HCI (S) Top Drive System

DOCUMENT NAME: 880001 REV A
System Description
HCI(S) Top Drive System
500/650T HCI(S) 750/1205HP
This page has been left blank intentionally .
SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER
880001 REV A 500/650T HCI(S) 750/1205HP TESCO CORPORATION, 2004
III
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 2004
Contact Information
Corporate Head Office
6204 - 6A St. S.E.
Calgary, AB T2H 2B7
Canada
www.tescocorp.com
Telephone: (403) 233-0757
Fax: (403) 252-3362
REVISION INFORMATION SYSTEM DESCRIPTION
TESCO CORPORATION, 2004 500/650T HCI(S) 750/1205HP 880001 REV A
IV
Revision Information
Version Date Description of Changes
Rev A April 2004 General revisions and conversion to FrameMaker
SYSTEM DESCRIPTION TABLE OF CONTENTS
V
TABLE OF CONTENTS
Chapter 1: About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: Top Drive System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shipping Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Container 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Collar and Load Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Top Drive Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump Drive and Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Reservoir/Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Extend Frame and Extend Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Beam and T-bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power (Closed-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drillers Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Integrated Rotary Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Elevators and Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Additional Safety Valve and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Grabber Drill Pipe Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotary Table Stabilizer Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TABLE OF CONTENTS SYSTEM DESCRIPTION
VI
Rotary Hose and Standpipe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Other Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
SYSTEM DESCRIPTION
1
CHAPTER 1: ABOUT THIS DOCUMENT
This document contains a description of the major components of the Hydraulic Compact Inte-
grated (HCI(S)) Top Drive System with integrated quill and optional integrated swivel.
A complete HCI(S) 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 avail-
able spares and options.
Table 1-1: Where to Find More Information
For information on Refer to
installation
rig up
commissioning
pre-operational checklists
rig out procedures
Installation Guide
setting torque and speed
driller's panel functions and operating descriptions
making connections
drilling ahead
tripping
freeing stuck pipe
Operations Guide
load path inspections
maintenance/service schedules
component disassembly and reassembly
Maintenance Guide
Tesco manufactured parts and part numbers Parts List
troubleshooting Troubleshooting Guide (where available)
electrical schematics
hydraulic schematics
cooling schematics
gearbox lubrication schematics
System schematics
available options and spares Tesco Representative
ABOUT THIS DOCUMENT SYSTEM DESCRIPTION
2
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SYSTEM DESCRIPTION
3
CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION
INTRODUCTION AND GENERAL SPECIFICATIONS
The HCI(S) top drive is designed for use on land and offshore rigs that require high torque and
rpm in a compact unit. The HCI(S) 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 com-
bines industry proven prime movers with its own series of hydraulic pump drives and filtration
equipment.
The HCI(S) top drive is powered using one of the following power unit configurations:
1205 hp prime mover with a six-pump drive
750 hp prime mover with a four-pump drive
Metric unit conversions (in brackets) have been provided for convenience only. All prod-
uct specifications use the original imperial units unless indicated otherwise.
All weight values are approximate.

Table 2-1: HCI(S) Top Drive Specifications
Specification Details
Top Drive 500/650T HCI(S) 750/1205HP
Rated Capacity 500 ton
(454.5 metric ton)
650 ton
(590.9 metric ton)
Weight of the top drive plus:
elevators
elevator links
counter balance
swivel (if applicable)
11,800 lb. (5352.39 kg)
17,800 lb. (8073.94 kg)
with optional swivel
12,300 lb. (5579.17 kg
18,300 lb. (8300.74 kg)
with optional swivel)
Length 14 ft. 4 in. (4.36 m)
20 ft. (6.1 m) with optional swivel
Width 47.25 in. (1.2 m)
Horsepower Dependent on the prime mover and pump
configuration:
1205 hp (898.57 kW)6 pump drive
750 hp (559.27 kW)4 pump drive
TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION
4

SHIPPING CONTAINERS
HCI(S) top drive systems are 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: 31,000 lb. (14061.36 kg)
Contents:
top drive
37 C multi-conductor cable and storage reels
links
transformer (optional)
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
Contents:
power unit and pump drive
torque arrest system components
Container 3
Contents:
two rig up baskets
hose reel skid
hydraulic oil reservoir and cooling skid
service loop components, including the cable reel
Table 2-2: Torque Arrest System Specifications
Specification Details
Weight of the following:
torque track
anchor beam
torque bushing
clamps
17,600 lb. (7983.23 kg)
Track Length 145 ft. (44.2 m) standard
SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION
5
TOP DRIVE COMPONENTS
Figure 2-1: HCI(S) Top Drive General Assembly
1. Optional Swivel
2. Quill
3. Gearbox
4. Mainframe Assembly
5. Load Collar
6. Pipe Handler Assembly
7. Load Nut
8. Link Tilt Cylinders
9. Mudsaver Valve
10.Saver Sub
11.Grabber Assembly
12.Elevator Links
13.Elevator
6
Main Frame
The main frame houses the gear train and the associated hydraulic control equipment for the
robotic functions of the top drive.
Gearbox
The gearbox couples two hydraulic motors to the gear train.
The motors are bi-directional hydraulic vane type, and the have pressures ratings of
5,000 psi (34.5 MPa) continuous.
The gearbox houses gear reduction and forced lubrication systems.
The integral drive hub is internally splined to accept the integrated drive quill and the
optional integrated swivel.
The quill can be removed easily without dismantling the gearbox.
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 and lower Kelly cock.
The mudsaver remote actuator can be operated from the drillers panel.
Pipe Handler
The pipe handler mechanism has the following features:
Continuous rotation: The pipe handler is capable of 360 bi-directional rotation. It can be
locked into position every 2.6.
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
3-1/8 in. to 8-3/4 in. OD. The grabber features an automatic thread feed compensation
for make up and break out operations, and uses standard tong dies.
Top Drive Power Supplies
The top drive motor is powered by axial pumps, which are located on the power unit. 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.
7
POWER UNIT
The HCI(S) power unit consists of the following:
prime mover module
pump drive and filter manifold module
hydraulic oil reservoir, cooling system and hose storage reel
Prime Mover
The prime mover is a skid-mounted diesel engine (750 hp Caterpillar 3412 or 1205 hp DDEC
16V92). Prime movers are equipped with a fuel day tank, an air starter, standard instrumenta-
tion 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 (four or six)
charge pump
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, 7gpm; 13.79 MPa, 26.5 liters/minute)
10 hp (7.46 kW) explosion-proof electric motor
associated filters and controls
Hydraulic Oil Reservoir/Cooler
The hydraulic oil reservoir/cooler is skid-mounted and contains the hydraulic oil storage reser-
voir and cooling system components. All reservoirs are equipped with a level gauge, tempera-
tures gauges, and return oil filters.
Cooling System Components
The cooling system components provide cooling for hydraulic oil used by the power and aux-
iliary hydraulics systems. The main components are:
air cooler: this is a Modine heat exchanger, controlled by a thermostat, that cools the
hydraulic oil before it is returned to the tank
(optional) water cooler: this is a frame and plate heat exchanger that provides additional
cooling; refer to Other Available Options on page 13
reservoir circulating pump: this pump provides cooling for the oil reservoir; this pump
can also be used as a replacement for the auxiliary hydraulic pump, if required
8
Figure 2-2: HCI(S) Prime Mover, Pumps and Filter Manifold
Prime Mover
Pump Drive
Filter Manifold
Figure 2-3: HCI(S) Oil Reservoir, Cooling System and Hose Reel
Electrical Panel
(480V)
Oil Reservoir
Air Cooler Hose Reel
9
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 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.
10

Figure 2-4: Torque Arrest System
1. Torque Bushing
2. Extend Frame
3. Extend Cylinders
4. Extend Arms
5. Torque Track
11
SERVICE LOOP
Service loop components, including the drillers panel and hose reel, are typically shipped in
the second standard sea container. The hoses are spooled onto the hose reel prior to shipping.
Power (Closed-Loop) Hydraulic Hoses
225 ft. (68.58 m) x 2 in., 5000 psi (34.5 MPa) hoses; these supply closed-loop hydraulic
oil from the pump drive module to the top drive motors
for 1205 hp units: two supply hoses and two return hoses
for 750 hp units: one supply hose and one return hose
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 auxil-
iary hydraulic oil and motor case drain flow from the top drive to the hydraulic oil reser-
voir
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
Drillers Panel
The drillers panel is a stainless steel enclosure that is mounted on the drill floor during instal-
lation 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 drillers panel.
All controls are electrically activated hydraulic (24 VDC) non-earth ground.
12
OPTIONS
The following options are available. For more detailed information, contact a Tesco represen-
tative.
Integrated Rotary Swivel
Rotary swivels with an integrated one-piece quill are available for the HCI(S) Top Drive Sys-
tem. Integrated swivel and quill configurations offer the following advantages:
no connections from the swivel bearing to the top of the mudsaver valve
increased reliability, which results in reduced maintenance
decrease in overall length and weight of the top drive
Elevators and Elevator Links
Elevators rated at 250 and 350 tons (226.8 and 317.5 metric tons), associated inserts for vari-
ous drill pipe sizes, and accessories are available. A variety of link lengths is also available.
Additional Safety Valve and Actuator
Several sizes and thread types are 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 deter-
mined 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
Optional equipment for non-standard and large mast torque arrest systems is available.
13
Other Available Options
stacking kit for power system components
air purge system for the driller's panel and top drive junction box
workshop/parts containers with workbench and storage cupboards
camera system
water-based oil coolers

HCI (S) Top Drive System

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DOCUMENT NAME: 880001 REV A

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