HH 350 B - Hydraulic Rotary Drilling Rig: Index

HH 350 B - HYDRAULIC ROTARY DRILLING RIG
INDEX
RIG’S LAYOUT Pag. 3 SERVICE JIB CRANE:

- Main features ………………..………………….………………………………………. Pag. 42
GENERAL DESCRIPTION:
- Safety systems ……..………………………….…........................………………. Pag. 43
- Main features ……………………………………….…………………............……. Pag. 4
- Rig orientation …………….……………………………………………………………. Pag. 4 DRILL FLOOR EQUIPMENT:
- Main components terminology ………………………………………………… Pag. 5 - Rotary table ..……………………………...............………………….……………… Pag. 44
- Rig dimensions and weights in working configuration …………….. Pag. 7 - Automatic slips ..……………..…………. ..............……………….……………… Pag. 44
- Rig dimensions and weights in transport configuration .……..….. Pag. 8 - Mouse hole ………………………………………………………………………………. Pag. 45
- Pipe handler with service jib crane dimensions and weights in - Bit breaker tong ………………………………………………..……………………… Pag. 46
transport configuration …………………………………………………………… Pag. 9 - BOP handling system ………………………………………………………………… Pag. 47
- Rig and mast handling system ……………………..………………………….. Pag. 10
CONTROL PANEL:
RIG-UP SEQUENCE: - Complete panel ………………..…......................................................... Pag. 48
- Drilling rig rig-up sequence ……………….........………………………………. Pag. 11 - End left side panel .……………………………………………………………………. Pag. 49
- Pipe handler rig-up sequence …..……...............................…………… Pag. 23 - PCR HMI ……………………………………………………………………………………. Pag. 50
MAIN HYDRAULIC POWER UNIT: - Left side panel …………..............................................……………………. Pag. 51
- Main components terminology …………....…………………………………. Pag. 27 - Gauges on left side panel.............................………………………….…… Pag. 52
- Main components description ………...............................…………… Pag. 28 - Central side panel ……………………………………………………………….…….. Pag. 53
- Simplified hydraulic scheme ..………………………………………………….. Pag. 30 - Right side panel ............................................……………………….…….. Pag. 54
- Description of simplified hydraulic scheme…………………….……….. Pag. 31 - Gauges on right side panel ……...................................………….…..... Pag. 55
- End right side panel .................………………..………………………….…….. Pag. 56
AUXILIARY HYDRAULIC POWER UNIT: Pag. 32 - Pipe handler control panel …………...................................…….…….. Pag. 57
- Pipe handler HMI ………………………………...……….............................. Pag. 58
MAST:
- Pipe handler remote radio control …………..………..............…………. Pag. 59
- Main features ……………...………………….………………………………………. Pag. 33
- Hydraulic Power Unit HMI ………………………………………………………… Pag. 60
- Main components terminology ……..…........................………………. Pag. 34
- General description …………………………...……….…………………………… Pag. 35 OPERATIONS DESCRIPTION Pag. 61
HYDRAULIC HOISTING CYLINDER: SAFETY DEVICES:
- Introduction ………………...………………….………………………………………. Pag. 36 - Safety devices placement .………...............………………….……………… Pag. 62
- First speed ……………………………………..…........................………………. Pag. 37 - Safety devices description ..………................……………….……………… Pag. 63
- Second speed ………..…………………………...……….…………………………… Pag. 38
- Third speed …….……………………………..…........................………………. Pag. 39 TOP DRIVE:
- Fourth speed ………..…………………………...……….…………………………… Pag. 40 - Main components terminology …………….…………………………………… Pag. 65
CROWN BLOCK Pag. 41 - Main components description …….…….…..............………………………. Pag. 66
1
INDEX
- Dolly ..…………………………………..………...…………………………………......... Pag. 67

- General description ..……….………………………………………………………… Pag. 68
- Sections ..……………………………..……....................………………………….. Pag. 69
- Sections description …………………………………………………………………. Pag. 70
- Lubrication ….……………………………………………………………………………. Pag. 71
- Performances ….………………………………………………………………………… Pag. 72
- Air compensators …….………………………………………………………………… Pag. 73
- Double hook ….…………………………………………………………………………… Pag. 76
TORQUE WRENCH:
- General description .………..............……………………………………………. Pag. 77
- Main components terminology ………..………......…………………………. Pag. 78
- Functioning …….….…………………………………………….………………………. Pag. 79
- Torque adjustment ..….…………………………………………………………….. Pag. 80
- Clamps rotation cylinders ..………………………………………………………. Pag. 81
POWER TONG:
- Main components ….……..........................…………………………………. Pag. 82
- General description ………………….……...............................…………… Pag. 83
- Hunger assy …………………………………………………………………………….. Pag. 84
- Mud saver bucket ……………………………………………………………………. Pag. 85
CASING DEVICE:
- Main features ……………………………………….…………………............……. Pag. 86
- Preparation to installation ………..……………………………………….……. Pag. 87
- Installation .. ………………………………………..…………………………………… Pag. 88
- Description ……………………………………………………………..……………….. Pag. 90
- Functioning …….………………………………………………………………………… Pag. 91
- Operations ……………………….……………………………………………………… Pag. 92
- Maintenance.. ………………….……………………………………………………… Pag. 93
- Dismantling ..…………………….…………………………………………………….. Pag. 93
2
RIG’S LAYOUT
3
GENERAL DESCRIPTION
MAIN FEATURES RIG ORIENTATION

DRILLMEC hydraulic rotary drilling rig HH 350 B (booster) type "fast moving",
with automatic drill pipes handling system, vertical pipe storage, trailer
mounted, is designed for drilling and work over operations of oil and gas wells.
The rig is designed in accordance with API specifications and all construction is
realized in accordance with API recommended standards governing fabrication,
welding, coating, storage, etc. of land drilling rig.
The electric equipment of the drilling rig is designed to satisfy the requirements
of API RP 500 – Class 1 - Division 1 (3m / 10 ft) radius around center well.
MAIN TECHNICAL DATA
DRILL PIPE STANDS HANDLING: Range 3 – single stand
DRILL PIPES STORAGE CAPACITY: 3627 m - (11.900 ft)
TOTAL POWER INSTALLED: 1150 kW - (1542 HP)
MAX. PULL: 317 MT - (350 short tons - 700.000 lbs)
MAX. PULL DOWN: 30 MT - (66.000 lbs)
MAX. HOISTING SPEED: 1,35 m/sec (with 100% efficiency)
TOP DRIVE STROKE: 16,6 m - (54,46 ft)
MAX. TOP DRIVE TORQUE: 4.910 daN∙m - (36.200 lbs∙ft)

7,71 m (25 ft) – from ground level
DRILLING FLOOR HEIGHT:
6,74 m (22 ft) – under rotary beams
TEMPERATURE RANGE: - 20°C + 40°C - (- 4 °F + 104°F)
4
GENERAL DESCRIPTION
MAIN COMPONENTS TERMINOLOGY MUD MANIFOLD
CROWN BLOCK
TOP DRIVE
POWER TONG TELESCOPIC MAST

DOUBLE HOOK
SUPPORT SECTION
IBOP VALVE
POWER TONG TOP DRIVE
CASING DEVICE
DRILL PIPES
AUTOMATIC SLIPS
CASING ELEVATOR
FIX MAST SECTION
TORQUE WRENCH
DRILL FLOOR
PIPE HANDLER GROUP
WITH SERVICE CRANE
MAST RAISING OUTRIGGERS
DOG HOUSE
DRILLFLOOR
OUTRIGGERS DRILL PIPES CONTAINERS
RIG SEMITRAILER
WALK WAY - HAND RAILS
HYDRAULIC POWER
UNIT (H.P.U.)
SUBSTRUCTURE STIFFEN BRACES BOP BASE PIPE AND CASING RACK GROUP
5
GENERAL DESCRIPTION
MAIN COMPONENTS TERMINOLOGY
RIG UP CONTROL PANEL
WORK SHOP
JIB CRANE CONTROL PANEL

AUXILIARY HYDRAULIC POWER UNIT
SUBSTRUCTURE TRAILER
CONTAINERS STAND
DRILL PIPE
TRAILER RAMP CONTAINERS
HYDRAULIC POWER UNIT DOG HOUSE

(H.P.U.)
STAIR WITH
DRILLING FLOOR MUD
HAND RAILS
MANIFOLD
ROTARY TABLE
DRILL PIPE AUTOMATIC POWER SLIP
6
GENERAL DESCRIPTION
DRILLING RIG DIMENSIONS IN WORKING CONFIGURATION
REMARKS: ALL DIMENSIONS SHOWN ARE IN MILLIMETERS
7
GENERAL DESCRIPTION
DRILLING RIG DIMENSIONS IN TRANSPORT CONFIGURATION
24 Ton 15.5 Ton 15.5 Ton

15.5 Ton 15.5 Ton
EXTIMATED TOTAL WEIGHT IN TRANSPORT CONDITION: 86 TON
REMARKS: IN TRANSPORT CONFIGURATION THE MAXIMUM ADMITTED WIND SPEED IS 130 km/h
IN TRANSPORT CONFIGURATION THE MAXIMUM ALLOWED SPEED IS 50 km/h
ALL DIMENSIONS SHOWN ARE IN MILLIMETERS 8
GENERAL DESCRIPTION
PIPE HANDLER DIMENSIONS IN TRANSPORT CONFIGURATION
EXTIMATED TOTAL WEIGHT IN TRANSPORT CONDITION: 38,8 TON
REMARKS: IN TRANSPORT CONFIGURATION THE MAXIMUM ADMITTED WIND SPEED IS 130 km/h
IN TRANSPORT CONFIGURATION THE MAXIMUM ALLOWED SPEED IS 50 km/h
ALL DIMENSIONS SHOWN ARE IN MILLIMETERS
9
GENERAL DESCRIPTION
RIG AND MAST HANDLING SYSTEM
BALANCING BEAM
LIFTING BEAM BRACKET
LIFTING BEAM
The drilling rig weights 86 MT. On the race side a special beam is installed. On the back side there are some pinned brackets, on the
top housing of the stabilizers. A special balancing beam is installed on the front of the lifting cables (race side).
To install and remove the mast, use two lifting points. In the rear side with a rope pinned to apposite ears, in the front side by
means of lifting bands.
10
RIG UP SEQUENCE
PHASE 1: PHASE 2:
- Place the intermediate skid to 1680 mm from the well center. - Position and pinning skids connection frames.
INTERMEDIATE SKID
INTERMEDIATE SKID
CONNECTION
FRAME
CONNECTION
FRAME
11
RIG UP SEQUENCE
PHASE 3: PHASE 4:
- Place rear skid (mouse hole skid) and pinning with skid connection frame. - Place and pin:
• Trailer base skid;
• Work shop and dog house pillar support frames.
FRAME PILLAR
WORK SHOP
(MOUSE HOLE SKID)
REAR SKID
SKID BASE TRAILER
SKID BASE TRAILER
FRAME PILLAR
DOG HOUSE
12
RIG UP SEQUENCE
PHASE 5:
- Place and pinning:
• Telescopic braces skid;
• Trailer ramps;
• Trailer ramp connection frames;
• Hydraulic power unit (HPU) positioning frame;
• BOP dolly.
TELESCOPIC BRACES
SKID
TRAILER RAMP
CONNECTION FRAMES
TRAILER RAMP
HPU POSITIONING FRAME
BOP DOLLY
13
RIG UP SEQUENCE
PHASE 6:
- Place and pin:
• Pipe handler support skid;
• Upper skid;
• Front skid.
PIPE HANDLER SUPPORT SKID
FRONT SKID
UPPER SKID
14
RIG UP SEQUENCE
PHASE 7:
- Place the rig on the appropriate ramp and make sure that the rear wheels are in contact with the mechanical stop. So doing it you are sure that the axis of the
stabilizers will be perfectly aligned with the appropriate housing placed on the substructure.
- Disconnect the truck from the trailer as follow procedure:
• Connect the hydraulic power unit (24 V) to the truck battery by means electric plug;
• Press the button neat to it and simultaneously you have to controlled the levers for go up or down with parking outriggers;
• Disconnect truck battery and remove it;
WELL CENTER
PARKING HYDRAULIC JACK
OIL PRESSURE GAUGE LEVER TO ACTIVATE PARKING

HYDRAULIC JACK
CONNECTION WITH TRUCK
BATTERY (24 V)
VISUAL OIL LEVEL INDICATOR
EMERGENCY HAND PUMP

PUSH BUTTON TO ACTIVATE
ELECTRIC PUMP
OIL TANK
15
RIG UP SEQUENCE
PHASE 8:
- Assemble the four lifting cylinder of semitrailer rig.
- Effectuate the hydraulic connection between semitrailer rig hydraulic cylinders – auxiliary HPU.
- Connect the auxiliary HPU to the generator and start it.
WELL CENTER
MOUNTIG OF HYDRAULIC CYLINDERS
HYDRAULIC CONNECTIONS
AUXILIARY HPU
16
RIG UP SEQUENCE
PHASE 9:
HYDRAULIC STABILIZERS OIL PRESSURE GAUGE
- Lower the four outriggers up to catch the proper housings on base skid, it's
possible to use the control on leveling panel.
- The outriggers have to be clamped.
MAST RAISING
ELECTRONIC LEVEL
TENSIONING CYLINDERS
LOCKING CLAMP
RIG UP CONTROL PANEL

CLOGGED OIL FILTER
HYDRAULIC OIL MAX.

24V DC TENSION TEMPERATURE
ON (75-80°C)
THERMAL OVERLOAD PIPE HANDLER

ELECTRIC POWER
EMERGENCY BY-PASS
CABLE
HYDRAULIC OIL
HEATING
START STOP
ELECTRIC BOX AUXILIARY HPU
NOTE: PIPE HANDLER EMERGENCY BY-PASS
17
EXCLUDE PIPE HANDLER EMERGENCY DURING RIG UP
RIG UP SEQUENCE
PHASE 10:
- Install: the telescopic diagonal braces, rotary table frame with related pillars and fix with blocking clamps.
WELL CENTER
ROTARY TABLE PILLARS
ROTARY TABLE FRAME PINNING ROTARY TABLE FRAME TO SEMITRAILER

TELESCOPIC DIAGONAL BRACES
18
RIG UP SEQUENCE
PHASE 11:
- Install the dog house support frame, install the drill floor complete with walkway handrails work shop and dog house.
- Install walkway complete with handrails and rails
1 2 3 4
ASSEMBLY DOG HOUSE FRAME ASSEMBLY DOG HOUSE FRAME DOG HOUSE SUPPORT FRAME INSTALL DOG HOUSE
5 6 7 8
FINGER BOARD FOR DRILL COLLARS ASSEMBLY WORK SHOP SUPPORT FRAME ASSEMBLY WORK SHOP DRILLING FLOOR
9 10
COMPLETE THE RIG WITH:
- HANDRAILS
- STAIRS
WALKWAYS
19
RIG UP SEQUENCE
PHASE 12:
- Lift the rig of 40-50 cm controlling the leveling .
- Always acting on rig-up control panel continue lifting the rig to the work position, check the level by means of the
electronic level mounted on the rig-up panel.
- Now insert the shims and the mechanic block in the appropriate locations.
ELECTRONIC LEVEL
WELL CENTER
SENSOR FOR ELECTRONIC LEVEL
SHIMS SEAT LEVELLING SHIMS

RIG UP CONTROL PANEL PLACE FOR INSERTION SHIMS AND SEAT
20
RIG UP SEQUENCE
PHASE 13:
- Lock the diagonals by means pins, it's possible to adjust them by means turnbuckle.
- Lock the front supports of drill floor by means hydraulic pins with hydraulic control.
- Connect the hydraulic hoses of rams. An operator checks the alignment of hole and pins, when the pins and hole
will be aligned the hydraulic control of ram has to be switched on
- Adjust the levelling of drill floor by means turnbuckles.
WHEN THE ROTARY TABLE FRAME IT’S IN FINAL POSITION,

BLOCK THE LEVELLINGG SISTEM WITH CLAMPS
WELL CENTER
INSTALLED AND PINNING CLAMPS ON DOG HOUSE PILLARS
INSTALLED AND PINNING THE CLAMPS ON THE

PIN TELESCOPIC BRACES HYDRAULIC PUMP FOR PIN ROTARY TABLE FRAME LIFTING HYDRAULIC JACKS
PINNING ROTARY TABLE FRAME
21
RIG UP SEQUENCE
PHASE 14:
- Raise the mast and it has to be connected to the drill floor by means screws
- To obtain the vertical position of mast it's possible to put some shims.
- It's possible to check the vertical position by means the instrumentation on mast.
REMOVE TIGTHENED INSTALLED DURING RAISE THE MAST WHEN WILL BE NEAR TO THE VERTICAL
TRANSPORT PHASE. POSITION A LIMIT SWITCH REDUCE THE RAISING OIL
PRESSURE AT ABOUT 50 bar AVOIDING DAMAGES OF
THE HYDRAULIC JACKS.
ANCHOR MAST SUPPORT ON ROTARY TABLE.
WITH THE MAST IN VERTICAL POSITON TO EXECUTE ANOTHER CONTROL

CHECK THE RIGHT VERTICALITY ON THE WITH TWO MOVABLE LEVEL
WELL CENTER THROUGH THE LEVEL POSITIONED ON THE MAIN JACK
FIXED ON THE MAST. FRAME AND THE TOP DRIVE SAVER
SUB.
22
PIPE HANDLER RIG UP SEQUENCE
PHASE 15:
- Check that the extension of the lower clamp has been mounted; also check the hydraulic and electric connections.
- Position the rod manipulator in the appropriate fulcrum of the manipulator base for lifting.
- Connect the auxiliary hydraulic power unit to the manipulator system, connect the lifting control panel.
- Mount the manipulator lifting rope transmission equipment on the drilling floor.
FULCRUMS BASE FRAME PIPE HANDLER MANIPULATOR
PIPE HANDLER LOWER CLAMP HYDRAULIC AND ELECTRIC CONNECTIONS ANCHOR TAIL SHEAVE ON DRILL FLOOR
EXTENSION
REMOTE CONTROL PANEL – PIPE HANDLER CONNECTIONS
AUX HPU CONNCETIONS TO MAIN HPU CONNECTION

PIPE HANDLER PIPE HANDLER
PIPE HANDLER REMOTE
CONTROL PANEL
PIPE HANDLER – AUXILIARY HPU CONNECTION

23

DEAD LINE ANCHOR
PHASE 16:
- On the pipe handler manipulator is installed a lifting sling one side hooked
to the crane (dead line anchor) and the other side fixed to the pipe handler
hook, thought a sheave anchored to the substructure. Rise by means the
wich installed on pipe handler to reach the almost vertical position. On the
base of pipe handler skid is installed a hydraulic jack user to bring it to the
final vertical position where will be fixed to the skid base.
PIPE HANDLER RAISING
PIPE HANDLER RAISING PIPE HANDLER RAISING
HYDRAULIC JACK
HYDRAULIC JACK ANCHOR PIPE HANDLER TO SKID BASE
24
PHASE 17:
- Mount the drill pipes container stiffening and support frames
- Mount the walkway of pipe handler manipulator with the relative handrail.
At this point the crane of the pipe handler manipulator is used for the vertical hoisting of the containers and for their
positioning in the positions required.
- Position a container full of drill pipes on the container tilting supports located at the end of the base skid.
- Position the lifting tie rods and tie them up to the crane hook. Pay particular attention when you carry out vertical
hoisting of the container. Detach the container from the base by lifting it about 20 cm.
- Slowly rotate the container and put it down in its final position. The centering pins must get into the relevant housings.
- Fix the container onto the base. Repeat the operation with all other containers as described above.
DRILL PIPES CONTAINERS

LOCK DEVICE
STIFFENING FRAMES
25
PHASE 19:
DRILL PIPE CONTAINERS (PIPE BEAMS) READY FOR POSITION A CONTAINER FULL OF DRILL PIPES CONTAINER TILTING POSITION THE LIFTING TIE
INSTALLATION SUPPORTS RODS AND TIE THEM UP TO
THE CRANE HOOK
LIFT DRILL PIPE CONTAINER HYDRAULIC JACK USED TO LIFT THE CONTAINER FROM SLOWLY ROTATE DRILL PIPE FINAL POSITION FIX THE CONTAINER ON TO
BRING DRILL PIPE CONTAINER THE BASE (ABOUT 20 cm) CONTAINER THE BASE
TO THE VERTICAL POSITION
26
MAIN HYDRAULIC POWER UNIT (HPU)
HYDRAULIC PUMPS DRAIN BLOCK CONNECTION HYDRAULIC BLOCK
HPU – SEMITRAILER (FLOW CONTROL)
VARIABLE DISPLACEMENT PISTON PUMP
AIR FILTER BLOCK DESCHARGE VALVE (DENISON - P260)
SUPERCHARGIN HYDRAULIC BLOCK
VARIABLE DISPLACEMENT PISTON BLOCK DRAIN SUPERCHARGIN G
SUBMERSIBLE SUPERCHARGING SOUND-PROOF GROUP
PUMP (DENISON - P260) HYDRAULIC MOTORS CONTROL
SCREW PUMP
DOUBLE VANE PUMP VARIABLE DISPLACEMENT PISTON VARIABLE DISPLACEMENT PISTON DOUBLE VANE PUMP
(DENISON - T6CC) PUMP (DENISON - P260) HYDRAULIC OIL PUMP (DENISON - P260) (DENISON - T6CC)
TANK
HYDRAULIC PUMPS SUCTION LINES HYDRAULIC PUMPS SUCTION LINES
VARIABLE DISPLACEMENT PISTON PUMP - (DENISON – PV92) VARIABLE DISPLACEMENT PISTON PUMP - (DENISON – PV92)
HYDRAULIC PUMPS SUCTION LINES BLOCK DESCHARGE VALVE HYDRAULIC OIL FILTER RETURN
SUPERCHARGIN HYDRAULIC BLOCK SUPERCHARGING
CONTROL
HEAT EXCHANGER ELECTRIC MOTOR #1 HEAT EXCHANGER

ELECTRIC MOTOR #2 ELECTRIC BOX
27
MAIN COMPONENTS DESCRIPTION
The Hydraulic Power Unit (HPU) is made up as follows:

Opposite the entrance doors and the electric panel there is a hydraulic oil tank which occupies the whole length; the tank capacity is 4.500 liters (1190
gal). It serves the whole system.
o On the top of the tank are installed:
- Oil return filters
- Main pipe for oil return from the flow control block to the tank
o On the extreme left and right side, are installed the supercharging pumps (two for each side, four in total), each group consisting of an external
electric motor and a screw pump submerged in the tank. There are used for filtration, cooling and replenishment of circuit hydraulic oil. Next to them
are installed the hydraulic blocks for their control.
o Two air exhaust filters complete with flange and butterfly valve to cut them out during transport.
o In the lower part of the tank are the intakes of the hydraulic pumps, made up of pipes and hoses complete with flanges and butterfly valves.
Delivery of the hydraulic pumps are conveyed to the central block (flow control) which occupies the whole container width. By means of a special ramp,
which connects the HPU with the rig, flexible pipes with stiff bends get to a connecting plate located at the end of the semi-trailer. From here, stiff and
flexible pipes branch out and feed all the system equipment (pull down block – pump sum block – top drive block, etc.)
The air-oil heat exchangers (radiators) are installed at the right and left end; they are electric powered used to disperse heat produced by the hydraulic
oil that circulates in the circuit. The heat exchange power is 420 kW, achieved by means of four 105 kW units.
Two electro-hydraulic power units; each unit is composed as follows:
o N°1 (one) electric motor 575 kW AC (771 HP) – 600 V – 60 Hz double shaft, with output from either side.
o N°1 (one) hydraulic piston pump variable displacement Denison – Parker P260 left-hand rotation on one side (pull down).
o N°1 (one) hydraulic piston pump variable displacement Denison – Parker P260 with right-hand rotation on one side (top drve).
28

DESCRIPTION OF MAIN COMPONENTS
VARIABLE DISPLACEMENT PISTON
PUMP (DENISON - P260)
DOUBLE VANE PUMP VARIABLE DISPLACEMENT PISTON VARIABLE DISPLACEMENT PISTON DOUBLE VANE PUMP
(DENISON - T6CC) PUMP (DENISON - P260) PUMP (DENISON - P260) (DENISON - T6CC)
VARIABLE DISPLACEMENT PISTON PUMP - (DENISON – PV92) VARIABLE DISPLACEMENT PISTON PUMP - (DENISON – PV92)
At the back of these pumps there are installed other hydraulic pumps; this is possible because the variable displacement piston pumps (Denison P260) have got a
through-shaft which can gear the torque from the electric motor to one side and the other side.
Other equipment :
o A smaller variable displacement piston pump, Parker PV 92 on the right side to gear the following equipment: Power tong – Power tong positioning – Torque
wrench – Mouse hole clamp – Bit breaker tong – Top drive tilting – Casing device – Pipe handler.
o A double vane pump, Denison T6CC, divided into two sections:
- The first section for the rotary table equipment.
- The second section is used to feed the pilot systems and provides pressure at 40 bar to operate the hydraulic servo-controls (manipulators) located in the
Dog house.
REMARKS: - Both power units are connected with the flow control hydraulic block to permit drilling operations even if there is a failure on one of them (in this case
the capacity is obviously halved).
- All flexible pipes are provided with metal joints and wear-proof protections.
29
SIMPLIFIED HYDRAULIC SCHEME SERVICES
• POWER TONG
• TORQUE WRENCH
PULL DOWN • MOUSE HOLE
BLOCK • POWER TONG POSITIONING
• TOP DRIVE TILTING
• CASING DEVICE
SERVOPRESSURE CIRCUIT • BIT BREAKER TONG
• PIPE HANDLER
• REMOTE CONTROLS
• TORQUE WRENCH RETURN
• AUTOMATIC SLIPS
• TENSIONER CYLINDERS (PULL DOWN)
TOP DRIVE PUMPS SUM
• TOP DRIVE MOTORS SERVO PRESSURE
BLOCK BLOCK • PUMPS WASHING SYSTEM
ROTARY
TABLE
FLOW CONTROL HYDRAULIC POWER UNIT

BLOCK
PV92 PV92
30
DESCRIPTION OF SIMPLIFIED HYDRAULIC SCHEME

The two electro-hydraulic power units are identical and symmetrical and work simultaneously to achieve the best functionality.
In the event of malfunction of one unit, fixing can be made while drilling continues with a single unit. In this case the system power is obviously halved but it is
sufficient to continue the activities, especially when stopping the drilling system completely might create serious problems and jeopardize the safety of the rig. A single
electro-hydraulic unit will develop a power of 575 kW.
The adjustment pressure of the two units is 350 bar, whereas the vane pumps are adjusted at 250 bar.
In the event of a total break out of the two generating sets that power the system, after resetting them to work again, it will be necessary to reset the HPU controls. As
you can see in the color diagram in the previous page, the two P260 variable displacement piston pumps (blue lines) join and pump oil in the "Pull Down" block, which
is made up of different valves with various functions and is located at the base of the mast, just behind the main cylinder.
The blocks "Pump sum" and "Rotary" are installed on the semitrailer. They receive oil from the P260 variable displacement piston pumps (red lines) – (blue lines),
which can join and go to the "Pull down" unit. From here start the stiff pipes and link assy which, getting connected with the hydraulic motors, operates all the
functions of the top drive. By means of a hand selector (hydraulic pump top-drive – hoisting) or a foot selector (pump sum), the operator can convey the hydraulic
power alternately to the "Rotary block" (drilling) or the "Pull Down" block (maneuvers - trip). It is also possible to sum the delivery of all P260 hydraulic pumps so as to
have all the oil available at the "Pull down" block. In this way you can achieve the highest level of performance, especially during the maneuvers of pulling and running
in the well.
The variable displacement piston pumps PV92 The biggest section of the T6EDCS The smallest sections of the T6CC vane pump
(dark blue lines) are pumps that serve the vane pumps (grey lines) joint and (green lines) joint and by means of appropriate
equipment. operate the rotary table. check valves, feed the pilot system:
They join to feed the following: Remote control
Power tong Torque wrench return
Power tong positioning Automatic slip
Torque wrench Tensioner
Mouse hole clamp Top drive motors servo pressure
Top drive tilting Pumps washing system
Casing device
Bit breaker tong
Pipe handler
31
AUXILIARY HYDRAULIC POWER UNIT
MAIN FEATURES
One auxiliary hydraulic power-pack independently powered and OIL FILTER
HYDRAULIC OIL
installed in the rig trailer, complete with: TANK RETURN
- One AC electric motor 34,5 kW (45 HP) REFILL PLUG TANK VENT
- One hydraulic piston pump variable displacement – Parker PV20
- One oil tank, 800 lt (210 gal) capacity, with oil level alarm
The auxiliary hydraulic power pack is designed to operate the four
stabilizers and the two mast raising cylinder. An additional hydraulic OIL VISUAL LEVEL OIL DRAIN
line is provided to operate the pipe handler tower raising and jib INDICATOR
crane operations. This auxiliary HPU is supplied to allow rig-up
operation without main hydraulic power system trailer available and
installed.
DELIVERY LINE
SUCTION LINE WITH
BALL VALVE
LIFTING POINT
NON RETURN VALVE
ELECTRIC
MOTOR
OIL PRESSURE
GAUGE
HYDRAULIC PISTON PUMP

VARAIBLE DISPLACEMENT PV20
32
MAST
MAIN FEATURES
• The telescopic tower is build in accordance with API 4F made of high tensile steel and electrically welded.
• The mast consist of two independent sections one fixed and one telescopic are transported together and mounted
on the same trailer.
• The mast is rise in vertical position by means of two hydraulic cylinders to three steps. DRILL LINES
Ø 42 mm
• The bottom of the mast is attached to the semitrailer.
• Four drilling line in steel with diameter of 1" 5/8 (42mm), with one end pinned on the top drive cradle and the other
end to the anchor system for load equalizing.
• The function of this component is to distribute evenly the load on the four ropes pull that you make. The pulling
system having four ropes use two system for load equalizing, each of which is connected to the two ropes.
• The central hinge bonded to the chassis of the trailer, ensure the same intensity of the top drive pull, even if the
ropes are not perfectly equal.
• Its designed to allow handling of API Range 3 drill pipes, 30' drill collars and API Range 3 casings.
MAIN TECHNICAL DATA

Static hook capacity: 317 MT - (350 short tons - 700.000 lbs)
Pull down capacity: 30 MT (66.000 lbs) MAST RAISING
CYLINDER
Max. top drive speed: 1,35 m/sec with 100 % efficiency.
Working stroke: 16.6 m (54.46")
Max casing length handling: 14.63 m (48 ft)
Distance mast - well centre: 900 mm (35" ½ )
- 272 drill pipe stands OD 5” R3 (16 DP for
Storage capacity:
each container) – 3.500 m.
(17 vertical racks with double
- 18 drill collar stands OD 6.1/2”. ANCHOR
line each, for tubular storage)
- 3 drill collar stands OD 8”. ANCHOR SYSTEM FOR LOAD EQUALIZING SYSTEM
33
MAST
CROWN BLOCK TOP DRIVE CRADLE ROLLER GUIDE
TOP DRIVE CRADLE
TELESCOPIC SECTION
TOP DRIVE CRADLE

GUIDE
DRILL LINES
TELESCOPIC SECTION TENSIONING ROPE

GUIDE SLIDING ANCHOR
TENSIONING
CYLINDER
LADDER
N° 2 TENSIONING SHEAVES TOP

DRIVE CRADLE (FIXED ON MAST
TELESCOPIC SECTION) FIX SECTION
MAIN HYDRAULIC
CYLINDER
TENSIONING
HYDRAULIC WINCH ROPE Ø 20 mm
ROD ANCHOR ON
MAST FIX SECTION
MAST RAISING – LOWERING
OUTRIGGERS
ROLLER GUIDE ROPE
PULL DOWN BLOCK
ANCHOR TO SEMITRAILER
FRAME
DEAD LINE ANCHOR
34
MAST
GENERAL DESCRIPTION
The fixed mast is a C-shaped lattice cantilever tied up to the trailer base surface.
The telescopic section is made up of a casing with two guide rollers outside which get
engaged in the relevant guides inside the fixed section of the mast.
At the top of the fixed section there are some rolls which get engaged into guides located in
the telescopic part. Other guides in the telescopic section allow the drive head carriage to
move. The frame of the top drive is fitted with four rolls which get engaged in the most
external guide of the telescopic section.
The mast is composed as follows:
- Hydraulic hoisting cylinder is installed inside the fixed mast section with the liner
downward-facing, tied up at mast fixed section, contrary compared to the other HH rigs.
The reason that the hoisting hydraulic cylinder, is mounted on the contrary than the other
HH rigs, is due to the fact that it would be difficult to bring the oil to the three hydraulic
cylinder chambers.
- The stroke of the hydraulic cylinder is 8300 mm, when you pull the telescopic part, the
wire ropes connect the top drive cradle and to the trailer through sheaves, installed at
the top of telescopic part, carrying out the doubling of the stroke: 8300 x 2 = 16600 mm.
- Two limit switches limit the up and down stroke. The real stroke, not to get to the
extreme end with the hydraulic pistons, is 16000 mm.
If required (extraction of the BHA - Bottom Hole Assembly) the limit switches can be cut
out and get to the mechanical end-of-stroke of the hydraulic cylinder.
- Crown block
- Top drive carriage with the four cable sockets
- Top drive slide guides
- Guides between the telescopic section and the mast
- Hydraulic blocks
35
HOISTING CYLINDER
INTRODUCTION
CHAMBER A CHAMBER B
HYDRAULIC OIL TANK

Chamber "A"area: 113.804 mm²
Chamber "B"area: 45631 mm²
Chamber "C"area: 45238 mm²

CHAMBER C
SUPERCHARGIN PUMPS
SUPERCHARGIN PUMPS
HYDRAULIC OIL TANK
The hoisting hydraulic cylinder is made up of three chambers:

- Chamber A: it’s the piston side chamber . It consist of a ring-shaped surface equivalent
to the liner reaming (450mm) with a inner rod of 240mm.
- Chamber B: it’s the rod side chamber. It’s a ring- shaped surface with a diameter of
450mm between the liner reaming and the 380mm of the main rod.
- Chamber C: it’s the chamber for the small inner drill pipe with a diameter of 240 mm.
36
HOISTING CYLINDER
FIRST SPEED
POMPE
DE
OIL PRESSURE (0-350 bar) SURALI
SUPERCHARGIN PUMPS
OIL PRESSURE (0-15 bar)

MENTATI PUMP (DENISON - P260)
OIL DRAIN
ON
PUSHING SURFACE
159043 mm²
HYDRAULIC OIL TANK
OPENING CHAMBER A
OPENING CHAMBER B
OPENING CHAMBER C
0-350 BAR
0-350 BAR
OPENING CHAMBER A
OIL DRAIN
OPENING CHAMBER B
HYDRAULIC BLOCK
The first gear corresponds to the lowest speed and the highest pull : 270 MT (300 st).
When running in first gear , the valves in the pull down unit are set to feed:
- Chamber A and chamber C .
Oil gets into chamber A passing through two openings, and from one opening for chamber C (see hydraulic block).
In this way all the area near the 450 mm reaming (piston side chamber) is under pressure and it is possible to thrust to the full at minimum speed. The oil at chamber C pushes on
the cylinder base and power is transmitted directly to the top of the telescopic section.
All the others operations are made by the piston through chamber A. The strength is transmitted on the rod and to the telescope as well.
On the other side of the rod, oil which goes to the tank is discharged with the one coming from the over charging pumps. In first gear , the over charging pumps aren’t working with
the cylinder as they are discharging.
37
HOISTING CYLINDER
SECOND SPEED

OIL PRESSURE (0-350 bar) PUMP (DENISON - P260)
OIL TRANSFER (>15 bar) SUPERCHARGIN PUMPS
PUSHING SURFACE
113804 mm²
OPENING CHAMBER A
OPENING CHAMBER B
OPENING CHAMBER C
0-350 BAR
15 BAR
OPENING CHAMBER A
OPENING CHAMBER B
HYDRAULIC BLOCK
When running in second gear, the valves in the pull down unit are set to feed chamber A.
Chamber C is kept full by the over charging pumps.
In chamber B the oil which is discharged goes to chamber C . In this way chamber C has been kept full, using the oil coming from chamber B , oil which comes from the over charging
pumps.
In this phase it is very important to keep always a pressure of 15 bar of over charging in chamber C because, if the pressure goes down, some phenomenons of cavitations could
appear. In the way down they could be like jumps.
The pushing is given by the pressure from chamber A with a diameter from 450 mm to 240 mm.
Comparing to the first gear the pushing area is reduced and as a result the speed has increased.
38
HOISTING CYLINDER
THIRD SPEED

SUPERCHARGIN PUMPS
PUSHING SURFACE
68565 mm²
OPENING CHAMBER A
OPENING CHAMBER B
OPENING CHAMBER C
OPENING CHAMBER A
OPENING CHAMBER B
HYDRAULIC BLOCK
In the third gear valves in the pull down unit are set to feed at the same time chamber A and chamber B.
Chamber C is always kept full by the over charging pumps.
Chamber B gets under pressure and helps the main pump. This phase is called "cylinder regenerative phase".
The effective thrust area corresponds to the chamber A area, minus the chamber B area.
In fact it is like thrusting between 380mm and 240mm, that is the rod inner space , thus an area is given by the ring between 380mm and 240mm.
Since the thrust area is further reduced, the result is higher speed and less pull.
NOTA: - The feed of chamber B is carried out by the two pull down block lines which go to the outside of the cylinder line.
- By pressurizing chamber A and chamber B at the same time, the result is a thrust upwards and downwards, thus a part is annulled and the remaining area is given by 380
mm and 240 mm. (450 mm boring – 380 mm main piston – 240 mm inner piston).
39
HOISTING CYLINDER
FOURTH SPEED
OIL TRANSFER (>15 bar)
PUSHING SURFACE
45238 mm²
OPENING CHAMBER A
OPENING CHAMBER B
OPENING CHAMBER C
OPENING CHAMBER A
OPENING CHAMBER B
HYDRAULIC BLOCK
In the fourth gear valves in pull down block are set to feed chamber C.
In chamber A over charging pumps keep it full to a pressure of 15 bar.
From chamber B oil is recycled and sent to chamber A.
Pumping in chamber C a pressure on a pushing area corresponding to a little rod with a diameter of 240mm is applied.
As a result you will get the smallest area and the higher speed with less pull.
40
CROWN BLOCK
The crown block is fixed at the top of the mast telescopic section and it’s complete with:
ROPE GUIDE NUMBER 8 SHEAVES EXTERNAL DIAMETER Ø
- Eight sheaves with hardened groove for wire rope diameter Ø 1"5/8 (42mm). 1000 mm FOR WIRE ROPE DIAMETER Ø 1"5/8
(42mm)
- Two additional sheaves with hardened groove for wire rope diameter Ø 1/4" (6 mm) for wire
line operations.
NOTE: - Sheaves are mounted on bearings.
- The crown block is complete with lubrication system.
MAIN BODY
CROWN BLOCK ASSEMBLY
BEARINGS
BEARINGS
LUBRICATOR PIN
CROWN BLOCK SECTION WIRE LINE ADDITIONAL SHEAVES

41
AUXILIARY JIB CRANE
MAIN FEATURES HYDRAULIC MOTOR FOR JIB ROTATION

Hydraulic jib crane installed on the side of bottom mast section and is operated from the drill
floor and complete with hydraulic winch (4 MT - 8800 lbs.) for rig floor services.
REDUCTION GEAR
ROTATING JIB
BEARING SHEAVE
SERVICE JIB CRANE
4000 KG
WIRE ROPE
DIAMETER Ø 14 mm
LENGHT 40 m
SWIVEL WITH HOOK
OIL PRESSURE – LIFT

HYDRAULIC MOTOR COUPLED CAPACITY GAUGE
WITH REDUCTION GEAR
JIB HOOK JIB ROTATION

WINCH
UP - DOWN RIGHT- LEFT
WINCH SUPPORT
WINCH SUPPORT EMERGENCY
CONTROL PANEL 42
AUXILIARY JIB CRANE

SAFETY SYSTEMS
ROTATION LIMITER
The mast jib crane, in normal conditions can’t arrive up to well center axle, because the rotation angle is reduced by an
electric limiter. This movement can be allowed by pressing the “LIMIT SWITCH BYPASS” on the driller’s console. Bypass the
limit switch and rotate the jib crane up to the well center is a dangerous operation, cause subsist the possibility of a crash
between top drive and crane.
LIMITER DISENGAGEMENT:
To disengage the limiter, rotate the crane’s arm in the opposite side by means of the apposite command.
HOOK LIFTING
A limit switch is installed on jib crane, to limit the movement of hook. This limiter is mechanical type, and is activated when LIMIT SWITCH BYPASS
the hook reaches a dangerous position in upward stroke. This control, when activated, stops the hydraulic winch of jib crane.
LIMITER DISENGAGEMENT:
To disengage the limit switch, lower the hook with the appropriate control.
HYDRAULIC SAFETY BLOCK
Hydraulic system of jib crane is complete with overcentre valve to avoid movement of crane, when there isn’t hydraulic
power. These system gives the possibility to maintain the load and the position of crane without hydraulic power. LIMIT SWITCH ON HOOK LIFTING
POSITION WHERE LIMIT SWITCH

STOP JIB CRANE ROTATION
WELL CENTER
LIMIT SWITCH ON JIB CRANE ROTATION LIMIT SWITCH ON HOOK LIFTING

43
DRILL FLOOR EQUIPMENT
ROTARY TABLE
One back-up type rotary table driven by two hydraulic motors, with a 37" 1/2 (952 mm) full
opening and complete with removable API master bushing. Rotary table can be easily and
quickly removed to leave 47 ¼" free passage (1200 mm) trough substructure. Fabricated in
compliance with API 7K Spec.
MAIN TECHNICAL DATA

Static hook load on table: 700.000 lbs (317 metric ton)
Max full opening: 37 1/2" (952 mm)
Max torque: 1,020 daN∙m (7,527 lbs∙ft)
Max speed: 45 rpm
TOOTH TO BLOCK ROTATION
DRILL PIPE AUTOMATIC POWER SLIPS

The slips are suspended from a lift arm that can be moved vertically by means of an
hydraulic cylinder incorporated in a vertical rod positioned outside the centre well.
Comprising a swivel table in which is located the master bushing and all the cone-shaped
bushings for slip-aided suspension of all the elements in the drilling string and the casings.
The bushings will have a proper clearance to be able to install easily them into the rotary
table.
Operated from driller’s panel with two selectors (In – Out). A powerful hydraulic operated
cylinder to provide pressure raising and pressure setting of slips. Power slips will be
located in central position but need to be removed during casing job to allow positioning
of casing back up device.
44

MOUSE HOLE
2.7/8" to 13.3/8" vices are attached to the main body. The hydraulic cylinder, the rod and the piston are stationary and are attached to the fixed body by means
of a "C-shaped" frame, flange and screws. The jaw unit slides forwards and backwards as a result of the hydraulic action. The oil is introduced through internal
channels which go across the stem and can reach the piston side chamber or the rod side chamber. The vices can therefore be opened or closed by relying on the
hydraulic system. Four little columns fitted to the drill floor position the vice, which is therefore free to float onto the probe floor itself.
MAIN BODY
VICE PISTON
ROD
PISTON SIDE CHAMBER FIX BOBY
DIES ROD SIDE CHAMBER
FOR INSTANCE
MOUSE HOLE SENSOR DRILL PIPE CENTRALIZER MOUSE HOLE CLAMP 45

BIT BREAK-OUT AND CASING BACK-UP TONG

• Special device for bit break-out and casing back-up composed of a manual
tong, actuated by an hydraulic cylinder controlled from main control panel.
• Complete with torque indicator and manual torque regulator.
• Possibility to install the cylinder at four different heights, by means of
apposite ears, welded on the mast’s driller side.
TECHNICAL SPECIFICATIONS
Maximum torque: 7450 daN∙m (55.000 lbs∙ft)
Functioning range: 3.1/2" – 25.1/2"
COMMANDS FOR ACTIVATION - TORQUE REGULATION TORQUE GAUGE

46
BOP HANDLING SYSTEM

The BOP handling system is composed by a dolly that supports the BOP and by two hydraulic cylinders for the lifting. The dolly for BOP is complete of roller
bearings and guide tracks. The commands of the two lifting cylinders are located on a movable frame to be positioned, so that the operator can visually control
the operations. Connect the control movable frame to the machine by means of the quick couplings P, R, LS, T.
Connect the lifting cylinders to the movable frame by the purposed flexible hoses
- A: piston side
- B: rod side
ROTARY TABLE FRAME SUPPORT
TECHNICAL SPECIFICATIONS
Maximum lifting capacity: 40 ton (88.000 lbs)
Hydraulic cylinders stroke: 1000 mm (3,2 ft)
LEVER FOR LIFTING BOP STACK LEVER FOR LOWERING BOP STACK
HYDRAULIC CYLINDERS
FOR LIFT BOP STACK
PRESSURE GAUGE
REGULATOR FOR SETTING

THE LIFTING FORCE
REMOTE CONTROL PANEL
REMOTE CONTROL PANEL 47

CONTROL PANEL
COMPLETE CONTROL PANEL
48
CONTROL PANEL
END LEFT SIDE PANEL
EMERGENCY
PCR HMI BLACK-OUT
MUD PUMP N° 1 MUD PUMP N° 2 MUD PUMP N° 3

ACCELERATOR ACCELERATOR ACCELERATOR
49
CONTROL PANEL
PCR HMI
50
CONTROL PANEL
LEFT SIDE PANEL
POWER TONG TORQUE WRENCH MOUSE HOLE MOUSE HOLE

BREAK OUT - RETURN AUTOMATIC SEQUENCE CLOSED LAMP CLOSING SIGNAL
CASING DEVICE
ACTIVATE - RETURN MOUSE HOLE
CLAMPING FORCE
MOUSE HOLE
CASING DEVICE OPEN - CLOSE
PUSHING FORCE
TOP DRIVE
TILT OUT - IN
POWER TONG
MAKE UP- RETURN
TOP DRIVE
ROTATION FWD – REV
TRIPPING PULL LIMIT
TOP DRIVE
SPEED (RPM)
POWER SLIPS
IN - NEUTRAL - OUT
51
CONTROL PANEL
GAUGES ON LEFT SIDE PANEL
MOUSE HOLE
TRIPPING PULL-UP PRESSURE
CLAMPING FORCE
52
CONTROL PANEL
CENTRAL SIDE PANEL
DRILLING HMI
DIGITAL WEIGHT INDICATOR
TOP DRIVE TORQUE
TOP DRIVE SPEED
MUD FLOW
ANALOGIC WEIGHT INDICATOR
WEIGHT VERNIER
PUMPS SUM PEDAL
53
CONTROL PANEL
RIGHT SIDE PANEL
ROTARY TABLE POWER TONG LOWER CLAMP

HORN
TORQUE OPEN - CLOSE
BIT BREAKER TONG

TORQUE
BIT BREAKER TONG

TOP DRIVE MAKE UP – BREAK OUT
PUSHING FORCE
TOP DRIVE POWER TONG

TRIPPING UP – DOWN PARK POSITION – WORK POSITION
ROTARY TABLE
ROTATION FWD – REV
POWER TONG
UP – DOWN
TOP DRIVE
PULLING FORCE
ROTARY TABLE
SPEED (RPM)
TOP DRIVE
TORQUE
TOP DRIVE – JIB CRANE
LIMIT SWITCHES OVERRIDE
54
CONTROL PANEL
GAUGES ON RIGHT SIDE PANEL
BIT BREAKER TONG PULL – DOWN CASING DEVICE

MAKE UP – BREAK OUT TORQUE PUSHING FORCE PUSHING FORCE
55
CONTROL PANEL
END RIGHT SIDE PANEL
CONTROLS CONTROLS CONTROLS EMERGENCY AIR COMPENSATORS AIR COMPENSATORS

STOP ON ENABLE HPU PRESSURE PRESSURE REGULATOR
ROTARY TABLE
OIL PRESSURE
MUD SAVER
OPEN – CLOSE WINDSCREEN WIPERS
HOISTING SPEED
1–2–3–4 SERVICES
OIL PRESSURE
TOP DRIVE
BRAKE ON IBOP VALVE
CLOSED
TOP DRIVE
NEUTRAL – BRAKED HYDRAULIC MANIPULATORS
OIL PRESSURE
TOP DRIVE
TRIPPING MODE – DRILLING MODE
IBOP VALVE
OPEN – CLOSE
TOP DRIVE
SPEED 1 – 2 – 3
AIR SYSTEM
PRESSURE
HYDRAULIC PUMPS TORQUE WRENCH TORQUE WRENCH 56

ROTATION – HOISTING MAKE-UP – BREAK-OUT DOWN – NEUTRAL - UP
CONTROL PANEL
PIPE HANDLER PANEL
CLAMP
UP – DOWN
PIPE HANDLER HMI
CLAMP
IN – OUT
MOUSE HOLE
OPEN – CLOSE
ROTATION
CONTROLS
ENABLE CW - CCW
CONTROLS CLAMP
OPEN – CLOSE
DOG HOUSE – O – REMOTE
EMERGENCY
PIPE HANDLER
57
CONTROL PANEL
PIPE HANDLER HMI
58
CONTROL PANEL
PIPE HANDLER REMOTE RADIO-CONTROL
CRANE CRANE
UP – DOWN ROTATION UP – DOWN
TILT IN – TILT OUT CW – CCW IN – OUT
CLACSON
RADIO-CONTROL KEY
SPEED EMERGENCY MOUSE HOLE BATTERY LEVEL

FAST – SLOW PIPE HANDLER OPEN – CLOSE
SELECTOR CLAMP
CLAMP – CRANE OPEN – CLOSE
59
CONTROL PANEL
HYDRAULIC POWER UNIT HMI
60
OPERATIONS DESCRIPTION
During the maneuvers by means of the manipulator you can control the top drive to go up and down. In this case ropes are tightened by the tension cylinders and
tension is constant (40 bar).
During drilling (floating phase), two max. pressure valves are engaged: one is for pushing and the other for pulling. In this case the oil that keeps the ropes tight
gets into the two tension cylinders but can’t get out because a one-way valve prevents that; in this way the downward thrust is also operated. Then, when the oil
gets into the rod chamber, the main cylinders tends to close. In this way the tension tackles are pushed downwards and thus the carriage is pushed downwards too
and the rods in the well get the final thrust.
In order to move a rod from the mouse hole to the well center: Operate the "floating" phase to start drilling.
- Move the top drive from the well center to the mouse hole (top drive tilting). - Rotate the bit slowly at the bottom of the well
- Screw the rod by means of the top drive (spinning). - After reading the weight indicator, adjust the weight to be loaded
- Open the mouse hole vice. onto the bit (WOB)
- Lift the top drive until the rod gets out of the mouse hole. - To achieve the set WOB, adjust the pull regulator keeping the drill
- Move the top drive from the mouse hole to the well center . string pulled and gradually discharging the weight on the bit. The
- Clamp the top connection with a torque wrench to the torque value required. main cylinder is driven by the pressure coming from the floating
- Screw up the single drill pipe onto the rod wedged in the rotary table (spinning). unit and controlled by the control panel.
- Tighten to the required torque value using the power tong. - During this phase the thrust pressure is kept low (P = 20 bar), as
- Lift the drill string to remove the wedges . much as to keep the chamber full. Then the pressure is gradually
- Re-start running. increased by means of the pull regulator until the top drive can
maintain the set weight pulled discharging the weight difference
onto the bit.
Hole reaming - After this setting has been made, the cylinder gets adjusted by
If the hole needs reaming before extracting the bit, the operation can be performed itself in that it in order to go down (drilling) it must discharge the
according to the "floating phase" method, using the pull regulator and increasing the oil pressure at the set value. This occurs by means of the floating
adjustment. unit, separated from the other unit (pull down) and located at the
If during the reaming or extraction phase the drill string gets stuck in the well (stuck pipe), base of the trailer.
the overpulling of the top drive stresses the drill string up to the previously set value. - Also in this phase the hydraulic circuit is made up of pipes and
To exceed such value it will be necessary to increase the pressure to achieve the valves which operate from the floating unit onto the cylinder.
maximum pulling admitted for the type of rods in use. - When drilling is over you get on to the maneuvers to extract the
If the bit must be lowered again, adjust the speed again via the pull regulator; in this case bit from the well.
you have to decrease the adjustment.
61
SAFETY DEVICES
SAFETY DEVICES PLACEMENT

The drilling rig and the equipments that composing it are equipped with integrated safety devices.
- All the cylinders are equipped with locking valves. Should either the connection pipes get broken or a sudden pressure drop , or total lack of pressure, take place
the cylinders will keep locked, so preventing any possible risk of generating any uncontrolled movements.
- The rig is equipped with limit switch to ensure the safety stop in safety stopping set point.
- Are also installed the following emergency stop push buttons and mechanical locks.
JIB CRANE STOP
RIG GENERAL SHUTDOWN

PIPE HANDLER STOP
RIG-UP CONTROL PANEL

STOP
PIPE HANDLER STOP

RIG GENERAL SHUTDOWN
ELECTRIC MOTOR #2
STOP
ELECTRIC MOTOR #1 MANIPULATOR STOP

RIG GENERAL SHUTDOWN STOP 62
SAFETY DEVICES
SAFETY DEVICES DESCRIPTION
Push button, locks all the rig

Push button for locking the pipe handler
functions (shutdown HPU).
in all its functions
Push button for locking the rig

controls (dog house manipulators)
Push button, locks all the rig functions Push button for locking the rig-up
(shutdown HPU). control panel and the auxiliary HPU.
Push button for stopping the electric

Push button for stopping the
motor # 1 power plant.
electric motor # 2 power plant.
Exclusion start electric motor # 1 of hydraulic Exclusion start electric motor # 2 of

power unit, in maintenace. hydraulic power unit, in maintenace.
63
SAFETY DEVICES
SAFETY DEVICES DESCRIPTION
Ring nut locking the lower end of

the posts, with its own seat on the Push button, positioned on the pipe
base skid. handler handrails, for locking the
pipe handler.
After rig positioning, on the four

stabilizers the purposed locking
plates must be inserted. Push button for locking the auxiliary
power plant in the handler hoisting
rig-up phase.
On the four stabilizers of the

Push button, positioned near the
hydraulic power plant, the ring
mast, power tong side, locks all the
nuts locking the stabilizer itself
rig functions (shutdown HPU)
are mounted.
64
TOP DRIVE
MUD INLET PIPE
CONNECTION TO ROTARY HOSE PLUG Ø 3"
WASH PIPE Ø 3"
SERVICE LOOP SUPPORT
PNEUMATIC BRAKE
TOP DRIVE HOUSING CRADLE CONNECTIONS EYES
HYDRAULIC MOTORS
AIR COMPENSATOR
MAIN SHAFT
DOUBLE HOOK
FIX FLANGE FOR CYLINDERS
IBOP - IBOP ACTIVATING CYLINDER
CASING SCREWING DEVICE -
FIRST SAVER SUB

IBOP VALVE
IBOP ACTIVATING FLANGE

SECOND SAVER SUB
65
TOP DRIVE
MAIN COMPONENTS DESCRIPTION

The architecture of the Top Drive is illustrated below. TOP DRIVE
From the top: CRADLE
STIFF PIPE
- Stiff pipe for feeling the mud, connected with the rotary FEELING
hose. MUD
- A 3" diameter wash pipe with plug on the head to PLUG Ø 3"
introduce tools during some drilling phases.
- Main shaft of the top drive which crosses it and comes out SERVICE LOOP
from the lower part. It is free-moving and its weight can be SUPPORT WASH PIPE Ø 3"
cancelled as a result of the air compensators fitted under
the top drive. ROTARY HOSE
- Double hook with the possibility to rotate manually; it is
fitted to a spherical oscillating bearing.
- Fixed flange under the double hook, where the actuating SERVICE LOOP TOP DRIVE
cylinders of the IBOP valve (115 mm stroke) are engaged
and, at 90°, two longer (285 mm stroke) cylinders which will
be used for the screwing of the casing. MAIN SHAFT
- IBOP valve (Inside Blow Out Preventer) for the internal
closing of rods (10.000 psi – 690 bar WP).
- Flange actuated by the cylinders; it drives the lever engaged AIR COMPENSATOR
in the central hexagon which, with a 90° rotation, leads the
internal ball of the IBOP valve to change position, by DOUBLE HOOK
opening or closing the mud flow (either fully open or fully
closed). FIX FLANGE
- Saver sub of a certain length so that the torque wrench is
positioned exactly in line with the connection of the rods IBOP VALVE
during the drilling phases.
66
TOP DRIVE
DOLLY
One dolly to allow tripping operation and with patented device to move the complete top
CRADLE FRAME
drive back and for from well center to mouse hole. Frame built of hi-tensile steel. DRILL LINE ANCHOR
ROLLER
DRILL LINES
FLOATING FRAME GUIDE
ARM
MOUSE HOLE CENTER

STIFFEN
FIXED FRAME BRACE
WELL CENTER
TOP DRIVE
HYDRAULIC CYLINDER
TILT IN (WELL CENTER) TILT OUT (MOUSE HOLE CENTER) TOP DRIVE DOLLY (CRADLE)
67
TOP DRIVE
GENERAL DESCRIPTION ENCODER

HYDRAULIC MOTOR
- Top drive head: the case houses all the gears and
bearings needed for the rotating and suspension of the
PNEUMATIC BRAKE
drill string and supports three hydraulic motors, one
above and two below, as well as the pneumatic brake
(airflex), installed near the upper hydraulic motor.
- Two large ears are fitted to the sides of the case, to
which are connected the arms of the top drive cradle
making up the exit parallelogram of the top drive from SERVICE LOOP
SUPPORT
the centre of the well to the mouse hole and vice versa
(tilting). CRADLE CONNECTION EARS
- The link assy support is fitted to the left-hand side,
(plastic hinged element). A multiple plate collects all
the hoses contained within the link assy which are TOP DRIVE CASE TOP VIEW
connected to the stiff pipes fitted to the mast, thus
allowing the top drive to be fed during the relative
stroke (16 meters). HYDRAULIC MOTOR
Other pipes and hoses feeding all the top drive HYDRAULIC MOTOR
equipment as illustrated below:
- Air for pneumatic brake and compensation springs.
- Oil for hydraulic motors - BOP valve - torque wrench -
LUBRICATION PUMP
power tong - casing screwing device - tilting.
TOP DRIVE
TILTING EYES
TOP DRIVE CASE LOW VIEW

68
TOP DRIVE
SECTIONS
ENCODER HYDRAULIC MOTOR

GUIDE RADIAL BEARING
SPLINE
PNEUMATIC BRAKE
GEAR WHEEL
M=8 – Z=37
PINION PINION
M=8 – Z=12 M=8 – Z=12 SLEEVE
MAIN GEAR WHEEL

M=12 – Z=53
(Ø 658 mm) TOP DRIVE
HOUSING
GEAR WHEEL
SHAFT M=12 – Z=12
MAIN BEARING
COUNTERSHAFT
THRUST BEARING
HYDRAULIC MOTOR
HYDRAULIC MOTOR
POMPE DE LUBRICATION
SECTION A SECTION B
69
TOP DRIVE
SECTIONS DESCRIPTION
- Section A refers to the motors on mast overlooking side, includes the three hydraulic motors (two in the lower and one in the upper part) and the
pneumatic brake. The shafts are driven by the hydraulic motors via the splines present at the edge. One hydraulic motors in the upper part and one in the
lower part act the shaft. The third turn the other shaft that transmits the motion at the top of the pneumatic brake.
Above the pneumatic brake is mounted the encoder connected to the revolution counter inside the dog house.
The two shafts connected with the motors have a pinion machined directly in the shaft. It has sprocket (M=8 - Z=12) and engages with a sprocket (M=8 –
Z=37), which is fitted to a countershaft placed at the centre of the two shafts, it has a pinion (M=12 Z=12) which engages with a main wheel (M=12 Z=53).
This wheel is fixed to the main sleeve (yellow) of the top drive by means of screws.
- Section B shows that the torque is transmitted from the motors to the sprocket. Through a key, it goes to the countershaft within which the corresponding
pinion is machined, which engages with the main wheel fixed to the main sleeve of the top drive.
The sleeve within the top drive has a spline which allows the main shaft to float upwards and downwards and receive the torque from the main gear. The
load coming from the drill string goes up through the main shaft till it gets to the driving case where, on the main shaft, there are rings divided into two
halves with their respective containment pipe. They transmit their load to the two mechanical bearing rings which, in their turn, rest on the main sleeve of
the top drive. The load is transmitted to the main bearing and will end up at the bottom of the top drive case. The possibility for the sliding sleeve to move
upwards and downwards is regulated by suitably loaded air compensators (springs). This is necessary when the connection between wear reduction (saver
sub) and drill string is established preventing the weight from resting and spoiling the threads.
The main sleeve bearings include a main thrust bearing fitted to the lower part, which bears the whole load (300 short tons = 272 metric tons), an axial
thrust bearing, which reacts the upward thrust from below, and radial guide bearings above and below. The gear system inside the top drive has a gear
ratio (reduction) of 13,6. This means that if motors turn at 2000 rpm the wheel and therefore the shaft turn at 147 rpm.
TO SUM UP
The torque path involves the following:
Hydraulic motors– shafts – gear wheel – counter shaft – pinion – main gear – main sleeve – spline – main shaft - wear reduction (saver sub) – drill string.
The path covered by the load hanging from the drill string involves the following:
Main shaft – main bearing – bottom of the top drive case –top drive ears – parallelogram arms (tilting), – cradle – wire ropes – crown block – main
hydraulic cylinder (which supports the load).
70
TOP DRIVE
LUBRICATION
Lubrication is carried out by means of a gear pump which draws oil from the tank at the
bottom of the case. Through stiff pipes, it lubricates the bearings above and then, by
gravity, ends up on the intermediate gears and, by agitation, lubricates the main gear
pinion coupling and the main bearing.
On average the oil level must reach 1/3 of the main gear sprocket. The level can be
checked by using a dipstick (min-max) fitted to the plug screwed to the upper part of the
case.
The lubrication oil level can also be visually checked from a porthole opened at the side of
the case and overlooking the mast.
ROTRA MP 80 W 90 is the oil used. It is a synthetic oil with additives suitable for the
lubrication of gears which is designed to work at temperatures as high as 105° C.
PLUG WITH LEVEL DIPSTICK
LUBRICATION PUMP
VISUAL OIL LEVEL
71
TOP DRIVE
PERFORMANCES
On the top drive are mounted three hydraulic motors and one
pneumatic brake.
The three hydraulic motors are piston type, variable displacement, and
in full displacement provide maximum torque and minimum speed.
The first speed is represented by the red line. From the diagram, at the
maximum speed 91 rpm, the theoretical torque value is near 4910
daNm ( 36.200 lbs/ft).
The continue red line represents the theoretical value, calculated with
mathematical formula, and the broken line represents the real value,
that considers the hydraulic motors efficiency.
Is possible to note that from 20 to 0 rpm, the torque value sensibly
decreases, from 5000 kgm to 4000 kgm (20% less). This zone is called
"stall torque area", when the motors are almost still and have low
efficiency.
To rotate faster than 90 rpm, is necessary to reduce the hydraulic
motors displacement, and this is done by means of a hydraulic
command.
In the second gear, the torque is lower 3210 daNm (23.670 lbs/ft), but
the rpm value goes up to 139.
In the third gear, 199 rpm can be reached, in which case the
displacement must be further reduced and a lower torque value of
approximately circa 2248 daNm (16.580 lbs/ft) will result.
In case of exceptional load the rig can reach 317 metric tons (350 short tons –
The use of gears depend on the drilling conditions and the tools in the 700.000 lbs) of pull, in drilling mode, with hydraulic cylinder stroke reduced at 13.6
well. It should be taken into account that, at practical level, there will m and hydraulic pressure of 410 bar.
always be a stall torque and the efficiency will be reduced by 20%.
72
TOP DRIVE
AIR COMPENSATORS
MAIN COMPONENTS MECHANIC BLOCK
UPPER PLATE (MOVING PART)
ROLL-SHAPED PNEUMATIC STOP CAM
AIR SPRINGS
FIX PART
FIX PART
PRESSURE
GAUGE REGULATOR
73
TOP DRIVE
AIR COMPENSATORS
GENERAL DESCRIPTION
During the coupling operation, the air springs compensate the weight of: the main shaft - IBOP valve - wear reduction - any torque wrench – drill pipe or
drill collar to be screwed to the drill string.
The assembly comprises a collar divided into two halves with omega-shaped ears resting on the air springs, through the upper plate directly connected to the
omega. The ring divided into two halves supports the whole weight of the lower part (fixed), transmits it to the upper plate (moving part), which presses
onto the spring within which the air pressure (variable) supports and compensate the weight attached under the double hook.
The whole assembly floats on the air springs. During the coupling operation, the thread is slowly approached to be engaged knowing that just a minimum
rather than the whole weight will be unloaded. Hence, there is no risk of damaging the threading.
The "spinning" operation is started, the shaft is then pulled downwards. As a result the springs gradually give in and the coupling is achieved (pin and box).
The pressure within the air springs can be regulated by operating the relevant regulator located on the driller panel.
Regulation is carried out as a function of the weight of the individual drill pipes or drill collars used.
The first phase involves drill collars. Given their weight and the weight of all the tools sent down the well, the air pressure onto the springs is increased until a
balance is reached, at which point the pressure shall be left unaltered.
Once the descent of heavy rods (BHA) has terminated and that of DPs has started, the air pressure on the springs will be regulated according to the weight of
the rods in use.
An automatic device fitted to the air spring area controls the balancing process.
It consists of two roll-shaped pneumatic stops, one above and one below, and a cam in the middle. According to the weight, the two stops can move and
come in contact with the fixed cam.
The valves fitted to the air circuit draw air from or introduce air into the spring so as to keep the central position of balance.
The maximum pressure introduced will be the one defined by the control panel regulator.
All this is valid and functional when the rod is taken from the mouse hole and brought to the centre of the well to perform the engagement. Clearly, by lifting
the driller string and unwedging, the whole weight will rest on the air springs which will be fully compressed and the load will follow the process described
above: from the mechanical bearings to the main shaft, then to the main bearing, the bottom of the case, the ears and so on up to the cylinder.
74
TOP DRIVE
AIR COMPENSATOR
FUNCTIONING
ROD
The air springs are engaged on two rods, which are screwed to
the bottom of the case of the top drive, and support the lower
part of the springs. On the rods is fitted a free-moving element
which terminates into the upper part. It is fitted with bushings
and can slide upwards and downwards. The same movement
is transmitted to the ring divided into two halves and the
omega, which also prevents rotation.
In the phase preceding the extraction of a drill collar from the
mouse hole, the compensator is balanced according to the
weight of the fixed tools (double hook – torque wrench, etc.),
the cam is placed in the central position. Once the drill collar
BUSHING
spinning operation has terminated, the vice is opened and the
collar is extracted from the mouse hole. At this stage, the
balance of the springs has changed, the cam rests onto one of OMEGA
the two stops, thus automatically drawing air from the circuit
to inflate the springs and compensate the weight of the drill
collars. When the drill collar comes to the centre, coupling is
performed and the floating will be defined by the weight of the
RING DIVIDED
fixed tools, as well as that of the drill collar. Once the drill collar INTO TWO HALVES
has been screwed, the drill string is lifted and the slips are
removed in order to go down the well. The springs are
compressed and the spring compensation effects wanes.
Subsequently, when the drill string is wedged in to reach a new
rod, the pressure will resume the previously defined value.
75
TOP DRIVE
DOUBLE HOOK
In the lower part are mounted belle ville springs for
absorber shock up to direction. On the fix flange are
installed cylinder connection for drive IBOP valve and
screwing casing device. On the flange are assembled
bearings direction to main shaft and to double hook. In
detail the double hook is supported by axial and spherical MAIN SHAFT
bearings to realize the possibility to oscillate in all
directions. The load from double hook – elevator –
elevator links – ball joint – axial load on the bearing is
transmitted to another axial bearing and then to rings in
two halves therefore to main shaft, come back to up part
and again on the housing. The main shaft support the
maximum over pull, the torque and the working pressure at
5000 psi. When we work with the torque wrench it’s BELLE VILLE SPRINGS
necessary to installed two bracket to block rotation.
When mounting the casing screwing device, you must
remove the brackets that lock the rotation and the torque
wrench. Therefore can rotate: the casing, the casing
screwing device, the elevator links and double hook .
AXIAL BEARINGS
DOUBLE HOOK
FIX FLANGE
CYLIDER CONNECTION
FOR IBOP
BRAKET TO BLOCK ROTATION

(TO ASSEMBLE ONLY WITH THE USE OF TORQUE WRENCH)
76
TORQUE WRENCH
GENERAL DESCRIPTION
Torque wrench (drill pipes screwing device) is
hydraulically operated; it provides the driving and BELLEVILLE
unscrewing torque for connecting the drill string WASHERS
during the drilling and manoeuvre operations. This SPRINGS TOP DRIVE CRADLE
device is installed under the top drive, connected to
the double hook ears by means of two hydraulic
cylinders for lifting and lowering the clamps (the one
at the top is movable, the one below is fixed).
These cylinders are fitted as follows:
TOP DOUBLE HOOK JOINT
- Rod side: fitted to the top joints (bells), then SECTION
inserted in the ears of the double hook TOP DRIVE
- Liner side: fitted to the lower vice by means of ball

articulations. This type of connection is important
in that the cylinders must work only by pulling; as DOUBLE HOOK
the rods are thin, they might bend under the BALL ARTICULATIONS DOUBLE HOOK EARS
action of any residual pressure.
SAFETY STEEL ROPE
Moreover, the top double hook joint is damped
further by some belleville washers. For more safety CASING SCREWING DEVICE
two steel ropes are fitted to connect the torque DRIVE CYLINDERS
wrench clamps to the double hook. The cylinders IBOP VALVE DRIVE CYLINDERS
that operate the casing screwing device with the CENTERING FLANGE
relative ears remain in place, but in the lower part TORQUE WRENCH DRIVE
they don’t have the whole equipment but only the CYLINDERS
centering flange to be used as a mechanical stop of BELL CENTERING
the torque wrench in the upper position (at rest).
LOW JOINT
LOWER CLAMP (FIX) UPPER CLAMP (MOBILE)
DETAIL
SAVER SUB
77
TORQUE WRENCH
ROD CLAMP
LINERS
PISTON SIDE
CHAMBER
CLAMP BODY
ROD SIDE CHAMBER

FIX FLANGE
SLIDING BODY
IBOP VALVE UPPER CLAMP BODY
1° SAVER SUB
BOX-PIN 6 5/8" API REG
LOWER CLAMP
2° SAVER SUB BODY
SAVER SUB BOX 6 5/8" REG - 4 " ½ IF
BOX 6 5/8" REG - 6 5/8" REG (DRILL PIPE)
(DRILL COLLAR)
CLAMP UP
CLAMP DOWN (REST POSITION)
(WORK POSITION) UPPER CLAMP ROTATION
CYLINDER 78
TORQUE WRENCH
FUNCTIONING
The torque wrench is lowered (work position) with the clamps in line with the joints (saver sub– drill
string).
The torque wrench is at the top (rest position). The fitting plate of the four cylinders (two of them
operate the casing screwing device, the other two operate the IBOP valve) is fitted under the double
hook. There are also two different saver subs, one for the drill pipes (4" ½ IF) and one for the drill
collars (6 5/8" REG).
The torque wrench is made up of two hydraulically operated clamps: the lower one is fixed, the one
at the top is movable. They both have a bell.
The rotation of the clamps and the relevant torque at connection is operated via two identical
opposite hydraulic cylinders. Rotation at lower clamp, cylinders and double hook is hindered by
brackets welded onto the upper joint which extend to the fixed flange installed under the double
hook.
The lengths of the two subs are calculated so as to have the clamps of the torque wrench in line with
the joint to be screwed/unscrewed.
When the upper clamp rotates, the cylinders are retracted (completely closed).
The clamp is made up of a steel structural frame inside of which a clamp body runs (it also works as a
hydraulic cylinder). To close the clamp, the oil is conveyed to the piston side chamber. It moves the
clamp forward and brings the liners to get engaged with the tool joint. To open the clamp, the oil is
conveyed to the rod side chamber, which will make the clamp withdraw. This is a double-acting
cylinder, fed by two openings fitted on the external block which permit an automatic sequence (see
picture beside). To carry out a connection with the torque wrench it is necessary to set the make up
phase, then start the automatic sequence. This device permits to provide the connection with the
final torque.
REMARKS: - During the connection phase with the top drive, the spinning is performed by applying
a 1500 daNm torque. The final torque will be applied by means of the torque wrench.
If you have to install the torque wrench , remove the casing screwing device.
79
TORQUE WRENCH
TORQUE ADJUSTMENT
A plate with an engraved Cartesian diagram is fitted on the torque
wrench. The diagram has the torque value in daNm on the x-axis and
the setting pressure to achieve the set torque on the y-axis.
A pressure gauge is fitted above it to show the setting pressure.
Once the torque to tighten the connection has been measured,
example 4500 daNm, (see dashed lines) moving to the make up
straight line you read 120 bar.
Using a set screw wrench on a special pressure control valve applied
onto the torque wrench, adjust the pressure (pressure gauge to 120
bar).
It is possible to clamp all the drill pipes having the same connection to
this torque.
The break out line, highlighted on the plate, is for control purposes.
The connection in the example has been brought to a make up torque
of 4500 daNm at a pressure of 120 bar.
A 4500 daNm torque plus approx. 20% (example about 6000 daNm )
will be required for unscrewing.
If you want to know if the torque wrench will be able to unscrew it,
you need to know the diameter of that connection tool joint (let’s
suppose it is 168 mm with a friction coefficient of 0.7).
On the diagram, to the right of the x-axis, sign 168 mm (see dashed
lines); the horizontal line crosses the break out line and, down on the
y-axis, you can read 9500 daNm on the same line.
MAKE-UP TORQUE REGULATOR

GAUGE AND PLATE FOR MAKE-UP
TORQUE REGULATION 80
TORQUE WRENCH
CLAMPS ROTATION CYLINDERS

When conveying oil to the rod side chamber (small section), the torque you achieve is quite low.
When unscrewing (break out), oil is conveyed to the piston side chamber. In this way it involves the
whole bore, thus achieving a greater torque. To sum up, the max screwing torque is 10000 daNm, the
max. unscrewing torque can be over 14000 daNm. Diameter of drill pipes tool joint size from 2. 7/8" to
8" OD (79 – 203 mm).
ROD CLAMP UPPER CLAMP

BODY
LINERS RIGHT LATERAL VIEW
PISTON SIDE LOWER CLAMP

CHAMBER BODY
CLAMP BODY
UPPER CLAMP
ROTATION CYLINDER
ROD SIDE CHAMBER
CLAMPS SECTIONS
LEFT LATERAL VIEW
81
POWER TONG
MAIN COMPONENTS
WELL CENTER
BRONZE DISC
MAKE-UP AND (N° 5)
BREAK-OUT CYLINDERS
BELLEVILLE
WASHERS
(N° 25)
SECTION HH
BLOCK
UPPER CLAMP
ROD - PISTON - CYLINDER LOWER CLAMP

82
POWER TONG
GENERAL DESCRIPTION
The power tong is composed of two main parts: the clamps assy, that allows to execute the make-up and the break-out of connections, and the hunger assy, that allows to
move the tong from the parking position to the well center.
CLAMPS ASSY:
The clamps assy is composed by a lower clamp (fix) and an upper clamp (mobile), acted by means of apposite hydraulic cylinders. The clamps rotation cylinders are fitted to
a frame which is integral with the lower clamp. The structural frame is realized in the shape of a "C", with a tail on which the two cylinders are integrated; they push directly
onto the lower vice. Between the two vices a sort of race with a cog to stand up to all tilting moments caused by the two cylinders when the one pulls and the other thrusts.
As these two forces are not perfectly balanced, they tend to create a moment which is counterbalanced by the two races. Between the two clamps are also installed friction
parts, made of bronze discs, installed at the top of some Belleville washers.
CLAMPS ACTIVATION:
The main body of the jaw, which is internally lapped, also works as a cylinder. The rod and the piston are fitted to the flange and to the body by means of screws. The tong is
fitted with interchangeable dies to catch from 3"1/2 at 11" (89 – 280 mm). The hydraulic block, installed on the external side of the flange is directly connected to the lapped
surface of the main body, and allows the introduction of oil to operate the power tong. A non-return valve is fitted in this block to keep the vices locked once they are closed.
WORKING SEQUENCE:
The automatic sequence is automatic, and consists in: lower clamp closing (it grabs on the TJ of the rod stuck onto the rotary table) – upper vice closing – upper clamp
rotation to perform make up or break out. In this case the cylinders apply the same power either during screwing or unscrewing; the one thrusts and the other pulls and vice
versa. On the structural work side is installed the integrated hydraulic block that controls the automatic sequences. The make up torque must be checked and can be adjusted
via the driller control panel, the break out torque is always set at maximum pressure to perform unscrewing (max. torque: 17.658 daN∙m).
WORKING MODES:
Manual mode: Acting on the regulators installed on the driller’s console is possible to perform the regulation of make-up torque and clamping force. The PLC doesn’t control
the operation and can’t stop the valve operation when reaching the set point. The operator must stop the function.
Automatic mode: The selection of make-up torque and clamping force values is made from an apposite page on the drilling HMI’s software.
• To set the preset value of the clamping force is possible to use a scroll button.
• To set the preset value of the make-up torque you can operate in 2 ways:
- Press the preset push-button related to the pipes dimension and recommended torque value as indicated in the tables;
- Press the "P" push-button (potentiometer) and use the side-scroll button to adjust the value as required.
In automatic mode, the sequences are controlled by the PLC. The PLC will operate the clamping until the set point isn’t reached, then it will operate the make-up sequence
until the set value isn’t reached. If one make-up cycle is not enough to reach the set point value, the operation is automatically repeated until the set point isn’t reached.
83
POWER TONG
HUNGER ASSY
It is made up of a skid on which the
power tong is fitted to by means of
staples to permit shifting position.
The vices can shift by means of a
VERTICAL STROKE 1200 mm

central cylinder which moves them
forwards and backwards to bring
them exactly to the center of the
well.
Rotation is operated by means of
another cylinder; the whole is
fitted to a column with an upper
ear operated by a hydraulic
cylinder which brings the vices
from the work to the parking
position, towards the mast side.
The height adjustment is made on
the central column through the
sliding of one pipe inside the other.
A pipe contains a hydraulic
cylinder which, by means of its rod
turned downwards, takes in the
"L" shaped skid with a joint on the
central pipe which can be lifted or
lowered by adjusting its height
position with a 1200 mm stroke.
84
POWER TONG
MUD SAVER BUCKET

Device installed on the power tong, that allows to avoid the drilling fluid loss on the drill floor during the break-out operations.
The opening and closing of the device is realized by means of an hydraulic cylinder, controlled by an apposite selector from the driller’s console.
MUD SAVER BUCKET OPERATING CYLINDER TO SHALE SHAKER
85
CASING DEVICE
MAIN FEATURES
The casing screwing device is connected to the lower part of the double hook by means of two hydraulic cylinders
pinned to a fixed plate bearing four attachments, two of which are reserved for the cylinders which actuate the short
stroke (115 mm) IBOP (Inside Blow Out Preventer) valve, and two longer ones (285 mm) for actuating the casing HYDRAULIC
CYLINDERS
screwing device.
These cylinders do not rotate but exert a force of differing magnitude on another flange which is also fixed. In this
system the part which rotates is the internal one fitted with intermediate bearings.
The chromed jacket will be screwed onto the saver sub(4" ½ IF) which, being connected to the main shaft of the top
drive, transmits the rotation to the casing being screwed and the mud seal during filling.
FIX FLANGE
ROLLER BEARINGS
86
CASING DEVICE
PREPARATION FOR INSTALLATION
To prepare top drive for install casing

screwing device, it’s necessary to
disassembling torque wrench as following
procedure.
• Lower top drive to lay weight of torque
wrench on drill floor.
• Open the ears of double hook, to
disconnect the hydraulic cylinders of
torque wrench.
• Disconnect hydraulic hoses from EAR
torque wrench.
• Remove the pins "B" and disassemble
the centering flange. The hydraulic
cylinders remain installed because DOUBLE HOOK
they will be utilized for activate the
HYDRAULIC PINS "B" PINS"B"
casing screwing device, when the CYLINDER
centering flange will be re-installed.
• Raise top drive up to correct position
CENTERING FLANGE
and unscrew saver sub "C" (BOX 6" 5/8
TORQUE WRENCH
REG – PIN 4" ½ IF ), with power tong. SAVER SUB "C"
At this point top drive system is ready to
install casing screwing device.
87
CASING DEVICE
INSTALLATION
HYDRAULIC THURST CYLINDERS MAIN SHAFT
GUIDE COLLAR
ROLLER BEARING
SLEEVE
SAVER SUB 6”5/8 REG
CHROMED JACKET 6”5/8 REG
MUD SEAL
CHROMED JACKET
GUIDE COLLAR
RETURN SPRING
POWER TONG UPPER CLAMP
KEYS
BELL LIFTING EYES
SLOPING PLANE
ELEVATOR 6”5/8 REG
ARM
SLEEVE EXTENSION TUBE
DIES SEAL GROUP
88
CASING DEVICE
INSTALLATION
• Mount the equipment, built of one arm, that will be pinned to the side of the mast in the area where the bit breaker tong is located.
• The sleeve, welded to the arm pinned to the mast, is necessary to install the chromed jacket. In the lower part, it houses an extension tube, that allows to block
it to the power tong clamps. This system provides a double check effect, as if there two hands keeping the assembly blocked.
• Above the sleeve will be fitted some guide collars, made of two halves and including hinge and bevel. Their aim is to help introducing the saver sub (PIN 6.5/8"
REG) crewed to the main shaft of the top drive.
• Lift up the chromed jacket using the elevators PIN 6.5/8" REG and introduce it inside the sleeve. When the chromed jacket will be inserted in the sleeve,
apposite key will block it, avoiding rotation.
• Lower the top drive and screw the PIN 6.5/8" REG (saver sub) in the BOX 6.5/8" REG of the chromed jacket, then tight the connection with a couple value of
2800 kgm.
• Remove the mounting equipment.
• Bring on the drill floor the casing make-up device, position it on the centre of the rotary table.
• Insert the chromed jacket in the seat of the casing make-up device. In this operation take care to don't damage the gasket.
• Lower down the top drive to adjust the height for the connection with the eyes of the casing make-up device.
• Connect the top drive eyes with the hydraulic cylinders by means of pins.
• Open the double hook, install the two links elevator in the double hook ears. During this phase the double hook is free to rotate. Two elevator links with length
108" and diameter 2.3/4" (350 tons) should be used.
• Install the casing elevator.
LINKS
CASING ELEVATOR
89
CASING DEVICE
DESCRIPTION
The internal part clearly rotate on bearings and the flange exerts a downward force by means of the hydraulic cylinders.
The assembly is free-moving; by pushing downward, the external part slides on the chromed jacket. A mud seal is fitted inside the intermediate flange. Since the
mud tends to come up from the central hole to the annular space, if stopped by the seal, it is forced to fall back inside the casing collar.
In the lower part of the equipment, on an apposite body, are installed a number of slips, able to exert a grip onto the collar external part.
The casing collar touches a flange, inside which is mounted, by forcing and also glued, a "vulcolan" gasket, that warranties the circulating mud seal.
Inside the bell, a sloping plane engages with another sloping plane, in the slips group.
By extending a downward force, a radial movement of the slips is initialized inwards until they end up gripping onto the collar.
Suitable return springs are open in the rest position to allow the introduction of the casing collar.
Once the operation has been completed, by lifting with the coupling screwed in, the weight is unloaded, the liners release their grip and the return springs help
them go back into their rest position.
The device is provided with four groups of casing slips, which sizes are:
a) 4.½ " - 7 "
b) 7.5/8 " – 9.5/8 "
c) 10.3/4 " – 13.3/8 "
d) 16 "
SLIPS GROUP 4.1/2" - 7 " SLIPS GROUP 7.5/8" – 9.5/8" SLIPS GROUP 10.3/4" – 13.3/8 "
90
CASING DEVICE
FUNCTIONING
By varying the pressure of the hydraulic cylinders, the thrust on the make-up device changes and,
as a result, a different radial force is exerted on the liners gripping onto casing collar. The torque
that can be applied to the casing when screwing to one stuck to the rotary table can be defined as
a function of this radial force and the friction coefficient between liners and collar.
The make-up torque values can be obtained from tables according to the diameter and features
of the casing used.
There is a gauge on the control panel which indicates:
• The pressure applied to the cylinders.
• The corresponding thrust on a scale stamped on the external circumference.
By means of a pressure regulator, the applied thrust can be adjusted. Moreover, if the friction
coefficient between liners and collar is taken into consideration, the maximum tightening torque
applicable with the top drive can be defined.
By adjusting the top drive torque, the torque effectively applied is obtained depending on the
gear of the top drive (1-2-3). Normally the screwing is carried out in the first gear.
The value of the applied torque cannot be directly read. Other methods need to be used
(reference triangles on the casing joints – back-up tongs and others).
When the top drive motors are dealt with, the torque value that may be read on the scale around
the top drive torque gauge is valid when the motor revolutions are higher than 20 rpm. This is
because from 20 to 0 rpm, the motors stall and the torque drastically goes down. For example, if
we define a torque value of 1500 kgm on the scale, during the stall phase we must multiply the
torque by a coefficient of 0,85 and the result will be: 1500 x 0,85 = 1275 kgm at stall.
It is therefore useful to increase the pressure and therefore, the torque value, by 20% at least, to
reach the desired make-up torque.
For example, to obtain a make-up torque of 1500 kgm it is convenient to adjust and read on the
scale of top drive torque gauge: 1500 x 1,20 = 1800 kgm.
91
CASING DEVICE
OPERATIONS
To slide the casings down, follow the steps below:
• The casings are placed horizontally next to the rig.
• A rubber protection is fitted to the male thread of the casing.
• The casings are rolled, one by one, on a slide on which the handling dolly is fitted.
• On the female collar side, the single joint elevator is hooked to the pipe handler crane.
• With the pipe handler crane bring the casing in inclined position on pipes ramp.
• Release the single joint elevator and engaged the casing with the casing elevator
• Bring the top drive where the casing screwing device, the 350 ton link elevators and the casing
elevator are located down onto the casing head
• Remove the rubber protection fitted to the male thread of the casing
• The screwing device liners are engaged, followed by spinning and torque.
• Once the final torque has been reached, the casings can be filled up and circulation may be started.
• The casing is lifted, the slips are removed and we go down inside the well.
• The casing is wedged into the rotary table, the thrust of the casing screwing device is removed so
that, by freeing itself, it allows the air trapped inside the casing to escape.
• The casing operation is continued with the following casing.
92
CASING DEVICE
MAINTENANCE
The casing screwing device does not need any particular maintenance.
- Clean it.
- Check all its components.
- Replace its slips if they are worn out.
- Replace the active mud seal.
PICTURE: 1 PICTURE : 2
DISMANTLING
To dismantle the casing screwing device, follow the steps below:
- Remove the head from the main body (Picture. 1)
- Turn the head with the slips upwards. (Picture. 2)
- Connect the slip pad with the suitable puller
- Remove the safety slip locks. This system locks are marked with a specific
number and will have to be assembled according to the correct PICTURE : 3 PICTURE : 4
numbering. (Picture. 3)
- After removing the slip locks with the appropriate puller, remove slips,
springs and the active mud seal. (Picture. 4)
- Picture 5 shows the head after being dismantled.
PICTURE : 5 93

HH 350 B - Hydraulic Rotary Drilling Rig: Index

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HH 350 B - Hydraulic Rotary Drilling Rig: Index

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HH 350 B - HYDRAULIC ROTARY DRILLING RIG

RIG’S LAYOUT Pag. 3 SERVICE JIB CRANE:

- Dolly ..…………………………………..………...…………………………………......... Pag. 67

MAIN FEATURES RIG ORIENTATION

MAIN TECHNICAL DATA

DRILL PIPE STANDS HANDLING: Range 3 – single stand

DRILL PIPES STORAGE CAPACITY: 3627 m - (11.900 ft)

TOTAL POWER INSTALLED: 1150 kW - (1542 HP)

MAX. PULL: 317 MT - (350 short tons - 700.000 lbs)

MAX. PULL DOWN: 30 MT - (66.000 lbs)

MAX. HOISTING SPEED: 1,35 m/sec (with 100% efficiency)

TOP DRIVE STROKE: 16,6 m - (54,46 ft)

MAX. TOP DRIVE TORQUE: 4.910 daN∙m - (36.200 lbs∙ft)

POWER TONG TELESCOPIC MAST

WALK WAY - HAND RAILS

RIG UP CONTROL PANEL

JIB CRANE CONTROL PANEL

HYDRAULIC POWER UNIT DOG HOUSE

DRILLING RIG DIMENSIONS IN WORKING CONFIGURATION

REMARKS: ALL DIMENSIONS SHOWN ARE IN MILLIMETERS

DRILLING RIG DIMENSIONS IN TRANSPORT CONFIGURATION

24 Ton 15.5 Ton 15.5 Ton

EXTIMATED TOTAL WEIGHT IN TRANSPORT CONDITION: 86 TON

EXTIMATED TOTAL WEIGHT IN TRANSPORT CONDITION: 38,8 TON

LIFTING BEAM BRACKET

SKID BASE TRAILER

SKID BASE TRAILER

HPU POSITIONING FRAME

PIPE HANDLER SUPPORT SKID

OIL PRESSURE GAUGE LEVER TO ACTIVATE PARKING

EMERGENCY HAND PUMP

RIG UP CONTROL PANEL

HYDRAULIC OIL MAX.

THERMAL OVERLOAD PIPE HANDLER

ROTARY TABLE FRAME PINNING ROTARY TABLE FRAME TO SEMITRAILER

SHIMS SEAT LEVELLING SHIMS

WHEN THE ROTARY TABLE FRAME IT’S IN FINAL POSITION,

INSTALLED AND PINNING THE CLAMPS ON THE

ANCHOR MAST SUPPORT ON ROTARY TABLE.

WITH THE MAST IN VERTICAL POSITON TO EXECUTE ANOTHER CONTROL

FULCRUMS BASE FRAME PIPE HANDLER MANIPULATOR

REMOTE CONTROL PANEL – PIPE HANDLER CONNECTIONS

AUX HPU CONNCETIONS TO MAIN HPU CONNECTION

PIPE HANDLER – AUXILIARY HPU CONNECTION

PIPE HANDLER RIG UP SEQUENCE

PIPE HANDLER RAISING

PIPE HANDLER RAISING PIPE HANDLER RAISING

HYDRAULIC JACK ANCHOR PIPE HANDLER TO SKID BASE

PIPE HANDLER RIG UP SEQUENCE

DRILL PIPES CONTAINERS

PIPE HANDLER RIG UP SEQUENCE

HEAT EXCHANGER ELECTRIC MOTOR #1 HEAT EXCHANGER

MAIN HYDRAULIC POWER UNIT (HPU)

MAIN COMPONENTS DESCRIPTION

The Hydraulic Power Unit (HPU) is made up as follows:

MAIN HYDRAULIC POWER UNIT (HPU)

FLOW CONTROL HYDRAULIC POWER UNIT

DESCRIPTION OF SIMPLIFIED HYDRAULIC SCHEME

AUXILIARY HYDRAULIC POWER UNIT

NON RETURN VALVE

HYDRAULIC PISTON PUMP

MAIN TECHNICAL DATA

CROWN BLOCK TOP DRIVE CRADLE ROLLER GUIDE