HMIS Top Drive System

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1 System Description HMIS Top Drive System 250TON HMIS 475HP DOCUMENT NAME: REV 2

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3 SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER Tesco Corporation ("TESCO") has made every effort to ensure that this document contains accurate and current information for the TESCO top drive, however, the document is intended to be used in conjunction with a complete training program and on-site supervision and TESCO does not warrant or guarantee that the information contained herein is either complete or accurate in every respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together with its directors, officers, employees and agents from and against all liability for personal injury, death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document. Tesco Corporation 2007 Contact Information Corporate Head Office 3993 W. Sam Houston Parkway No., Suite 100 Houston, Texas, USA Telephone: (713) Fax: (713) REV 2 250TON HMIS 475HP TESCO CORPORATION, 2007 I

4 REVISION INFORMATION SYSTEM DESCRIPTION Version Date Description of Changes Revision Information A April 2004 Engineering review, revisions, and additions. 1 Oct 2007 Added caution symbols to all warnings and caution notes. Added more safety warnings. Updated revision numbering to comply with new engineering numbering standards. 2 Nov 2007 New revision to remove CE-ATEX standards from manual. TESCO CORPORATION, TON HMIS 475HP REV 2 II

5 SYSTEM DESCRIPTION TABLE OF CONTENTS CHAPTER 1: ABOUT THIS DOCUMENT CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION Introduction and General Specifications Shipping Containers Container Container Container Top Drive Components Gearbox Load Collar and Load Nut Mudsaver Valve Pipe Handling Counter-Balance Swivel Top Drive Power Supplies Handling Frame Power Unit Prime Mover Pump Drive and Filter Manifold Hydraulic Oil Reservoir/Cooler Torque Arrest System Extend Frame and Extend Arms Torque Bushing Torque Track Torque Beam, Torque Anchor and T-bar Power (Closed-Loop) Hydraulic Hoses Auxiliary Hydraulics Case Drain Control Cables Driller s Panel Options Elevators and Elevator Links Subs Grabber Drill Pipe Guides Rotary Table Stabilizer Bushings Rotary Hose and Standpipe Extension Torque Arrest System REV 2 250TON HMIS 475HP TESCO CORPORATION, 2007 III

6 SYSTEM DESCRIPTION Other Available Options ENGINEERING SIGN-OFF TESCO CORPORATION, TON HMIS 475HP REV 2 IV

7 SYSTEM DESCRIPTION CHAPTER 1: ABOUT THIS DOCUMENT This document contains a description of the major components of the 250TON HMIS 475HP Top Drive System with integrated quill. A complete HMIS Top Drive System consists of the following: top drive power unit interconnecting service loop and reel torque arrest system associated buildings, containers and equipment This document provides a brief description of each major component, as well as a list of available spares and options. Table 1-1: Where to find more information For information on installation rig up commissioning pre-operational checklists rig out procedures setting torque and speed driller's panel functions and operating descriptions making connections drilling ahead tripping freeing stuck pipe load path inspections maintenance/service schedules component disassembly and reassembly TESCO manufactured parts and part numbers electrical schematics hydraulic schematics cooling schematics gearbox lubrication schematics available options and spares Refer to HMIS Installation Guide HMIS Operations Guide HMIS Maintenance Guide HMI Parts List System schematics TESCO Representative REV 2 250TON HMIS 475HP TESCO CORPORATION,

8 ABOUT THIS DOCUMENT SYSTEM DESCRIPTION TESCO CORPORATION, TON HMIS 475HP REV 2 2

9 SYSTEM DESCRIPTION CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION INTRODUCTION AND GENERAL SPECIFICATIONS The HMIS top drive is designed for use on small drilling rigs and workover rigs. The HMIS top drive is powered using an independent hydraulic power unit. To create the optimum power supply system required for each of its top drives, TESCO combines industry proven prime movers with its own series of hydraulic pump drives and filtration equipment. The HMIS top drive is powered using one of the following power unit configurations: 475 hp prime mover with a two-pump drive (Detroit Diesel Series 60)-most common 460 hp prime mover with a two-pump drive (Caterpillar 3406B) Metric unit conversions (in brackets) have been provided for convenience only. All product specifications use the original imperial units unless indicated otherwise. Note: All weight values are approximate. Table 2-1: HMIS Top Drive specifications Specification Top Drive Rated Capacity Weight of the top drive plus: elevators elevator links counter balance swivel Details 250TON HMIS 475HP 250 ton (226.8 metric ton) 8,900 lb. (4,037 kg) Length 13 ft. 5 in. (4.089 m) Width 33 in. (0.84 m) Horsepower Dependent on the prime mover: 475 hp (354.2 kw) 2 pump drive 460 hp (343.0 kw) 2 pump drive REV 2 250TON HMIS 475HP TESCO CORPORATION,

10 TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION Table 2-2: Torque Arrest System specifications Specification Weight of the following: torque track anchor beam torque bushing extend frame clamps Std Track Length Details 7,200 lb. ( kg) 91 ft. (27.7 m); more length is available SHIPPING CONTAINERS The HMIS top drive is typically shipped in ocean shipping containers. Each container is 20 ft (length) x 8 ft (width) x 8 ft 6 in. (height) (6.1 m x 2.4 m x 2.6 m). Container 1 Approximate weight: 20,000 lb. ( kg) Contents: top drive and transportation stand multi-conductor cable storage reels links spare parts Note: Some countries require that spare parts be shipped separately from the original equipment. In these cases, spare parts will be crated and shipped in a separate container. Container 2 Approximate weight: 18,000 lb. ( kg) Contents: power unit (without the hose reel skid) Container 3 Approximate weight: 18,000 lb. ( kg)contents: torque arrest system components one rig up basket hose reel skid TESCO CORPORATION, TON HMIS 475HP REV 2 4

11 SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION TOP DRIVE COMPONENTS Figure 2-1: HMIS Top Drive general assembly 1. Torque Bushing 72 in. 2. Swivel Link and Counter-Balance 3. Swivel Station Manifold 5. Spoon Assembly 6. Motor Manifold 7. Link Carrier Assembly 8. Gearbox and Spline Drive Assembly 9. Load Nut and Load Collar 10.Link Tilt Cylinders 11.Mudsaver Valve 12.Grabber (with legs) 13.Elevator Link Tilt Assembly 14.Elevator 15.Torque Track Assembly REV 2 250TON HMIS 475HP TESCO CORPORATION,

12 TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION Gearbox The gearbox couples one hydraulic motor to the gear train. The motor is a bi-directional hydraulic vane type, and it has pressure ratings of 4,000 psi (27.6 MPa) continuous and 4,500 psi (31.0 MPa) intermittent. The HMIS top drive system is configured with a standard gear ratio of 2.19:1. An optional 1.64:1 gear ratio is also available. The gearbox houses gear reduction and forced lubrication systems as required for the unit. The integral drive hub is internally splined to accept the integrated swivel and quill. Load Collar and Load Nut The load collar and load nut transfer loads from the elevator links to the quill. Mudsaver Valve The mudsaver valve is a double-ball crank valve that acts as a mudsaver. It replaces the upper and lower Kelly cock. The valve does not descend below the rotary table, except in emergency situations, and it is always easily accessible. The mudsaver valve actuator can be operated remotely from the driller s panel.! Caution: The actuated upper ball valve is not for well control; it functions solely as a mudsaver. The manual operating lower valve is for well control. Ensure that the valve selected can fit into the existing casing. Pipe Handling The pipe handling abilities of the HMIS include the following: Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35 forward from the vertical position and 55 backward from the vertical position. Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking connections at any point in the mast. The grabber will accommodate tool joints from 2-3/8 in. to 5 in. OD. Counter-Balance The top drive features an automatic thread feed compensation for make up and break out operations. TESCO CORPORATION, TON HMIS 475HP REV 2 6

13 SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION Swivel The HMIS top drive features a drilling swivel with an integrated one-piece quill. This configuration offers the following advantages: no connections from the swivel bearing to the top of the mudsaver valve increased reliability/reduced maintenance decrease in the overall length and weight of the top drive readily available replacement parts Top Drive Power Supplies The top drive motor is powered by two axial piston pumps, which are located on the rear of the prime mover. All top drive robotic functions are powered by an auxiliary hydraulic system, which is located on the prime mover module. Handling Frame The top drive is shipped in its own handling frame. This frame allows you to transport and handle the top drive by using standard rig moving equipment. POWER UNIT The HMIS Top Drive power unit consists of the following: prime mover module, which includes the pump drive and filter manifold, the oil reservoir and cooling system, and the auxiliary system components hose storage reel Prime Mover The prime mover is a skid-mounted diesel engine (Detroit Diesel Series 60). Prime movers are equipped with a fuel day tank, an air starter, standard instrumentation packages, and appropriate safety and emergency shutoffs. Pump Drive and Filter Manifold The pump drive/filter manifold is skid-mounted and includes the following equipment: variable displacement, bi-directional axial piston pumps (two) flow meters and temperature gauges a series of hydraulic oil filters hot oil shuttle (to assist with oil cooling) auxiliary hydraulic pump and motor The auxiliary hydraulic equipment includes the following: a gear pump (2,000 psi, 7 gal/min; MPa, 26.5 liters/minute) 10 hp (7.46 kw) explosion-proof electric motor associated filters and controls REV 2 250TON HMIS 475HP TESCO CORPORATION,

14 TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION Hydraulic Oil Reservoir/Cooler The hydraulic oil reservoir/cooler is skid-mounted and contains the hydraulic oil storage reservoir and cooling system components. All reservoirs are equipped with a level gauge, temperatures gauges, and return oil filters. Cooling System Components The cooling system components provide cooling for hydraulic oil used by the power and auxiliary hydraulics systems. An air/oil heat exchanger (controlled by a thermostat) cools the hydraulic oil before it is returned to the tank. Figure 2-2: HMIS power unit configuration 1. Prime Mover (Detroit Diesel Series 60) 2. Air/Oil Cooler 3. Hose Reel Module 4. Auxiliary Hydraulic Pump and Motor 5. Oil Reservoir 6. Variable displacement, bi-directional axial pumps (not visible in this illustration) TESCO CORPORATION, TON HMIS 475HP REV 2 8

15 SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION TORQUE ARREST SYSTEM The torque arrest system is typically shipped in the second standard sea container. It consists of the following components: extend frame torque bushing extend arms extend hydraulic cylinders torque track T-bar torque beam, torque beam clamps, stabilization devices, and all required rig up items Extend Frame and Extend Arms The extend frame is pinned to the top drive. It allows you to extend the top drive away from the torque track. Torque Bushing The torque bushing is attached to the extend frame. Ultra High Molecular Weight (UHMW) inserts reduce friction as the top drive moves along the torque track. No lubrication is required. Torque Track The torque track, in conjunction with the torque beam and T-bar, transfers reactive torque to the lower section of the derrick and the substructure.the track is suspended from the crown by a cable hanging assembly, and is mounted with a simple clamp anchoring arrangement. Track components can be configured to fit most mast heights. Torque Beam, Torque Anchor and T-bar The torque beam is mounted on the rig, typically to the lowest strongback. It is then connected to the torque track via a T-bar. An offset torque anchor beam and post is available for use on service rigs. This torque anchoring system compensates for the 3.5 lean of the service rig mast REV 2 250TON HMIS 475HP TESCO CORPORATION,

16 TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION Figure 2-3: HMIS torque arrest system 1. F Clamps 2. Torque Track 3. Turnbuckles 4. F Clamps 5. F Clamp Assembly 6. Nuts, Washers and Ready Rod 7. Torque Track 8. Final Assembly, 72 in. Torque Bushing 9. Gearbox 10.Optional Torque Anchor Assembly 11.Mast 12.Torque Beam Assembly 13.Torque Track TESCO CORPORATION, TON HMIS 475HP REV 2 10

17 SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION SERVICE LOOP The hoses are spooled onto the hose reel prior to shipping. Power (Closed-Loop) Hydraulic Hoses two 225 ft. (68.58 m) x 1-1/2 in., 5,000 psi (34.5 MPa) hoses (one supply, one return); these supply closed-loop hydraulic oil from the pump drive module to the top drive motor Auxiliary Hydraulics one 225 ft. (68.58 m) x 3/4 in. R2, 2,000 psi (13.8 MPa) hydraulic hose; this supplies hydraulic oil from the pump drive module to the top drive robotics system Case Drain one 225 ft. (68.58 m) x 1-1/4 in. 1,625 psi (11.2 MPa) hydraulic hose; this returns auxiliary hydraulic oil and motor case drain flow from the top drive to the hydraulic oil reservoir Control Cables The 225 ft. control cable is spooled onto its own cable reel. The 160 ft. control cable remains attached to the main electrical panel on the power unit and hangs from a cable hook during storage. one 225 ft. (68.58 m) 37-conductor cable: this cable connects the driller's panel to the top drive one 160 ft. (48.77 m) 37-conductor cable: this cable connects the driller's panel to the main electrical panel on the power unit DRILLER S PANEL The driller s panel is a stainless steel enclosure that is mounted on the drill floor during installation procedures. It contains all controls, indicators, mounts, gauges and connectors required to operate the top drive. There is an optional air-purge system available for the driller s panel. All controls are electrically activated hydraulic (24 VDC) non-earth ground REV 2 250TON HMIS 475HP TESCO CORPORATION,

18 TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION OPTIONS The following options are available. For more detailed information, contact a TESCO representative. Elevators and Elevator Links Elevators rated at 150 and 250 tons (136.1 and metric tons), associated inserts for various drill pipe sizes, and accessories are available. A variety of link lengths is also available. Subs A complete selection of commonly used saver, casing, cross-over and drill collar handling subs is available. Non-standard subs can be manufactured if requested; delivery can be determined at time of order. Grabber Drill Pipe Guides These are used to guide the drill string into the grabber box. The drill pipe guide must match the box of the drill pipe in use. There is a range of sizes available. Rotary Table Stabilizer Bushings These urethane bushings fit the standard rotary table profile and protect the table and Blowout Preventer (BOP) from excessive wear. There is a range of sizes available. Rotary Hose and Standpipe Extension All equipment and accessories for these modifications are available. Torque Arrest System Other Available Options air purge system for the driller's panel and top drive junction box workshop/parts containers with workbench and storage cupboards camera system TESCO CORPORATION, TON HMIS 475HP REV 2 12

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