Tesco HPU

System Description
250 HXI 700 Top Drive System
PLC System
250TON HXI 700HP with D4P-700 Power Unit
DOCUMENT NAME: 1570012 REV 1

SYSTEM DESCRIPTION COPYRIGHT AND DISCLAIMER
Tesco Corporation ("TESCO") has made every effort to ensure that this document contains accurate
and current information for the TESCO top drive, however, the document is intended to be used in
conjunction with a complete training program and on-site supervision and TESCO does not
warrant or guarantee that the information contained herein is either complete or accurate in every
respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together
with its directors, officers, employees and agents from and against all liability for personal injury,
death or property damage to any person arising directly or indirectly from the use by the reader of the
information contained in the document.
This equipment was filled at the factory with TESCO ULTREX™ brand fluids and greases. To ensure
maximum performance and to avoid cross-contamination, we strongly recommend the continued
usage of TESCO ULTREX™ lubricants, unless otherwise specified.
TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.
Tesco Corporation © 2009
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
www.tescoparts.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
After Market Sales and Service Contact

Toll Free North America: 1-877-TESCO-77
International: 713-359-7295
CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

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REVISION INFORMATION SYSTEM DESCRIPTION
Revision Information
Version Date Description of Changes

Rev 0 July 2008 First release of document
Rev 1 April 2009 Add CE-ATEX information

INTL: 713-359-7295 II WWW.TESCOPARTS.COM
SYSTEM DESCRIPTION TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Top Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Collar and Load Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter-Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Top Drive Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auxiliary (Open-Loop) Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power (Closed-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary (Open-Loop) Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Case Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Extend Frame and Extend Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque Beam and T-bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency Shut Down (E.S.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Elevators and Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Grabber Drill Pipe Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rotary Table Stabilizer Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rotary Hose and Standpipe Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Driller’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Other Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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TABLE OF CONTENTS SYSTEM DESCRIPTION
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SYSTEM DESCRIPTION SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
Warning! Before operating and servicing this top drive

system, always read and follow all safety
! instructions such as the warnings and cautions
mentioned below and throughout the manual.
Top Drive System users risk injury to themselves and to others if the top drive is used
improperly and/or safety precautions are not followed. TESCO advises personnel who
work with or near the equipment to always wear proper personal protective equipment
(PPE). Proper PPE consists of, but is not limited to, the following:
• hearing protection (ear defenders)
• hard hat
• safety glasses
• steel toe shoes
• fall protection when working above 6.5 ft (2 m), or the minimum height
requirement as directed by local jurisdiction.
Caution: This equipment is designed and certified for use in a

hazardous environment. When maintenance requires replacement
! of parts, only identical parts can be used. Using alternate, non-iden-
tical parts as a substitution may void compliance and certification.
Caution: Always perform the correct lock-out procedures as
! recommended by the Safety or Loss Prevention department

before implementing maintenance.
Caution: Only authorized personnel can install and operate the top
! drive system.
Caution: Only trained personnel must perform inspections and

! related activities.
Caution: Safe access must be provided to all areas where

! adjustments and maintenance are necessary.

INTL: 713-359-7295 V WWW.TESCOPARTS.COM
SAFETY INSTRUCTIONS SYSTEM DESCRIPTION
Caution: This equipment can generate noise up to 100 decibels at

the prime mover and 86 decibels at the top drive. Hearing protection
! suitable for this noise level must be worn when operating this
equipment.
Warning! Electrical voltages of different potentials are used

throughout the TESCO top drive components
(480 VAC, 380 VAC, 208 VAC, 120 VAC). It is
imperative that only qualified personnel install,
! maintain and/or troubleshoot the electrical
systems. A severe hazard exists to personnel not
accustomed to, or familiar with, electrical hazards
and procedures.
Warning! Accumulators used in the auxiliary hydraulic

system are under pressure from gas. Release
! this pressure before any maintenance is done on
the auxiliary hydraulic system.

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SYSTEM DESCRIPTION ABOUT THIS DOCUMENT
CHAPTER 1: ABOUT THIS DOCUMENT

This document contains a description of the major components of the 250TON HXI 700HP
Top Drive System.
A complete 250 HXI 700 Top Drive System consists of the following:
• top drive
• hydraulic power unit
• interconnecting service loop and reel
• driller’s panel
• torque arrest system
• associated buildings, containers and equipment
This document provides a brief description of each major component, as well as a list of
available spares and options.
Important Note: Illustrations contained herein are provided for reference purposes only,
equipment shown may differ from the actual unit appearance.
Table 1-1: Where to find more information
For information on Refer to

• installation Installation Guide
• rig up
• commissioning
• pre-operational checklists
• rig out procedures
• setting torque and speed Operations Guide
• driller's panel functions and operating descriptions
• making connections
• drilling ahead
• tripping
• freeing stuck pipe
• load path inspections Maintenance Guide
• maintenance/service schedules
• component disassembly and reassembly
TESCO manufactured parts and part numbers Parts List
troubleshooting Troubleshooting Guide (where available)
• electrical schematics System schematics
• hydraulic schematics
• cooling schematics
available options and spares TESCO representative

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ABOUT THIS DOCUMENT SYSTEM DESCRIPTION

SYSTEM DESCRIPTION TOP DRIVE SYSTEM DESCRIPTION
CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION
INTRODUCTION AND GENERAL SPECIFICATIONS

The 250 HXI 700 Top Drive System is designed for use on land-based drilling rigs and
workover rigs. The top drive is powered using an independent hydraulic power unit.
To create the optimum power supply system required for each of its top drives, TESCO combines
industry proven prime movers, hydraulic pump drives, pumps and filtration equipment.
The 250 HXI 700 Top Drive is powered using a 700 hp (522kW) Caterpillar C18 prime mover
with a four-pump drive.
Metric unit conversions (in brackets) have been provided for convenience only. All
product specifications use the original Imperial units unless indicated otherwise.
Note: All weight values are approximate.
Table 2-1: 250-HXI-700 Top Drive specifications

Imperial Metric
Rated capacity through load collar 250 Ton 227 tonne
Rated horsepower 700 hp 522 kW
Max. continuous drill torque 24,000 ft-lb 3,254.5 daN-m
Make-up/Breakout torque 32,000 ft-lb 4,339.4 daN-m
Max. speed 200 rpm
Weight of the top drive plus: 14,000 lb 6350 kg
• elevators
• elevator links
• yoke + links (counterbalance system)
Length (250T, with 9 ft. links) 17.5 ft. 5.3 m
Width 4 ft. 1.2 m
Quill connection NC50
Hazardous area certification CSA Class 1 Div II or II 2 G

TOP DRIVE SYSTEM DESCRIPTION SYSTEM DESCRIPTION
Table 2-2: Torque Arrest System specifications
Imperial Metric
Weight of the following: 8,400 lb 3,810 kg
• torque track (92 ft long)
• anchor beam
• torque bushing
• extend frame
• clamps
Standard track length 92 to 146 ft 28.4 to 44.5 m
Hazardous area certification II 2 G
Table 2-3: Hydraulic Power Unit specifications

Imperial Metric
Total weight, wet 31,020 lb (includes weight of 14 070 kg
service loop)
Dimensions 31.5(L) x 5.5(W) x 9.2(H) ft. 9.6(L) x 1.7(W) x 2.8(H) m
Closed-loop flow 262 gpm max. 992 l/min max.

Closed-loop pressure 4,600 psi max. 31,716 kPa max.
Auxiliary hydraulic power flow 11 to 22 gpm max. 41.6 to 83.3 l/min max.
Auxiliary hydraulic pressure 3,000 psi max. 20,684 kPa max.
Motor voltage 480 (380) VAC, 20 (15) hp, 60 (50) Hz
Hazardous area certification CSA general purpose or safe area
Table 2-4: Service Loop specifications

Imperial Metric
Weight of the following: 11,700 lb 5307 kg
• reels
• cables
• hoses
Length 225 ft 68.6 m
Hazardous area certification CSA Class 1 Div II or II 2 G
Table 2-5: Driller’s Panel specifications

Imperial Metric
Weight 80 lb 36.3 kg
Dimensions 33.5 (L) x 15.5 (W) x 7 (H) in. 0.85 (L) x 0.39 (W) x 0.18 (H) m
Hazardous area certification CSA class 1 Div II or II 3 G /
II 2 G (with optional purge kit)

TOP DRIVE COMPONENTS

Figure 2-1: 250 HXI 700 Top Drive general assembly

Gearbox
• The gearbox is an integrated gearbox and swivel containing the main swivel bearing
and gear train to drive the quill.
• Single reduction helical gears (2.28:1) are utilized for high capacity, extended service
life, and maximum efficiency.
• The gear train is driven with a single bi-directional, hydraulic vane type motor. It has
a pressure rating of 4,500 psi (31,026 kPa) continuous, and 5,000 psi (34,474 kPa)
intermittent.
• The gearbox is flooded with oil for maximum gear and bearing lubrication and
reliability.
Load Collar and Load Nut

The load collar and load nut transfer loads from the elevator links to the quill.
Mudsaver Valve
The mudsaver valve is a double-ball crank valve that acts as a mudsaver. It replaces the upper
and lower kelly cock. The valve does not descend below the rotary table, except in emergency
situations, and it is always easily accessible. The mudsaver valve actuator can be operated
remotely from the driller’s panel.
Caution: The actuated upper ball valve is not for well control;
it functions solely as a mudsaver. The manual operating lower
! valve is for well control. Ensure that the valve selected can fit
into the existing casing.
Pipe Handling
The pipe handling abilities of the 250 HXI 700 Top Drive include the following:
• Pipe Handler Rotation: The HXI pipe handler rotate mechanism, powered by a single
hydraulic motor, provides 360° rotation and can be locked into any orientation. This
feature is used to resolve grabber torque when making or breaking connections.
• Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35°
forward from the vertical position and 55° backward from the vertical position.
• Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking
connections at any point in the mast. The grabber will accommodate tool joints from
3-1/8 in. (8 cm) to 8-3/4 in. (22 cm) OD.
Note: For tool joints smaller than 4-3/4 in. (12 cm) OD, non-standard dies or a shim
kit must be installed. Grabber intensifier pressures must also be adjusted when
smaller OD pipe is used.
Counter-Balance
The top drive features an automatic thread feed compensation for make up and break out
operations.

Top Drive Power

The top drive main motor is powered by four axial piston pumps, which are driven by a 700 hp
(522 kW) diesel prime mover. All top drive robotic functions are powered by an auxiliary
power hydraulic system. Both the prime mover and auxiliary power hydraulic system are
located on the power unit skid.
Handling Frame
The top drive is shipped in its own handling frame. This frame allows the top drive to be
transported and handled using standard rig moving equipment.
POWER UNIT
The primary function of the power unit is to provide hydraulic power to the top drive to
rotate the main top drive motor. This is achieved by a closed-loop hydraulic circuit, in which
a diesel engine or prime mover drives four variable displacement pumps that provides the
flow of hydraulic fluid to the top drive motor through the service loop. The return hydraulic
fluid is fed back directly to the variable displacement pumps. Some of the return flow is
tapped off by the hot oil shuttle valve and is circulated through an air-to-liquid cooler before
it is returned to a hydraulic fluid reservoir.
Piggybacked onto the variable displacement pumps are two vane pumps, used to “charge” the
closed-loop circuit due to the extract of hydraulic fluid by the hot oil shuttle relief (HOSR) /
reverse relief manifold and internal leakage of the pumps and top drive motor. Two other vane
pumps, also piggybacked onto the variable displacement pumps, are used to circulate additional
hydraulic fluid through the cooler to keep the hydraulic fluid in the reservoir from overheating.
The speed of the top drive motor varies by adjusting the displacement of the pumps. The
power unit is controlled by a PLC. The top drive operator only needs to select the desired
speed and the PLC will adjust the pump displacement to achieve the selected speed.
The secondary function of the power unit is to provide auxiliary hydraulic power to the top
drive to operate the robotic functions. A small auxiliary power unit, located on the power unit
skid, provides the auxiliary hydraulic power.
The power unit consists of two modules that are bolted together – the engine or prime
mover module and the hose reel/auxiliary HPU module. The engine module contains the
following equipment:
• prime mover
• pump drive and pumps
• closed-loop manifolds and hoses
• closed-loop hydraulic fluid reservoir and cooler
• main electrical panel and PLC panel
The hose reel/auxiliary HPU module contains the following equipment:

• auxiliary HPU
• hose reel with service loop

Figure 2-2: 250 HXI 700 power unit configuration
1. Prime Mover 5. Cooler

2. Pump Drive and Pumps 6. Main Panel
3. Closed-Loop Hydraulic 7. PLC Panel
Fluid Reservoir 8. Auxiliary HPU
4. Closed-Loop Manifolds 9. Service Loop and Hose Reel
Prime Mover
The prime mover for this power unit is a 700 hp (522 kW) Caterpillar C18 diesel engine. It is
equipped with a dual purpose radiator (air-to-liquid radiator for the engine coolant and an
air-to-air cooler for the compressed intake air), an air starter, turbo chargers, air filter,
exhaust system with built-in spark arrestor in the muffler, instrumentation panel, and the
appropriate safety and emergency shutoffs.
Pump Drive and Pumps
The pump drive is a gearbox mounted directly onto the prime mover. The gear ratio of the
pump drive is 1:1.3. A heavy duty coupling provides the connection to the prime mover
flywheel. The following equipment is attached to the pump drive:
• Four 130cc variable displacement, bi-directional axial piston pumps
• Four 58cc vane pumps, piggybacked onto the variable displacement pumps
• An internal lubrication-circulation pump

Closed-Loop Manifolds and Hoses
The closed-loop manifolds include:

• One charge filter manifold with one filter canister rated at 6,500 psi (44,816 kPa)
working pressure and 100 US gpm (378.5 liters/min.) flow. This filter manifold
ensures that the hydraulic fluid charged back into the closed-loop is filtered.
• One reverse filter manifold with four filter canisters each rated at 6,500 psi (44,816 kPa)
and 100 US gpm (378.5 liters/min.) flow. This filter manifold filters the return oil before
it enters the variable displacement pumps.
• One forward filter manifold with one filter canister rated at 6,500 psi (44,816 kPa) working
pressure and 100 US gpm (378.5 liters/min.) flow. It filters the return fluid when the top
drive operates in reverse.
• One hot oil shuttle relief (HOSR)/reverse relief manifold. This manifold contains the hot
oil shuttle relief valve and can be adjusted as required to bleed off some return oil and
send it through the cooler. Also, a reverse relief valve is located on this manifold to limit
the reverse flow pressure.
All hoses used in the closed-loop circuit are rated at 5,000 psi (34,474 kPa) working pressure.
Hydraulic Oil Reservoir and Cooler
The hydraulic oil reservoir contains the closed-loop hydraulic fluid and has a capacity of 330
US gallons (1,249 liters). Two vane pumps extract hydraulic fluid from the tank to charge the
closed-loop system. Another two vane pumps circulate the hydraulic fluid in the reservoir
through an air-to-liquid cooler to ensure the temperature of the hydraulic fluid remains below a
set value (190ºF/88ºC). The reservoir is equipped with a level switch, a heater, a temperature
gauge, two return oil filters and a temperature transducer. The function of the temperature
transducer is to signal the PLC to start the cooler fan once the temperature of the hydraulic
fluid in the tank rises above a set value (100ºF/38ºC).
Main Electrical Panel and PLC Panel
The main electrical panel contains the 480VAC and 120VAC distribution centers, breakers for
electrical equipment, cooling fan conductors and the 24VDC control power distribution center.
High voltage terminals are covered to avoid accidental contact when the panel door is open.
The PLC panel contains the PLC that controls the functions of the power unit and top drive.
Various alarm indicators are located on the panel door for easy troubleshooting.
Auxiliary (Open-Loop) Hydraulic Power Unit

The main function of the auxiliary hydraulic power unit (HPU) is to provide the top drive
and other ancillary equipment (such as CDS, power tongs, stabbing equipment, etc.) with
auxiliary hydraulic power. The auxiliary HPU is a standalone HPU mounted on the main
power unit skid. It contains two pressure compensated pumps, a 40 US gallon (151 liter)
auxiliary hydraulic fluid reservoir and a hydraulic fluid cooler. The pumps can be run simul-
taneously or individually depending on the auxiliary hydraulic flow demand. Each pump is
able to supply 11 US gpm (41.6 liters/min.) of hydraulic fluid. The auxiliary hydraulic circuit
is completely separate from the closed-loop circuit.
The auxiliary hydraulic system also has a small oil cooler with a hydraulically driven fan.
The fan can be turned on and off using a bypass valve located below the cooler on the cooler
manifold.

Figure 2-3: Auxiliary hydraulic power unit
1. Electrical Panel 4. Secondary Pump

2. Auxiliary Hydraulic Fluid 5. Return Manifold
Reservoir 6. Pressure Manifold
3. Primary Pump 7. Cooler

SERVICE LOOP
The service loop hoses are spooled onto the hose reel for shipping and storage.
Power (Closed-Loop) Hydraulic Hoses

• Two 240 ft. (73 m) × 2 in. (5 cm), 5,000 psi (34,474 kPa) hoses (one supply, one return);
these supply closed-loop hydraulic oil from the pump drive module to the top drive motor.
These hoses are made up of four 120 ft. (36.6 m) sections.
Auxiliary (Open-Loop) Hydraulic Hoses

• One 225 ft. (68.6 m) × 3/4 in. (2 cm), 2,500 psi (17,237 kPa) hydraulic supply hose, and
one 225 ft. (68.6 m) × 1 in. (2.5 cm), 2,500 psi (17,237 kPa) hydraulic return hose. The
hoses supply hydraulic oil from the auxiliary HPU to the top drive robotics system. Each
hose is made up of three 75 ft. (23 m) sections.
Case Drain Hose

• One 225 ft (68.6 m) x 3/4 in. (2 cm), 2,500 psi (17,237 kPa) hydraulic hose; this returns
motor case drain flow from the top drive to the auxiliary hydraulic fluid reservoir at the
auxiliary HPU. The drain hose is made up of three 75 ft. (23 m) sections.
Control Cables
The 225 ft (68.6 m) control cable is coiled onto a cable hanger located on the power unit.
The 160 ft (48.8 m) control cable remains attached to the main electrical panel on the power
unit and is coiled onto a cable hanger, located on the power unit, for storage.
• One 225 ft (68.6 m) 37-conductor cable: this cable connects the PLC panel to the top
drive.
• One 160 ft. (48.8 m) 4TP communication cable: this cable connects the driller’s panel to
the PLC panel on the power unit.

TORQUE ARREST SYSTEM

The torque arrest system consists of the following components:
• torque bushing
• extend frame
• extend arms
• extend hydraulic cylinders
• torque track
• T-bar
• torque beam, torque beam clamps, stabilization devices, and all required rig up items
Torque Bushing
The torque bushing is attached to the extend frame. It transfers reactive torque from the top
drive to the torque track. Ultra High Molecular Weight (UHMW) Polyethylene inserts reduce
friction as the top drive moves along the torque track. No lubrication is required.
Extend Frame and Extend Arms

The extend frame is pinned to the top drive. It allows the top drive to extend away from the
torque track, enabling improved pipe handling.
Torque Track
The torque track, in conjunction with the torque beam and T-bar, transfers reactive torque to
the lower section of the mast and the substructure. The track is suspended from the crown by a
cable hanging assembly, and is mounted with a simple clamp anchoring arrangement. Track
components can be configured to fit most mast heights.
Torque Beam and T-bar

The torque beam is mounted to the mast, typically to the lowest strongback. It is then connected
to the torque track via a T-bar. An offset torque anchor beam and post is available for use on
service rigs. This torque anchoring system compensates for the 3.5° lean of the service rig mast.

Figure 2-4: HXI torque arrest system

DRILLER ’S PANEL
The driller’s panel is a stainless steel enclosure that is mounted on the drill floor during
installation procedures. It contains all controls, indicators, mounts, gauges and connectors
required to operate the top drive. There is an optional air-purge system available for the
driller’s panel. All controls are electrically activated hydraulic (24 VDC) non-earth ground.
SAFETY INTERLOCKS
Emergency Shut Down (E.S.D.)

There are two E.S.D. circuits, each with its own specific function.
E.S.D. on the Driller’s Panel
The red E.S.D. mushroom button on the driller’s panel trips the C18 air solenoid valve. The
quill stops rotating. This E.S.D. also deactivates the auxiliary hydraulic pump. All devices that
operate or rotate at the drill floor become inactive.
E.S.D. on the Engine Panel
The red E.S.D. mushroom button on the door of the CAT engine panel activates the fuel
shut-off valve and shuts down the C18 engine.
Air interlocks
Drawworks Interlock and Override
The drum clutch interlock stops the air supply to the drum clutch so that the driller cannot
hoist the top drive while the grabber is closed. A push button on the brake handle is used to
override this lockout feature during slide drilling operations, etc.
Mud Pump Interlock
The mud pump air interlock is designed to disallow operation of the mud pump unless the
mudsaver valve is open.

Figure 2-5: Driller’s panel

OPTIONS
The following options are available. For more detailed information, contact a TESCO
representative.
Elevators and Elevator Links

Elevators rated at 150 and 250 tons (136.1 and 226.8 tonnes), associated inserts for various
drill pipe sizes, and accessories are available. A variety of link lengths is also available.
Subs
A complete selection of commonly used saver, casing, cross-over and drill collar handling
subs is available. Non-standard subs can be manufactured if requested; delivery can be
determined at time of order.
Grabber Drill Pipe Guides

These are used to guide the drill string into the grabber box. The drill pipe guide must match
the box of the drill pipe in use. There is a range of sizes available.
Rotary Table Stabilizer Bushings

These urethane bushings fit the standard rotary table profile and protect the table and Blowout
Preventer (BOP) from excessive wear. There is a range of sizes available.
Rotary Hose and Standpipe Extension

All equipment and accessories for these modifications are available.
Torque Arrest System

Optional equipment for non-standard and large mast torque arrest systems is available.
Alarms
The following optional alarm are available:
• extend alert features
Driller’s Panel
Driller’s panel with hazardous area certification of II 2 G is available.

Other Available Options

• Air purge system for the driller’s panel and top drive junction box.
• Workshop/parts containers with workbench and storage cupboards, complete with
interior lighting, optional stepdown transformer, power outlets and space heater.
• Video monitoring system, with cameras mounted in the derrick at the monkey board
and crown levels.
A complete list of all available options and accessories is available from a local TESCO
representative.


SYSTEM DESCRIPTION ENGINEERING SIGN-OFF
ENGINEERING SIGN-OFF
This sign-off sheet indicates that this document has been approved for release by the
Engineering Department at TESCO.
Document Completed By Signature Date Signed
Edward Chan 20 May 2009
Document Reviewed/Approved Date Signed
20 May 09

ENGINEERING SIGN-OFF SYSTEM DESCRIPTION


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System Description

250 HXI 700 Top Drive System

250TON HXI 700HP with D4P-700 Power Unit

DOCUMENT NAME: 1570012 REV 1

TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.

Tesco Corporation © 2009

After Market Sales and Service Contact

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Version Date Description of Changes

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

This page has been left blank intentionally.

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Warning! Before operating and servicing this top drive

Caution: This equipment is designed and certified for use in a

Caution: Always perform the correct lock-out procedures as

! recommended by the Safety or Loss Prevention department

Caution: Only trained personnel must perform inspections and

Caution: Safe access must be provided to all areas where

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Caution: This equipment can generate noise up to 100 decibels at

Warning! Electrical voltages of different potentials are used

Warning! Accumulators used in the auxiliary hydraulic

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

CHAPTER 1: ABOUT THIS DOCUMENT

For information on Refer to

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

This page has been left blank intentionally.

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

CHAPTER 2: TOP DRIVE SYSTEM DESCRIPTION

INTRODUCTION AND GENERAL SPECIFICATIONS

Table 2-1: 250-HXI-700 Top Drive specifications

Hazardous area certification CSA Class 1 Div II or II 2 G

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Table 2-2: Torque Arrest System specifications

Hazardous area certification II 2 G

Table 2-3: Hydraulic Power Unit specifications

Closed-loop flow 262 gpm max. 992 l/min max.

Hazardous area certification CSA general purpose or safe area

Table 2-4: Service Loop specifications

Hazardous area certification CSA Class 1 Div II or II 2 G

Table 2-5: Driller’s Panel specifications

Hazardous area certification CSA class 1 Div II or II 3 G /

II 2 G (with optional purge kit)

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

TOP DRIVE COMPONENTS

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Load Collar and Load Nut

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Top Drive Power

The hose reel/auxiliary HPU module contains the following equipment:

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM

Figure 2-2: 250 HXI 700 power unit configuration

1. Prime Mover 5. Cooler

Pump Drive and Pumps

CONTACT: 1-877-TESCO-77 250TON HXI 700HP WWW.TESCOCORP.COM