PDF13

Installation Guide
HMIS Top Drive System
250TON HMIS 475HP
DOCUMENT NAME: 880026 REV 3
INSTALLATION GUIDE
COPYRIGHT AND DISCLAIMER
Tesco Corporation (TESCO) has made every effort to ensure that this document contains accurate
and current documentation for the TESCO top drive, however, the document is intended to be used
in conjunction with a complete training program and on-site supervision and TESCO does not
warrant or guarantee that the information contained herein is either complete or accurate in every
respect, and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together
with its directors, officers, employees and agents from and against all liability for personal injury,
death or property damage to any person arising directly or indirectly from the use by the reader of the
information contained in the document.
Tesco Corporation 2007
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
880026 REV 3
250TON HMIS 475HP
TESCO CORPORATION, 2007

I
REVISION INFORMATION
INSTALLATION GUIDE
Revision Information
Version Date
Description of Changes
Rev A
May 2004
General Engineering updates and additions
Rev 1
April 2007
General Updates
Rev 2
Oct 2007
Added caution symbols to all warnings and caution notes. Added more safety
warnings.
Rev 3
Nov 2007
New revision to remove CE-ATEX standards from manual.

II
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 2: PRE-INSTALLATION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rig Installation and Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power/Service Connection Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Inspection (Pre-installation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHAPTER 3: RIG UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Equipment Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Optimal Placement of the Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How to Place the Power Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Optimal Placement of the Hose Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Install the Hose Hanging Saddle and Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Before You Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque Arrest System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Arrest System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to Determine the Torque Track Configuration (where an application drawing is not supplied) . . . . . . . . . . . . 14
Sample Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to Install the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to Install the HMI Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Counter-Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to Set the Counter-Balance Cushion Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driller's Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
How to Install the Drillers Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Air Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to Install the Drawworks Interlock and Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
About the Mud Pump Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CHAPTER 4: SYSTEM INSPECTION AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Inspection-General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
880026 REV 3
250TON HMIS 475HP

III
TABLE OF CONTENTS
INSTALLATION GUIDE
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
System Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Power Unit: Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
How to Start the Electrical System for the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Before You Start the Prime Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to Start the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Closed-Loop Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Top Drive Robotic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
CHAPTER 5: RIG OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Remove the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Remove the Torque Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Remove the Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Remove the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
APPENDIX A: PRE-INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

APPENDIX B: VISUAL INSPECTION CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
APPENDIX C: SLING LOAD RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
APPENDIX D: HAND SIGNALS FOR BOOM EQUIPMENT OPERATION . . . . . . . . . . . . . . . . .47
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
ENGINEERING SIGN-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

IV
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
LIST OF FIGURES
Figure 2-1:
Figure 2-2:
Figure 3-1:
Figure 3-2:
Figure 3-3:
Figure 3-4:
Figure 3-5:
Figure 3-6:
Figure 3-7:
Figure 3-8:
Figure 3-9:
Figure 3-10:
Figure 5-1:
880026 REV 3
Power, air and fuel connections - option 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Power, air and fuel connections - option 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HMI optimal equipment placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HMI hose saddle placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HMIS cable/hose saddle clamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HMIS hose saddle capture clamp configuration . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hoisting the hose saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Positioning the hose saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque arrest system configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F-clamp and turnbuckle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Counter-balance system interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawworks override installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service loop removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
250TON HMIS 475HP

V
LIST OF FIGURES
INSTALLATION GUIDE
This page has been left blank intentionally.

VI
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
LIST OF TABLES
Table 1-1:
Table 3-1:
Table B-1:
Table B-2:
Table B-3:
Table B-4:
Table B-5:
Table B-6:
Table B-7:
Table B-8:
Table B-9:
Table C-1:
Table C-2:
Table D-1:
880026 REV 3
Where to find more information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

HMI - cable and hoses for 460 and 475 HP prime movers. . . . . . . . . . . . . . . . . . . . . . 11
Top drive inspection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power unit inspection - cable reel/service loop . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power unit inspection - oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power unit inspection - oil storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power unit inspection - filter manifold headers . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power unit inspection - pump drive/pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power unit inspection - electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power unit inspection - prime mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drillers panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maximum safe working loads (pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rope diameter efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hand signals for boom operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
250TON HMIS 475HP

VII
LIST OF TABLES
INSTALLATION GUIDE

VIII
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
CHAPTER 1: ABOUT THIS DOCUMENT

This document contains information on how to install the 250TON HMIS 475HP top drive,
power unit, torque arrest system, and service loop.
You can alter the installation sequence described in this document to accommodate current rig
activity. The procedures described in this document provide instuctions on how to do the following:
perform a pre-installation assessment and equipment check

place equipment
install the service loop and connect services
install the torque arrest system
install the counter-balance system
install the top drive
connect the driller's panel and safety interlocks
perform a system inspection and system start up
rig out
Table 1-1: Where to find more information

For information on
Refer to
system components
System Description
setting torque and speed

driller's panel functions and operating descriptions
making connections
drilling ahead
tripping
freeing stuck pipe
Operations Guide
load path inspections

maintenance/service schedules
component disassembly and reassembly
880026 REV 3
Maintenance Guide
TESCO manufactured parts and part numbers
Parts List
electrical schematics
hydraulic schematics
cooling schematics
gearbox lubrication schematics
System schematics
available options and spares
TESCO Representative
250TON HMIS 475HP

1
ABOUT THIS DOCUMENT
INSTALLATION GUIDE

2
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
CHAPTER 2: PRE-INSTALLATION ACTIVITIES

RIG INSTALLATION AND MEASUREMENT
To ensure that top drive installation progresses smoothly, complete a detailed rig measurement
package before ordering equipment. Rig measurement packages are available from TESCO.
Accurate rig measurement helps you do the following:
Determine an equipment placement plan
Determine the best method for installing the top drive
Identify specialized equipment requirements, including the following:
swivel bail clamps
torque track hanging pad eye
components and subs (top drive to drill string)
service connection lengths and specific accessories
air/electric safety interlocks
torque arrest system components
hose saddle hanging requirements
mud hose connection
standpipe extension
Ask a qualified TESCO representative to help you complete the rig measurement package.
This will help to ensure that the equipment will fit properly within your rigs configuration.
POWER/SERVICE CONNECTION REQUIREMENTS

Discuss the following items with a qualified TESCO representative before you request shipment of the top drive system:
diesel fuel interface with rig fuel supply
starter air supply from rig
electrical power
480VAC
100 amp recommended (60 amp minimum)
60 Hz
or
380 VAC
50 Hz
880026 REV 3
250TON HMIS 475HP

3
PRE-INSTALLATION ACTIVITIES
INSTALLATION GUIDE
The following figures illustrate the connection considerations to address before the top drive
system arrives on location.
Note: If the customer is providing the main power supply (interconnection package), consult TESCO.
Figure 2-1: Power, air and fuel connections - option 1
Figure 2-2: Power, air and fuel connections - option 2

4
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
Electrical Considerations
1. Determine a location for the power unit.
Note: If the rig configuration has not been finalized, select two possible locations
for the power unit. The power unit should be placed on the same side of the rig as
the standpipe.
2. Determine the distance from the 480V, 100 amp plug at the motor control centre
(MCC) to the power unit.
Note: The standard power cable length is 250 ft. (76.2 m).
3. Determine if any special equipment is required. Examples: penetration or plug
boards.
Note: This equipment is required if the power cables must pass through walls on
their way from the MCC breaker to the power unit.
4. Determine if a cableway or suitable space is available to accommodate the power
cable that starts at the MCC breaker and goes to the power unit.
Note: If adequate space is not available, determine what materials would be
required to protect the cables from the breaker to the power unit.
Fuel Considerations
If the top drive unit is equipped with an integrated generator, then the connection requirements
for fuel and air should be considered.
1. Determine the location and type of the fuel supply.
Note: The fuel connector line should be 1 in. minimum, and it should be able to
supply enough fuel for the power units maximum consumption. The fuel return
line should also be 1 in. minimum.
For the Caterpillar 460 hp prime mover, maximum consumption is 21 gallons
(U.S.) per hour (79.5 litres per hour)
For the Detroit Diesel 475 hp prime mover, maximum consumption is 22.8
gallons (U.S.) per hour (86 litres per hour)
2. Determine the required length of the fuel line. Determine the route it will take
from the fuel supply to the power unit.
Note: Avoid routing the fuel line where it might become damaged or pinched.
3. Verify the quality of the fuel supply.
Note: Poor fuel quality might require special treatment. For example, fuel line
heaters might be required in areas where diesel fuel contains high levels of paraffin.
Air Considerations
If the top drive unit is equipped with an integrated generator, then the connection requirements
for fuel and air should be considered.
1. Determine if the air supply is adequate.
Note: 100 psi minimum with a 1 in. supply line
2. Verify the quality of the air supply.
Note: If you are in an area with high humidity, then a moisture trap might be
required to remove moisture from the starters air supply.
3. Determine the required length and route of the air supply line.
Note: Avoid routing the line where it might become damaged or pinched. If you
place the air receiver close to the power unit, this might help it start more easily.
880026 REV 3
250TON HMIS 475HP

5
INSTALLATION GUIDE
EQUIPMENT INSPECTION (PRE-INSTALLATION)

TESCO inspects all top drive equipment before shipping, however, some damage might occur
while equipment is in transit.
It is important to identify any shipping damage as quickly as possible. This allows you to make
necessary repairs, order equipment replacements, and optimize system readiness.
As part of a pre-installation equipment inspection, do the following:
Check all shipping containers for damage. External damage may indicate damage to contents.
Visually inspect all principle components for damage or missing parts.
If the top drive system is shipped with fluid levels at full, check the fluid levels. Low
fluid levels may indicate a leak in the hydraulic, cooling, or lubrication system.
A sample equipment checklist is included in Appendix A: Pre-Installation Checklist.

6
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
CHAPTER 3: RIG UP PROCEDURE

EQUIPMENT PLACEMENT
Optimal Placement of the Power Unit
The following diagram shows the optimal placement of the power unit. This placement is considered ideal for the following reasons:
The power unit is located on the same side as the standpipe.

The placement allows straight-line access from the cable reel to the roller saddle.
The cooling fans are not obstructed.
There is adequate space in front of and behind the power unit (15 ft.).
There is working access for personnel around the perimeter (3 ft. on each side).
Figure 3-1: HMI optimal equipment placement
Although the location of the power unit depends on the rig configuration, it is important that
you consider the factors discussed above when you place the equipment. If space is very limited, you can order an optional stacking kit to mount the hydraulic oil storage tank, cooler and
cable reel on top of the prime mover, pump drive, and filter manifold.
Note: If you require a stacking kit, you must specify this requirement well before the
unit is shipped.
880026 REV 3
250TON HMIS 475HP

7
RIG UP PROCEDURE
INSTALLATION GUIDE
How to Place the Power Unit Components

1. Ensure the ground surface is level; remove any major obstructions.
2. Install rig matting or another secure material under the equipment location.
Note: Ensure the rig matting extends far enough beyond the equipment to provide
a walkway for outside service activity.
3. Use a crane or loader to place the prime mover on the rig matting.
4. Connect the following items:
Connect This
From Here
To Here
37C electrical control cable
Power unit
Drillers panel
Closed loop high pressure

supply and return lines
Hose reel
Filter manifold
Diesel fuel line
Fuel source
Prime mover
Air line
Air source
Diesel engine starter
480VAC (or 600VAC) power

electrical cable
Power unit
Master Control Centre

(MCC)
5. Connect the auxiliary hydraulic fluid lines from the auxiliary quick-connectors to
the hose reel control.
Note: Auxiliary hydraulic power is required to spool off the service loop when
you install the hose hanging saddle.
Optimal Placement of the Hose Saddle

The following illustration shows the optimal placement of the hose saddle. This placement is
considered ideal because the hose saddle is situated as follows:
High enough to prevent cables or hoses from landing on the rig floor when top drive is
lowered:
If the mast height is 100 ft.-125 ft. (30.5m-38.1m), it is 55 ft.-65 ft. (16.8m-19.8m)
above the rig floor.
Low enough to allow the top drive to reach the highest position in the mast without
straining or damaging hoses,
Where the service hoses will follow the mud (Kelly) hose and reduce the risk of the service hoses interfering with the overhead equipment as the top drive travels up and down
the mast, and
Where the hose will not be damaged during top drive operations.

8
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
RIG UP PROCEDURE
Attach protective equipment to any points that might be subject to wear during top drive operations.
Figure 3-2: HMI hose saddle placement
100-125 ft.
For Triple:
For Double:
Service Loop:
Approximately 60-65 ft.
between top drive
and hose saddle
capture clamp
Service Loop:
Approximately 50-60 ft.
between top drive
and hose saddle
capture clamp
Hose Saddle:
Mounted 55-65 ft.
above drill floor
(depending on
racking platform height
and sling length)
Hose Saddle:
Mounted 45-55 ft.
above drill floor
(depending on
and sling length)
Standpipe Hose
Power Unit:
Located on standpipe side
Although the arrangement shown here is considered optimal, placement of the cable roller saddle is determined by several factors:
mast height
length of traveling equipment (drill string, compensator, blocks, and swivel)
saddle hanging mechanism and configuration
available hose length (standard hose length is 225 ft.(76.2 m) unless otherwise
requested)
power unit location
How to Install the Hose Hanging Saddle and Service Loop

TESCO recommends that you suspend the hose saddle from a pad eye attached to the racking
platform. If no pad eye is available, wrap a sling around a secure beam at the racking platform.
The hose saddle can be shackled to the sling and suspended from the beam. The total weight
suspended from the sling or pad eye is
The hose saddle includes a clamp that holds the service loop cable and hoses in place at the
racking platform. The hoses and cable are clamped into the saddle at ground level, then the
saddle is hoisted into position.
Before you begin this procedure, you must calculate the length of service loop that will travel
with the top drive.
1. Ensure that the auxiliary hydraulic fluid lines are connected to the hose reel control.
Note: Hydraulic power is required to un-spool the service loop for connection to
the hose saddle.
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2. Use a soft sling to bundle the end of the service loop.

3. Attach the bundled end to the cable of the floor tugger or loader.
4. Use the hose reel and tugger to lay out the length of the service loop that will
travel with the top drive.
Note: Measure the length of the service loop, starting at the hammer union
hydraulic connectors. Keep the service loop tidy, and ensure the ends of all
hydraulic hoses are as even with each other as possible.
Figure 3-3: HMIS cable/hose saddle clamping location
1 - Hammer union hydraulic connectors

2 - Hose saddle
When the hose saddle is in place, the hoses to the top drive should
reach the rig floor, and approximately 3 ft. (.9 m) of hose should be
lying on the floor.
5. When the correct length has been spooled off the reel, insert the hoses and cable in
the cable/hose saddle capture clamp.
Figure 3-4: HMIS hose saddle capture clamp configuration
1. Hydraulic supply/return line

2. Hydraulic supply/return line
3. Auxiliary and case drain
return line
4. Auxiliary supply hose
5. 37 multi-conductor cable for
robotic functions

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Table 3-1: HMI - cable and hoses for 460 and 475 HP prime movers
Quantity Description
2
1-1/2 in. high pressure closed loop hoses (1 supply, 1 return)
3/4 in. auxiliary hydraulic supply hose
1-1/4 in. auxiliary and case drain return line
37 multi-conductor cable for robotic functions
6. Connect the hose saddle to the cable of the floor tugger or crane.
7. Hoist the saddle and hoses into position below the racking platform.
Note: Hoist the saddle slightly higher than its final position.
Figure 3-5: Hoisting the hose saddle
Figure 3-6: Positioning the hose saddle
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8. Install the hanging sling for the hose saddle at the racking platform.
Note: Attach the hanging sling to the pad eye with a shackle, or wrap it around a
suitable beam.
9. Use a shackle to attach the hose saddle to the hanging sling.
Note: The hose saddle sling must be strong enough to hold loads of more than
2,000 lbs (907.2 kg).
10. Use the floor tugger or crane to lower the saddle until the weight transfers to the
hanging sling.
11. Install a back-up safety sling around the hose saddle.
Caution: This back-up sling is considered critical safety equipment.
12. Lower the crane or floor tugger cable.

13. Attach the crane or floor tugger cable to the sling at the free end of the service
loop.
14. Hoist the free end of the service loop to the rig floor and secure it in place until it
can be connected to the top drive and driller's panel.
15. Bring the 160 ft. (48.8 m) 37C control cable, connected to the main panel on the
power unit, to the drill floor.
TORQUE ARREST SYSTEM

Before You Install the Torque Arrest System
Install a hanging pad eye in the crown before you install the torque arrest system. This pad eye
must be designed and installed to support the hanging weight of the entire torque assembly
(safe working load of 5,000 lb. (2,268 kg) plus the recommended safety factor for overhead
equipment).
The pad eye is typically placed 18 in. (45.72 cm) back from the crown cluster centre. It is easiest to install the pad eye when the mast is down. Discuss installation procedures with a
TESCO representative as part of pre-installation activities.
Danger! Design and installation of the pad eye should

meet or exceed all safety specifications for the
operating area and operating conditions.
A variety of stabilization devices can be used to hold the torque arrest system in place during
operations. It is easiest to install the stabilization systems before raising the mast.
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Torque Arrest System Components

A standard torque arrest system includes the torque beam, T-bar, and the following torque
track sections (typical). The number of torque track sections depends on the free working
height of the mast and is shown on the application drawing supplied with the top drive system:
one adjustable hanging sling

one cable clamp mount and cable capture clamp
one 18.5 ft. (5.6m) reversible, bolted, bottom torque track section
three 18.5 ft. (5.6m) standard torque track sections
one 10 ft. (3.1m) torque track section
one 5 ft. (1.5m) torque track section
The total length of the torque track sections is 91 ft. (27.7m).Obtain additional length by
lengthening the top section hanging sling. Purchase additional torque track sections to accommodate larger masts.
One 1.3 ft. (.4m) deflector section (bull nose) of torque track is included.
Caution: Never subject the deflector section to torque. Mount it

below the torque beam only.
The deflector section is always mounted at the bottom. Its tapered design assists in mounting
the torque bushing onto the torque track.
Torque Arrest System Configuration

You must know the following before you can determine the torque track configuration:
height of the hanging pad eye for the torque track, measured from the rig floor (A)
position (height above rig floor) where the torque beam and T-bar will be mounted (B)
length of the hanging assembly for the torque track, including hanging swivel, nut, and
shackles (2.5 ft. minimum (.8 m) to 15 ft. (4.6 m) maximum)
Note: Shorter configurations are safer and more practical.
Note: Correct calculations will help ensure that the torque bushing will not come off of
the torque tube when the blocks are fully hoisted to the crown.
the location of any upper strongback that may interfere with the vertical hanging of the
torque track
Note: If the torque track is to remain in the mast during rig moves, match the torque
track connections to the mast connections wherever possible.
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Figure 3-7: Torque arrest system configuration

A = Mast height from rig floor to water
table (underside of crown)
B = Height of T-Bar and anchor beam
C = Clearance beneath torque track
deflector (to be a minimum of 7 ft)
D = Length of torque track hanging
assembly
E = Distance from top of travelling block
down to top of torque bushing
F = Distance from bottom of torque bushing down to bottom of elevator
G = Stump height above rig floor
How to Determine the Torque Track Configuration (where an application drawing is not supplied)
Sketch and calculate the following on paper before you connect sections of torque track.
1. Place the bottom of the deflector section 8 ft-10 ft (ideally) above the drill floor,
but no less than 7 ft (min) and no more than dimension F+G (max) to ensure it
does not come off the bottom end of the torque track when it is in the lowermost
position.
2. Place the bottom bolted section of torque track above the deflector section such
that it coincides with elevation B.
Note: Ensure that a suitable strongback for mounting the torque beam and T-bar is
available somewhere along the length of the bolted section of torque track.
Remember that the bolted section is reversible.
3. Stack the track sections (18.5 ft., 5 ft. and 10 ft. sections) until you reach 5 ft.-15
ft. (1.5 m-4.6 m), ideally, from the pad eye.
Note: Dimension D is to be no more than dimenstion E to ensure that it will not
come off the top end of the torque track when it is in the uppermost position.
4. Determine the length of hanging assembly required.
Note: Ensure that the length of hanging assembly is incorporated into the calculation.

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Sample Calculation
If the mast height is 142 ft. (43.3m):
1. 142 ft. less 9 ft. (2.7 m) (height above rig floor for the deflector section) = 133 ft.
(40.6 m)
2. 133 ft. less 2.5 ft. (.76 m) (minimum hang assembly length) = 130.5 ft. (39.8 m)
3. 130.5 ft. divided by 18.5 ft. = 7 full-length tracks; this does not include the deflector section.
Torque beam desired height = 11 ft. (3.4 m)
The rig up would be as follows:
Track Part
Qty Length (ft.)
Total Length (ft.)
Hanging Track
18.5
18.5
Standard Tracks
74 (18.5 x 4)
92.5
10 ft. section
10
102.5
5 ft. section
107.5
*Bolted section
18.5
126
Deflector
1.3
127.3
Set to 6 feet
133.3
**Pinned Section Length or 1

Hanging Assembly
142 (mast height) - 133.3 = 8.7 feet above the rig floor)
*The bolted track section would be run with the bolt section down, below the
standard track sections and 10 ft. and 5 ft. sections. The deflector track section
would be mounted below the bolted section.
**Hanging assembly length should not be more than 1 ft longer than the height
differential between the top of the travelling block to the top of the torque bushing.
How to Install the Torque Arrest System

Use this procedure to install the torque arrest track system. Refer to Figure 3-8 on page 19.
1. Ensure the hanging pad-eye for the torque track is installed in the crown.
Note: Normal placement for a standard track is 18 in. back from the crown cluster
centre.
2. Assemble the torque beam, T-bar, and T-bar clamp.
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Warning! Assemble the above with the T-bar at mid-length.

This balances the assembly during lifting.The
assembly should not be fully torqued, but it
should hold the T-bar securely in place.
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3. Use the tugger to move the torque beam onto the drill floor and up to the lowest,
most practical strongback beam.
Note: Install the torque beam low in the mast. Attach it to a large beam anywhere
between 10 ft. and 16 ft. above the drill floor. If you install it any higher, you
might require additional stabilization below the torque beam. TESCO can supply
additional stabilization, if required.
4. Use four clamps to mount the torque beam to the selected supporting beam.
Note: On a permanent installation, you may weld the anchor beam clamp onto the
mast.
5. Slide the T-bar to the most rearward position.
6. Use the calculation method described in How to Determine the Torque Track
Configuration (where an application drawing is not supplied) on page 14 to calculate the required torque track section configuration.
Note: When the torque track is suspended, the bottom of the deflector section
should be 7 ft.-8 ft. off the floor.
7. When the torque track section rig-up is determined, set and secure the calculated
hanging sling length.
Caution: Torque sling bolt clamps to 230 ftlbs.
Note: When you tighten the sling clamp bolts, ensure that the sling is compressed
evenly along its length. It will take several repetitions to ensure that the clamping
force is distributed evenly across all of the cable clamps.
8. Fasten the hanging sling plate to the top section of torque track.
Note: Use a soft sling to hold the sling in place so that it will be easily accessible
when the torque track is lifted to the hanging pad eye.
9. Use the rig floor tuggers to hoist the first track section up to the floor.
Note: On most rigs, two full-length sections of torque track can be assembled on
the ground before being lifted to the rig floor. If the rig is very small, you will
have to bring the torque track lengths to the rig floor one at a time.
Note: As the first section is installed, make up additional sections on the ground.
10. Lower the first track section through the rotary table or mousehole.
Note: If the rotary table is too small to permit the torque track to pass through, use
an alternate location on the rig floor. If no alternate location exists, mate the sections above the rig floor.
11. Lower the blocks and install two handling slings on the torque track.
Note: Thread the slings through the block becket and attach them to the top track
using the handling assembly for the torque track.
Caution: Attach the top section of track such that the top portion of
track extends above the blocks. This allows the hanging assembly
to reach the pad eye without crowning out the blocks.
12. Place a ratchet strap around the top of the blocks and thread it around the torque
track.
13. Use the ratchet strap to pull the blocks and track together.
Note: This immobilizes the track section and keeps it hanging vertically as it travels up the mast.
14. Hoist the blocks until they support the weight of the torque track.
15. Remove the floor tugger.

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16. Hoist the blocks until the bottom of the first section is 8 ft. above the drill floor.
17. Connect the floor tugger to the second section of torque track and hoist it to the rig
floor.
18. Lower the second section of track through the rotary table or into the mousehole
until it reaches the appropriate level for connecting to the upper section (which is
currently suspended from the blocks).
19. Use chains to secure the second section in place, or place a strong bar through the
back strap of the torque track.
20. Lower the blocks and upper section of track and connect the two sections. Bolt the
sections together, ensuring a flush connection.
Note: Coat all bolts with an anti-seize compound before installation.
21. Torque the bolts to 350 ftlbs.
22. Repeat steps 17.21. until all sections are connected and supported by the blocks.
Note: The last section that is installed is typically composed of the reversible
bolted section, the deflector section and, if required, the two-foot track section.
23. Use a ratchet strap to secure the extend arms of the torque bushing in place.
24. Attach a tugger to the torque bushing and move the bushing onto the drill floor.
Note: Ensure that the extend frame is down.
25. Position the torque bushing over hole centre.
26. Use the blocks to lower the assembled torque track and stab it through the torque
bushing.
27. When the torque bushing is in position, pin it in place.
Note: Ensure that the top drive pin ends are at least 8 ft. above the drill floor. If the
torque bushing is too tight to move freely along the torque track, adjust the torque
bushing by adding additional shim packs. To ensure a proper fit, periodically
check the bushing during the first few days of operation.
28. After the torque bushing is installed, raise the blocks to the crown.
29. Connect the hanging assembly of the torque track to the pad eye.
30. When the hanging assembly is connected to the pad eye, lower the blocks until the
weight of the track is transferred to the pad eye.
Note: Do not remove the handling assembly yet. Use the blocks to raise and lower
the torque track while you make the fine adjustments required to connect the T-bar
to the bolted section.
31. Connect the T-bar to the bolted section of the torque track.
Caution: When you connect the bolted section of the torque track,
ensure you suspend the full weight of the torque track from the pad
eye.
Note: If the T-bar and bolted sections are not vertically aligned, then use the
blocks to hoist the track. While the track weight is suspended from the blocks,
adjust the hanging swivel as required. Up to 2 in. of adjustment is available in the
hanging assembly and the lock nut.
32. When all T-bar fastening bolts are tight, move the T-bar to the correct position in
the T-bar seat and tighten the clamp to hold it in position.
Note: Hang the centre of the torque track vertically,18 in. back from the hole centre.
33. Tighten the lock nut on the hanging assembly.
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34. Remove the handling assembly at the crown and lower the blocks.
Caution: Before you move the top drive onto the rig floor, ensure
the following is in place:
the swivel yoke link (with an integral counter-balance) is installed
in the block becket
the accumulators are facing the torque track
the gauge, coupler and valve are facing the drillers side
35. Install stabilization systems.

Note: Three sets are usually installed: one at the top strongback, one at the racking platform, and one between the racking platform and the torque beam. These
are most easily installed when the mast is down, but can also be installed during
rig-up.
36. Attach the stabilization devices to the torque track as shown in the following illustrations.

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If your rig set-up requires a customized stabilization installation, contact TESCO.

Figure 3-8: F-clamp and turnbuckle assembly
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TOP DRIVE
How to Install the HMI Top Drive
Before you move the top drive onto the rig floor, ensure the following conditions exist:
You have installed the swivel yoke link (with integral counter-balance) in the becket of
the block.
The accumulators are facing the torque track, and the gauge, coupler and valve face the
drillers side.
1. Using blocks or a crane, move the top drive to the rig floor.
Note: If using the block, attach a hold-back line from the handling frame of the
top drive to a loader or cat line tugger. Use the line to prevent the top drive from
swinging when it is lifted off the rig floor.
Caution: Always attach the hoisting line to the top drive handling
frame and not to any part of the top drive when the top drive is
installed in the handling frame.
2. Position the top drive over the hole center.

3. Lower the blocks and remove the lifting sling.
4. Connect the links of the swivel yoke to the swivel on the top drive.
Note: The grease zerks (on the pins of the yoke link) must face the load.
5. Raise the blocks to support weight of the top drive.
Caution: Do not lift the top drive off the floor.
!
6. Remove the pins on the handling frame of the top drive (three or four in total,
depending on the unit type).
Caution: Ensure the link locks are set so that the top drive will not
tilt forward.
7. Lift the top drive until it is clear of the handling frame.

8. Use the floor tugger to remove the handling frame from the rig floor.
9. Use the blocks to position the top drive so that it can be joined to the extend
frame.
Note: Align the ears on the top drive with the extend frame and extend arms and
pin them in place.
10. Remove the pin that is holding the torque bushing in place on the torque track.
Note: The weight of the top drive and torque bushing are now suspended from the
blocks.
11. Remove the link locks so that the links can swivel freely.
12. Lower the top drive to the rig floor.
13. Check if the top drive hangs vertical.
14. Reposition the T-bar so the top drive sits over the hole center, and secure it in
place (if required).
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15. Tighten the T-bar connection to secure it in place.

16. Locate the service loop. It should have been installed before this point. If the service loop has not been installed, see Figure 3-2 on page 9.
17. Connect the following hoses and cables for the service loop to the top drive:
supply and return hoses for the closed-loop hydraulic system
supply hose for the auxiliary hydraulic system
return hose for the case drain and auxiliary hydraulics system
37C control cable, 225 ft.
18. When all service loop hoses and cable are attached, check the loop position.
The loop should be off the floor.
There should not be any snagging/interference.
19. Re-check all hose connections.
20. Ensure that all required valves are open.
four at the top drive: 2 on the hoses, 2 on the top drive
five at the hose reel: 2 on the reel, 2 on the hoses, 1 on the auxiliary line
21. When the top drive and driller's panel are connected, continue with additional setup procedures, or begin rig commissioning.
Note: The counter-balance cushion height can be set after all support systems are
running. The cushion height must be set before any drilling operations start. See
How to Set the Counter-Balance Cushion Height on page 22.
COUNTER-BALANCE SYSTEM
Figure 3-9: Counter-balance system interface
1. Accumulators:
N2-Nitrogen and Oil
2. Counter-balance cylinder
3. Needle Valve
4. Auxiliary system quickcoupler
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How to Set the Counter-Balance Cushion Height

The following conditions must exist before the following portion of the counter-balance installation can be completed.
The top drive must be installed.

The hydraulic circuit must be connected.
The drillers panel must be operational.
The top drive must be positioned at the racking platform.
1. Connect the hose quick-coupler for the elevator to the charge fitting for the
counter-balance system.
2. Shut off the auxiliary pump.
3. Set the ELEVATOR switch (at the drillers panel) to CLOSE.
4. Open the needle valve on the counter-balance manifold.
Note: This relieves all pressure on the counter-balance system.
5. Check the nitrogen pressure, and adjust if required.
Note: The nitrogen pressure must be 800psi.
6. Ensure the counter-balance relief valve is set at 1200 psi.
7. Close the needle valve on the counter-balance manifold.
8. Start the auxiliary pump.
9. Set the ELEVATOR switch (drillers panel) to OPEN, and push and hold the ELEVATOR SAFTEYOPEN button.
Note: This will send 1500 psi hydraulic pressure to the needle valve on the
counter-balance manifold.
10. Slowly open the needle valve and allow the hydraulic oil to charge the counterbalance system.

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11. Monitor the counter-balance cushion by watching the gap that develops between
the swivel bail and the block hook.
12. Continue to charge the system until the gap is 1-1/2 in. to 2 in. (the yoke pin
should now be located in the center of the slotted eye of the link).
13. Close the needle valve.
14. Shut off the auxiliary pump.
Note: This will allow the oil pressure in the auxiliary system to decrease.
15. Set the ELEVATOR switch to OPEN, then to CLOSE. This will relieve any pressure in the system.
16. Remove the elevator hydraulic hose from the counter-balance manifold.
Warning! If you disconnect a quick coupler while there is

pressure in the system, it will be extremely
difficult to reconnect the coupler.
DRILLER'S PANEL
How to Install the Drillers Panel
The drillers panel cannot be connected to the top drive until the hose saddle and service loop
have been installed.
The location you select for the drillers panel should be as follows:
within reach of the driller
where there is an unobstructed view of the rig floor
in a safe position
The bottom of the driller's panel is equipped with a four-bolt mounting plate. Use this to attach
the control panel to a custom-built pedestal or existing framework. Some on-site fabrication of
a mounting site might be required.
1. Locate the position for the driller's panel.
2. Fabricate a mounting location if required.
3. Drill bolt holes in the mounting location.
Note: A second mounting plate is provided to use as a template.
Caution: To avoid damaging components, avoid mounting the

driller's panel in a location that is exposed to vibration.
4. Locate the 225 ft. 37C control cable.

Note: This cable is installed in the hose saddle with the service loop.
5. Connect the cable to the drillers panel.
6. Connect the second 37C control cable coming from the power unit to the drillers
panel.
7. Mount the brake handle control box to the brake handle.
8. Connect the brake handle control box to the driller's panel.
Note: The driller's panel has three labeled extension cords with military connectors. Use the correct cord (cord F).
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SAFETY AIR INTERLOCKS

For detailed information about safety interlocks, refer to the schematics for your unit and/or
contact a qualified TESCO representative.
How to Install the 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. Use the push button on the brake handle to
override this lockout feature. You cannot install the drawworks interlock override until the
driller's panel is in place.
Figure 3-10: Drawworks override installation
1. Supply air
2. Air/Electric solenoid valve
3. Air line
4. Drum clutch valve
5. Air line
6. Drawworks
7. Drillers panel
8. Grabber Open/Close switch
9. Elevator button
10.Grabber override button
11.Control box for the brake handle
1. Shut off the air supply from the compressor to the drum clutch control.
Note: Use an isolator valve if necessary.
2. Disconnect the hose for the drum clutch air supply from the control valve.
3. Connect the air supply hose to an C-cord solenoid valve.
Note: If two air supply hoses are present, connect each hose to an air/electric solenoid valve (one for low clutch and one for high clutch).
4. Connect the air supply from the air/electric solenoid valve to the drum clutch air
control valve.

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5. Connect an electric cable from the air/electric solenoid valve to the extension cord
at the driller's panel. The cord is labeledC-Drawworks.
Note: If two air/electric solenoid valves are required, use a splitter to establish a
connection from both valves to the driller's panel.
6. Ensure the control box for the brake handle is connected to the driller's panel.
About the Mud Pump Interlock

The mud pump air interlock is designed to disallow operation of the mud pump unless the
mudsaver valve is open.
Before you attempt to install this safety interlock, discuss equipment requirements and operational considerations with a qualified TESCO representative.
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CHAPTER 4: SYSTEM INSPECTION AND

START UP
INSPECTION-GENERAL NOTES
When the installation procedures are complete, perform a visual inspection of the complete
system.
Caution: Perform visual inspections before applying power to the
system.
Inspection checklists for the following are included in Appendix B: Visual Inspection Checklists.
top drive
power unit
control cables
cable/hose reel
drillers panel
WARNINGS
Ensure the gearbox breather is installed and the ball valve is opened prior to operating.
Note: The breather may not be installed for shipping purposes and some new units may
have the ball valve handle wired closed.
Install a saver sub in the grabber on the top drive before you test for hydraulic leaks or
operate any robotics function.
Before you start any pumps, ensure that all appropriate valves on tanks and pumps are
open.
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INSTALLATION GUIDE
SYSTEM START UP
After you have completed all visual inspections, begin the system start up process.This section
provides instructions on how to do the following:
power up the power unit electrical system

power up the diesel prime mover
test the closed-loop hydraulic system
test the robotics functions and operations of the top drive
Note: Refer to the electrical schematics supplied with your unit.
Power Unit: Electrical System
Danger! Only qualified electrical personnel should test the

power supply and AC power circuits.
How to Start the Electrical System for the Power Unit

1. Ensure that the main breaker that supplies the power is in the off position.
2. Connect the power cable from the power unit to the Motor Control Centre (MCC).
Note: Power supply should be as follows:
Normal
480 VAC
100 amp recommended
(60 amp minimum)
60 Hz
Optional
380 VAC
100 amp recommended
(60 amp minimum)
50 Hz
Danger! Only qualified electrical personnel should test the

power supply and AC power circuits.
3. Ensure that all cables from the following items to the electrical cabinet on the
power unit are in place and correctly connected:
motor for the fan
motor for the auxiliary pump
skid transformer on the power unit
4. Set the breaker labeled TRANSFORMER to ON. This will activate the power
supply.
5. Set the breaker labeled LIGHT to ON (if applicable).
6. Find the breaker labeled 120V FOR 24V POWER SUPPLY. Switch the 24V
breaker to ON.

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7. Set the breaker labeled ENGINE HEATER to ON, then check the operation of the
heater.
Note: If ambient temperatures are below 32 Fahrenheit (0 Celsius), run the
engine heater for four hours before you start the prime mover.
8. Set the breaker labeled COOLING FAN to ON.
9. Use the cooling fan on/off switch to activate the fan briefly. Check the fan for
proper rotation.
Note: If the cooling fan does not rotate in the required direction, then the incoming phases of the power supply must be switched. First, SHUT OFF THE MAIN
POWER SUPPLY, then switch two of the incoming power phases at the incoming
fuses of the main panel.
Caution: If you switch the phases, ensure the incoming power

cables are correctly labeled.
10. Check the oil level in the hydraulic oil storage tank.
11. Ensure that any required hydraulic oil valves are in the open position.
12. Briefly activate the auxiliary pump (use the AUX PUMP switch).
13. Listen for correct operation.
Note: If the pump does not operate properly, check for correct rotation of the
pump. Monitor the motor-to-pump coupler to confirm the direction of rotation.
14. Ensure that the lines for the auxiliary supply and case drain return are connected
to the top drive.
Note: If you connect the auxiliary supply and return lines to the top drive, you can
test the system by connecting the supply and return jumpers to the hose reel.
15. Set the auxiliary pump 3-position switch to HAND; this will turn the auxiliary
pump ON.
16. Ensure that the flow meter near the oil cooler is registering flow.
17. When electrical power connection has been confirmed, continue with the procedure for starting the prime mover.
Prime Mover
Before You Start the Prime Mover
1. Ensure the supply lines for the air and rig fuel are connected to the prime mover.
2. Check the oil level for the engine.
3. Check the oil level for the pump drive.
4. Check the coolant level.
Caution: Only check the coolant level when the engine is cold.
!
5. Ensure that the valves on the suction line from the hydraulic oil tank to the charge
pumps are open.
880026 REV 3
250TON HMIS 475HP

29
INSTALLATION GUIDE
6. Connect the supply and return hoses for the closed-loop system to the top drive.
Caution: Ensure that all isolation valves are open.
!
7. Use the Kill/E.S.D. (Emergency Shut Down) button at the drillers panel to test
the operation of the rig savers.
Caution: After you test the rig savers, reset them to the fully open
position.
How to Start the Engine

1. At the drillers panel, set the MODE switch to CONN.
Note: The prime mover will start to operate at low rpm.
2. Start the prime mover engine by using one of the following procedures.
Caterpillar Engines
1. Engage the air starter for one short burst (approximately three seconds).
Note: Do this to ensure that the unit will turn over easily.
2. Hold the manual shut-off knob in the RUN position.
Note: The knob is located on the left side of the engine above the air starter.
3. Engage the air starter until the fuel charge pressure gage indicates that pressure is
present.
4. With the shut-off knob in the RUN position, press the air starter and hold it until
the engine starts.
Note: If the engine does not start in ten seconds, release the air starter and try
again. If, after three attempts, the engine does not start, refer to the Maintenance
Guide and the Troubleshooting Guide for your unit.
Detroit Diesel Engines
1. Engage the air starter for one short burst (approximately three seconds).
Note: Do this to ensure that the unit will turn over easily.
2. Engage the air starter until the charge pressure gage indicates that pressure is
present.
3. Turn the POWER switch to ON. The POWER switch is located on the Detroit
Operator's Panel.
4. Monitor the red and yellow lights.
Caution: These lights will extinguish when the unit is ready to start.
Do not start the unit until these lights are extinguished.
5. When the lights extinguish, press the air starter and hold it until the engine starts.
Note: If the engine does not start in ten seconds, release the air starter and try
again. If, after three attempts, the engine does not start, refer to the Maintenance
Guide and the Troubleshooting Guide for your unit.

30
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
After the engine is running, perform the following steps.

1. Check the fuel charge pressure.
Caution: If, after 30 seconds of operation, the charge pressure fails

to rise to 280-400 psi, deactivate the engine. Refer to the Maintenance Guide and the Troubleshooting Guide for your unit for information on charge pressure.
2. Check the closed-loop system for leaks.
Closed-Loop Hydraulic System

Use the following procedure to test the close-loop hydraulic system.
1. Start the prime mover according to the previous procedures.
2. Go to the drillers panel.
3. Ensure that the quill on the top drive is unobstructed.
Note: Ensure that personnel are clear of the top drive.
4. Set the MODE switch to DRILL.
Note: The prime mover should increase to the maximum rated speed (approximately 2100 rpm).
5. Set the MODE switch to CONN.
Note: The idle speed of the engine should decrease.
6. Set the PUMPSREV/FWD switch to FWD.
Caution: The MODE switch must be set to CONN.
Note: The quill should begin rotating at 17-20 rpm.

7. Use the remote pressure gauge at the drillers panel to monitor the loop pressure.
Note: This pressure should be between 400-500 psi. If the loop pressure rises
above 700 psi, set the PUMPSREV/FWD switch to neutral, then check the quill
for obstruction. If no obstruction is observed, ensure all valves are in the proper
position.
Note: In cold weather, the oil will be more viscous, which might cause the loop
pressure to rise above normal.
8. The top drive should now be rotating at Connect-Forward speed. Go to the power
unit.
9. Check the flow meters for the closed loop (2).
Note: All values on the meters should be within 5% of each other.
10. Ensure that the reservoir level for the hydraulic oil remains adequate.
11. Return to the drillers panel.
12. Set the PUMPSREV/FWD switch to neutral.
13. Set the MODE switch to DRILL (low speed).
14. Set the PUMPSDECR/INCR switch to DECR and hold this position for ten seconds.
Note: If the speed setting for the pumps has been left at a high rpm, this will
reduce the speed to a safe level.
15. Set the PUMPSREV/FWD switch to FWD.
880026 REV 3
250TON HMIS 475HP

31
INSTALLATION GUIDE
16. Use the PUMPSDECR/INCR switch to increase the speed in small increments
until the quill begins to rotate slowly.
17. When proper quill operation is confirmed, turn the PUMPSREV/FWD switch to
neutral.
18. Remove the cover from the tank level switch.
Note: This allows you to access the float-activated micro-switch for the tank
level.
19. Operate the switch by hand.
Note: This switch should interrupt the fuel supply to the prime mover. If the
switch works properly, then the wiring for the following emergency shutdowns is
correct and working:
low oil reservoir level shutdown
high loop temperature shutdown (>190F)(>88C)
high tank temperature shutdown (>165F)(>74C)
20. Verify that the automatic cooling fan is functioning properly.
Top Drive Robotic Functions

Test the robotic functions for the top drive before you start drilling operations.
1. Start the auxiliary pump at the power unit.
2. Check the meter for the return flow.
Note: The return flow should be approximately 6 gpm.
3. Make a note of the circulating pressure.
Note: Circulating pressure is valuable information for troubleshooting.
4. Go to the drillers panel.
5. Use the AUX PUMP switch to select OFF, then select ON.
Note: Confirm that the control for the auxiliary pump at the drillers panel is functioning properly.
6. Use the controls at the drillers panel to test all robotic functions for correct operation.

32
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
CHAPTER 5: RIG OUT PROCEDURE

The top drive rig-out (removal) procedure is divided into the following separate activities:
remove the top drive
remove the torque arrest system
remove the service loop
When the rig-out procedures are complete, store all equipment in shipping containers. For
more information on long term storage, please consult the Maintenance Guide for your unit
type.
REMOVE THE TOP DRIVE

1. Move the top drive handling frame to the rig floor.
2. Locate a pin position on the torque track and pin the torque bushing to the torque
track.
Note: This pin connection holds the torque bushing in place when it is disconnected from the top drive.
3. Disconnect the top drive from the extend frame.
4. Hoist the top drive.
5. Position the top drive handling frame over the hole center.
6. Lower the top drive into the handling frame and pin it in place.
7. When the top drive is secured properly in the handling frame, use the chain tongs
to disconnect the swivel connection.
8. Disconnect all service loop items from the top drive.
9. Remove the top drive from the rig floor.
880026 REV 3
Caution: Connect the hoisting cable to the top drive handling frame
and not to any part of the top drive.
250TON HMIS 475HP

33
RIG OUT PROCEDURE
INSTALLATION GUIDE
REMOVE THE TORQUE ARREST SYSTEM

This procedure assumes that the top drive is disconnected from the swivel and removed from
the rig floor.
Note: If you intend to reinstall the top drive into the existing mast, leave the
torque track stabilization equipment in place. If you do not plan to reinstall the top
drive, remove the stabilization equipment when you lower the mast.
1. Connect the tugger to the torque bushing and extend frame. Take the weight of the
load with the tugger.
Note: The bushing will be pinned near the bottom of the torque track. See
Remove the Top Drive on page 33.
2. Remove the pin and carefully lower the torque bushing off the bottom of the
torque track and onto the rig floor.
3. Use the tugger to move the bushing out the V-door.
4. Run two torque track handling slings through the becket of the blocks.
5. Attach the pick-up pin of the torque track to the slings.
6. Raise the blocks to the crown.
7. Connect the torque track to the blocks by placing the pick-up pin of the torque
track through the hole in the torque track. Then, attach the slings to both sides of
the pick-up pin.
8. With the slings and pick-up pin in position, hoist the blocks to transfer the weight
of the torque track from the torque track hanging assembly to the block slings.
9. Unbolt the T-bar from the torque track.
10. Loosen the T-bar clamp.
11. Slide the T-bar to its most rearward position.
Note: This prevents the T-bar from obstructing the torque track during
disassembly.
12. Re-tighten two bolts on the T-bar clamp.
13. Disconnect the hanging assembly from the pad eye in the crown.
14. Use the blocks to lower the torque track through the rotary table until the first
flanged connection is at working height.
15. Use a 4-3/4 ton shackle through the stabilizer attachment bar (on the back of the
torque track) to attach the rig tugger to the bottom section of track. This will hold
it in place while it is unbolted.
Caution: If a wellhead is not installed, ensure that the casing bowl is

covered to prevent objects from falling into the hole.
16. Hoist the remaining track (suspended from the blocks) 10-15 ft. above the rig
floor.
17. Use the rig tugger (already attached) to lift the bottom section of track out of the
rotary table and off the rig floor.
18. Repeat steps 14.-17. for each section of torque track.

34
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
RIG OUT PROCEDURE
19. Remove the handling slings from the blocks and hoist the blocks clear of the rig
floor.
20. Connect the tugger line to the T-bar/torque anchor beam.
21. Loosen and remove the anchor beam clamps.
22. Use the tugger to lower the T-bar/torque anchor beam and move it off the rig floor.
REMOVE THE SERVICE LOOP

1. Connect a sling to the hose saddle.
2. Connect the sling on the hose saddle to the floor tugger.
3. Raise the floor tugger until it takes the weight of the hose saddle.
4. Remove the hanging sling for the hose saddle and the safety line.
5. Use the floor tugger to lower the hose saddle and service loop to the rig floor.
6. Use the hose reel controls to reel in the hydraulic hoses as they are lowered.
7. When the saddle reaches the rig floor, stop lowering and spooling.
8. Remove the service loop elements from the capture clamp.
9. Use tape or paint to mark all hoses where they were held by the capture clamp.
Note: If you reinstall the top drive on the same mast, use these markings to position the capture clamp before you install the hanging saddle in the mast.
10. Continue to spool the service loop onto the hose reel.
Note: Ensure that the ends of all cables and hoses are clean and properly protected.
Caution: Do not store multi-conductor cables on the hose reel.
880026 REV 3
250TON HMIS 475HP

35
RIG OUT PROCEDURE
INSTALLATION GUIDE
Figure 5-1: Service loop removal
11. Disconnect the control cable from the drillers panel and spool it onto a separate
reel.
12. Disconnect the second control cable from the drillers panel. This control cable
comes from the power unit.
13. Remove the interlocks from the mud pumps and drawworks (if applicable), and
disconnect the interlock cables from the drillers panel.
14. Remove the drillers panel from the rig floor.
Note: Wrap or box the drillers panel before putting it into storage. This will help
prevent damage to switches and meters.
15. Disconnect the all quick-connectors for the cooling system that run between the
mechanical and power modules.

36
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
RIG OUT PROCEDURE
REMOVE THE POWER UNIT

The power unit may be moved in its assembled state (on a bed truck, for example), or you may
dismantle it for alternative methods of shipping. Use the following procedure to separate the
power unit components.
1. Close all isolator valves.
2. Disconnect the suction lines that lead to the pump drive.
Note: Disconnect these at the hammer unions. Use a basin or absorbent pads to
catch any fluid that might spill.
3. Turn off all electrical breakers.
4. Disconnect all air and fuel lines.
5. Disconnect any shutdown connections between the pump drive and the filter manifold/oil reservoir.
6. Remove the bolts that connect the sections of the power unit.
7. Secure all hoses and loose items to the power unit.
Note: Ensure that no loose parts can fall or catch under the skid during transport.
880026 REV 3
250TON HMIS 475HP

37
RIG OUT PROCEDURE
INSTALLATION GUIDE

38
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
PRE-INSTALLATION CHECKLIST
APPENDIX A: PRE-INSTALLATION CHECKLIST

Use the following checklist to check for possible damage during shipment before beginning
installation procedures.
Component
Description
Date
Containers
Containers 1, 2, and 3
Top Drive
Transportation stand
Initials
Main Frame
Gearbox
Gearbox oil level
Rineer/manifold
Top Drive hoses
Auxiliary system (11-Station Manifold and
solenoids)
Mudsaver valve
Link Tilt cylinders
Power Unit
Prime mover
Pump drive
Pumps
Filter manifold
Flow meters
AC distribution center/control panel
System fittings
Auxiliary pump and motor
Cooling fan/oil cooler
Re-circulation pump
Oil tank
Oil tank level
Return filters (top of tank)
High pressure plumbing
Tranter plate exchangers
Service Loop
Hose hanging saddle

Urethane inserts
Hose reel
Hose reel control
Slings, shackles, and safety pins
880026 REV 3
250TON HMIS 475HP

39
PRE-INSTALLATION CHECKLIST
INSTALLATION GUIDE
Component
Description
Drillers Panel
Instrumentation
Date
Initials
Switches
Connectors
Internal wiring
Auxiliary hoses
1 x 225 ft. auxiliary return hose (1-1/4 in.)

1 x 225 ft. auxiliary supply hose (3/4 in.)
2 x 10 ft. auxiliary jumper hoses (1 in. - R2)
Main Fluid Hoses 2 x 225 ft. 5,000 psi hose (2 in.)

(750 hp)
2 x 15 ft. 5,000 psi hose (2 in.)
Main Fluid Hoses 4 x 225 ft. 5,000 psi hose (2 in.)
(1205 hp)
2 x 15 ft. 5,000 psi hose (2 in.)
Other Cables
2 x 160 ft. 37C robotics control cable
Other Cables
1 x 225 ft. 37C robotics control cable

1 x 225 ft. 18 TP motor sensor cable
1 x 225 ft. blower motor/heater cable
3 x 225 ft. motor power cables
1 x 225 ft. motor ground cable
2 x 8 ft. 18/4 mud pump interlock cable
2 x 8 ft. 18/4 drawworks interlock cable
2 x 8 ft. 18/4 splitter box cable
Torque Arrest
System
Extend frame
Torque bushing
Torque beam and T-bar
Torque track
Hanging sling assembly

40
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
VISUAL INSPECTION CHECKLISTS
APPENDIX B: VISUAL INSPECTION CHECKLISTS

Use this checklist after installation procedures are complete, but before you start the system.
Danger! Do the following before proceeding with the

checklists:
1. Ensure the gearbox breather is installed and the ball valve is opened prior to operating.
Note: The breather may not be installed for shipping purposes and some new units
may have the ball valve handle wired closed.
Table B-1: Top drive inspection list
880026 REV 3
Component
Activity
Steps
Quill
Inspect the listed components.
1. Quill
2. Ringfeder/locking segments to gearbox
3. Load nut and locking pins
4. Mudsaver
5. Load collar stops (set)
6. Saver sub
7. Locking clamps
High Pressure
Closed Loop
Hydraulics
1. Motor manifold
2. Hydraulic hoses (ensure all are in the correct
place)
3. All flange bolts on the high pressure piping
4. Rineer motor fluid connections
5. Lines and hammer unions for the high pressure
service loop
6. Safety sling or chain (ensure it is installed)
Grabber
1. The safety chain is installed.

2. All drilled bolts are safety wired.
3. Hoses are installed and routed correctly.
Extend Frame
Mount
Inspect all pins and bolts.
1. Check for missing fasteners.

2. Check the ears on the extend frame for damage.
Robotics
1. 10-Station manifold
1. 11-Station manifold
2. Solenoids and wiring
3. Auxiliary hydraulic hosing
4. 37C control cable
5. All fittings (for tightness and correct engagement)
Gearbox
Inspect the listed items.
1. Check for leaks.

2. Check the oil level.
250TON HMIS 475HP

41
INSTALLATION GUIDE
Table B-2: Power unit inspection - cable reel/service loop

Component
Activity
Steps
Reel Lock
Inspect
Ensure the reel lock is locked into position.
Valves
Open
Ensure all the required valves are in the OPEN

position.
Service Loop
Protection
Inspect
Ensure all wear points are protected and secure.
Service Loop
Inspect cables and hoses.
Inspect cables and hoses for the following:

cuts
abrasions
signs of stretching
Service Loop
Terminations
Inspect connectors and fittings. 1. Inspect connectors for damage to the pins.
2. Ensure that all pin connectors are correctly
seated.
3. Check the threads on all brass fittings.
4. Ensure that all connectors are clean and free of
moisture.
Table B-3: Power unit inspection - oil cooler

Component
Activity
Steps
Cooling Core
Inspect
Ensure the cooling core is clear and undamaged.
Fan/motor
Inspect
1. Ensure the guard is in place.

2. Ensure all parts are secure.
Table B-4: Power unit inspection - oil storage tank

Component
Activity
Steps
Valves
Inspect
Ensure all valves are set to the correct position.
Return Filters
Inspect
Ensure all filters are in place.
Table B-5: Power unit inspection - filter manifold headers

Component
Activity
Steps
All
Inspect
1. Ensure there are no visible leaks.

2. Ensure all equipment is in place and secure.

42
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
Table B-6: Power unit inspection - pump drive/pumps

Component
Activity
Steps
Pump Drive
Inspect
Check the oil level.
All
Inspect
Ensure all equipment is in place and secure.
Table B-7: Power unit inspection - electrical panel

Component
Activity
Steps
All
Inspect
1. Ensure all wiring is in place.

2. Ensure all terminal connections are tight.
3. Check for moisture and remove if necessary.
Danger! Only qualified electrical personnel should check

electrical equipment.
Table B-8: Power unit inspection - prime mover

Component
Activity
Steps
Cooling/Radiator Inspect
1. Ensure there are no visible leaks or damage.

2. Check the coolant level.
3. Check all fan belts and drive belts.
Engine
Inspect
1. Check the oil level.

2. Ensure that the exhaust system is in place and
tightly connected.
3. Ensure the fuel line is in place and correctly connected.
Starter
Inspect
Ensure the air line is in place and correctly

connected.
Table B-9: Drillers panel
880026 REV 3
Component
Activity
Steps
Drillers Panel
Inspect panel and connectors.
1. Inspect all switches.

2. Ensure all switches are in the neutral position.
3. Inspect all instrumentation.
4. Inspect all connectors.
5. Ensure that all the cords are operational.
6. Activate the heat tape if there is moisture in the
panel.
250TON HMIS 475HP

43
INSTALLATION GUIDE

44
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
SLING LOAD RATINGS
APPENDIX C: SLING LOAD RATINGS

Table values below are for slings with eyes and thimbles in both ends, as well as Flemish
Spliced Eyes and mechanical sleeves.
Caution: Reduce loads if hand-tucked spliced eyes are used.
Reduce loads by 20% if eyes are formed by cable clips.
Table C-1: Maximum safe working loads (pounds)

Safety Factor = 5
Rope
Diameter
880026 REV 3
Single
Vertical
Hitch
Single
Choker
Hitch
Single
Basket
Hitch
(vertical
legs)
2-leg Bridle Hitch and Single Basket

Hitch with legs included
60 in.
45 in.
30 in.
3/16
600
450
1,200
1,050
850
600
1,100
825
2,200
1,900
1,550
1,100
5/16
1,650
1,250
3,300
2,850
2,350
1,650
3/8
2,400
1,800
4,800
4,150
3,400
2,400
7/16
3,200
2,400
6,400
5,550
4,500
3,200
4,400
3,300
8,800
7,600
6,200
4,400
9/16
5,300
4,000
10,600
9,200
7,500
5,300
5/8
6,600
4,950
13,200
11,400
9,350
6,600
9,500
7,100
19,000
16,500
13,400
9,500
7/8
12,800
9,600
25,600
22,200
18,100
12,800
16,700
12,500
33,400
28,900
23,600
16,700
1 1/8
21,200
15,900
42,400
36,700
30,000
21,200
26,200
19,700
52,400
45,400
37,000
26,200
1 3/8
32,400
24,300
64,800
56,100
45,800
32,400
38,400
28,800
76,800
66,500
54,300
38,400
1 5/8
45,200
33,900
90,400
78,300
63,900
45,200
52,000
39,000
104,000
90,000
73,500
52,000
1 7/8
60,800
45,600
121,600
105,300
86,000
60,800
67,600
50,700
135,200
117,100
95,600
67,600
84,000
63,000
168,000
145,500
118,800
84,000
104,000
78,000
208,000
180,100
147,000
104,000
250TON HMIS 475HP

45
SLING LOAD RATINGS
INSTALLATION GUIDE
Table C-1: Maximum safe working loads (pounds)

2
122,000
91,500
244,000
211,300
172,500
122,000
If you use a choker hitch, multiply the previous table values by 3/4.
If you use a double basket hitch, multiply the previous table values by 2.
Table C-2: Rope diameter efficiencies

Rope Diameter
Efficiency
1/4 in. and smaller
95%
5/16 to 3/4 in.
90%
7/8 to 1 in.
85%
1-1/8 to 1-1/2 in.
80%
1-5/8 to 2 in.
75%
2-1/8 in. and larger
70%

46
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
HAND SIGNALS FOR BOOM EQUIPMENT OPERATION
APPENDIX D: HAND SIGNALS FOR BOOM

EQUIPMENT OPERATION
The following chart contains examples of typical signals used by the signalman during boom
equipment operations. If your project requires special signals, agree on what they will be
before you begin operations.
Boom operators will not respond to unclear signals.
Designate one signalman before operation begins. The boom operator accepts signals only
from the designated signalman.
Table D-1: Hand signals for boom operation
This Signal
Means This
Use Load Line

Tap fist on head, then use regular signals.
Use Whip Line

Tab elbow with one hand, then use regular
signals.
Raise Load
Lower Load
880026 REV 3
250TON HMIS 475HP

47
INSTALLATION GUIDE

This Signal
Means This
Raise Load Slowly
Lower Load Slowly
Raise Boom
Lower Boom
Raise Boom and Lower Load

Extend thumb upward and flex fingers in and out
as long as load movement is required.
Lower Boom and Raise Load

Extend thumb downward and flex fingers in and
out as long as load movement is required.
Swing
Extend arm. Use forefinger to indicate direction of
swing.

48
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE

This Signal
Means This
Stop
Extend forearm and hand in horizontal position.
Make a slicing motion.
Dog Everything
Emergency Stop
Travel (Both Tracks)

Use both fists to make a circular motion to indicate
the direction of travel (forward or backward).
Travel (One Track)

Raise fist to indicate which side of the track to
lock. Move the other fist in a circular motion to
indicate the direction of travel (forward or
backward)
Open Clamshell Bucket
Close Clamshell Bucket
880026 REV 3
250TON HMIS 475HP

49
INSTALLATION GUIDE

This Signal
Means This
Move Carriage In
Move Carriage Out

50
250TON HMIS 475HP
880026 REV 3
INSTALLATION GUIDE
INDEX
A
air considerations, 5
measurement
rig, 3
mechanical module
placement during rig up, 7
mud pump interlock, 25
B
blocks, 20
counter balance system

installation, 21
optimal placement
power unit, 7
damage
pre-installation inspection, 6
drillers panel
installation, 23
power
connection requirements, 3
power module
power unit
placement procedure, 8
pre-installation
inspection, 6
main power connection requirements, 3
measurement, 3
E
electrical considerations, 5
equipment
hose saddle, 8
inspecting, 6
inspecting for damage, 6
placement of power unit, 8
spotting, 7
R
rig out, 33
rig up
equipment spotting, 7
F
fuel considerations, 5
hose reel, 27
hose saddle
optimal placement, 8
placement factors, 9
safety air interlocks

installation, 24
saver sub, 27
service loop, 33
calculate length, 9
removing, 35
inspecting equipment
pre-installation, 6
inspection
general notes, 27
installation
pre-installation measurement, 3
rig measurement, 3
top drive, 20
installing drawworks interlock and override, 24
880026 REV 3
top drive installation, 20

torque arrest system
before you install, 12
components, 13
configuration sample calculation, 15
determine the configuration, 13
removing, 33, 34
torque track, 15
torque bushing, 20
torque track
250TON HMIS 475HP

51
INDEX
INSTALLATION GUIDE
mounting, 15
W
warnings
before start up, 27

52
250TON HMIS 475HP
880026 REV 3

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Installation Guide

HMIS Top Drive System

250TON HMIS 475HP

DOCUMENT NAME: 880026 REV 3

COPYRIGHT AND DISCLAIMER

250TON HMIS 475HP

TESCO CORPORATION, 2007

General Engineering updates and additions

New revision to remove CE-ATEX standards from manual.

TESCO CORPORATION, 2007

250TON HMIS 475HP

CHAPTER 3: RIG UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CHAPTER 4: SYSTEM INSPECTION AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

250TON HMIS 475HP

TESCO CORPORATION, 2007

CHAPTER 5: RIG OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

APPENDIX A: PRE-INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

TESCO CORPORATION, 2007

250TON HMIS 475HP

Power, air and fuel connections - option 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

250TON HMIS 475HP

TESCO CORPORATION, 2007

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TESCO CORPORATION, 2007

250TON HMIS 475HP

Where to find more information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

250TON HMIS 475HP

TESCO CORPORATION, 2007

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TESCO CORPORATION, 2007

250TON HMIS 475HP

CHAPTER 1: ABOUT THIS DOCUMENT

perform a pre-installation assessment and equipment check

Table 1-1: Where to find more information

setting torque and speed

load path inspections

TESCO manufactured parts and part numbers

available options and spares

250TON HMIS 475HP

TESCO CORPORATION, 2007

ABOUT THIS DOCUMENT

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TESCO CORPORATION, 2007

250TON HMIS 475HP

CHAPTER 2: PRE-INSTALLATION ACTIVITIES

POWER/SERVICE CONNECTION REQUIREMENTS

250TON HMIS 475HP

TESCO CORPORATION, 2007

Figure 2-2: Power, air and fuel connections - option 2

TESCO CORPORATION, 2007

250TON HMIS 475HP

250TON HMIS 475HP

TESCO CORPORATION, 2007

EQUIPMENT INSPECTION (PRE-INSTALLATION)

TESCO CORPORATION, 2007

250TON HMIS 475HP

CHAPTER 3: RIG UP PROCEDURE

The power unit is located on the same side as the standpipe.

Figure 3-1: HMI optimal equipment placement

250TON HMIS 475HP

TESCO CORPORATION, 2007

How to Place the Power Unit Components

37C electrical control cable