2 - Tesco Top Drive Safety Manual

Bulletin 20900e
TOP DRIVES
CASING DRILLING
CASING RUNNING
Top Drive Rig Floor Safety

Orientation
Doghouse Manual
Email: topdrive@tescocorp.com
Corporate Headquarters
6204 - 6A Street S.E.
Calgary, Alberta, Canada T2H 2B7
Tel: 403 233-0757 Fax: 403 252-3362
Web: www.tescocorp.com
World Wide Operations
11330 Brittmoore Park Drive
Houston, Texas, USA 77041
Tel: 713 849-5900 Fax: 713 849-0075
Printed in Canada / April 2004 / TC

Due to ongoing product development, all specifications are subject to change without notice.
The Drilling Innovation Company

www.tescocorp.com
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
Page 19
TABLE OF CONTENTS
INTRODUCTION FOR DRILLERS
CHAPTER 5
MAKING CONNECTIONS
CHAPTER 1
RIGGING UP THE EQUIPMENT
Torque System
Power Module
Service Loop
Top Drive
4
5
6
6
Safety
Breaking Out
Making Up Singles
Making Up Doubles
Making Up Triples
12
12
12
12
13
CHAPTER 6
OPERATIONS
CHAPTER 2
COMPONENT IDENTIFICATION
Top Drive
CHAPTER 3
THE DRILLERS PANEL
Description
Position
Indicator Lights
Safety Interlocks
8
8
8
9
Drilling
Tripping
Cold Climate
Reaming
Working Tight Hole
Jarring
Running Casing
Cementing
13
14
14
15
15
16
16
16
CHAPTER 7
TOP DRIVE CONSIDERATIONS
CHAPTER 4
CONTROLS AND ROBOTICS
Clearance and Visibility
Extend
Link Tilt
Grabber
Grabber Lift
Pipe Handler
Elevators
Mud Saver Valve and Actuator
Page 18
10
10
10
10
10
10
11
11
Slip and Cut Drilling Line

Maintenance
17
17
DISCLAIMER
17
Page 3
INTRODUCTION
FOR DRILLERS
This manual is intended to
provide basic information
only, and does not constitute
a comprehensive guide to
the functioning or operation
of a Tesco Top Drive. It is to
be used only in conjunction
with the orientation and on
site supervision provided by
Tesco personnel. The Tesco
Top Drive Technician must
be notified of any concerns
or incidents involving Tesco
equipment and its operation.
OTHER
THAN
AS
DESCRIBED IN THE
PRECEDING PARAGRAPH,
TESCO CORPORATION, ITS AFFILIATED
COMPANIES
AND
EMPLOYEES ASSUME NO
RESPONSIBILITY FOR USE
OF THE INFORMATION
CONTAINED
IN
THIS
MANUAL.
At Tesco, we put a lot of effort
into developing ways to make
drilling a well more efficient.
Training the operators to run
the equipment in the most
effective manner makes the
job easier by reducing
downtime and safer by
eliminating the risk of injury to
workers.
This manual will provide you
with information to present to your crew during a
pre-job safety meeting or whenever you need to
reinforce what you already know.
Page 4
Chapter 1
Chapter 7
RIGGING UP THE
EQUIPMENT
Top Drive
Considerations
The Torque System:

After measuring the rig and determining the torque
system configuration, the top drive technician will require
the help of a select number of crewmembers. As a
driller, its up to you to choose workers who are confident
working at heights and follow instructions well. A well
thought out pre-job meeting and the right people can
make rigging up the top drive much easier and safer.
The torque system includes the following:
1. Torque Track
2. Torque Anchor Beam
3. T-Bar
In the next few pages we will describe the parts of the
torque system, what they do and some effective ways
of installing them.
Torque Track:
The torque track consists of varying lengths of track.
Each section is designed to fit another by lining up the
flanges and tightening the bolts. The length of the track
depends on the size of the rig mast but in all cases the
bottom of the track, called the deflector section, should
be between 7 and 8 feet from the floor. The track is
hung by attaching an adjustable hanging cluster to a
pad eye that has been welded to the crowns beams.
The bottom of the track is secured to the derrick by
bolting on the T-bar and fastening it in to the torque
anchor beam. Using turnbuckles we can center the
track and provide rigidity along the length of the derrick.
The turnbuckles are attached to the torque track and
derrick using clamps or by welding in pad eyes on the
derrick beams prior to rig up.
In some cases our technicians may pre-assemble the
torque track on the ground and hoist up to 2 sections at
once. When hoisting the torque track, good
communication and the use of a hold back line are
required.
Once the first section of track has been lifted to the drill
floor with the tugger line, it is then lowered through the
rotary table so that the top of the track can be attached
to the traveling block. After raising the track above the
floor with the blocks, the rest of the track sections can
be hoisted to the floor and placed in the rotary table
individually and bolted into the previous sections.
Disclaimer
This manual is intended to provide basic information

only, and does not constitute a comprehensive
guide to the functioning or operation of a Tesco Top
Slip and Cut Drilling Line:
Some daily rig operations change when a rig is fitted Drive. It is to be used only in conjunction with the
with a top drive. Some simple procedures that your orientation and on site supervision provided by
crew has performed regularly will need to be adjusted Tesco personnel. The Tesco Top Drive Technician
must be notified of any concerns or incidents
to consider top drive issues.
involving Tesco equipment and its operation.
To slip and cut drilling line, obviously the weight of the
top drive cannot hang from the same line as the blocks
alone did. The top drive technician will assist you in
determining the length of a block-hanging sling to be
installed in the derrick to a suitable beam so that the
top drive is positioned at floor level. If your rig is already
fitted with a block-hanging sling, the sling and the eye
on the blocks should be rated to support the weight of
the top drive as well as the traveling block. The top
drive will have to be connected to the drillstring and set
in the slips as low as the block-hanging sling will allow,
to help distribute the additional weight of the top drive.
OTHER THAN AS DESCRIBED IN THE

PRECEDING
PARAGRAPH,
TESCO
CORPORATION, ITS AFFILIATED COMPANIES
AND
EMPLOYEES
ASSUME
NO
RESPONSIBILITY FOR USE OF THE
INFORMATION CONTAINED IN THIS MANUAL.
Tesco Corporation (Tesco) has made every effort

to ensure that this manual describes the basic
knowledge needed to provide a quick reference for
Note When performing a slip and cut with a top top drive operators.
drive it is possible to pump fluid into the well if
necessary.
Important The blocks should never be hung from
a floor tugger.
This manual is to be used in conjunction

with an orientation and on site
supervision.
Top Drive Maintenance:

The regular daily maintenance and inspections on the
top drive do not have to interfere with rig operations. In
order to keep the top drive running safely and efficiently,
up to 15 minutes every tour must be available to service
the equipment. The top drive technicians knowledge
of drilling allows him to choose a window of opportunity
to do this when the top drive is accessible from a ladder
on the rig floor, while minimizing the impact on the
customers operation.
If any service or repairs need to be done on the top
drive, all of the drawworks controls and the drillers
panel must be locked out and tagged to ensure the
safety of the personnel.
Important The top drive technician must be
notified of any concerns or incidents involving
Tesco equipment.
Page 17
By decreasing forward pump pressure, there will not

be enough hydraulic flow to rotate the pipe. Now, slowly
increase the pumps until the pipe begins to rotate.
Maintain enough pressure on the hydraulic gauge to
hold drillstring in torsion without reaching the torque
relief setting on the top drive. When maintaining static
torque over extended time periods, it is recommended
to increase the pumps to a value less than the torque
relief setting and allow the pumps to control the desired
torque. If the top drive torque relief is activated, the
hydraulic oil passing through the relief over time, will
create excessive heat. The hot oil may, in turn, activate
a power unit shut down, resulting in an untimely torque
release of the drill string.
The power module is equipped with numerous
safety shutdowns. When the hydraulic oil reaches
the high oil temperature shutdown setting, the prime
mover will shut down. This should be avoided,
especially in situations where hole problems are
encountered.
Continue working the drillstring while maintaining torque
with the top drive until a free point is established. When
the pipe begins to rotate at this torque setting keep
raising and lowering pipe in the free point increasing
the travel distance until the obstruction is cleared.
Jarring:
If jarring is required, the torque applied to the drillstring
will need to be released. By slowly decreasing the quill
torque shown on the hydraulic gauge, the reactive
torque in the string will overcome the quill torque and
the pipe will, in a controlled manner, rotate in reverse
until torsion is released. Once this is done, set the slips
in order to break out the top drive.
Logging:
When using the hydraulic elevators to support a wire
line sheave, disconnect the hydraulic hoses at the
elevator quick connects to reduce the chances of
accidental opening.
Note: The hoses should also be disconnected to prevent
accidental opening in any other operation where the
elevators support a load other than the drillstring (for
example, when a set of secondary elevators are
supported from a nubbin in the hydraulic elevators).
Running Casing:
Using the top drive for
running casing offers
some advantages over
conventional methods.
At the customer s
request, Tesco can
provide a crossover sub
to connect the quill to
the casing, eliminating
the need to rig-up
chiksans and fill up
hoses. The top drive
also provides pipe handling functions to make handling
casing much simpler and safer.
Cementing:
Unless it is absolutely necessary, never attempt to
cement through the top drive. With the exception of
this rule, cementing with a top drive is similar to
When the torque track is fastened together in the length

required to allow the top drive to travel between the
highest and lowest points in the derrick, it then needs
to be secured to the crown. This is done by attaching
the hanging cluster at the top of the track to a weldedon pad eye with a shackle.
Next we need to position the torque track so that we
can fasten the t-bar to it and make sure that the torque
anchor beam will accept it as well.
Once the torque track is in place the turnbuckles need
to be attached to it and secured in predetermined
locations on the derrick strongbacks. Using these
adjustable, locking turnbuckles we can center the track
and help provide rigidity along the length of it.
When the torque system is installed it should be straight
and at the proper distance from well center and the rig
floor.
Torque Anchor Beam:

The torque anchor beam
accepts the torque directly
from the quill and transfers it
to the derrick. On some rigs
we can weld the anchor in
place, on others we need to
install the beam using clamps.
The beam is usually attached
to the lowest strongback
where the energy can be
displaced across the widest
point of the derrick. Periodic
inspection of the welds or the
clamps tightness must be
performed to prevent any
movement of the torque track.
Tesco does not recommend jarring with the

drillstring connected to the quill. The drillstring
should be suspended from the elevators before
jarring commences.
Position the hoisting sling and tugger line on the center

of the load. Carefully raise the anchor beam to the
appropriate strongback.
Disconnect hydraulic hoses at the elevator quick

connects to reduce the chances of elevators opening
accidentally.
The top drive technician will need assistance to position

the anchor beam on the strongback and hold it in place
until the clamps can be secured.
After any jarring is done the top drive technician will

need the time to perform a visual inspection of the top
drive components and fill out a Post Jarring Checklist.
In the event of excessive jarring a load path inspection
may need to be performed at the earliest convenience.
Safety - Make sure all workers are connected to an

approved fall arrest system.
Page 16
T-Bar:
The T-bar is a solid steel arm that bolts on to the torque
track at its lowest point and takes the drilling torque
from the top drive and transfers it through the anchor
beam and across the derrick.
The T-bar can be installed
in the torque anchor as
soon as the beam is
secured to the derrick.
The T-bar can also be
bolted on to the torque
track just before the track
is hung from the crown when the bolt pattern section of
track is at a comfortable height.
When the T-bar is attached to the torque track and
the track is hanging from the pad eye at the crown,
the T-bar should be just slightly higher than the
anchor. This way, when the anchor clamp is
tightened down it will pull the track into tension.
After all the main components of the torque system are
installed the turnbuckles can be adjusted to straighten
the track.
Note: All shackles, turnbuckles, and similar items should
be secured with cotter pins or safety wires, to prevent
accidental loosening.
The Power Module:

The Tesco hydraulic
top drive comes with a
building containing a
prime mover that
drives a series of
v a r i a b l e
displacement, bidirectional hydraulic
pumps. These pumps
send hydraulic flow
through a closed
loop, high-pressure system to the top drive motor(s),
which provide quill rotation before returning to the skid
to be filtered. Additional gear pumps send hydraulic
flow through an auxiliary system to the top drive,
operating the various robotic functions as well as
circulate oil through a filtration and cooling system
before returning to the reservoir. The power module
also contains an electrical panel, which accepts a 480
Page 5
or 600 volt AC input from the rigs 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 drillers
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 drillers 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.
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.
14. Link tilt back to vertical.

15. Lower the top drive to the floor and continue back
reaming if necessary.
Reaming:
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.
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 operators
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.
5. Remove the slips.
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:
Working Tight Hole:
1.
2.
3.
4.
5.
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.
Stop rotation.
Stop the mud pumps.
Set the slips.
Break out the lowest connection with the rig tongs.
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.
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.
2.
3.
4.
Drill mode
Decrease pumps
Forward pumps
Slowly Increase pumps
Page 15
Chapter 2
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.
climate function should be used. To activate cold

climate follow these steps:
1. Push in the cold climate button (on the left side of
the drillers panel).
2. Select engine speed slow.
3. Drill mode.
4. Forward pumps.
5. Increase or decrease pumps, to maintain 700psi
on the hydraulic pressure gauge.
Component Identification
Top Drive:
When the cold climate button is pushed in it deenergizes 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.
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
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.
2.
3.
4.
Neutral pumps.
Connection mode.
Neutral engine speed.
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.
Page 7
Chapter 3
The Drillers Panel
Chapter 6
The Rosemount Gauge receives a milliamp signal from
a pressure transducer located on the top drive. The
Description:
The drillers panel
is a stainless steel
e n c l o s u r e
equipped with all
of the controls,
indicator lights,
mounts, gauges
and connectors
required to operate
the top drive from
the
driller s
position. All of the
controls are 24
volts DC electric
over hydraulic. The two main cables to the panel are
37 pin conductor cables with each wire serving a specific
function. One 37-pin cable connects the power module
to the drillers panel and the other connects the top drive
with the drillers panel. The four smaller cables are 4 or
5 pin Amphenol connectors which control input to the
safety interlocks, overrides and digital gauges for quill
torque and RPM.
Positioning:
When deciding where
to mount the drillers
panel it is important
that your view of the rig
floor from the drillers
position
is
not
obstructed and that
you can reach the
controls well enough to
operate the drawworks and top drive simultaneously.
All of the cables to the panel should be routed in such a
manner that moving parts will not damage them and
they should be elevated from the floor.
Instrument Gauges:
There are two digital gauges on the drillers panel, the
RPM Gauge that meters quill rotation and the
Rosemount Gauge, which reads quill torque. Separate
from the drillers panel is the Hydraulic Pressure
Gauge, which reads the closed loop pressure in psi.
The RPM Gauge gives an exact reading of the quill
speed.
Page 8
Note: If the rig floor is too large to pickup singles from

the v-door with the link tilt and extend, it is still possible
to make double (or triple) connection. Make a single
connection as described above. Raise the top drive
and joint of pipe. Place another joint of pipe in the
mousehole and make up as per off-bottom connection.
Repeat if a triple is required.
Although it is possible to make up triple stands in the
mouse hole with the top drive, it may be more
efficient to make up stands in advance and leave
them racked in the derrick if drilling with triple stands
is required.
Drilling:
When drilling ahead with a top drive, adhere to the same
safety and operating practices and procedures as with
conventional rotary drilling.
Rotating Once you have made a connection and the
slips have cleared the table, select valve open and start
up the mud pump, then select drill mode immediately.
The preset functions in connection mode will be disabled
and now you can manipulate the quill RPM by selecting
forward and increasing or decreasing the pumps.
Slide Drilling In order to hold toolface while sliding,
you must close the grabber on the saver sub, allow the
grabber cylinder to pressure-up, and then switch the
pumps forward/reverse, to neutral. The grabber light
will remain on.
transducer measures the differential between the high

and low pressure sides of the top drive hydraulic
motor(s). This measurement gives you the most
accurate torque reading while drilling, when the
hydraulic oil in the loop is in a high flow state.
When sliding, the grabber is closed and the hoisting

clutch interlock is activated. In order to work the
drillstring you must push and hold the override button
on the brake handle control box while hoisting. This
allows the drawworks drum clutch to engage.
The Hydraulic Pressure Gauge is used primarily to

set the torque reliefs, which control the amount of torque
that can be applied to the quill. This gauge is also very
accurate when making and breaking connections, when
the hydraulic oil in the loop is in a semi-static condition
and pressure losses are at a minimum.
When running a mud motor, keep accurate records of

the reactive torque (motor pressure) in the string. At
any given time, you may need to orient the toolface of
the downhole motor. To do this the grabber will need to
be opened; if you do not track downhole torque history,
turning the string in small increments will be impossible.
Assuming that you know the amount of torque present,
follow these steps to orient the toolface:
Indicator Lights:
There are indicator lights installed in the drillers panel
reminding you that a function is, or has been performed.
The response to an illuminated indicator light should
be:
Stop - Why it is illuminated and how will it effect
further operations?
1. Select drill forward.

2. Decrease the pumps so that x psi (the pressure equal
to the reactive torque) is present on the hydraulic
pressure gauge.
3. Select grabber open.
4. If the value of x provides enough torque, the string
should not turn.
There are indicator lights for the following:

DC Power This green light should be illuminated at all
times, indicating that the power supply to the drillers
panel is on.
Grabber When the grabber is closed, the light will
come on and will not go off until grabber open is
selected.
Turn the string to the right by selecting:

5. Increase pumps until the pipe turns very slowly and
under control.
6. When you have achieved the new orientation, quickly
close the grabber.
Valve When the mud saver valve is closed, the light

will come on will not go out until valve open is selected.
Operations
Page 13
Chapter 5
Making Connections
connection instead of the top drive. In this method a

working single remains on the top drive.
Safety:
Note: Make sure that all connections are properly

doped.
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
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.
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:
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
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.
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.
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 rigs 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.
Connection Mode/Forward To make a connection,

the drillers 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
Controls and Robotics
Clearance and Visibility:
The top drive takes up much more space on the rig
floor than a kelly would, so this work area must be kept
clear of obstacles that may interfere with the movement
of the top drive and that of the personnel. When the
top drive is moving through the derrick, you must be
aware of its position at all times. Because you are not
always able to see the top drive, the other members of
your crew must also watch and be aware of the top
drives position and movement at all times.
Note: If you are unsure about any situation, stop
and ask for help. This will save more time in the
end and reduce the likelihood of an incident
occurring.
Robotic Functions:
Extend This feature allows the top drive to reach
forward over the mouse hole, giving it the ability to make
up stands in the mouse hole for drilling as well as aiding
the process of handling tools to and from the v-door.
Note: An optional extend alarm is available if requested.
This device provides an alarm if the top drive is
extended.
Note: If you leave the top drive extended out while
hoisting with blocks, the top drive could make
contact with the monkey board.
Link Tilt Commonly known as the bails, the links can
be tilted to move the elevators up to 35 degrees forward
and 55 degrees back from vertical, extending the reach
of the top drive to perform many tasks associated with
pipe handling.
Grabber The grabber acts like a back-up tong and
closes onto a tool joint to arrest the reactive torque when
making up or breaking out a connection.
Rule of thumb: Allow 10 seconds for the grabber
to close before applying torque.
When breaking out, close the grabber and leave the
switch in the close position until the connection breaks.
Then open it while reversing out of the thread box. This
way, you can hoist out of the tool joint once completely
un-threaded without the interlock disabling the hoisting
clutch. For making-up a joint, leave the grabber switch
in the close position until the specified torque is reached
Page 10
and the top drive stalls. Return the pumps switch from
forward to neutral and allow the pressure on the
hydraulic gauge to bleed off below 1000psi before
selecting grabber open.
Allow 5 seconds for the grabber to fully open before
switching the grabber to neutral.
Grabber Lift
(Tesco Top Drive Model HMI, not

equipped): A hydraulic
cylinder, located in the
grabber leg, raises and
lowers the grabber to the
required height for backingup the tool joint. Always
position the grabber at the
top tool joint before raising
the top drive from the floor
level. If for any reason,
such as having to begin a
trip before the stand has
been drilled, you can simply
close the grabber to breakout of the stand at the
monkeyboard
height
without having to guess whether or not the grabber is
in the correct position.
Pipe Handler
In order to turn the elevators in the
direction needed for a certain operation, the pipe handler
will have to be used. To perform this, proper operation
is critical for worker and equipment safety.
The following steps must be followed before
unlocking the pipe handler:
All personnel must clear the area of the top drive,
elevators, and links.
Link tilt vertical (if possible, latch the elevators on the
pipe).
Pumps to neutral.
Pipe handler unlock and return to neutral.
Grabber close (on the saver sub).
Pumps forward or reverse.
Push pipe handler caution button (rotate)
The pipe handler section of the top drive will now rotate
up to 360 degrees at 4 RPM. Once the orientation of
the pipe handler is correct, these steps must be
followed to disengage pipe handler rotation.
Release rotate or caution button.
Pumps to neutral.
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.
Page 11
Chapter 4
Controls and Robotics
Clearance and Visibility:
The top drive takes up much more space on the rig
floor than a kelly would, so this work area must be kept
clear of obstacles that may interfere with the movement
of the top drive and that of the personnel. When the
top drive is moving through the derrick, you must be
aware of its position at all times. Because you are not
always able to see the top drive, the other members of
your crew must also watch and be aware of the top
drives position and movement at all times.
Note: If you are unsure about any situation, stop
and ask for help. This will save more time in the
end and reduce the likelihood of an incident
occurring.
Robotic Functions:
Extend This feature allows the top drive to reach
forward over the mouse hole, giving it the ability to make
up stands in the mouse hole for drilling as well as aiding
the process of handling tools to and from the v-door.
Note: An optional extend alarm is available if requested.
This device provides an alarm if the top drive is
extended.
Note: If you leave the top drive extended out while
hoisting with blocks, the top drive could make
contact with the monkey board.
Link Tilt Commonly known as the bails, the links can
be tilted to move the elevators up to 35 degrees forward
and 55 degrees back from vertical, extending the reach
of the top drive to perform many tasks associated with
pipe handling.
Grabber The grabber acts like a back-up tong and
closes onto a tool joint to arrest the reactive torque when
making up or breaking out a connection.
Rule of thumb: Allow 10 seconds for the grabber
to close before applying torque.
When breaking out, close the grabber and leave the
switch in the close position until the connection breaks.
Then open it while reversing out of the thread box. This
way, you can hoist out of the tool joint once completely
un-threaded without the interlock disabling the hoisting
clutch. For making-up a joint, leave the grabber switch
in the close position until the specified torque is reached
Page 10
and the top drive stalls. Return the pumps switch from
forward to neutral and allow the pressure on the
hydraulic gauge to bleed off below 1000psi before
selecting grabber open.
Allow 5 seconds for the grabber to fully open before
switching the grabber to neutral.
Grabber Lift
(Tesco Top Drive Model HMI, not

equipped): A hydraulic
cylinder, located in the
grabber leg, raises and
lowers the grabber to the
required height for backingup the tool joint. Always
position the grabber at the
top tool joint before raising
the top drive from the floor
level. If for any reason,
such as having to begin a
trip before the stand has
been drilled, you can simply
close the grabber to breakout of the stand at the
monkeyboard
height
without having to guess whether or not the grabber is
in the correct position.
Pipe Handler
In order to turn the elevators in the
direction needed for a certain operation, the pipe handler
will have to be used. To perform this, proper operation
is critical for worker and equipment safety.
The following steps must be followed before
unlocking the pipe handler:
All personnel must clear the area of the top drive,
elevators, and links.
Link tilt vertical (if possible, latch the elevators on the
pipe).
Pumps to neutral.
Pipe handler unlock and return to neutral.
Grabber close (on the saver sub).
Pumps forward or reverse.
Push pipe handler caution button (rotate)
The pipe handler section of the top drive will now rotate
up to 360 degrees at 4 RPM. Once the orientation of
the pipe handler is correct, these steps must be
followed to disengage pipe handler rotation.
Release rotate or caution button.
Pumps to neutral.
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.
Page 11
Chapter 5
Making Connections
connection instead of the top drive. In this method a

working single remains on the top drive.
Safety:
Note: Make sure that all connections are properly

doped.
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
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
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.
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:
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
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.
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.
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 rigs 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.
Connection Mode/Forward To make a connection,

the drillers 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
The Drillers Panel
Chapter 6
The Rosemount Gauge receives a milliamp signal from
a pressure transducer located on the top drive. The
Description:
The drillers panel
is a stainless steel
e n c l o s u r e
equipped with all
of the controls,
indicator lights,
mounts, gauges
and connectors
required to operate
the top drive from
the
driller s
position. All of the
controls are 24
volts DC electric
over hydraulic. The two main cables to the panel are
37 pin conductor cables with each wire serving a specific
function. One 37-pin cable connects the power module
to the drillers panel and the other connects the top drive
with the drillers panel. The four smaller cables are 4 or
5 pin Amphenol connectors which control input to the
safety interlocks, overrides and digital gauges for quill
torque and RPM.
Positioning:
When deciding where
to mount the drillers
panel it is important
that your view of the rig
floor from the drillers
position
is
not
obstructed and that
you can reach the
controls well enough to
operate the drawworks and top drive simultaneously.
All of the cables to the panel should be routed in such a
manner that moving parts will not damage them and
they should be elevated from the floor.
Instrument Gauges:
There are two digital gauges on the drillers panel, the
RPM Gauge that meters quill rotation and the
Rosemount Gauge, which reads quill torque. Separate
from the drillers panel is the Hydraulic Pressure
Gauge, which reads the closed loop pressure in psi.
The RPM Gauge gives an exact reading of the quill
speed.
Page 8
Note: If the rig floor is too large to pickup singles from

the v-door with the link tilt and extend, it is still possible
to make double (or triple) connection. Make a single
connection as described above. Raise the top drive
and joint of pipe. Place another joint of pipe in the
mousehole and make up as per off-bottom connection.
Repeat if a triple is required.
Although it is possible to make up triple stands in the
mouse hole with the top drive, it may be more
efficient to make up stands in advance and leave
them racked in the derrick if drilling with triple stands
is required.
Drilling:
When drilling ahead with a top drive, adhere to the same
safety and operating practices and procedures as with
conventional rotary drilling.
Rotating Once you have made a connection and the
slips have cleared the table, select valve open and start
up the mud pump, then select drill mode immediately.
The preset functions in connection mode will be disabled
and now you can manipulate the quill RPM by selecting
forward and increasing or decreasing the pumps.
Slide Drilling In order to hold toolface while sliding,
you must close the grabber on the saver sub, allow the
grabber cylinder to pressure-up, and then switch the
pumps forward/reverse, to neutral. The grabber light
will remain on.
transducer measures the differential between the high

and low pressure sides of the top drive hydraulic
motor(s). This measurement gives you the most
accurate torque reading while drilling, when the
hydraulic oil in the loop is in a high flow state.
When sliding, the grabber is closed and the hoisting

clutch interlock is activated. In order to work the
drillstring you must push and hold the override button
on the brake handle control box while hoisting. This
allows the drawworks drum clutch to engage.
The Hydraulic Pressure Gauge is used primarily to

set the torque reliefs, which control the amount of torque
that can be applied to the quill. This gauge is also very
accurate when making and breaking connections, when
the hydraulic oil in the loop is in a semi-static condition
and pressure losses are at a minimum.
When running a mud motor, keep accurate records of

the reactive torque (motor pressure) in the string. At
any given time, you may need to orient the toolface of
the downhole motor. To do this the grabber will need to
be opened; if you do not track downhole torque history,
turning the string in small increments will be impossible.
Assuming that you know the amount of torque present,
follow these steps to orient the toolface:
Indicator Lights:
There are indicator lights installed in the drillers panel
reminding you that a function is, or has been performed.
The response to an illuminated indicator light should
be:
Stop - Why it is illuminated and how will it effect
further operations?
1. Select drill forward.

2. Decrease the pumps so that x psi (the pressure equal
to the reactive torque) is present on the hydraulic
pressure gauge.
3. Select grabber open.
4. If the value of x provides enough torque, the string
should not turn.
There are indicator lights for the following:

DC Power This green light should be illuminated at all
times, indicating that the power supply to the drillers
panel is on.
Grabber When the grabber is closed, the light will
come on and will not go off until grabber open is
selected.
Turn the string to the right by selecting:

5. Increase pumps until the pipe turns very slowly and
under control.
6. When you have achieved the new orientation, quickly
close the grabber.
Valve When the mud saver valve is closed, the light

will come on will not go out until valve open is selected.
Operations
Page 13
Chapter 2
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.
climate function should be used. To activate cold

climate follow these steps:
1. Push in the cold climate button (on the left side of
the drillers panel).
2. Select engine speed slow.
3. Drill mode.
4. Forward pumps.
5. Increase or decrease pumps, to maintain 700psi
on the hydraulic pressure gauge.
Component Identification
Top Drive:
When the cold climate button is pushed in it deenergizes 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.
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
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.
2.
3.
4.
Neutral pumps.
Connection mode.
Neutral engine speed.
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.
Page 7
or 600 volt AC input from the rigs 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 drillers
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 drillers 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.
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.
14. Link tilt back to vertical.

15. Lower the top drive to the floor and continue back
reaming if necessary.
Reaming:
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.
8. Remove the tongs and the slips.
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.
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 operators
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.
5. Remove the slips.
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:
Working Tight Hole:
1.
2.
3.
4.
5.
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.
Stop rotation.
Stop the mud pumps.
Set the slips.
Break out the lowest connection with the rig tongs.
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.
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.
2.
3.
4.
Drill mode
Decrease pumps
Forward pumps
Slowly Increase pumps
Page 15
By decreasing forward pump pressure, there will not

be enough hydraulic flow to rotate the pipe. Now, slowly
increase the pumps until the pipe begins to rotate.
Maintain enough pressure on the hydraulic gauge to
hold drillstring in torsion without reaching the torque
relief setting on the top drive. When maintaining static
torque over extended time periods, it is recommended
to increase the pumps to a value less than the torque
relief setting and allow the pumps to control the desired
torque. If the top drive torque relief is activated, the
hydraulic oil passing through the relief over time, will
create excessive heat. The hot oil may, in turn, activate
a power unit shut down, resulting in an untimely torque
release of the drill string.
The power module is equipped with numerous
safety shutdowns. When the hydraulic oil reaches
the high oil temperature shutdown setting, the prime
mover will shut down. This should be avoided,
especially in situations where hole problems are
encountered.
Continue working the drillstring while maintaining torque
with the top drive until a free point is established. When
the pipe begins to rotate at this torque setting keep
raising and lowering pipe in the free point increasing
the travel distance until the obstruction is cleared.
Jarring:
If jarring is required, the torque applied to the drillstring
will need to be released. By slowly decreasing the quill
torque shown on the hydraulic gauge, the reactive
torque in the string will overcome the quill torque and
the pipe will, in a controlled manner, rotate in reverse
until torsion is released. Once this is done, set the slips
in order to break out the top drive.
Logging:
When using the hydraulic elevators to support a wire
line sheave, disconnect the hydraulic hoses at the
elevator quick connects to reduce the chances of
accidental opening.
Note: The hoses should also be disconnected to prevent
accidental opening in any other operation where the
elevators support a load other than the drillstring (for
example, when a set of secondary elevators are
supported from a nubbin in the hydraulic elevators).
Running Casing:
Using the top drive for
running casing offers
some advantages over
At the customer s
request, Tesco can
provide a crossover sub
to connect the quill to
the casing, eliminating
the need to rig-up
chiksans and fill up
hoses. The top drive
also provides pipe handling functions to make handling
casing much simpler and safer.
Cementing:
Unless it is absolutely necessary, never attempt to
cement through the top drive. With the exception of
this rule, cementing with a top drive is similar to
When the torque track is fastened together in the length

required to allow the top drive to travel between the
highest and lowest points in the derrick, it then needs
to be secured to the crown. This is done by attaching
the hanging cluster at the top of the track to a weldedon pad eye with a shackle.
Next we need to position the torque track so that we
can fasten the t-bar to it and make sure that the torque
anchor beam will accept it as well.
Once the torque track is in place the turnbuckles need
to be attached to it and secured in predetermined
locations on the derrick strongbacks. Using these
adjustable, locking turnbuckles we can center the track
and help provide rigidity along the length of it.
When the torque system is installed it should be straight
and at the proper distance from well center and the rig
floor.
Torque Anchor Beam:

The torque anchor beam
accepts the torque directly
from the quill and transfers it
to the derrick. On some rigs
we can weld the anchor in
place, on others we need to
install the beam using clamps.
The beam is usually attached
to the lowest strongback
where the energy can be
displaced across the widest
point of the derrick. Periodic
inspection of the welds or the
clamps tightness must be
performed to prevent any
movement of the torque track.
Tesco does not recommend jarring with the

drillstring connected to the quill. The drillstring
should be suspended from the elevators before
jarring commences.
Position the hoisting sling and tugger line on the center

of the load. Carefully raise the anchor beam to the
appropriate strongback.
Disconnect hydraulic hoses at the elevator quick

connects to reduce the chances of elevators opening
accidentally.
The top drive technician will need assistance to position

the anchor beam on the strongback and hold it in place
until the clamps can be secured.
After any jarring is done the top drive technician will

need the time to perform a visual inspection of the top
drive components and fill out a Post Jarring Checklist.
In the event of excessive jarring a load path inspection
may need to be performed at the earliest convenience.
Safety - Make sure all workers are connected to an

approved fall arrest system.
Page 16
T-Bar:
The T-bar is a solid steel arm that bolts on to the torque
track at its lowest point and takes the drilling torque
from the top drive and transfers it through the anchor
beam and across the derrick.
The T-bar can be installed
in the torque anchor as
soon as the beam is
secured to the derrick.
The T-bar can also be
bolted on to the torque
track just before the track
is hung from the crown when the bolt pattern section of
track is at a comfortable height.
When the T-bar is attached to the torque track and
the track is hanging from the pad eye at the crown,
the T-bar should be just slightly higher than the
anchor. This way, when the anchor clamp is
tightened down it will pull the track into tension.
After all the main components of the torque system are
installed the turnbuckles can be adjusted to straighten
the track.
Note: All shackles, turnbuckles, and similar items should
be secured with cotter pins or safety wires, to prevent
accidental loosening.
The Power Module:

The Tesco hydraulic
top drive comes with a
building containing a
prime mover that
drives a series of
v a r i a b l e
displacement, bidirectional hydraulic
pumps. These pumps
send hydraulic flow
through a closed
loop, high-pressure system to the top drive motor(s),
which provide quill rotation before returning to the skid
to be filtered. Additional gear pumps send hydraulic
flow through an auxiliary system to the top drive,
operating the various robotic functions as well as
circulate oil through a filtration and cooling system
before returning to the reservoir. The power module
also contains an electrical panel, which accepts a 480
Page 5
INTRODUCTION
FOR DRILLERS
This manual is intended to
provide basic information
only, and does not constitute
a comprehensive guide to
the functioning or operation
of a Tesco Top Drive. It is to
be used only in conjunction
with the orientation and on
site supervision provided by
Tesco personnel. The Tesco
Top Drive Technician must
be notified of any concerns
or incidents involving Tesco
equipment and its operation.
OTHER
THAN
AS
DESCRIBED IN THE
PRECEDING PARAGRAPH,
TESCO CORPORATION, ITS AFFILIATED
COMPANIES
AND
EMPLOYEES ASSUME NO
RESPONSIBILITY FOR USE
OF THE INFORMATION
CONTAINED
IN
THIS
MANUAL.
At Tesco, we put a lot of effort
into developing ways to make
drilling a well more efficient.
Training the operators to run
the equipment in the most
effective manner makes the
job easier by reducing
downtime and safer by
eliminating the risk of injury to
workers.
This manual will provide you
with information to present to your crew during a
pre-job safety meeting or whenever you need to
reinforce what you already know.
Page 4
Chapter 1
Chapter 7
RIGGING UP THE
EQUIPMENT
Top Drive
Considerations
The Torque System:

After measuring the rig and determining the torque
system configuration, the top drive technician will require
the help of a select number of crewmembers. As a
driller, its up to you to choose workers who are confident
working at heights and follow instructions well. A well
thought out pre-job meeting and the right people can
make rigging up the top drive much easier and safer.
The torque system includes the following:
1. Torque Track
2. Torque Anchor Beam
3. T-Bar
In the next few pages we will describe the parts of the
torque system, what they do and some effective ways
of installing them.
Torque Track:
The torque track consists of varying lengths of track.
Each section is designed to fit another by lining up the
flanges and tightening the bolts. The length of the track
depends on the size of the rig mast but in all cases the
bottom of the track, called the deflector section, should
be between 7 and 8 feet from the floor. The track is
hung by attaching an adjustable hanging cluster to a
pad eye that has been welded to the crowns beams.
The bottom of the track is secured to the derrick by
bolting on the T-bar and fastening it in to the torque
anchor beam. Using turnbuckles we can center the
track and provide rigidity along the length of the derrick.
The turnbuckles are attached to the torque track and
derrick using clamps or by welding in pad eyes on the
derrick beams prior to rig up.
In some cases our technicians may pre-assemble the
torque track on the ground and hoist up to 2 sections at
once. When hoisting the torque track, good
communication and the use of a hold back line are
required.
Once the first section of track has been lifted to the drill
floor with the tugger line, it is then lowered through the
rotary table so that the top of the track can be attached
to the traveling block. After raising the track above the
floor with the blocks, the rest of the track sections can
be hoisted to the floor and placed in the rotary table
individually and bolted into the previous sections.
Disclaimer
This manual is intended to provide basic information

only, and does not constitute a comprehensive
guide to the functioning or operation of a Tesco Top
Slip and Cut Drilling Line:
Some daily rig operations change when a rig is fitted Drive. It is to be used only in conjunction with the
with a top drive. Some simple procedures that your orientation and on site supervision provided by
crew has performed regularly will need to be adjusted Tesco personnel. The Tesco Top Drive Technician
must be notified of any concerns or incidents
to consider top drive issues.
involving Tesco equipment and its operation.
To slip and cut drilling line, obviously the weight of the
top drive cannot hang from the same line as the blocks
alone did. The top drive technician will assist you in
determining the length of a block-hanging sling to be
installed in the derrick to a suitable beam so that the
top drive is positioned at floor level. If your rig is already
fitted with a block-hanging sling, the sling and the eye
on the blocks should be rated to support the weight of
the top drive as well as the traveling block. The top
drive will have to be connected to the drillstring and set
in the slips as low as the block-hanging sling will allow,
to help distribute the additional weight of the top drive.
OTHER THAN AS DESCRIBED IN THE

PRECEDING
PARAGRAPH,
TESCO
CORPORATION, ITS AFFILIATED COMPANIES
AND
EMPLOYEES
ASSUME
NO
RESPONSIBILITY FOR USE OF THE
INFORMATION CONTAINED IN THIS MANUAL.
Tesco Corporation (Tesco) has made every effort

to ensure that this manual describes the basic
knowledge needed to provide a quick reference for
Note When performing a slip and cut with a top top drive operators.
drive it is possible to pump fluid into the well if
necessary.
Important The blocks should never be hung from
a floor tugger.
This manual is to be used in conjunction

with an orientation and on site
supervision.
Top Drive Maintenance:

The regular daily maintenance and inspections on the
top drive do not have to interfere with rig operations. In
order to keep the top drive running safely and efficiently,
up to 15 minutes every tour must be available to service
the equipment. The top drive technicians knowledge
of drilling allows him to choose a window of opportunity
to do this when the top drive is accessible from a ladder
on the rig floor, while minimizing the impact on the
customers operation.
If any service or repairs need to be done on the top
drive, all of the drawworks controls and the drillers
panel must be locked out and tagged to ensure the
safety of the personnel.
Important The top drive technician must be
notified of any concerns or incidents involving
Tesco equipment.
Page 17
Bulletin 20900e
TOP DRIVES
CASING DRILLING
CASING RUNNING
Top Drive Rig Floor Safety

Orientation
Doghouse Manual
Email: topdrive@tescocorp.com
Corporate Headquarters
6204 - 6A Street S.E.
Calgary, Alberta, Canada T2H 2B7
Tel: 403 233-0757 Fax: 403 252-3362
Web: www.tescocorp.com
World Wide Operations
11330 Brittmoore Park Drive
Houston, Texas, USA 77041
Tel: 713 849-5900 Fax: 713 849-0075
Printed in Canada / April 2004 / TC

Due to ongoing product development, all specifications are subject to change without notice.

www.tescocorp.com

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Bulletin 20900e

Top Drive Rig Floor Safety

Printed in Canada / April 2004 / TC

The Drilling Innovation Company

The Drilling Innovation Company

The Drilling Innovation Company

Top Drive Rig Floor

Top Drive Rig Floor Safety Orientation Doghouse Manual

Top Drive Rig Floor Safety Orientation Doghouse Manual

Top Drive Rig Floor Safety Orientation Doghouse Manual

Top Drive Rig Floor Safety Orientation Doghouse Manual

Slip and Cut Drilling Line

The Torque System:

This manual is intended to provide basic information

OTHER THAN AS DESCRIBED IN THE

Tesco Corporation (Tesco) has made every effort

This manual is to be used in conjunction

Top Drive Maintenance:

By decreasing forward pump pressure, there will not

When the torque track is fastened together in the length

Torque Anchor Beam:

Tesco does not recommend jarring with the

Position the hoisting sling and tugger line on the center

Disconnect hydraulic hoses at the elevator quick

The top drive technician will need assistance to position

After any jarring is done the top drive technician will

Safety - Make sure all workers are connected to an

Top Drive Rig Floor Safety Orientation Doghouse Manual

Top Drive Rig Floor Safety Orientation Doghouse Manual

The Power Module:

or 600 volt AC input from the rigs generators and

The Service Loop:

The Top Drive:

Before the top drive is raised

Top Drive Rig Floor Safety Orientation Doghouse Manual

Tip: If the top drive will rotate and everything else is

14. Link tilt back to vertical.

If an obstruction is encountered when tripping in the

Back reaming out of the hole is one of the greatest

Working Tight Hole:

It is important to know that when torque is applied

Top Drive Rig Floor Safety Orientation Doghouse Manual

In tight hole situations, it will be necessary to free the

climate function should be used. To activate cold

Selecting engine speed slow brings the prime mover to

By selecting neutral pumps, the flow of hydraulic oil is

Top Drive Rig Floor Safety Orientation Doghouse Manual

Top Drive Rig Floor Safety Orientation Doghouse Manual

Note: If the rig floor is too large to pickup singles from

transducer measures the differential between the high

When sliding, the grabber is closed and the hoisting

The Hydraulic Pressure Gauge is used primarily to

When running a mud motor, keep accurate records of

1. Select drill forward.

There are indicator lights for the following:

Turn the string to the right by selecting:

Valve When the mud saver valve is closed, the light

Top Drive Rig Floor Safety Orientation Doghouse Manual