Bulletin 20900e

TOP DRIVES CASING DRILLING™ CASING RUNNING

Top Drive Rig Floor Safety

Orientation
Doghouse Manual

Due to ongoing product development, all specifications are subject to change without notice.
Printed in Canada / April 2004 / TC

The Drilling Innovation Company™

Email: topdrive@tescocorp.com Web: www.tescocorp.com

Corporate Headquarters
6204 - 6A Street S.E.
World Wide Operations
11330 Brittmoore Park Drive The Drilling Innovation Company™
Calgary, Alberta, Canada T2H 2B7 Houston, Texas, USA 77041 www.tescocorp.com
Tel: 403 233-0757 • Fax: 403 252-3362 Tel: 713 849-5900 • Fax: 713 849-0075
 The Drilling Innovation Company™

TESCO CORPORATION
WELL SITE OPERATIONS
6204-BURBANK ROAD S.E.
CALGARY, ALBERTA
CANADA T2H 2C2

Phone: 403 720 2858

Fax: 403 203 2295
Web:www.tescocorp.com
email: topdrives@tescocorp.com

Top Drive Rig Floor

Safety Orientation
Printed in Canada / Dec. 2002 TC120
©Tesco Corporation

Page 2 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 19
 TABLE OF CONTENTS
INTRODUCTION FOR DRILLERS 4 CHAPTER 5
MAKING CONNECTIONS
CHAPTER 1
RIGGING UP THE EQUIPMENT Safety 12
Breaking Out 12
Torque System 4 Making Up Singles 12
Power Module 5 Making Up Doubles 12
Service Loop 6 Making Up Triples 13
Top Drive 6
CHAPTER 6
CHAPTER 2 OPERATIONS
COMPONENT IDENTIFICATION
Drilling 13
Top Drive 7 Tripping 14
Cold Climate 14
CHAPTER 3 Reaming 15
THE DRILLERS PANEL Working Tight Hole 15
Jarring 16
Description 8 Running Casing 16
Position 8 Cementing 16
Indicator Lights 8
Safety Interlocks 9 CHAPTER 7
TOP DRIVE CONSIDERATIONS
CHAPTER 4
CONTROLS AND ROBOTICS Slip and Cut Drilling Line 17
Maintenance 17
Clearance and Visibility 10
Extend 10 DISCLAIMER 17
Link Tilt 10
Grabber 10
Grabber Lift 10
Pipe Handler 10
Elevators 11
Mud Saver Valve and Actuator 11

Page 18 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 3
 Chapter 1 Chapter 7
INTRODUCTION RIGGING UP THE Top Drive Disclaimer
FOR DRILLERS EQUIPMENT Considerations This manual is intended to provide basic information
The Torque System: only, and does not constitute a comprehensive
This manual is intended to guide to the functioning or operation of a Tesco Top
After measuring the rig and determining the torque Slip and Cut Drilling Line:
provide basic information system configuration, the top drive technician will require Some daily rig operations change when a rig is fitted Drive. It is to be used only in conjunction with the
only, and does not constitute the help of a select number of crewmembers. As a with a top drive. Some simple procedures that your orientation and on site supervision provided by
a comprehensive guide to driller, it’s up to you to choose workers who are confident crew has performed regularly will need to be adjusted Tesco personnel. The Tesco Top Drive Technician
the functioning or operation working at heights and follow instructions well. A well to consider top drive issues. must be notified of any concerns or incidents
of a Tesco Top Drive. It is to thought out pre-job meeting and the right people can involving Tesco equipment and its operation.
be used only in conjunction make rigging up the top drive much easier and safer. To slip and cut drilling line, obviously the weight of the
with the orientation and on The torque system includes the following: top drive cannot hang from the same line as the blocks OTHER THAN AS DESCRIBED IN THE
site supervision provided by 1. Torque Track alone did. The top drive technician will assist you in PRECEDING PARAGRAPH, TESCO
Tesco personnel. The Tesco 2. Torque Anchor Beam determining the length of a block-hanging sling to be
CORPORATION, ITS AFFILIATED COMPANIES
3. T-Bar installed in the derrick to a suitable beam so that the
Top Drive Technician must AND EMPLOYEES ASSUME NO
In the next few pages we will describe the parts of the top drive is positioned at floor level. If your rig is already
be notified of any concerns RESPONSIBILITY FOR USE OF THE
torque system, what they do and some effective ways fitted with a block-hanging sling, the sling and the eye
or incidents involving Tesco of installing them. INFORMATION CONTAINED IN THIS MANUAL.
on the blocks should be rated to support the weight of
equipment and its operation. the top drive as well as the traveling block. The top
Torque Track: drive will have to be connected to the drillstring and set
OTHER THAN AS Tesco Corporation (“Tesco”) has made every effort
in the slips as low as the block-hanging sling will allow,
The torque track consists of varying lengths of track.
DESCRIBED IN THE to help distribute the additional weight of the top drive.
to ensure that this manual describes the basic
Each section is designed to fit another by lining up the
PRECEDING PARAGRAPH, knowledge needed to provide a quick reference for
flanges and tightening the bolts. The length of the track
TESCO CORPORATION, ITS AFFILIATED Note – When performing a slip and cut with a top top drive operators.
depends on the size of the rig mast but in all cases the
COMPANIES AND drive it is possible to pump fluid into the well if
bottom of the track, called the deflector section, should
EMPLOYEES ASSUME NO necessary.
be between 7 and 8 feet from the floor. The track is
RESPONSIBILITY FOR USE hung by attaching an adjustable hanging cluster to a This manual is to be used in conjunction
Important – The blocks should never be hung from
OF THE INFORMATION pad eye that has been welded to the crown’s beams.
a floor tugger. with an orientation and on site
CONTAINED IN THIS The bottom of the track is secured to the derrick by
MANUAL. bolting on the T-bar and fastening it in to the torque supervision.
Top Drive Maintenance:
anchor beam. Using turnbuckles we can center the
The regular daily maintenance and inspections on the
At Tesco, we put a lot of effort track and provide rigidity along the length of the derrick.
top drive do not have to interfere with rig operations. In
The turnbuckles are attached to the torque track and
into developing ways to make order to keep the top drive running safely and efficiently,
derrick using clamps or by welding in pad eyes on the
drilling a well more efficient. up to 15 minutes every tour must be available to service
derrick beams prior to rig up.
Training the operators to run the equipment. The top drive technician’s knowledge
the equipment in the most of drilling allows him to choose a ‘window of opportunity’
In some cases our technicians may pre-assemble the
effective manner makes the to do this when the top drive is accessible from a ladder
torque track on the ground and hoist up to 2 sections at
job easier by reducing on the rig floor, while minimizing the impact on the
once. When hoisting the torque track, good
customer’s operation.
downtime and safer by communication and the use of a hold back line are
eliminating the risk of injury to required.
If any service or repairs need to be done on the top
workers. drive, all of the drawworks controls and the driller’s
Once the first section of track has been lifted to the drill
panel must be locked out and tagged to ensure the
This manual will provide you floor with the tugger line, it is then lowered through the
safety of the personnel.
rotary table so that the top of the track can be attached
with information to present to your crew during a
to the traveling block. After raising the track above the
pre-job safety meeting or whenever you need to Important – The top drive technician must be
floor with the blocks, the rest of the track sections can
reinforce what you already know. notified of any concerns or incidents involving
be hoisted to the floor and placed in the rotary table
Tesco equipment.
individually and bolted into the previous sections.

Page 4 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 17
By decreasing forward pump pressure, there will not Logging: When the torque track is fastened together in the length T-Bar:
be enough hydraulic flow to rotate the pipe. Now, slowly When using the hydraulic elevators to support a wire required to allow the top drive to travel between the The T-bar is a solid steel arm that bolts on to the torque
‘increase’ the pumps until the pipe begins to rotate. line sheave, disconnect the hydraulic hoses at the highest and lowest points in the derrick, it then needs track at it’s lowest point and takes the drilling torque
Maintain enough pressure on the hydraulic gauge to elevator quick connects to reduce the chances of to be secured to the crown. This is done by attaching from the top drive and transfers it through the anchor
hold drillstring in torsion without reaching the torque accidental opening. the hanging cluster at the top of the track to a welded- beam and across the derrick.
relief setting on the top drive. When maintaining static on pad eye with a shackle.
torque over extended time periods, it is recommended Note: The hoses should also be disconnected to prevent Next we need to position the torque track so that we The T-bar can be installed
to increase the pumps to a value less than the torque accidental opening in any other operation where the can fasten the t-bar to it and make sure that the torque in the torque anchor as
relief setting and allow the pumps to control the desired elevators support a load other than the drillstring (for anchor beam will accept it as well. soon as the beam is
torque. If the top drive torque relief is activated, the example, when a set of secondary elevators are secured to the derrick.
hydraulic oil passing through the relief over time, will supported from a nubbin in the hydraulic elevators). Once the torque track is in place the turnbuckles need
create excessive heat. The hot oil may, in turn, activate to be attached to it and secured in predetermined The T-bar can also be
a power unit shut down, resulting in an untimely torque locations on the derrick strongbacks. Using these bolted on to the torque
Running Casing:
release of the drill string. adjustable, locking turnbuckles we can center the track track just before the track
Using the top drive for
and help provide rigidity along the length of it. is hung from the crown when the bolt pattern section of
running casing offers
The power module is equipped with numerous track is at a comfortable height.
some advantages over
safety shutdowns. When the hydraulic oil reaches When the torque system is installed it should be straight
conventional methods.
the high oil temperature shutdown setting, the prime and at the proper distance from well center and the rig When the T-bar is attached to the torque track and
At the customer ’s
mover will shut down. This should be avoided, floor. the track is hanging from the pad eye at the crown,
request, Tesco can
especially in situations where hole problems are the T-bar should be just slightly higher than the
provide a crossover sub
encountered.
to connect the quill to
Torque Anchor Beam: anchor. This way, when the anchor clamp is
the casing, eliminating The torque anchor beam tightened down it will pull the track into tension.
Continue working the drillstring while maintaining torque accepts the torque directly
the need to rig-up
with the top drive until a free point is established. When from the quill and transfers it After all the main components of the torque system are
chiksans and fill up
the pipe begins to rotate at this torque setting keep to the derrick. On some rigs installed the turnbuckles can be adjusted to straighten
hoses. The top drive
raising and lowering pipe in the free point increasing we can weld the anchor in the track.
also provides pipe handling functions to make handling
the travel distance until the obstruction is cleared. place, on others we need to
casing much simpler and safer.
install the beam using clamps. Note: All shackles, turnbuckles, and similar items should
Jarring: The beam is usually attached be secured with cotter pins or safety wires, to prevent
Cementing: to the lowest strongback
If jarring is required, the torque applied to the drillstring accidental loosening.
Unless it is absolutely necessary, never attempt to where the energy can be
will need to be released. By slowly decreasing the quill
cement through the top drive. With the exception of displaced across the widest
torque shown on the hydraulic gauge, the reactive The Power Module:
this rule, cementing with a top drive is similar to point of the derrick. Periodic
torque in the string will overcome the quill torque and The Tesco hydraulic
conventional methods. inspection of the welds or the
the pipe will, in a controlled manner, rotate in reverse top drive comes with a
until torsion is released. Once this is done, set the slips clamps tightness must be building containing a
in order to break out the top drive. performed to prevent any prime mover that
movement of the torque track. drives a series of
Tesco does not recommend jarring with the v a r i a b l e
drillstring connected to the quill. The drillstring Position the hoisting sling and tugger line on the center displacement, bi-
should be suspended from the elevators before of the load. Carefully raise the anchor beam to the directional hydraulic
jarring commences. appropriate strongback. pumps. These pumps
send hydraulic flow
Disconnect hydraulic hoses at the elevator quick The top drive technician will need assistance to position through a closed
connects to reduce the chances of elevators opening the anchor beam on the strongback and hold it in place loop, high-pressure system to the top drive motor(s),
accidentally. until the clamps can be secured. which provide quill rotation before returning to the skid
to be filtered. Additional gear pumps send hydraulic
After any jarring is done the top drive technician will Safety - Make sure all workers are connected to an flow through an auxiliary system to the top drive,
need the time to perform a visual inspection of the top approved fall arrest system. operating the various robotic functions as well as
drive components and fill out a ‘Post Jarring Checklist’. circulate oil through a filtration and cooling system
In the event of excessive jarring a load path inspection before returning to the reservoir. The power module
may need to be performed at the earliest convenience. also contains an electrical panel, which accepts a 480

Page 16 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 5
or 600 volt AC input from the rig’s generators and
converts it to other voltages that operate the electrical
components of the top drive system. When spotting
the power module, it must be lifted using proper hoisting
techniques and placed in an ideal position for the service
loop to reach the derrick. If the service reel is not
attached to the power module skid, then it should be
placed on rig matting with the power module and
connected to the auxiliary hydraulic system.
The Service Loop:
The service loop sends and receives electrical
communication from the power unit and the driller’s
panel as well as hydraulic flow to and from the top drive.
It is critical that these lines not be damaged due to
improper lifting or obstructions in the derrick. Once the
service loop has been installed, observe its movement
along the entire travel of the top drive.
The service loop should make no contact with any
part of the rig.
Using a soft hoisting sling and the floor tugger, the
operator will raise the service loop into the derrick while
the top drive technician reels out enough slack to install
the lines into the hose saddle and capture clamp.
Once the hose saddle position has been determined it
is then attached to the derrick. The rig design and top
drive model will determine where the saddle is located.
A safety sling should always be installed around the
hose saddle and hoses, and then attached to either a
welded in pad eye or a suitable beam. Safety slings
should also be installed between the hose ends and
the top drive.
The Top Drive:
The top drive is a heavy, unbalanced load and should
be carefully handled to prevent injury or equipment
damage. The top drive technician should always be
present to oversee any loading or unloading of Tesco
equipment.
Once the top drive arrives on location, it should be
placed on the catwalk so that it can be hoisted to the rig
floor using 2 point, load rated slings attached to the
blocks. A hold back line should be used to prevent the
top drive from shifting once it is lifted.
Page 6
Before the top drive is raised
to the rig floor, the torque
bushing and extend frame
need to be installed onto the
torque track and pinned in
place.
With the top drive stand
positioned over hole center
and secured to the derrick
legs using chains and
boomers, the swivel can now
be properly doped and
threaded into the quill with a
chain tong.
On top drives equipped
with an integrated swivel,
the swivel bail or yoke is
directly installed into the becket or block hook.
Now the top drive can be lifted from the transport stand
by raising the blocks and the transport stand removed
from the rig floor.
Using the blocks, line-up the pin holes between the
extend frame and the top drive and insert the drive pins
and keepers.
With the weight of the top drive hanging on the overhead
blocks and swivel, remove the torque bushing pin.
The top drive technician will connect the service loop to
the top drive and install the driller’s panel.
With the power unit now running and the service loop
and drillers panel connected to the top drive, we can
now make up the swivel to the specified torque. To do
this the off-drillers side tongs must be raised to the
required height to bite against the swivel or cross over
and back up slings attached to a suitable point on the
derrick.
It is critical that the bottom of the top drive be
secured with a cross chain on the grabber leg or a
joint of heavy weight drill pipe connected to the
saver sub and set in the slips - or both. Torque
should always be applied to the swivel connection
in ‘drill mode’ and only the required personnel to
do the job should remain on the rig floor.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Tip: If the top drive will rotate and everything else is
operating normally, double check that the cold climate
button has not been accidentally operated.
Reaming:
Back reaming out of the hole is one of the greatest
features the Tesco top drive provides. These steps
should be followed before commencing:
Note – Reaming is to commence only at operator’s
discretion and until the driller is experienced with
this operation, the Tesco technician should be
alerted.
1. Ensure the correct saver sub is installed on the top
drive and keep it properly doped while reaming or
back-reaming.
2. Connect the top drive to the drillstring.
3. Open the mud saver valve.
4. Start the mud pumps and establish circulation.
5. Remove the slips.
6. Select ‘drill’ mode.
7. Pumps ‘forward’ Set quill speed to 30-40 RPM.
8. Hoist the drill string and close the elevators on
the stand.
9. Work the drill string until free of obstruction.
When you are ready to rack the stand in the derrick,
the procedure is as follows:
1. Stop rotation.
2. Stop the mud pumps.
3. Set the slips.
4. Break out the lowest connection with the rig tongs.
5. Hoist stand out of the stump and allow the pipe to
drain.
6. Close the mud saver valve.
7. Lower the stand to approximately 2 inches above
the rotary table.
8. Ensure the grabber is in position at the top tool joint.
9. Close the grabber and break out the top drive.
10. Once the top drive is unscrewed from the pipe, open
the grabber and the stand will rest on the floor.
11. Hoist the top drive until the elevators pick up the
stand.
12. Link tilt forward until the derrickhand has control of
the stand and it has been placed in the birdbath.
13. Open the elevators.
Top Drive Rig Floor Safety Orientation Doghouse Manual
14. Link tilt back to vertical.
15. Lower the top drive to the floor and continue back
reaming if necessary.
If an obstruction is encountered when tripping in the
hole, or if for any reason it is necessary to establish
circulation, i.e. well control, the top drive can be
connected to the drillstring quickly by following these
steps:
1. If an obstruction is encountered, hoist until the
drillstring is free, and a connection is at floor level.
2. Set the slips.
3. Lower the top drive and guide the top tool joint into
the grabber. Set backup tongs on tool joint at floor
level.
4. Select ‘connection’ mode.
5. Rotate the top drive into the top tool joint and
shoulder it up.
6. Make up the connection to the specified torque.
7. Open the mud saver valve.
8. Remove the tongs and the slips.
9. Start the mud pumps and establish circulation.
10. Select ‘drill’ mode.
11. Set quill speed to 30-40 RPM.
12. Ream through the obstruction until the string is free.
13. Lower top drive to the floor and disconnect the
topdrive – see, break out connection procedures.
Working Tight Hole:
It is important to know that when torque is applied
to the drillstring you cannot pull up to the maximum
force that the pipe is rated for. The top drive
technician will provide information on specific
classes of tubulars and their torsion/tension
thresholds.
In tight hole situations, it will be necessary to free the
pipe using the top drive. With the top drive, the ability
to maintain mud pump flow, raise and lower the drillstring
and hold torque all at the same time is possible. It is
recommended that when working tight hole, some
torque can be applied to the drillstring.
This is best done by selecting:
1. ‘Drill’ mode
2. ‘Decrease’ pumps
3. ‘Forward’ pumps
4. Slowly ‘Increase’ pumps
Page 15

The amount of loop pressure needed to hold the
drillstring when the grabber is opened will change as
depth, and angle of build increase. This is why you
should record a downhole torque history, because the
x value will be easier to predict.
Turn the string to the left by decreasing loop pressure
(‘decrease pumps’), and, if there is not much reactive
torque present, select ‘reverse’ until positioning is
complete, then close the grabber.
Note: The maximum reverse torque is set to prevent
the string unscrewing. Do not engage the ‘breakout’
function or the drillstring could come apart.
Tripping:
The Tesco top drive reduces the amount of time and
work involved in tripping and reaming by giving you the
ability to thread into the drillstring at any point in the
derrick. This is useful when encountering hole problems
while tripping (for instance, pulling tight, bridging off or
when a kick is evident). In short, any time when the
need to pump fluid into the well exists, it can be done
without having to position the drillstring at floor level in
order to install the kelly.
Tripping pipe with a top drive is similar to conventional
methods, with the exception that the robotic functions
ease pipe-handling procedures. At no time is it
necessary for the rig crew to position the elevators or
open and close them. The link tilt function can push
the stand of pipe to be racked to the worker, both on
the rig floor and to the derrickhand. When running in
the hole, the derrickhand does not need to lean out to
throw the stand in the elevators; he can simply ease
the stand into the elevators, which are extended toward
him. Once the stand is placed in the elevators, they
can be closed hydraulically. After the stand is racked in
the derrick or added to the string the links should be
returned to the vertical hanging position by selecting
the ‘float’ function.
Important – The links and elevators should never
be manually operated by a worker.
Cold Climate:
When the hydraulic top drive is working in a freezing
environment, the oil quickly becomes thick and this will
reduce its effectiveness. While drilling, the heat from
the top drive motor(s) warms the oil enough so that this
is not a concern, but whenever the quill is not rotating,
such as when you are slide drilling or tripping, the cold
Page 14
Chapter 2
climate function should be used. To activate cold
climate follow these steps: Component Identification
1. Push in the cold climate button (on the left side of
the drillers panel).
Top Drive:
2. Select engine speed ‘slow’.
3. ‘Drill’ mode.
4. ‘Forward’ pumps.
5. ‘Increase or decrease’ pumps, to maintain 700psi
on the hydraulic pressure gauge.
When the cold climate button is pushed in it de-
energizes the circuit to the top drive speed control valve
and allows the flow of loop oil to pass through the motor
manifold and circulates the closed loop system without
turning the quill.
Selecting engine speed slow brings the prime mover to
idle speed for cold climate operation. This saves overall
wear and tear on the engine when it has a low load on
it.
Drill mode allows you to control the hydraulic pumps
internal swash plates, which command the amount of
oil flow to maintain 700psi.
Forward pumps directs the oil flow in such a way that it
passes through the maximum amount of filtration before
going through the pumps again.
Follow these steps in order to properly disengage the
cold climate function:
1. ‘Neutral’ pumps.
2. ‘Connection’ mode.
3. ‘Neutral’ engine speed.
4. Pull out the cold climate button.
By selecting neutral pumps, the flow of hydraulic oil is
stopped.
Important: Never push out the cold climate button
without the preceding 3 steps.
Connection mode keeps the prime mover at an idle
when the engine speed is switched to neutral.
After pulling out the cold climate button the top drive
can now return to normal operation.
Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 7
Chapter 3 Chapter 6
The Rosemount Gauge receives a milliamp signal from Note: If the rig floor is too large to pickup singles from
The Drillers Panel a pressure transducer located on the top drive. The the v-door with the link tilt and extend, it is still possible Operations
to make double (or triple) connection. Make a single
Description: connection as described above. Raise the top drive
The drillers panel Drilling:
and joint of pipe. Place another joint of pipe in the
is a stainless steel When drilling ahead with a top drive, adhere to the same
mousehole and make up as per ‘off-bottom’ connection.
e n c l o s u r e safety and operating practices and procedures as with
Repeat if a ‘triple’ is required.
equipped with all conventional rotary drilling.
of the controls, Although it is possible to make up triple stands in the
indicator lights, Rotating Once you have made a connection and the
mouse hole with the top drive, it may be more
mounts, gauges slips have cleared the table, select ‘valve open’ and start
efficient to make up stands in advance and leave
and connectors up the mud pump, then select ‘drill’ mode immediately.
them racked in the derrick if drilling with triple stands
required to operate The preset functions in connection mode will be disabled
is required.
the top drive from and now you can manipulate the quill RPM by selecting
the driller ’s ‘forward’ and ‘increasing or decreasing’ the pumps.
position. All of the
controls are 24 Slide Drilling In order to hold toolface while sliding,
volts DC electric you must close the grabber on the saver sub, allow the
transducer measures the differential between the high
over hydraulic. The two main cables to the panel are grabber cylinder to pressure-up, and then switch the
and low pressure sides of the top drive hydraulic
37 pin conductor cables with each wire serving a specific ‘pumps – forward/reverse’, to neutral. The grabber light
motor(s). This measurement gives you the most
function. One 37-pin cable connects the power module will remain on.
accurate torque reading while drilling, when the
to the driller’s panel and the other connects the top drive hydraulic oil in the loop is in a high flow state.
with the driller’s panel. The four smaller cables are 4 or When sliding, the grabber is closed and the hoisting
5 pin Amphenol connectors which control input to the clutch interlock is activated. In order to work the
The Hydraulic Pressure Gauge is used primarily to
safety interlocks, overrides and digital gauges for quill drillstring you must push and hold the ‘override’ button
set the torque reliefs, which control the amount of torque
torque and RPM. on the brake handle control box while hoisting. This
that can be applied to the quill. This gauge is also very
allows the drawworks drum clutch to engage.
accurate when making and breaking connections, when
Positioning: the hydraulic oil in the loop is in a semi-static condition
When deciding where When running a mud motor, keep accurate records of
and pressure losses are at a minimum.
to mount the driller’s the reactive torque (motor pressure) in the string. At
panel it is important any given time, you may need to orient the toolface of
Indicator Lights: the downhole motor. To do this the grabber will need to
that your view of the rig There are indicator lights installed in the driller’s panel
floor from the driller’s be opened; if you do not track downhole torque history,
reminding you that a function is, or has been performed. turning the string in small increments will be impossible.
position is not The response to an illuminated indicator light should
obstructed and that Assuming that you know the amount of torque present,
be: follow these steps to orient the toolface:
you can reach the
controls well enough to Stop - Why it is illuminated and how will it effect
operate the drawworks and top drive simultaneously. 1. Select ‘drill forward’.
further operations? 2. Decrease the pumps so that x psi (the pressure equal
All of the cables to the panel should be routed in such a
manner that moving parts will not damage them and to the reactive torque) is present on the hydraulic
There are indicator lights for the following: pressure gauge.
they should be elevated from the floor. DC Power This green light should be illuminated at all 3. Select ‘grabber open’.
times, indicating that the power supply to the driller’s 4. If the value of x provides enough torque, the string
Instrument Gauges: panel is on. should not turn.
There are two digital gauges on the driller’s panel, the
RPM Gauge that meters quill rotation and the Grabber When the grabber is closed, the light will Turn the string to the right by selecting:
Rosemount Gauge, which reads quill torque. Separate come on and will not go off until ‘grabber open’ is
from the driller’s panel is the Hydraulic Pressure selected. 5. ‘Increase pumps’ until the pipe turns very slowly and
Gauge, which reads the closed loop pressure in psi. under control.
The RPM Gauge gives an exact reading of the quill Valve When the mud saver valve is closed, the light 6. When you have achieved the new orientation, quickly
speed. will come on will not go out until ‘valve open’ is selected. close the grabber.

Page 8 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 13
Chapter 5
Making Connections
Safety:
Making connections with a Tesco top drive greatly
reduces time and manpower needed to get back to
bottom and drilling ahead. We can add pipe to the
drillstring in single joints and double or triple stands.
When making a connection, many tasks are being
performed by the top drive and it is critical that all
personnel are aware of pinch point locations and
stand clear of the top drive. All connection torque
values must be agreed upon by the customer prior to
drilling, and a connection worksheet signed. The Tesco
technician sets the torque parameters and these cannot
be exceeded.
Breaking Out:
The top drive can be drilled down to floor height by
opening the elevators and selecting link tilt ‘back’. To
make a connection, rotation is stopped, the mud pumps
are turned off, the slips set, and drillers panel set to
‘connection’ mode.
Know the weight of the top drive and overhead
hoisting equipment. This amount should be read
on the weight indicator gauge when the slips are
set. If you have less than the weight of the top drive
on the weight indicator, the counter balance system
will not be able to lift the top drive out of the thread
box and thread damage will occur. If you have more
than the weight of the top drive reading on the
weight indicator, the threads will be damaged and
the top drive could bounce out of the threads and
also damage the seal face.
Once the mud pump SPM and standpipe pressure
gauge read zero, it is safe to close the mud saver valve.
Switch the grabber to ‘close’, wait for the dies to set,
and then select ‘reverse’. The connection will not break
until the ‘break out’ button is pushed and held. Once
the connection has broken, the break out button can
be released and the grabber opened. Continue
reversing until the connection is completely unthreaded
and the counter balance system has gently lifted the
top drive saver sub out of the thread box.
If preferred, connections can be made ‘off bottom’ by
hoisting one single through the table, before setting the
slips. The rig tongs must be used to break the
Page 12
connection instead of the top drive. In this method a
“working single” remains on the top drive.
Note: Make sure that all connections are properly
doped.
Making Up Singles:
Extend out and stab into the mousehole single. Latch
the rig tong on to mousehole single and rotate the quill
forward to shoulder up the connection.
Important – Do not torque the connection in the
mousehole with the top drive.
Carefully retract the top drive into the torque track while
hoisting out of mousehole. Position the new single
above hole center and slowly lower it into the stump.
Latch the rig tong on the stump and rotate the quill
forward to make up the connection to the specified
torque. The torque value will be read on both the
hydraulic pressure gauge and the Rosemount gauge.
Similar procedures are used for an ‘off-bottom
connection’, but extra care must be taken when hoisting
to retract the top drive and avoid contact with the
monkey-board.
Making Up Doubles:
Using the floor tugger, install one single in the
mousehole and another single on the v-door left
connected to the tugger. Extend top drive over the
mousehole and link tilt forward so that the elevators
can close on the v-door single. Hoist the v-door single
above the rig floor and stab it into the mousehole single.
Shoulder up the connection by using either a chain tong
or by carefully guiding the top of the new stand into the
top drive with the link tilt function and rotate the quill
until both connections have shouldered up. Use the rig
tongs to back up the single in the mousehole while
making up a connection with the top drive.
Important - Do not torque connection in the
mousehole with the top drive.
Now, carefully retract top drive into the torque track while
hoisting out of the mousehole. Ensure top drive and
blocks are clear of monkey-board. Position the new
stand above hole center and slowly lower it into the
stump. Latch the rig tong on to the stump and rotate
the quill forward and make up both connections to the
specified torque.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Auxiliary Pump This amber light will illuminate if the
auxiliary pump is already running and then a robotic
function is selected. This indicates that the hydraulic
pressure needed to operate the robotics has been
delivered. If you notice that the light is on, check to see
if any switches have been left in the energized state.
When the pump is left pressured-up, the oil return is
restricted and the oil must pass over a relief. When
this occurs, the hydraulic oil will quickly become very
hot and the pump may eventually fail.
If a robotic function is selected and this light does
not come on, the function has not occurred.
Pipe Handler Unlock When the pipe handler is
unlocked, a proximity switch located on the top drive
will activate a light on the drillers panel, indicating the
locking assembly has been disabled. There is also an
interlock associated with this circuit that will be
described in the following section. (Tesco Model HCI
only)
Safety Interlocks:
An interlock is a term used to describe an electrical
input from one function that prevents the use of another
by cutting off the flow of electrical current. Interlocks
are used on the top drive to minimize the possibility of
an unsafe condition. The following describes which
functions have interlocks, how they work and why:
Grabber When the grabber is switched to the closed
position, a signal is sent to the drawworks interlock
installed in the rig’s drawworks console. This device is
a solenoid actuated air valve, which closes and cuts off
the air supply to the hoisting clutch controls. This will
prevent the accidental lifting of the blocks when the top
drive quill is not connected to the tool joint against which
grabber has been closed (i.e. after a connection has
been broken). The grabber is not designed to accept
any significant amount of load; this could result in pulling
the grabber components from the top drive. Override
– In order to hold toolface while directional drilling, the
grabber will remain closed on the top tool joint. If the
drillstring needs to be worked while holding toolface,
the grabber close interlock must be overridden. To do
this, push and hold the red button, located on the
brake handle control box and hoist simultaneously.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Mud Saver Valve When the valve is switched to close
an interlock exactly like the
drawworks one is energized to cut
off the air supply to the mud pump
clutch controls. This prevents
accidentally starting of the mud pump
and dead-ending pump flow against
the mud saver valve.
Connection Mode/Forward To make a connection,
the driller’s panel must be switched to ‘connection’
mode. When in this mode, several preset functions
occur and the drawworks interlock is part of those
functions. Once the tool joint has been made up to
specified torque, it would be possible to leave the top
drive in ‘forward’ and hoist the drillstring to remove the
slips. The drillstring would then turn and the slip handles
could injure the floorhands trying to remove them. The
interlock cuts off the air supply to the hoisting clutch,
preventing this from happening. Once the slips have
been removed, do not switch to ‘forward’ until ‘drill’
mode has been selected.
Pipe Handler The improper use of the pipe handler
can have serious consequences, but with safety
interlocks and proper training we can minimize the risk
of any incidents. When the pipe handler “unlock” is
actuated, a proximity switch locks out the quill rotation
unless the pipe handler caution (rotate) button is pushed
and held while in ‘connection forward or reverse’.
(Tesco Top Drive Model HCI, ECI &EMI only)
Page 9
Chapter 4
and the top drive stalls. Return the ‘pumps’ switch from
Controls and Robotics forward to neutral and allow the pressure on the
hydraulic gauge to bleed off below 1000psi before
selecting grabber ‘open’.
Clearance and Visibility:
The top drive takes up much more space on the rig Allow 5 seconds for the grabber to fully open before
floor than a kelly would, so this work area must be kept switching the grabber to neutral.
clear of obstacles that may interfere with the movement
of the top drive and that of the personnel. When the Grabber Lift (Tesco Top Drive Model HMI, not
top drive is moving through the derrick, you must be equipped): A hydraulic
aware of it’s position at all times. Because you are not cylinder, located in the
always able to see the top drive, the other members of grabber leg, raises and
your crew must also watch and be aware of the top lowers the grabber to the
drive’s position and movement at all times. required height for backing-
up the tool joint. Always
Note: If you are unsure about any situation, stop position the grabber at the
and ask for help. This will save more time in the top tool joint before raising
end and reduce the likelihood of an incident the top drive from the floor
occurring. level. If for any reason,
such as having to begin a
Robotic Functions: trip before the stand has
Extend This feature allows the top drive to reach been drilled, you can simply
forward over the mouse hole, giving it the ability to make close the grabber to break-
up stands in the mouse hole for drilling as well as aiding out of the stand at the
the process of handling tools to and from the v-door. monkeyboard height
Note: An optional extend alarm is available if requested. without having to guess whether or not the grabber is
This device provides an alarm if the top drive is in the correct position.
extended.
Pipe Handler In order to turn the elevators in the
Note: If you leave the top drive extended out while direction needed for a certain operation, the pipe handler
hoisting with blocks, the top drive could make will have to be used. To perform this, proper operation
contact with the monkey board. is critical for worker and equipment safety.
Link Tilt Commonly known as ‘the bails’, the links can The following steps must be followed before
be tilted to move the elevators up to 35 degrees forward unlocking the pipe handler:
and 55 degrees back from vertical, extending the reach • All personnel must clear the area of the top drive,
of the top drive to perform many tasks associated with elevators, and links.
pipe handling. • Link tilt vertical (if possible, latch the elevators on the
pipe).
Grabber The grabber acts like a back-up tong and • Pumps to ‘neutral’.
closes onto a tool joint to arrest the reactive torque when • Pipe handler ‘unlock’ and return to neutral.
making up or breaking out a connection. • Grabber ‘close’ (on the saver sub).
• Pumps ‘forward’ or ‘reverse’.
Rule of thumb: Allow 10 seconds for the grabber • Push ‘pipe handler – caution’ button (rotate)
to close before applying torque.
When breaking out, close the grabber and leave the The pipe handler section of the top drive will now rotate
switch in the ‘close’ position until the connection breaks. up to 360 degrees at 4 RPM. Once the orientation of
Then open it while reversing out of the thread box. This the pipe handler is correct, these steps must be
way, you can hoist out of the tool joint once completely followed to disengage pipe handler rotation.
un-threaded without the interlock disabling the hoisting • Release ‘rotate or caution’ button.
clutch. For making-up a joint, leave the grabber switch • Pumps to neutral.
in the ‘close’ position until the specified torque is reached
Page 10 Top Drive Rig Floor Safety Orientation Doghouse Manual
• Grabber ‘open’.
• Pipe handler ‘lock’ and return to neutral - a visual
confirmation is critical to ensure the locking
mechanism has fully engaged the lock ring gear.
The top drive can now return to normal operation.
Hydraulic Elevators The Tesco top drive comes
equipped with
automatic
elevators, which
eliminate the
need to have a
person manually
operate them.
This gives the
ability to open
and close the elevators on extremely tall stands of BHA
and reduces worker exposure to additional hazards
associated with manual operation of the elevators. The
3-position switch must be turned to ‘open’ and a safety
push button held at the same time with no load in the
elevators for them to open. This way, selecting the
wrong switch cannot accidentally open the elevators.
The elevators can be closed by either switching to ‘close’
on the drillers panel or by pushing the close button
located on the brake handle control box. When closing
the elevators, visually confirm the latch has closed.
Mud Saver Valve and Actuator Tesco top drives
incorporate a double ball
mud saver valve with a
remote actuator to act as
both a mud saver and as an
emergency blow out
prevention valve. The
actuator is designed to
allow you to open or close
the mud saver valve at any
point in the derrick. It is critical that the actuator is
never functioned while the quill is rotating; this will
damage the internal components and lead to failure of
the actuator. When you select valve ‘close’ the actuator
will close with up to 5000 psi of hydrostatic well bore
pressure against it. Once you have selected valve ‘open’
the actuator will open and cannot be closed again for 7
seconds. This prevents the accidental re-closure of the
valve once the mud pumps have been started.
Top Drive Rig Floor Safety Orientation Doghouse Manual Page 11
Chapter 4
and the top drive stalls. Return the ‘pumps’ switch from
Controls and Robotics forward to neutral and allow the pressure on the
hydraulic gauge to bleed off below 1000psi before
selecting grabber ‘open’.
Clearance and Visibility:
The top drive takes up much more space on the rig Allow 5 seconds for the grabber to fully open before
floor than a kelly would, so this work area must be kept switching the grabber to neutral.
clear of obstacles that may interfere with the movement
of the top drive and that of the personnel. When the Grabber Lift (Tesco Top Drive Model HMI, not
top drive is moving through the derrick, you must be equipped): A hydraulic
aware of it’s position at all times. Because you are not cylinder, located in the
always able to see the top drive, the other members of grabber leg, raises and
your crew must also watch and be aware of the top lowers the grabber to the
drive’s position and movement at all times. required height for backing-
up the tool joint. Always
Note: If you are unsure about any situation, stop position the grabber at the
and ask for help. This will save more time in the top tool joint before raising
end and reduce the likelihood of an incident the top drive from the floor
occurring. level. If for any reason,
such as having to begin a
Robotic Functions: trip before the stand has
Extend This feature allows the top drive to reach been drilled, you can simply
forward over the mouse hole, giving it the ability to make close the grabber to break-
up stands in the mouse hole for drilling as well as aiding out of the stand at the
the process of handling tools to and from the v-door. monkeyboard height
Note: An optional extend alarm is available if requested. without having to guess whether or not the grabber is
This device provides an alarm if the top drive is in the correct position.
extended.
Pipe Handler In order to turn the elevators in the
Note: If you leave the top drive extended out while direction needed for a certain operation, the pipe handler
hoisting with blocks, the top drive could make will have to be used. To perform this, proper operation
contact with the monkey board. is critical for worker and equipment safety.
Link Tilt Commonly known as ‘the bails’, the links can The following steps must be followed before
be tilted to move the elevators up to 35 degrees forward unlocking the pipe handler:
and 55 degrees back from vertical, extending the reach • All personnel must clear the area of the top drive,
of the top drive to perform many tasks associated with elevators, and links.
pipe handling. • Link tilt vertical (if possible, latch the elevators on the
pipe).
Grabber The grabber acts like a back-up tong and • Pumps to ‘neutral’.
closes onto a tool joint to arrest the reactive torque when • Pipe handler ‘unlock’ and return to neutral.
making up or breaking out a connection. • Grabber ‘close’ (on the saver sub).
• Pumps ‘forward’ or ‘reverse’.
Rule of thumb: Allow 10 seconds for the grabber • Push ‘pipe handler – caution’ button (rotate)
to close before applying torque.
When breaking out, close the grabber and leave the The pipe handler section of the top drive will now rotate
switch in the ‘close’ position until the connection breaks. up to 360 degrees at 4 RPM. Once the orientation of
Then open it while reversing out of the thread box. This the pipe handler is correct, these steps must be
way, you can hoist out of the tool joint once completely followed to disengage pipe handler rotation.
un-threaded without the interlock disabling the hoisting • Release ‘rotate or caution’ button.
clutch. For making-up a joint, leave the grabber switch • Pumps to neutral.
in the ‘close’ position until the specified torque is reached
Page 10 Top Drive Rig Floor Safety Orientation Doghouse Manual
• Grabber ‘open’.
• Pipe handler ‘lock’ and return to neutral - a visual
confirmation is critical to ensure the locking
mechanism has fully engaged the lock ring gear.
The top drive can now return to normal operation.
Hydraulic Elevators The Tesco top drive comes
equipped with
automatic
elevators, which
eliminate the
need to have a
person manually
operate them.
This gives the
ability to open
and close the elevators on extremely tall stands of BHA
and reduces worker exposure to additional hazards
associated with manual operation of the elevators. The
3-position switch must be turned to ‘open’ and a safety
push button held at the same time with no load in the
elevators for them to open. This way, selecting the
wrong switch cannot accidentally open the elevators.
The elevators can be closed by either switching to ‘close’
on the drillers panel or by pushing the close button
located on the brake handle control box. When closing
the elevators, visually confirm the latch has closed.
Mud Saver Valve and Actuator Tesco top drives
incorporate a double ball
mud saver valve with a
remote actuator to act as
both a mud saver and as an
emergency blow out
prevention valve. The
actuator is designed to
allow you to open or close
the mud saver valve at any
point in the derrick. It is critical that the actuator is
never functioned while the quill is rotating; this will
damage the internal components and lead to failure of
the actuator. When you select valve ‘close’ the actuator
will close with up to 5000 psi of hydrostatic well bore
pressure against it. Once you have selected valve ‘open’
the actuator will open and cannot be closed again for 7
seconds. This prevents the accidental re-closure of the
valve once the mud pumps have been started.
Top Drive Rig Floor Safety Orientation Doghouse Manual Page 11
Chapter 5
Making Connections
Safety:
Making connections with a Tesco top drive greatly
reduces time and manpower needed to get back to
bottom and drilling ahead. We can add pipe to the
drillstring in single joints and double or triple stands.
When making a connection, many tasks are being
performed by the top drive and it is critical that all
personnel are aware of pinch point locations and
stand clear of the top drive. All connection torque
values must be agreed upon by the customer prior to
drilling, and a connection worksheet signed. The Tesco
technician sets the torque parameters and these cannot
be exceeded.
Breaking Out:
The top drive can be drilled down to floor height by
opening the elevators and selecting link tilt ‘back’. To
make a connection, rotation is stopped, the mud pumps
are turned off, the slips set, and drillers panel set to
‘connection’ mode.
Know the weight of the top drive and overhead
hoisting equipment. This amount should be read
on the weight indicator gauge when the slips are
set. If you have less than the weight of the top drive
on the weight indicator, the counter balance system
will not be able to lift the top drive out of the thread
box and thread damage will occur. If you have more
than the weight of the top drive reading on the
weight indicator, the threads will be damaged and
the top drive could bounce out of the threads and
also damage the seal face.
Once the mud pump SPM and standpipe pressure
gauge read zero, it is safe to close the mud saver valve.
Switch the grabber to ‘close’, wait for the dies to set,
and then select ‘reverse’. The connection will not break
until the ‘break out’ button is pushed and held. Once
the connection has broken, the break out button can
be released and the grabber opened. Continue
reversing until the connection is completely unthreaded
and the counter balance system has gently lifted the
top drive saver sub out of the thread box.
If preferred, connections can be made ‘off bottom’ by
hoisting one single through the table, before setting the
slips. The rig tongs must be used to break the
Page 12
connection instead of the top drive. In this method a
“working single” remains on the top drive.
Note: Make sure that all connections are properly
doped.
Making Up Singles:
Extend out and stab into the mousehole single. Latch
the rig tong on to mousehole single and rotate the quill
forward to shoulder up the connection.
Important – Do not torque the connection in the
mousehole with the top drive.
Carefully retract the top drive into the torque track while
hoisting out of mousehole. Position the new single
above hole center and slowly lower it into the stump.
Latch the rig tong on the stump and rotate the quill
forward to make up the connection to the specified
torque. The torque value will be read on both the
hydraulic pressure gauge and the Rosemount gauge.
Similar procedures are used for an ‘off-bottom
connection’, but extra care must be taken when hoisting
to retract the top drive and avoid contact with the
monkey-board.
Making Up Doubles:
Using the floor tugger, install one single in the
mousehole and another single on the v-door left
connected to the tugger. Extend top drive over the
mousehole and link tilt forward so that the elevators
can close on the v-door single. Hoist the v-door single
above the rig floor and stab it into the mousehole single.
Shoulder up the connection by using either a chain tong
or by carefully guiding the top of the new stand into the
top drive with the link tilt function and rotate the quill
until both connections have shouldered up. Use the rig
tongs to back up the single in the mousehole while
making up a connection with the top drive.
Important - Do not torque connection in the
mousehole with the top drive.
Now, carefully retract top drive into the torque track while
hoisting out of the mousehole. Ensure top drive and
blocks are clear of monkey-board. Position the new
stand above hole center and slowly lower it into the
stump. Latch the rig tong on to the stump and rotate
the quill forward and make up both connections to the
specified torque.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Auxiliary Pump This amber light will illuminate if the
auxiliary pump is already running and then a robotic
function is selected. This indicates that the hydraulic
pressure needed to operate the robotics has been
delivered. If you notice that the light is on, check to see
if any switches have been left in the energized state.
When the pump is left pressured-up, the oil return is
restricted and the oil must pass over a relief. When
this occurs, the hydraulic oil will quickly become very
hot and the pump may eventually fail.
If a robotic function is selected and this light does
not come on, the function has not occurred.
Pipe Handler Unlock When the pipe handler is
unlocked, a proximity switch located on the top drive
will activate a light on the drillers panel, indicating the
locking assembly has been disabled. There is also an
interlock associated with this circuit that will be
described in the following section. (Tesco Model HCI
only)
Safety Interlocks:
An interlock is a term used to describe an electrical
input from one function that prevents the use of another
by cutting off the flow of electrical current. Interlocks
are used on the top drive to minimize the possibility of
an unsafe condition. The following describes which
functions have interlocks, how they work and why:
Grabber When the grabber is switched to the closed
position, a signal is sent to the drawworks interlock
installed in the rig’s drawworks console. This device is
a solenoid actuated air valve, which closes and cuts off
the air supply to the hoisting clutch controls. This will
prevent the accidental lifting of the blocks when the top
drive quill is not connected to the tool joint against which
grabber has been closed (i.e. after a connection has
been broken). The grabber is not designed to accept
any significant amount of load; this could result in pulling
the grabber components from the top drive. Override
– In order to hold toolface while directional drilling, the
grabber will remain closed on the top tool joint. If the
drillstring needs to be worked while holding toolface,
the grabber close interlock must be overridden. To do
this, push and hold the red button, located on the
brake handle control box and hoist simultaneously.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Mud Saver Valve When the valve is switched to close
an interlock exactly like the
drawworks one is energized to cut
off the air supply to the mud pump
clutch controls. This prevents
accidentally starting of the mud pump
and dead-ending pump flow against
the mud saver valve.
Connection Mode/Forward To make a connection,
the driller’s panel must be switched to ‘connection’
mode. When in this mode, several preset functions
occur and the drawworks interlock is part of those
functions. Once the tool joint has been made up to
specified torque, it would be possible to leave the top
drive in ‘forward’ and hoist the drillstring to remove the
slips. The drillstring would then turn and the slip handles
could injure the floorhands trying to remove them. The
interlock cuts off the air supply to the hoisting clutch,
preventing this from happening. Once the slips have
been removed, do not switch to ‘forward’ until ‘drill’
mode has been selected.
Pipe Handler The improper use of the pipe handler
can have serious consequences, but with safety
interlocks and proper training we can minimize the risk
of any incidents. When the pipe handler “unlock” is
actuated, a proximity switch locks out the quill rotation
unless the pipe handler caution (rotate) button is pushed
and held while in ‘connection forward or reverse’.
(Tesco Top Drive Model HCI, ECI &EMI only)
Page 9
Chapter 3 Chapter 6
The Rosemount Gauge receives a milliamp signal from Note: If the rig floor is too large to pickup singles from
The Drillers Panel a pressure transducer located on the top drive. The the v-door with the link tilt and extend, it is still possible Operations
to make double (or triple) connection. Make a single
Description: connection as described above. Raise the top drive
The drillers panel Drilling:
and joint of pipe. Place another joint of pipe in the
is a stainless steel When drilling ahead with a top drive, adhere to the same
mousehole and make up as per ‘off-bottom’ connection.
e n c l o s u r e safety and operating practices and procedures as with
Repeat if a ‘triple’ is required.
equipped with all conventional rotary drilling.
of the controls, Although it is possible to make up triple stands in the
indicator lights, Rotating Once you have made a connection and the
mouse hole with the top drive, it may be more
mounts, gauges slips have cleared the table, select ‘valve open’ and start
efficient to make up stands in advance and leave
and connectors up the mud pump, then select ‘drill’ mode immediately.
them racked in the derrick if drilling with triple stands
required to operate The preset functions in connection mode will be disabled
is required.
the top drive from and now you can manipulate the quill RPM by selecting
the driller ’s ‘forward’ and ‘increasing or decreasing’ the pumps.
position. All of the
controls are 24 Slide Drilling In order to hold toolface while sliding,
volts DC electric you must close the grabber on the saver sub, allow the
transducer measures the differential between the high
over hydraulic. The two main cables to the panel are grabber cylinder to pressure-up, and then switch the
and low pressure sides of the top drive hydraulic
37 pin conductor cables with each wire serving a specific ‘pumps – forward/reverse’, to neutral. The grabber light
motor(s). This measurement gives you the most
function. One 37-pin cable connects the power module will remain on.
accurate torque reading while drilling, when the
to the driller’s panel and the other connects the top drive hydraulic oil in the loop is in a high flow state.
with the driller’s panel. The four smaller cables are 4 or When sliding, the grabber is closed and the hoisting
5 pin Amphenol connectors which control input to the clutch interlock is activated. In order to work the
The Hydraulic Pressure Gauge is used primarily to
safety interlocks, overrides and digital gauges for quill drillstring you must push and hold the ‘override’ button
set the torque reliefs, which control the amount of torque
torque and RPM. on the brake handle control box while hoisting. This
that can be applied to the quill. This gauge is also very
allows the drawworks drum clutch to engage.
accurate when making and breaking connections, when
Positioning: the hydraulic oil in the loop is in a semi-static condition
When deciding where When running a mud motor, keep accurate records of
and pressure losses are at a minimum.
to mount the driller’s the reactive torque (motor pressure) in the string. At
panel it is important any given time, you may need to orient the toolface of
Indicator Lights: the downhole motor. To do this the grabber will need to
that your view of the rig There are indicator lights installed in the driller’s panel
floor from the driller’s be opened; if you do not track downhole torque history,
reminding you that a function is, or has been performed. turning the string in small increments will be impossible.
position is not The response to an illuminated indicator light should
obstructed and that Assuming that you know the amount of torque present,
be: follow these steps to orient the toolface:
you can reach the
controls well enough to Stop - Why it is illuminated and how will it effect
operate the drawworks and top drive simultaneously. 1. Select ‘drill forward’.
further operations? 2. Decrease the pumps so that x psi (the pressure equal
All of the cables to the panel should be routed in such a
manner that moving parts will not damage them and to the reactive torque) is present on the hydraulic
There are indicator lights for the following: pressure gauge.
they should be elevated from the floor. DC Power This green light should be illuminated at all 3. Select ‘grabber open’.
times, indicating that the power supply to the driller’s 4. If the value of x provides enough torque, the string
Instrument Gauges: panel is on. should not turn.
There are two digital gauges on the driller’s panel, the
RPM Gauge that meters quill rotation and the Grabber When the grabber is closed, the light will Turn the string to the right by selecting:
Rosemount Gauge, which reads quill torque. Separate come on and will not go off until ‘grabber open’ is
from the driller’s panel is the Hydraulic Pressure selected. 5. ‘Increase pumps’ until the pipe turns very slowly and
Gauge, which reads the closed loop pressure in psi. under control.
The RPM Gauge gives an exact reading of the quill Valve When the mud saver valve is closed, the light 6. When you have achieved the new orientation, quickly
speed. will come on will not go out until ‘valve open’ is selected. close the grabber.

Page 8 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 13

The amount of loop pressure needed to hold the
drillstring when the grabber is opened will change as
depth, and angle of build increase. This is why you
should record a downhole torque history, because the
x value will be easier to predict.
Turn the string to the left by decreasing loop pressure
(‘decrease pumps’), and, if there is not much reactive
torque present, select ‘reverse’ until positioning is
complete, then close the grabber.
Note: The maximum reverse torque is set to prevent
the string unscrewing. Do not engage the ‘breakout’
function or the drillstring could come apart.
Tripping:
The Tesco top drive reduces the amount of time and
work involved in tripping and reaming by giving you the
ability to thread into the drillstring at any point in the
derrick. This is useful when encountering hole problems
while tripping (for instance, pulling tight, bridging off or
when a kick is evident). In short, any time when the
need to pump fluid into the well exists, it can be done
without having to position the drillstring at floor level in
order to install the kelly.
Tripping pipe with a top drive is similar to conventional
methods, with the exception that the robotic functions
ease pipe-handling procedures. At no time is it
necessary for the rig crew to position the elevators or
open and close them. The link tilt function can push
the stand of pipe to be racked to the worker, both on
the rig floor and to the derrickhand. When running in
the hole, the derrickhand does not need to lean out to
throw the stand in the elevators; he can simply ease
the stand into the elevators, which are extended toward
him. Once the stand is placed in the elevators, they
can be closed hydraulically. After the stand is racked in
the derrick or added to the string the links should be
returned to the vertical hanging position by selecting
the ‘float’ function.
Important – The links and elevators should never
be manually operated by a worker.
Cold Climate:
When the hydraulic top drive is working in a freezing
environment, the oil quickly becomes thick and this will
reduce its effectiveness. While drilling, the heat from
the top drive motor(s) warms the oil enough so that this
is not a concern, but whenever the quill is not rotating,
such as when you are slide drilling or tripping, the cold
Page 14
Chapter 2
climate function should be used. To activate cold
climate follow these steps: Component Identification
1. Push in the cold climate button (on the left side of
the drillers panel).
Top Drive:
2. Select engine speed ‘slow’.
3. ‘Drill’ mode.
4. ‘Forward’ pumps.
5. ‘Increase or decrease’ pumps, to maintain 700psi
on the hydraulic pressure gauge.
When the cold climate button is pushed in it de-
energizes the circuit to the top drive speed control valve
and allows the flow of loop oil to pass through the motor
manifold and circulates the closed loop system without
turning the quill.
Selecting engine speed slow brings the prime mover to
idle speed for cold climate operation. This saves overall
wear and tear on the engine when it has a low load on
it.
Drill mode allows you to control the hydraulic pumps
internal swash plates, which command the amount of
oil flow to maintain 700psi.
Forward pumps directs the oil flow in such a way that it
passes through the maximum amount of filtration before
going through the pumps again.
Follow these steps in order to properly disengage the
cold climate function:
1. ‘Neutral’ pumps.
2. ‘Connection’ mode.
3. ‘Neutral’ engine speed.
4. Pull out the cold climate button.
By selecting neutral pumps, the flow of hydraulic oil is
stopped.
Important: Never push out the cold climate button
without the preceding 3 steps.
Connection mode keeps the prime mover at an idle
when the engine speed is switched to neutral.
After pulling out the cold climate button the top drive
can now return to normal operation.
Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 7
or 600 volt AC input from the rig’s generators and
converts it to other voltages that operate the electrical
components of the top drive system. When spotting
the power module, it must be lifted using proper hoisting
techniques and placed in an ideal position for the service
loop to reach the derrick. If the service reel is not
attached to the power module skid, then it should be
placed on rig matting with the power module and
connected to the auxiliary hydraulic system.
The Service Loop:
The service loop sends and receives electrical
communication from the power unit and the driller’s
panel as well as hydraulic flow to and from the top drive.
It is critical that these lines not be damaged due to
improper lifting or obstructions in the derrick. Once the
service loop has been installed, observe its movement
along the entire travel of the top drive.
The service loop should make no contact with any
part of the rig.
Using a soft hoisting sling and the floor tugger, the
operator will raise the service loop into the derrick while
the top drive technician reels out enough slack to install
the lines into the hose saddle and capture clamp.
Once the hose saddle position has been determined it
is then attached to the derrick. The rig design and top
drive model will determine where the saddle is located.
A safety sling should always be installed around the
hose saddle and hoses, and then attached to either a
welded in pad eye or a suitable beam. Safety slings
should also be installed between the hose ends and
the top drive.
The Top Drive:
The top drive is a heavy, unbalanced load and should
be carefully handled to prevent injury or equipment
damage. The top drive technician should always be
present to oversee any loading or unloading of Tesco
equipment.
Once the top drive arrives on location, it should be
placed on the catwalk so that it can be hoisted to the rig
floor using 2 point, load rated slings attached to the
blocks. A hold back line should be used to prevent the
top drive from shifting once it is lifted.
Page 6
Before the top drive is raised
to the rig floor, the torque
bushing and extend frame
need to be installed onto the
torque track and pinned in
place.
With the top drive stand
positioned over hole center
and secured to the derrick
legs using chains and
boomers, the swivel can now
be properly doped and
threaded into the quill with a
chain tong.
On top drives equipped
with an integrated swivel,
the swivel bail or yoke is
directly installed into the becket or block hook.
Now the top drive can be lifted from the transport stand
by raising the blocks and the transport stand removed
from the rig floor.
Using the blocks, line-up the pin holes between the
extend frame and the top drive and insert the drive pins
and keepers.
With the weight of the top drive hanging on the overhead
blocks and swivel, remove the torque bushing pin.
The top drive technician will connect the service loop to
the top drive and install the driller’s panel.
With the power unit now running and the service loop
and drillers panel connected to the top drive, we can
now make up the swivel to the specified torque. To do
this the off-drillers side tongs must be raised to the
required height to bite against the swivel or cross over
and back up slings attached to a suitable point on the
derrick.
It is critical that the bottom of the top drive be
secured with a cross chain on the grabber leg or a
joint of heavy weight drill pipe connected to the
saver sub and set in the slips - or both. Torque
should always be applied to the swivel connection
in ‘drill mode’ and only the required personnel to
do the job should remain on the rig floor.
Top Drive Rig Floor Safety Orientation Doghouse Manual
Tip: If the top drive will rotate and everything else is
operating normally, double check that the cold climate
button has not been accidentally operated.
Reaming:
Back reaming out of the hole is one of the greatest
features the Tesco top drive provides. These steps
should be followed before commencing:
Note – Reaming is to commence only at operator’s
discretion and until the driller is experienced with
this operation, the Tesco technician should be
alerted.
1. Ensure the correct saver sub is installed on the top
drive and keep it properly doped while reaming or
back-reaming.
2. Connect the top drive to the drillstring.
3. Open the mud saver valve.
4. Start the mud pumps and establish circulation.
5. Remove the slips.
6. Select ‘drill’ mode.
7. Pumps ‘forward’ Set quill speed to 30-40 RPM.
8. Hoist the drill string and close the elevators on
the stand.
9. Work the drill string until free of obstruction.
When you are ready to rack the stand in the derrick,
the procedure is as follows:
1. Stop rotation.
2. Stop the mud pumps.
3. Set the slips.
4. Break out the lowest connection with the rig tongs.
5. Hoist stand out of the stump and allow the pipe to
drain.
6. Close the mud saver valve.
7. Lower the stand to approximately 2 inches above
the rotary table.
8. Ensure the grabber is in position at the top tool joint.
9. Close the grabber and break out the top drive.
10. Once the top drive is unscrewed from the pipe, open
the grabber and the stand will rest on the floor.
11. Hoist the top drive until the elevators pick up the
stand.
12. Link tilt forward until the derrickhand has control of
the stand and it has been placed in the birdbath.
13. Open the elevators.
Top Drive Rig Floor Safety Orientation Doghouse Manual
14. Link tilt back to vertical.
15. Lower the top drive to the floor and continue back
reaming if necessary.
If an obstruction is encountered when tripping in the
hole, or if for any reason it is necessary to establish
circulation, i.e. well control, the top drive can be
connected to the drillstring quickly by following these
steps:
1. If an obstruction is encountered, hoist until the
drillstring is free, and a connection is at floor level.
2. Set the slips.
3. Lower the top drive and guide the top tool joint into
the grabber. Set backup tongs on tool joint at floor
level.
4. Select ‘connection’ mode.
5. Rotate the top drive into the top tool joint and
shoulder it up.
6. Make up the connection to the specified torque.
7. Open the mud saver valve.
8. Remove the tongs and the slips.
9. Start the mud pumps and establish circulation.
10. Select ‘drill’ mode.
11. Set quill speed to 30-40 RPM.
12. Ream through the obstruction until the string is free.
13. Lower top drive to the floor and disconnect the
topdrive – see, break out connection procedures.
Working Tight Hole:
It is important to know that when torque is applied
to the drillstring you cannot pull up to the maximum
force that the pipe is rated for. The top drive
technician will provide information on specific
classes of tubulars and their torsion/tension
thresholds.
In tight hole situations, it will be necessary to free the
pipe using the top drive. With the top drive, the ability
to maintain mud pump flow, raise and lower the drillstring
and hold torque all at the same time is possible. It is
recommended that when working tight hole, some
torque can be applied to the drillstring.
This is best done by selecting:
1. ‘Drill’ mode
2. ‘Decrease’ pumps
3. ‘Forward’ pumps
4. Slowly ‘Increase’ pumps
Page 15
By decreasing forward pump pressure, there will not Logging: When the torque track is fastened together in the length T-Bar:
be enough hydraulic flow to rotate the pipe. Now, slowly When using the hydraulic elevators to support a wire required to allow the top drive to travel between the The T-bar is a solid steel arm that bolts on to the torque
‘increase’ the pumps until the pipe begins to rotate. line sheave, disconnect the hydraulic hoses at the highest and lowest points in the derrick, it then needs track at it’s lowest point and takes the drilling torque
Maintain enough pressure on the hydraulic gauge to elevator quick connects to reduce the chances of to be secured to the crown. This is done by attaching from the top drive and transfers it through the anchor
hold drillstring in torsion without reaching the torque accidental opening. the hanging cluster at the top of the track to a welded- beam and across the derrick.
relief setting on the top drive. When maintaining static on pad eye with a shackle.
torque over extended time periods, it is recommended Note: The hoses should also be disconnected to prevent Next we need to position the torque track so that we The T-bar can be installed
to increase the pumps to a value less than the torque accidental opening in any other operation where the can fasten the t-bar to it and make sure that the torque in the torque anchor as
relief setting and allow the pumps to control the desired elevators support a load other than the drillstring (for anchor beam will accept it as well. soon as the beam is
torque. If the top drive torque relief is activated, the example, when a set of secondary elevators are secured to the derrick.
hydraulic oil passing through the relief over time, will supported from a nubbin in the hydraulic elevators). Once the torque track is in place the turnbuckles need
create excessive heat. The hot oil may, in turn, activate to be attached to it and secured in predetermined The T-bar can also be
a power unit shut down, resulting in an untimely torque locations on the derrick strongbacks. Using these bolted on to the torque
Running Casing:
release of the drill string. adjustable, locking turnbuckles we can center the track track just before the track
Using the top drive for
and help provide rigidity along the length of it. is hung from the crown when the bolt pattern section of
running casing offers
The power module is equipped with numerous track is at a comfortable height.
some advantages over
safety shutdowns. When the hydraulic oil reaches When the torque system is installed it should be straight
conventional methods.
the high oil temperature shutdown setting, the prime and at the proper distance from well center and the rig When the T-bar is attached to the torque track and
At the customer ’s
mover will shut down. This should be avoided, floor. the track is hanging from the pad eye at the crown,
request, Tesco can
especially in situations where hole problems are the T-bar should be just slightly higher than the
provide a crossover sub
encountered.
to connect the quill to
Torque Anchor Beam: anchor. This way, when the anchor clamp is
the casing, eliminating The torque anchor beam tightened down it will pull the track into tension.
Continue working the drillstring while maintaining torque accepts the torque directly
the need to rig-up
with the top drive until a free point is established. When from the quill and transfers it After all the main components of the torque system are
chiksans and fill up
the pipe begins to rotate at this torque setting keep to the derrick. On some rigs installed the turnbuckles can be adjusted to straighten
hoses. The top drive
raising and lowering pipe in the free point increasing we can weld the anchor in the track.
also provides pipe handling functions to make handling
the travel distance until the obstruction is cleared. place, on others we need to
casing much simpler and safer.
install the beam using clamps. Note: All shackles, turnbuckles, and similar items should
Jarring: The beam is usually attached be secured with cotter pins or safety wires, to prevent
Cementing: to the lowest strongback
If jarring is required, the torque applied to the drillstring accidental loosening.
Unless it is absolutely necessary, never attempt to where the energy can be
will need to be released. By slowly decreasing the quill
cement through the top drive. With the exception of displaced across the widest
torque shown on the hydraulic gauge, the reactive The Power Module:
this rule, cementing with a top drive is similar to point of the derrick. Periodic
torque in the string will overcome the quill torque and The Tesco hydraulic
conventional methods. inspection of the welds or the
the pipe will, in a controlled manner, rotate in reverse top drive comes with a
until torsion is released. Once this is done, set the slips clamps tightness must be building containing a
in order to break out the top drive. performed to prevent any prime mover that
movement of the torque track. drives a series of
Tesco does not recommend jarring with the v a r i a b l e
drillstring connected to the quill. The drillstring Position the hoisting sling and tugger line on the center displacement, bi-
should be suspended from the elevators before of the load. Carefully raise the anchor beam to the directional hydraulic
jarring commences. appropriate strongback. pumps. These pumps
send hydraulic flow
Disconnect hydraulic hoses at the elevator quick The top drive technician will need assistance to position through a closed
connects to reduce the chances of elevators opening the anchor beam on the strongback and hold it in place loop, high-pressure system to the top drive motor(s),
accidentally. until the clamps can be secured. which provide quill rotation before returning to the skid
to be filtered. Additional gear pumps send hydraulic
After any jarring is done the top drive technician will Safety - Make sure all workers are connected to an flow through an auxiliary system to the top drive,
need the time to perform a visual inspection of the top approved fall arrest system. operating the various robotic functions as well as
drive components and fill out a ‘Post Jarring Checklist’. circulate oil through a filtration and cooling system
In the event of excessive jarring a load path inspection before returning to the reservoir. The power module
may need to be performed at the earliest convenience. also contains an electrical panel, which accepts a 480

Page 16 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 5
 Chapter 1 Chapter 7
INTRODUCTION RIGGING UP THE Top Drive Disclaimer
FOR DRILLERS EQUIPMENT Considerations This manual is intended to provide basic information
The Torque System: only, and does not constitute a comprehensive
This manual is intended to guide to the functioning or operation of a Tesco Top
After measuring the rig and determining the torque Slip and Cut Drilling Line:
provide basic information system configuration, the top drive technician will require Some daily rig operations change when a rig is fitted Drive. It is to be used only in conjunction with the
only, and does not constitute the help of a select number of crewmembers. As a with a top drive. Some simple procedures that your orientation and on site supervision provided by
a comprehensive guide to driller, it’s up to you to choose workers who are confident crew has performed regularly will need to be adjusted Tesco personnel. The Tesco Top Drive Technician
the functioning or operation working at heights and follow instructions well. A well to consider top drive issues. must be notified of any concerns or incidents
of a Tesco Top Drive. It is to thought out pre-job meeting and the right people can involving Tesco equipment and its operation.
be used only in conjunction make rigging up the top drive much easier and safer. To slip and cut drilling line, obviously the weight of the
with the orientation and on The torque system includes the following: top drive cannot hang from the same line as the blocks OTHER THAN AS DESCRIBED IN THE
site supervision provided by 1. Torque Track alone did. The top drive technician will assist you in PRECEDING PARAGRAPH, TESCO
Tesco personnel. The Tesco 2. Torque Anchor Beam determining the length of a block-hanging sling to be
CORPORATION, ITS AFFILIATED COMPANIES
3. T-Bar installed in the derrick to a suitable beam so that the
Top Drive Technician must AND EMPLOYEES ASSUME NO
In the next few pages we will describe the parts of the top drive is positioned at floor level. If your rig is already
be notified of any concerns RESPONSIBILITY FOR USE OF THE
torque system, what they do and some effective ways fitted with a block-hanging sling, the sling and the eye
or incidents involving Tesco of installing them. INFORMATION CONTAINED IN THIS MANUAL.
on the blocks should be rated to support the weight of
equipment and its operation. the top drive as well as the traveling block. The top
Torque Track: drive will have to be connected to the drillstring and set
OTHER THAN AS Tesco Corporation (“Tesco”) has made every effort
in the slips as low as the block-hanging sling will allow,
The torque track consists of varying lengths of track.
DESCRIBED IN THE to help distribute the additional weight of the top drive.
to ensure that this manual describes the basic
Each section is designed to fit another by lining up the
PRECEDING PARAGRAPH, knowledge needed to provide a quick reference for
flanges and tightening the bolts. The length of the track
TESCO CORPORATION, ITS AFFILIATED Note – When performing a slip and cut with a top top drive operators.
depends on the size of the rig mast but in all cases the
COMPANIES AND drive it is possible to pump fluid into the well if
bottom of the track, called the deflector section, should
EMPLOYEES ASSUME NO necessary.
be between 7 and 8 feet from the floor. The track is
RESPONSIBILITY FOR USE hung by attaching an adjustable hanging cluster to a This manual is to be used in conjunction
Important – The blocks should never be hung from
OF THE INFORMATION pad eye that has been welded to the crown’s beams.
a floor tugger. with an orientation and on site
CONTAINED IN THIS The bottom of the track is secured to the derrick by
MANUAL. bolting on the T-bar and fastening it in to the torque supervision.
Top Drive Maintenance:
anchor beam. Using turnbuckles we can center the
The regular daily maintenance and inspections on the
At Tesco, we put a lot of effort track and provide rigidity along the length of the derrick.
top drive do not have to interfere with rig operations. In
The turnbuckles are attached to the torque track and
into developing ways to make order to keep the top drive running safely and efficiently,
derrick using clamps or by welding in pad eyes on the
drilling a well more efficient. up to 15 minutes every tour must be available to service
derrick beams prior to rig up.
Training the operators to run the equipment. The top drive technician’s knowledge
the equipment in the most of drilling allows him to choose a ‘window of opportunity’
In some cases our technicians may pre-assemble the
effective manner makes the to do this when the top drive is accessible from a ladder
torque track on the ground and hoist up to 2 sections at
job easier by reducing on the rig floor, while minimizing the impact on the
once. When hoisting the torque track, good
customer’s operation.
downtime and safer by communication and the use of a hold back line are
eliminating the risk of injury to required.
If any service or repairs need to be done on the top
workers. drive, all of the drawworks controls and the driller’s
Once the first section of track has been lifted to the drill
panel must be locked out and tagged to ensure the
This manual will provide you floor with the tugger line, it is then lowered through the
safety of the personnel.
rotary table so that the top of the track can be attached
with information to present to your crew during a
to the traveling block. After raising the track above the
pre-job safety meeting or whenever you need to Important – The top drive technician must be
floor with the blocks, the rest of the track sections can
reinforce what you already know. notified of any concerns or incidents involving
be hoisted to the floor and placed in the rotary table
Tesco equipment.
individually and bolted into the previous sections.

Page 4 Top Drive Rig Floor Safety Orientation Doghouse Manual Top Drive Rig Floor Safety Orientation Doghouse Manual Page 17
 Bulletin 20900e

TOP DRIVES CASING DRILLING™ CASING RUNNING

Top Drive Rig Floor Safety

Orientation
Doghouse Manual

Due to ongoing product development, all specifications are subject to change without notice.
Printed in Canada / April 2004 / TC

The Drilling Innovation Company™

Email: topdrive@tescocorp.com Web: www.tescocorp.com

Corporate Headquarters
6204 - 6A Street S.E.
World Wide Operations
11330 Brittmoore Park Drive The Drilling Innovation Company™
Calgary, Alberta, Canada T2H 2B7 Houston, Texas, USA 77041 www.tescocorp.com
Tel: 403 233-0757 • Fax: 403 252-3362 Tel: 713 849-5900 • Fax: 713 849-0075