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HMIS Top Drive System - Total Energy Services Inc.

1. Date Supervisor Rig Time Daily Top Drive Inspect For Inspector Gearbox oil correct oil level Hydraulic hoses and connections at the top drive leaks Grabber dies excessive wear Mudsaver valve lower ball manually operate the valve to check function Saver sub threads excessive wear Swivel oil level correct level Grabber check and reset grabber height Lubricate With Inspector Upper quill bearing retainer 1 EP2 mutli purpose grease Lower quill bearin retainer 1 EP2 mutli purpose grease Upper input shaft retainer 1 EP2 mutli purpose grease Lower input shaft retainer 1 EP2 mutli purpose grease Slew drive grease nipple 2 200 Schaeffer Silver Streak or Shell 3 each Malleus Grease GL Grease nipples on the EXTEND cylinder 4 if applicable EP2 multi purpose grease Lower bearing retainer of gearbox grease ports EP2 multi purpose grease Upper bearing retainer of gearbox grease ports 2 EP2 multi purpose grease Swivel pins 6 EP2 multi purpose grease Grease ports on the load collar 1 EP2 multi purpose grease LINK TILT cylinders 4 EP2 multi purpose grease Grease ports on the elevator 3 EP2 multi purpose grease Elevator handle pins 2 EP2 multi purpose grease Elevator hinge pin 1 EP2 multi purpose grease Yoke pins 2 if applicable EP2 multi purpose grease Mudsaver valve actuato
2. Inspect For Inspector Battery if applicable correct electrolyte level evidence of corrosion Water pump seal drain evidence of leaks Weep hole plugs correct placement evidence of leaks Fan hub correct lubrication see the appropriate Engineering Memo document for lubrication specifications Universal joint on the drive shaft correct lubrication grease if required do not over lubricate or this can damage the seals Weekly Pump Drive Inspect For Inspector Breather filter cap cleanliness Mating bolts mounting to prime mover tightness Weekly Auxiliary Hydraulic Power Unit Service Inspect For Inspector Electric motor and hydraulic pump Unnatural noise Comments Notes TESCO CORPORATION 2007 100 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS MONTHLY CHECKLISTS Date Supervisor Rig Time Monthly Top Drive Inspect For Inspector Gearbox oil abnormalities take samples to test for water metal particles etc every 900 operating hours Roto actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 40 Grabber dies excessive wear Sensor panel moisture tightness of wire terminations Quill hub preload correct preload
3. 64 Junction Boxes Auxiliary Panel 64 Mains rive Quills an ossi itc ee oce eee e IU eq mou etos 64 Beiler TEE 64 Grabber WEE 64 Elevator Ss ee ee e eer cfi 65 Mudsaver Valve EU EINDE AES 65 DAVE EE 65 Hose Storage Heel 66 MainiStorage Reel sco dece e ERE RAE ied p ERE LE EE Ea S 66 Drillers Panel dete eS eto t e mb eM 66 ue id ER RI R ERE Rt Ritt nb s 67 Torque Arrest System 67 Torque Track Assembly sur pedo e tret t ure t ar e pt t Den 67 Torque Bushing Extend 67 Studs for Torque Track 67 Hanging Sling Assembly 0 0 0 cece aa m nns 68 Torque Beam and eee eee rn 68 Power oe RE geen Fee xe ee ETE 68 Hydraulic Oil Storage Tank 68 GOOler ge ee eee eo Ree ei e Rie Reo eee tee Ree te RO Rd 69 Optional Stand Alone Plate 69 Auxiliary Oil P mp z3 ia enon eee ts Be tle ARREST RA ote e E EVE 69 Filter Manifold a ea tne 69 Pump Drive and Main Hydraulic Pumps 0 0 02 cee eee 69 Prime oput ata peg tee erecta etie tran m he 70 Main Electrical Panel 70 EN EAE CEDENS o UC YU CU RC 70 Storage C
4. Inspection Point Notes Data Actions Inspector Power building dust dirt clean if required use dry air or vacuum Driller s panel replace desiccant packs Top drive robotics junction box replace desiccant packs PA44 motors on top drive perform an insulation Megger test record the results Load path components MPI WMPI tests Cooling fan motor amps Drive pump motor amps Top drive circulation pump motor amps Heat pump motor amps Chiller circulation pump motor high amps ambient Chiller compressors amps Chiller condenser fan high ambient amps Lubrication Lubricate With Inspector Top and bottom motor bearings Shell Cyprina Grease RA Worm drive bearings EP2 multi purpose grease Slewing bearing EP2 multi purpose grease Comments TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 106 MAINTENANCE GUIDE MEGGER TEST CHART APPENDIX E SERVICE CHECKLISTS Set the Megger to 1000V 2000Mohm Test for 5 seconds Use this chart to record the test results for the following feed cable connections to drive motors motor connection terminals Motor and Pigtail Grd A B X B X X Service Loop Grd B A X B X Any reading below 1 mega ohm at 1 000 volts is unacceptable Any reading below 5 mega ohms at 1 000 volts should be flagged 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 APPENDIX E
5. Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Days in Service Inspected By Results Comments Next Service Date Cumulative Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 91 APPENDIX D SAMPLE INSPECTION LOGS MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 92 MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS This Appendix contains examples of the following checklists Daily Checklist see also Maintenance and Service Schedules Weekly Checklist see also Maintenance and Service Schedules Monthly Checklist see also Maintenance and Service Schedules Six Month Checklist Megger Test Chart Daily Top Drive Report APPENDIX E SERVICE CHECKLISTS The Daily Top Drive Report exists in booklet form and can be ordered from TESCO 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 93 APPENDIX E SERVICE CHECKLISTS DAILY CHECKLISTS MAINTENANCE GUIDE
6. TESCO will not assume responsibility or liability for any component product or material that has been repaired rebuilt welded or heat treated outside of TESCO facilities 880028 REv 8 250TON HMIS 475HP 5 CORPORATION 2007 17 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE GUIDELINES FOR COMPONENT INSPECTORS Only qualified personnel can inspect load path torque arrest system and critical components Inspectors must use only fully operational regularly maintained testing equipment To ensure accurate test results each component must be thoroughly cleaned before inspection In some cases removal of paint is required Visual and magnetic particle inspection shall be conducted in accordance with API 8C ISO 13535 If you are inspecting a TESCO load path torque arrest system or critical component you must provide the top drive owner with the following information General information for each component tested e type of test or inspection performed MPI WFMPI etc type of equipment used to perform the testing operating conditions name and type of inspecting company name and signature of the inspector date of inspection Inspection results for each component tested part description name size etc serial number of the inspected part exact location of all points of damage measured from a recognizable point of reference including the follow
7. TESCO Maintenance Guide HMIS Top Drive System 250TON HMIS 475HP DOCUMENT NAME 880028 REv 8 MAINTENANCE GUIDE COPYRIGHT AND DISCLAIMER Tesco Corporation TESCO has made every effort to ensure that this document contains accurate and current information for the TESCO top drive however the document is intended to be used in conjunction with a complete training program and on site supervision and TESCO does not warrant or guarantee that the information contained herein is either complete or accurate in every respect and the reader hereby protects indemnifies and holds harmless Tesco Corporation together with its directors officers employees and agents from and against all liability for personal injury death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document Tesco Corporation O 2007 Contact Information Corporate Head Office 3993 W Sam Houston Parkway No Suite 100 Houston Texas 77043 USA www tescocorp com Telephone 713 359 7000 Fax 713 359 7001 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 1 REVISION INFORMATION MAINTENANCE GUIDE Revision Information Version Date Description of Changes Rev A June 2004 HMI model general engineering review with updates and additions for 2004 Rev B March 2005 All models updated the Service Checklist Appendix to reflect information in the Maintenance and Se
8. 11 station manifold general condition leaks Load collar correct spacing between load collar and load nut Mud valve lower ball manually operate to ensure correct function All fasteners nuts bolts and lock wires correct location tightness Top Drive hydraulic connections and hoses oil leaks deformation Saver sub threads excessive thread wear seal face condition Connection locking clamps correct location tightness Grabber leg safety chain shackles broken components lock wires Pipe bumper motor guard dents or bends that may indicate bolt damage Counter balance system ensure proper function setup cushion height pressure and hose integrity Hammer union on Kelly hose integrity and tightness Grabber drawworks and mud valve mud pump interlocks function test Gearbox lubrication system hoses oil leaks adequate circulation press 60 120 psi Motor cooling fan function test unnatural noises 880028 REv 8 Torquewear liners if applicable wear damage Block support wear liners if applicable wear damage Wash pipe leakage 250TON HMIS 475HP OTESCO CORPORATION 2007 101 APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE Inspect For Inspector Pipe handler slew
9. C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 85 APPENDIX D SAMPLE INSPECTION LOGS MAINTENANCE GUIDE LOAD NUT RETAINER AND SPLIT COLLAR INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments TESCO CORPORATION 2007 86 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS MUDSAVER VALVE INSPECTION LoG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Days in Service Inspected By Results Comments Next Service Date Cumulat
10. CHAPTER 6 LONG TERM PRESERVATION AND STORAGE Elevators 1 ai Uu c Remove the elevator inserts Use a wire brush to clean and brush the inserts Apply a thin coat of grease or anti seize compound to the inside of the elevators and all sides of the inserts Apply anti seize compound to all stop bolts Install the elevator inserts Operate the elevators and thoroughly grease the body and hinge Apply grease to the exposed rod shafts of the elevator operating cylinders Grease all retainer bolts on the elevator link s Mudsaver Valve SEP Goo zt Ser CU oo ke Emo be m o Fa gt Remove the actuator Clean and inspect the threads on the mudsaver valve Clean the inside of the valve Manually close the valve Pour oil into the ball of the valve Operate the valve Repeat steps 4 6 for both sides of both balls Apply liberal amounts of thread dope to all connections Use a wire brush to clean and brush the outside of the valve Apply grease to the valve stem area and valve body Clean and inspect the actuator Grease the inside of the actuator Reinstall the actuator on the mudsaver valve Note Use anti seize compound on all fasteners and hex nuts Saver Subs 1 2 880028 REv 8 Clean and inspect all threads Apply pipe dope and install thread protectors 250TON HMIS 475HP TESCO CORPORATION 2007 65 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE M
11. MAINTENANCE GUIDE Frequency Operating Days and Inspection Type Point Name pue Every 250 At 1000 1 Entire length of link A B C 2 Top eye load collar eye A B C 3 Bottom eye elevator eye A B C 4 Length between the eyes A B C Refer to Table 3 1 on page 19 for inspection type details As recommended by equipment manufacturer TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 26 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 8 Elevators HMI A H e A s L Frequency Operating Days and Inspection Type Point Name At 250 1 Main hinge pin 2 3 Secondary latch 4 Elevator link ears 5 Elevator body 6 Latch pins 7 Elevator inserts 8 Insert grooves top and bottom Ensure the insert does not fall out Refer to Table 3 1 on page 19 for inspection type details As recommended by equipment manufacturer 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 27 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES THREADED CONNECTIONS MAINTENANCE GUIDE All threaded connections listed in the following table must be subjected periodically to wet fluorescent magnetic particle inspection WFMPI by a qualified inspector Each piece should be inspecte
12. OTESCO CORPORATION 2007 104 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE Monthly Filter Manifold APPENDIX E SERVICE CHECKLISTS Inspect For Inspector Cil filters closed loop cleanliness oil filters should be replaced as indicated by oil analysis or every 4 000 operating hours use the manufacturer s recommended filter Cil filters tank cleanliness oil filters should be replaced every 900 operating hours or as indicated by the canister dirt alarms use the manufacturer s recommended filter Monthly Oil Reservoir Inspect For Inspector Return oil tank filter correct connections inspect visually Filter canister correct bolt correct torque Tank all sides including underneath leaks Monthly Cooling System Inspect For Inspector All mounting bolts and fittings tightness Comments Notes 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 105 APPENDIX E SERVICE CHECKLISTS SIX MONTH CHECKLIST MAINTENANCE GUIDE Date Supervisor Rig Time The six month checklist repeats many of the tests and inspections required in the weekly and monthly checklists Complete the regular weekly and monthly checklist requirements and perform the follow ing additional tests and inspections
13. actuating piston grabber 56 actuator lubrication 4 actuator sleeve monthly inspection 6 actuator valve orientation 34 air starter filter inspection 10 air oil cooler inspection 15 annual inspection tank screen filters 15 annual service oil reservoir 15 assembly and disassembly instructions 49 auxiliary pressure relief 38 auxiliary system function light pressure switch 39 C cable reel storage 66 chart tool joint usage 77 commissioning 1 component inspection guidelines 18 coolant analysis 47 coolant level inspection 9 cooling schematics 1 cooling system daily service 15 cooling system monthly inspection 15 cooling system monthly service 15 cooling system service requirements 15 counter balance height 35 counter balance system monthly inspection 6 counter balance system weekly inspection 5 D daily inspection air oil cooler 15 coolant level 9 exhaust system 9 grabber dies 3 grabber height 3 mudsaver valve 3 oil level 9 oil pressure 9 operating pressure 9 prime mover 9 rig saver 9 saver sub 3 swivel oil level 3 top drive 3 top drive gearbox oil 3 94 880028 REv 8 250TON HMIS 475HP INDEX top drive hoses and connections 3 torque arrest system 8 water oil cooler 15 daily lubrication elevator 4 link tilt cylinders 4 mudsaver valve actuator 4 swivel 5 swivel yoke 5 top drive 4 daily service cooling system 15 filter manifold 13 oil reservoir 14
14. CORPORATION 2007 14 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Annual Cil Reservoir Service Replace the tank screen filters at least once every operating year POWER UNIT COOLING SYSTEM SERVICE REQUIREMENTS Daily Cooling System Service The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Air oil cooler leaks correct fan operation Note Set the fan switch to manual before you check operation fan cleanliness correct hot oil shuttle flow Note if the unit is operating check the flow meter on the opposite side of the electrical panel Water oil cooler if installed leaks or damage check visually All sides including under leaks complete visual inspection Cooler core debris blockages Hydraulic hoses and connections leaks tightness Monthly Periodic Cooling System Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All mounting bolts and fittings tightness 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 15 CHAPTER 2 MAINTENANCE AND SERVICE SCHED
15. TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 50 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Remove the Load Nut Remove the snap rings from the locking pin s on the load nut Remove the locking pins Pry the top debris o ring out of its groove in the load nut and slide it up the quill Remove the lock wires from the load nut bolts 8 Remove all the bolts on the load nut Slide the bolt retainer off the bottom of the quill Gently tap the outer retainer to expose the inner split collars SE DX ON CODY GRECO CEA m Remove the inner split collars from the quill Note This exposes the groove profile of the quill 9 Slide the top plate of the load shoulder off the quill Note The locking pins on the top plate prevent the load nut from rotating on the quill Remove the Quill and Swivel Body The quill and swivel body cannot be removed until the quill collars and the load nut have been removed The quill must be connected to a lifting apparatus 1 Remove the lockwires from the bolts on the quill drive hub Note These bolts combined with the drive hub hold the quill in the quill gear 2 Remove the socket head bolts 12 Note The quill is now free 3 Secure the quill and swivel body by running a sling through the yoke of the swivel Note If you removed the yoke and links wrap a soft sling around the bail pins in the side of the swivel 4 Hoist the swivel body and quill out
16. Close and reseal the junction box When these procedures are complete seal all junction boxes with corrosion inhibitor tape Also ensure that all breather openings are sealed Main Drive Quill 1 Clean and inspect the quill connections Note The mudsaver valve must be removed before you can inspect the lower connection Coat all connections with thread compound or preservative grease Wrap all connections with corrosion inhibitor tape Load Nut If you remove the quill service the load nut as follows 1 Clean and inspect all parts of the load nut 2 Coatall segments with light oil then reinstall 3 Applya coat of grease to the outside of the load nut particularly the load shoulder Grabber Leg Remove the grabber leg Apply a liberal coat of grease to the sliding section of the lower leg Apply grease or anti seize compound to all pin pockets and threads Reinstall the grabber leg meom Ip cd rm Remove the grabber cylinder from the grabber assembly See How to Remove the Grabber Actuating Piston on page 56 Remove the die holder plates and dies Inspect and clean all die holder plates and dies Apply grease or anti seize compound to all die holder plates and dies Reassemble the grabber components 10 Coat the entire torque box with a light film of grease 11 Install the grabber cylinder in the grabber assembly TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 64 MAINTENANCE GUIDE
17. Figure 5 3 HMI grabber assembly HMI Gearbox Height Adjustment Pin Safety Wired Upper Grabber Leg Safety 2 Wired sP Hinged Pin Retainer Roto Actuator Stop Grabber Leg Spring Assembly Lower Grabber Leg Grabber Safety Chain Grabber Safety Wired Typ 10 places Safety Wired Typ 6 places Safety Wired 39000752r0 ai 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 59 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How TO CHANGE THE HMI GEAR RATIO Figure 5 4 Gear ratio configuration Set up for the 2 19 1 Set up for the 1 64 1 Gear Ratio Gear Ratio Pinion Gear Upper Bearing 0686 amp O ring 0592 2 19 1 1 64 1 Pinion Gear Pinion Gear 3769 3770 Idler Bore Idler Bore Plug 113 Plug 5113 Pinion Gear Lower Bearing 0686 O ring 5797 gt E ec h Se 249 Idler Gear fF ar 5655 Yn K O Ring Idler G II er Gear 4040 di 5655 Pinion Gear m AN Retainer 4924 O Ring 4040 Idler Trunnion O Rings Bore Plug O Rings 6178 5692 6178 Idler Trunion Trunnion Trunion Idler Shaft Retainer Idler 5691 6265 Shaft 5691 Motor Hydraulic Motor Manifold Motor Flange Motor Pilot Counter Bore 7 d 39000272r0 ai CORPORATION 2007 60 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS
18. Install a magnetic base dial gauge Note Attach the magnetic base to the bonnet so that the needle rests on the quill Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive Monitor the dial gauge for movement Values on the dial gauge should be within acceptable preload parameters new bearings 0 003 in used bearings 0 001 to 0 003 in 6 Ifthe values are outside acceptable preload parameters adjust the preload a Remove the bolts that attach the bonnet upper bearing retainer to the swivel housing b Remove the required number of shims See Sample Calculation on page 45 c Reattach the bonnet upper bearing retainer to the swivel housing 880028 REV 8 250TON HMIS 475HP TESCO CORPORATION 2007 43 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE Check the Quill to Quill Gear Drive Bushing Drive Spacer Endplay 1 Check that the quill drive hub to quill hub bolts are tight 2 Install a dial gauge on the quill between the swivel and the gearbox Note Attach the magnetic base to the quill such that the needle rests on the quill gear drive bushing Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive Monitor the dial gauge for movement There should be no movement S If there is movement this indicates that the spacer is not the correct size Contact Tesco as the spacer
19. Install the die holder plate on the end of the grabber cylinder 2 Torque the retainer plate bolts to 40 ft Ib 3 Slide the cylinder assembly into the clamping box Note Ensure that the port extensions are oriented upward 4 Install the retraction place and piston retaining bolts 2 and torque the bolts to 100 ft Ib 5 Install the port extensions 2 6 Invert the clamping box 7 Install the dies keeper plates and die keeper bolts 8 Secure all drilled bolts in place with lockwire 9 Slide the clamping box into the outer torquing box 10 Install the retraction pins 2 and secure them in place with lock wire 11 Connect the grabber open close hydraulic lines 12 Reset the grabber height For more information refer to How to Reset the Grab ber Height on page 37 CORPORATION 2007 250 475 880028Rev8 56 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS How to Repair the Grabber Cylinder This procedure assumes that the grabber cylinder has been removed from the clamping box Refer to Appendix B Tool Joint Usage Chart to determine which dies and spacers to use for the tool joint in use 880028 REv 8 1 Remove the die holder plate from the cylinder assembly 2 Usethe gland nut spanner supplied by TESCO to remove the brass gland nut from the end of the cylinder Pull the piston out of the cylinder Replace the seals and inspect the cylinder for
20. Other Serial Inspection Days in Service Inspected By Results Comments Next Service Date Cumulative Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 89 APPENDIX D SAMPLE INSPECTION LOGS ELEVATOR LiNKS INSPECTION LoG MAINTENANCE GUIDE Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments OTESCO CORPORATION 2007 90 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS ELEVATOR INSPECTION LoG
21. and use a low flow rate Open the valve at the filter manifold and allow the oil to flow for several seconds Ut de Collect a sample from the running stream of oil Note Ensure that you do not allow outside dirt or contaminants into the sample bottle 9 Submit for analysis according to laboratory instructions Note When submitting oil for analysis include any information that may assist the lab in conducting the analysis For example list any recent component changes or equipment problems If you have any questions regarding the results or would like assistance contact Tesco s tech nical support 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 45 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO SERVICE THE CENTRIFUGAL OIL FILTER ENGINE This procedure is performed as part of periodic power unit maintenance 1 mw SN om 10 11 12 13 14 15 Shut off the engine and wait until the centrifuge in the oil filter stops spinning Remove the filter cover Lift the centrifuge turbine assembly slightly and hold Allow oil to drain out of the hoses Loosen the bowl nut until the face of the nut extends beyond the bushing face Strike the face of the nut to separate the centrifuge bowl from the turbine base Note Do not strike the nut with any hard object the palm of your hand will work Remove the bowl nut completely Remove the bowl and baffle screen Remove the accumulate
22. 2 in 6 UNC 2283 1713 2742 2056 3200 2400 pressures whichever is less Recommended torques are based on bolt tensions of approximately 80 of the yield strength and a minimum of one bolt diameter class 2B thread engagement in the material or bolt head bearing OTESCO CORPORATION 2007 74 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS Table A 2 Special fastener torques Fastener Description Minimum Mild Steel ft lbs High Strength Steel ft lbs E hgagement Dry Lubricated Dry Lubricated UNBRAKO 5 16 in 18 UNRC 3 8 in 27 20 35 26 UNBRAKO 1 2 13 UNRC 1 2 in 118 88 154 115 UNBRAKO 5 8 in 11 UNRC 5 8 in 217 162 283 212 Special fasteners shall be used only in critical locations or special applications Thread engagement is based on the minimum class 2B tapped threads in mild steel capable of developing bolt tension 8096 of bolt yield When using hardened steel washers on mild steel use torque values for high strength steel Table A 3 B7 Stud torques Stud Size Dry ft lbs Lubricated ft lbs 1 2 in 3 UNC 85 64 5 8 in 11 UNC 175 131 3 4 in 10 UNC 300 225 7 8 in 9 UNC 450 338 1 in 8 UNC 680 510 1 1 8 in 7 UNC 880 660 1 1 4 in 7 UNC 1260 945 1 3 8 in 6 UNC 1700 1275 1 1 2 in 8 UN 2300 1725 Recommended torques are based on bolt tensions of approximately
23. Apply lubrication to the idler bearings Note This will help maintain alignment when you install the idler pin Install a long bolt or ready rod in the idler pin Pull the pin into the 2 19 1 gearbox bore Caution Do not misalign the bearing set in the idler gear Secure the pin with the retaining plate for the idler pin Install the 2 19 1 pinion gear Caution Do not misalign the bearings in the pinion bore Install the idler bore plug in the 1 64 1 position top of gearbox Apply silicone to the frost plug Replace the O ring on the trunnion bore plug and install the plug in the 1 64 1 position bottom of the gearbox 250TON HMIS 475HP TESCO CORPORATION 2007 61 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE 18 Replace the O ring on the motor pilot flange and apply silicone to the space plate 19 Replace the motor and manifold assembly 20 Replace the gearbox oil Note Refer to fluid specification EM000042 for information on what lubricants can be used in this application TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 62 MAINTENANCE GUIDE CHAPTER 6 LoNG TERM PRESERVATION AND STORAGE INTRODUCTION Use the following guidelines whenever you place a TESCO top drive into long term storage Before you begin these procedures ensure that all necessary unit maintenance is complete and the unit is fully functional If all repairs cannot be completed ensure that you create t
24. C 5 Length of valve body C Refer to Table 3 1 on page 19 for inspection type details 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 23 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 5 Saver sub HMI 39000813r1 ai Frequency Operating Days and Inspection Type Point Name Every 60 250 At 500 At 750 At1000 1 Upper seal face A B C 2 Upper threads C 3 Lower seal face C 4 Lower threads C 5 Entre length of body C Refer to Table 3 1 on page 19 for inspection type details TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 24 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 6 Load collar HMI Frequency Operating Days and Inspection Type Point Name Every At At At At 60 250 500 750 1000 1 Load collar ears A 2 Load shoulder check for cracks galling and heat damage 3 Complete load collar A C Refer to Table 3 1 on page 19 for inspection type details 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 25 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 7 Elevator links bails HMI
25. Check for visible damage and repair if required Prepare the cooler unit for storage Note If the unit will be stored in a shipping container no further preparation is required Note If the unit will be exposed to the elements during storage fabricate a cooler cover using tarps plywood or other available materials Optional Stand Alone Plate Exchanger 1 Open the unions to the water side of the cooler 2 Ensure that the inside is dry 3 Ifthe unit has been operated using seawater flush with fresh water 4 Apply light coat of grease to all unions and reinstall the caps Auxiliary Oil Pump Open the electrical junction box Ensure the box is clean and dry Apply a light coat of grease to the sealing surface of the cover plate Coat all bolts with an anti seize compound and reinstall the bolts Remove the coupler cover plate Spray light penetrating oil onto the coupler DE RS DA de Reinstall the cover plates Filter Manifold 1 Remove the caps on the hammer union 2 Lightly grease the caps and reinstall them 3 Apply a light grease to all filter caps and relief plugs Pump Drive and Main Hydraulic Pumps Apply light grease to all unpainted metal parts to protect against corrosion 2 Apply grease to the threads of all mounting studs Add corrosion inhibitor to the pump drive oil Note Check the manufacturer s specifications for correct inhibitor concentration 4 Sealand cover all breather po
26. How to Remove and Reinstall the Grabber Leg The grabber might require disassembly and repair if the following problems occur The grabber will not open or close even though electrical and hydraulic circuits are oper ating normally The grabber will not hold the required pressure A hydraulic oil leak is detected How to Change the Grabber Dies It is easiest to perform this procedure if the drill pipe is disconnected and the saver sub is removed however grabber dies can be changed with the drill pipe connected to the saver sub if required Caution This procedure requires the removal and replacement of small parts If possible use the EXTEND function to move the bot tom of the grabber away from hole center Cover all exposed areas around well center to prevent parts from falling through the table ber is partially closed Do not allow the grabber to close fully Remove the lower die keeper plates 2 and the retaining bolts 2 per plate Caution It is easier to access the grabber dies and bolts if the grab 1 2 Use a long pin punch or similar tool to tap the dies downward and out of the die holder blocks Remove spacers if used 4 Use a film of grease or pipe dope to lubricate the new dies Install the new dies and spacers Note Select dies and spacers that are appropriate for the drill pipe in use Refer to Appendix B Tool Joint Usage Chart 6 Install the die keeper plates Note Torque the ret
27. IX CHAPTER 1 ABOUT THIS DOCUMENT 00 cece eee ee eee eee n n nn nnn 1 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES 3 Top Drive Service Requirements 3 Daily Top Drive Service Requirements 3 Swivel Lubrication Requirements a n sussun 0c e cect cette eee ae 5 Weekly Top Drive Service 5 Swivel Inspection Requirements 5 Monthly Periodic Top Drive Genee 6 Service Loop Service 8 Weekly Service Loop Service Requirements 8 Monthly Periodic Service Loop Service Requirements 8 Torque Arrest System Service Requirements 00 00 0c ccc ete ees 8 Daily Torque Arrest System Service 8 Weekly Torque Arrest System Service 9 Power Unit Prime Mover Service Requirements 9 Daily Prime Mover Service ress e toppin o pi 9 Weekly Prime Mover 10 Monthly Periodic Prime Mover Service 10
28. Torque data U N O 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 73 APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS MAINTENANCE GUIDE 10 For torque values for B7 studs with 2H nuts see Table 3 11 Lubricated fasteners must have oil or thread locking compound applied to the threads only TABLES 12 Where metals with strongly varying electromotive properties are bolted together such as steel and aluminum thread locking compounds should be applied to limit the effects of galvanic corrosion A minimum of two full threads should project above any nut or locknut installed on a stud or as part of a bolted connection Additional length is allowed to install safety pines or cotter pins to prevent fasteners from falling into overhead equip ment Table A 1 Standard torques Material Aluminum ft lbs Mild Steel ft lbs High Strength Steel ft lbs Size Dry Lubricated Dry Lubricated Dry Lubricated 1 4 20 UNC 9 7 10 8 12 9 5 16 in 18 UNC 16 12 19 15 25 19 3 8 in 16 UNC 33 25 40 30 45 34 7 16 in 14 UNC 47 36 57 43 70 53 1 2 in 13 UNC 86 64 100 75 110 83 9 16 in 12 UNC 118 88 141 106 160 120 5 8 in 11 UNC 163 122 195 146 220 165 3 4 in 10 UNC 278 209 333 250 400 300 7 8 in 9 UNC 436 327 523 393 645 484 1 in 8 UNC 667 500 800 600 970 728 1 1 8 in 7 UNC 950 713 1142 856 1370 1028 1 1 4 in 7 UNC 1317 988 1575 1181 1900 1425 1 1
29. Torque track stabilization components cracks or loose fasteners close visual inspection is required POWER UNIT PRIME MOVER SERVICE REQUIREMENTS Daily Prime Mover Service The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All hose connections and belts leaks tightness Exhaust system routing loose clamps and bolts check visually Cil level low idle oil level check for leaks Coolant level correct level Cil pressure correct operating range consult the manufacturer s service and maintenance documentation for your prime mover module Operating fuel pressure adequate pressure consult the manufacturer s service and maintenance documentation for your prime mover module Air filter restriction indicator consult the manufacturer s service and maintenance documentation for your prime mover module Rig saver confirm correct position open 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 9 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Weekly Prime Mover Service The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments In
30. Use the following procedure to move the idler gear and change pinion gear from 21T 1 64 1 to 28T 2 19 1 1 10 11 12 15 16 17 880028 REv 8 Drain all of the oil from the gearbox Note If you replace the oil ensure that all waste oil is correctly disposed of Remove the motor and manifold as a single unit To remove the motor and manifold you must remove the six bolts that hold the motor in place Label all control hoses disconnect and put protective covers on all hose ends Remove the 21T pinion gear from the motor pilot bore Caution Ensure that the bearing below the pinion gear in the base of the gearbox is not moved out of alignment when you remove the pinion gear Inspect the lower bore area for metal deposits or debris If you find dirt or debris thoroughly clean the gearbox Remove the retainer plate for the 1 64 1 trunnion idler pin from the bottom of the gearbox Remove the 2 19 1 idler bore plugs from the top and bottom of the gearbox Note At the top of the gearbox this is a frost plug at the bottom it is a blank plate Remove the retainer plate for the trunnion idler and immediately install a thread protecting bolt into the tapped idler pin hole Caution These threads are important for correct gear installation Do not damage these threads Remove the idler pin and replace both O rings Move the idler gear to align with the bore position of the 2 19 1 trunnion idler pin
31. damage excessive wear Urethane capture blocks hose placement tightness at top drive and roller saddle Fluid quick couplers auxiliary and damage or decay tightness cooling All cable connections tightness power sensor robotics and ground cables Weekly Torque Arrest System Inspect For Inspector All bolts and threaded rods damage or decay tightness Torque track hanging assembly damage close visual inspection is required Torque bushing liners or torque arrest wear the bushing liner must be replaced before the beam liners liner mounting bolts come in contact with the torque tube Torque bushing clearance amount of clearance it might be necessary to remove a torque bushing shim if there is more than 1 4 in clearance between the torque bushing and the torque tube or if there is excessive torque bushing movement Torque track stabilization components cracks or loose fasteners close visual inspection is required Weekly Power Module Inspect For Inspector Air filters on the heat pump cleanliness filters can be washed Air filters on the door fan and chopper module cleanliness filters can be washed Ventilation louvers cleanliness obstructions restrictions Cooling ducts cleanliness obstructions restrictions 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 99 APPENDIX E SERVICE CHECKLISTS Weekly Prime Mover MAINTENANCE GUIDE
32. desired make up torque Release the MAX TORQUE button when desired torque is achieved Open and lower the grabber Install the mudsaver die lock clamp and retainer ring Use a die lock clamp to install the saver sub into the mudsaver valve Note For more information refer to the Operations Guide for your unit 250TON HMIS 475HP TESCO CORPORATION 2007 53 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How TO DISASSEMBLE AND ASSEMBLE THE GRABBER Figure 5 2 HMI grabber box components Seal Alignment Grabber Cylinder Gland Nut Tong Dies Die Holder Retainer Plate Piston Die Holder O Ring Gland Nut Seals Breakaway Tabs Cylinder Assembly Top Die Holder Retainer 4 Inner Die Holder Tong Di oh ter Top Die Holder bd Retainer QN Die Holder Retainer Plate Pf 1 1 y i de e Die Holder Breakaway Tabs Inner Die Holder B g Safety Wired Y Blue Loctite 242 gt Retracting Pins Grabber Close 6 Safety Wired Lee Safety Wired Blue Loctite 242 Clamping Box Grabber Open Retracting Plate 39000751 0 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 54 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Introduction This section contains the procedures that explain how to disassemble and assemble the grabber components How to Change the Grabber Dies How to Remove Service and Reinstall the Grabber Actuating Piston
33. hours Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Hydraulic fittings tightness TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 10 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Inspect For Fuel filters primary and secondary use cleanliness inspect periodically replace recommended OEM filters according to manufacturer s specifications Note More frequent replacement might be required where the fuel supply quality is poor Exhaust system carbon build up also use rig up or operational downtime to inspect bolts and flanges Centrifugal oil filter if equipped cleanliness service every 900 operating hours or according to manufacturer s specifications Cooling system filter cleanliness replace every 900 operating hours Coolant perform a coolant analysis every 900 operating hours replace as required POWER UNIT PumP DRIVE SERVICE REQUIREMENTS Daily Pump Drive Service The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Cil level adequate oil level fill if required Oil system leaks Coo
34. operating hours or as indicated by the canister dirt alarms use the manufacturer s recommended fil ter Hydraulic fittings tightness 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 13 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE POWER UNIT OIL RESERVOIR SERVICE REQUIREMENTS Daily Oil Reservoir Service The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Reservoir and area leaks Return oil tank filters dirt inspect the dirt alarm and replace the filter if required Low oil level shutoff equipment correct connection inspect visually Tank oil see Figure 2 4 Hydraulic hoses and connections correct operating level leaks tightness Figure 2 4 Oil tank level Monthly Periodic Oil Reservoir Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Return oil tank filter correct connections inspect visually Filter canister correct bolt correct torque Tank all sides including underneath leaks Hydraulic fittings tightness
35. operating month or as indicated in the following table More frequent inspection might be required if you are operat ing the top drive in harsh or demanding drilling environments Inspect For Gearbox oil abnormalities take samples to test for water metal particles etc every 900 operating hours Hydraulic fittings tightness Roto actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 33 Counter balance system correct cushion height see How to Set the Counter Balance Cushion Height on page 35 Sensor panel moisture tightness of wire terminations Quill hub preload correct preload see How to Check and Adjust Preload on page 40 The following lubrication should be performed at least once every operating month More fre quent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments Lubricate With Hinge pins and extend frame if applicable spray with penetrating oil WD 40 or spray lithium TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 6 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Figure 2 2 Lubrication points for the Top Drive Washpipe 1 Swivel Yoke Hinge Pins 2 Swivel Pin 1 D s Bag Swivel Pin Se
36. the outlet of the charge pressure manifold correct differential pressure maximum differential is 100 psi if differential is greater than 100 psi replace the filter elements use the manufacturer s recommended filter ele ment TESCO CORPORATION 2007 96 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE Daily Oil Reservoir APPENDIX E SERVICE CHECKLISTS Inspect For Inspector Reservoir and area leaks Return oil tank filters dirt inspect the dirt alarm and replace the filter if required Low oil level shutoff equipment correct connection inspect visually Tank oil correct operating level Daily Cooling System Inspect For Inspector Air oil cooler leaks Correct fan operation Note Set the fan switch to manual before you check operation fan cleanliness correct hot oil shuttle flow Note if the unit is operating check the flow meter on the opposite side of the electrical panel Water oil cooler if installed leaks or damage check visually All sides including under leaks complete visual inspection Cooler core debris blockages Comments Notes 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 97 APPENDIX E SERVICE CHECKLISTS WEEKLY CHECKLISTS MAINTENANCE GUIDE D
37. weekly inspection 8 V valves monthly inspection 8 W water pump inspection 10 water oil cooler inspection 15 weekly inspection counter balance system 5 fasteners 5 fluid quick couplers 8 grabber chain 5 load collar 5 prime mover 10 service loop 8 service loop components 8 swivel 5 swivel hammer unions 5 top drive 5 torque arrest system 9 urethane capture blocks 8 water pump 10 weep hole plugs 10 weekly service pump drive 12 service loop 8 top drive 5 weep hole plugs inspection 10 wet fluorescent magnetic particle inspection 28 WFMPI inspection 28 WFMPI testing 28 250TON HMIS 475HP 880028 REv 8
38. will have to be removed and resized CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 44 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How to Calculate the Preload Adjustment If the previous procedure reveals any amount of quill end play the quill preload must be adjusted To decrease end play in the quill increase the preload you must remove shims from the shim pack Use the following calculation to determine how many shims to remove observed quill end play in 0 000 in 0 010 in the thickness of shims to be removed Sample Calculation If the quill end play is 0 019 in then 0 019 0 010 in 0 029 in 50 002 Between 0 027 to 0 031 in of shims must be removed to adjust the preload to the correct force How TO PERFORM A HYDRAULIC OIL ANALYSIS Hydraulic oil analysis is part of periodic power unit maintenance Note Test ports for the hydraulic oil are located at the closed loop filter manifold 1 Ensure that the oil is warm and recently circulated Note If the oil is cold or has been static particulate will settle to the bottom of the tank and you will not get an accurate sample 2 Ensure that you have a small clean sample bottle ready Note If the oil sample is contaminated with debris or grime the analysis will be inaccurate Shut off the power unit Install a tee and valve at the filter manifold at the driller s gauge port Start the power unit Set the PUMPS REV FWD switch to FWD
39. 75 of stud yield strength 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 75 APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS Table A 4 Thread engagements Material Aluminum Mild Steel High Strength Steel Engagement 96 of Full Torque of Full Torque of Full Torque 10096 10096 100 100 90 100 100 100 80 100 100 100 70 100 100 100 60 90 100 100 50 70 100 100 40 60 75 100 30 45 60 75 20 30 40 55 approval Engagement as of the bolt diameter Values represent the percentage of torque from Table 1 Engagement does not include chamfer or incomplete threads Engagements of less than one bolt diameter in tapped holes shall not be used without the engineer s OTESCO CORPORATION 2007 76 250TON HMIS 475HP MAINTENANCE GUIDE 880028 REv 8 MAINTENANCE GUIDE APPENDIX B TOOL JOINT USAGE CHART APPENDIX B TooL JoiNT USAGE CHART Use the following chart to configure the grabber and grabber dies to accommodate the current drill pipe Table B 1 Tool joint usage chart Tool Joint TESCO Part 3 1 8 in 6 5 8 in Description Die holder Socket head capscrew 1 2 13UNC x 2 1 2 in Bottom keeper plate Top die retainer plate Hex head capscrew 3 8 16UNC x 1 in Socket head capscrew 1 2 13UNC x 1 in Spacer 4891 opt Tong die 1 in thick x 1 1 4 in
40. A A C Torque beam clamp bar A A A C Redi rod nuts torque arrest system A A A C Connection to the derrick leg A A A C Torque track A A A C Refer to Table 3 1 on page 19 for inspection type details TESCO CORPORATION 2007 30 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES PiPE HANDLER ROTATION SYSTEM INSPECTION FRE QUENCY Figure 3 10 Other non destructive testing HMI 880028 REv 8 Gearbox Grabber Leg Bolts Typ 12 places Upper Grabber Leg Lower Grabber Leg Torque Box Bol ts Typ 10 places 39000270r2 ai 250TON HMIS 475HP Torque Box Clamping Box CORPORATION 2007 31 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Frequency Operating Days and Inspection Type Name Every At At At At 60 250 500 750 1000 Torque box A C Clamping box A A A C Torque box bolts A A A Replace Grabber bolts A A A Replace Gearbox grabber leg bolts Replace Upper grabber leg A A A C Lower grabber leg Refer to Table 3 1 on page 19 for inspection type details OTESCO CORPORATION 2007 32 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES INTRODUCTION The service procedures described in this chapter are an extension of the service activiti
41. AINTENANCE GUIDE HOSE STORAGE REEL Main Storage Reel 1 A wm E M Perform the following for all hose ends and quick couplers clean and inspect apply a thin coat of grease wrap with corrosion inhibitor tape check the rubber seals within the hammer unions ensure the isolation valves are closed Grease the bearings on the storage reel saddle Ensure that protective caps are installed on all hose connections Grease the drive chain on the storage reel Remove the hydraulic control for the storage reel Store the hydraulic control in the top drive shipping container or other sheltered location Perform the following steps for the 37C conductor cables 2 1 2 3 4 Spool the 225 ft cable onto a shipping reel Spool the 160 ft pigtail onto a power cable post Spray the connector ends with light oil Wrap the connectors with corrosion inhibitor tape DRILLER S PANEL See Cl cem Open the driller s panel Check for moisture or damage Clean the interior Verify that all wire terminals are torqued to specification Install a new desiccant bag Clean all the connectors Spray the ends of the connectors with light oil Wrap all of the connectors with corrosion inhibitor tape Store the driller s panel in the top drive shipping container or other sheltered loca tion TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 66 MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAG
42. D push button correct function replace if required Braking register module for sign of overheating Comments Notes 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 95 APPENDIX E SERVICE CHECKLISTS Daily Prime Mover MAINTENANCE GUIDE Inspect For Inspector All hoses and belts leaks tightness Exhaust system routing loose clamps and bolts check visually Cil level low idle oil level check for leaks Coolant level correct level Cil pressure correct operating range consult the manufacturer s service and maintenance documentation for your prime mover module Operating fuel pressure adequate pressure consult the manufacturer s service and maintenance documentation for your prime mover module Air filter restriction indicator consult the manufacturer s service and maintenance documentation for your prime mover module Rig saver confirm correct position open Daily Pump Drive Inspect For Inspector Cil level adequate oil level fill if required Cil system leaks Cooling system excessive dirt general condition check the heat exchanger Pump drive lubrication system correct lubrication of the pump splines check at the oil filler cap Daily Filter Manifold Inspect For Inspector Filter housing and manifold leaks Charge pressure differential gauge on the inlet and one gauge on
43. E Interlocks Clean all interlock valves Spray the valves with light oil Clean all of the connectors Spray the ends of the connector with light oil Ur ode om Wrap all of the connectors with corrosion inhibitor tape TORQUE ARREST SYSTEM Torque Track Assembly Clean and inspect all sections of the torque track Use a wire brush on the end connection points of all torque track sections Clean and dry the ends of the track sections Apply a thin coat of grease to the ends of the track sections Install protective end caps Coat all bolts and studs with anti seize compound Sat UN LUV Ros i Apply paint or corrosion inhibitor to any bare spots along the length of the torque tracks Torque Bushing Extend Frame Clean and inspect all pin sockets Apply a thin coat of grease to all pin sockets Wrap all pin sockets with corrosion inhibitor tape Grease the ends of all cylinder pivots and the exposed cylinder rods Clean the hydraulic quick couplers for the EXTEND mechanism Apply a thin coat of grease to all quick couplers Wrap the quick couplers with corrosion inhibitor tape we EU mom nc Inspect the liner of the torque bushing for wear Note Replace the liner prior to storage if required Studs for Torque Track Clean and grease 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 67 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE Hanging Sling Assembly Clean and insp
44. Ev 8 34 MAINTENANCE GUIDE 10 11 12 13 14 15 16 17 18 19 CHAPTER 4 SERVICE PROCEDURES Slowly raise the grabber to move the actuator to the correct position The actuator should slide smoothly onto the double ball valve Install four brass shims 0 010 in or a 0 010 in feeler gauge between the body of the mud valve and the actuator Note The shims help to align the valve and actuator concentrically during assem bly Coat all locking pins and setscrews with a thin coat of anti seize compound Install the locking pins springs and setscrews as follows a Put all locking pins spring and setscrews in place b Turn the setscrews until they meet the springs but do not tighten them c Start the locking pins Install the hex drives 2 Install the snap rings into snap ring grooves Tighten all setscrews evenly to 100 ft Ib Install a hose clamp over the locking pins Remove the brass centering shims Lower the grabber Remove the wooden blocks Rotate the quill with the top drive to position the locking mechanism to accept the stop bracket of the actuator Install the stop bracket Connect the hydraulic lines for the mud valve open valve close circuit Test the actuator to confirm that it is working correctly How TO SET THE COUNTER BALANCE CUSHION HEIGHT Perform this procedure as part of monthly top drive maintenance Ensure the top drive is posi tioned at the racking platform before y
45. OR switch to OPEN then to CLOSE This will relieve any pres sure in the system Remove the elevator hydraulic hose from the counter balance manifold Caution If you disconnect a quick coupler while there is pressure in the system it will be extremely difficult to reconnect the coupler Figure 4 2 Counter balance cushion height Pin Position in Link Eye Weight off Weight on 39000299 0 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 36 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO RESET THE GRABBER HEIGHT Use this procedure to reset the grabber height Perform this procedure as part of monthly top drive maintenance Use a pin located on the back side of the grabber leg to adjust the height You can use one of several pin locators to position the grabber leg Figure 4 3 Grabber position Height adjustment pin positions on the back of the grabber leg 880028 REv 8 10 11 Bottom seal face Before You Start Measure the distance from the top of the grabber die to the lower seal face of the saver sub Note This measurement should be 1 in If the distance is not 1 in adjust the grabber height by changing the pin locations as follows Open the hinged pin retainer on the upper grabber leg Lower the top drive until the grabber is resting on the floor Adjust the height of the top drive so that the weight of the grabber leg is removed from the height adjustment pi
46. ORPORATION 2007 3 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Figure 2 1 HMI swivel oil level Lubrication The following lubrication should be performed at least once every operating day More fre quent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments Lubricate With Shots Grease nipples on the EXTEND EP2 multi purpose grease 2 each cylinder 4 Lower bearing retainer of gearbox EP2 multi purpose grease 2 each grease ports 2 Upper bearing retainer of gearbox EP2 multi purpose grease 2 each grease ports 2 LINK TILT cylinders 4 per side 8 EP2 multi purpose grease 2 each total Grease ports on the elevator 3 EP2 multi purpose grease 3 each Mudsaver valve actuator 3 Mystik J76 TESCO Part Fill grease reservoir 4409 or Metalon EP1 5 TESCO Part 2996 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 4 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Swivel Lubrication Requirements The following lubrication should be performed at least once every operating day if the top drive is equipped with the optional swivel More frequent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments Lubricate With Ports on the swivel link hinge points 2 EP2 multi purpose grease Wash pipe port 1 EP2 multi purpos
47. Power Unit Pump Drive Service 11 Daily Pump Drive Genee 11 Weekly Pump Drive 12 Monthly Periodic Pump Drive Service 12 Power Unit Filter Manifold Service Requirements 13 Daily Filter Manifold Service 0 00 00 cette teens 13 Monthly Periodic Filter Manifold Service 13 Power Unit Oil Reservoir Service 14 Daily Oil Reservoir Service 0 2 0 cette s 14 Monthly Periodic Oil Reservoir Service 2 0 0 0 ccc eee 14 Annual Oil Reservoir Service ke rest dras rene ttt tenet ene ene 15 Power Unit Cooling System Service 15 Daily Cooling System Service 15 Monthly Periodic Cooling System Genee 15 880028 Rev8 250TONHMIS47bHP OTESCO CORPORATION 2007 TABLE OF CONTENTS MAINTENANCE GUIDE CHAPTER 3 NoN DESTRUCTIVE TESTING AND INSPECTION SCHEDULES 17 Top Drive Owner s Guidelines e eme nier mte sen RE Sene RT eka Sa 17 Guidelines for Component Inspectors 18 Load Path Components and Inspection Information 18 Threaded Connectio
48. SERVICE CHECKLISTS DAiLY ToP DRIVE REPORT CORPORATION 2007 108 MAINTENANCE GUIDE Order the Daily Top Drive Report booklet from TESCO EMI 400 ELECTRIC TOP DRIVE DAILY OPERATIONS CHECKLIST M 400 2507 400 1507 Top Drive Information Gear box press T psiTORPM Gear box temp C Gear box oil level tun Wl wal ety pins are in place Information from main electrical panels in power module indicators are ON Building thermostat vet GP Record Building temp 00 F 68 F Information from Mechanical Module normal operating parameters are listed in brackets Hy Tank temp oc Hyd Circ Press 300 400 psi 300 400 psi Top drive serviced by daylight crew Top drive serviced by night crew Hydrantic cybnder eyes damaged New saver sub installed 4 yr Total Current 7 7 Concerns and Corrective Actions 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS Hydraulic Top Drive Daily Operations Report Duc 1 1 71 jTopDmeUnt PUA Opmtor ob TD Tech f Contractor Rig 0 Location P Current Depth J Wels 5 ooo ProieedDephim __ WeaberTemp PO Job ays Remaining Casing Size Depth Tubular rosa MakeupTorque Surface _ Interm
49. TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 Vill MAINTENANCE GUIDE LIST OF TABLES LisT OF TABLES Table 1 1 Where to find more information 1 Table 3 1 Inspectiontypes liiisilessseslssesseeeles e tees 19 Table 1 Standard torques ls 74 Table 2 Special fastener 75 Table A 3 B7 Stud torques 75 Table 4 Thread engagements 76 Table B 1 Tool joint usage 77 Table B 2 Tool joint usage chat 78 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 IX LisT OF TABLES MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 X MAINTENANCE GUIDE CHAPTER 1 ABOUT THIS DOCUMENT This document contains information on how to service and maintain your HMIS Top Drive System Table 1 1 Where to find more information For information on Refer to system components System Description installing the top drive Installation Guide rig up procedure commissioning pre operational checklists rig out procedure setting torque and speed Operations Guide driller s panel function and operating descriptions making connections e drilling ahead tripping stuck pipe TESCO manufactured parts a
50. TESCO Engineering for disposition B Perform MPI or WFMPI for cracks All cracked components should be referred to TESCO Engineering for disposition C Return to a TESCO authorized service centre for complete dimensional visual WFMPI MPI inspection for recertification Upon completion of Type C inspection the inspection schedule starts at zero operating days 250TON HMIS 475HP TESCO CORPORATION 2007 19 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 1 Swivel HMI E em Frequency Operating Days and Inspection Type At 250 At 500 At 750 At 1000 1 Hook contact point A B 2 Swivel yoke A A A C 3 Swivel yoke pin holes 4 Yoke pins A B A B A B C 5 Swivel links A A A C 6 Swivel link yoke pin holes A B A B A B C 7 Swivel link swivel pin holes A B 8 Swivel pins A B A B A B C 9 Swivel body pin holes A B A B A B C 10 Swivel body A A A C Refer to Table 3 1 on page 19 for inspection type details OrEsco CORPORATION 2007 250TONHMIS475HP 880028Rev8 20 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 2 Quill HMI Frequency Operating Days and Inspection Type Point Name Every At At At At 60 250 500 750 1000 1 Threads and bore A A A 2 Upp
51. UCTIONS 49 How to Disassemble the Load 50 Break Out the Load Path 50 Removeithe Load Nub zoo ei te are UELLE VERE veg egi 51 Remove the Quill and Swivel 51 How to Assemble the Load 51 Iristall thi ir inb reta wo ton dee e drea cud os ea rs 52 Install the Load cue reae ette epe pe et eti er tet ette er eti ee ms 52 Install the Mudsaver Valve 53 ari at Lp 55 How to Change the Grabber Dies 55 How to Remove the Grabber Actuating 5 56 How to Reinstall the Grabber Actuating 1 5 56 How to Repair the Grabber 57 How to Remove and Reinstall the Lower Grabber 58 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 IV MAINTENANCE GUIDE TABLE OF CONTENTS How to Change the HMI Gear PHano ete eens 60 CHAPTER 6 LONG TERM PRESERVATION AND 63 Introduction wea eye ine Ses 63 Before System Shut Down 63
52. ULES MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 16 MAINTENANCE GUIDE CHAPTER 3 NoN DESTRUCTIVE TESTING AND INSPECTION SCHEDULES ToP DRIVE OWNER S GUIDELINES The integrity performance and safe operation of TESCO s top drives depend on sound main tenance and inspection of all load path torque arrest system and critical components This chapter describes TESCO s minimum recommended inspection schedule including the fol lowing recommended reporting format for third party inspections recommended minimum inspection frequency for each load path torque arrest system or critical component specific areas of concern for each component Caution In addition to the schedule suggested here all load path torque arrest system and critical components must be inspected following rough drilling excessive jarring or any other exceptional circumstance that might increase fatigue failure When you receive inspection reports file them in accordance with procedures in your operat ing area Itis critical that you maintain complete inspection and service records for all load path torque arrest system and other critical components information must be used in conjunction with a regular inspection and maintenance program as defined in Chapter 2 Maintenance and Service Schedules Caution This guide addresses MPI and WFMPI testing only This
53. ainer and split collar 1 22 Figure 3 4 Mudsaver valve and actuator 0 23 Figure 3 5 Saver sub UM 24 Figure 3 6 Load collar 25 Figure 3 7 Elevator links bails 26 Foure 3 8 Elevators AMI ceed bed dee deb Le LR nee eee ewe neu ERES 27 Figure 3 9 Non destructive testing for the standard torque arrest system 29 Figure 3 10 Other non destructive testing 31 Figure 4 1 Actuator valve 34 Figure 4 2 Counter balance cushion 36 Figure 4 3 Grabber position 37 Figure 4 4 Auxiliary relief valve 38 Figure 4 5 Description of preload III 40 Figure 5 1 Load path components 49 Figure 5 2 HMI grabber box 54 Figure 5 3 HMI grabber assembly 59 Figure 5 4 Gear ratio configuration 60 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 Vil LIST OF FIGURES MAINTENANCE GUIDE This page has been left blank intentionally
54. aining bolts to 100 ft Ib 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 55 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How to Remove the Grabber Actuating Piston The grabber must be empty before you can perform this procedure IN Caution This procedure requires the removal and replacement of small parts If possible use the EXTEND function to move the bot tom of the grabber away from hole center Cover all exposed areas around well center to prevent parts from falling through the table Cut the lock wires on the lower grabber retractor pins Remove the retractor pins 2 Label the grabber open and grabber close hydraulic hoses then remove them Cap the hoses Caution Ensure that the GRABBER switch is in the neutral position and the auxiliary pump is shut off Slide the complete clamping box assembly out of the torquing box Remove the piston retaining bolts 2 and the retraction plate from the clamping box Remove the hydraulic extension ports 2 Slide the cylinder assembly out of the clamping box You do not need to remove the die and die holder at this time Repair or replace the piston or seals as required Note If you are replacing the piston assembly then you must remove the die holder and install it onto the new piston How to Reinstall the Grabber Actuating Piston The following procedure assumes that all grabber cylinder components are assembled 1
55. al Housing 2 1 Pog Extend Frame Hinge Pins m Extend Cylinders One each 7 end 4 Mud aes Ss Upper amp 8 Quill Bushing 1 Lower Bearing Typical p Elevator Hinge 1 H am e 1 Elevator Handle Pin 2 One at each m end of pin 39000268 ai 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 7 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE SERVICE LooP SERVICE REQUIREMENTS Weekly Service Loop Service Requirements The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All service loop components damage excessive wear Urethane capture blocks hose placement tightness at top drive and roller saddle Fluid quick couplers auxiliary hydraulics damage or decay tightness Monthly Periodic Service Loop Service Requirements The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Wire terminals in the driller s panel tightness All hoses leaks damage Threa
56. ality products rework cost warranty claims late delivery customer dissatisfaction lower production STANDARDS 1 Allcapscrews bolts and nuts have to be Grade 8 or equivalent unless noted other wise U N O 2 Fasteners must be torqued in accordance with tables 1 2 and 3 U N O Torques should be applied smoothly and with a calibrated wrench 3 Multiple fastener arrays must be made up evenly using an appropriate torque sequence to minimize distortion Fasteners shall be tightened using intermediate torque settings of 4096 and 75 of values in the tables fasteners must be made up snug prior to starting the tightening sequence 4 Fastener torques for bolting dissimilar materials must be based on the torque requirements for the lower strength material U N O 5 Fasteners and holes should be free of burrs or damage Damaged threads must be repaired using the appropriate tooling to ensure a free and smooth assembly 6 When thread locking compound is used holes and fasteners should be cleaned free of oil or grease and the compound should be applied in conformance with manufacturer s recommendations 7 Allowable bolt tension and torque based on bolt thread engagement must be in accordance with Table 4 U N O Special fasteners must be installed and torqued in accordance with Table 2 When threadlock is used fasteners must be torqued in accordance with Table 1 Table 2 and Table 3 using the Lubricated
57. amp Nuts VA Driver s Side N 9 Wear Pad Torque Track Back Wear Connectors _ 7 Pad Off Drivers Torque Track 4 SideWear Pad zu Redi Rod Ze Nuts amp d Washers F P3 Torque Bushing e Bolts amp Nuts S p Torque Beam Clamp Bars Gear Bo Torque Track Torque Bushing SZ Bolts amp Nuts I Torque Beam gt Torque Clamp Plate Beam amp Bolts _ Extend Arm Extend _ Frame Extend Frame Upper amp Lower Clevis s W Bolts Nuts amp Pins 3900027 1 ai 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 29 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Torque Arrest System Inspection Frequency HMI MAINTENANCE GUIDE Frequency Operating Days and Inspection Type Name At At At At 250 500 750 1000 Bolts gearbox to extend frame mount A A Replace Complete extend frame mounts A A C Extend frame A A A C Extend arms A Torque bushing front plate A A A C Torque bushing side plates A A A C Torque bushing bolts nuts A A A Replace Torque track connectors A A A C Torque track mounting plate on bottom A section include all bolt holes Torque track studs nuts A A A Replace T bar A T bar clamp bolts A A A Replace T bar extension A A A C T bar clamp plate A A A C Torque beam A
58. ate Supervisor Rig Time Weekly Top Drive Inspect For Inspector All fasteners nuts bolts and lock wires correct location tightness Auxiliary manifold general condition Connection locking clamps correct location tightness Hydraulic fittings tightness leaks Hydraulic connections and hoses on the ol leaks top drive Load collar adequate load ride height on the spring load ride height should be 3 8 1 2 if it is not contact Tesco s Maintenance and Service Group Mud saver valve actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 56 Motor termination boxes moisture terminal nut Robotics and sensor panels moisture tightness of wire terminations Gearbox lubrication filter cleanliness check filter bypass and magnetic plug Upper quill bearing preload proper preload see How to Adjust the Preload on page 69 Pipe handler rotation motors check for tightness Load collar springs damage breaks Weekly Swivel Inspect For Inspector Hammer unions damage decay and tightness Swivel oil level correct level OTESCO CORPORATION 2007 98 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE Weekly Service Loop APPENDIX E SERVICE CHECKLISTS Inspect For Inspector All service loop components
59. ating components For this reason quill end play should be checked every month or after any severe operating events such as jarring or rough drilling Figure 4 5 Description of preload 1 Dial gauge 2 Upper quill hub bearing 3 Shim pack 4 Preload Preload is the amount of compression between the upper and lower quill hub bearings To increase the preload remove shims To decrease the preload add shims 5 Gearbox 6 Lower quill hub bearing 7 Quill 8 Protective block 9 Bottle jack or grabber TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 40 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How to Check for Quill Hub End Play When the Top Drive is Installed in the Derrick This procedure describes only one method for checking the quill endplay when the top drive is in the derrick If you are not sure if your method will be effective contact a qualified TESCO representative 1 Secure the top drive in the mast Pin the torque bushing to the track or support the top drive mainframe directly in the mast with slings tugger line hoists come a longs or other supports Note Whichever method you use to secure the top drive in the mast make sure the travelling blocks and the counter balance are not supporting any weight from the top drive When the top drive is secure the weight of the swivel and quill should be supported by the top drive gearbox and should rest on the lower bearing in the g
60. ck x 1 1 4 in wide x 5 in long Break away tab Die retainer 3 1 4 in 4 1 2 in Cap screw hex head 3 8 in x 1 1 2 in Die holder retainer for 1 2 in shims Shim 1 2 in Tong die 1 in thick x 1 1 4 in wide x 5 long Break away tab Die retainer 3 1 2 in 6 5 8 in Cap screw hex head 3 8 in x 1 1 2 in Die holder retainer Tong die 1 in thick x 1 1 4 in wide x 5 in long Break away tab Die retainer TESCO CORPORATION 2007 78 250TON HMIS 475HP Cap screw hex head 3 8 in x 1 in 880028 REv 8 MAINTENANCE GUIDE APPENDIX C FUSES FOR THE CONTROL TRANSFORMER APPENDIX C FUSES FOR THE CONTROL TRANSFORMER throughout the Tesco top drive components ONLY qualified personnel should install maintain and or troubleshoot the electrical systems A severe safety hazard exists for personnel not accustomed to or familiar with electrical hazards and procedures Danger Electrical voltages of different potentials are used GENERAL The electrical protection requirements for the primary and secondary of this transformer will be clearly marked in an area close to the fuse locations This will be on the Plexiglas barrier The information will indicate the following e Type e Voltage Rating e Current Rating e Interrupting Rating CAT II Power supply to control power transformer and receptacle outlet circuits 120 volt AC The fus
61. ctions Spray all electrical connections with light oil Wrap all cable ends with corrosion inhibitor tape Grease all hose end unions Install protective caps TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 70 MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE STORAGE CONTAINERS When the final inspection is complete all equipment should be placed in shipping containers shipping containers should be stored in a cool dry place Equipment can be efficiently stored in the following configuration Container 1 power unit Container 2 top drive assorted small items multi conductor cables Container 3 torque arrest system components cable storage reel 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 71 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 72 MAINTENANCE GUIDE APPENDIX A TORQUE STANDARDS FOR HiGH STRENGTH FASTENERS APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS The following information originated from the Standards document STD0015 PURPOSE This Standard should be used as a guideline for all fasteners used in production where the torque values are not specified on the Engineering documentation and drawings TESCO Standards on fasteners should be adhered to as non conformance can lead to the following low qu
62. d dirt from the centrifuge bowl Note Use an implement that will not damage the bowl Wipe the bowl with sol vent after you remove the debris Clean the baffle and turbine base Check the bowl seal and replace it if necessary Remove the cover and cover seal Clean the mating surface and replace the cover seal if required Reassemble the filter and ensure that all moving parts rotate freely Start the engine and monitor the filter connections and joints for leaks TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 46 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO PERFORM A COOLANT ANALYSIS ENGINE 1 Ensure that you have a coolant test kit available Note These are available from the equipment manufacturer 2 Ensure that your test area is clean and free of contaminants 3 Using the test kit and supplied instructions evaluate the coolant fluid for the fol lowing Nitrite concentration If nitrite concentration is inadequate system corrosion can occur Glycol concentration If glycol concentration is inadequate freezing or boil over can occur any inhibitor or anti freeze additives Never introduce unapproved Caution Consult the manufacturer s documentation before you use additives sealer additives for example into the coolant system How TO CHECK THE SPLINES ON THE PUMP SHAFT Note This procedure takes several hours to perform Pump shaft splines can only be inspected when an extended peri
63. d for surface defects Also an inspection of threads should be conducted in accor dance with the following schedule Note Any part of an operating day should be considered one day formed following any episode of rough drilling excessive jarring or Caution All inspections listed in the following table should be per any other exceptional circumstance that might increase fatigue fail ure Operator discretion is critical in determining when this testing should occur Threaded Connection Inspection Frequency HMI pin X pin connections lower threads and seal face require daily visual inspection Frequency z the number of operating days Description Minimum Frequency Inspection Type Mud saver stabbing valve 60 operating days WFMPI box X box connections Saver sub 60 operating days WFMPI TORQUE ARREST SYSTEM All components of the torque arrest system must be subjected to periodic magnetic particle inspection MPI by a qualified inspector Each piece should be inspected for surface defects according to the following schedule Any part of an operating day should be considered one day Removal of paint may be required for inspection OTESCO CORPORATION 2007 28 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 9 Non destructive testing for the standard torque arrest system HMI Torque Track Studs
64. ds isolation valves damage loose parts TORQUE ARREST SYSTEM SERVICE REQUIREMENTS Daily Torque Arrest System Service Requirements The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All connections damage or decay All overhead equipment T bar torque damage or decay beam torque track torque bushing TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 8 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Weekly Torque Arrest System Service Requirements The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All bolts and threaded rods damage or decay tightness Torque track hanging assembly damage close visual inspection is required Torque bushing liner or torque arrest wear the bushing liner must be replaced beam liners before the liner mounting bolts come in contact with the torque tube Torque bushing clearance amount of clearance it might be necessary to remove a torque bushing shim if there is more than 1 4 in clearance between the torque bushing and the torque tube or if there is excessive torque bushing movement
65. e grease Swivel yoke hinge pins 2 EP2 multi purpose grease Upper bearing retainer 1 EP2 multi purpose grease Lower bearing retainer 2 EP2 multi purpose grease Weekly Top Drive Service The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All fasteners nuts bolts and lock wires correct location tightness Connection locking clamps correct location tightness Counter balance system correct installation and function Load collar adequate load ride height on the spring load ride height should be 3 8 to 1 2 in if it is not contact TESCO s Maintenance and Service Group Safety chain on the grabber leg broken components loose wires Swivel Inspection Requirements The following inspection should be performed at least once every operating week if the top drive is equipped with the optional swivel More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Hammer unions damage decay and tightness 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 5 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Monthly Periodic Top Drive Service The following visual checks should be performed at least once every
66. e wires at the junction box for the pressure switch b Attach a digital multi meter DMM in Q ohm range to the wires from the switch c Adjust the wheel on the switch until the switch closes Note The DMM will switch from O L overload to 000 1 0 2 which indi cates a short circuit d Ensure the auxiliary system is at 800 psi e Re install the wires f Close the junction box Reset the auxiliary relief valve to the operating setting Note See How to Set the Pressure Relief Valve for the Auxiliary System on page 38 for more information Operate any hydraulic function to confirm that the indicator light is operating cor rectly 250TON HMIS 475HP OTESCO CORPORATION 2007 39 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO CHECK AND ADJUST PRELOAD When the top drive is manufactured TESCO adjusts the preload for the quill upper bearing by placing a shim pack between the top bearing retainer and the gearbox When the retainer bolts on the top bearing are torqued this exerts a clamping force on the quill upper bearing and thrust bearing This force prevents the quill from exhibiting end play during operation of the top drive Preload is measured in 0 000 of an inch The ideal preload is 0 008 0 010 in Over time bearing and component wear will reduce the preload If the preload is reduced too much quill end play will result Even the smallest amount of end play will result in damage to the bearings and m
67. earbox top drive is not supported by the counter balance system Discon nect the counter balance system or lower the travelling equipment enough so that the counter balance system is slack Caution It is critical that all top drive weight is off the quill and the 2 Mount a dial indicator gauge on the quill with the stem contacting a point on the bottom face of the lower bearing retainer 3 Select a bottle jack that is appropriate for the combined swivel and quill weight of the top drive If combined quill and swivel weight is less than 5000 Ib then a 5 ton bottle jack is recommended If combined quill and swivel weight exceeds 5000 Ib then a 7 1 2 ton bottle jack is recommended Caution Ensure the bottle jack is rated appropriately for the load Caution Use blocking and suitable protection to prevent damage to the connection and grabber 4 Insert the bottle jack between the grabber box and the end of the quill Note For an HMI top drive where the grabber is supported by a spring insert blocking between the top of the elevators and the underside of the grabber so that you can apply load to the quill Use the bottle jack to hoist the quill Monitor the dial gauge for movement Hoist the quill several times to confirm endplay readings 7 Remove shims as required to eliminate endplay 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 41 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How to C
68. ect the hanging sling assembly Apply a thin film of grease to the entire assembly including cables and cable clamps Torque Beam and T Bar et Sr Ure ES D E Clean and inspect the T bar Apply a thin film of grease to the entire T bar Clean and inspect the T bar clamp on the torque beam Apply grease to the inside of the clamp plates Apply anti seize compound to all bolts Reinstall the clamp Apply a thin coat of grease to the threaded rods of the clamp Note Apply grease to the entire length of rods POWER UNIT Hydraulic Oil Storage Tank 1 d 59 EN BUN cta E Add oil inhibitor to the tank Note Check the manufacturer s specifications for correct inhibitor concentration Close all valves Apply a light coat of grease to all valve stems Seal all tank breather ports Apply a light coat of grease to hose end connectors Wrap hose ends with corrosion inhibitor tape Open the terminal boxes for the tank thermostat on the forward side of the tank Check the boxes for moisture Place a desiccant bag in each box 10 Apply anti seize compound to the cover bolts and reinstall the covers 11 Grease the cover seal to prevent moisture from entering TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 68 MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE Air Oil Cooler 1 Clean the cooler Caution The cooler fins are easily damaged Use extreme care dur ing cleaning
69. ediate Production polea ew nx sl L0 pos rill Range Switch Setting SeToqe MaxTorque toco Hie COT sm s ol Lowco High CO meme fpewmme xum 1 ambien tee _ _ Change Flow chan Toe Mese J swash Plate Pres Rosemount Reading Pump Case Drain L gemein fark Temperature 4 PumpDrive pw LL ube Flow Tel m poirPressure ows os Lube Temp GI LG m e m hs Sample Taken 0 Chanse verco reco Sample Taken a Oit Craneo veo wo Operating Days Since 500 Day Re certification In shop Major Rebuild of all Components in Top Drive Sample Taken Last Oit Change Leger voso Tec Swier pem Tv Saver Sub in Service ser fo Document any changes in overhead serial numbered equipment White Copy Business Unit Office Pink Copy Issuer Critical Information Binder Copyright Tesco Corporation 2004 881034 Rev B Last Updated May 05 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 109 APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 110 MAINTENANCE GUIDE INDEX A
70. er Sub Inspection Log 88 Load Collar Inspection Log rh 89 Elevator Links Inspection Log cerit IRR 90 Elevator Inspection Leg eter eee ENEE 91 APPENDIX E SERVICE CHECKLISTS lessen nnne 93 REI Checklists usten Dern reds E ad 94 Weekly Checker 98 Monthly Chechklets RI Ihres 101 Six Month Checklist 9 Ee R3 OEC Pe EUER RU EE 106 Megger Test Ghaft ec ee CV Eae e ego we gos X one VR i NC koe ae OR 107 Motor and Plgtall ERU AERE REESE SEES ELS ER 107 Service Loft ve ae ts EEN EE 107 Daly TOP Drive Repone s anete 36 4 abo 4 Meda ES nt Red he ete SA RE Aen gi Pe E ES 108 INDEX Sos ce gaat aa nr bd TEE 111 ENGINEERING SIGN OFF eee eee 115 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 VI MAINTENANCE GUIDE LisT OF FIGURES LisT FIGURES Figure 2 1 HMI swivel 4 Figure 2 2 Lubrication points for the 7 Figure 2 3 D2P oil level engine not running 12 Figure 2 4 Oil tank level 20 0 RR RR n ns 14 Figure 3 1 Swivel HMI ete rns 20 Figure 3 2 Quill AMi pesenna e a a a E e e a E E aa e E e EE a E AE D a 21 Figure 3 3 Load nut ret
71. er thrust surface C 3 Lower thrust surface C 4 Splines C 5 Load nut grooves 6 Quill pin end A B C also refer to Threaded Connections on page 28 Refer to Table 3 1 on page 19 for inspection type details 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 21 CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 3 Load nut retainer and split collar HMI Frequency Operating Days and Inspection Type Point Name Every At At At At 60 250 500 750 1000 1 Load nut retainer shoulder A B A B A B C 2 Entire load nut retainer A B A B A B C 3 Split collar 4 Splitcollar grooves 5 Top plate 6 plate A A A C not a load area Refer to Table 3 1 on page 19 for inspection type details TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 22 MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES Figure 3 4 Mudsaver valve and actuator HMI Frequency Operating Days and Inspection Type Point Name Every 60 At250 At 500 At 750 At1000 1 Top box connection A B C 2 Upper valve stem hole C 3 Lower valve stem hole C 4 Lower box connection
72. es dis cussed in Maintenance and Service Schedules How TO DISASSEMBLE AND SERVICE THE ROTO ACTUATOR This procedure is performed as part of monthly top drive maintenance This procedure explains how to clean the internal bore of the actuator and the outer diameter of the mud valve body If you need to replace a seal or if any other type of service is required refer to the manufacturer s service manual 1 St Pe Zei 10 11 12 880028 REv 8 Remove the hydraulic lines for the mud valve open valve close circuit Plug and cap the hydraulic line terminations to prevent dirt accumulation Remove the actuator stop bracket Remove the internal snap rings on the hex drive shaft Remove the hex drives 2 Note The strip kit contains a slide hammer for this purpose Loosen the upper and lower hose clamps Note It is easier to loosen them until they can be repositioned above the locator pins than to try to remove them entirely Loosen all setscrews except 2 by 1 2 turn Note Leave two opposing screws tight to hold the actuator in place until you are ready to remove it Remove the connection locking clamp for the saver sub Remove the saver sub Visually inspect the lower portion of the valve body for raised die marks Note Any raised spots will impede the removal of the actuator Buff them smooth to ensure smooth removal Place wooden blocks on top of the grabber Note These blocks will support the actuator during t
73. es on the 120 volt primary side of the control transformer are 10 amps CAT I Protected electronic control circuits control power 24 volt DC The fuses on the 24 volt secondary side of the control transformer are 20 amps FUSE MAIN POWER 480 VAC 3 PHASE L1 L2 L3 Manufacture Bullet Type 80 Amp CSA Type D HRCI R Dual Element Class RK 5 Current Limiting Listed Fuse DL 93 91 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 79 APPENDIX C FUSES FOR THE CONTROL TRANSFORMER MAINTENANCE GUIDE FUSE 120 VOLT L1 L2 amp AC 15 L1 Power Supply to 15 amp breakers for AC 15 Primary side of control transformer AC _ 4 Receptacles e AC_ 3 Lights e Type BAF e 250 VAC 30 amp e IR10kA OMT 30 L2 Control power to Auxiliary pump Circulation pump Cooling Fan Type Edison Fast Acting MOL 8 amp 250 VAC IR 200 amp 125 VAC IR 10 e AC 15 24 VDC Power Supply Input Type BAF 10 250 VAC IR 200 amp 125 VAC IR 10 FUSE 24 VDC POWER SUPPLY OUTPUT Type Buss AGC 20 32 volt 20 amp FUSE 24 VDC POWER SUPPLY TO TORQUE CIRCUIT Type Edison Fast Acting MOL 1 amp 250 VAC IR 100 amp e 125 VAC IR 10 TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 80 MAINTENANCE GUIDE APPENDIX C FUSES FOR THE CONTROL TRANSFORMER CoNTROL PowER SUPPLY NAMEPLATE INFORMATION Custom Rectifier Level I ACME Electric Power Products Grou
74. gments with a non marking hammer to seat them Ensure the outer retainer is clean and coated with a light film of rust inhibitor oil or anti seize compound Slide the outer retainer onto the split collar segments Slide the bottom plate into position Use the first boltto line up the bottom retainer plate with the outer retainer and top plate Insert the remaining bolts Note Torque the bolts in a cross pattern gradually increasing the torque on all bolts to 140 ft Ib Secure all bolts with lockwire Install the Mudsaver Valve Before you can perform this procedure the quill must be fully installed as per previous proce dures 880028 REv 8 10 11 12 Reduce SET and MAX TORQUE values to levels much lower than what is required for normal operations Apply thread dope to the mudsaver valve and the quill pin Lift the mudsaver valve and start the mudsaver quill connection by hand Screw the mudsaver quill connection together by hand Caution Do not use the top drive to make the connection this can damage the valve threads Manually reset the grabber height so that it closes on the mudsaver valve At the driller s panel set the GRABBER switch to CLOSE it should close on the mudsaver valve Set the MODE switch to CONN and set the PUMPS REV FWD switch to FWD Push and hold the MAX TORQUE button Note Use the Bosch control valve on the filter manifold of the power unit to increase MAX TORQUE to the
75. h checklist 106 six month inspection top drive 106 spline inspection 12 splines pump shaft 47 split collar inspection 22 storage junction boxes 64 storage preparation 63 stuck pipe 1 studs storage 67 swivel daily service 5 swivel daily lubrication 5 swivel hammer unions weekly inspection 5 swivel inspection 20 21 swivel oil level daily inspection 3 swivel weekly inspection 5 swivel yoke daily lubrication 5 T tank filters replacement 15 T bar daily inspection 8 T bar storage 68 testing inspection schedules 17 threaded connections inspection 28 threaded connections testing 28 tool joint usage chart 77 top drive daily inspection 3 daily lubrication 4 daily operations checklist 108 daily service 3 monthly lubrication 6 monthly service 6 weekly inspection 5 weekly service 5 top drive gearbox oil daily inspection 3 94 top drive lubrication points 7 top drive storage 64 torque arrest system long term storage 67 service requirements 8 torque arrest system daily inspection 8 torque arrest system MPI testing 28 torque arrest system weekly inspection 9 TESCO CORPORATION 2007 114 MAINTENANCE GUIDE torque beam daily inspection 8 torque beam storage 68 torque bushing daily inspection 8 torque bushing storage 67 torque standards for high strength fasteners 73 torque track daily inspection 8 torque track storage 67 tripping operations 1 U urethane capture blocks
76. he following detailed list of maintenance repair requirements a complete list of parts required BEFORE SYSTEM SHUT DOWN Before you shut down the top drive system do the following 1 Add corrosion inhibitor to the gearbox Most oil inhibitors require some mixing with the base oil Prepare the corrosion inhibitor according to the manufacturer s instruction 2 Check the cooling fluid If the system will be stored at temperatures below 0 Celsius ensure the prime mover cooling fluid level is at full If required add GDX Diesel anti freeze If necessary drain the cooling system replace the cooling fluid 3 Determine if you will need to perform a load path inspection before you re start the unit If an inspection will be required ensure that all load path connections are broken out now This will allow you or another inspector to inspect the top drive system without having to supply power to the unit The following procedures assume that the top drive system has already been correctly decom missioned as described in the Rig Out Procedures section of the Installation Guide for your unit 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 63 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE TOP DRIVE Junction Boxes Auxiliary Panel Open the motor sensor junction box Check for moisture Install a new desiccant pack Tighten all wire terminals in the junction box St ES 6
77. he next part of this proce dure Raise the grabber to support the weight of the actuator 250TON HMIS 475HP TESCO CORPORATION 2007 33 13 14 15 16 17 18 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE Remove all setscrews 8 and springs 8 Remove the locator pins 8 using the slide hammer if required Note The actuator is now separated from the double ball valve Before you continue note the orientation of the actuator in relation to the double ball valve Lower the grabber Remove the actuator from the double ball valve Note The strip kit includes two lifting handles for moving the actuator These handles screw into any of the locking pin locations Clean the internal bore of the actuator and the outer diameter of the mud valve body Re assembly 1 Lightly grease the internal bore of the actuator and the outer diameter of the mud valve body Position the actuator on top of the wooden blocks on the grabber Ensure that the actuator and valve are either both open or both closed Ensure that the actuator and valve are oriented in the same way as they were when removed See Figure 4 1 Danger If the orientation is not correct the valve will not open when required This causes a serious safety hazard Figure 4 1 Actuator valve orientation Align the valve sockets before sliding the actuator over the valve TESCO CORPORATION 2007 250TON HMIS 475HP 880028 R
78. heck and Adjust HMI Specific Preloads There are three preload checks that must be performed for HMI top drive units gearbox bearing preload swivel bearing preload quill to quill gear drive bushing spacer preload Check the Gearbox Bearing Endplay 1 Install a magnetic base dial gauge on the quill Note Put the magnetic end on the quill and the needle on the bearing retainer Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive Monitor the dial gauge for movement Values on the dial gauge should be within acceptable preload parameters new bearings 0 008 to 0 010 in used bearings 0 000 to 0 005 in 5 If the dial gauge indicates movement outside acceptable parameters test the quill to quill gear drive bushing endplay first to isolate the actual endplay location See Check the Quill to Quill Gear Drive Bushing Drive Spacer Endplay on page 44 6 Ifthe test for quill to quill gear drive bushing preload indicates no endplay then adjust the gearbox preload a Unbolt the bearing retainer b Remove the required number of shims that are located under the upper bear ing retainer See Sample Calculation on page 45 c Reinstall the bearing retainer CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 42 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES Check the Swivel Bearing Preload 1 Remove the wash pipe from the bonnet 2
79. ing cracks excessive wear deformation corrosion erosion all dimensions for all cracks length depth width a photograph or illustration indicating all cracks or damage points confirmation that all indicated inspection areas have been checked LOAD PATH COMPONENTS AND INSPECTION INFORMATION This chapter contains illustrations of all components in the top drive load path Each illustra tion indicates the inspection points for the specific component It also describes any special considerations that must be addressed when inspecting the component It is critical that all components of the load path be subjected to periodic magnetic particle inspection MPI by a qualified inspector Each piece should be inspected for surface defects according to the schedules that follow Note Any part of an operating day should be considered one day Removal of paint might be required for inspection TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 18 MAINTENANCE GUIDE Inspection Types CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES The three inspection types are outlined in Table 3 1 880028 REv 8 Table 3 1 Inspection types Inspection Type Description A Visually inspect for wear deformation cracks corrosion e galling heat damage other irregularities If a crack is suspected perform local paint strip and MPI inspection All cracked components should be referred to
80. ing drive backlash 0 60 damage Auxiliary manifold general condition Grabber dies excessive wear Lubricate With Inspector Hinge pins and extend frame spray with penetrating oil WD 40 or spray lithium Monthly Service Loop Inspect For Wire terminals in the driller s panel tightness All multi conductor connections moisture dirt open and check then spray with electrical cleaner moisture dispersant Main service cable connectors cleanliness open clean reinstall All hoses leaks damage Threads isolation valves damage loose parts Monthly Auxiliary Hydraulic Power Unit Inspect For Inspector Auxiliary system pressure relief correct setting Auxiliary system function light pressure correct setting switch Auxiliary hydraulic filter cleanliness inspect and change Auxiliary hydraulic fluid complete fluid analysis every 900 operating hours Monthly Power Module Danger Do not perform he following checks unless the main breaker panel is disconnected and locked out Danger Only qualified personnel should perform the N following maintenance activities Inspect For Inspector All wire terminal screws tightness All bolted connections on both the tightness incoming and outgoing waterfall input and output power connections OTESCO CORPORATION 2007 102 correct position and tightness 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS Inspect For Ins
81. inge pins monthly lubrication 6 hydraulic fittings monthly inspection 6 hydraulic oil analysis 45 hydraulic oil tank storage 68 hydraulic schematics 1 information where to find more 1 inspection guidelines 18 inspection types 19 install the top drive 1 interlocks storage 67 J junction boxes storage 64 L link tilt cylinders daily lubrication 4 load collar weekly inspection 5 load nut inspection 22 load nut installation 52 load nut storage 64 load nut removing 51 load path assembly 51 load nut 52 mudsaver valve 53 quill 52 OTESCO CORPORATION 2007 112 MAINTENANCE GUIDE load path components 49 load path disassembly 50 break out 50 load nut 51 quill 51 swivel body 51 load path inspection 18 logs sample inspection 83 long term storage 63 before shut down 63 driller s panel 66 elevators 65 extend frame 67 grabber leg 64 hanging assembly 68 hydraulic oil tank 68 interlocks 67 load nut 64 main cable reel 66 mudsaver 65 power unit 68 quill 64 saver subs 65 studs 67 T bar 68 top drive 64 torque arrest system 67 torque beam 68 torque bushing 67 torque tracks 67 lubrication points top drive 7 M make connections 1 Megger test chart 93 107 monthly checklists 101 monthly inspection air starter filter 10 cooling system 15 counter balance system 6 drive belts 10 gearbox oil 6 hydraulic fitting 6 prime mover 10 pump drive oil 12 pu
82. internal damage Note Use a fine emery cloth or a fine grit cylinder hone to remove small surface defects Install new gland seals as required Caution Exercise caution when you reassemble this component The piston open close ports can damage the gland seals Assemble the piston components Note Ensure that all bolts and O rings are coated with light grease before assem bly Actuate the cylinder with oil to purge the air from the cylinder Danger Air in the cylinder will act as an accumulator Accumulation of pressure can cause injury when the piston is tested 8 Pressure test the piston assembly to 2 000 psi on both the open and close side of the circuit 250TON HMIS 475HP TESCO CORPORATION 2007 57 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How to Remove and Reinstall the Lower Grabber Leg Remove the Lower Grabber Leg 1 2 Remove the safety chain from the back of the lower grabber leg Prepare the leg for removal according to one of the following conditions f the top drive can be hoisted off of the grabber leg then lower the grabber to the end of its travel stroke and use blocks to support it f the top drive cannot be hoisted ensure that there is enough clearance below the top drive to remove the grabber leg This might require setting the top drive handling frame on blocks Ensure that the grabber is fully supported from beneath Note The weight of the leg is appr
83. ive Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 87 APPENDIX D SAMPLE INSPECTION LOGS SAVER SUB INSPECTION LoG MAINTENANCE GUIDE Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments CORPORATION 2007 88 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS LOAD COLLAR INSPECTION LoG Top Drive Number Service Facility Service Activation Date Top Drive Type Location
84. ive must be fully functional for you to disassemble the load path 1 Putthe top drive into its shipping stand 2 Move the top drive to a firm level location where you have the following overhead hoisting equipment enough overhead clearance so that you can remove the quill If you want to remove the saver sub loosen and remove it now Loosen and remove the mudsaver quill die lock clamp Remove the hydraulic hoses for the open and close circuits for the mudsaver valve 6 Position the grabber so that it will close on the mudsaver valve Note Use the pin set on the back of the grabber leg to change the position of the grabber Place blocks between the valve actuator and the grabber When the grabber is in position on the mudsaver valve set the GRABBER switch to CLOSE 9 Clearall tools from the quill area 10 Set the MODE switch to CONN 11 Set the PUMPS REV FWD switch to REV 12 With the grabber closed on the mudsaver valve press and hold the BREAKOUT button 13 Break out the mudsaver valve and allow the quill to unscrew the connection 14 When the connection is unscrewed lower the grabber and the mudsaver valve 15 Verify that the blocks that you installed earlier will support the weight of the mud saver valve 16 Open the grabber to release the mudsaver valve 17 Install a valve handling nubbin and remove the mudsaver valve 18 Refer to the Rig Out Procedures as described in the Installation Guide for your unit
85. ling system excessive dirt general condition check the heat exchanger Pump drive lubrication system correct lubrication of the pump splines check at the oil filler cap Hydraulic hoses and connections leaks tightness 880028 ReEv8 250TONHMIS475SHP OTESCO CORPORATION 2007 11 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Figure 2 3 D2P oil level engine not running Weekly Pump Drive Service MAINTENANCE GUIDE The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Breather filter cap cleanliness Mating bolts tightness mounting to prime mover Monthly Periodic Pump Drive Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Pump shaft splines and adapters wear correct lubrication refer to TESCO s fluid specifications for hydraulic units EM000039 EM000041 EM000042 Pump drive oil cleanliness change as required do not over fill excess oil causes heat build up refer to TESCO s fluid specifications for hydraulic units EM000039 EM000041 EM000042 it is best to change the oil immediately after equipment operation when the
86. lve Note Some Tesco top drives are equipped with a secondary auxiliary relief at the auxiliary manifold This is used to warm the oil in the lines for cold climate appli cations If your top drive is equipped with this secondary relief valve set the main tank relief valve to 150 200 psi higher than the top drive relief valve The top drive relief valve should be set to 2 000 psi 50 Tighten the lock nut Set the GRABBER switch to neutral Set the AUX PUMP switch to OFF GO TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 38 MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO SET THE FUNCTION LiGHT PRESSURE SWITCH FOR THE AUXILIARY SYSTEM Perform this procedure as part of monthly power unit maintenance 880028 REv 8 Note The function light pressure switch for the auxiliary system should be set to 800 psi It is easier if two people perform this procedure Set the AUX PUMP switch to ON Set the GRABBER switch to OPEN Note Leave the switch in the OPEN position This allows system pressure to build Use the relief valve setscrew to reduce the auxiliary pressure relief setting to 800 psi Use the adjustment wheel on the pressure switch to adjust the pressure switch until the AUX PUMP ONT indicator light on the driller s panel illuminates Note You might have to have someone stand at the driller s panel to monitor the light If no assistance is available use a digital multi meter as follows a Disconnect th
87. ly service 11 pump drive monthly service 12 880028 REv 8 250TON HMIS 475HP INDEX pump drive oil inspection 12 pump drive weekly service 12 pump shaft inspection 12 pump shaft splines service 47 Q quick couplers service loop 8 quill installation 52 quill preload 40 quill preload calculation 45 quill preload inspection 6 quill storage 64 R rig out 1 rig saver inspection 9 rig up 1 roto actuator disassemble 33 reassemble 34 service 33 S safety chain inspection 5 sample inspection logs 83 saver sub daily inspection 3 saver subs storage 65 schedule non destructive testing 17 sensor panel monthly inspection 6 service loop monthly inspection 8 service requirements 8 weekly requirements 8 service loop components weekly inspection 8 service loop hoses monthly inspection 8 service loop quick couplers weekly inspection 8 service loop weekly inspection 8 service procedures 33 auxiliary function light 39 auxiliary pressure relief 38 calculate preload adjustment 45 centrifugal oil filter 46 coolant analysis 47 counter balance height 35 hydraulic oil analysis 45 pump shaft splines 47 quill preload 40 reset grabber height 37 roto actuator 33 service requirements cooling system 15 OTESCO CORPORATION 2007 INDEX filter manifold 13 oil reservoir 14 power unit 11 prime mover 9 service loop 8 torque arrest system 8 set torque and speed 1 six mont
88. mp shaft 12 quill preload 6 roto actuator sleeve 6 sensor panel 6 service loop 8 service loop hoses 8 service loop threads and valves 8 top drive 101 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE monthly lubrication extend frame 6 hinge pins 6 top drive 6 monthly service cooling system 15 filter manifold 13 oil reservoir 14 prime mover 10 pump drive 12 top drive 6 MPI inspection 28 MPI testing pipe handler rotation system 31 torque arrest system 30 MPI testing for torque arrest 28 mudsaver storage 65 mudsaver valve actuator daily lubrication 4 mudsaver valve daily inspection 3 mudsaver valve installation 53 N non destructive testing torque arrest system 28 non destructive testing schedules 17 oil analysis hydraulic 45 oil filter centrifugal 46 oil level inspection 9 oil pressure inspection 9 oil reservoir annual service 15 oil reservoir daily service 14 oil reservoir monthly service 14 oil reservoir service requirements 14 operating pressure inspection 9 options and spares 1 P parts lists 1 periodic magnetic particle inspection 28 power unit service requirements 11 power unit storage 68 preload inspection 6 pre operational checklists 1 prime mover daily inspection 9 prime mover daily service 9 prime mover monthly inspection 10 prime mover monthly service 10 prime mover service requirements 9 prime mover weekly inspection 10 pump drive dai
89. n Remove the height adjustment pin Lower or raise the top drive to obtain the required lin dimension see Figure 4 3 Find the closest aligned holes between the grabber leg spring and the grabber leg If no holes align raise the top drive slightly until two holes align Insert the height adjustment pin When the height adjustment pin is in place raise the top drive to transfer weight back onto the grabber leg spring Push up and down on the grabber leg Note This ensures the leg floats on the spring and comes to rest in the proper position Measure the die sub distance again Note If the distance is not 1 in repeat this procedure to adjust the grabber height When the correct distance is achieved install all safety devices 250TON HMIS 475HP OTESCO CORPORATION 2007 37 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO SET THE PRESSURE RELIEF VALVE FOR THE AUXILIARY SYSTEM Perform this procedure as part of monthly power unit maintenance The pressure relief valve for the auxiliary system is located on the hydraulic oil cooler 1 Setthe AUX PUMP switch at the driller s panel to ON 2 Setthe GRABBER switch to OPEN 3 Loosen the lock nut on the adjustment screw of the relief valve 4 Unscrew the lock nut a few turns but do not remove it 5 Adjust the set screw on the relief valve until the pressure gauge near the relief valve reads 1900 psi min 2000 psi max Figure 4 4 Auxiliary relief va
90. nd part numbers Parts List electrical schematics System schematics hydraulic schematics cooling schematics gearbox lubrication schematics available options and spares TESCO Representative 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 1 CHAPTER 1 ABOUT THIS DOCUMENT MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 2 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Note To ensure the equipment operates properly and to prevent downtime check the pressure and temperature gauges all fluid levels and flow meters daily ToP DRIVE SERVICE REQUIREMENTS Daily Top Drive Service Requirements Inspection Perform the following visual inspection at least once every operating day More frequent inspections might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Gearbox oil level correct gearbox oil level halfway up sight glass Hydraulic hoses and connections at the top drive Grabber dies excessive wear Mudsaver valve lower ball manually operate the valve to check function Saver sub threads excessive wear Swivel oil level see Figure 2 1 on page 4 correct level Grabber check and reset grabber height see How to Reset the Grabber Height on page 37 880028 REv 8 250TON HMIS 475HP TESCO C
91. ns rre 28 Threaded Connection Inspection Frequency HMI 28 Torque Arrest System ec et eee retenue e date dee dereen 28 Torque Arrest System Inspection Frequency HMI 30 CHAPTER 4 SERVICE PROCEDURES EE 33 Juttel tert IER 33 How to Disassemble and Service the Roto Actuator 33 How to Set the Counter Balance Cushion Height 35 How to Reset the Grabber Height 00 0 cece tenet eee 37 How to Set the Pressure Relief Valve for the Auxiliary System 38 How to Set the Function Light Pressure Switch for the Auxiliary System 39 How to Check and Adjust Preload 0 0 0 cece eet teen nent n eens 40 How to Check for Quill Hub End Play When the Top Drive is Installed in the Derrick 41 How to Check and Adjust HMI Specific Preloads 42 How to Calculate the Preload 45 How to Perform a Hydraulic Oil Angst 45 How to Service the Centrifugal Oil Filter 46 How to Perform a Coolant Analysis 47 How to Check the Splines on the Pump 47 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTR
92. od of downtime is anticipated mended by your Safety or Loss Prevention Department before you Caution Always perform correct lock out procedures as recom attempt this procedure 1 Close the isolation valves to isolate the hydraulic lines that go to the pump drive Shut off the suction valve s to the pump s ai If you must remove the hydraulic hoses from the pumps ensure the ends of the hoses are protected from dirt and grime Loosen the hold down nuts studs for the pump Using a soft sling create a basket sling for the pump Attach the sling to an overhead lifting device D D E Hoist the sling until the weight of the pump is supported with the lifting device Note Do not lift the pump Hoist it only enough to support the pump weight 8 Pull the pump backwards to disengage the pump spline connection Note Move the pump back far enough to get a good view of the splines and inter nal components 9 Remove and inspect the pump adaptor plate Replace it if necessary 10 Ensure that there is residual oil between the pump and the pump adapter Caution If these areas are dry inspect the lubrication hoses pump until the problem is located Inadequate lubrication will cause severe equipment damage 11 Check all load areas for spline deterioration 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 47 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE 12 When inspection is complete reinstall the
93. of the gearbox bushing of the quill will not separate from the drive hub use the Caution The lifting apparatus must be rated for 6 000 Ib If the drive N jacking screws 2 on the top of the drive hub to separate them How TO ASSEMBLE THE LOAD PATH Use the following procedures to assemble the load path nstall the Quill Install the Load Nut Connect the Mudsaver Valve 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 51 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Install the Quill Inspect clean and deburr the following components before you reassemble the load path quill threads Joad nut profiles drive bushing and drive spacer bolts load nut components 1 R ena we 10 11 12 13 14 15 16 Ensure all required maintenance for the gearbox and swivel body is completed before you perform this procedure Ensure the quill is clean Ensure the lower quill connection is properly protected use a lifting nubbin or other suitable protection Lightly grease the quill splines and drive bushing areas Ensure the dowel pins are installed in the drive hub of the gearbox Ensure the load collar is in place Install the gear drive bushing and spacers onto the quill Ensure that the radial location bushing for the quill gear is properly installed and that it uses a spiral lock retaining ring Note These are located at the bottom of the drive hub H
94. oil is warm Hydraulic fittings tightness CORPORATION 2007 12 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES POWER UNIT FILTER MANIFOLD SERVICE REQUIREMENTS Daily Filter Manifold Service The following visual checks should be performed at least once every operating day More fre quent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Filter housing and manifold leaks Charge pressure differential correct differential pressure one gauge on the inlet and one gauge maximum differential is 100 psi if differen the outlet of the charge pressure manifold tial is greater than 100 psi replace the fil ter elements use the manufacturer s recommended fil ter element Hydraulic hoses and connections leaks tightness Monthly Periodic Filter Manifold Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Oil filters closed loop cleanliness oil filters should be replaced as indicated by oil analysis or every 4 000 operating hours use the manufacturer s recommended fil ter Oil filters tank cleanliness oil filters should be replaced every 900
95. oist the swivel and quill gear above the gearbox Note Use a lifting device rated for at least 6 000 Ib Ensure the top drive stand is on a solid and level surface Slowly lower the quill through the quill drive gear When the quill drive gear is close to the top of the drive hub rotate the drive gear to align it with the dowel pins Lower the quill until the dowels are visible at the top of the drive hub If required reset the jacking set screws 2 These are located on top of the drive bushing hub Put a drop of blue Loctite thread fastener in each hole and install socket head cap screws Note Torque bolts in a cross pattern gradually increasing the torque on all bolts to 140 ft Ib Secure all bolts in place with lock wire Install the Load Nut The swivel body and quill must be in place before you can perform this procedure 1 2 3 Raise the top plate of the load shoulder into position with the bevel side facing up Loosely install the locking pins This will hold the top plate in position Ensure the quill profile is clean TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 52 MAINTENANCE GUIDE 10 11 12 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Coat the quill profile area with a light coat of anti seize compound or rust inhibi tor oil Ensure the inner segments of the split collar are clean Install the inner segments of the split collar on the quill Note Tap the se
96. ontainers 71 Container e 71 CONTAINS 21 s pcr or e toe Ro RO re Ro C o t AE e d etti sod eer n 71 CONTAINS 1B ed eed eter e e Ee E RR Ele EROR Te e E e e e EROR AEN a 71 APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS 7 Purpose EE ERR 73 ee 73 880028 REv 8 250TON HMIS 475HP OTESCO CORPORATION 2007 V TABLE OF CONTENTS MAINTENANCE GUIDE Table Sae et E EE 74 APPENDIX TOOL JOINT USAGE 77 APPENDIX C FUSES FOR THE CONTROL TRANSFORMER 79 General M 79 Fuse Main Power 480 VAC Phase L1 L2 03 79 Fuse 1 20 Volts E28 AG a1 5s saa aces Peor der e e uda 80 Fuse 24 VDC Power Supply Out 80 Fuse 24 VDC Power Supply to Torque Circuit lel 80 Control Power Supply Nameplate 1 81 APPENDIX D SAMPLE INSPECTION LOGS 83 Quill Inspection Log 84 Integrated Swivel Inspection Log 85 Load Nut Retainer and Split Collar Inspection Log 86 Mudsaver Valve Inspection Log 87 Sav
97. ou start this procedure 1 880028 REv 8 Connect the hose quick coupler for the elevator to the charge fitting for the counter balance system Shut off the auxiliary pump Set the ELEVATOR switch at the driller s panel to CLOSE Open the needle valve on the counter balance manifold Note This relieves all pressure on the counter balance system Check the nitrogen pressure and adjust if required Note The nitrogen pressure must be 800 psi Ensure the counter balance relief valve is set at 1200 psi Close the needle valve on the counter balance manifold Start the auxiliary pump 250TON HMIS 475HP OTESCO CORPORATION 2007 35 CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE 10 11 12 13 14 15 16 Set the ELEVATOR switch driller s panel to OPEN and push and hold the ELE VATOR SAFTEY OPEN button Note This will send 1500 psi hydraulic pressure to the needle valve on the counter balance manifold Slowly open the needle valve and allow the hydraulic oil to charge the counter balance system Monitor the counter balance cushion by watching the gap that develops between the swivel bail and the block hook Continue to charge the system until the gap is 1 1 2 to 2 in the yoke pin should now be located in the center of the slotted eye of the link Close the needle valve Shut off the auxiliary pump Note This will allow the oil pressure in the auxiliary system to decrease Set the ELEVAT
98. oximately 400 16 181 kg Remove and cap the grabber open and grabber close hydraulic lines Note Label all hoses to make it easier to reinstall them correctly If possible hoist the top drive off the grabber leg Note If it is not possible to hoist the top drive use a manual chain fall to support the weight of the grabber leg Remove the support blocks and lower the leg to the ground Remove the height adjustment pins to release the grabber leg Remove the grabber leg assembly from the working area Repair the components as required Reinstall the Lower Grabber Leg 9 10 IN 11 12 13 14 Position the grabber leg below the top drive If possible lower the top drive and allow the grabber leg to travel into the upper grabber leg If the top drive cannot be lowered raise the grabber leg into position using manual chain fall or similar device Caution Be careful while inserting the grabber leg so that no dam age occurs to the cylinder or hydraulic lines Carefully monitor the spring assembly When the grabber leg is in position insert the height adjustment pin Adjust the height of the grabber as described in How to Reset the Grabber Height on page 37 Install the grabber leg safety chain Install the hydraulic lines for the GRABBER OPEN and GRABBER CLOSE cir cuits TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 58 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS
99. p Standard Power 500 B 24H 0002 101943 01 e 115 230 volt 50 60 Hz 24 v 20 OA DC EIA 413974440 G 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 81 APPENDIX C FUSES FOR THE CONTROL TRANSFORMER MAINTENANCE GUIDE This page has been left blank intentionally TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 82 MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS APPENDIX D SAMPLE INSPECTION LOGS The following pages contain examples of inspection logs It is important to keep detailed inspection records for all load path and torque arrest system components Please use the fol lowing pages as a guide Use this log to schedule and track inspections for each load path component In this field Do this Serial Number Record the component serial number Inspection Date Days in Service Enter the date of the most recent component inspection Enter the cumulative hours or days of service the component has been in service on the date of inspection Inspected By Enter the name of the company that performed the inspection Note Attach a copy of the inspection results to this inspection log Results Comments Summarize the test results and note any special action taken in the Additional Comments section at the bottom of the page If a component is replaced include the serial number for the replacement part Next Service Due Enter the hou
100. pector Electrical connections for the main drive component correct torque Critical These connections must be torqued to specification Severe component damage can result if they are over tightened IGBT s and related bus works correct torque Critical These connections must be torqued to specification Severe component damage can result if they are over tightened Cooling connectors tightness All external power connections to the top drive from the mechanical module cleanliness moisture these should be disassembled sprayed with electrical cleaner moisture dispersant and reconnected 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 103 APPENDIX E SERVICE CHECKLISTS Monthly Prime Mover MAINTENANCE GUIDE Inspect For Inspector Electrical control panels dirt moisture replace desiccant packs Radiator cap damage or corrosion Drive belts correct tension cracks and erosion Air starter filter cleanliness clean as required Crankcase oil and filter cleanliness these filters should be changed every use recommended OEM filters refer to 300 operating hours refer to the equipment service the prime mover manual for frequency manual for the correct oil a complete oil analysis should be conducted every third oil change 900 operating hours Note It is best to change the oil immediately after equipment ope
101. prime mover 9 pump drive 11 swivel 5 top drive 3 daily top drive report 108 disassembly assembly instructions 49 drill ahead 1 driller s panel functions 1 driller s panel storage 66 drive belts inspection 10 E electrical schematics 1 elevator daily lubrication 4 elevator links inspection 26 elevator storage 65 elevators inspection 27 engine coolant analysis 47 engine oil filter 46 exhaust system inspection 9 extend frame monthly lubrication 6 extend frame storage 67 F fasteners weekly inspection 5 filter manifold daily service 13 filter manifold monthly service 13 filter manifold service requirements 13 function light pressure switch 39 G gear ratio configuration 60 gear ratio change 60 gearbox lubrication schematics 1 OTESCO CORPORATION 2007 111 INDEX gearbox oil monthly inspection 6 grabber change grabber dies 55 service actuating piston 56 grabber actuating piston reinstallation 56 grabber actuating piston removal 56 grabber chain weekly inspection 5 grabber cylinder repair 57 grabber dies daily inspection 3 grabber dies changing 55 grabber disassembly and assembly 54 grabber height daily inspection 3 grabber height reset 37 grabber leg reinstall 58 remove 58 grabber leg service 58 grabber service 54 grabber storage 64 guidelines for component inspectors 18 H hanging assembly storage 68 high strength fasteners torque standards 73 h
102. pumps in their original position 13 Torque all hold down bolts to 350 ft Ib When you restart the unit check the oil supply to each pump drive as follows 14 Start the pump drive 15 Allow the lubrication pump to circulate for one minute 16 Slightly loosen the lubrication line to each pump adapter plate 17 Ensure that each line has adequate oil flow Note The volume of flow should be low but continuous If a line does not exhibit correct flow shut down and completely remove the line Inspect the line for clogs pump failure or filter problems if a filter is present TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 48 MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Figure 5 1 Load path components Typ 12 places Safety wired Quill Gear Spacer GC Drive Hub Typical 10 places gt zc Die Lock Clamp Debris O Ring Outer Retainer Split Collar Load Shoulder Top Plate Bolt Retainer Load Nut Bolt Typ 8 places 39000750 0 880028 REv 8 250TON HMIS 475HP CORPORATION 2007 49 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How TO DISASSEMBLE THE LOAD PATH Use the following procedures to disassemble the load path Break Out the Load Path Remove the Load Nut Remove the Quill and Swivel Body Break Out the Load Path Perform the following steps before you disconnect the service loop hoses and cables from the top drive The top dr
103. r 3 Metalon EP1 5 TESCO Part 2996 Pipe handler lock 1 EP2 multi purpose grease Sheave pins 4 if applicable EP2 multi purpose grease Adaptor link pins 2 if applicable Swivel link pins 2 if applicable OTESCO CORPORATION 2007 94 EP2 multi purpose grease EP2 multi purpose grease 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS Lubricate With Inspector Wash pipe 1 EP2 multi purpose grease Daily Torque Arrest System Inspect For Inspector All connections damage or decay All overhead equipment T bar torque beam damage or decay torque track torque bushing Daily Auxiliary Hydraulic Power Unit Inspect For Inspector Auxiliary hydraulic oil tank correct oil level Coolant tank correct coolant level Modine air exchanger radiator cleanliness Cooling coil on the Trane chiller cleanliness All flow meters reporting correct flow Daily Power Module Inspect For Inspector All panels and floor coolant leaks Drive components Caution Condensation in the drive components can cause severe damage if not immediately addressed See Condensation on page 13 moisture Indicator lights correct function replace if required VFD Blower proper operation Door fan proper operation Chopper fan proper operation Selection switch ES
104. ration when the current oil is warm Radiator and heat exchanger cleanliness inspect and clean every 300 operating hours Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Fuel filters primary and secondary use cleanliness inspect periodically replace according recommended OEM filters to manufacturer s specifications Note More frequent replacement might be required where the fuel supply quality is poor Exhaust system carbon build up also use rig up or operational downtime to inspect bolts and flanges Centrifugal oil filter if equipped cleanliness service every 900 operating hours or according to manufacturer s specifications Cooling system filter cleanliness replace every 900 operating hours Coolant perform a coolant analysis every 900 operating hours replace as required Monthly Pump Drive Inspect For Inspector Pump shaft splines and adapters wear correct lubrication refer to Tesco s fluid specifications for hydraulic units EM000039 EM000041 EM000042 Pump drive oil cleanliness change as required do not over fill excess oil causes heat build up refer to Tesco s fluid specifications for hydraulic units EM000039 EM000041 EM000042 itis best to change the oil immediately after equipment operation when the oil is warm
105. rs or days of service when the component requires its next inspection Additional Comments Enter additional information as required 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 83 APPENDIX D SAMPLE INSPECTION LOGS QuiLL INSPECTION LoG MAINTENANCE GUIDE Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced C Good Condition Repaired Replaced Additional Comments OTESCO CORPORATION 2007 84 250TON HMIS 475HP 880028 REv 8 MAINTENANCE GUIDE INTEGRATED SWIVEL INSPECTION LoG APPENDIX D SAMPLE INSPECTION LOGS Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition Repaired Replaced C Good Condition Repaired Replaced
106. rts and vents 880028 REv 8 250TON HMIS 475HP TESCO CORPORATION 2007 69 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE Prime Mover 1 9e nA CEN UA 9 Add corrosion inhibitor oil to the engine crankcase Note Check the manufacturer s specifications for correct inhibitor concentration Change the oil and the filter Service and protect the radiator Note See Air Oil Cooler on page 69 for more information Grease all belt tensioners and pulleys Perform the following battery maintenance if required and if equipped a Remove the battery terminals and coat them with grease b Check the electrolyte level of the battery c Ensure battery is fully charged prior to storage Seal all crank case breathers and wrap them with corrosion inhibitor tape Wrap the alternator if equipped in an airtight bag that contains desiccant packs Ensure the bag is completely sealed Wrap the ECM modules if equipped in an airtight bag that contains desiccant packs Ensure the bags are completely sealed 10 Spray the engine air starter with light penetrating oil 11 Coat the connection for the air line with grease Main Electrical Panel 1 H 3 4 General Ure ES Open the panel and check for moisture Replace all desiccant packs Seal the door and wrap the seam with corrosion inhibitor tape Spray light inhibitor oil on all external switch points Clean and inspect all electrical conne
107. rvice Schedules chapter updated the Mudsaver Valve and Actuator Inspection chapter Rev C June 2005 All models added information about how to adjust the preload when the top drive is installed in the derrick HMI model added information on how to perform three separate preload checks for the HMI top drive units separated non destructive testing images from text to conform with Tesco technical documentation standards Rev D May 2006 HMI model updated non destructive testing and inspection schedules as per ICD HLR 020 Rev 4 February 2007 Added note about checking gauges and fluid levels to Maintenance and Service Schedules chapter as per ECN 133 0001 Updated version numbering from alphabetic to numeric Rev 5 March 2007 Updated Non Destructive Testing and Inspection Schedules chapter as per ECN 122 0017 Rev 6 June 2007 Updated Non Destructive Testing and Inspection Shedules chapter as per ECN 122 0025 added sentence about accordance with API 8C ISO 13535 Rev 7 October 2007 Added caution symbols to all Warning Caution and Danger notes Added more safety warnings Rev 8 November 2007 New revision to remove CE ATEX standards from manual TESCO CORPORATION 2007 250TON HMIS 475HP 880028 REv 8 II MAINTENANCE GUIDE TABLE OF CONTENTS TABLE OF CONTENTS LIST OF FIGURES axe e Ee NR e X Ach e e XR CR CR CR RO CR E ae VII LIST OF TABLES i is nn er dE Oe eR Red cH Kc e ee EC
108. spect For Battery if applicable correct electrolyte level evidence of corrosion Water pump seal drain evidence of leaks Weep hole plugs correct placement evidence of leaks Fan hub correct lubrication see the appropriate Engineering Memo document for lubrication specifications Universal joint on the drive shaft correct lubrication grease if required do not over lubricate or this can damage the seals Monthly Periodic Prime Mover Service The following visual checks or procedures should be performed at least every operating month or according to the schedule below More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Electrical control panels dirt moisture replace desiccant packs Radiator cap damage or corrosion Drive belts correct tension cracks and erosion Air starter filter cleanliness clean as required Crankcase oil and filter cleanliness these filters should be changed use recommended OEM filters refer to the every 300 operating hours refer to the prime mover manual for frequency equipment service manual for the correct oil a complete oil analysis should be conducted every third oil change 900 operating hours Note It is best to change the oil immediately after equipment operation when the current oil is warm Radiator and heat exchanger cleanliness inspect and clean every 300 operating
109. wide x 5 7 8 in long Tong die 1 in thick x 1 1 4 in wide x 3 7 8 in long 3055 opt 4 in 7 1 2 in Die spacer Die holder Socket head capscrew 1 2 13UNC x 2 1 2 in Bottom keeper plate Top die retainer plate Hex head capscrew 3 8 16UNC x 1 in Socket head capscrew 1 2 13UNC x 1 in Spacer 2526 opt Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in 3055 opt 5 in 8 1 2 in 3051 Die spacer Die holder standard 1044 Socket head capscrew 1 2 13UNC x 1 in 3054 Bottom keeper plate 1045 Socket head capscrew 1 2 13UNC x 1 in 1676 Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in 2526 opt Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in 3055 opt 8 1 2 in 8 3 4 in 8760 Die spacer Die holder 1045 Socket head capscrew 1 2 13UNC x 1 in 7443 Shim 1 8 in 1676 Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in 2526 opt 3055 opt 880028 REv 8 250TON HMIS 475HP Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in Die spacer OTESCO CORPORATION 2007 77 APPENDIX B TOOL JOINT USAGE CHART Table B 2 Tool joint usage chart Tool Joint O D TESCO Part 2 7 8 in 4 in MAINTENANCE GUIDE Description Die holder retainer for 1 2 in shims Shim 1 2 in Tong die 1 in thi

HMIS Top Drive System - Total Energy Services Inc.

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