPERATIONS GUIDE INDEX
INDEX
A how to connect drill pipe at the mousehole, 42

about the top drive, 1 how to fully torque, 43
AUX PUMP switch, 15 make up BHA (collars and tools), 51
make up pipe stands, 48
make up triples, 48
B
make up with grabber to V-door, 42
BHA
mousehole, 42
make up, 51
pre-operational procedures, 40
trip in, 78
trip out, 76
brake handle, 24 D
elevator-close, 24 DELIVERED RPM calibration, 25
BREAKOUT push button, 17, 23 DELIVERED SPEED meter, 17
BREAKOUT speed, set, 31 DELIVERED SPEED recommended settings, 27
DELIVERED TORQUE
how to calibrate, 25
C
DELIVERED TORQUE recommended settings, 27
cautions
die lock clamp installation, 35
collars, 51
DNm, 17
elevator links, 52
DRILL mode
EXTEND function, 46
forward rotation, 22
making or breaking connections, 39
forward speed, 22
mudsaver valve, 39
forward torque, 22
pick-up elevators, 51
reverse rotation, 22
pick-up sub, 51
reverse speed, 22
slips, 39
reverse torque, 22
tilt links, 42
drill pipe
trapped torque, 39
connect to the drill string, 44
Vernier dampening valve, 41
connect to the top drive at the mousehole, 42
collars and tools
make connections, general, 40
make up, 51
make up triples, 48
CONNECT Forward
DRILL Reverse
set speed, 31
set speed, 31
set torque, 31
set torque, 31
CONNECT mode
driller’s panel
forward rotation, 23
calibrate meters, 25
forward speed, 23
controls, 15
forward torque, 23
drive controls and indicators, 16
reverse rotation, 23
E.S.D., 21
reverse speed, 23
features, 13
reverse torque, 23
general description, 3, 13
CONNECT Reverse
indicators, 15
set speed, 31
meters, 17
set torque, 31
quill controls, 17
connections
robotic functions, 15
break connection to top drive, 45
switch naming convention, 18
cautions, 39
warning lights, 15
connect collars above the rotary table, 53
drive controls and indicators, 16
connect pipe single to drill sting, 44
Drive Data Manager, 3
general overview, 40
drive parameters

INDEX OPERATIONS GUIDE
BREAKOUT speed, 31 Motor Maximum Capacity, 29

CONNECT Forward, 31 mousehole
CONNECT Reverse, 31 make up stands, 48
DRILL Reverse, 31 use to make connections, 42
how to set or change, 30 mudsaver valve
overview, 30 cautions, 39
DRIVE SET switch, 16
N
E naming conventions for switch settings, 18
E.S.D. description, 21
E.S.D. on the driller’s panel, 21 O
E.S.D. on the main panel, 21 override
E.S.D. push button, 16 ELEVATOR-CLOSE, 24
ELEVATOR function description, 18 GRABBER-Drawworks, 24
ELEVATOR switch, 15
ELEVATOR-CLOSE
brake handle, 24 P
ELEVATOR-SAFETY-OPEN, 18 pipe
Emergency Shut Down, 21 break connection with top drive, 45
ENABLE switch, 16 connect to drill string, 44
EXTEND function make up triples, 48
cautions, 46 pipe handler
description, 19 function description, 20
EXTEND switch, 15 PIPE HANDLER ’CAUTION’ light, 16
PIPE HANDLER ROTATE push button, 16
PIPE HANDLER switch, 16
F pipe stands
FLOAT push button, 15 make up in mousehole, 48
function descriptions make up in rotary table, 46
E.S.D., 21 pre-operational procedures
ELEVATOR, 18 install the die lock clamp, 35
EXTEND, 19 install the saver sub, 35
GRABBER, 20
PIPE HANDLER, 20
TILT, 18 Q
VALVE, 19 quill rotation controls, 17
QUILL switch, 17
G
GRABBER ’CLOSED’ light, 16 R
GRABBER function description, 20 READY light, 16
GRABBER switch, 15 remote brake handle, 24
GRABBER-Drawworks override, 24 RESET push button, 16
robotic functions
controls and indicators, 15
M ROBOTICS ’ON’ light, 15
make connections rotary table
general, 40 connect collars, 53
precautions, 40 make up pipe stands, 46
meters
driller’s panel, 17
how to calibrate, 25 S
recommended settings, 27 SAFETY OPEN push button, 15
MODE switch, 17 saver sub installation, 35
MODULE ’ON’ light, 16 SET RPM
how to calibrate, 25

OPERATIONS GUIDE INDEX
SET SPEED meter, 17

SET SPEED recommended settings, 27
SET TORQUE calibration, 25
SET TORQUE meter, 17
SET TORQUE recommended settings, 27
speed available, 21
speed settings, 27
SPEED switch, 17
System Description, 3
T
TILT function description, 18
TILT switch, 15
Top Drive, 11
Reset, 11
Start/Stop, 11
torque
trapped in drill string, 39
torque available, 21
torque meter, display DNm, 17
torque settings, 27
TORQUE switch, 17
torquing connections, 43
V
VALVE ’CLOSED’ light, 15
VALVE function description, 19
VALVE switch, 15

INDEX OPERATIONS GUIDE

OPERATIONS GUIDE
ENGINEERING SIGN-OFF
This sign-off sheet indicates that this document has been approved for release by the 
Engineering Department at TESCO.
Document Complete By Signature Date Signed
Pamela Digitally signed by Pamela Smith

DN: cn=Pamela Smith, o=Tesco
Manufacturing, ou=Engineering,
Smith
email=pamela_smith@tescocorp.
com, c=CA
Date: 2013.07.24 14:20:28 -06'00'
Document Reviewed/Approved Date Signed
ENGIN
AL E
N N M EL A
ER
KE X
OFESSIO
ALBERTA
13 Aug. 2013
PR
Member# M51185
TESCO Corp. permit to practice# P06505

ENGINEERING SIGN-OFF OPERATIONS GUIDE


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Operations Guide

EMI 400 Top Drive System

250TON EMI 400HP 50Hz

DOCUMENT NAME: 1270412 REV 1

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

© 2010 Tesco Corporation. All rights reserved.

After Market Sales and Service Contact

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

Version Date ECN Description of Changes

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

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IX

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

CHAPTER 2: DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 3: DRILLER’S PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

Controls for Torque and Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

CHAPTER 4: TORQUE AND SPEED LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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

CHAPTER 5: OTHER PRE-OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 35

CHAPTER 6: MAKING/BREAKING CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

CHAPTER 7: DRILLING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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

CHAPTER 8: TRIPPING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

CHAPTER 9: STUCK PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

CHAPTER 10: RUN AND PULL CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

CHAPTER 11: TOP DRIVE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

APPENDIX A: POST JARRING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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

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

This page has been left blank intentionally.

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

Warning! Before operating or servicing this top drive system,

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

Caution: Always perform the correct lock-out procedures as

! recommended by the Safety or Loss Prevention department

Caution: Never attempt to perform services procedures or repairs

! when equipment is operating.

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

Caution: Only trained personnel must perform inspections and

Caution: Safe access must be provided to all areas where

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

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

! 5 rpm - even if the QUILL switch is set to neutral. This is to prevent

Warning! Electrical voltages of different potentials are used

Warning! There are high voltage capacitors installed in the

Warning! Accumulators used in the auxiliary hydraulic

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

CHAPTER 1: ABOUT THIS DOCUMENT

Table 1-1: Where to find more information

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

Warnings and Notices

Warning! Electrical voltages of different potentials are

Warning! There are high voltage capacitors installed in the

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

CHAPTER 2: DRIVE SYSTEM

Drive Control Panel

Important: Only qualified TESCO personnel certified by ABB should

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

Figure 2-1: ACS800 Drive Control Panel

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

Figure 2-2: Panel operation mode keys and displays

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

Figure 2-3: Actual signal display mode

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