900ECI_1_SYSTEMDESCRIPTION

DOCUMENT NAME: TDD900ECIBAS00System Description900 ECI(S) Top Drive MD500 ModelCOPYRIGHT AND DISCLAIMER Tesco Corporation ("Tesco") has made every effort to ensure that this document contains accurate and up-to-date information for the 900 ECI 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 2003900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 2003IIITABLE OF CONTENTS Table of ContentsSection 1: About This Document (1)Other Information on ECI(S) Top Drives (1)Section 2: System Description (3)Introduction (3)Shipping Containers (4)Standard Shipping Container #1 (4)Standard Shipping Container #2 (4)Standard Shipping Container #3 (5)Standard Shipping Container #4 (5)Top Drive (6)Principle Top Drive Components (7)Main Frame (7)Gearbox (7)Load Collar/Load Nut (7)Mudsaver Valve (7)Pipe Handler (7)Top Drive Operation (8)Shipping and Handling (8)Power Module (8)MD500 (8)Main Panel Control System (8)AC Breaker Distribution Center (9)Diagnostic Computer (9)Drive Module: Electronics Cooling (9)Mechanical Module (10)Cooling Systems (10)MD500 Drive (10)Top Drive (10)Auxiliary Hydraulics (11)900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 2003VTABLE OF CONTENTSTorque Arrest System (11)Extend Frame (11)Torque Bushing (11)Torque Track (11)Torque Beam and T-bar (12)Service Loop (13)Electrical (13)Hydraulics (13)Cooling (13)Driller's Control Panel (13)Options (14)Integrated Drilling Swivel (14)Elevators and Elevator Links (14)Additional Safety Valve and Actuator (14)Subs (14)Grabber Drill Pipe Guides (14)Rotary Table Stabilizer Bushings (14)Rotary Hose and Standpipe Extension (15)Torque Arrest System (15)Alarms (15)Other Available Options (15)List of Illustrations (17)900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 2003VISECTION 1: ABOUT THIS DOCUMENT 900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 20031Section 1: About T his DocumentThis document contains a description of the major components of the 900 MD500 model Electric Compact top drive with Integrated quill (ECI) or optional Integrated Swivel (ECIS).A complete ECI(S) top drive system consists of the following:top drivepower modulemechanical moduleinterconnecting service looptorque arrest systemassociated buildings, containers, and equipmentThis document provides a brief description of each principle component and a list of available options.Other Information on ECI(S) T op Drives For information onRefer to installingrigging upcommissioningpre-operational checklists900 ECI(S) (MD500) Installation Guide setting torque and speeddriller's panel functions andoperating descriptionsmaking connectionsdrilling aheadtrippingstuck pipe and free point900 ECI(S) (MD500) Operations Guide load path inspectionsmaintenance/service schedulesdisassemblytroubleshooting900 ECI(S) (MD500) Maintenance Guide Tesco manufactured parts and partnumbers900 ECI(S) (MD500) Parts List electrical schematicshydraulic schematicscooling schematics900 ECI(S) (MD500) System Schematics available options and spares Tesco RepresentativeSECTION 2: SYSTEM DESCRIPTION 900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 20033Section 2: System Description IntroductionThe ECI(S) top drive system is designed for use on larger AC electric land rigs and in offshore applications. Tesco electric top drives feature the Kaman permanent magnet, synchronous, electric motor and drive system. The ECI(S) top drive is operated from standard rig AC power (600 VAC – 60 cycle, or optional 50 cycle).Metric unit conversions (in brackets) are provided for convenience only. All product specifications use the original imperial units unless otherwise indicated. Top Drive900 ECI(S) (MD500) Rated Capacity500 or 650 ton (454.5 or 590.9 metric ton) Weight (includes driller'spanel, elevators, links,counter balance and(swivel).12,500 lb (18,500 lb with optional swivel) 5669.9 kg (8391.5 kg with optional swivel) Length14. 25 ft (21 ft) 4.3m (6.4m) Width62 in (1.57m) Horsepowertwo motor - 900 hp 671.1KWTorque Arrest System 900 ECI(S) (MD500)Weight (includes track,anchor beam, torquebushing, clamps)10,400 lb (4717.4 kg) Track length145 ft (44.2m)Power Module900 ECI(S) (MD500) Weight (includesMD500, connectionpanel, heat pump, andall breakers)8,500 lb (3855.5kg) Dimensions115” l x 91” w x 88” h 2.92m x 2.31m x 2.24mSECTION 2: SYSTEM DESCRIPTION 900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 20034 Mechanical ModuleStandard (10 Ton Chiller) High Ambient (25 Ton Chiller) Weight (includes chiller,air exchanger, hydraulicand cooling pumps)9,000 lbs 4082.3 kg 12,000 lbs 5443.1 kg Dimensions 115” l x 91” w x 88” h2.92m x 2.31m x 2.24mThe height dimensionassumes the chillerdischarger is removed –if not, add 12” (.3m) tothe height. 115” l x 91” w x 88” h 2.92m x 2.31m x 2.24m The height dimension assumes the fan motor and chiller hood is removed – if not, add 39” (.99m) to the height.Service Loop900 ECI(S) (MD500) Reels with Cables and HosesWeight 7,000 lb (3175.2 kg) Shipping Containers900 ECI (S) (MD500) top drive systems and associated high ambient cooling packages (if required) are typically shipped in three ocean certified shipping containers.Note: A fourth ocean container is required if you purchase a high ambient package.Each container is 20’ l x 8' x w 8'6" h (6.1 m x 2.4 m x 2.6 m). Standard Shipping Container #1Container #1 contains the following:top drivespare partsStandard Shipping Container #2Container #2 contains the following:power modulemechanical moduleStandard Shipping Container #3Container #3 contains the following:torque arrest system componentsrig-up equipmentelevators and accessoriesservice loop reel (if a fourth container is not required) Standard Shipping Container #4(if required)Container #4 contains the following:service loop reelhigh ambient chiller motor, and hoodNote: Some countries require that spare parts be shippedseparately from original equipment. In these cases, spare partswill be crated and shipped separately.Top DriveIllustration 1: ECI(S) Top Drive General AssemblyPrinciple T op Drive ComponentsMain FrameThe main frame houses the gear train and associated hydraulic control equipment for the top drive robotic functions.GearboxThe gearbox couples the Kaman permanent magnet, synchronousmotor(s) to the gear train. It houses gear reduction and forced lubrication systems, and oil temperature monitoring. The integral drive hub isinternally splined to accept the integrated drive quill or the optionalintegrated swivel quill.The quill can be easily removed without dismantling the gearbox.Load Collar/Load NutThis mechanism transmits load from the links to the quill.Mudsaver ValveThis double-ball valve acts as a mudsaver valve and lower Kelly cock.The remote actuator can be operated from the driller's control panel.Pipe HandlerThe pipe handler incorporates the following:Continuous rotation: The pipe handler is capable of 360orotation. It can be locked into position every 2.6 degrees.Elevator Link-Tilt Cylinders: These allow extension andretraction of the elevators 35º forward or 55º backward.Grabber(Back-up wrench): The grabber acts as a back-up tong for making or breaking connections, at any point in themast. The grabber will accommodate tool joints from 3 1/8” to8¾” OD and is rated for 140,000 lb (622,751 N) clampingforce.The grabber leg features an automatic thread feedcompensation for make-up and breakout, and utilizesstandard tong dies.T op Drive OperationThe top drive motors are powered by the proprietary Kaman drivesystem housed in the power module.All top drive robotic functions are powered by an auxiliary hydraulicsystem, which is mounted in the mechanical module for easymaintenance.Shipping and HandlingThe top drive is shipped in a handling stand. The stand allows the topdrive to be safely moved using standard rig equipment.Power ModuleAll drive module components are housed in a single enclosure.MD500The MD500 input module and buck module rectify and filter incomingthree-phase power from a diesel generator or from the rig's generators.They supply clean, regulated DC power to the Vbus and invertermodule.The MD500 inverter module receives variable DC power and, whencommanded, synthesizes it to create a three-phase AC output. Thispower drives the Kaman permanent magnet PA44 motors. Each MD500drive supplies power to one 450 hp (335.6 KW) PA44 motor.The MD500 controller governs the drive system operation. It regulatesthe drive using inputs from the PLC and supplies instrumentation outputsto the driller's control panel (delivered speed and torque). LabVIEWsoftware interfaces with the MD500 controller to monitor drive statusand operating conditions.Main Panel Control SystemThe main panel provides the interface between the PLC, the driller'scontrol panel, and sensor information from the top drive panel.Information and commands are processed and distributed to the relevantcomponents.AC Breaker Distribution CenterThis provides overload and overcurrent protection for all 600 VACcircuits.Diagnostic ComputerThis computer interfaces with the MD500 controller, which constantly monitors the MD500 and motor. It provides status and fault information for the Kaman drive system only. LabVIEW software provides a simple, graphical user interface.Drive Module: Electronics CoolingDrive electronics have a dedicated, self-contained cooling system (10 ton or 25 ton chiller and backup Modine heat-exchanger/fan). This system circulates UCARTHERM™ through the Kaman drive system coldplates. The heat pump in the drive module building controls ambienttemperature and humidity.Mechanical ModuleThe mechanical module houses the cooling and the auxiliary hydraulicssystems.Cooling SystemsIllustration 2: Cooling SystemsMD500 DriveA 10 ton or 25 ton chiller system provides UCARTHERM cooling ofthe MD500 Drives.T op DriveA pump/ambient cooling package provides cooling fluid to the t opd rive motor and gearbox oil cooler.Auxiliary HydraulicsThe hydraulic unit consists of a 40-gallon (151.4 l) oil reservoir, 7gallons per minute (26.5 liters/minute) gear pump coupled to a 10-hp(7.5 kW) electric motor, and all necessary piping and control features.Basic control circuitry for the hydraulic system is mounted on the topdrive. The auxiliary system operates at 2,300± psi (15.9 MPa) at thepump level.Torque Arrest SystemThe torque arrest system is typically shipped in the third standard seacontainer. It consists of the following components:extend frametorque bushingextend armsextend hydraulic cylinderstorque trackT-bartorque beam, torque beam clamps, and all required rig upitems.Extend FrameThe extend frame is pinned to the top drive. It allows the top drive toextend away from the torque track.T orque BushingThe torque bushing is attached to the extend frame. UHMW insertsreduce friction as the top drive moves along the torque track. Nolubrication is required.T orque T rackThe torque track, in conjunction with the torque beam and T-bar,transfers reactive torque to the lower section of the derrick and thesubstructure. The track is suspended from the crown using a telescopichanging assembly or a cable sling hang assembly. Track components canbe configured to fit most mast heights.T orque Beam and T-barThe torque beam is mounted on the rig, typically to the loweststrongback. It is then connected to the torque track using a T-bar. Illustration 3: Torque Arrest SystemService LoopService loop components are typically shipped in the third standard seacontainer if a fourth container is not required (for the high ambientpackage). The following cables and hoses are spooled onto the reel priorto shipping:ElectricalElectrical components include the following:Four 3 conductor 4/0 cables, and 1 - 1 conductor 4/0 cable(ground); these connect the Kaman drive system to theelectric motors.One 37 conductor cable; this supplies 24 VDC power forrobotic functions.One 18 TWP shielded conductor cable; this connects theresolvers and temperature sensors for each motor to the CCB.HydraulicsTwo - 3/4" R2, 2,000 psi (13.8 MPa) hydraulic hoses; thesesupply and return hydraulic oil from the mechanical moduleto the top drive.CoolingOne 1" R2 2,000 psi supply hoseOne 3/4" R2 2,000 psi return hose; these supply and returncooling fluid from the mechanical module to the top drivemotors and lubrication fluid heat exchanger.OptionsThe following options are available. For more detailed informationcontact a Tesco representative.Integrated Drilling Swivel500 and 650 ton drilling swivels (453.6 and 589.7 metric ton) withintegrated one-piece quill are available for 900 ECI top drives. Integratedswivel and quill arrangements offer these advantages:No connections from the swivel bearing to top of themudsaver valveIncreased reliability results in reduced maintenanceDecrease in overall length and weight of the top drive Elevators and Elevator LinksElevators rated at 250 and 350 tons (226.8 and 317.5 metric tons),associated inserts for various drill pipe sizes, and accessories areavailable. A selection of link lengths is also available.Additional Mudsaver Valve and ActuatorSeveral sizes and thread types are available.SubsA complete selection of commonly used saver, casing, cross-over anddrill collar handling subs is available. Non-standard subs can bemanufactured if requested; delivery can be determined at time of order.Grabber Drill Pipe GuidesThese are used to guide the drill string into the grabber box. The drillpipe guide must match the box of drill pipe in use. There is a range ofsizes available.Rotary T able Stabilizer BushingsThese urethane bushings fit the standard rotary table profile and protectthe table and BOP from excessive wear. There is a range of sizesavailable.SECTION 2: SYSTEM DESCRIPTION 900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 200315Rotary Hose and Standpipe ExtensionAll equipment and accessories for these modifications are available.T orque Arrest SystemOptional equipment for non-standard and large mast torque arrestsystems is available.AlarmsDriller’s panel purge alarm Extend alert featuresOther Available OptionsAir purge system for driller's control panel and top drive junction boxWorkshop/parts containers with workbench and storage cupboards Camera systemLIST OF ILLUSTRATIONS List of IllustrationsIllustration 1: ECI(S) Top Drive General Assembly (6)Illustration 2: Cooling Systems (10)Illustration 3: Torque Arrest System (12)900 ECI(S) TOP DRIVE MD500 MODEL SYSTEM DESCRIPTIONTDD900ECIBAS00TESCO CORPORATION 200317。