Beruflich Dokumente
Kultur Dokumente
User Manual
Prologue
The users should read this manual before using the equipment.
In order to prevent the accident, the operator should pay more attention to the safety
all the time.
The design, manufacturing and service of this product comply with the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000
API SPEC Q1
This manual includes top drive electrical system, hydraulic system, mechanical
structure and installation, test-running, operation, and maintenance.
Refers to other
contents which arent included in the manuals and other problems during the course of
installation, usage and maintenance, if necessary, please contact us:
Tel 86-452-2345069
Fax 86-452-2340601
E-mail clb@jh-pm.com
Address No.3-2Nanyuan Road, Nanyuan Investment Zone, Longsha district, Qiqihar
City, Heilongjiang
Zip code 161005
Summary
Top drive drilling system (hereafter referred to as top drive) is a new type of drilling
equipment that instand of traditional rotary table. The top drive is an important
petroleum drilling equipment developed since late 1980s. Using the top drive drilling
system could greatly decrease the accident of drill pipe sticking. Improve the working
performance and working security. The top drive drilling system is honored as one of
three great technical revolutions of drilling equipments in modern time.
Jinghong company developed the DQ70BS-JH top drive drilling system with
independent intellectual property rights. It integrated the mechanical, electrical and
hydraulic control technology. Our top drive drilling system takes a fully consideration of
operation while drilling, Our top drive drilling system has the advantages of simple
structure, easy operations and long service life, etc. All above features fully satisfy the
technological requirements on site. It is an important equipment for the drilling of deep
well, super deep well, horizontal well and controlled directional well in complex geologic
condition.
8. The hydraulic system is integrated on the main body of top drive, it is convenient to
installment.
9. The device of anti-loosen device with single direction tong dies, this device can load
more torque and be installed and disassembled easily.
10. The materials of cable is low-temperature resistible and wearable, which improved
the mechanical strength of cable and increased the reliability.
11. The rotating link adaptor connects with the gear box through shaft sleeve. When
tripping of raising and lowering or making a break off with bumper jars, there is no force
on the main shaft, which increases the service life of the main shaft bearing.
12. Patent technology of casing running tool, during the casing running, when the pipe
sticking or well kicking happens, it could realize the fast connection of top drive and
casing pipe, cycling the mud, avoid accidents (customer optional)
13. Equipped with the trolley of slip with pneumatic lift device, reduced the labor
intensity, and increased drilling speed (optional).
Contents
Prologue......................................................................................................................................................... 1
Summary........................................................................................................................................................ 2
Contents......................................................................................................................................................... 4
Part I Technical Parameters of Top Drive DQ70BS-JH.......................................................................... 8
I General Data ...................................................................................................................................... 8
II Drilling Parameter ............................................................................................................................... 8
III Main Motor Parameter ....................................................................................................................... 8
IV Cooling Air-blower ............................................................................................................................ 8
V Hydraulic Disc Brake .......................................................................................................................... 9
VI Electric Control System ..................................................................................................................... 9
VII Reducing gear box ............................................................................................................................ 9
VIII Pipe Handler system ........................................................................................................................ 9
IX Working Curve of Top Drive DQ70BS-JH...................................................................................... 10
Part II Mechanical Manual......................................................................................................................... 12
Chapter I Structure and function Introduction....................................................................................... 12
I. Structure and function introduction....................................................................................... 13
II. Top Drive DQ70BS-JH Working Curve............................................................................... 13
III. Power Swivel ......................................................................................................................... 14
IV. Pipe Handler Device............................................................................................................. 17
V Guide beam and carriage ...................................................................................................... 20
Part III Electrical Manual............................................................................................................................ 21
Chapter I Safety Operation Specification.............................................................................................. 21
I Safety Notice............................................................................................................................. 21
Chapter II Electric System Component................................................................................................. 22
I. Incoming Line Power Distributor and Protect System ....................................................... 23
II. AC Frequency Converter Driving System........................................................................ 24
III. PLC Combination Control System...................................................................................... 24
IV. Relay Box............................................................................................................................... 26
V. Hydraulic Lubrication station................................................................................................ 26
VI. Driller Panel ........................................................................................................................... 27
VII. Touch Screen ....................................................................................................................... 30
VIII. Main Power Cable .............................................................................................................. 33
IX. Other Cable ........................................................................................................................... 34
Chapter III Monitoring System (WINCC) ............................................................................................ 35
I. Screen Instruction ................................................................................................................... 35
II. System Structure.................................................................................................................... 36
III. Top Drive Drilling System .................................................................................................... 37
IV. Network Topology................................................................................................................. 38
V. Auxiliary Interface .................................................................................................................. 39
VI. Alarm History......................................................................................................................... 40
VII. Curvilinear Trend ................................................................................................................. 41
General Data
Rated Drilling Depth:
4500 kN (350ton)
Main channel:
75mm
35MPa5000psi
System Weight:
12.5tMain body
Working Height:
Electric Volt:
600VAC
Rated Power:
315KWX2
Ambient Temperature:
-3550
Altitude:
1000m
422HPX2
II Drilling Parameter
Rotary speed:
0230r/min
adjustable
Work torque:
55kNm (continuous)
Max. Torque:
82kNmdiscontinuous
315KW X2 continuous
1150r/min
2600r/min
IV Cooling Air-blower
Model:
M2JA132S2A
Rated Power:
5.5kW
Rated Volt:
380VAC
Rated Frequency:
50Hz
Rated Currency:
10.7A
2905r/min
8
68kNm (50,000ft-lb)
7.5MPa
600VAC
0121Hz
200
80
80
10.97:1
Lube:
13.5MPa
216mm
87216mm
boxpin70MPa
Link:
2740mm, 350t
Leaning angle:
IX
10
11
Bail
Air cooling Device
Counterbalance device
Brake Device
Main Motor
Wash pipe
packing
assembly
Gear Box
Cover Assembly
Link
Anti-loosen Device
Manual IBOP
Back-up Tong
12
Power swivel
13
The main function of power swivel is to drive the main shaft rotate to
drill, make up and break out, as well as circulate mud to ensure the drilling work
carrying on regularly.
Counterbalance device
Brake and
cooling Device
Bail
Main Motor
1. Main motor
2 sets of Main motors are installed on the gear box. Motor
has double axles, the lower axle connects with main
transmit gear, upper axle connects with braking system.
Each main motor could supply 315KW power
continuously. The rated rotary speed is 1200r/min in
60.6Hz frequency, stepless speed is adjusted by AC
speed adjusting system. The rated output torque value of
motor could be set by currency, Output torque is
proportional to currency. The motor is protect type
compel air, cooled air pass through the motor inside and
discharge from the air outlet.
14
air
disc, springs could reset when the braking discs release. The braking device has 3
functions while the top drive system working.
A. Bearing the reversed torque of drilling tools in well.
B. When touch sticking, if the motor torque is equal to the reversed torque, the drilling
tool would bounce, so take measures to brake the main shaft to prevent the drilling tool
drop out while reversal rotating.
C. It works as brakes while the motor galloping.
Encoder
Encoder Frame
Brake Body
Brake Pad
Brake Disc
Protect Cover
Main Motor
15
3. Gear Box
Gear Box adopts double-geared drive,
transmission ratio is 10.97:1, the gears are all
helical gear, large transfer torque, little noise.
Bearing are SKF bearing, strong anti-seismic
capability and anti-attack capability.
The lubricate system of gear box is gear pump
force lubrication. The lube pump is driven by
motor of 1.1KW produced by ABB. The motor
spreads lubricate oil on oil points of double filter
and cooling device, via main shaft return to oil
cabinet. DQ70BS-JH top drive system adopts
force lubricate mode, bearing and gear could
contact the oil sufficiently to ensure the
reliability of lubrication. Install the pressure
detector and temperature cell in the lube pipes,
inspect and alarm the pressure and oil temperature of lube system.
so
regular
inspection
and
maintenance
is
5. Gooseneck
Gooseneck is installed on the washing pipe frame, bottom
is connected with washing pipe, the sealed top is the
transmission channel of mud circling, open the top to start
fishing and well logging. Its top is connected with drilling
hose, it is the inlet of drilling fluid.
16
Leaning Device
Thread Anti-loosen Device
IBOP
Backup Tong
17
2.
IBOP
18
3.
19
Carriage
Bearing
Wheel
20
Note
Caution
Warning
I Safety Notice
The following safe notices are very important for correct installation, using,
maintenance of the Top Drive, all the operator and the attendant must read it carefully
and understand it:
1. Forbidden livewire work, electric system maintainer and operator must be
qualified and follow close to safety operation specification.
2. When working, do not open the safety cover over the high-voltage equipment,
do not maintenance or remove any electric element, do not pull out/connect wire with
current.
3. Forbidden open the relay box, driller consol or pull out/connect wire under
combustible gas environment.
21
with Electroscope and make sure no voltage before replace the PLC electric elements in
cabinet.
6. Keep protective gas pressure when turn the drillers console on. If the drillers
console protective gas pressure lost, it is required to resume quickly or turn off the
drillers console controlling power.
7. Electric control house should be connected to ground wire correctly.
8. Forbidden relieve the link of software and hardware. If really needed, resume as
soon as possible after clearing fault.
9. If the temperature higher than 40, or the humidity higher than 95% or there is
dewing, do not start the frequency converter or other control power before start air
conditioner to cooling and dehumidify.
10. Check the electric control board if there is dewing before starting, when main
power was off more than 30 minutes.
11. When the temperature outside is high, do not set the air conditioning too low to
prevent electric equipment to dewing.
produced when switch. The major switch connects the major power to 2 sets of frequency
converter. The other circuit is connected to auxiliary transformer, which provides main
power to the PLC cabinet of 380V.
auxiliary
transformer,
controlling
is
transforming
the
three
phases
23
II.
The electric motor is added cooling fan and preheating unit. These solve the problem
of cooling and working in cold area.
24
A. Indicator light
a. Power indicator light of 24V: switch on the system, then power of all units is OK;
system is ready, indicator lights.
b. Hydraulic oil heating light: light on while heating hydraulic oil.
c. Motor hearting indicator: light on while motor heater working.
d. Fault/alarm light: while system alarm, light flashes (1 Hz); while fault, light
keeps.
e. Back up indicator.
B. Hand switch
a. A/B system select switch : at A position, first PLC work; at B position, second
PLC work.
b. Hydraulic oil heater switch
c. Motor heater: used for controlling major motor heater. This switch can work
independent upon PLC. The indicator displays the working state of heater. After
turn on the power of the frequency converter, the link-control is added, and the
main motor stops to be heated.
d. Reset/silence button (SB1): when system alarm, the indicator flashes, the
Warner alarms. Press silence button, the fault/alarm indicator keep state.
25
e. Photoelectric encoder of the main electric motor (SA5): when drilling normally,
switch to normal, and this can control the rotary torque accuracy. When fault of
encoder appears, switch to unmoral, and this can stop the efficient of drilling
rate.
f. Mud pump link switch (SA6): use for mud pump link-control. In link-control state,
if the mud pump did not give the stop order, when switch the IBOP to close, the
IBOP can not close. If well blowout happen, press well control button, the mud
pump will stop and the IBOP close. In unlink-control state, operate the IBOP
switch on drillers console can control the IBOP.
g. Back up switch
Lubrication station
26
No
name
Type
frequency
conversion
emergency
stop button
1SB1
self-locking
Function
When the frequency conversion or main motor
break down, press this button and then frequency
conversion stop. After eliminated the fault, should
reset (CW rotation)
27
Ready light
Fault/alarm
light
Brake light
Brake mode
Brake/off/auto
1SA10
three
positions switch
IBOP light
IBOP
closed/ope
n
1SA11
two
positions switch
Well control
Motor
selection
A/A+B/B
1SA5
button
10
Hydraulic
pump running
light
11
Hydraulic
pump
switch
auto/stop/st
art
1SA6
three
positions button
12
Elevator
centre
1SB3 button
13
Elevator
link
rotary
Counterclockw
ise/clockwise
ISA9
Three
positions
resetting key
14
link incline
backward/forw
ard
1SA7
three
positions,
resetting key
15
Hydraulic
elevator
1SA8
three
positions button
Shut/pen elevator
16
motor cooling
fan auto/off/on
1SA2
three
positions button
17
motor
rotary
direction
1SA3
three
positions button
link
3 turn
28
backward/stop
/forward
18
operation
mode
drill/spin/torqu
e
1SA4
three
positions switch
resetting on right
19
backup tong
Release/Lock
1SA4
two
position button
Reset to left
20
makeup torque
potentiometer
21
Drilling torque
potentiometer
22
setting speed
of drilling
potentiometer
23
Torque Guage
indicator
24
Rotary Gauge
indicator
25
Return/Mute
Green button
26
Green button
29
30
Hydraulic system includes: hydraulic pump run, hydraulic system oil low, oil
temperature high alarm, oil heating as well as oil temperature note.
Lubrication system include: lubrication pump run, low pressure, temperature high
alarm, heating and lubrication temperature notice.
Other system include: IBOP valve open, IBOP valve closed, backup tong clamping,
backup tong loosen, braking notice.
And include other working state notice of top drive drilling system.
31
32
Frame is as follow after login. Green is current state. User can decide by self
whether test and whether turn back.
33
power, two cores for stop emergency control, two cores for transform of A/B
system, and other two cores are spare.
2. Two core communicate cable: total 2 cable, one for A system communicates,
and another for B system communicates. There are marked on joints and
sockets.
34
feedback line of detectable signal, signal line of motor encoder, and etc.
3. The two cable is divided into three section: ground cable 26m; mast cable 48m;
travelling cable 26m.
The two earth electrodes are 1.8m long, outer layer galvanized. The earth terminal
connects to earth electrode with 5m long lead. The state of picture is as follow, earth
electrode is knock into ground 300mm.
All cable joint adapt fast plug connection, the plug and socket both
mark, take care when connecting or the plug may be damaged. Ensure that
lock the nut.
35
In this screen, the basic information and construction frame can be seen as follow:
36
Running state of A Cooling fan of electric motor, Running state of B Cooling fan of
electric motor
Running state of A Main electric motor, Running state of B Main electric motor
Running state of hydraulic pump; running state of lubrication pump; valve of IBOP as
well as elevator link state
In any function module, red state means closed and green means open
In this screen, it is mainly show the top drive drilling system running state and data,
this is helpful for operator to know well of the state of top drive drilling system.
37
In this screen, operator can know all networks state well of system, so as to make
decision fast.
In this screen, it shows remote I/O module, and network state of NO. 1 and 2 frequency
converter
38
V. Auxiliary Interface
Chick on auxiliary interface to enter interface as follow:
In this interface, it show the work state of any other auxiliary units exept top drive
driling system. General speaking, it can be divided into six parts.
1. Elevator system, show the work state of elevator.
2. Hydraulic system, show the on/off of hydraulic pump, current temperature, and
if there are fault.
3. Lubrication system, show on/off of lubrication pump, current temperature, as
well as fault.
4. Auxiliary system, show state of IBOP, electric house temperature, state of
backup tong.
5. Show body working state, include drilling waiting, drilling and others, totally 7
items.
6. Control panel indicator, include show A/B system running, and items showed
39
The alarm contents include date, time, number, state and messege text.
When alarming, characters and background is the color of red, the status bar appears
a mark of +.
When alarm disappeared, characters and background color change to general color,
the status bar appears -.
Alarm confirm
then scrollbar will appear on right when the history too long, then
40
the first button is for given the first alarm, and the second one is for
the last alarm.
In this interface, include two mode: realtime curvilinear and history curvilinear, these
two modes can be cut over by button of realtime curvilinear and history curvilinear.
Output torque and speed of the top drive drilling can be seen though curvilinear.
41
42
All buttons in this interface can operate only by people login. According to different
user grade, the operation limited is different. No matter in which interface, press
43
44
limiter.
FC19: Implement the main inverter speed and torque output indicator.
FC20: implement the read and write capabilities of the inverter and PLC.
FC21: implement the alarm function when hydraulic oil, lubricating oil temperature
is over.
FC22: Implement the indicating function of system failure.
FC23: implement the communication failure function.
FC24: implement the warning function of main motor temperature over.
FC25: implement the additional function of program.
FC26: implement the transformation function of the main inverter "There encoder
run / non-encoder run".
FC27: Implement the indicating function of work state.
BUSF
ed)
DC5V
Inner power
FRCE
pushed
output
output
46
RUN
CPU
running
STOP
CPU stop
Middle
Stop
CPU stop
Down
memory dump
47
SF
System fault
Hardware
configuration
or
Bus fault
ON
Inner power
Normal
light
light
(green)
DC24V Input/output
power
Normal
(green)
A PLC
2#
DP
B PLC
3#
1#
4#
DP
OFF
2#
5#
OFF
CZ12
DP5
DP4
DP3
DP2
DP1
ON
OFF
1
2
3
B1
A2
B2
A1
B1
A2
B2
A1
B1
A2
B2
KA1
A1
B1
A2
B2
A1
KA2
DP
B1
A2
1
2
3
B2
A PLC
7#
DP
DP7
DP6
1
2
3
ON
CZ13
A1
A PLC
6#
CZ22
OFF
ON
CZ23
1
2
3
A1
B1
A2
B2
A1
B1
A2
B2
KA3
II.
Cupboard
Transmission
Unit
Communication adapter.
3. Swing-door structure
installed optional control panel
fuse-switch operating handle
contactor control the operation
of switches and emergency
stop button.
Control Panel
Connector
External
analog/digital
signal.
control
by
inputs/outputs
AC Power Supply
RPBA,
Motor Control
I/O Panel
= ~
~ =
Frequency Convertor
Output
Brake Unit
Brake Resistance
50
fairly due to the primary/secondary function. The outside control signal could only
connected with Primary Motor. Primary motor controls the secondary by Optical fiber.
Primary motor is typical speed control, other transmission units follow the torque and
speed of primary motor. Normally, when the motor shaft of primary and secondary
motor is connected by gear or chain, the secondary should adopt torque control mode
to delete the speed gap between transmission units.
This transmission drive system has single motor mode (A or B) and double motor mode
(A+B). Double motor mode adopts the control of primary/secondary
54
Note
Caution
Warning
Please read this hydraulic manual before operating, testing, maintaining and repairing
of this hydraulic equipment in order to avoid personal injury and equipment damage.
This manual contains notes, caution and warning and so on besides text. These
contents are to prompt the influence of the related operation to the safety of personal
and equipment. Please give sufficient importance to these important advices.
To avoid the damage to personal and equipment, the installing, operating and
maintaining of hydraulic system should be finished by the qualified people with the
corresponding experience. Please read this manual and the related technical
documents carefully before operation.
The above people and other people close to system equipment should accept the
training of well drilling operation, well drilling safe knowledge and using tool, and use
proper protective appliances.
55
It is impossible that this manual involves all safety knowledge with which operator
should be equipped, so such knowledge should be collected, judged and used by
operator. Strictly forbid any maintaining, repairing and adjusting equipment in the
course of top driven operating. Strictly forbid any detecting unfamiliar parts. Please
read and understand all safety warning before maintaining and detecting.
56
5) Before hydraulic system run formally, gas should be discharged. Otherwise, the
stability or stiffness may not be sure.
6System commissioning should be carried out before hydraulic control system
running.
7) After hydraulic control system run formally, several examine and record should be
done regularly, including oil temperature, oil pressure, oil pollution level, run stability,
executing agency running condition, condition of action element Tracking Signal, etc.
When taking and putting components and parts, take care to avoid hurt
certain accurate fitting surface on it.
Please wear eye protector for avoiding the damage of the high voltage oil
57
Do not try to examine hydraulic oil leakiness with your hand. Please
release pressure in accumulator thoroughly before maintaining hydraulic
system, and then operate it.
Before
opening
hydraulic
system,
please
clean
operating
area
The hydraulic system of top drive well drilling includes Counterbalancing system,
braking system, rotary head gyrating system, hanging ring declining system, inner
blowout preventer control system, hydraulic elevator, back up tong and so on, which is
made up of the following parts:
1) Hydraulic source
2) Hydraulic valve block
3) Actuating device (braking cylinder, balancing cylinder, rotating link adaptor motor,
backup tong cylinder, Leaning cylinder, IBOP control cylinder and so on).
4) Hydraulic pipe
5) Auxiliary
13 MPa
Rated flow
37L/min
Power
380 VAC / 50 HZ
5.5 Kw Level 6
100 L
DC24 V
Explosion-proof grade
EXdIIBT4
Filter accuracy:
59
2. Oil tank
The oil tank is made of stainless steel, and its effective volume is 100L; in addition to
storing hydraulic oil, it also has the functions of dissipating some heat produced in
system operation, separating gas and sediment in oil.
Oil surface of the tank should connect with atmosphere. An air filter is set on the tank
in to reduce oil pollution. When working, pay attention to cleaning and replacement of
filter.
The oil level gauge and oil thermograph are set at the side of tank, so as to check the
oil level and temperature conveniently.
3. Pump unit
Main specifications of Explosion-proof Motor (produced by ABB)
Type
M2JA132M6B
Explosion-proof grade
Rated power
5.5KW
Rated speed
950r/min
Pressure
limited
(ExdBT4)
variable
flow
ram
pump
(produced
by
Japanese
YUKEN):
A37-F-R-01-H-S-K
Work condition and parameter describe:
A. In order to increase the life of pump, we adopt grade 6 motor because it can provide
rated pump output with a lower speed.
B. Pump closure features: When the system pressure increases, close to the pump
preset closure pressure, pump flow automatically decrease, but maintain the same set
pressure, adjust pump flow and total closure of the pressure manually when necessary.
This pump is characterized by a better closure properties, can reduce the overall
heating system, and the closure is effective to reduce power consumption. System
pressure is set by pump.
60
24-M10 Depth 19
Decrease
Flow adjust blot
Outlet?32
Oil Drain Port
Locking nut
S17
Max 247
202
178.5
59
86
86
22.23 -0.03
0
25.01 -0.16
0
101.6 -0.05 -
112
30
58.7
32
202
Pressure Increase
Pressure adjusting bolt
Rc12"
30.2
6.35 +0.03
0
Inlet
Outlet
4.
5. Oil filter
Filter is the element to clean the oil, oil filter is installed in the oil tank by thread, it could
filter pump.
Oil filter parameters:
Model: WU-100X100J
Currency: 100L/min
Filter accuracy: 100m
Inspect the filter station via drillers panel, when the clean or replace it when alarm light
powered on.
61
Liquid level controller is set at the bottom in the oil tank connected
by screw thread. The oil level and temperature can be seen freely,
and alarm will appear when level too low or the oil temperature is
too high.
62
9. Air Filter
Air filter is set on the top of the tank cover board, also can be used as oil filler.
Main activity:
1. Exchange air so that keep balance with atmosphere.
2. Filter the impurities in the air
63
9 MPa
6
12
13
3 MPa
11
G13
M181.5
G2'
M181.5
G2
(103)
MP2
G4
M181.5
G5
M181.5
G6
M181.5
M181.5
G7
M181.5
G8
MP8
MP9
G9
M181.5
M141.5
M141.5
M181.5
G10
MP10
M181.5
1.2
G11
M141.5
M181.5
(38)
1.1
G3
M141.5
M141.5
M141.5
10MPa
(203)
(205)
10
MP12
M141.5
(208)
(39) (37)
G12
M181.5
(102)
MP1
G1' G1
M181.5 M141.5
ab
T1
M181.5
8.4
8.3
8.2
(58) (56)
(206)
3.1
(207)
(29) (27)
(19) (17)
(9) (7)
(28) (26)
2.2
a
(18) (16)
2.1
(8) (6)
(204)
8.1
17MPa
(201)
(59) (57)
(202)
1.3mm
(105)
7 MPa
(48) (46)
5.1
5.2
(106)
5MPa
5.4
(49) (47)
(222) (242)
T
M221.5
MP T
M141.5
P
M221.5
18MPa
5.3
3.2
8MPa
a
(104)
7 MPa
(101)
(221) (241)
MPP
M141.5
MPT
T
MPP
G2'
64
G1'
T1
G5
G3
G12
G8
G1
G2
G4
G13
G9
G7
G6
G11
G10
BASPM22
MVSPM22
BASPM22
MP8
Leaning relief
MVSPM22
MVSPM22
MP1
MP2
MVSPM22
PC10
Counterbalance
pressure reduce
BASPM22
RNXPM22
BASPM22
Hydraulic elevator
pressurereduce
Leaning relief
Counterbalance High
Pressure control
MP9
MP10
MP12
sloping cylinder
G10Rodless chamber of sloping cylinder
BOP cylinder
G13 Brake accumulator
T1
G1' G1
M181.5
M181.5 M141.5
MP1
M141.5
(102)
(201)
7 MPa
T
M221.5
66
P
M221.5
18MPa
MPP
M141.5
G13
M181.5
9 MPa
G2'
G2
M181.5
MP2
M141.5
M141.5
10MPa
(203)
(204)
of
accumulator
and
repairing
the
air
(202)
7 MPa
T
M221.5
MP T
M141.5
M221.5
18MPa
G4
M181.5
M181.5
(8) (6)
(9) (7)
67
T
M221.5
P
M221.5
18MPa
G5
G6
M181.5
M181.5
(18) (16)
(19) (17)
T
M221.5
P
M221.5
18MPa
G7
M181.5
(28) (26)
(29) (27)
(105)
8MPa
68
M221.5
P
M221.5
18MPa
G8
MP8
M181.5
M141.5
G11
M181.5
G12
MP12
M181.5
M141.5
(208)
(58) (56)
(59) (57)
(106)
5MPa
T
M221.5
P
M221.5
18MPa
MP9
G9
M141.5
M181.5
G10
MP10
M181.5
M141.5
(206)
(207)
(48) (46)
speed.
(49) (47)
T
M221.5
P
M221.5
18MPa
(39) (37)
69
ab
(38)
-6 to 20
21to 55
10
32
46
Mobil
DTE21
Mobil
DTE24
Mobil
DTE25
Hydraulic oil is the important component of hydraulic system. The hydraulic oil
performance affects the system performance and life time directly, as well as the
system reliability, so high attention should be put on it.
The oil should be replaced after half year, then change it once every year. The cleanse
of oil is very important, keep to use one brand and type of oil, keep rubbish and water
away from the system.
71
Rotating heading is oil motor loop, its steady pressure is gained by adjusting
pressure reducing spillover valve.
IBOP Oil tank is two-way cylinder, its pressure is gained by adjusting pressure
reducing spillover valve.
Check the juice level gauge of oil tank, oil level could not be lower than the
middle line of juice level gauge.
(2)
(3)
(2)
(3)
Inspect the heat exchange capacity of air cooler, oil temperature at inlet should
higher than outlets.
(4)
73
Note
Caution
Warning
The top drive drilling system should be installed and tested by the
qualified operator with experiences. This manual and related technical data
should be read carefully before operation. Working personnel and other
personnel who enter the working area of the system should have got the
training of drilling operation and safe knowledge.
When the system is running, do not touch the rotating parts of the
device, avoid to get a badly hurt of person or get damage of the device.
Before installation and maintenance of the hydraulic system, cut off the
power supply, close the valve and release the pressure of accumulator.
74
This manual only includes the basic safety knowledge which operator
should know, other knowledge should be collected, judged by the
operator.
All the installation work should meet the requirements of the related
standards and specifications inside this manual, and should be
confirmed by the installation technology personnel and safety
personnel.
Before operating the electric system, the operator should read the
<electrical manual> to get a well known of the electric circuit diagram.
Before operating the hydraulic system, the operator should read the
<hydraulic manual> to get a well known of the hydraulic system
principle.
75
3. The installation technical staff and safety staff should arrange a technical discussion
to ensure that everyone who participates in the installation knows the installation
scheme and safety measure. Set out a detailed working schemes and working site
layout to increase the working efficiency. We suggest carrying out the working
according to <installation reference table>.
Device needed
truck crane (over 30
tons)
pneumatic winch,
truck crane(over 50
tons)
Centering and
connecting the wires
System testing
Note:
Staff
Working time
3-5 persons
2 hours
5-7 persons
2 hours
2-3 persons
1 hour
1 hour
Turn off the limiting device of the travelling crane; make sure the hook block could
77
78
79
The connecting bolt must be the M30 grade 12.9. After it being fixed, it
must locked with the pin.
Connection (welding) must firm and reliable, take care when working at
the high position.
2. Lifting the guide beam adjust unit and guide beam docking assembly to the drill floor
by the crane
80
Install the guide beam adjust unit, make sure the rig height first and calculate the
guide beam length base on the rig height.(connect the different guide beam adjust
plate according to the chart),connecting the guide beam adjust plate and guide beam
adjust back plate.
Adjusting
Back plate
Adjusting Plate
81
4. Install the upper guide beam connection device, using the supplied mount pin
connect the connection device with the guide beam adjust plate, and lock the pin.
5. Using the supplied wirerope fix the guide beam plate on the hook block.
Steel Rope
Crane hook
82
6. The installation staff climbs to the travelling crane to assistance and operate the
guide beam and main body installation process.
7. Lifting the traveling block with the guide beam adjust plate to the top of the rig.
Justify the adjusting plate and the crane crown lug; connect them with the U-ring and
connecting pin. Setup the lock pin.
Crown Lug
U Ring
Adjust
Back plate
8. Remove the wirerope between guide beam adjust plate and traveling
block.(attention: connect the wirerope with the traveling block)lower the traveling
block.
83
When working at height, the working staff should be careful about the
fallen things.
If it is the first time install the rig, it could fix the crown lug and guide
beam adjust component on the rig before rising.
9. Using the traveling block lift the guide beam to drill floor, put them under the hook
block in order to install conveniently.
10. Penetrate the upper guide beam connection device wirerope into the lower part of
the guide beam connection device.
84
11. Connect the travelling hook with the lift locking device of install cart. Fix the
installing cart and travelling hook by the wire rope and U ring, rise up the crane slowly,
lift the 5th section guide beam to reach the connection panel.
Travelling Hook
Lifting Lock
Wire rope
85
12. Operator on the drill floor pulls the wirerope to connect the guide beam. Fix the wire
rope on the derrick back beam, avoid from disturbing drilling.
Joint State
When working at height, the working staff should be careful about the
fallen things.
86
14. Lower the traveling block, carriage moves down, make the guide beam adjust
component bear the weight, the guide beam will connect together automatic by its
weight and keep vertical.
Install State
7thGuide Beam
Vertical State
87
15. Lock the centralizer block shaft of top guide beam adjusting panel.
Centralizer Shaft
16. After the guide beam gets vertical, measure the guide beam safe distance (The
distance from guide beam bottom to the drilling floor is 2-2.2m), lower the hook to
guide the cart to the end of guide beam, move the cart.
Lift Locking
Wire rope
This State is dangerous
88
17. Adjust the flexible distance of reactive torque through guide screw. Preset the
center of guide beam to the center distance of installed guide beam.
89
1. Lift the top drive to drilling floor by crane, put it in front of guide beam.
2. Lower the hook to proper height. Connect the 3 points (2 points on the transport
frame, 1 point on bail) with hook by the supplied wire rope. Lift the 2 points on the
bottom of transport frame by crane.
90
3. Upright the assemble frame by Hook and crane, the back of assemble frame is right
to installed guide beam, ensure the transport frame lean on guide beam surface.
Crane and hook must cooperate while uprighting assemble frame, avoid
crashing.
4. Dismount the locating pin on bottom guide beam, regulate guide screw on it, ensure
bottom guide beam and transport frame in the same vertical plane.
Guide Pin
Adjust Screw
91
5. Assemble frame of Top Drive connect with guide beam by pressure plate, insert pins.
Pressure Plate
6. Dismount the pulley of guide beam block, disconnect the transport frame and top
drive.
92
7. Connect the hook and lifting ring, pull up the hook slowly, top drive moves upward
along with guide beam. Disassemble pressure plate to disconnect guide beam from
transport frame, move the assemble frame away by crane.
Pressure plate
8. Regulate guide screw on the bottom guide beam, get the bottom guide beam back.
Fix the locating pin and insert pins.
Guide Pin
93
9. Re-adjust the reactive torque beam, keep the center of main shaft and wellhead in
the same line. Fix all the bolts, insert pins.
Keep the top drive are not jammed while slipping up and down.
11. If the top drive slides up and down without problem, then connect the crane
anti-collision limit device.
94
2. Inspect the bolts and card condition on the movable section cable, install it on
the derrick by pneumatic crane (position refers to well site plan), move the cable box.
95
3. Install derrick cable hanger on rear beam of derrick (keep the same height with trip
cable hanger)
4. Hang cable in derrick cable box up, connect with derrick cable hanger and lock. The
cable drop to reach ground, it should be paralleled on derrick and not crossed.
Power Cable
96
5. Connect the trip cable and derrick cable, joint 700509 and 700503, 700510 and
700501, 7200511 and 700502. Connecting as follows:
700509A
Derrick
700502
Back
beam
700510
700503A
Trip
Power
Cable
(700503B)
All cables are connected by quick connector, Marks on the joint of plug
and jack (label and color), alignment mark while connecting.
Connection must be safe and reliable.
6. Lay the cable on ground from cable box to derrick bottom. Place the cable on ground
to derrick bottom. Cables connect with the derrick cable.
97
Remark: Ground cable length 26m. If the cable length is 48m, it could connect
the trip cable and electric control house, ground cable can be used as backup.
Refer to the well site condition to connect or disconnect the ground cable.
Keep the cable properly when it is unnecessary to join ground cable.
All cables are connected by quick connector, Marks on the joint of plug
and jack (label and color), alignment mark while connecting.
After finishing installation of guide beam, Top Drive System, and cable,
distribute personnel to start the following install at the same time.
1.
2. Connect the trip power cable (700503), auxiliary power cable (7005011),
comprehensive control cable (700510) plug with the cable of top drive body
(Distinguish from color).
3. Install drilling hose (position according to the well site layout)
4. Install electrical control house, at the position of the 2 opposite angle of electric
control room, stab steel into ground at 1.6m. Connect steel and control house with
ground lead.
Control House must connect with earth to ensuring operator and equipment safe.
5. Move the Driller panel from electric control room to drilling floor, put it in a wide place
in the driller house for easily operating.
6. Connect the cable of driller panel (include 10 core control cable (700513), 2 pcs of
communicate cable (4 core A: 700514/ 4 core B: 700515)).
98
All cables are connected by push fit, Marks on the joint of plug and jack.
7. Connect air pipes, adjust input air pressure, ensures the air pressure on driller panel
is lower than 0.2Mpa, higher than 0.12 Mpa.
8. Feed lubricate into gearing box by oil cart. Feed hydraulic oil into hydraulic oil tank.
9. Connect generator and electrical control house, generator offers 600V main power
and 380V auxiliary power supply.
99
100
4. While the temperature is higher than 40 and wetness is higher than 95% or has
condensation, start air conditioner to remove dampness or drop temperature.
101
6. Start the lubricate pump, hydraulic pump and cooling fan on drillers panel, inspect
rotating direction and running condition.
7. The pressure of hydraulic system is already set before delivery. Operator on site is not
allowed to adjust it. In special condition, adjust operator must be professional personnel
who is familiar with the principle of top drive hydraulic system. The detailed adjusting
procedure refers to <hydraulic manual>.
8. Start the main motor, check the running condition. Operating procedure refers to
<Operate manual>
102
103
Dissemble Cables
4. Disconnect the driller panels cables joints. (include 10 core control cable (700513),
2 pcs of communicate cable (4 core A: 700514/ 4 core B: 700515)). Pack the cable
for next installing.
5. Disconnect the ground cable and derrick cable in the condition of connecting the
ground cable.
6. Disconnect the plugs of Power cable (700503), assist power cable (7005011),
general control cable (700510) and the plug of top drive cable. Protect the connector
by cover from damaging in dissembling.
7. Disassemble the elevator.
A. Release the bolts and shafts on the elevator shelter and joints, move the
elevator.
B. Fix these bolts and shafts on Top drive main body.
C. Lift the elevator link to the easily delivery position.
Elevator
shelter
bolt
Elevator
Joint shaft
105
II Cables disassemble
1. Disconnect the joints of the travel cable and derrick cable. Disconnect the main
power cable, general control cable and assist control cable in turn.
2. Remove the connection between derrick and cable hanger, lift the cable hanger and
cable into the cable box, and put the cable box in position convenient for delivery.
2. Disconnect the guide pin on the bottom of guide beam, rotating adjust screw, make
106
3. Fix the top drive transport frame and guide beam by the backup press panel and
bolts.
Pressure plate
107
4. Lower down the hook of Traveling Block, when the top drive along the guide beam
near to transport frame, lower the hook slowly, inspect whether the wheel of block
enter into fixed guide beam surface of transport frame. After the block transit to the
fixed guide beam surface, lower down the hook until top drive insert into the transport
frame completely.
5. Insert the pulley pin of guide beam, fix the top drive mainbody and transport frame,
disassemble the hook and link.
6. Dismount the guide beam and top drive body, separate the guide beam and transport
frame.
108
7. Connect the 3 points (2 points on the transport frame, 1 point on bail) and hook by
wire rope. Hang the 2 points on the bottom of transport frame by crane. Lay it down by
hook and crane
9. Lift the top drive main body to the easily delivery position by backup wire rope.
109
Lift locking
Wire rope
2. Raise the hook, slip the assemble cart to the top of guide beam.
3. Disconnect the reactive torque beam and guide beam, move the anti-torque beam to
the position easy to package.
110
5. Install Operator climbs to the clown block for conducting the disassemble process.
Command the crane raises slowly, the install cart bearing the weight of guide beam,
withdrawal plate falls to the top guide beam by its gravity, the guide beam joints open.
111
6. Lower the hook, hang the bottom guide beam to transport frame by crane, continue
to lower the hook, put all guide beam into transport frame.
7. Disconnect the crane hook and cart, fix the cart on the guide beam.
8. Hang the adjusting back panel, guide beam and transport frame under the drilling
floor for packing.
9. Packing the dissembled top drive and auxiliary components.
112
Attachment I
Inspecting list
No.
Item
Electric
1
leakage
Inspect
Electrical
control house
Inspect Content
1.
Through
the
inspecting,
Result
Check
the
Main body
power cable
Assist Power
control cable
General
control cable
Driller panel
locked well.
3. Air Pressure is regular.
4. Panel lights works well, meters display
regularly.
Remarks:
Record
Check
113
No.
1.
Item
Inspect Content
Guide
beam
hang
2.
Guide
beam
body
and
connection
3.
4.
Lifting
ring
connects
with
crane or hook
installing is in place
Reactive torque
beam
5.
Top Drive main
body
6.
Main
shafts
three anti-loose
blocks.
7.
Pulley
Remark
Record
Check
114
Result
Attachment
III
Top
Drive
System
Installation
Commissioning Record
No.
Item
Rotating direction of
1
lube pump,
motor
of hydraulic pump
and air-blower
1. Normal voice
2. Motor rotating direction is correct
3. Air pressure is normal
1. Hydraulic lubricating system runs
Hydraulic,
lubricating system
Indicator on Driller
panel
wheel
on
drillers
work well.
panel
Frequency house
Motor
starts
and
stops
2.
No-loading testing
normal.
2. No omit, smell or block.
3.
115
Result
and
10
test
1. Act well
floating test
2. moving smoothly
11
Breaking
testing
12
13
device
Counterbalance
device movement
1. Action accurate.
2. Main shaft breaking regularly.
1. Clamp and loosen correctly
2. No omit
1. Make up and breakout is normal, top
drive upward jumping is realizable.
test
14
Remark:
Record
Check
116
Part VI
Operation Manual
Note
Caution
Warning
1. The top drive drilling system should be operated by the qualified operator with
experiences. This manual and related technical data should be read carefully before
operation.
2. Working personnel and other personnel who enter the working area of the system
should have got the training of drilling operation and safe knowledge.
3. The working personnel should wear the suitable protective articles, such as glove,
clothing etc.
5. Repairing and maintenance could not be carried out while the system working.
117
1) Read the electrical parts and electrical drafts carefully, familiar with the circuit
diagram.
2) Before confirm each works, please hang the signal of Working state, switch-on is
forbidden
5) Remark the cable and cable ends before disconnecting the electrics to ensure correct
reconnecting.
6) Keep the protective air pressure while powering on the drillers panel. When the
protective air lose pressure, recovery the pressure quickly or stop drilling and cut the
power supplied to drillers panel.
9) While the temperature is higher than 40, humidity larger than 95% or have dew,
dont start the drive and other control powers before air conditioner lower the
temperature and humidity.
118
10) Re-supply power after power off more than 30mins, must confirm there is not any
dew in electrical control cabinet.
2) While disassemble the hydraulic system, release system pressure slowly and confirm
there is not any pressure in the system pipe lines.
5) Prepare proper tank, cotton yarn, and blocks etc before disassemble the hydraulic
pipe lines, avoid the rest hydraulic oil releasing and pollute the equipment and space
when open the pipe line.
1) Read and understand the design requirement of drilling and technique requirements
of well control.
2) Carry out the industry standard, stipulation and recommends when meet with the
high pressure oil layer or gas with H2SSO2.
3) Keep equipments in good working station while drilling in the oil layer, carry out while
shaft handing over. For instance: the Inspection and testing of IBOP, well control
operation, handle with the problems in time.
119
DQ70BS-JH Top Drive Drilling System is composed of power swivel, pipe handler, guide
beam and carriage, electrical control system, hydraulic control system, and auxiliary
device.
The following is the draft of main body of top drive system
Power swivel
Pipe handler
120
a. Turn on the general power switch Q1, then close up the primary power switch of
converter and the switch of assist transformer Q2. After that close up all the power
switches (except the spares), and check the power work condition.
b. Inspect whether the 24V power light (HL1) on PLC cabinet panel works well,
Fault/Alarmindictor is neither light nor indicating alarm.
121
Fault/Alarm
122
Fault/Alarm
Motor Direction
Throttle
b. Turn off the power switches of 2 transducers and assist transformer, turn the main
power off, the whole electric system stops.
123
Operate Selection
(2) Start: Turn the hydraulic pumpStop/Startto start, hydraulic pump starts,
indicator is light.
(3) Stop: Turn the hydraulic pumpStop/Startto stop, hydraulic pump stops, indicator
is off. In this state, if there is no brake signal hydraulic pump could not start, but it could
start when well control.
124
(4) Hydraulic pump is on Auto position when drilling, turn it to start when rising
up.
Hydraulic Pump
b.
c. Hydraulic system stop process: Rotate the button to stop, the hydraulic pump stops,
the hydraulic pump indicator off.
d. Lubrication oil stop and start in same step with main motor.
system
inspecting
items:
1. Hydraulic oil temperature
inspect Pt100
2. Hydraulic oil liquid level
lower warning inspect
3. Lube oil pressure inspect
4.Lube oil temperature inspect
Pt100
125
Motor Heater
2. There is interlock between heater and drive system. When the heater works, the
frequency convertor power on, main motor starts, the heater stop heating
automatically, the frequency convertor power on and main motor run, the heater
does not work.
126
3). Stop: air cooler r stops running. Main motor can not start.
Motor aire-blower
When there is not any air pressure signal, main motor does not start, the
main motor lose air in running, the system fault stop.
2. Brake position
i. In brake state, braking solenoid valve powered on and stop the main shaft directly.
ii. In shaft running state, if switch to brake position, fault appear and stop.
127
3. Closed position
if the braking solenoid pilot actuated valve can not given power on, no matter
operate select on any position, the top drive drilling system braking fail, except well
control.
Break Mode
128
6. In tripping time, hydraulic is on start position. At this timeit does not carry
out hydraulic pump intermittent working.
Switch brake mode to off, top drive starts running, but brake device
can not brake automatically when system stops.
When emergency stop, system will stop rapidly, braking disc would be
worn seriously, so it is forbidden to use this stop function in normal
braking except the emergency.
While system switch to spin or strain at state, disc brake will open
automatically, no matter switch brake mode to any position, brake
does not close.
Motor Direction
129
Throttle
B. Put the Motor Selection on top drive running position, the required motor work
mode (A motor, A+B motor, B motor)
Motor Selection
C. Before system doesnt run and THROTTLE is in zero positions, operating the
ROTATION DIRECTION switch to select rotation.
Motor Direction
Motor Selection
2. Operation Practice
a. Air motor is on Auto or Start
Air Motor
b. Operate operation switch to drilling mode.
Operation
c. Put the Motor Select on top drive running position, the required motor work
mode (A motor, A+B motor, B motor)
otor Selection
131
d Rotate the Motor Select Direction to CW, if the hand wheel is on Zero and
the transducer is ready.
Motor direction
e. Movedrilling torqueaway from zero position regularly, set torque as needed.
Drilling Torque
e. Move the THEOTTLE away from Zero, the main motor CW as the set speed.
Throttle
132
Drilling Torque
Throttle
2. After getting to rated power, speed keep increasing, and the torque of motor
begin dropping, and keep exporting the same power. (constant power).
Throttle
b. If the torque of drill pipe over limit torque, the principal axis will stop rotating
(stop), the torque will keep. When load reduces, the driver speed comes back
to the value of THROTTLE handle. And it can change to speed control again.
133
Motor Direction
Operation
Backup Tong
Throttle
2. During system running, switching backup tong button can not change the
status of backup tong.
Back up Tong
tools from mouse hole and Kelly board. Turn Elevator link leaning to backward to
lean it 55, drill the pipe socket into drilling panel surface.
Link leaning
2. Put done Elevator suspend button, electromagnetic valve would connect the front
and back tank with oil tank. Link and the things on elevator is in the self-weight state.
Elevator suspend
3. Push Elevator suspend button, rotary head would turn left and right freely.
link lock. When the cline cylinder work, the rotating turret can not act. Only
when press middle button and the elevator link go back to middle position, the
rotating turret can rotate. In special condition, modify the setting on PLC linking
if need to spin rotating head after leaning. Return to the factory setting when
finish the operation, prevent the link hurt staff.
135
Elevator and link could not hold more than 3T when rotary or leaning.
When exceed 3 T, push the Elevator Suspend button prevent from damaging
the leaning tank.
Before operate the rotating head, make sure the link return to the middle
after operating the link middle button, avoids accidents.
Motor Direction
b. Turn the Motor Select to A+B mode.
Motor Selection
136
Throttle
c.
Opeartion
d. Hydraulic pump control switch is on Auto or Start
e. Air Motor is on Auto or Start.
Motor Direction
137
b. Turn Operation to Spin, system will spin with fixed speed 12r/min, fixed
torque 6kNm. When achieve at 6 kNm, the rotary and torque are set zero, speed
reduce and stop.
Throttle
When the THROTTLE hand wheel is not on Zero,, operation of
ROTATION DIRECTION is inactive.
When top driver is spinning normally, If the THROTTLE handle goes
back to zero position, or operating the DIRECTION switch by
mistake, the speed and torque will be reduced to zero automatically.
Fastening:
This operation should be carried on when the main shaft stops, this required operate
state is same to the spin state, main shaft rotary of top drive is 0, output torque is the
spin rated output toque: 6KNm.
a. Put THROTTLE hand wheel of driller panel on ZERO position, and switch
DIRECTION to rotation.
Throttle
Motor direction
138
Makeup Torque
c. Switch the OPERATION handle to make up and breakout position, turn the backup
tong to fastening, then backup tong will fasten. 5 min later, backup tong will rotary
forward, when up to the limited torque, system will stop. Take off hands, backup tong
loose.
Operation
Backup Tong
Operation
139
Keep the hydraulic pump start when fastening to supply hydraulic power
of back-up tong.
When main shaft is rotating, do not fasten avoid damaging the tooth of
back up tong.
3. Breakout operation
Support the released drilling tools before breakout, prevent hurting from tools falling
after release.
Inspect the button position whether in the first item required state.
a.Turn Motor select direction on CCW position
Motor direction
Throttle
Break up
140
c. Left hand turn OPERATIONto Strain at mode, right head push backup tong to
CLAMP.
After 5 seconds, the system will rotate in CCW direction until the torque get
to the Max. torque. When the system rotary speed get break up fixed rotary speed
6r/min, release both hands, Operate Select return to make up, main shaft would
break up by make up mode.
Operation
d. After complete Break Up, push Operate Select to drilling position, so the Break
up finished
. System would press on the balance cylinder in 1 minute after put down
Break up, rise the Top Drive body up, conquer self-weight to protect
joints of drilling tools. After 1 minute, pressure increasing is finished.
Repeat press the button, pressure increased again.
The maximum torque of Break up is the max. output torque of Top
Drive (150% of normal output torque), so when could not break up while
get the max. torque, close motor to break up long time is not allowed
( Longest time is 1 min), try to break up by other method.
141
rod;
4Start elevator tipping device to swing the lifting ring onto the joint of the single in
the mouse hole and fasten the elevator;
5Lift the single out of the mouse hole, move the single to the center of well head.
6Lock the drilling rod connecting buckle of the well head, put the top drive drilling
system down, Put the upper side of the single goes into the guiding shoe.
7Make up the single with the saver sub of the top drive drilling system;
8Fix the drilling pipe in well, connect the joints between drilling tool and single,
single and protective joint by drilling machine (preset the drilling torque as need)
9Rotate and fasten by top drive according to the procedure of VII-1.
10Pull the slip, open IBOP, start pump to circulate the mud.
Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.
Before single drilling, open IBOP, then start mud pump.
142
platform, start the elevator tipping device to push the elevator to the triples where is to
be connected;
4Well workers will make up the triples into the elevator, and take the elevator
tipping device back to the well head;
5Drilling machine operator put the triples into the box threads of the drilling rod;
6Put the top drive drilling down slowly to put the upper side of the triples into the
guiding shoe and make up with the saver sub of top drive drilling system;
7Make up by Motor (e. g. Single Drilling)
8Lock tight by Top drive according to IX-2.
9Pull the slip out, start circulate mud, open IBOP, continue drilling.
Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.
Before single drilling, open IBOP, then start mud pump.
XII.
Backreaming
During the course of pulling out, if the drilling devices are blocked, connect them with
the top drive drilling system at once, and circulate mud. Lift the drilling and
backreaming at the same time to avoid drill rod being clamped and key box being
reamed though.
Procedures of backreaming are as follows:
(1) Circulating mud and rotating to pull the drilling devices out until one triple is lifted
outside;
(2) Stop mud circulating and rotating, set the slip;
(3) Unlink the connection on the surface of drilling floor by hydraulic tong, and unlink
the connection thread with the top drive drilling system on the triples;
(4) Pull out the triples, arrange the triples into the drilling rod box;
(5) Set the top drive drilling system down to of drilling floor.
(6) Lift the drilling rod to pull the slip out. Set the drilling rod down to the head of the
well and set it onto the slip.
(7) Loosen the elevator, operate theLink incline to slope it backward a little and
deviate it from the drilling rod. Lift the traveling crane to the kelly board. Repeat the
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above operations.
2Operate Link incline to Front, make elevator close to the kelly board to put
the drilling rod down, then workers will put the drilling rod into the elevator and buckle
door bar;
3Operate Link incline to Rear to return to the head of the well approximately,
then operate Link center, at this time, the tipping device is in floating state;
Link incline
Link center
144
4Pull the drilling rod to return the center position, during this course, the drilling
workers should hold back the lower side of the drilling rod with ropes and release it
slowly in order not to damage the joint of the drilling rod;
5Put the traveling crane down, buckle the carried drilling rod with the drilling rod
of the rotary face, Rotate and make up with hydraulic tong;
6Lift the drilling rod to pull the slip out. Set the drilling rod down to the head of the
well and set it onto the slip.
7Loosen the elevator, operate theLink incline to slope it backward a little and
deviate it from the drilling rod. Lift the traveling crane to the kelly board. Repeat the
above operations.
Link incline
B. Tripping out
1Loosen the connecting thread between the main arbor and drilling rod, and lift the
top drive drilling system. Operate the Link inclineto slop it forward in order to buckle
the main arbor of the lift sub into the joint of the drilling rod;
2Lift the top drive drilling system above the kelly board. Set the slip on the drilling
floor, put the top drive drilling system under the slip;
3Breakout with hydraulic tong;
4Pull the top drive drilling system, operate the Lind inclineto front in order to
make the elevator close to the kelly board. Drilling workers pull the triples to the
arranging area, lower down the top drive to put the triples steady. Workers open the
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elevator and put the drilling rod into the triples box;
5Operate Link center, set the top drive drilling system down to the joint of the
drilling platform. Operate Link incline to front in order to buckle the elevator into
the joint of the drilling rod.
Link incline
Link center
If there are reducing radius or key groove during the course of round-trip, connect the
drilling rod with electric engine of the top drive drilling system at any height of the well
frame, and starting the circulation and rotating removable drilling tools immediately to
make the drilling tools pass the blocking position;
or close the IBOP. In the drilling process or the mud pump running status, it is not
allowed to close the IBOP (except the well control status).
2Under the urgent condition such as well blowout, push the well controlswitch will
enter the well control status, operating procedure showed as follows:
a. Start the hydraulic pump (Ignore the state before)
b. Stop the mud pump (Give the connect point signal, connect the control to mud
pump)
c. Stop top drive system (Fast stop)
d. Shut the IBOP off.
3. Operators should replace all switches to original position. (Attachment I)
4. After obviating the urgent situation, and insuring there are no trouble alarm in
system, push the reset switch, then the well control statue is cancelled.
Well Control
IBOP
Reset
If jarring with Top Drive Drilling System can not avoid, please assess comprehensively
about the possible damage of jarring to the Top Drive Drilling System.
When lock-rotor happen, the driller first should lift up and move the drill pipe string
to release the torque stored in drill pipe. If this method failed, the Top Drive Drilling
System also provides other two methods, and normally, we adopt the following one.
148
Keep the speed setting and the brake handwheel still to ensure the motor
outputs torque continually, and turn down the drilling torque handwheel slowly to
reduce the output torque of the electric motor, and then the drill pipe string will rotate
back slowly until the drilling torque fall to zero, and the drill pipe string rotate speed
reduces to zero at the same time, then release the brake handle and lift out drill pipe
string. Only when the drive system can not work normally the following method will be
used.
Keep the drilling torque setting handwheel still, operate the brake handwhell
to brake the system and speed setting handwheel to zero, then the electric motor
stop. Close the brake handwheel, then the drill pipe string will rotate back slowly,
and the driller operate brake properly to reducing the rotate back speed in case of
releasing the pipe string connecting. Repeat the process above until the pipe string
rotary speed reduce to zero, then loose the brake handle and lift up the drill pipe string.
XIX Reset/Mute
When system has fault, the error indicator would light up, voice alarm warn up. Push
Reset/Mute to mute. The error indicator would keep light until the fault is not solved
XX Stop System
Return Throttle hand wheel to Zero When stop system, turn Rotary Direction to
stop. Then switch house switch of 380V power or Assistance Transformer in
Electrical Control Room. Turn off the switch of transducer and assistance transformer,
shut off the Main Power, Whole system stops.
149
Button or switch
Emergency stop
Initial position
Open
Note
Emergency-stop button is NC
contact
Button or switch
Emergency stop
Brake mode
HPu
Link rotation
Link incline
IBOP
Fan
Initial
position
Loose
Auto
Stop
Center
Center
Open
Close
Note
Emergency stop button is NC contact
Brake by PLC system
Stop the hydraulic system
rotator is in inactive state
Link is in balanceable state
When drilling normally
In initial position, it is in close position
Motor select
Operation
Backup tong
Motor
Select
direction
Makeup torque
A+B
Spin
Loose
Stop
Zero
Drilling torque
Zero
Speed
Zero
150
Initial position
Note
Loose
Doghouse control
emergency
stop
Motor heat
Stop
linkage
Initial
Note
position
Link rotation
Center
Link incline
Center
151
Part VII
Maintenance Manual
Note
Caution
Warning
Before maintenance work, the operator should make a safety maintenance plan; need
the safety analysis and safety training.
During the maintenance period, if the maintenance plan is changed, it needs to revise
the safety working plan and guarantees all in involved working personal knows about
the maintenance term so that it could ensure all the working staffs safety and the
devices are in a good condition.
1. Every time before the maintenance, it needs the safety analysis, guarantee all the
power switch is on the switch off status. When lubricating, checking or replacing the
system, it should cut off the power supply.
2. During the maintenance and repair period, the operator must be equipped with
suitable protective equipment, such as glove, helmet.
3. When the system is running, it not allowed to maintenance and repair.
4. Before repairing the hydraulic system, should release the pressure in the
accumulator.
5. Check the hydraulic oil leaks by hand is forbidden, hydraulic oil leaked from the hole
is almost invisible in the high pressure. Hydraulic oil is not only high temperature but
also it could penetrate the skin and cause injury, use wood, inspecting should be carried
out by bamboo and other hard-board, and wear protecting appliance.
6. Dont try to repair the part which you arent familiar with.
152
7. Before repairing the top drive drilling system, please read the related manual
carefully.
Term
Visual check all the fastener no loose, safety lock wire no rust,
break, loose.
cables connection
and connector
the requirement.
oil
Anti-explosion of the Check the air treatment component, clean the water.
drillers panel
Check the panel cables joint. No loose, no bend too hard and so
on.
Drillers panel display Check the drillers panel indicator lights and meters
electrical cabinet
condition
Observe the pulley wheel, lock nut tightly, no serious wear on
Pulley wheel
153
Observe the pins connected with guide rail, pins lock normally.
Observe the guide rail, adjust the backplane and connect pins,
there is no abnormal wear and tear, etc.
All the motor and transmission no abnormal noise during the top
drive running.
Inspect Item:
a. Whether the guide plate and wheel bolts loose, wear out or lost.
b. BOP pulley situation of lubricates and slanted and wear out.
154
3. Centralize Ring
Centralizer Ring
Oil Point
Inside surface of Centralize Ring
Lube Method
Feed grease into the glib by grease gun.
Inspect Item
Inspect the wear out of centralize ring, change it regularly.
155
3.
1Rotate Body
Oil point
3 points on the rotating head.
Lubricate method
Feed grease into the glib by grease gun
4 washes for each
Maintenance Item
aDaub grease on rotating link adaptor regularly.
bUse guide tools to replace the 7 circles of Rotating Gland circle to avoid damaging.
2Big gear of Rotating link adaptor and small gear of drive motor.
Oil point
gear joggled joint and teeth
lube method
Daub the grease on the joint and teeth.
Maintenance Items:
Check the fixed bolts on motor frame often, lock it tight if there is any loose.
156
5. Leaning Device
Inspect Item:
a. Wearing situation on bolts of link
leaning hydraulic tank.
b. The position and clamps of lock
collar clamp on link.
c. The lubrication and lock of joint bearing.
Lubricate Point:
Connecting pins of Joint bearings and rings.
Lubricate method:
Lock collar
clamp on link
157
7. BOP Maintenance
Oil Site
Remote control IBOP glib point 1, manual IBOP glib point 1.
Lubricating mode
Feed lubricating grease into glib by grease gun, twice for each points.
Remote IBOP
Manual IBOP
8. Anti-loosen Device
Inspect Items:
a Bolt fixture.
b Safety lock rope.
Installation of anti-loosing device
a. Cover molybdenum lubricating grease below bolt head
on the surface of locking bolt.
b. Make sure all the connecting joints are locked to the
required torque before installing the anti-loose device.
c. Clear the surface of IBOP, main shaft and protecting
158
connector. Ensure surfaces are bright and clean without any grease.
d. Put pairs of anti-loosing device on the joint.
e. Put the tong dies on the center of connection.
f. Fasten bolts by torque wrench, till the torque to 350 Nm.
g. Fix all bolts by steel wire.
Brake Body
Brake Pad
Brake Disc
Protect Cover
Main Motor
159
Maintenance Items:
Change the brake-friction disc.
Change the brake-friction disc when its material is thinner than 2mm.
Note: It needs some time to backfit with new brake-friction disc before getting the
rated torque.
Release the system oil pressure of braking device.
Disassemble the shelter, remove the M14, and disconnect the brakes pipe lines, remove
the brake assembly entirely.
c) Release the guide pin and screws of retracing spring.
d) Replace to new brake disc.
e) Install the guide pin and screws of retracing spring.
f) Lock the screws, install the guide pin.
g). Fix the brake assembly by M14, connect the pipe lines, install shelter.
Drape hanger
Inspect Items:
a. Inspect the welding point and welding line.
Fixed Pin
U
URing
Connect Pin
3.
Gooseneck
Inspect Item
a. Whether is there any sunken, abrasion or corrosion.
b. Check for leakage.
160
4.
Inspect Item
a. Inspect the damage on the outlet cable of motor.
b. Inspect the damage and loose of the bolts and lock line.
c. Inspect damages on uptake blind and filters.
d. Whether the debris attach to Heat exchanger.
Maintenance Item:
a. The heater of main motor would heat automatically when the main motor stops, shut
off it if dont use in long time.
b. Inspect the air-blower preliminary, whether there is any part broken or sundries in
air-blower channels after transportation or long time stock.
c. Clean the heat exchanger regularly.
5. Back-up Tong
Inspect Item:
Check the abrasion of tong teeth.
Inspect the looseness of bolts on tong teeth seat.
c. Check trumpet fixed bolts, wear ring bolts and fixed
pins and other fasteners whether there is loose and
damages, the reliability of locking.
Maintenance Item:
Clear the dirt on the surface and gash of tooth in time.
Smear grease on fixed pins while installing.
Please disconnect the right side fixed pin only (initial
position of back-up tong, refers to the direction facing
to the top drive),
4 oil seals in the Left side fixed pin.
e. While changing tong key, replace the 4 at the
same time to ensure geometry and mechanical
strength same.
161
Fixed
pin
Note. Please contact with technical dept of Jinghong for further maintenance
and repairing.
Tel: 0452-2345069
Fax: 0452-2340601
Email: clb@jh-pm.com
Add: No.3-2, Nanyuan Road, Nanyuan Investment Zone, Longsha District, Qiqihar,
Heilongjiang, China.
Zip: 161005
163
Thread Type
Recommend force
N.m10.9
Recommendfor
ceN.m12.9
M8
22
30
37
M10
45
63
75
M12
78
109
131
M16
193
271
325
M20
328
531
637
M24
653
906
1101
M30
1300
1828
2193
-30 to
-7
-6 to
20
21 to
55
32
68
220
Mobil
Mobil
SHC624
Mobil
XMP68
Mobil
XMP220
Extreme
pressure
lithium based
grease
Synthesis of lithium-based
grease
Precision
Instrument
Grease
Type
ZL-1H
ZT-53-7
Remarks
GB7323-87
ZL-2H
ZL-3H
ZL-4H
Use in Winter
164