Beruflich Dokumente
Kultur Dokumente
1 Safety cautions...........................................................................................1
2 Safety operation prompts.........................................................................2
2.1 Safety operation prompts of electricity......................................................................2
2.2 Safety operation prompts of hydraulic pressure.......................................................3
2.3 Safety operation prompts of well control...................................................................4
5 Operating instructions.............................................................................52
5.1 Check before startup.................................................................................................52
5.2 Operation of electric system......................................................................................53
5.3 Operation of hydraulic system..................................................................................53
5.4 Driller console control...............................................................................................54
6 Drilling steps.............................................................................................65
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1 Safety cautions
Besides to introduce the contents of main body, this manual has also included the
following contents, such as 'note' , 'caution' and 'warns', they are marked and used for
prompting the possible danger which may caused in operation, the symbolic meanings
are as follows:
Note
Caution
Warns
Only qualified and experienced personnel are allowed to conduct installation and
commissioning to top drive unit, prior to operation please read and follow this
specification and related technical documents carefully.
The personnel who accepted the training about drilling operation and drilling safety
are allowed to conduct the installation, commissioning and close to the system device. Be
sure to keep in mind that uses the proper protective articles such as gloves and safety
wares.
Note
Caution
Warns
Never try to install, test, operate and maintain the electrical system
without profession and training; otherwise, it may lead to the
personal injury or equipment accident. Maintain and repair the
equipment in stopped status.
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Caution
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high, so they need to be cooled for a long time to recover the normal
temperature.
2.3 Safety operation prompts of well control
Pay attention to following items in installation and application of top drive, and
understand the condition of strata pressure and requirements of well control at any time.
1) Read carefully and understand the design requirements of drilling and technical
requirements of well control.
2) Carry out related industrial standards and regulations as per the requirements of
recommended practices under the circumstance of hi-pressure hydrocarbon reservoir or
harmful gas such as H2SSO2 etc during drilling.
3) During drilling in the hydrocarbon reservoir, keep the equipment in good condition,
check and drill the operation of IBOP etc operation of well control during shift every day,
and process it timely if there are problems.
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DQ450DBZ
Drive mode
(AC VFD)
7000m
4500kN(500tons)
16MPa
75mm (3in)
35MPa (5000psi)
Dead weight
15.8t
9.6 t
Working height
5.7m
575~690VAC (50/60Hz)
Rated current
774A
Rated power
580kW
Ambient temp.
-35~50
Altitude
1000m
7000m
Range of speeds
Working torque
50kN.m
Max. torque
75kN.m
580kW
Rated voltage
575VAC
Rated frequency
16.9Hz
Rated current
774A
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Rated speed
125r/min
Max. speed
220r/min
5kW
Rated voltage
380V
Rated frequency
50Hz
Rated current
13.1A
Rated speed
3190r/min
50kN.m
10MPa
575~690VAC (50/60Hz)
0~87.1Hz
70
3~8r/min (adjustable)
14MPa
86~216mm
75kN.m
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16MPa
Working flow
28L/min
Voltage of electromotor
600 VAC
Power of electromotor
11kW
Speed of electromotor
1460r/min
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Counterbalance
system
Hydraulic
system
Motor
housing
Pipe
unit
processing
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Bail
Gooseneck
Centre tube
S-pipe
Disc brake mechanism
Systematic accumulator
Lift box
Main shaft
Elevator link
Locking device
Elevator link clamp
Back-up clamp
Bell guide
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frequency traction motor, bail, washpipe packing assembly and hydraulic disc brake
in the lifting box located on the top of motor. The bail is fixed on the lifting box body,
and upper end of it connected with travelling block. The centre shaft of AC variable
frequency motor is the traction shaft of top drive, and the operation such as rotary
drilling, makeup & breakout and mud circulation can be conducted by driving the top
drive to make sure the normal drilling operation.
Bail
Washpipe packing assembly
Hydraulic disc brake
Lift box
Bail pin
Electric control box, main motor
Blower of main motor
AC VF motor
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of 580kW can also be provided, and realize stepless speed regulating by frequency
speed control system.
Main motor is variable frequency and variable speed asynchronous motor and
adopts firm and high-quality carbon structural steel welded type housing with high
strength, decreased the vibration during running of motor. Class of insulation is grade
H, and the lubrication grease adopts Arcanol L135V (FAG) or special selection as per
special environment.
Limit values of rated output torque are limited by current, output torque is in
direct proportion to electric current.
It is equipped with air-cooled motor at the right side of main motor; the blower is
driven by three-phase current asynchronous motor, after rotating of blower, it sucks
the wind from exhaust inlet of lower cover and discharged from air outlet of air-duct
blower through air outlet of motor skid and air duct inside main motor. Reliable
ventilated is guaranteed with the simple structure and durability of the design.
It is equipped with wind pressure switch on the top of main motor terminal for
checking whether the wind pressure is normal and rotating direction of blower is
correct. There are 2 temperature sensors PT100 are embedded in winding head inside
the motor, one is for detecting the temperature of main motor, and the other one is for
standby.
4.1.2 Brake apparatus
Shaft-extension end on the top of main shaft of main motor equipped with
hydraulic operating disc brake to realized brake through 2 pairs of brake cylinders
clamping the brake disc, its braking energy is in direct proportion to imposed
pressure. The structure of brake apparatus is as shown:
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Disc
brake
tong
Brake disc
Main shaft
Expansion sleeve
Encoder
Brake apparatus
Every brake body equipped two reset springs to make the brake friction plate
reset automatically when releasing the brake. Abrasion loss of brake friction plate can
compensated automatically through increasing the piston stroke.
The functions of brake apparatus are as follows:
1) Bear the reactive torque of drilling tools in downhole;
2) When the drill pipe get stuck in down hole, drilling tools will be rebounded
quickly if the motor stopped, so at the moment, skid the drill tools to avoid inversion
and tripping.
3) Brake the motor when it is out of order.
4.1.3 Washing pipe assembly
Washing pipe assembly is installed
between main shaft and gooseneck,
maintain the washing pipe packing
assembly periodically to extend its
service life.
Method to change washing pipe:
1Before install a complete set of
Washing pipe assembly
Washing
pipe
assembly
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4.1.5 Gooseneck
As the passage of drilling fluid, the gooseneck is installed on the support of
washing pipe. Its lower end connected with washing pipe, and the operation of
salvage and logging shall be conducted after opened the upper end. As the inlet of
drilling fluid, goose mouth end connected with rotary hose through S-tube.
4.2 Pipe processing unit
As the key part of top drive unit, the pipe processing unit can increase the
automaticity of the operation of drilling. It consists of back-up tong, IBOP, control
mechanism, leaning device, elevator link and elevator. The structure is as shown:
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Main shaft
Tilting cylinder, elevator link
IBOP (Inner Blowout Preventer)
Elevator link
BOP (manual)
Elevator link clamp
Locking device
Back-up tong
Bell guide
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rotation of powered rotating head is driven by bull gear disc which driven by
hydraulic motor and the speed of hydraulic motor is adjusted by speed regulating
valve. Generally, setting speed of powered rotating head is 5~8 r/min. The powered
rotating head can rotate clockwise and anticlockwise of 360 and also drive the
elevator link and elevator to adopt to operating requirements of different directions.
Powered rotating head
with
seat.
main
It
has
shaft
the
through
Lowershell
Bull gear disc
stabilized
Hang-off padeye,
elevator link
Hydraulic
motor
with
many
hydraulic
mechanisms.
Because
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the IBOP and cut off the interior passage of drill stem in order to prevent the well kick
or blowout when the pressure in well is higher than internal pressure of drill stem.
The IBOP consists of upper IBOP (remote) and lower IBOP (manual).The upper
IBOP (remote) connected with main shaft of power swivel, and lower IBOP (manual)
connected with saver sub which connected to drill pipe during drilling.
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Cut
casing
off
Locking device
Pretecting
connector
Locking
device
Locking
Cover
and
Manual BOP device Auto BOP fixing bolt
Fixing bolt
Rocker
assembly
arm
Main shaft
Support seat of
cylinder cut off
IBOP structure
Install the locking device between connectors to prevent the screw thread
between main shaft and IBOP connector from loosing during break out of top drive.
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Its structure is as
Bolt
Upper flange
Taper sleeve
Lower flange
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driller console. Cylinder support seat connects two groups of upper and lower
trolleys, the two groups of upper and lower trolleys touch edge of casing cutting off,
inner hexagonal rocker arm assembly which correspond to IBOP is embedded in
casing, and drive rocker arm assembly mechanism inside of casing cutting off rotate
to achieve cutting off of IBOP. The entire mechanism can switch IBOP on and off on
driller's console.
The cylinder push the IBOP sleeve upward, rotate the crank and rotating pin and
close the ball valve of IBOP when there is a electric signal from drill floor to the
IBOP return circuit of hydraulic control valve set, conversely, if the cylinder push the
IBOP sleeve downward, the ball valve of IBOP opened. The connecting bottom end
between cylinder and sleeve is contacting roller, so the rolling motion of sleeve which
rotated with main shaft and roller on the piston rod of cylinder can be guaranteed.
Cylinder
cutting off
Guiding rod
Retainer ring
Fixing bolt of
guiding rod
Drum
Grease Washer
nipple
Nut
Support seat
Casing
Drum shaft
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correct mode. IBOP cylinder should be checked frequently. It should be checked more
frequently after maintenance or after valves, sleeves and cranks are replaced. Oil
supply pressure of IBOP cylinder is adjusted to 40bar. Pressure is checked by
operating handle on valve block. Pressure can be displayed on pressure gauge in
hydraulic schematic diagram. Pressure can be adjusted by block valve of IBOP.
Steps of adjusting IBOP cylinder:
1) detach cylinder from suspension board;
2) detach sleeves and cranks from BOP;
3) open BOP by a hexagonal head wrench and be sure that BOP has been
opened;
4) place crank hexagon head in inner hexagon of IBOP;
5) supply pressure oil to cylinder so that piston rod is completely stretched out
before cylinder installation;
6) fix cylinder on suspension board with bolts after piston rod is completely
stretched out;
7) if plastic gasket on cylinder and cam sleeve contact or have 3-5mm interval,
position of cylinder is adjusted in place when opening blowout preventer valve; if
interval between the two is more than 5mm, bracket must be adjusted by rotating
piston rod of cylinder clockwise.
Caution
8) remove cylinder and sleeves/cranks, close BOP and make sure that the BOP
has been closed, and reinstall sleeves/cranks;
9) before cylinder installation, supply pressure oil to cylinder so that piston rod is
completely retracted;
10) reinstall cylinder;
11) if trolley contacts with flange end part of sleeve, adjustment of bracket and
cylinder is completed;
12) release pressure inside cylinder, install cylinder on suspension board;
13) operate IBOP cylinder on operating panel to open blowout preventer valve
and then retract plastic gasket/cylinder 5mm.
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If this distance is too small, wearing of plastic gasket will be caused during
drilling. If this distance is too large, trolley contacts with lower end of flange of
sleeve, it will close blowout preventer valve locally and the BOP is excessively worn.
When BOP is opened, plastic gasket and trolley must have proper interval with other
parts. When BOP is closed, trolley is always pressed at lower end of sleeve flange.
Steps of replacing protection joint and IBOP:
Method 1: use torque tong:
1) during breakout of protection joint with torque tong, install forceps holder
with an outer diameter of 6 5/8'' and tool joints with an outer diameter of 7 3/4'';
2) lift torque tong upward to needed height (about 220mm);
3) place torque tong mode switch at manual position on control panel;
4) break out twice;
5) screw off protection joint with hands;
6) install new protection joint and make up.
Method 2: use drill pipe tong;
1) take down four hydraulic quick connectors on oil block of torque tong;
2) remove torque tong from guide rod;
3) lower torque tong to drill floor;
4) retract guide rod if necessary;
5) break out with drill pipe tong; in order to detach cock and install IBOP or
intermediate joint, first remove IBOP sleeve and cylinder.
Caution
When free end of joint is not fixed on rotary table, do not use drill
pipe tongue.
Recommended makeup torque of IBOP and protection joint is 63000N.m
(47000ft.lbs).
Steps of detaching IBOP and cylinder:
1) pull out two pins, remove sleeve and open;
2) remove crank;
3) remove bolts on cylinder and then take off cylinder.
Under normal drilling condition and when main shaft rotates, do not
Caution
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Supporting
plate
Rotating
head
U bolt
Bail
Forerake
Dump ram
Hypsokinesis
Elevator
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ground forward tilting distance and maximum ground backward tilting distance are
related with length of elevator link.
Elevator link tilting device mainly comprises parts of tilting cylinder, cylinder
support plate, elevator link and elevator etc and whole mechanism moves under the
control of hydraulic mechanism.
Structure characteristics of elevator link tilting device are as follows:
1) Elevator link tilting cylinder and elevator link of top drive are connected by
elevator with convenient detachment and easy adjustment.
2) Elevator link tilting cylinder and elevator seat are connected by oscillating
bearing so that cylinder can oscillate in certain range while tilting, transverse distance
between elevator links is adjusted conveniently and service life of joint is greatly
increased.
3) Connecting pin of cylinder and rotating head and connecting pin of cylinder and
cylinder elevator are provided with oil passages, grease directly by grease gun, and
maintenance is convenient.
4.2.4 Backup tong
Backup tong is core component of pipe processing mechanism of top drive and
mainly completes clamping operation to pipes so that top drive can carry out makeup,
breakout, threading on and detachment of protection joint etc on pipes.
Backup tong mainly consists of suspension device, sliding part, alignment
system, clamp system and guide stabilizing part. Its structure is showed in following
drawing.
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Rear pillar
Transmission
shaft
Amendment
trolley
Movable
pillar
Backup tong
Guiding
cover
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pressure of hydraulic cylinder is released, tong dies on workholding jaw block return
as per primary route, main shaft of top drive rotates to retract and move upward to
complete breakout action.
Cylinder
Tong body
Cylinder
Installation
bolt of jaw
Die block
Jaw
Block bolt
Piston guiding
Movabledevice
pillar
PistonJaw
Pin
Bite
Right
cover
end
Fixing bolt
Fixing bolt
Installation
bolt of jaw
27
Fixing bolt
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Installation rib
plate
Suspension
bolt
Pillar cover
Butterfly
spring
Spring seat
Compression
spring
Cover bolt
Split pin
Suspension
bolt
Transmission
shaft
Suspension
bolt & nut
Rear pillar
Movable
pillar
Positioning
block
Pillar cover
Caliper Body
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Rotation
shaft
rib
Fixing bolt
Rib plate fixing
bolt
Backup tong
Rotation
head
Fixing bolt and
washer
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Amendment
shaft
Amendment
trolley
Support fixing
bolt
Fixing
seat
support
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Fixing bolt of
guiding cover Rubber
washer Locking nut
Fixing bolt of
installation seat
Adjusting
shaft
Guiding
cover
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Elevator link
Balance cylinder
Balance system
4.4 Guide rail and pulley
4.4.1 Guide rail
Guide rail adopts locking block automatic positioning single guide plate structure
with convenient installation and detachment. Guide rail is divided into 5 sections
totally, each section is about 7 m long, and the sections of guide rail are connected by
pins and positioned by locking core and locking block. Whole guide rail is in single
guide plate mode.
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along
guide
rail
when
carriage
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Pulley can be fixed on the first section of guide rail of folding single guide rail by 4
single-taper pins. After folding guide rail and top drive are installed on mast, take out
4 single-taper pins so that carrier can freely slide on guide rail. Installation of carrier
and guide is showed in following drawing.
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contravariant cabin, BU/MCC control cabin, 400V variable frequency power source
cabin, PLC cabin, outlet cabin, air condition, brake resistor, fluorescent lamp, house
cable and connectors etc, rectifier and inverter drive a set of 700kW AC variable
frequency motor, direct drive main shaft rotation to drill and make up.
The function is as following:
1 System is numerical control and variable frequency, digital operation control
system and peak torque output with 0 rotate speed.
2 Digital control technology is used; make VFD house and driller's cabin
achieve control signal, diagnostic message and digital transfer of
corresponding parameters.
3 Real time monitoring, direction for faults, warning and protection can be
achieved. During installation of inner components, use modular construction
easy for disassembling and installation to reduce maintenance time and
decrease system rate of closing down.
4 Use function of electronic control system to achieve real time monitoring
of top drive.
5 System has impeccable protection functions: max. torque set, electric
losing protecting, emergency stop of transmission system and so on.
4.5.2 Driller's control box
Driller's console has all operation functions needed for drilling and can set top drive
speed, rotating torque, operation mode and all auxiliary operations for drilling.
Driller's console is positive pressure explosion-proof EXpniaIIT4 and can be powered
on only when pressure of protective gas is normal.
All buttons and indicator lamps on panel of driller's console are showed in
following table
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A) Instrument
SN
1
Description
'Rotation
type
Measuring
Functions
Display actual rotation speed output by main
speed'
instrument
Measuring
0-250 r/min.
Display torque output by main shaft with
instrument
'Torque'
B) Potentiometer
SN
1
Description
'Makeup
type
Functions
Potentiometer Makeup torque limitation is set to be makeup
torque
limitation'
'Drilling
torque
limitation'
'Rotation
speed setting'
C) Operation device
SN
Description
type
Functions
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'Working
Lighting-free
mode'
switch
standard
'Balance
black handle
Lighting-free
system'
Breakout
and
jump
switch.
During
'HPU motor'
handle.
Lighting-free
with
standard black
4
'Main motor'
handle
Lighting-free
'Disc brake'
Lighting-free
switch
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IBOP
handle
Lighting-free
position.
Cooperate with running signal of mud
switch
valve.
'Rotation
handle
Lighting-free
motor'
3-position
double
automatic
resetting
option
with
8
'Backup tong'
switch
standard
black handle.
Planar
red Backup tong engagement button, press the
momentary
button
manipulator
and breakout.
with lighting
'Elevator link Lighting-free
Elevator
tilt'
3-position
double
at 'STOP' position.
link
tilting
switch.
Retract
automatic
resetting
option
with
10
'Suspension'
switch
standard
black handle.
Lighting-free
planar
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green down,
backward
tilting
elevator
link
'System
manipulator
Emergency
emergency
stop
stop'
manipulator
12
'failure
Lighting-free
resetting'
planar
momentary
button
manipulator
D) Indicator
SN
1
Description
type
'Air pressure Green
Functions
When main motor air pressure losing alarm
signal'
indicator lamp
maintenance man
When pressure of top drive backup tong is
clamping'
indicator lamp
4
5
lamp
turned on.
indicator When pressure inside operation box is
relatively low, pressure switch acts and
indicator lamp is turned on
indicator See 5.5.10 failures and alarm for details.
'Failure'
Red
'IBOP
lamp
Red indicator When IBOP is closed, the lamp is turned
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closing'
lamp
on.
'Disc brake Red indicator When brake works, the lamp is turned on.
closing'
4.5.3 External cables
lamp
Top drive external cables mainly comprise top drive main motor cable, top drive
auxiliary power supply cable, top drive control cable, 600VAC inlet cable and driller's
control cable.
A) Main motor cable of top drive
Main motor cable is used for connecting variable-frequency output of top drive
electric control room to main motor at upper part of top drive.
In order to be convenient for field installation and connection, cable is divided into
three sections
1
The first section is ground cable (option) from electric control room to mast
bottom with a length of 30 meters (100 feet). A, B and C phases adopt 646MCM
cables and ground wire adopts 444MCM cable.
The second section is vertical cable from mast bottom to guide wheel bracket at
upper part of mast. The second section of cable is processed by special process
and plastically packaged by outer sheath. Sheath is 41 meters (135 feet) long;
there is no flange on side of mast bottom; extension length of cable is 7.5 meters
(25feet); there is flange on side of guide wheel bracket; extension length of cable
is 1.2 meters (4 feet); and two ends have plugs and sockets.
The third section is travelling cable from guide wheel bracket of mast to top drive
body. The third section of cable is processed by special process and plastically
packaged by outer sheath. Sheath is 26 meters (86 feet) long; there is flange on
side of guide wheel bracket; extension length of cable is 1.2 meters (4 feet); there
is flange on side of top drive body; extension length of cable is 1 meter (3 feet);
and two ends have plugs and sockets.
Three sections of cables, main power cable and top drive body, and main power cable
and top drive electric control room are all connected quickly by connector with
convenient field operation.
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The first section is ground cable (option) from electric control room to mast
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44
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45
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more than set value, display screen alarms or oil pump stop. Pressure control of the
complete set of system uses accumulator reaction unloading valve to achieve
hydraulic pressure unloading. When system pressure is up to the setting pressure of
reaction valve 18, reverse spool and unload main pump; when system pressure is
lower than set value of valve 18, add pressur to main pump and provide pressure oil to
accumulator and executive component. Pressure sensor 20 can display system
pressure on screen for driller observing. Pressure switch 10 can detect service
condition of oil return filter. When oil return filter is blocked, pressure switch detects
pressure rise, and alarm lamp of driller's cabin prompts to change filter.
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system is always in pressurizing state under above two working condition and is used
for maintaining stable oil pressure and compensating leakage.
If move mode change valve 20 to right position, or put it in shut-off working
condition, and accumulator releases pressure. Hook bears full weight of top drive, so
two ends of balance cylinder are low pressure.
Relief valve 28 is used for limiting its max. pressure at the two ends of rod
chamber to avoid HP in rod chamber when oil return is blocked. Its pressure can be
tested by pressure test connector 16.3, and
Schemetic
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4. BOP: when the electromagnet c04 of the electromagnetic reversing valve 27.2 is
not powered, BOP is in open state, the time-delay accumulator 36 releases pressure, nonrod end chamber of BOP is maintained under high pressure always; and the pressure is
spring set value of the pressure reduction valve 30.2.
If the electromagnet c04 is powered on, BOP is closed, and the time-delay
accumulator 36 is pressurized. When it needs to open the BOP, the electromagnet c04 is
power off, the BOP cylinder becomes a differential cylinder due to the action of the logic
valve 35, the BOP can be not only quickly opened and also act under a relatively high
pressure as the spring cavity of the pressure reduction valve 30.2 is filled with pressure
oil. The pressure oil in spring cavity of the pressure reduction valve 30.2 is provided by
the time-delay accumulator 36. The liquid oil pressure in the accumulator is delayed for
certain time and then increased to the atmospheric pressure due to the action of throttle
holes of check throttle valve. Therefore, pressure in non-rod end chamber of BOP
cylinder is also delayed for the same time and then decreased to spring set value of the
pressure reduction valve is 30.2. System pressure can be measured at the pressure test
point 16.7. Its schematic diagram is showed as follows:
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pressure reduction valve 22.2. Thus, the liquid oil flow entering the rotating head motor
46 is not influenced by the variation of motor load. The relief valves 45.1 and 45.2 are
respectively arranged at two oil ports of the motor 46. On the one hand, the highest
pressure of motor inlet is limited; one the other hand, counterbalance valve as motor
outlet limits rise of outlet pressure caused by inertial rotation of electromagnetic
directional valve 38.2, motor can firstly fast stop during reversing.
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valves, the major function of balanced valve is to make the elevator link stop at any
position instead of sliding because of action of gravity. Electromagnetic directional valve
27.3 is suspending action electromagnetic valve, when the electromagnet c12 is out of
energization, hydraulic control ends of two hydraulic control one-way valves 39.1 and
39.2 lead to oil return, and rod chamber of elevator link tilting cylinder does not lead to
oil return; when it is powered on, suspending function is opened, the pressure oil opens
the hydraulic control one-way valve through change valve, oil in rod chamber of two
tilting cylinders flow back to oil tank via port XT through hydraulic control one-way
valve, and then tilting cylinder goes back to position by its dead weight, the suspending is
achieved.
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5 Operating instructions
The trained personnel with corresponding qualification and experience are allowed to
use top drive device and should read this operation manual and related technical
documentations before operation.
5.1 Check before startup
All personnel engaged in operation of top drive should be trained for drilling
operation and drilling safety knowledge and use protection articles of gloves and clothing
etc.
Refer to 'installation and commissioning instruction book of top drive'
Note
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Startup and stop of top drive HPU heater: start up heater when oil temperature of top
drive HPU is lower than 15 DEG C and automatically stop heater when oil temperature
of top drive HPU is higher than 30 DEG C.
Operation procedures of hydraulic system at driller's control cabinet are as follows:
1) Push HPU motor switch to 'startup' position to start up HPU motor.
2) Push HPU motor switch to automatic' position to start up and stop HPU motor by
PLC program.
3) Generally, push HPU motor switch to 'automatic' position.
5.4 Driller console control
5.4.1 Drilling mode
Start the system properly before operation. System state after start the system properly
are shown below
position
driller console
press-button or switch
HPU motor
status
Auto
Disc brake
Rotatable motor
Tilting elevator link
IBOP
Operating mode
traction motor
Auto
stop
stop
open
drilling
stop
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Warning: check the braking condition and the limit value of drilling torque for correction
between the time the traction motor has been started and the rotation speed has not been
set. Increase the limitative drilling torque value which should not be set too high after
start the traction motor.
5.4.2 Reversal operation under drilling mode
Normally, reversal operation under drilling mode is not allowed, but the top drive
device provides reversal drilling operation to deal with some complex working
conditions, then some simple settings on the HMI are needed.
Start the system properly before do the reversal operation. The system states are shown
below.
position
driller console
press-button or switch
HPU motor
status
Auto
Disc brake
Auto
Rotatable motor
stop
Tilting elevator link
stop
IBOP
open
Operating mode
drilling
traction motor
stop
make up torque limit
zero
Drilling torque limit
zero
Rotary speed setting
zero
Carry out the following steps after make sure the system is in correct states:
1 Spin off the wheel handle drilling torque limit slowly from zero to the needed
torque value
2Turn the switch traction motor to the position backward
3Spin off the wheel handle rotary speed setting slowly from zero to the needed
torque value, The traction motor rotates backward at a given rotary speed.
Warning: pay attention to the set value of drilling torque during using the reversing
function under drilling mode and to avoid drill pipe broken.
5.4.3 Make up/ break out operation
Started the system properly before perform the make-up or break-out operation .The
system states are shown below:
position
press-button or switch
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status
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HPU motor
Auto
Disc brake
Rotary table motor
Tilting elevator link
IBOP
Operating mode
traction motor
Auto
stop
stop
open
drilling
stop
zero
zero
zero
the system is really
in correct state.
5.4.3.1 Make up operation
The connection between drilling tool joint and main shaft of top drive should be
greased with antiseize thread dope when perform the make-up operation
There are two ways of the make-up operation.
1The first method is to use backup tong to do the make-up operation: clamp the
upper joint of the stand (or single) with the backup tong, make the connection between
main shaft of top drive and the upper of the stand (or single pipe) tight through the
driving force of top drive. The backup tong will bear the make-up torque.
The operation steps are as follows
(1)Firstly, make sure all console switches, wheel handles and all indicator lights of
the drillers console are normal. Then make sure the HPU has been started.
(2)Operate the switch operating mode to the position drilling
(3)Operate the switch traction motor to the position forward.
(4) Inspect whether the disc brake is in good condition after the top drive motor is
started .turn the switch operating mode to the position thread on after the disc brake
is released. Then the main shaft of top drive rotates at 10rpm and lower the travelling
block slowly at the same time to make the upper joint of the stand (or single) enter into
backup tong and stab with the main shaft of top drive. Continue to lower the top drive to
make the main shaft of top drive screw in the upper joint of the stand (or single), then the
top drive is in forward working condition. The driller can observe the rotation situation of
main shaft, the main shaft stop rotating which means the pre-set make-up torque has been
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is away from the switch operating mode and the right hand releases the switch backup
tong, then the make-up operation has been completed.
Return the wheel handle rotary speed setting to the zero-position
So far, the make-up operation has been finished and the connection between main shaft of
top drive and the upper end of the stand (or single), the connection among each section of
the stand, the connection between the lower the stand (or single) and the drill string in the
well have been tightened.
Warning: the rotating head must be locked before do the make-up operation
Do operate the wheel handle rotary speed setting slowly and steadily to avoid the
attached impact torque when make up
Note: this method can tighten the connection between main shaft of top drive and the
upper end of the stand (or single), the connection among each section of the stand, the
connection between the lower the stand (or single) and the drill string in the well for the
first time. It is operated simply and effective to improve the working efficiency, so it is
recommended to the following working conditions: to connect pipe the stand (or single
joint) for drilling operation, to ream for tripping out operation and so on
5.5.3.2 Break out
(1)Firstly, make sure all console switches, wheel handles and all indicator lights of the
drillers console are normal. Then make sure the HPU has been started.
(2)Turn the switch operating mode to the position drilling
(3)Turn the switch traction motor to the position backward
(4) Operate the handle wheel to set the maximum break out torque valve which should be
greater than the maximum make up torque valve.
(5) Press and hold the button backup tong and the indicator light backup tong clamp
is on , then the backup tong grips the drilling tool joint. Turn the switch operating mode
to the position torque
(6) The driller should observe the value on the torque gauge or the state of the main shaft
of the top drive which starts to rotate when the break out torque is greater than the makeup torque. When the break out torque valve drops to the small valve suddenly that means
right now the connection has been loosened.
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(7) Turn the switch operating mode to be in the drilling mode and release the button
backup tongat the same time , then the indicator light backup tong clamp goes out
which means the backup tong is loosening the drilling tool joint. Main shaft of top drive
starts to thread on backward evenly. At the same time the driller starts to lift the traveling
block slowly to make the main shaft of top drive removed from the drilling tool joint
gradually.
(8) Turn the switch operating mode to the position drilling when then drill string
joint is loosened completely. Then the traction motor of top drive stops rotating.
(9) Turn the switch traction motor to the position stop and stop lifting the traveling
block.
So far, the break out operation has been completed, so all the switches and the wheel
handles should be returned to original position
Note: The backup tong should be loosened when the locking operation has been
completed, otherwise the backup tong will bear the total weight of drilling tool when the
traveling block is hoisted and it is possible to cause damage to the equipment or personal
injury
5.4.4 Backup tong operation
The actual rotation speed of top drive is less than 1rpm in drilling or thread on mode and
the button backup tong cannot be operated unless the rotating head is on the state of
ceasing. The backup tong still keeps the state of clamping even through the switch
operating mode is switched to torque mode. The pressure of top drive backup tong is
greater than 10MPa which means the top drive backup tong clamps and the indicator light
backup tong clamp will be on
5.4.5 Rotating head operation
The rotating head is interlocked with elevator link which means they can be operated at
the same time. The rotating head cannot be operated until elevator link suspends for
3seconds (that is, 3 seconds after Press and hold the button of elevator link suspension),
otherwise the rotating head cannot be rotated. Rotating head lockpin operation: the
rotating head lockpin can only move when the backup tong clamps. The rotating head can
keep still during makeup/break out the drill pipe by using the backup tong button to
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the state of neutral which means the elevator link is free when hoist the overweight
objects such as drilling collar.
5.4.7 IBOP operation
The IBOP can be controlled by the switch IBOP when the top drive is in the stationary
state.
When the emergencies such as blowout occur, it will enter into a state of well control, and
the system will do the following operations
1
2Stop the mud pups (the top drive is interlocked with the mud pumps)
3Stop driving device rapidly
4Close the IBOP
Perform the following operation immediately after it has been in a state of well control.
1 Spin off the wheel handle rotary speed setting to the zero position, turn the
switch traction motor to the position stop and turn the switch operating
mode to the position drilling.
2 Eliminate the emergencies and affirm the system can alarm without fault
3 Press the button fault reset on the drillers console to make the loudspeaker
silent.
Lock the IBOP in the position OFF by the locking key switch on the PLC cabinet
to ensure the cable in the well will not be pinched off by the IBOP during well logging.
Note: Note: be sure to turn the switch IBOP to the position OFF to prevent the cable
in the well from being pinched off during logging.
5.4.8 Emergency stop operation
The operator can press any button system emergency stop nearby to make all
equipment for top drive system stop rapidly when the system is in emergency.
The following steps have to be done immediately after the button system emergency
stop has been pressed.
1 Spin off the wheel handle rotary speed to the zero position , turn the switch
traction motor to the position stop, operate the switch operating mode to the
position drilling
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Eliminate the emergencies and affirm the system can alarm without faults.
Press the button system emergency stop to be back to the reset position
Press the switch fault reset of the driller console to make the buzzer silent
Press the button start on the rectifying cabinet to restart the top drive.
5.4.9 Faults and alarm
1Air pressure alarm of top drive: if the top drive motor starts and the air pressure
signal cannot be received in 10 seconds, then the air pressure alarm signal will be
transmitted. If the blower has a fault during the top drive motor running and the air
pressure signal is lost over 10 seconds, then the absent air pressure alarm signal will be
transmitted. The alarm information lasts 10 seconds on HMI, afterward the alarm signal
will disappear.
2Oil pressure alarm of top drive: if the top drive motor starts and the oil pressure
signal cannot be received in 5 seconds, then the oil pressure alarm signal will be
transmitted. If the oil pump has a fault during the top drive motor running and the air
pressure signal is lost over 5 seconds, then the absent air alarm signal will be transmitted.
The alarm information lasts 10 seconds on HM I, afterward the alarm signal will
disappear.
3If the elevator link stretches out and the hook height is over 19.5m and then the
alarm signal will be transmitted and the travelling block cannot move upward.
4Turn off the IBOP of the top drive to alarm and prompt to pay attention to the
pump stroke setting.
5If the HPU liquid level for top drive is under 150mm and then the alarm signal
will be transmitted. If the HPU liquid level for top drive is 560mm above and then the
alarm signal will be transmitted.
6If the HPU oil temperature for top drive is under 80 and then the fault signal
will be transmitted. If the HPU oil temperature for top drive is 70 above or 15 below
and then the alarm signal will be transmitted.
7 Frequency converter of top drive, coder, lock out switch and communicating
faults alarm
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When the coder of traction motor is damaged or out of order which means the
top drive has to be braked and the rotation speed is back to zero, the HMI will show its
alarm signal. Right now turn the rotation speed setting to the original position firstly
and turn the switch traction motor to the position stop to make the top drive enable.
2
Turn the switch coder switch on the control cabinet of top drive electric
control room from the position normal to by pass, do open-loop control by utilizing
the computation speed signal of coder
Turn the switch coder switch from the position by pass to normal as per the above
operations after the coder is replaced or in order, then the system will be back to normal
and do the open-loop control.
6 Drilling steps
6.1 Tripping in /out
Adopt the conventional method by using the pipe handler to trip in, this method is in
favor of relieving the labor force and improving the efficiency.
6.1.1 Tripping out
1Loosen the connection between saver sub and drilling pipe, then hoist the top drive,
operate the switch elevator link suspension to the position neutral(right now the
elevator link is backward),use the elevator to grip the drill string joint when the elevator
link moves to be neutral
2Lift the top drive to monkey board above, place the slip and lower the top drive
3Use the hydraulic tong /iron roughneck to break out
4 Lift the top drive and operate the switch tilting elevator link to make the
elevator link forward; The derrickman should open the slip and put the lifted the stand
into setback when the elevator is near to monkey board.
5) Operate the switch elevator link suspension to the position neutral, lower the top
drive to the drill string which will be gripped with the elevator.
6Repeat the steps 2-5
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6.1.2 Dripping in
1 Lift the top drive to the monkey board and operate the switch rotatable motor to
make the inclined arm of elevator link rotate to the location the derrickman on the
monkey board need.
2Operate the switch tilting elevator link to the position forward to approach
elevator to the location where the drilling pipe will be racked through monkey board.
Then the derrickman should put the the stand into the elevator which should be fastened
tightly subsequently
3Firstly turn the switch tilting elevator link to the position backward, operate
the switch elevator link suspension to the position neutral after the elevator link is
back to the wellbore center, then the tilt cylinder is in a floating state.
4 Lift the top drive and the lifted stand returns to the neutral position. The
derrickman should pull the lower end of the stand with rope and release it slowly, lest
damage of drilling pipe joint during this process.
5 Lower the travelling block and stab the lifted lower end of the stand with the
upper end of drill string on the drilling floor, then use the hydraulic tong/iron roughneck
to make-up
6Lift the top drive and pull the slip out; lower the top drive to the upper end of the
stand which should be approached to drilling floor, place the slip and make the drill string
gripped by the slip firmly.
7loosen the elevator, operate the switch tilting elevator link to make the elevator
link backward a bit and removed from drilling string. Lift the top drive to the monkey
board
Repeat the above steps
Note: use the motor of top drive to connect the saver sub and drill string at the height of
mast and establish circulation and turn drilling tool to make the drilling tool pass the
blockup position if the hole shrinkage or key way occurs during dripping in /out.
6.2 Drilling work condition
1 Turn the wheel handle rotary speed setting to the zero position, turn the switch
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operating mode to the position drilling and turn the switch traction motor to the
position forward
2Spin off the switch drilling torque limit slowly from zero to the needed torque
value
3 Spin off the switch rotary speed setting from zero and the main shaft of top
drive rotates forward at given rotary speed.
Note: the blockup phenomenon occurs when the load torque in well is greater than the
pre-set one. The top drive has two methods for solving the blcokup:
A. keep the wheel handle rotary speed setting and disc brake still, ensure the traction
motor can output torque continually, reduce the limitative torque value which is set by the
wheel handle drilling torque limit slowly to make the output torque reduced slowly, the
drilling rotates slowly reversely until the pre-set limitative torque value is zero and its
reversal speed is zero. Loosen the handle and lift the drilling tool
B. keep the wheel handle drilling torque limit still, return the wheel handle rotary
speed setting to the zero position ,the motor stops output and then the system brakes.
The switches operating mode and traction motor remain still and then the drilling
tool starts to rotate reversely, the driller should turn the switch disc brake to the
position brake at the right time as per the reverse speed to ensure drilling tool joint
cannot be removed; Repeat the above braking processes until the reversal speed of
drilling tool declines to zero. Loosen the handle and lift the drilling tool
The recommended method is A, because the method B is subject to the effects of driller
skills and braking performance, so it is only available when the top drive is out of
condition.
Warning: the drilling tool has the ditching risk when solve the blcokup. The control of
Reversal speed of drilling tool should be in strict accordance with operating rules in case
of an accident.
4 Return the wheel handle rotary speed setting to the zero position when the
system is in drilling mode and needed to stop normally, then the device will stop
normally at a reduced speed. If the switch disc brake is in position auto, the button
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disc brake will be linked to the movement of the top drive motor. The button disc
brake will release when the top drive motor is started, the button disc brake will
execute the brake order when the top drive motor is stopped.
6.2.1 Single drilling
1Place the slip, stop the circulated mud fluid and turn off the IBOP
2Do the break out operation with backup tong as per the steps in the chapter5
3Lift the top drive a bit to make the elevator removed from the drill string joint
4Lean the elevator link to the mouse hole and use the elevator to grip the single
joint
5Lift out the single from mouse hole, turn the switch elevator link suspension to
be neutral, right now move the single to the wellhead center
6Lower the top drive and stab the connection at the top and bottom of the stand
respectively.
7Use the top drive to thread on and make up as per the steps in chapter5
8Lift out the slip, open the IBOP and circulate the mud fluid
6.2.2 Stand drilling
1Place the slip, stop circulating the mud fluid and turn off the IBOP
2Do the break out operation by backup tong as per the steps in the chapter5
3Lift the top drive to make the elevator removed from drill string joint, operate the
elevator link inline mechanism to approach the elevator link to the derrickman when the
top drive is lifted to the monkey board
4The derrickman uses the elevator to grip the stand and turns the switch elevator
link suspension to make the elevator neutral
5Lower the top drive and stab the connections at the top and bottom of the stand
respectively.
6Use the top drive to thread on and make up as per the steps in chapter5
7Lift the slip out, open the IBOP and open the mud pump to circulate the mud fluid
6.3 Back reaming
Connect the drill string and main shaft of top drive and circulate the mud fluid
immediately when the sticking occurs during dripping out. Reaming while lifting to
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6Open the elevator and lean the elevator link to grip the new casing.
7Repeat the above steps.
6.5 Well control
The upper remote IBOP which is always in the ready state is usable immediately once the
kick occurs. The bottom IBOP which only can be operated by spanner is always installed
onto the drill string, so at least one BOP is available.
Below are the well control steps during dripping in /out:
1 Place the slip immediately and stab the main shaft of top drive and drill string
when there is kick in the drill string
2Use the motor of top drive and backup tong to make up.
3 Turn off the upper remote IBOP, the driller should turn off the bottom IBOP
manually if the upper remote IBOP is not available,
Install the check valves and well control attachments which are needed during in the
normal well control process onto drill string by the IBOP.
Below are the steps to installing the check valves to drilling string:
1 Lower the drill string to drilling floor and place the slip
2 Turn off the bottom IBOP manually
3 Remove the bottom IBOP and saver sub from the top drive by hydraulic tong
4 Install the adapter, check valve or circulating sub onto the upper IBOP
Perform the normal well control steps.
6.6 Jarring
The jar use has impact to the top drive, but the extent is hard to assess because of the
uncertainty of jarring (it changes along with well depth, the drill string, neutral point and
the jar types) and the difference of every well.
Warning: The surface bumper sub is not available on any account; otherwise the top drive
will be damaged.
Check the top drive after every jarring, below are the check items:
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Check all the connections between cables and rubber, reconnect them if
loose.
5 Check whether all the guards and cover plates get loose.
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