DQ70BS-JH Top Drive Drilling System

User Manual

Daqing Jinghong Petroleum Equipment Manufacturing Co., Ltd.

 Prologue
The users should read this manual before using the equipment.

In order to prevent the accident, the operator should pay more attention to the safety
all the time.

The design, manufacturing and service of this product comply with the following quality
assurance system:

GB/T19001:2000 idt ISO9001:2000 Quality Assurance System

API SPEC Q1 Quality Program Specification for Petroleum and Natural Gas Industry,

This manual includes top drive electrical system, hydraulic system, mechanical
structure and installation, test-running, operation, and maintenance. Refers to other
contents which arent included in the manuals and other problems during the course of
installation, usage and maintenance, if necessary, please contact us:

Tel 86-452-2345069
Fax 86-452-2340601
E-mail [email protected]
Address No.3-2Nanyuan Road, Nanyuan Investment Zone, Longsha district, Qiqihar
City, Heilongjiang
Zip code 161005

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 Summary
Top drive drilling system (hereafter referred to as top drive) is a new type of drilling
equipment that instand of traditional rotary table. The top drive is an important
petroleum drilling equipment developed since late 1980s. Using the top drive drilling
system could greatly decrease the accident of drill pipe sticking. Improve the working
performance and working security. The top drive drilling system is honored as one of
three great technical revolutions of drilling equipments in modern time.

Jinghong company developed the DQ70BS-JH top drive drilling system with
independent intellectual property rights. It integrated the mechanical, electrical and
hydraulic control technology. Our top drive drilling system takes a fully consideration of
operation while drilling, Our top drive drilling system has the advantages of simple
structure, easy operations and long service life, etc. All above features fully satisfy the
technological requirements on site. It is an important equipment for the drilling of deep
well, super deep well, horizontal well and controlled directional well in complex geologic
condition.

The main technical features are:

1. Adopt the double cylinder opposite clamping type backup tong, it could makeup and
breakout without lock the rotating link adaptor. It is more applicable, convenient and
easier to handle, makeup and breakout is fast and easy.

2. The patented structure of rack and pinion is used in IBOP of hydraulic control; the
hydraulic pipe is embedded into the body of structure in order to avoid the damage of
the hydraulic pipe for bump, which makes the operation of IBOP more reliable.

3. The patent slid-inserting type foldable structure is used in the guide beam. It is quick,
convenient and safe to install and dismantle. Comparing with the other brand top drive
drilling system, installment time of our guide beam could save 2~3 hours.

4. The patent structure of reversed oil cup is used in the main shaft seal of the gear box,
which guarantees that the lubrication will not leak in the process because the seal of the

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main shaft is out of order.

5. Driller panel is equipped with touch screen which displays the condition of system
operation and can also monitor emergency point of equipment in time, increase the
reliability of equipment operation.

6. The counterbalance system with patent technology adopts single cylinder, it has
good balance performance.

7. The system equipped with double PLC control systems which backup each other. This
design has a great improvement of the reliability of top drive drilling system.

8. The hydraulic system is integrated on the main body of top drive, it is convenient to
installment.

9. The device of anti-loosen device with single direction tong dies, this device can load
more torque and be installed and disassembled easily.

10. The materials of cable is low-temperature resistible and wearable, which improved
the mechanical strength of cable and increased the reliability.

11. The rotating link adaptor connects with the gear box through shaft sleeve. When
tripping of raising and lowering or making a break off with bumper jars, there is no force
on the main shaft, which increases the service life of the main shaft bearing.

12. Patent technology of casing running tool, during the casing running, when the pipe
sticking or well kicking happens, it could realize the fast connection of top drive and
casing pipe, cycling the mud, avoid accidents (customer optional)

13. Equipped with the trolley of slip with pneumatic lift device, reduced the labor
intensity, and increased drilling speed (optional).

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 Contents
Prologue......................................................................................................................................................... 1
Summary........................................................................................................................................................ 2
Contents......................................................................................................................................................... 4
Part I Technical Parameters of Top Drive DQ70BS-JH.......................................................................... 8
I General Data ...................................................................................................................................... 8
II Drilling Parameter ............................................................................................................................... 8
III Main Motor Parameter ....................................................................................................................... 8
IV Cooling Air-blower ............................................................................................................................ 8
V Hydraulic Disc Brake .......................................................................................................................... 9
VI Electric Control System ..................................................................................................................... 9
VII Reducing gear box ............................................................................................................................ 9
VIII Pipe Handler system ........................................................................................................................ 9
IX Working Curve of Top Drive DQ70BS-JH...................................................................................... 10
Part II Mechanical Manual......................................................................................................................... 12
Chapter I Structure and function Introduction....................................................................................... 12
I. Structure and function introduction....................................................................................... 13
II. Top Drive DQ70BS-JH Working Curve............................................................................... 13
III. Power Swivel ......................................................................................................................... 14
IV. Pipe Handler Device............................................................................................................. 17
V Guide beam and carriage ...................................................................................................... 20
Part III Electrical Manual............................................................................................................................ 21
Chapter I Safety Operation Specification.............................................................................................. 21
I Safety Notice............................................................................................................................. 21
Chapter II Electric System Component................................................................................................. 22
I. Incoming Line Power Distributor and Protect System ....................................................... 23
II. AC Frequency Converter Driving System........................................................................ 24
III. PLC Combination Control System...................................................................................... 24
IV. Relay Box............................................................................................................................... 26
V. Hydraulic Lubrication station................................................................................................ 26
VI. Driller Panel ........................................................................................................................... 27
VII. Touch Screen ....................................................................................................................... 30
VIII. Main Power Cable .............................................................................................................. 33
IX. Other Cable ........................................................................................................................... 34
Chapter III Monitoring System (WINCC) ............................................................................................ 35
I. Screen Instruction ................................................................................................................... 35
II. System Structure.................................................................................................................... 36
III. Top Drive Drilling System .................................................................................................... 37
IV. Network Topology................................................................................................................. 38
V. Auxiliary Interface .................................................................................................................. 39
VI. Alarm History......................................................................................................................... 40
VII. Curvilinear Trend ................................................................................................................. 41

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 VIII. System Login ...................................................................................................................... 43
IX. Logout System ...................................................................................................................... 44
Chapter IV PLC System Software and Hardware ................................................................................. 45
I. PLC Program Structure .......................................................................................................... 45
II. The hardware Structure of PLC System ............................................................................. 46
III. Switch Position and State Light Meaning on CPU ........................................................... 46
IV. Module installation, Power Distribution and Indicator ..................................................... 47
V. Programmer Upload and Download.................................................................................... 47
VI. ET200M Remote Station ..................................................................................................... 48
VII. Indicator on Interface Module ............................................................................................ 48
VIII. Remote station ET200M and module remove as well as power deploy and indicator
....................................................................................................................................................... 48
IX. Communication system ....................................................................................................... 49
Chapter VI Main Electric Motor Drive System .................................................................................... 49
I. Main Electric Motor and Frequency Converters ................................................................. 49
II. Cupboard Transmission Unit Structure and Operate Principle ....................................... 49
III. Main Circuit and Control Circuit Sketch Plan.................................................................... 50
IV. Connection of Standard Control Line ................................................................................ 50
V. Extensive Characteristic of Standard Software Provide Protect for Transform, Electric
Motor and Process ..................................................................................................................... 51
VI. Adjustable Power Limiter..................................................................................................... 51
VII The primary / secondary control of Transmission ......................................................... 51
Chapter VII Installation, Commission and Maintenance ...................................................................... 52
I. Electric installation and commission notices ....................................................................... 52
II. Electric system reinstallation ................................................................................................ 53
III. Galvanization examine ......................................................................................................... 53
IV. Daily maintenance ................................................................................................................ 54
Part IV Hydraulic Manual........................................................................................................................... 55
Chapter I Safety Operation Specification.............................................................................................. 55
I Safety operation notification ................................................................................................... 55
II Electric system operation notification................................................................................... 56
III Hydraulic system operation notification .............................................................................. 56
Chapter II Hydraulic system structure and Principle............................................................................. 58
I Hydraulic System Structure and Working Principle............................................................. 59
II. Control valve unit and execute device ................................................................................ 63
III Control Loop on Hydraulic valve block................................................................................ 66
Chapter III Hydraulic oil ....................................................................................................................... 70
I Selection of hydraulic oil.......................................................................................................... 70
II Hydraulic oil Changing............................................................................................................ 70
Chapter IV Hydraulic system Commissioning and Maintenance.......................................................... 71
I System pressure adjusting...................................................................................................... 71
II Pre-setting and adjusting of hydraulic system pressure.................................................... 72
III Hydraulic system daily maintenance request..................................................................... 72
Part V Installation and Commissioning ................................................................................................... 74

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 Chapter I Safety Operation Discipline .................................................................................................. 74
I Safety operation note............................................................................................................... 74
Chapter IIInstalling preparation
............................................................................................................................................................... 76
Chapter III Installation .......................................................................................................................... 79
I. Installing the guide beam ....................................................................................................... 80
II. Installation of Top Drive Main Body..................................................................................... 89
III. Cable installation ................................................................................................................... 95
III Auxiliary Device Installation .................................................................................................. 98
Chapter IV Inspect after installation ................................................................................................... 100
Chapter V Test Running...................................................................................................................... 101
I Electric Device Test-running................................................................................................. 101
II Assist Function Test Running.............................................................................................. 103
Chapter VI Top Drive Disassemble .................................................................................................... 104
I Accessory equipments disassemble ................................................................................... 104
II Cables disassemble.............................................................................................................. 106
III Disassemble Top Drive Main Body ................................................................................... 106
IV Disassemble the guide beam............................................................................................. 110
Attachment I Top Drive System Electric Wiring Installation Inspecting list ................. 113
Attachment II Top Drive System mechanical installation inspecting list........................... 114
Attachment III Top Drive System Installation and Commissioning Record ..................... 115
Part VI Operation Manual ................................................................................................................... 117
Chapter I Safety Operation Rules........................................................................................................ 117
I. Safety operation notification ............................................................................................. 117
II. Operator safety operation notes ........................................................................................ 118
Chapter II Operating Procedure .......................................................................................................... 121
I. Inspection before starting..................................................................................................... 121
II Hydraulic system operation............................................................................................. 124
III. Main Motor Heater .............................................................................................................. 126
IV. Main Electric Motor air Cooler........................................................................................... 126
V. Braking mode selection....................................................................................................... 127
VI. Drilling operation ................................................................................................................. 129
VII. Backup tong operation...................................................................................................... 134
VIII. Elevator link operation ..................................................................................................... 134
XI. Make Up and Breakout Operation.................................................................................... 136
X Drilling ahead by single........................................................................................................ 141
XI. Drilling ahead by triples ..................................................................................................... 142
XII. Backreaming...................................................................................................................... 143
XIII Pulling out operations ....................................................................................................... 144
XIV Running Casing ................................................................................................................. 146
XV Well Control Operation ...................................................................................................... 146
XVI Jarring operation ............................................................................................................... 147
XVII Release drilling torque operation................................................................................... 148
XVIII Emergency stop operation............................................................................................. 149

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 XIX Reset/Mute......................................................................................................................... 149
XX Stop System ........................................................................................................................ 149
Appendix I System Initial State........................................................................................................... 150
Attachment I. Driver cabinet initial state................................................................................ 150
Attachment II Driller panel initial state ................................................................................... 150
Attachment III PLC Cabinet Initial State................................................................................ 151
Attachment IV Monkey board operation box initial state .................................................... 151
Part VII Maintenance Manual ............................................................................................................ 152
Chapter I Safety Operating Rules........................................................................................................ 152
I Safety Operating Rules ......................................................................................................... 152
Chapter II Daily Inspection ................................................................................................................. 153
I It is important to inspect the following items....................................................................... 153
Chapter III Maintenance Items and period.......................................................................................... 154
I Daily maintenance Items ....................................................................................................... 154
II Weekly Maintenance Items.................................................................................................. 155
III Monthly Maintenance Item.................................................................................................. 159
IV Maintenance Items in each quarter................................................................................... 162
V. Maintenance Items in half year .......................................................................................... 162
VI Maintenance Items every year........................................................................................... 163
Attachment A Torque value of thread hastening .................................................................. 164
Attachment B Recommendation of gear oil selects............................................................. 164
Attachment C Recommendation of Greases selects .......................................................... 164

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Part I Technical Parameters of Top Drive DQ70BS-JH

I General Data

Rated Drilling Depth: 7000 m114 drill stem

Max. Load capacity: 4500 kN (350ton)
Main channel: 75mm
Rated circulating pressure: 35MPa5000psi
System Weight: 12.5tMain body
Working Height: 5.9m (Bail surface to elevator upper surface)
Electric Volt: 600VAC
Rated Power: 315KWX2 422HPX2
Ambient Temperature: -3550
Altitude: 1000m

II Drilling Parameter

Rotary speed: 0230r/min adjustable

Work torque: 55kNm (continuous)
Max. Torque: 82kNmdiscontinuous

III Main Motor Parameter

Related Power: 315KW X2 continuous

Related Rotary speed: 1150r/min
Max. Rotary Speed: 2600r/min

IV Cooling Air-blower

Model: M2JA132S2A
Rated Power: 5.5kW
Rated Volt: 380VAC
Rated Frequency: 50Hz
Rated Currency: 10.7A
Rated Rotary Speed: 2905r/min

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V Hydraulic Disc Brake

Braking Torque: 68kNm (50,000ft-lb)

Cylinder Work Pressure: 7.5MPa

VI Electric Control System

VFD Input Volt: 600VAC

VFD Output Frequency: 0121Hz
Motor alarm temperature: 200
Lube oil temperature alarm: 80
Hydraulic source oil temperature alarm: 80

VII Reducing gear box

Ratio of velocity: 10.97:1 double grades speed reducing

Lube: Gear pump forced lubrication, air cooling

VIII Pipe Handler system

Rotate Head adapter rotating Speed: Factory set 3r/min

Hydraulic motor work pressure: 13.5MPa
Upper of IBOP (remote control): 6 5/8" API REG boxpin70MPa
Lower of IBOP (manual): 6 5/8" API REG boxpin70MPa
Backup Tong Diameter: 216mm
Backup tong retaining range: 87216mm
Link: 2740mm, 350t
Leaning angle: forward 35, backward 55

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IX Working Curve of Top Drive DQ70BS-JH

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Top Drive DQ70BS-JH Dimension

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 Part II Mechanical Manual

Chapter I Structure and function Introduction

The Top Drive System used on oil drilling rig could drive the drilling drill string rotate
from the top of drilling tool directly, it also could rotate and release the drilling bit, it
could move along with the guide beam up and down to finish drilling.

Top Drive DQ70BS-JH Dimension

Bail
Air cooling Device
Counterbalance device
Brake Device
Main Motor

Wash pipe
packing
assembly

Gear Box

Cover Assembly

Rotating Link Adapter

IBOP Control Device
Link
Anti-loosen Device
Manual IBOP

Back-up Tong

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I. Structure and function introduction

Mechanical structure of Top Dive Drilling System includes assembly and

components as follows:
Power swivel
Pipe handler System
Guide Beam and tackle

II. Top Drive DQ70BS-JH Working Curve

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 III. Power Swivel

The Power swivel consists of main motor, break above the motor and air cooling system
on the top of motor, balance device, bail, washing pipe assembly, gear box and other
components. The main function of power swivel is to drive the main shaft rotate to
drill, make up and break out, as well as circulate mud to ensure the drilling work
carrying on regularly.

Counterbalance device Brake and air

cooling Device

Bail
Main Motor

Wash pipe Assembly

Gear Box

1. Main motor
2 sets of Main motors are installed on the gear box. Motor
has double axles, the lower axle connects with main
transmit gear, upper axle connects with braking system.

Each main motor could supply 315KW power

continuously. The rated rotary speed is 1200r/min in
60.6Hz frequency, stepless speed is adjusted by AC
speed adjusting system. The rated output torque value of
motor could be set by currency, Output torque is
proportional to currency. The motor is protect type
compel air, cooled air pass through the motor inside and
discharge from the air outlet.

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2. Air-blower and Braking Device
Air-blower is installed above brake system, driven by the flameproof 3P AC
asynchronous motor which power is 5.5KW. Air blower starts to absorb air from air inlet
on cooler shell, release it from the air outlet on the lower part, this simple and strong
guarantee reliable airy.
The hydraulic operating disc brakes installed on the upper axle of motor, it brakes via
the brake disc on hydraulic oil tank. The brake energy is proportional to the pressured
pressed by hydraulic system, the wearing of brake disc is compensated by increasing
the movement of hydraulic cylinder. There are 2 self reset springs on each braking
disc, springs could reset when the braking discs release. The braking device has 3
functions while the top drive system working.
A. Bearing the reversed torque of drilling tools in well.
B. When touch sticking, if the motor torque is equal to the reversed torque, the drilling
tool would bounce, so take measures to brake the main shaft to prevent the drilling tool
drop out while reversal rotating.
C. It works as brakes while the motor galloping.

Encoder

Encoder Frame

Brake Body

Brake Pad
Brake Disc

Protect Cover

Brake Fix Seat

Main Motor 15
3. Gear Box

Gear Box adopts double-geared drive,

transmission ratio is 10.97:1, the gears are all
helical gear, large transfer torque, little noise.
Bearing are SKF bearing, strong anti-seismic
capability and anti-attack capability.

The lubricate system of gear box is gear pump

force lubrication. The lube pump is driven by
motor of 1.1KW produced by ABB. The motor
spreads lubricate oil on oil points of double filter
and cooling device, via main shaft return to oil
cabinet. DQ70BS-JH top drive system adopts
force lubricate mode, bearing and gear could
contact the oil sufficiently to ensure the
reliability of lubrication. Install the pressure
detector and temperature cell in the lube pipes,
inspect and alarm the pressure and oil temperature of lube system.

4. Wash Pipe Assembly

Washing pipe assembly is installed between the mail

shaft and gooseneck, the mail shaft rotating drives the
four loops of sealing ring in washing pipe packing to
rotate, so regular inspection and maintenance is
necessary to prolong its service life.

5. Gooseneck
Gooseneck is installed on the washing pipe frame, bottom
is connected with washing pipe, the sealed top is the
transmission channel of mud circling, open the top to start
fishing and well logging. Its top is connected with drilling
hose, it is the inlet of drilling fluid.

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 6. Bail balance system

Bail is the importance bearing component of Top

Drive System. The bail is connected with gear box
via bail pin, its top is hanged on the hook of crane.
Balance cylinder is fixed on bail, the main function is
to balance the weight of main body. Jinghong top
drive system adopts single hydraulic cylinder
balance mode to solve the problem of unfair force
on connecting rod in double cylinder system. Single
hydraulic cylinder designing ensure the system
works more safe and reliable.
Bail could connect with crane as well as the hook,
ensure enough well sites requires.

IV. Pipe Handler Device

Pipe handler device is the important element of top drive system, it consists of leaning
unit, back-up tong assembly, thread loose-proof device, IBOP, rotate head and other
components. It could highly improve the automation of drilling.

Rotating Link Adaptor

Leaning Device

Thread Anti-loosen Device

IBOP

Backup Tong

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1. Rotating Link Adaptor

Rotating Link Adaptor is installed on the fixed shaft

connected with gear box, and moving independently
from main shaft, the structure as the draft.
The rotation of Rotating Link Adaptor i is driven by
hydraulic motor, it could rotate CW and CCW, it
propels the link to rotate 360, it is easy to catch the
drilling stem in mouse hole. It is also convenient to
catch the drilling pipe on rack frame while the main
body is moved to Kelly board. The rotary of rotate
head normally be set at 3 r/min. It could be adjusted according to the customer
requirements.

2. IBOP
The Function of IBOP: when the pressure in well is higher than
the pressure in drilling string, cut down the channel inside of
drilling string by close up the IBOP to avoid well kick or blowout.
IBOP is installed between the saver sub and main shaft. It is
composed of remote IBOP upside and manual IBOP in low part.
Remote IBOP upside is connected with the main shaft of power
swivel, the manual IBOP in low part connects with saver sub, the
saver sub is connects with drilling stem while drilling. The inner
and outer threads in IBOP are 6 5/8REG.

The remote IBOP changes direction operated by hydraulic

tank. The gears work with rock running drives the ball valve
to rotate 90 opening and closing the IBOP. The Top drive
adopts gears and rack to realize the open and close of IBOP,
process the advantages of simple structure, driving accuracy,
and high transmission reliability.

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3. Side-hanging couple clamp

Backup tong serves for Strain at during a trip. The couple

clamp backup tong on Jinghong Top Drive system operates
only once on drillers panel directly to make up and breakout
without locking rotating head. This design is convenient to
change clip tooth, it clamps tightly. Oil pipe lines are
designed inside the body. Not any pipe lines explored to
avoid scratching as well as improving work reliability.

4 Drilling string anti-loosing assemble

Install anti-loosing assemble between the joints of main

shaft and IBOP joint and the thread of saver sub in order to
prevent them from loosing when the top drive system
breakout. See the structure on the right.

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V Guide beam and carriage

The main function of the guide beam is to bear reverse torque when top drive system
working.

The carriage connects with gear box inputs in the guide beam, and slide along with top
drive, transmits the torque to the guide beam. The upper guide beam is connected with
the bottom beam of crown block. Lower guide beam is connected with spreader beam
of the derrick. The torque can be directly transmitted to the lower derrick. The main
point is guide beam produced by JH is folding structure without install lock pins, which
makes installation convenient and reduces risk and cost.

Carriage

Bearing
Wheel

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 Part III Electrical Manual

Chapter I Safety Operation Specification

Before install, set up, operate and maintain Top Drive Drilling System, please read this
manual first.

The Top Drive Drilling System installing, debugging, operation and maintenance must
be done by professional or specially trained people, if not, it maybe cause personal
injury or machine damage.

Note It is a sign that used to the additional note about safely item
with personal and equipment.

Caution It is sign that used for to causing the suggestion of personal or

equipment injury.

Warning It is a sign used for to extremely easy to cause personal or

equipment damage.

I Safety Notice

The following safe notices are very important for correct installation, using,
maintenance of the Top Drive, all the operator and the attendant must read it carefully
and understand it:

1. Forbidden livewire work, electric system maintainer and operator must be

qualified and follow close to safety operation specification.

2. When working, do not open the safety cover over the high-voltage equipment,
do not maintenance or remove any electric element, do not pull out/connect wire with
current.

3. Forbidden open the relay box, driller consol or pull out/connect wire under
combustible gas environment.

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 4. Before maintain Frequency Converter or variable-frequency motor, turn off the
power of the Frequency Converter, test the electric current and hanging the caution
sign DO NOT shut the switch, people working. Do not maintain major loop, before DC
bus voltage lower in the safety area (DC 24V), (normal after 30 minutes). It is
dangerous for human safety and electrical equipment!

5. Cut off the mechanical interlock switch 1QF or 2QF, test the electric current
with Electroscope and make sure no voltage before replace the PLC electric elements in
cabinet.

6. Keep protective gas pressure when turn the drillers console on. If the drillers
console protective gas pressure lost, it is required to resume quickly or turn off the
drillers console controlling power.

7. Electric control house should be connected to ground wire correctly.

8. Forbidden relieve the link of software and hardware. If really needed, resume as
soon as possible after clearing fault.

9. If the temperature higher than 40, or the humidity higher than 95% or there is
dewing, do not start the frequency converter or other control power before start air
conditioner to cooling and dehumidify.

10. Check the electric control board if there is dewing before starting, when main
power was off more than 30 minutes.

11. When the temperature outside is high, do not set the air conditioning too low to
prevent electric equipment to dewing.

Chapter II Electric System Component

Electric control system is mainly composed of Coil-in electric energy power splitting protect
system, frequency conversion driving system and PLC combination control system.

The generator supplies 600V main power to the primary air switch (EIN1000) produced by
ABB in electrical control room. The air switch is perfect in bearing powerful current

22
produced when switch. The major switch connects the major power to 2 sets of frequency
converter. The other circuit is connected to auxiliary transformer, which provides main
power to the PLC cabinet of 380V.

Frequency-converter driver system is component of 2 sets of separate frequency-converter,

they drive 2 sets of 315KW AC motor separately. These 2 motors work separately or drive
together (primary and secondary mode), could self-detect and protect.

As the center of driving control system, the PLC produced by ABB adopt the mode of one
using and one preparing to ensure system working safely and reliably. This mode is: when
one system is working, another same system is prepared always, and when the running
system work wrong, another system can work immediately, so drilling will not be delayed.
PLC integrated control cabinet is needed to control the Top Drive Drilling System. The PLC
system is connected with driller consol and drilling system with the help of PROFIBUS line.
The system main PLC controller is S7-300 system programmable controller produced by
Siemens, and the CPU is 315-2DP, the remote control station is ET200M.

I. Incoming Line Power Distributor and Protect System

This system is mainly component of Income

cabinet. The Income Cabinet includes main air
switch, auxiliary transformer, controlling
transformer, and electric relay etc.

The major air switch is the master switch of the

Top Drive Drilling System produced by ABB;
auxiliary transformer power is 80KVA, and its
function is transforming the three phases
alternating current from 600 V to 380 V and
supply to integrated cabinet as power station. T1
is control station, and the power is 630VA.
Transform 600 V AC to 220V and 24V AC, as to
scram and no-voltage protection, and control the
main air switch. SB1 is installed on the integrated
cabinet, 1SB3 is the dead-stop button, installed on the drillers panel.

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 II. AC Frequency Converter Driving System

It is mainly composed of 2 sets of frequency converter and 2 AC variable frequency

motors. The frequency converter is produced by ABB, and the model is ACS800.
Three-phase alternating current of 600V is input frequency converterrectified and
inversed to transform to three-phase variable frequency power, and used to drive the
AC variable frequency motor.

AC frequency motor is produced by WARDLEONARD in U.S.A, which power is 315KW,

and rated currency is 405 A. This system has the foundation of anti-rotate. When the
drill pipe locked, the motor speed will reduced rapidly; when reactive torque is bigger
than the drive torque, the motor stop rotary, and this is called motor-blocking. When
the drive torque is bigger than the reactive torque, the motor will speed up to setting
speed.

The electric motor is added cooling fan and preheating unit. These solve the problem
of cooling and working in cold area.

III. PLC Combination Control System

Include logic control system and AC distribution system of all units. PLC Integrated
Control Panels is as follow

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A. Indicator light
a. Power indicator light of 24V: switch on the system, then power of all units is OK;
system is ready, indicator lights.
b. Hydraulic oil heating light: light on while heating hydraulic oil.
c. Motor hearting indicator: light on while motor heater working.
d. Fault/alarm light: while system alarm, light flashes (1 Hz); while fault, light
keeps.
e. Back up indicator.

B. Hand switch
a. A/B system select switch : at A position, first PLC work; at B position, second
PLC work.
b. Hydraulic oil heater switch
c. Motor heater: used for controlling major motor heater. This switch can work
independent upon PLC. The indicator displays the working state of heater. After
turn on the power of the frequency converter, the link-control is added, and the
main motor stops to be heated.
d. Reset/silence button (SB1): when system alarm, the indicator flashes, the
Warner alarms. Press silence button, the fault/alarm indicator keep state.

25
 e. Photoelectric encoder of the main electric motor (SA5): when drilling normally,
switch to normal, and this can control the rotary torque accuracy. When fault of
encoder appears, switch to unmoral, and this can stop the efficient of drilling
rate.
f. Mud pump link switch (SA6): use for mud pump link-control. In link-control state,
if the mud pump did not give the stop order, when switch the IBOP to close, the
IBOP can not close. If well blowout happen, press well control button, the mud
pump will stop and the IBOP close. In unlink-control state, operate the IBOP
switch on drillers console can control the IBOP.
g. Back up switch

IV. Relay Box

Relay box is set on the body of top drive, the function of it is providing power for
detecting element, feedback detection signal, and provide control power signal for
control valve.

It can read out air pressure signal of main cooling motor, temperature signal of main
motor, over temperature alarm, temperature signal of hydraulic oil, pressure signal of
lubricating oil, pulse signal of main motor encoder, and etc.

V. Hydraulic Lubrication station

Lubrication station of hydraulic is composed of hydraulic pump motor (5.5KW),

lubricating pump motor (1.1KW), etc. It is controlled by drillers console. The electric
motor adopts flame-proof type three-phase asynchronous motor. Lubrication station
is set on top drive body.
1. Hydraulic pump have three tap positions: 1). auto, 2). start, 3). stop.
1). Auto: switch to auto, the system will run based on the PLC program.
2). start: switch to start, the hydraulic pump will run.
3). Stop: switch to stop, the hydraulic pump will stop.

2. Lubrication pump start and stop the same time as the main electric motor.

26
VI. Driller Panel

The Driller panel has all functions for drilling operation and any other auxiliary
operation for driller; it can set top driver speed, torque, operation mode.
The Driller panel is EX type; it can only be powered on when driller panel inter pressure
is normal, otherwise, it would indicate air pressure losing on touch screen.

1). Indicator, Button/Knob Switchs Functions Showed as Followed:

No name Type Function

1 frequency 1SB1 When the frequency conversion or main motor

conversion self-locking break down, press this button and then frequency
emergency conversion stop. After eliminated the fault, should
stop button reset (CW rotation)

27
2 Ready light 1HL1 green light When systems all are ready, it lights.
3 Fault/alarm 1HL4 red light When system alarm, it flash once a second; when
light break down, it lighting.
4 Brake light 1HL2 red light When braking, it light.
5 Brake mode 1SA10 three At brake mode, when electron magnetic valve work,
Brake/off/auto positions switch system braking and it light. At auto mode, PLC
control system braking auto. At off mode, solenoid
valve releases, main shaft rotate freely.
6 IBOP light 1HL3 red light When IBOP closed, it lights.
7 IBOP 1SA11 two At closed positions, hydraulic valve close the IBOP,
closed/ope positions switch so as to close the mud circulatory system.
n
8 Well control 1SB2 red button When well blowout, press this button to link with
other equipment.
9 Motor 1SA5 3 turn Select motor of top drive: M1 or M1+M2 or M2
selection button
A/A+B/B
10 Hydraulic 1HL5 green light When hydraulic pump running normally, it lighting.
pump running
light
11 Hydraulic 1SA6 three At stop positions, hydraulic pump stop; at start
pump positions button positions, hydraulic running; at auto positions, run
switch as the PLC result.
auto/stop/st
art
12 Elevator link 1SB3 button This button controls the electric valve of link center.
centre When press it, the link is over the well
13 Elevator link ISA9 Three It is a resetting key with spring. When turn it on
rotary positions counterclockwise positions, the link rotate
Counterclockw resetting key counterclockwise; when turn it on clockwise
ise/clockwise positions, the link rotate clockwise; when unclench
it, it go back center positions automatically.
14 link incline 1SA7 three A resetting key with spring. Oil case will be
backward/forw positions, locked, when its on center positions. Turn it on
ard resetting key forward, incline oil case will push the links and
elevator to the rat hole; when reclinedwill make
the elevator be off the drilling tool when drilling.
15 Hydraulic 1SA8 three Shut/pen elevator
elevator positions button
16 motor cooling 1SA2 three For control the cooling fan running. At on, fan
fan auto/off/on positions button starts, at off fan stops. At auto, according to PLC
output result.
17 motor rotary 1SA3 three Control the direction of main motor
direction positions button

28
 backward/stop
/forward
18 operation 1SA4 three Setting according to the value of the limited max
mode positions switch torque.
drill/spin/torqu resetting on right
e
19 backup tong 1SA4 two Rotary to right, start backup tong tight the drill pipe.
Release/Lock position button Leaving hand reset to left automatic, backup tong
Reset to left loose.
20 makeup torque potentiometer In makeup operation, set limit in transducer, and set
max torque.
21 Drilling torque potentiometer In drilling operation ,set limit in transducer, and set
max torque
22 setting speed potentiometer In normal drilling operation, set limit in transducer,
of drilling and set max speed.
23 Torque Guage indicator Show true torque of Top driver output with KNm
unit.
24 Rotary Gauge indicator Show true rev of master axis with r/min unit.
25 Return/Mute Green button Back to start and mute
26 Break out jump Green button Press this button, hydraulic pump increase press to
balance oil tank, lift top drive 7cm, protect from
damaging the connect thread of pipe.

2). Throttle hand wheel

Throttle hand wheel is used for set normal drilling rotary speed limiting on frequency
converser. Handle scale is set. When rotate hand wheel inverse hour, the drilling speed
low down, and the minimum is zero. When rotate hand wheel clockwise, the drilling
speed increase, and the maximum is 230r/min. The rated speed is the main shaft
output speed 110r/min.

3). Drilling Torque

The scale of drilling torque handle is set by system. Turn the handle counterclockwise,
will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn
the handle clockwise, will increase the limit torque, while getting to the limit positions,
the limit torque the rated torque (55kN.m).

The full quantity torque of MAKEUP TORQUE is 55kN.m (set in factory).

29
4). Makeup Torque
The scale of drilling torque handle is set by system. Turn the handle counterclockwise,
will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn
the handle clockwise, will increase the limit torque, while getting to the limit positions,
the limit torque the rated torque (55kN.m).
The full quantity torque of MAKEUP TORQUE is 55kN.m (set in factory).

VII. Touch Screen

Generally, all operation interface can be divided into 3 areas, each of them display
separate information.
Toolbar: at the bottom of the screen, frame switch, data and time are all in toolbar.
Display area: in the centre of the screen, it is used for oversee and controlling.
Title panel: display name
Chick on the button to enter interface as follow:
1). Main frame; 2). Auxiliary frame;
3). Alarm frame; 4). Senior management.

1). Main Frame

Display output torque, output speed, as well as both motor parameters, include: motor
speed, running frequency, motor electric current, motor power, motor temperature,
alarm, fan running order, and etc.

30
2). Auxiliary Frame
Include elevator system, hydraulic system, lubrication system, other system notes.
Elevator system includes elevator co-rotation, elevator reversal, elevator incline back
and elevator middle position.

Hydraulic system includes: hydraulic pump run, hydraulic system oil low, oil
temperature high alarm, oil heating as well as oil temperature note.

Lubrication system include: lubrication pump run, low pressure, temperature high
alarm, heating and lubrication temperature notice.

Other system include: IBOP valve open, IBOP valve closed, backup tong clamping,
backup tong loosen, braking notice.

And include other working state notice of top drive drilling system.

31
3). Alarm Frame
Recording all alarm events when running.

4). Senior management

Frame can only enter after login; user name JH and password 8888 can login
through flashing window.

32
 Frame is as follow after login. Green is current state. User can decide by self
whether test and whether turn back.

VIII. Main Power Cable

The function of main power cable is to send the frequency conversion output of main
control cabinet to master motor on Top driver.
For installing and connecting easily cable has three segments:
1. The first segment is ground cable; its 26m, from main control cabinet to derricks
base.
2. The second segment is derrick cable; its 48m, from derrick base to top.
3. The third segment is traveling cable, its 26m, and one joint connect to the main
electric motor, another to derrick cable.

Every cable joint have four plugs, and there are labeled separated by U (yellow)k, V
(green), W (red) and zero curve (white). When joint the plugs, be sure joint U to U, V

33
to V, W to W, zero curve to zero curve.

The joint of three cable and the joint between main motor and coil out cabinet adapt
CIRCULAR CONNECTOR, and operate conveniently outside.

Pay attention of insert enough and lock reliably.

According to distance between top drive electric control room and derrick, the power
cable length is chosen. If the traveling cable and the mast cable (total 74m) is enough,
the ground cable is not need.

If the ground cable length is the same to the traveling cable, it is allowed to exchange.

IX. Other Cable

1. Driller panel Control Cable

Driller panel control and communicate totally adapt three cables.
1. Ten core driller panel control cable: Four cores for drillers console control
power, two cores for stop emergency control, two cores for transform of A/B
system, and other two cores are spare.
2. Two core communicate cable: total 2 cable, one for A system communicates,
and another for B system communicates. There are marked on joints and
sockets.

2. Cable of Relay Box

The relay box is set on top drive body. Its function is transit the assist power, control
power and control signal to the functor on body, and feedback the functor actuating
signal and detectable signal to the composite controller cabinet or frequency converser.

Cable between coil output cabinet and relay box is two.

1.15 core assist power cable: cable size 36+64+52.5
2
Among of them, provide to hydraulic pump power is 36 mm ; to 2 sets of main motor
2 2
fan is 64 mm ; to lubricate pump motor is 32.5mm ; to hydraulic oil heater is
2 2
12.5mm , lubricate heater is 12.5mm
2. 60 core composite control cable: cable size 3021
Most of them are 24v power, thirteen control power line of solenoid pilot actuated valve,

34
feedback line of detectable signal, signal line of motor encoder, and etc.
3. The two cable is divided into three section: ground cable 26m; mast cable 48m;
travelling cable 26m.

3. Repeat Earth electrode

Electric controlling system of top drive drilling system adopts three phase four-wire
system. on the cross position set the earth terminal. The earth terminal connects to
earth electrode with copper wire of 70 mm2.

The two earth electrodes are 1.8m long, outer layer galvanized. The earth terminal
connects to earth electrode with 5m long lead. The state of picture is as follow, earth
electrode is knock into ground 300mm.

All cable joint adapt fast plug connection, the plug and socket both
mark, take care when connecting or the plug may be damaged. Ensure that
lock the nut.

Chapter III Monitoring System (WINCC)

I. Screen Instruction

Each operate panel can be divide into three areas as follow to give different
information.
Toolbar: displayed at the bottom of the screen, usually used to exchange button in the
area and show current date and time.
Display area: in the central section of the screen, it is main area for monitoring and
operation.

35
 Title bar: show name.
Chick on the icon on toolbar to enter corresponding screen:
System structure screen
Top drive drilling system screen
Network topology screen
Auxiliary interface screen
Alarm history screen
curvilinear trend screen
System login screen
System logout screen

II. System Structure

Chick on system structure to enter screen as follow:

In this screen, the basic information and construction frame can be seen as follow:

36
Running state of A Cooling fan of electric motor, Running state of B Cooling fan of
electric motor

Running state of A Main electric motor, Running state of B Main electric motor

Running state of hydraulic pump; running state of lubrication pump; valve of IBOP as
well as elevator link state
In any function module, red state means closed and green means open

III. Top Drive Drilling System

Chick on the top drive drilling system in toolbar to enter interface as follow

In this screen, it is mainly show the top drive drilling system running state and data,
this is helpful for operator to know well of the state of top drive drilling system.

37
In this screen, operator can know:
A main motor parameter: Motor current, motor pressure and others totally 8 data.
B main motor parameter: Motor current, motor pressure and others totally 8 data.
Running state of A cooling fan, Running state of B cooling fan
And also top drive drilling real torque and speed
In any function module, red state means closed and green means open.

IV. Network Topology

Chick on the network topology to enter screen as follow:

In this screen, operator can know all networks state well of system, so as to make
decision fast.

In this screen, it shows remote I/O module, and network state of NO. 1 and 2 frequency
converter

38
V. Auxiliary Interface

Chick on auxiliary interface to enter interface as follow:

In this interface, it show the work state of any other auxiliary units exept top drive
driling system. General speaking, it can be divided into six parts.
1. Elevator system, show the work state of elevator.
2. Hydraulic system, show the on/off of hydraulic pump, current temperature, and
if there are fault.
3. Lubrication system, show on/off of lubrication pump, current temperature, as
well as fault.
4. Auxiliary system, show state of IBOP, electric house temperature, state of
backup tong.
5. Show body working state, include drilling waiting, drilling and others, totally 7
items.
6. Control panel indicator, include show A/B system running, and items showed

39
 with panel synchronously.
In each function module, red state means closed and green means open.

VI. Alarm History

Chick on alarm history button in toolbar, enter interface as follow:

The alarm contents include date, time, number, state and messege text.
When alarming, characters and background is the color of red, the status bar appears
a mark of +.
When alarm disappeared, characters and background color change to general color,
the status bar appears -.
Alarm confirm when alarming, button in alarm toolbar can be used to confirm.
Chick recent pigeonhole or future pigeonhole can see alarm history.

Chick on then scrollbar will appear on right when the history too long, then

alarm history can be seen totally.

40
 the first button is for given the first alarm, and the second one is for

the last alarm.

VII. Curvilinear Trend

Chick on curvilinear trend in toolbar to enter interface as follow:

In this interface, include two mode: realtime curvilinear and history curvilinear, these
two modes can be cut over by button of realtime curvilinear and history curvilinear.

Output torque and speed of the top drive drilling can be seen though curvilinear.

41
42
VIII. System Login

Chick on system login in toolbar to enter interface:

All buttons in this interface can operate only by people login. According to different
user grade, the operation limited is different. No matter in which interface, press

43
 ctrl+A can login.
Include: Reversal rotary allowed; Reversal rotary forbidden; Cut over to Chinese
interface; Cut over to English interface; User manage

IX. Logout System

Chick on logout button in toolbar, enter interface as follow

In this interface, follow mode can be used to logout, include:

Logout and return to WINDOWS, logout current monitoring system, and return to
WINDOWS.
Logoff system, logoff current user and return to welcome interface.
Reset compute,
Turn off computer

44
 Chapter IV PLC System Software and Hardware

I. PLC Program Structure

OB1: Main loop block, periodic cycle execute main program, switch over the
implementation system emergency operation mode, use function block
required to complete the driver communication and control, to achieve the
work requirement of Top Drive process control.
OB82OB85OB86OB87OB121OB122Diagnostic interrupt organization block,
it is used for the PLC system in the I / O access error, OB errors, rack failures,
communication errors, programming errors and module errors to provide
diagnostic information, and to prevent the CPU shut down.
FC3: emergency stop signal of implementation system, according to requires to
control the emergency stop signal.
FC4: control functions of implementation pump; complete the automatic control of
hydraulic pump and lubrication pump.
FC5: The ability to control the rings, to realize the control function of ring moving
forward, backwards, forward, reverses control functions.
FC6: Implement the control functions of back clamp.
FC7: Implement the spindle drive brake control functions, based on options,
achieve the shaft brake control as required.
FC8: Realize the well control state and IBOP control.
FC11: Implement the motor selection, according to working conditions, select the
working condition of spindle motor.
FC12: implement the main motor fan control function, based on selection state of
the spindle motor, control ventilation motor and spindle motor.
FC13: implement the output signal to the spindle motor inverter, select according
to the spindle motor, output signal to the converter to keep the inverter in a
standby state.
FC14: implement the data transfer functions, based on control instructions to
control the inverter to run / stop.
FC15: implement the speed of a given data conversion.
FC16: implement the torque limiter of a given data conversion.
FC17: implement the drilling process memory.
FC18: implement the given function of main inverter rotary speed and torque

45
 limiter.
FC19: Implement the main inverter speed and torque output indicator.
FC20: implement the read and write capabilities of the inverter and PLC.
FC21: implement the alarm function when hydraulic oil, lubricating oil temperature
is over.
FC22: Implement the indicating function of system failure.
FC23: implement the communication failure function.
FC24: implement the warning function of main motor temperature over.
FC25: implement the additional function of program.
FC26: implement the transformation function of the main inverter "There encoder
run / non-encoder run".
FC27: Implement the indicating function of work state.

II. The hardware Structure of PLC System

A PLC system adopts Siemens S7-300 series of products, CPU is CPU315-2DP.

Master is composed of power supply module, CPU, switch input, the switch output,
analog input, analog module.

The remote station by: ET200X (IM153-1 interface module), the switch input, the
switch output, analog input, analog module.

III. Switch Position and State Light Meaning on CPU

1. State light on CPU

SF System fault Normal on (red) Hardware or software error
or fault
BUSF Double Bus Normal light on/flash Network fault or site lose
Fault ed)
DC5V Inner power Normal light on (green) CPU power normal
FRCE pushed Normal light on (green) Programming unit pushed
output output

46
 RUN CPU Normal light on (green) CPU running state
running
STOP CPU stop Normal light on /flash CPU stop state
yellow)

2. CPU Work mode select switch to three position

Up Running+programme CPU running and can revision programme online
Middle Stop CPU stop
Down memory dump Clear inner RAM

IV. Module installation, Power Distribution and Indicator

1). All modules of PLC system are set on guide beam, when replaced loosen the
fastening screw at the bottom of the module. Install modules from front to behind one
by one, and remove the opposite order.
2). Each channel of switch valve input/ switch valve output module has one indicator,
green light means channel in 1 logic state.

3). Analog quantity input/ analog quantity output module is set to 0-10V input/output.
If the hardware configuration fault or DC24V power breakdown, the red light on module
will turn on.

4). Logging signal is analog output, factory set to 4 ~ 20mA current output signal.

V. Programmer Upload and Download

The software of PLC system can be uploaded to CUP or downloaded to CPU upper
computer.
If replace the CPU or memory of CPU damaged, the follow two methods can be used for
return routine: one is insert the memory to he new CPU while no power, then reapplied
power, the program will load to CPU automatically. * Upload and download program
should be only done by professional.

47
 VI. ET200M Remote Station

The hydraulic system is set on the body of the top drive drilling system, this reduce one
remote station, as well as assistance floor control is option, so the top drive drilling
system electric system has only one remote station. With this design, the fault rate
reduces. The remote station has 8 wave bands Code Switch used for set Profibus station
address. On the Profibus plug has switch, the last station of the system must connects
to a terminal resistance. While switch to on position, the Profibus plug connects to
terminal resistance.

VII. Indicator on Interface Module

The work state of interface module showed by ET200X interface module indicator

SF System fault Normal light on (red) Hardware configuration or

software error or damaged
BF Bus fault Normal light on/flash Communication fault with CPU
(red)
ON Inner power Normal light on Control power normal
(green)
DC24V Input/output Normal light on Input/output power normal
power (green)

VIII. Remote station ET200M and module remove as well as

power deploy and indicator

1). ET200M and module are both installed on guide beam, when replace the
module first loosen the screw at the bottom of the module. While install from
front to behind one by one; while remove from behind to front one by one. The
detail can be seen jin S7-300 hardware installation manual.
2). Each channel of switch valve input/ switch valve output module has one
indicator, green light means channel in 1 logic state.
3). Analog quantity input/ analog quantity output module is set to 0-10V

48
 input/output. If the hardware configuration fault or DC24V power breakdown,
the red light on module will turn on.

IX. Communication system

A PLC DP B PLC DP 1# 2# A PLC DP A PLC DP

1# 2# 3# 4# 5# 6# 7#
CZ12 CZ22
DP1 DP2 DP3 DP4 DP5 1 1 DP6 DP7
2 2
3 3
ON OFF OFF OFF OFF ON ON

CZ13 CZ23
A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 1 1
2 2 A1 B1 A2 B2 A1 B1 A2 B2
3 3

KA1 KA2 KA3

Chapter VI Main Electric Motor Drive System

I. Main Electric Motor and Frequency Converters

Top drive drill system has 2 frequency conversion transmission units, control electric
motor separately. The transmission units mode are ACS800-07-0490-7.

II. Cupboard Transmission Unit

Structure and Operate Principle

1). Protection grade of cupboard transmission unit is

IP 21;

2). Cupboard transmission unit components:

Fuse cutout (main button/);
Auxiliary circuit fuse plug;
Inlet contactor;
EMC Filter cupboard with +E202;
Transmission control units (RDCU, RMIO); Frequency
conversion module;
Internal braking carrier;
Profibus-DP adapter;
Pulse coder port;

49
 Communication adapter.

3. Swing-door structure
installed optional control panel
fuse-switch operating handle
contactor control the operation
of switches and emergency
stop button.

III. Main Circuit and Control Circuit Sketch Plan

Communication Model Port 1:

Control Panel
RPBA,
Connector

Communication Port 2: RATA-02C

External control by Motor Control
analog/digital inputs/outputs I/O Panel Communication optional Module:
signal. RDCO-02

AC Power Supply Frequency Convertor

~ = = ~ Output

Brake Unit

Brake Resistance

IV. Connection of Standard Control Line

3 programmable difference mimic input port: 1 voltage source signal, 2 current source
signal.

50
6 programmable digital input port
2 programmable mimic input port
3 programmable relay input port

V. Extensive Characteristic of Standard Software Provide

Protect for Transform, Electric Motor and Process

1). Environment Temperature

2). DC Overvoltage
3). DC Undervoltage
4). Transform Temperature
5). Input Shortage
6). Overcurrent
7). Power Limiter
8). Short Circuit
9). Defencive Function of Programmable

VI. Adjustable Power Limiter

1). Control signal oversee;

2). Danger frequency step over;
3). Current and torque amplitude limiting;
4). ground fault protection;
5).EXTERNAL FAULT;
6). MOTOR PHASE LOSS;
7). Protection of locked-rotor;
8). Electric motor Over-temperature protection;
9). Electric motor buffer under run protection;
10). Control PANEL LOSS.

VII The primary / secondary control of Transmission

Primary/secondary is designed for multi-transmission, which is composed of many

ACS 800 frequency conversion transmissions, meanwhile, motor shifts connect each
other via gear, chain and convey belt. Loading could be divided in to transmission units

51
fairly due to the primary/secondary function. The outside control signal could only
connected with Primary Motor. Primary motor controls the secondary by Optical fiber.

Primary motor is typical speed control, other transmission units follow the torque and
speed of primary motor. Normally, when the motor shaft of primary and secondary
motor is connected by gear or chain, the secondary should adopt torque control mode
to delete the speed gap between transmission units.

This transmission drive system has single motor mode (A or B) and double motor mode
(A+B). Double motor mode adopts the control of primary/secondary

Chapter VII Installation, Commission and Maintenance

After carried to the well site, install and commission as follow. This manual mainly
provides general requirements and notices about electric system installing and
commission.

I. Electric installation and commission notices

Notices before installation

1). Before unload electrical system, mark the cables and joints, to benefit for
reconnection correctly.
2). Before confirm everything is OK, keep power off and hang no switch on, people
working mark.
3). Generally, after installation finished completely and examined, then connect the
power cable, to ensure people and equipment safe.
4). Install worker must wear labor protection appliance.
5). While equipment unloading, confirm that power off, forbidden working while power
on.
6). Wearing safety belt while working aloft, tools and spares should put into tool bag, in
order to prevent to drop off.
7). Forbidden working outside while high windy, thunderstorm or sleet weather.
8). Pay attention to pressure level and insulating property, select suitable protection.
9). Read the electric manual carefully, master electric theory and circuit diagram.
10). Electric controlling room is designed of anti-explosion, therefore, around of room

52
should have no flammability or explosive dangerous goods.

II. Electric system reinstallation

1). Turn off the main power switch, auxiliary transformer power switch 600v power and
380v room coil in power switch before installing.
2). Electric controlling room should placement level and off the ground, to prevent
water inlet through floor. Socket of coil-out cabinet is face to the mast.
3). In the position off the electric room cape on the cross 4m, knock in earth pole, earth
resistance should smaller than 4.
4). Notice plug direction while fix the cable, first insert electric and relay box plug while
connect cable, then insert traveling cable and ground cable plug, last insert room plug.
5). All cable plug should screw down to prevent drop off or water inlet.
6). Do measure the electric motor and cable before connect the cable to the electric
controlling room.
7). Examine the cable before turn on the power.
8). Examine the element and strut of electric controlling room if where disrepair or get
loose.
9). Check and confirm selection switch in original position.

III. Galvanization examine

All cable connect right, element no disrepair, and 600v main power is preparing, the top
drive drilling system power can be turn on.
1). Check if the main power inlet cable is 600v10%, joint the main Power switch Q1
over.
2). Turn on the assistant transformer Q2 and assistant transformer coil in 1QF of PLC
composite controlling cabinet.
3). Switch on PLC composite controlling cabinet and socket. If the air damp or
temperature high, it is needed to start air controlling system to dehumidify or reduce
temperature.
4). Give power to all units from high level to low level switch.
5). Turn on the frequency converser.
6). Turn on the supervisory system.
7). Start lubrication pump, hydraulic pump and cooling fan on drillers console, and
check them rotary direction and running state.

53
8). Check if the motor of A, B, A+B runs normally.
9). Check if assistant function works normally.

IV. Daily maintenance

Daily maintenance is a necessary guarantee for electric running normally. Therefore, it

is necessary to maintenance, examine and go around regularly.

1). The most important is deducting and damp proof for electric system maintenance.
After a period of time deposited, deducting with cleaner then blow-dry with air-dryer
before start electric system. If needed, measure the insulating resistance ,ensure that
when voltage below 380v the insulating resistance above 1M and when 380-600v the
insulating resistance above 5M. According to working condition, clean dust regularly,
if condensation appears, stop the electric system and dehumidify.

2). The connection of all parts should be firm, the screw of electric element should not
be loosen, plug connector should not drop.

3). Check the cable regularly, generally 4-6 year once.

4). Pay attention to current and torque when motor running.

5). Drillers console is explosion-proof of positive pressure system, and need provide air
filter and oil-water separator to confirm air dry and clean, not have explosive and
flammable gas.

54
 Part IV Hydraulic Manual

Chapter I Safety Operation Specification

I Safety operation notification

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

Caution This sign alerts the user to procedures involving a risk of

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite risk
of injury to rig personnel.

Please read this hydraulic manual before operating, testing, maintaining and repairing

of this hydraulic equipment in order to avoid personal injury and equipment damage.

This manual contains notes, caution and warning and so on besides text. These

contents are to prompt the influence of the related operation to the safety of personal

and equipment. Please give sufficient importance to these important advices.

To avoid the damage to personal and equipment, the installing, operating and

maintaining of hydraulic system should be finished by the qualified people with the

corresponding experience. Please read this manual and the related technical

documents carefully before operation.

The above people and other people close to system equipment should accept the

training of well drilling operation, well drilling safe knowledge and using tool, and use

proper protective appliances.

55
It is impossible that this manual involves all safety knowledge with which operator

should be equipped, so such knowledge should be collected, judged and used by

operator. Strictly forbid any maintaining, repairing and adjusting equipment in the

course of top driven operating. Strictly forbid any detecting unfamiliar parts. Please

read and understand all safety warning before maintaining and detecting.

II Electric system operation notification

The hydraulic system contains electric control loop and element. Before operating
equipment and its electrical system, please notice the following proceedings:
1) Read electric manual carefully, and acquaint electric circuit diagram and equipment
demand to power and voltage;
2) Using special instrument of electric operation, and affirm the instrument with
suitable stand voltage grade and eligible protection;
3) During any operation, make sure wearing right safety ware.
4) Please disconnect all power supply, and hang sign board someone operating, not
switch on when carrying through all sorts of electric operation.
5) Before dismantling electric joint, please make out the mark to wire(cable) and
connection terminal to assure reconnect properly.

III Hydraulic system operation notification

Before operating equipment and its hydraulic system, please pay attention to the

following proceedings:

1) Read hydraulic manual carefully, and acquaint the operating principle of hydraulic

system and the structure, function and action of hydraulic component;

2) Use relief valve in system, and discharge all system pressure slowly, and affirm no oil

pressure in system pipeline and accumulator;

3) Before dismantling pipeline, please make marks to connection locations in order to

assure reconnection correctly;

4) Take effective measure to prevent hydraulic oil leakiness from going into other

electric and machinery parts.

56
5) Before hydraulic system run formally, gas should be discharged. Otherwise, the

stability or stiffness may not be sure.

6System commissioning should be carried out before hydraulic control system

running.

7) After hydraulic control system run formally, several examine and record should be

done regularly, including oil temperature, oil pressure, oil pollution level, run stability,

executing agency running condition, condition of action element Tracking Signal, etc.

Before disconnecting hydraulic pipeline, please shut down valve in

system, and prepare suitable container, oil plug, cotton, silk and so on,
in order to avoid the flow out of residual hydraulic liquid in pipeline, which will
pollute equipment and ambience.

The temperature of hydraulic equipment and hydraulic oil may be so high

as to hurt personal safety, which can reach the temperature approached
by person only after a period of time cooling.

When taking and putting components and parts, take care to avoid hurt
certain accurate fitting surface on it.

Before installing and maintaining hydraulic system equipment and so on,

please cut off the energy source of electric power, hydraulic oil and
compressed air, and release the pressure of all system accumulators.

Please lock main source of power correctly before greasing, detecting

and replacing components and parts except having special explain in
this manual.

Please wear eye protector for avoiding the damage of the high voltage oil

57
and other risks to operators.

When system is operating, the temperature of hydraulic equipment and

hydraulic oil may be very high, and please take care of protection.

Do not try to examine hydraulic oil leakiness with your hand. Please
release pressure in accumulator thoroughly before maintaining hydraulic
system, and then operate it.

Before opening hydraulic system, please clean operating area

thoroughly. Be sure to seal the hydraulic pipeline unloaded in time. The
dust is harmful to hydraulic system, and may result in equipment
operating malfunction and even personal injury.

Please check hydraulic system everyday to confirm whether pipe fittings

is of leak; hydraulic pose surface layer is of damage; pose is of snarl,
split or harden; and pipe fittings is of damage or abrasion or not. In
Addition, when detecting, screwing down or replacing any pipeline
connection of leak, please clean away the dirt on hydraulic components
and parts in time.

Chapter II Hydraulic system structure and Principle

This chapter mainly describes the structure and working principle of hydraulic system,
it would help operator operate and maintain correctly. Detailed principle of hydraulic
system is at hydraulic atlas.

Hydraulic drive system is important component of top driven system. Besides main
revolve driven by main electric motor, other functions such as up-shackle, hanging ring
declining and gyrating, IBOP switching, main electric motor braking, main body weight
balancing and so on are controlled and realized by Hydraulic drive. Therefore
maintaining and using hydraulic system correctly is crucial to run top driven properly.

58
The hydraulic system of top drive well drilling includes Counterbalancing system,
braking system, rotary head gyrating system, hanging ring declining system, inner
blowout preventer control system, hydraulic elevator, back up tong and so on, which is
made up of the following parts:

1) Hydraulic source

2) Hydraulic valve block

3) Actuating device (braking cylinder, balancing cylinder, rotating link adaptor motor,

backup tong cylinder, Leaning cylinder, IBOP control cylinder and so on).

4) Hydraulic pipe

5) Auxiliary

Hydraulic system main technical specifications are as follows:

Rated pressure 13 MPa
Rated flow 37L/min
Power 380 VAC / 50 HZ
Electric motor power of oil pump 5.5 Kw Level 6
Effective volume of oil tank 100 L
Control voltage of magnet valve DC24 V
Explosion-proof grade EXdIIBT4
The media clearance Level 7 (NAS1638), 16/13(ISO4406)
Filter accuracy: oil sorbent filter 100 um, High pressure
filter 10 um, lubricate filter 60 um

I Hydraulic System Structure and Working Principle

1. Hydraulic source
Hydraulic source consists of oil tank, oil pump motor, and etc, which supplies hydraulic
power for the system and actuating units of operating system. The oil tank and pump
unit are both installed on the top drive system body, with this design there are several
advantage: energy saving, strong property of integration, short pipeline, rapid
response of actuator element.

59
2. Oil tank
The oil tank is made of stainless steel, and its effective volume is 100L; in addition to
storing hydraulic oil, it also has the functions of dissipating some heat produced in
system operation, separating gas and sediment in oil.
Oil surface of the tank should connect with atmosphere. An air filter is set on the tank
in to reduce oil pollution. When working, pay attention to cleaning and replacement of
filter.
The oil level gauge and oil thermograph are set at the side of tank, so as to check the
oil level and temperature conveniently.

3. Pump unit
Main specifications of Explosion-proof Motor (produced by ABB)
Type M2JA132M6B
Explosion-proof grade (ExdBT4)
Rated power 5.5KW
Rated speed 950r/min
Pressure limited variable flow ram pump (produced by Japanese YUKEN):
A37-F-R-01-H-S-K

Work condition and parameter describe:

A. In order to increase the life of pump, we adopt grade 6 motor because it can provide
rated pump output with a lower speed.

B. Pump closure features: When the system pressure increases, close to the pump
preset closure pressure, pump flow automatically decrease, but maintain the same set
pressure, adjust pump flow and total closure of the pressure manually when necessary.
This pump is characterized by a better closure properties, can reduce the overall
heating system, and the closure is effective to reduce power consumption. System
pressure is set by pump.

60
24-M10 Depth 19
Decrease Pressure Increase
Outlet?32 Flow adjust blot
Oil Drain Port Rc12" Pressure adjusting bolt
Locking nut
Max 247 202
S17
178.5 59 86 86
30

22.23 -0.03
25.01 -0.16
112

0
32

101.6 -0.05 -
202

58.7

0
30.2

Inlet 6.35 +0.03

0

Outlet

4. Liquid Indicator and Thermometer

Direct reading type liquid indicator and thermometer is set

at the side of the oil tank, and the level and temperature
of the oil tank can be read out directly.
Model YWZ-150

5. Oil filter
Filter is the element to clean the oil, oil filter is installed in the oil tank by thread, it could
filter pump.
Oil filter parameters:
Model: WU-100X100J
Currency: 100L/min
Filter accuracy: 100m
Inspect the filter station via drillers panel, when the clean or replace it when alarm light
powered on.

61
6. UQK-80 ball float Liquid level controller
Model: UQK-80SDISO-400-350
Switch Position: 350-400
Explosion-proof signExdIICT4-T6

Environment Temperature: -40-70

Liquid level controller is set at the bottom in the oil tank connected
by screw thread. The oil level and temperature can be seen freely,
and alarm will appear when level too low or the oil temperature is
too high.

7. Air type oil cooler

The oil temperature allowed of hydraulic
system is no more than 80, when over 60,
air type oil cooler can be used to cool the
hydraulic oil. The cooler should be clean
regularly to remove the dust and bur on
surface.

8. 3-way ball valve

There are 2 pieces of 3-way ball valve on Top Drive body. One is installed outside of

valve group, the other is installed on the side of oil-return filter. Operators could adjust

the 3-way valve wrench according to the working temperature to decide whether the

hydraulic oil, lubricate oil needs to be cooled by air cooler. (Factory set the 3-way ball

valve wrench on the side of radiator, when the working temperature is over low, the oil

does not need to be cooled by radiator, switch the valve wrench to the by-pass)

62
9. Air Filter
Air filter is set on the top of the tank cover board, also can be used as oil filler.

Main activity:
1. Exchange air so that keep balance with atmosphere.
2. Filter the impurities in the air

10. High Pressure oil filter

Main specifications of pressure oil filter:
ModelZU-H6310
Normal flow rate 63L/min
Filter fineness10um

Oil pressure filter is set at the outlet of the pump, which is

connected with the high pressure pipeline. The filter is used to
remove the mechanical impurity in medium and pectin caused by
chemical reaction of medium, so as to prevent to block the control
valve of hydraulic valve and wear out too fast of hydraulic element. We need to
concentrate, the filter precision is very high, so we advice to change a new
filter element but not to clean when blocking.

11. Cooling of oil tank

The system for cooling the oil tank use the wind produced by main motor blower, but
not separate air blower. A cooling plate unit is set at the outlet of the main motor blower,
and when the hydraulic oil flow through the unit to the oil tank, the heat loss. This
design also saves energy well.

II. Control valve unit and execute device

The control valve unit is composed of 7 control oil channels, they control different
operational function. Each oil channel has a pressure testing point to supervise the
pressure, meanwhile, it could also discharge the gas in tank, keep system work
steadily.

63
 1. Hydraulic system schematic diagram and element list

9 MPa 6
12

13

3 MPa

11
T1 G1' G1 MP1 G13 G2' G2 MP2 G3 G4 G5 G6 G7 G8 MP8 MP9 G9 G10 MP10 G11 G12 MP12
M181.5 M181.5 M141.5 M141.5 M181.5 M181.5 M141.5 M141.5 M181.5 M181.5 M181.5 M181.5 M181.5 M181.5 M141.5 M141.5 M181.5 M181.5 M141.5 M181.5 M181.5 M141.5

(102) (103) (38) 4

(208)
1.1

ab
1.2

b
a
7
(39) (37)
10MPa (203) (205)
10

8.4

17MPa (204) 8.2 8.3

(201)
(8) (6) 2.1 (18) (16) (28) (26) (58) (56)
2.2 3.1 9
8.1 (206) (207)
b

a
a

a
b

b
(9) (7) (19) (17) (29) (27) (59) (57)

(202)

1.3mm

(48) (46)
3.2
(101) 7 MPa (104) 7 MPa (105) 8MPa (106) 5MPa

a
b
5.1 5.2 5.3 (49) (47) 5.4

(222) (242)
T
M221.5
MP T
M141.5
(221) (241)
P
M221.5
18MPa MPP
M141.5

2. Distribution of oiling port on valve block

T MPT
T

P MPP

G2' G1'

P oil input port T oil return port

MPP: system pressure test point MPT: Oil return pressure test point

4 pieces of installing screw: M16

64
 T1 G5 G12
G3 G8
G1

G2
G9
G13 G4 G7
G6
G10 G11

MVSPM22 BASPM22 MP8 BASPM22

IBOP pressure reduce MVSPM22
Counterbalance Low
Pressure control Leaning relief
MVSPM22 MVSPM22
Brake pressure reduce
MP1 RNXPM22
MP2 Counterbalance PC10 BASPM22
pressure reduce Hydraulic elevator
BASPM22 pressurereduce

Leaning relief
Counterbalance High
Pressure control MP9 MP10 MP12

Detailed control valve units specifications:

T1Braking cylinder exclusive oil return port. (Reserved)
G1: Braking cylinder MP1: pressure testing point on cylinder
G2: Balance cylinder MP2: pressure testing point on Balance cylinder
G3 Rotating Link Adaptor
G4 Rotating Link Adaptor
G5 Rodless chamber of Back up tong cylinder
G6 Rod chamber of Back up tong cylinder
G7 Rod chamber of hydraulic elevator
G8 Rodless chamber of hydraulic elevator MP8 Pressure Testing Point in Rodless
chamber of hydraulic elevator
G9: Rod chamber of sloping cylinder MP9: Pressure Testing Point in Rod chamber of

65
sloping cylinder
G10Rodless chamber of sloping cylinder MP10: Pressure Testing Point in Rodless
chamber of sloping cylinder
G11: Rod chamber of BOP cylinder
G12: Rodless chamber of BOP cylinder MP12: Testing point in Rodless chamber of
BOP cylinder
G13 Brake accumulator

III Control Loop on Hydraulic valve block

Valve group has 7 control loops to realize different operation separately.

1. Braking cylinder control loop

The Braking cylinder is the kind of spring returning
single acting cylinder, 4 cylinders consist of a
3 MPa

braking block. The pressure for braking cylinder is

lower than system pressure, so designed the T1
M181.5
G1' G1
M181.5 M141.5
MP1
M141.5
G13
M181.5

pressure reducing valve in the loop, and setting

before delivery is 7.5Mpa (This valve could be tested (102)

on the pressure testing port MP1). The pressure

could be set refers to different cases. The braking

cylinder should be safe and reliable, so we adopt the
(201)

electromagnetic ball valve as the change valve, set a

pressure reserving single valve on P port, and put an

accumulator on the port of cylinder to ensure the

(101) 7 MPa

braking brakes tightly. In the braking state, the

increased back pressure would cause braking

incorrectly, so we connect the oil return port of T
M221.5

braking cylinder back to the oil tank to ensure no P

M221.5
18MPa MPP
M141.5

back pressure.

66
2. Counterbalance System Control Loop
The main function of counterbalance system is to 9 MPa

balance the weight of equipment. It works as the

hook-compensate spring protects the thread from
wearing while making up and breakout. There are 3
grades of pressure in counterbalance system: system
G2' G2 MP2
pressure 13Mpa, sub-pressure 8 MPa, safe pressure
M181.5 M141.5 M141.5

17Mpa. The exchanging of sub-pressure could be

(103)
realized by the electric magnet of electromagnetic ball.

10MPa (203)

Accumulator is a pressure container, please attention to

its safety, blow nitrogen gas by specialized nitrogen (204)

feeding tool, this tool is used to feeding, releasing,

measuring of accumulator and repairing the air (202)

pressure. Only nitrogen gas could be charged into the

(104)
accumulator, other kinds of gas are not accepted. The
7 MPa

function of accumulator is cushion, absorbing and
dwelling. T
M221.5

MP T
P M141.5
M221.5
18MPa

Safety valve in the counterbalance system

loop is not lower than the system pressure. Otherwise, it
could not be safe enough and would impact the system
pressure to heat the system which would cause serious
system errors.

G3 G4
M181.5 M181.5

3. Rotating link adaptor control loop

Rotating link adaptor loop adopts a hydraulic motor. Although

the loop uses the system pressure, a fixed damp installed on the
P port is used to control the pressure and speed of oil motor. This (8) (6)
a
b

a
b

(9) (7)
design completes the function of this control loop by saving the
adjustment process.

T
67 M221.5

P
M221.5
18MPa
4. Backup tong device control loop
Backup tong uses the system pressure, the hydraulic G5 G6
M181.5 M181.5

one-way valve keeps the piston of backup tong cylinder at the

striction. It is mainly used to protect tong dies from crashing
while drilling.
(205)

(18) (16)

a
b

a
b
(19) (17)

T
M221.5

P
M221.5
18MPa

5. Hydraulic elevator control loop

The pressure supplied to Hydraulic elevator cylinder is

G7 G8 MP8
M181.5 M181.5 M141.5

lower than system pressure, so set the pressure reducing

valve in the loop. The value is 8MPa before delivery (This
valve could be tested on the pressure testing port MP8),
the pressure could be set according to different situation.

(28) (26)
b

a
b

(29) (27)

(105) 8MPa

T
M221.5
68
P
M221.5
18MPa
6. IBOP Control Loop

Pressure for cylinder of IBOP is lower than system pressure,

so set the pressure reducing valve in the loop. The value is
5MPa before delivery (This valve could be tested on the
pressure testing port MP12), the pressure could be set G11 G12 MP12
M181.5 M181.5 M141.5

according to different situation. The changing valve in loop

is M type, when the assist loop doesnt work, this valve stay (208)

in the neutral, whole auxiliary system release pressure.

Please note: Change this valve direction before any cylinder

acting in assist lop, otherwise the system would lose
pressure. The function of hydraulic single valve in loop is to (58) (56)

a
b

a
b
(59) (57)
lock the cylinder upward moving position (prevent cylinder
down sliping).
(106) 5MPa

T
M221.5

P
M221.5
18MPa

7. Leaning device control loop

The Leaning loop is supported by system pressure,
while the 0 type explosion proof change valve stays
in the neutral, the leaning arm and connected ring
MP9 G9 G10 MP10
and elevator could stay in any position. The function M141.5 M181.5 M181.5 M141.5

of 2 overflow valves: This valve prevent over flow

when incorrect operating happens (such as crash (38)
ab
o

b
a

(39) (37)

other parts etc), ensure the leaning arm could not

be distorted. While both of the 2 electric magnetic of
blastproof electric lock valves are supplied power,

the ring and elevator are in the nature state while (206) (207)

drilling to protect from elevator wearing. Install

fixed damp on T rode to limit the elevator returning (48) (46)
b

a
b

speed.
(49) (47)

T
M221.5

P
M221.5
18MPa

69
 Do not adjust the preset pressure of adjusting valve without permission.

Chapter III Hydraulic oil

Hydraulic oil is the important component of hydraulic system. The hydraulic oil
performance affects the system performance and life time directly, as well as the
system reliability. So high attention should be put on it, and selecting the famous brand
products is necessary.

I Selection of hydraulic oil

In order to meet the requirements of hydraulic driving, please choose the recommend
hydraulic oil in the table below. Choose the high viscosity oil when the ambient
temperature is high, otherwise choose the low viscosity oil.

Recommend hydraulic oil and specialized temperature

Hydraulic oil

Specialized temperature range

Manufacturer
-30to -7 -6 to 20 21to 55

ISO Viscosity Grade 10 32 46

Mobil Mobil Mobil
Mobil
DTE21 DTE24 DTE25

II Hydraulic oil Changing

1. Change the hydraulic oil following the principles below:

a. Change the hydraulic oil after 3 months for the first use of the new system.
b. In normally using period, recommend to change the oil in 6-12 months.
c. Change the oil according to the analyzing result or experiences.
2. Feed or change hydraulic oil should notify the following items.
a. According the stipulation to change the hydraulic oil, the feeding oil must be

70
same to the precious oil brand and grade.
b. While feeding, oil must through a filter cart which filter accuracy is 20um,feed
oil through oil feeding port, and keep clean of each parts.
c. Quantity in oil tank: First time feeding, oil should fill full tank (observe oil mark
on the tank). Re-feeding oil to top limit of oil mark after the pipes and cylinder fed oil
when the test-running finished.

Forbid to mix oil in different brands or grades.

Do you use the fuel oil instead of hydraulic oil.

Hydraulic oil is the important component of hydraulic system. The hydraulic oil
performance affects the system performance and life time directly, as well as the
system reliability, so high attention should be put on it.

The oil should be replaced after half year, then change it once every year. The cleanse
of oil is very important, keep to use one brand and type of oil, keep rubbish and water
away from the system.

Forbid to mix oil in different brands or grades.

Chapter IV Hydraulic system Commissioning and

Maintenance

I System pressure adjusting

The adjusting of system pressure depends on the extra-connected pump, meanwhile.

There is a safe spillover valve, please note: the valve is mainly to protect. The adjusted
pressure of this valve could be higher than the pressure supplied by pump in the system
normal state, although adjusting this valve might influent system pressure. If operate
this valve incorrectly, the adjusted pressure is lower than pump pressure, which would
increase the system temperature and cause problems.

71
II Pre-setting and adjusting of hydraulic system pressure

1) Oil tank pressure setting

z Leaning tank is two-way cylinder, the pressure is supplied by pump source.
z Braking tank is one-way cylinder, its pressure supplied by adjusting pressure
reducing spillover valve.
z Rotating heading is oil motor loop, its steady pressure is gained by adjusting
pressure reducing spillover valve.
z Clamping tank is two-way cylinder, its pressure is gained by adjusting pressure
reducing spillover valve.
z IBOP Oil tank is two-way cylinder, its pressure is gained by adjusting pressure
reducing spillover valve.
z Counterbalance tank is one-way cylinder, its pressure is gained by adjusting
pressure reducing spillover valve. Connect an accumulator to keep the pressure.
In order to prevent the pressure in accumulator is too large, connect a spillover
valve in the loop to limit the pressure.
2) Commissioning of Hydraulic system
(1) Silt up the connect block of balance cylinder pipes. Make sure the spillover valve
of hydraulic pump is open, start the motor of hydraulic pump, inspect running
direction of the motor.
(2) Test the hydraulic system in the condition of motor running correctly, including
IBOP oil channel, Back-up Tong oil channel, Braking oil channel, rotating head oil
channel, leaning oil channel, counterbalance oil channel.

III Hydraulic system daily maintenance request

1) Daily inspect Item

Inspect the hydraulic source, the items include:

(1) Check the juice level gauge of oil tank, oil level could not be lower than the
middle line of juice level gauge.
(2) Whether the working pump shake, noise or heat abnormally.
(3) Inspect the system pipe leakiness.
2) Regular inspect (every 3 months)
(1) Fasten the bolts on motor.
(2) Inspect the air pressure of accumulator.

72
(3) Inspect the heat exchange capacity of air cooler, oil temperature at inlet should
higher than outlets.
(4) Inspect and clean the air filter.
3) Braking device maintenance
1. Inspecting
1) Wear of friction plate on Brake.
2) Symmetrical wear of friction plate on Brake.
3) Whether the hydraulic brake pipe leak.
2. Exhaust of brake oil channel
1) Press on the braking system oil channel.
2) Open the air discharging connector on the top of hydraulic brake, fix the
connector up when air discharged.
3) Operate the other brake as the above operation.
3. Replacement of the brake chips
Replace the brake chip when it only 2mm. The new brake chip need sometime to
run-in before get the rated torque.
Replace procedure:
1). Release the oil pressure of the hydraulic system.
2). Loose the bolts and spring pins.
3). Upward and out-moving the brake chip.
4). Slid the new chips in.
5). Install the bolts and spring pins.
6). Fix the bolts.

73
 Part V Installation and Commissioning

Chapter I Safety Operation Discipline

I Safety operation note

In order to avoid personal injury or equipment damage while the installation and
disassembly of the top drive drilling system, this manual including warning, caution
and note three level of information.

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

Caution This sign alerts the user to procedures involving a risk of

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite

risk of injury to rig personnel.

The top drive drilling system should be installed and tested by the
qualified operator with experiences. This manual and related technical data
should be read carefully before operation. Working personnel and other
personnel who enter the working area of the system should have got the
training of drilling operation and safe knowledge.

When the system is running, do not touch the rotating parts of the
device, avoid to get a badly hurt of person or get damage of the device.

Before installation and maintenance of the hydraulic system, cut off the
power supply, close the valve and release the pressure of accumulator.

74
In the installation, dismantle and maintenance process, the power
switch must keep off status and hang mark plate of No Switching
On.

Before install and dismantle the electricity connection, the operator

must mark the electric wires (cables) and wire connectors to ensure
the correct reconnection.

The working personnel should wear the suitable protective articles,

such as glove, helmet, etc.

This manual only includes the basic safety knowledge which operator
should know, other knowledge should be collected, judged by the
operator.

All the installation work should meet the requirements of the related
standards and specifications inside this manual, and should be
confirmed by the installation technology personnel and safety
personnel.

Before operating the electric system, the operator should read the
<electrical manual> to get a well known of the electric circuit diagram.

Before operating the hydraulic system, the operator should read the
<hydraulic manual> to get a well known of the hydraulic system
principle.

75
 Chapter II Installing preparation

1. Before installing the top drive drilling system, the relevant personnel should
prospect the working site and have a meeting to confirm the installation plan.

2. Installation person should check all the equipment according to the packing list,
confirm that all the devices, accessories and installation tools are prepared and in a
good condition to avoid the stoppage in the process of installation.

3. The installation technical staff and safety staff should arrange a technical discussion
to ensure that everyone who participates in the installation knows the installation
scheme and safety measure. Set out a detailed working schemes and working site
layout to increase the working efficiency. We suggest carrying out the working
according to <installation reference table>.

Installation reference table

Item Device needed Staff Working time

Arrangement of electric
control house, driller truck crane (over 30
3-5 persons 2 hours
panel, the body and tons)
guide beam
pneumatic winch,
Hanging of the main
truck crane(over 50 5-7 persons 2 hours
body and guide beam
tons)
Centering and
2-3 persons 1 hour
connecting the wires
Driller and auxiliary
System testing 1 hour
devices

Note: 1. Installation time is about 6 hours (reference time)

2. The working time is not fixed, it will change with the practical
conditions of each well.
3. Training time is depends on the situation of the operator, but the
total training time is no less than 16 hours.
76
 4. Well site arrangement
Before installing the top drive drilling system, please consider carefully the
arrangement of site, including:
1) Put the electrical control house on the flat ground.

The ground where the control house placed must be flat.

2) Put the electrical control house, rig cable box on the left back of the drilling
platform.
3) According to the layout of the well field, put the top drive drilling system main
body (with transport frame), guide beam (with transport frame) and moveable cable
box on the place which is convenient to install.

It should be consideration the layout position of guide beam, main body,

cable box and installation accessories when the item reach the well site.
Try to put them on the suitable place in order to convenient to hoisting, avoid
repetitive operation, save the installment time.
4) Measure the derrick beam installing of anti-torque, according to the width of the
derrick beam, weld " block" on anti-torque beam components.
5. Turn off the limiting device of the travelling crane; make sure the hook block could
reach the top of the rig.

77
Top Drive well field facade layout

78
 Chapter III Installation

Procedure of Top drive Installation

Set up the lifting lug (the first time install the top drive on the rig )

Adjust the guide beam adjusting unit

Install Guide Rail Joint Device

Set up the Sliding-insert folding type guide beam

Set up the main body of the top drive drilling system

Set up the anti-torque beam

Set up the cables

Set up the auxiliary devices

Testing and commissioning the system

79
I. Installing the guide beam

1. According to mast situation, the lifting lug of the guide beam should be installed on
the top of rig for first time. General, we adopt welding or bolting. The material of the
lifting lug is Q345B. Take care of the direction when welding (see the chart below). It
must use high strength bolt and the bolting joint should be safe and reliable.

Welding requirement: doing the job by the technical staff directed.

The welding staff must passed the welder test.

The connecting bolt must be the M30 grade 12.9. After it being fixed, it
must locked with the pin.

Connection (welding) must firm and reliable, take care when working at
the high position.

2. Lifting the guide beam adjust unit and guide beam docking assembly to the drill floor
by the crane

80
3 Install the guide beam adjust unit, make sure the rig height first and calculate the
guide beam length base on the rig height.(connect the different guide beam adjust
plate according to the chart),connecting the guide beam adjust plate and guide beam
adjust back plate.

Used to derrick 43m

Adjusting For Derrick 45m

Back plate

Adjusting Plate

Connect different positioning point to meet different height rig requirements.

81
4. Install the upper guide beam connection device, using the supplied mount pin
connect the connection device with the guide beam adjust plate, and lock the pin.

Adjusting plate of Guide

Beam

Connecting Device of Guide

beam

Steel rope length 50m

5. Using the supplied wirerope fix the guide beam plate on the hook block.

Adjusting Back plate

Steel Rope

Crane hook

82
6. The installation staff climbs to the travelling crane to assistance and operate the
guide beam and main body installation process.

7. Lifting the traveling block with the guide beam adjust plate to the top of the rig.
Justify the adjusting plate and the crane crown lug; connect them with the U-ring and
connecting pin. Setup the lock pin.

Crown Lug
U Ring

Adjust
Back plate

8. Remove the wirerope between guide beam adjust plate and traveling
block.(attention: connect the wirerope with the traveling block)lower the traveling
block.

Adjust Back plate

Remove the connection

Crane Hook

83
 When working at height, the working staff should be careful about the
fallen things.

If it is the first time install the rig, it could fix the crown lug and guide
beam adjust component on the rig before rising.

9. Using the traveling block lift the guide beam to drill floor, put them under the hook
block in order to install conveniently.

10. Penetrate the upper guide beam connection device wirerope into the lower part of
the guide beam connection device.

84
11. Connect the travelling hook with the lift locking device of install cart. Fix the
installing cart and travelling hook by the wire rope and U ring, rise up the crane slowly,
lift the 5th section guide beam to reach the connection panel.

Travelling Hook

Lifting Lock
Wire rope

85
12. Operator on the drill floor pulls the wirerope to connect the guide beam. Fix the wire
rope on the derrick back beam, avoid from disturbing drilling.

Joint State

When working at height, the working staff should be careful about the
fallen things.

13. Move the guide beam carrier.

86
 14. Lower the traveling block, carriage moves down, make the guide beam adjust
component bear the weight, the guide beam will connect together automatic by its
weight and keep vertical.

Install State
7thGuide Beam

Vertical State

2nd, 3rd, 4th, 5th, 6th Guide

1st Guide Beam

87
15. Lock the centralizer block shaft of top guide beam adjusting panel.

Centralizer Shaft Cap Centralizer Shaft

16. After the guide beam gets vertical, measure the guide beam safe distance (The
distance from guide beam bottom to the drilling floor is 2-2.2m), lower the hook to
guide the cart to the end of guide beam, move the cart.

Lift Locking

Wire rope

This State is dangerous

88
17. Adjust the flexible distance of reactive torque through guide screw. Preset the

center of guide beam to the center distance of installed guide beam.

Rotate the guide screw in CW

and CCW, adjust the center of
guide beam to its center
distance.

II. Installation of Top Drive Main Body

Chart of top drive main body and transport frame hoist.

89
1. Lift the top drive to drilling floor by crane, put it in front of guide beam.

2. Lower the hook to proper height. Connect the 3 points (2 points on the transport

frame, 1 point on bail) with hook by the supplied wire rope. Lift the 2 points on the

bottom of transport frame by crane.

90
3. Upright the assemble frame by Hook and crane, the back of assemble frame is right

to installed guide beam, ensure the transport frame lean on guide beam surface.

Crane and hook must cooperate while uprighting assemble frame, avoid
crashing.

4. Dismount the locating pin on bottom guide beam, regulate guide screw on it, ensure

bottom guide beam and transport frame in the same vertical plane.

Guide Pin

Adjust Screw

91
5. Assemble frame of Top Drive connect with guide beam by pressure plate, insert pins.

Pressure Plate

6. Dismount the pulley of guide beam block, disconnect the transport frame and top

drive.

Pulley of guide beam block

92
7. Connect the hook and lifting ring, pull up the hook slowly, top drive moves upward

along with guide beam. Disassemble pressure plate to disconnect guide beam from

transport frame, move the assemble frame away by crane.

Pressure plate

8. Regulate guide screw on the bottom guide beam, get the bottom guide beam back.
Fix the locating pin and insert pins.

Guide Pin

93
9. Re-adjust the reactive torque beam, keep the center of main shaft and wellhead in

the same line. Fix all the bolts, insert pins.

Rotate guide screw in CW and CCW, adjust the center

of guide beam to the center distance of installed guide
beam.

All connects must be fixed, reliable and safe.

10. Observe top drive slipping condition while moving up and down in the

movement scope.

Keep the top drive are not jammed while slipping up and down.

11. If the top drive slides up and down without problem, then connect the crane

anti-collision limit device.

94
III. Cable installation

1. Hang the movable cable box onto drilling floor, put it on the left back of drilling floor.

2. Inspect the bolts and card condition on the movable section cable, install it on

the derrick by pneumatic crane (position refers to well site plan), move the cable box.

95
3. Install derrick cable hanger on rear beam of derrick (keep the same height with trip

cable hanger)

Power Cable Frame

Derrick Back Beam

4. Hang cable in derrick cable box up, connect with derrick cable hanger and lock. The
cable drop to reach ground, it should be paralleled on derrick and not crossed.

Power Cable

General Control Cable Auxiliary Power Cable

96
 5. Connect the trip cable and derrick cable, joint 700509 and 700503, 700510 and

700501, 7200511 and 700502. Connecting as follows:

Derrick Side Beam

Derrick Power Cable

Trip Auxiliary Power Cable
700509A 700502

Derrick Back
beam

Trip General Control Cable

700501

Derrick Power Cable

700509B Derrick General Control Cable Trip Power Cable Trip Power Cable
700510 700503A (700503B)
Derrick Auxiliary Power
Cable700511

All cables are connected by quick connector, Marks on the joint of plug
and jack (label and color), alignment mark while connecting.

Connection must be safe and reliable.

6. Lay the cable on ground from cable box to derrick bottom. Place the cable on ground
to derrick bottom. Cables connect with the derrick cable.

97
Remark: Ground cable length 26m. If the cable length is 48m, it could connect
the trip cable and electric control house, ground cable can be used as backup.
Refer to the well site condition to connect or disconnect the ground cable.

Keep the cable properly when it is unnecessary to join ground cable.

All cables are connected by quick connector, Marks on the joint of plug
and jack (label and color), alignment mark while connecting.

III Auxiliary Device Installation

After finishing installation of guide beam, Top Drive System, and cable,
distribute personnel to start the following install at the same time.

1. Install the elevator link on Top Drive body.

2. Connect the trip power cable (700503), auxiliary power cable (7005011),
comprehensive control cable (700510) plug with the cable of top drive body
(Distinguish from color).
3. Install drilling hose (position according to the well site layout)
4. Install electrical control house, at the position of the 2 opposite angle of electric
control room, stab steel into ground at 1.6m. Connect steel and control house with
ground lead.

Control House must connect with earth to ensuring operator and equipment safe.

5. Move the Driller panel from electric control room to drilling floor, put it in a wide place

in the driller house for easily operating.

6. Connect the cable of driller panel (include 10 core control cable (700513), 2 pcs of

communicate cable (4 core A: 700514/ 4 core B: 700515)).

98
 All cables are connected by push fit, Marks on the joint of plug and jack.
7. Connect air pipes, adjust input air pressure, ensures the air pressure on driller panel

is lower than 0.2Mpa, higher than 0.12 Mpa.

8. Feed lubricate into gearing box by oil cart. Feed hydraulic oil into hydraulic oil tank.

Hydraulic oil inlet

Lubricate oil inlet

9. Connect generator and electrical control house, generator offers 600V main power

and 380V auxiliary power supply.

99
 Chapter IV Inspect after installation

1. Throughout inspection is necessary after installation of Top Drive System, confirm

every installation is correct, all the transport and fixing device has been removed, each
part are ready for test-running.
2. Inspection should be carried out by technical supervisor of Top Drive installation.
3. Installation should be carried out according to attachment I < Top Drive System
Installation Line Connecting Inspect list >, attachment II <Top Drive System
Installation Inspecting list>.
4. Inspecting procedure and methods refer to <Operating Manual>.

Inspection must be carried out by professional operator.

100
 Chapter V Test Running

I Electric Device Test-running

1. Switch on the main power switch.

2. Power on the accessory transformer switch in power switch box and power switch of
PLC which is from accessory transformer or wire feeding switch in PLC box.
3. After supply power, Check the Power Phase sequence Relay in General control box. If
the phase sequence is correct, the light on relay does not work, otherwise, the light
powers on. For 600V Power Input line system, it needs to re-adjust the phrase
sequence. For the power system supplied by 600V and 380V, adjust the sequence of
380V only, go ahead to operate the electric operation when the relay director is not
light.

Operator must ensure the phase sequence is correct before operation,

otherwise all electrical elements might be destroyed.

4. While the temperature is higher than 40 and wetness is higher than 95% or has
condensation, start air conditioner to remove dampness or drop temperature.

101
5. Supply power to each function unit. Processes are as follows:

6. Start the lubricate pump, hydraulic pump and cooling fan on drillers panel, inspect
rotating direction and running condition.

7. The pressure of hydraulic system is already set before delivery. Operator on site is not
allowed to adjust it. In special condition, adjust operator must be professional personnel
who is familiar with the principle of top drive hydraulic system. The detailed adjusting
procedure refers to <hydraulic manual>.

8. Start the main motor, check the running condition. Operating procedure refers to
<Operate manual>

102
II Assist Function Test Running

Start the hydraulic pump, rotate the buttons on drillers panel, test its assist function.

1. Inspect rotating head rotate CW and CCW condition.

2. Check whether the link move forward, backward and middle correctly.
3. Check whether the Back-up tong clamps and releases flexible.
4. Break device acts correctly.
5. Inspect IBOP switch.
6. Start well control button, inspect the main motor and IBOP shut down.

Please fill the form in operate manual.

Attachment III <Top Drive Device Installation and Commissioning Record >

103
 Chapter VI Top Drive Disassemble

Top Drive disassemble procedure

Cut off the once power and each function block

Dissemble Auxiliary Equipment

Dissemble Cables

Dissemble anti-torque beam

Dissemble Top drive main body

Dissemble the slid-insert type foldable guide beam

Dissemble the guide beam connection device

Dissemble adjusting components of guide beam

I Accessory equipments disassemble

1. Cut off the ONCE power switch.

2.Switch off all function units.

3. Shut down the active force power switch.

104
4. Disconnect the driller panels cables joints. (include 10 core control cable (700513),

2 pcs of communicate cable (4 core A: 700514/ 4 core B: 700515)). Pack the cable

for next installing.

5. Disconnect the ground cable and derrick cable in the condition of connecting the

ground cable.

6. Disconnect the plugs of Power cable (700503), assist power cable (7005011),

general control cable (700510) and the plug of top drive cable. Protect the connector

by cover from damaging in dissembling.

7. Disassemble the elevator.

A. Release the bolts and shafts on the elevator shelter and joints, move the
elevator.
B. Fix these bolts and shafts on Top drive main body.
C. Lift the elevator link to the easily delivery position.

Elevator
shelter
bolt

Elevator

Joint shaft

105
8. Disassemble the elevator, fix the leaning cylinder.

9. Disassemble drilling hoses and top drive mud pipe.

II Cables disassemble

1. Disconnect the joints of the travel cable and derrick cable. Disconnect the main
power cable, general control cable and assist control cable in turn.

2. Remove the connection between derrick and cable hanger, lift the cable hanger and

cable into the cable box, and put the cable box in position convenient for delivery.

III Disassemble Top Drive Main Body

1. Lift the transport frame to drilling floor and close to guide beam.

2. Disconnect the guide pin on the bottom of guide beam, rotating adjust screw, make

106
bottom guide beams and transport frame alignment.

3. Fix the top drive transport frame and guide beam by the backup press panel and

bolts.

Pressure plate

107
4. Lower down the hook of Traveling Block, when the top drive along the guide beam

near to transport frame, lower the hook slowly, inspect whether the wheel of block

enter into fixed guide beam surface of transport frame. After the block transit to the

fixed guide beam surface, lower down the hook until top drive insert into the transport

frame completely.

5. Insert the pulley pin of guide beam, fix the top drive mainbody and transport frame,

disassemble the hook and link.

Pulley of guide beam block

6. Dismount the guide beam and top drive body, separate the guide beam and transport

frame.

108
7. Connect the 3 points (2 points on the transport frame, 1 point on bail) and hook by

wire rope. Hang the 2 points on the bottom of transport frame by crane. Lay it down by

hook and crane

8. Adjust screw and return the bottom of guide beam.

9. Lift the top drive main body to the easily delivery position by backup wire rope.

109
IV Disassemble the guide beam

1. Lift the assemble cart to the drilling floor, connect with the hook by rope and U ring.

Lift the cart top by pneumatic hoist, balance its center in the lifting process avoid

overturning and hurting operators.

Lift locking
Wire rope

This state is dangerous!

2. Raise the hook, slip the assemble cart to the top of guide beam.

3. Disconnect the reactive torque beam and guide beam, move the anti-torque beam to

the position easy to package.

110
4. Lift the guide beam frame to drilling floor.

5. Install Operator climbs to the clown block for conducting the disassemble process.

Command the crane raises slowly, the install cart bearing the weight of guide beam,

withdrawal plate falls to the top guide beam by its gravity, the guide beam joints open.

111
6. Lower the hook, hang the bottom guide beam to transport frame by crane, continue

to lower the hook, put all guide beam into transport frame.

Crane assists this

part guide beam

7. Disconnect the crane hook and cart, fix the cart on the guide beam.

8. Hang the adjusting back panel, guide beam and transport frame under the drilling

floor for packing.

9. Packing the dissembled top drive and auxiliary components.

112
Attachment I Top Drive System Electric Wiring Installation

Inspecting list

No. Item Inspect Content Result

Electric
1. Through the inspecting, Check the
1 leakage
equipment cabinet has electricity or not.
Inspect
1. earth cable is installed correctly, measure
Electrical earth resistance.
2 2. Air conditioner test running well.
control house
3. Supply voltage is regular.

1. Power cable is connected correctly

3 Main body 2. Cable plugging device is locked correctly.
power cable 3. Trip cable does not scratch other devices.

1. Power cable is connected correctly

Assist Power
4 2. Cable plugging device is locked correctly.
control cable
3. Trip cable does not scratch other devices.

1. Control cable is connected correctly

General
5 2. Cable plugging device is locked correctly.
control cable
3. Trip cable does not scratch other devices.

1. Stable laying, reasonable arrangement.

2. Cable plugging connected correctly and
locked well.
6 Driller panel
3. Air Pressure is regular.
4. Panel lights works well, meters display
regularly.
Remarks:

Record Check

113
Attachment II Top Drive System mechanical installation

inspecting list

No. Item Inspect Content Result

1. Guide beam 1. Check the connection between U ring
hang and guide beam.
2. Check if the affix connection is reliable.
2. Guide beam 1. Whether the guide beam is vertical and
body and neat.
connection 2Whether the bolts locked tight.
3. Lifting ring 1. Inspect the connection between lifting
connects with ring and hook, whether the anti-off device
crane or hook installing is in place
4. Reactive torque 1. Whether the bolt is fastening.
beam 2. Whether the joint pin with guide beam
is in place.
5. 1. Whether all auxiliary devices are taken
off.
Top Drive main
2. Whether the liquid level of Lube oil
body
and hydraulic oil normal.
3. Is there any crash between each part on
top drive body.
4. Inspect the components of top drive.
5. No obstacles in top drives routine.
6. Main shafts Inspect the bolts of anti-loose block.
three anti-loose Whether the anchor is firm.
blocks.
7. Pulley Inspect whether the back of pulley friction
with guide beam.

Remark

Record Check

114
Attachment III Top Drive System Installation and

Commissioning Record

No. Item Testing Technical Request Result

Rotating direction of
1. Normal voice
lube pump, motor
1 2. Motor rotating direction is correct
of hydraulic pump
3. Air pressure is normal
and air-blower
1. Hydraulic lubricating system runs
Hydraulic, well, pump sound is normal.
2
lubricating system 2. Gear oil, hydraulic oil pressure,
temperature is normal.
1 Indicator works well.
Indicator on Driller
3 2 Indicating correctly.
panel
3 No alarming.
Button switch hand
All the button switch hand wheel
4 wheel on drillers
work well.
panel
1. Every function unit runs well.
2. Air conditioner runs well.
5 Frequency house
3. Frequency houses panel indicates
running well.
1.Rotating direction is correct.
2. Start and run regularly without
Motor starts and
6 sluggish and crawl.
stops
3. Normal stopping and delay breaks is
regular.
1. No noise in gear box, running sound is
normal.
7 No-loading testing
2. No omit, smell or block.
3. No calibration while test-running.

115
 Temperature of Motor raises lower than
Load test and make rated temperature in limited time. (Note:
8
up and break out Torque value and curve displayed on the
test win CC screen in electric control house)

1. Rotate move smoothly

9 Rotating link adaptor 2. Direction changing without shock.
CW and CCW test 3. No omit

Link leaning, neutral 1. Act well

10
floating test 2. moving smoothly

Breaking device 1. Action accurate.

11
testing 2. Main shaft breaking regularly.
1. Clamp and loosen correctly
12 Back-up tong test
2. No omit

Counterbalance 1. Make up and breakout is normal, top

13
device movement drive upward jumping is realizable.
test
1. Act flexibly, no blocks.
14 IBOP function test
2. Signal outputting correctly.
Remark:

Record Check

116
 Part VI Operation Manual

Chapter I Safety Operation Rules

I. Safety operation notification

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

Caution This sign alerts the user to procedures involving a risk of

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite risk of
injury to rig personnel.
1. The top drive drilling system should be operated by the qualified operator with

experiences. This manual and related technical data should be read carefully before

operation.

2. Working personnel and other personnel who enter the working area of the system

should have got the training of drilling operation and safe knowledge.

3. The working personnel should wear the suitable protective articles, such as glove,

clothing etc.

4. In this manual, signalmeans it is the operate elements of electric control system,

such as buttons, switches etc. Non-professional staff and non-qualified personnel could

not install, test-run, operate or maintain the top drive system avoid physical and

equipment injuring.

5. Repairing and maintenance could not be carried out while the system working.

117
II. Operator safety operation notes

1. Electric system operating notes

1) Read the electrical parts and electrical drafts carefully, familiar with the circuit

diagram.

2) Before confirm each works, please hang the signal of Working state, switch-on is

forbidden

3) Use professional tools and protective facility.

4) Maintenance while switch-on is not allowed or disassemble any electric elements,

dont pull any plugs while power on.

5) Remark the cable and cable ends before disconnecting the electrics to ensure correct

reconnecting.

6) Keep the protective air pressure while powering on the drillers panel. When the

protective air lose pressure, recovery the pressure quickly or stop drilling and cut the

power supplied to drillers panel.

7) Dont turn the transfer cabinet or driller panel in dangerous gas.

8) Non-professional personnel are not allowed to modify the parameters in convert,

avoid dangerous.

9) While the temperature is higher than 40, humidity larger than 95% or have dew,

dont start the drive and other control powers before air conditioner lower the

temperature and humidity.

118
10) Re-supply power after power off more than 30mins, must confirm there is not any

dew in electrical control cabinet.

2. Hydraulic system operating notes

1) Read the Hydraulic Manual to familiar with hydraulic system principle.

2) While disassemble the hydraulic system, release system pressure slowly and confirm

there is not any pressure in the system pipe lines.

3) Cut power off before disassembling the pipe lines.

4) Mark on the connection part before disassembling to ensure re-connecting correctly.

5) Prepare proper tank, cotton yarn, and blocks etc before disassemble the hydraulic

pipe lines, avoid the rest hydraulic oil releasing and pollute the equipment and space

when open the pipe line.

3. Well control Operating Notes.

1) Read and understand the design requirement of drilling and technique requirements

of well control.

2) Carry out the industry standard, stipulation and recommends when meet with the

high pressure oil layer or gas with H2SSO2.

3) Keep equipments in good working station while drilling in the oil layer, carry out while

shaft handing over. For instance: the Inspection and testing of IBOP, well control

operation, handle with the problems in time.

119
DQ70BS-JH Top Drive Drilling System is composed of power swivel, pipe handler, guide

beam and carriage, electrical control system, hydraulic control system, and auxiliary

device.

The following is the draft of main body of top drive system

Power swivel

Pipe handler

120
 Chapter II Operating Procedure

Only qualified, experienced and trained personnel can operate the Top Drive Drilling
Equipment.
Reading carefully and understanding the manual and relevant technical documents
before operation.

Before operating, the operator should check the following items:

a. Check the running record. Look over the running records to check the working
station of last shift.
b. Carry on the maintenance to the maintenance points
c. Check the condition of protective junction and backup tong tooth.
d. Inspect the regular inspecting items by professional personnel.

I. Inspection before starting

1. Inspecting before starting

Before starting electrical system, should check the following items:
a. Check and insure that the machine and hydraulic system is ready.
b. Check the operation components and instrument of driller operation panel and PLC
cabinet, make them on initial status.
c. All indicators of the electronic system can be tested by pushing the button of
MUTE/TEST.
d. Confirm the AC380V/50Hz is supplied by the assist transformer or drilling electrical
control room. If supplying by assist transformer, switch on 1QF, cut 2QF off. Otherwise,
cut off 1QF and switch on 2QF. 1QF and 2QF adopt mechanical chain control.

2. Procedure of Power Start System

a. Turn on the general power switch Q1, then close up the primary power switch of
converter and the switch of assist transformer Q2. After that close up all the power
switches (except the spares), and check the power work condition.

b. Inspect whether the 24V power light (HL1) on PLC cabinet panel works well,
Fault/Alarmindictor is neither light nor indicating alarm.

121
 24V Power Indicator Fault/Alarm

c. CheckA/B system optionwhether A or B system works.

A/B System Selection

122
 d Fault/Alarmindicator 1HL4 on Drillers panel shows no fault,Ready indicator
1HL1 lights constantly which demonstrates electric system are ready for drilling and
assist operation.

Fault/Alarm

3 Stop System Work

a. Turn the THROTTLEof Drillers panel to the zero position, and turn theMOTOR
DIRECTION to the stop position

Motor Direction Throttle

b. Turn off the power switches of 2 transducers and assist transformer, turn the main
power off, the whole electric system stops.

123
 II Hydraulic system operation

1. Start/stop operation of hydraulic system

a. Hydraulic pump have three states: 1). auto, 2). start, 3). stop.

(1) Auto: When Operate Selectionswitch is on Drill with brake signal, or Operate
Selectionon turn-lock clasp or make up and breakout, hydraulic pump starts
automatically, and the indicator is light.

When Operate Selectionswitch is on Drill and hand wheel left zero position 20s,
the hydraulic pump stops and go to normally drilling hydraulic pump dormancy state.
When hand wheel return to Zero, Brake works when the main shaft rotary speed near
to Zero, hydraulic pump starts to work, prevent to supply brake pressure.

Operate Selection

(2) Start: Turn the hydraulic pumpStop/Startto start, hydraulic pump starts,
indicator is light.
(3) Stop: Turn the hydraulic pumpStop/Startto stop, hydraulic pump stops, indicator
is off. In this state, if there is no brake signal hydraulic pump could not start, but it could
start when well control.

124
 (4) Hydraulic pump is on Auto position when drilling, turn it to start when rising
up.

Hydraulic Pump
b. Lubricate Pump start and stop is same with main motor.

c. Hydraulic system stop process: Rotate the button to stop, the hydraulic pump stops,
the hydraulic pump indicator off.
d. Lubrication oil stop and start in same step with main motor.

2. Hydraulic System Inspecting

Inspect the hydraulic system

by Driller panel
Hydraulic system inspecting
items:
1. Hydraulic oil temperature
inspect Pt100
2. Hydraulic oil liquid level
lower warning inspect
3. Lube oil pressure inspect
4.Lube oil temperature inspect
Pt100

125
III. Main Motor Heater

1. The heater of main motor is normal, frequency convertor is power off, switch the
Motor Heat to ON. The heating indicator shows working status.

Motor Heater

2. There is interlock between heater and drive system. When the heater works, the
frequency convertor power on, main motor starts, the heater stop heating
automatically, the frequency convertor power on and main motor run, the heater
does not work.

IV. Main Electric Motor air Cooler

Motor fan switch has three positions: 1). Auto; 2). Start; 3). stop.
1). Auto: air cooler auto starts according to primary motor temperature, hydraulic oil
temperature, lubrication oil temperature.
(1) Motor temperature, hydraulic oil temperature, gear oil temperature when
anyone of the three temperature over 35 , the air cooler will start
automatically.
(2) Motor temperature, hydraulic oil temperature, gear oil temperature are all below
25, the air cooler will stop.
2). Start: Switch to this position, air-blower starts; if air pressure switch do not have
feedback signal, this shows air-lose, main motor can start.

126
 3). Stop: air cooler r stops running. Main motor can not start.

Motor aire-blower

When there is not any air pressure signal, main motor does not start, the
main motor lose air in running, the system fault stop.

V. Braking mode selection

1. Automatic position
(1) Normal brake: In the normal drilling, when need brake, turn the hand wheel back
to zero position, then the main shaft speed reduce to 3rpm, brake solenoid valve will
operate and stop the main shaft.
(2) Reactive torque brake: Under special drilling conditions, if the down hole anti-
torque is more than drilling limit torque, although the hand wheel is not back to zero,
the main shaft will quickly reversed. When the speed up to -3rpm, brake solenoid
valve will operate and stop the main shaft.
(3) Emergency stop: when push the emergency button, the variable frequency signal
will stop first, whatever the top drive in which status, brake solenoid valve will operate
and stop the main shaft.
(4) Fault brake: when the top drive fault stops, the brake is the same as normal stop.

2. Brake position
i. In brake state, braking solenoid valve powered on and stop the main shaft directly.
ii. In shaft running state, if switch to brake position, fault appear and stop.

127
3. Closed position
if the braking solenoid pilot actuated valve can not given power on, no matter
operate select on any position, the top drive drilling system braking fail, except well
control.

Break Mode

4. In braking state, hydraulic pump intermittent working

1). Hydraulic intermittent working: while given brake signal, hydraulic pump start, 8
min later hydraulic pump stop, 30 min pause, hydraulic run 3 min, again pause 30 min,
again run 3 min like this circle continuously.
2). In the term of hydraulic pump pause, because of brake signal, so the hydraulic
pump run, and at the same time, IBOP solenoid valve was given power on, hydraulic
system pressure added to supply pressure to energy storage of brake.
3). In the term of hydraulic pump pause, if the valve group have solenoid valve action
(balance, middle position except), IBOP solenoid valve was turn on the power,
hydraulic pump stat running 8 min, then turn to intermittent working state.
5.Relation between Operate select and braking
Brake mode on auto , whileoperate selectin drillingstate mode, brake can
be used, but onSpinand Strain atposition no brake.
In drillingstate. switchbrake modeto auto.
In directional compound drilling state, if directional drilling time too short (less
than 40 min), switchoperate selectto drillingstate, switch brake mode to auto;
if directional drilling time a little long (longer than 40 min), switch electric motor
select directionto stop, brake mode to brake. At this time frequency convertor

128
has no enable signal, this means main motor doesnt work.
Switchingbrake modeto brake given brake signal, if have brake signal, the
system carries out hydraulic pump intermittent working. At this time, it have no relation
with position of operate select.
6. In tripping time, hydraulic is on start position. At this timeit does not carry
out hydraulic pump intermittent working.

Switch brake mode to off, top drive starts running, but brake device
can not brake automatically when system stops.

When emergency stop, system will stop rapidly, braking disc would be
worn seriously, so it is forbidden to use this stop function in normal
braking except the emergency.

While system switch to spin or strain at state, disc brake will open
automatically, no matter switch brake mode to any position, brake
does not close.

VI. Drilling operation

1. Inspection before Drilling

Check the system before doing the operation, and make it in the original stated
showed in appendix 1. it includes:
A. Putting THROTTLE handle of driller control console on ZERO position and
DIRECTION switch on stop position.

Motor Direction Throttle

129
 B. Put the Motor Selection on top drive running position, the required motor work
mode (A motor, A+B motor, B motor)

Motor Selection

C. Before system doesnt run and THROTTLE is in zero positions, operating the
ROTATION DIRECTION switch to select rotation.

Motor Direction Motor Selection

If THROTTLE handle is not in zero positions, or motor select

direction is not on stop, the act of motor select is inactive.

In drilling mode, selecting ROTATION DIRECTION switch to

overturn is inactive

THROTTLE hand wheel is not on Zero, operation of Motor

Select direction is inactive.

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2. Operation Practice
a. Air motor is on Auto or Start

Air Motor
b. Operate operation switch to drilling mode.

Operation

c. Put the Motor Select on top drive running position, the required motor work
mode (A motor, A+B motor, B motor)

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otor Selection
 d Rotate the Motor Select Direction to CW, if the hand wheel is on Zero and
the transducer is ready.

Motor direction

e. Movedrilling torqueaway from zero position regularly, set torque as needed.

Drilling Torque
e. Move the THEOTTLE away from Zero, the main motor CW as the set speed.

Throttle

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3Constant Torque and Constant Power
1. Turning THROTTLE handle clockwise, then the speed of principal axis
increases two, before getting to rated power, the motor will keep running
according to the set torque value of drilling torque handle (constant torque).

Drilling Torque Throttle

2. After getting to rated power, speed keep increasing, and the torque of motor
begin dropping, and keep exporting the same power. (constant power).

4Speed Control and Torque Control

a. During drilling, when the torque of drill pipe gets to limit torque, main shaft
will rotary at the speed set handle set speed

Throttle

b. If the torque of drill pipe over limit torque, the principal axis will stop rotating
(stop), the torque will keep. When load reduces, the driver speed comes back
to the value of THROTTLE handle. And it can change to speed control again.

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VII. Backup tong operation

1. Hand wheel at Zero choose the makeup and break out working mode, switch
the backup tong, backup tong will close or loose. The solenoid valve power down
5 seconds after loose.

Motor Direction Operation Backup Tong Throttle

2. During system running, switching backup tong button can not change the
status of backup tong.

Back up Tong

VIII. Elevator link operation

After hydraulic system starting, the elevator link operation could begin. The ELEVATOR
LINK ROTATION switch include: forward, backward, turn left/right, suspending.
1. Turn Elevator link leaning to forward to lean it 35, realize to catch the drilling

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tools from mouse hole and Kelly board. Turn Elevator link leaning to backward to
lean it 55, drill the pipe socket into drilling panel surface.

Link leaning

2. Put done Elevator suspend button, electromagnetic valve would connect the front
and back tank with oil tank. Link and the things on elevator is in the self-weight state.

Elevator suspend

3. Push Elevator suspend button, rotary head would turn left and right freely.

ELEVATOR LINK ROTATION and ELEVATOR LINK INCLINE operation is

link lock. When the cline cylinder work, the rotating turret can not act. Only
when press middle button and the elevator link go back to middle position, the
rotating turret can rotate. In special condition, modify the setting on PLC linking
if need to spin rotating head after leaning. Return to the factory setting when
finish the operation, prevent the link hurt staff.

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 Elevator and link could not hold more than 3T when rotary or leaning.
When exceed 3 T, push the Elevator Suspend button prevent from damaging
the leaning tank.
Before operate the rotating head, make sure the link return to the middle
after operating the link middle button, avoids accidents.

XI. Make Up and Breakout Operation

1. Make Up and Breakout Operation

a. Put the THROTTLE handle of driller control console onto ZERO position, and
DIRECTION switch onto stop position.

Motor Direction Throttle

b. Turn the Motor Select to A+B mode.

Motor Selection

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 c. Operation is on Drilling mode.

Opeartion

d. Hydraulic pump control switch is on Auto or Start

e. Air Motor is on Auto or Start.
If THROTTLE handle is not in zero position, or ROTATION
DIRECTION switch is in other position, operating operation switch is
inactive (cant change to spin mode).

2. Make Up Operation
Spin:
a. Operation the Direction switch to select positive rotation, change system
to spin working mode.

Motor Direction

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 b. Turn Operation to Spin, system will spin with fixed speed 12r/min, fixed
torque 6kNm. When achieve at 6 kNm, the rotary and torque are set zero, speed
reduce and stop.

Throttle
When the THROTTLE hand wheel is not on Zero,, operation of
ROTATION DIRECTION is inactive.
When top driver is spinning normally, If the THROTTLE handle goes
back to zero position, or operating the DIRECTION switch by
mistake, the speed and torque will be reduced to zero automatically.
Fastening:
This operation should be carried on when the main shaft stops, this required operate
state is same to the spin state, main shaft rotary of top drive is 0, output torque is the
spin rated output toque: 6KNm.
a. Put THROTTLE hand wheel of driller panel on ZERO position, and switch
DIRECTION to rotation.

Motor direction Throttle

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b. Set torque by MAKEUP TORQUE handle to required torque.

Makeup Torque
c. Switch the OPERATION handle to make up and breakout position, turn the backup
tong to fastening, then backup tong will fasten. 5 min later, backup tong will rotary
forward, when up to the limited torque, system will stop. Take off hands, backup tong
loose.

Operation Backup Tong

d. Turn the Operation button from Spin to Drilling.

Operation
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 Keep the hydraulic pump start when fastening to supply hydraulic power
of back-up tong.
When main shaft is rotating, do not fasten avoid damaging the tooth of
back up tong.

3. Breakout operation
Support the released drilling tools before breakout, prevent hurting from tools falling
after release.

Inspect the button position whether in the first item required state.

a.Turn Motor select direction on CCW position

Motor direction Throttle

b.Click Break up Button

Break up

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c. Left hand turn OPERATIONto Strain at mode, right head push backup tong to
CLAMP. After 5 seconds, the system will rotate in CCW direction until the torque get
to the Max. torque. When the system rotary speed get break up fixed rotary speed
6r/min, release both hands, Operate Select return to make up, main shaft would
break up by make up mode.

Operation

d. After complete Break Up, push Operate Select to drilling position, so the Break
up finished
. System would press on the balance cylinder in 1 minute after put down
Break up, rise the Top Drive body up, conquer self-weight to protect
joints of drilling tools. After 1 minute, pressure increasing is finished.
Repeat press the button, pressure increased again.
The maximum torque of Break up is the max. output torque of Top
Drive (150% of normal output torque), so when could not break up while
get the max. torque, close motor to break up long time is not allowed
( Longest time is 1 min), try to break up by other method.

X Drilling ahead by single

1. Procedures for drilling ahead by single

1Set slip on the connection in the drilled well, stop mud circulation and close IBOP;
2Break out according the VII-3 instructions.

3Pull the top drive drilling system up. Make the elevator goes off the joint of drilling

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rod;
4Start elevator tipping device to swing the lifting ring onto the joint of the single in
the mouse hole and fasten the elevator;
5Lift the single out of the mouse hole, move the single to the center of well head.
6Lock the drilling rod connecting buckle of the well head, put the top drive drilling
system down, Put the upper side of the single goes into the guiding shoe.
7Make up the single with the saver sub of the top drive drilling system;
8Fix the drilling pipe in well, connect the joints between drilling tool and single,
single and protective joint by drilling machine (preset the drilling torque as need)
9Rotate and fasten by top drive according to the procedure of VII-1.
10Pull the slip, open IBOP, start pump to circulate the mud.

Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.

Before single drilling, open IBOP, then start mud pump.

XI. Drilling ahead by triples

Drilling ahead by triples is the normal drilling method of DQ50BS top drive drilling
system. If there arent the existent triples on the well frame, it can be connected into
the mouse hole during the course drilling or at the leisure time. In view of safety, the
drilling rod in the mouse hole must be vertical to assure them butted each other inside
vertical plane, then, what should to do is to rotate the single connection into box
threads, because the electric engine will apply making up to fasten the joint. In addition,
when drilling by making a connection, the triples left in the well frame can also be used
for drilling by making up in triples after drilling start.

There is the procedure for drilling ahead by triples as followed:

1Set slip on the single connection in the drilled well, stop circulating mud, (close
IBOP);
2Break out according the IX-3 instructions.
3Pull the top drive drilling system upward to make the elevator goes off the joint
of drilling rod. After the top drive drilling system has been lifted to the Kelly borad

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platform, start the elevator tipping device to push the elevator to the triples where is to
be connected;
4Well workers will make up the triples into the elevator, and take the elevator
tipping device back to the well head;
5Drilling machine operator put the triples into the box threads of the drilling rod;
6Put the top drive drilling down slowly to put the upper side of the triples into the
guiding shoe and make up with the saver sub of top drive drilling system;
7Make up by Motor (e. g. Single Drilling)
8Lock tight by Top drive according to IX-2.
9Pull the slip out, start circulate mud, open IBOP, continue drilling.

Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.

Before single drilling, open IBOP, then start mud pump.

XII. Backreaming

During the course of pulling out, if the drilling devices are blocked, connect them with
the top drive drilling system at once, and circulate mud. Lift the drilling and
backreaming at the same time to avoid drill rod being clamped and key box being
reamed though.

Procedures of backreaming are as follows:

(1) Circulating mud and rotating to pull the drilling devices out until one triple is lifted
outside;
(2) Stop mud circulating and rotating, set the slip;
(3) Unlink the connection on the surface of drilling floor by hydraulic tong, and unlink
the connection thread with the top drive drilling system on the triples;
(4) Pull out the triples, arrange the triples into the drilling rod box;
(5) Set the top drive drilling system down to of drilling floor.
(6) Lift the drilling rod to pull the slip out. Set the drilling rod down to the head of the
well and set it onto the slip.
(7) Loosen the elevator, operate theLink incline to slope it backward a little and
deviate it from the drilling rod. Lift the traveling crane to the kelly board. Repeat the

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above operations.

XIII Pulling out operations

Pulling out runs in conventional ways, with the help of pipe handle unit, it could reduce
labors intensity and improve working efficiency.
A Tripping in
1Move the top drive drilling system to kelly board by hoisting system, operate
Swiveling head rotating to rotate the elevator tipping device to the direction which
the workers needed on Kelly board;

2Operate Link incline to Front, make elevator close to the kelly board to put
the drilling rod down, then workers will put the drilling rod into the elevator and buckle
door bar;
3Operate Link incline to Rear to return to the head of the well approximately,
then operate Link center, at this time, the tipping device is in floating state;

Link incline Link center

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 4Pull the drilling rod to return the center position, during this course, the drilling
workers should hold back the lower side of the drilling rod with ropes and release it
slowly in order not to damage the joint of the drilling rod;
5Put the traveling crane down, buckle the carried drilling rod with the drilling rod
of the rotary face, Rotate and make up with hydraulic tong;
6Lift the drilling rod to pull the slip out. Set the drilling rod down to the head of the
well and set it onto the slip.
7Loosen the elevator, operate theLink incline to slope it backward a little and
deviate it from the drilling rod. Lift the traveling crane to the kelly board. Repeat the
above operations.

Link incline

B. Tripping out
1Loosen the connecting thread between the main arbor and drilling rod, and lift the
top drive drilling system. Operate the Link inclineto slop it forward in order to buckle
the main arbor of the lift sub into the joint of the drilling rod;

2Lift the top drive drilling system above the kelly board. Set the slip on the drilling
floor, put the top drive drilling system under the slip;

3Breakout with hydraulic tong;

4Pull the top drive drilling system, operate the Lind inclineto front in order to
make the elevator close to the kelly board. Drilling workers pull the triples to the
arranging area, lower down the top drive to put the triples steady. Workers open the

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elevator and put the drilling rod into the triples box;

5Operate Link center, set the top drive drilling system down to the joint of the
drilling platform. Operate Link incline to front in order to buckle the elevator into
the joint of the drilling rod.

Link incline Link center

6Repeat the procedures from 2 to 5.

If there are reducing radius or key groove during the course of round-trip, connect the
drilling rod with electric engine of the top drive drilling system at any height of the well
frame, and starting the circulation and rotating removable drilling tools immediately to
make the drilling tools pass the blocking position;

XIV Running Casing

Running casing with the top drive drilling system can improve the operating speed,
Jinghong top drive is different from others, adopt a special device for running in casing,
the main function is when the drill string is stick or well kick happen in down-hole, the
top drive can joint with the casing quickly and starting the mud cycle, rotating the pipe.
Prevent the well kick and deal with the stick problem in time. Enhanced the safety and
speed of running casing.

XV Well Control Operation

1. When the top drive drill system is on the stop status, turn the IBOP could open

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or close the IBOP. In the drilling process or the mud pump running status, it is not
allowed to close the IBOP (except the well control status).

2Under the urgent condition such as well blowout, push the well controlswitch will
enter the well control status, operating procedure showed as follows:
a. Start the hydraulic pump (Ignore the state before)
b. Stop the mud pump (Give the connect point signal, connect the control to mud
pump)
c. Stop top drive system (Fast stop)
d. Shut the IBOP off.
3. Operators should replace all switches to original position. (Attachment I)
4. After obviating the urgent situation, and insuring there are no trouble alarm in
system, push the reset switch, then the well control statue is cancelled.

Well Control IBOP

Reset

XVI Jarring operation

Because every well has special condition, and the parameters, such as drilling depth,
drill pipe weight, bumper jarring type and so on, are not decided, so it is impossible to
give a standard rule or specification, in addition, the damage of jarring in various
conditions to the Top Drive Drilling System is not predictable. For these reasons, we
suggest that dont jarring while equipping Top Drive Drilling System and forbidden
using surface bumper sub, or it may caused damage to the Top Drive Drilling System.

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If jarring with Top Drive Drilling System can not avoid, please assess comprehensively
about the possible damage of jarring to the Top Drive Drilling System.

After jarring, do a comprehensive examine of Top Drive Drilling System according to

following guideline. A detailed examine and maintenance plan should be made to
ensure all functions of the Top Drive Driling System well and convenient for next time
using.

1. Take a general visual inspection to Top Drive Drilling System to ensure that no
damage exists.
2. Check the safe wire rope damaged and the connecting bolts. If any bolt loosing,
please tighten it and refasten the safe wire rope.
3. Check all cable joints, electric cabinet terminals, and device connectors of Top
Drive Drilling System. If any loosing, fasten again.
4. Check if any pipeline joints loosing or leaking, if the pipeline is damaged or
deformed.
5. According to jarring intensity to decide if disassemble load-carrying components
on loading path (including lifting pin, elevator link, rotating hanging ear and main shaft)
and inspect them.
6. According to jarring intensity to decide if do further examination to Top Drive
Drilling System.

XVII Release drilling torque operation

Generally, when the torque of downhole load torque is bigger than the setting
drilling torque, the lock-rotor happens. While release the reactive torque, following
guiding methods should be respected.

The drill pipe may be throw away while release the reactive torque, so the operation
specification should be respected strictly, and the rotary back speed should be limited
strictly also to prevent to accident.

When lock-rotor happen, the driller first should lift up and move the drill pipe string
to release the torque stored in drill pipe. If this method failed, the Top Drive Drilling
System also provides other two methods, and normally, we adopt the following one.

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 Keep the speed setting and the brake handwheel still to ensure the motor
outputs torque continually, and turn down the drilling torque handwheel slowly to
reduce the output torque of the electric motor, and then the drill pipe string will rotate
back slowly until the drilling torque fall to zero, and the drill pipe string rotate speed
reduces to zero at the same time, then release the brake handle and lift out drill pipe
string. Only when the drive system can not work normally the following method will be
used.

Keep the drilling torque setting handwheel still, operate the brake handwhell
to brake the system and speed setting handwheel to zero, then the electric motor
stop. Close the brake handwheel, then the drill pipe string will rotate back slowly,
and the driller operate brake properly to reducing the rotate back speed in case of
releasing the pipe string connecting. Repeat the process above until the pipe string
rotary speed reduce to zero, then loose the brake handle and lift up the drill pipe string.

XVIII Emergency stop operation

1.In emergency station, all equipments of system would stop when operator push ever
Emergency Stop button. Operator should reset all the switches to initial position.

2.When system back to normal, make sure there is no alarms, reset the Emergency
Stop. Push Reset on drillers panel, system is reset, start normal operation.

XIX Reset/Mute

When system has fault, the error indicator would light up, voice alarm warn up. Push
Reset/Mute to mute. The error indicator would keep light until the fault is not solved

XX Stop System

Return Throttle hand wheel to Zero When stop system, turn Rotary Direction to
stop. Then switch house switch of 380V power or Assistance Transformer in
Electrical Control Room. Turn off the switch of transducer and assistance transformer,
shut off the Main Power, Whole system stops.

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Appendix I System Initial State

Attachment I. Driver cabinet initial state

Before starting system, should make sure that all switches or buttons of driver cabinet
are in the following initial state.

Button or switch Initial position Note

Emergency stop Open Emergency-stop button is NC
contact

Attachment II Driller panel initial state

Before starting system, should make sure that all switches or buttons of driver cabinet
are in the following initial state.

Button or switch Initial Note

position
Emergency stop Loose Emergency stop button is NC contact
Brake mode Auto Brake by PLC system
HPu Stop Stop the hydraulic system
Link rotation Center rotator is in inactive state
Link incline Center Link is in balanceable state
IBOP Open When drilling normally
Fan Close In initial position, it is in close position
Motor select A+B Select motor according to need
Operation Spin Initial position
Backup tong Loose Initial position
Motor Select
direction Stop Switch Initial position
Makeup torque Zero Set the value of torque before makeup
operating
Drilling torque Zero Set the value of torque before drilling
operating
Speed Zero Set the value of speed before drilling
operating.

150
Attachment III PLC Cabinet Initial State

Before starting system, should make sure that all switches or buttons of PLC/MCC
cabinet are in the following initial state.

Button or switch Initial position Note

Emergency-stop Loose emergency-stop switch button is NC

contact

Doghouse control emergency On the left side, allowed the doghouse use
stop the emergency stop operation

Motor heat Stop Use only under the low temperature or

high humidity

Mud pump linkage linkage The system linkage with the mud pump

Attachment IV Monkey board operation box initial state

Before starting system, make sure that all switches or buttons of monkey board
operation box are in the following initial state.

Button or switch Initial Note

position
Link rotation Center Rotator is in inactive state
Link incline Center Link is in balanceable state

151
 Part VII Maintenance Manual

Chapter I Safety Operating Rules

I Safety Operating Rules

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment
damage.

Caution This sign alerts the user to procedures involving a risk of

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite risk
of injury to rig personnel.
Before maintenance work, the operator should make a safety maintenance plan; need
the safety analysis and safety training.

During the maintenance period, if the maintenance plan is changed, it needs to revise
the safety working plan and guarantees all in involved working personal knows about
the maintenance term so that it could ensure all the working staffs safety and the
devices are in a good condition.
1. Every time before the maintenance, it needs the safety analysis, guarantee all the
power switch is on the switch off status. When lubricating, checking or replacing the
system, it should cut off the power supply.
2. During the maintenance and repair period, the operator must be equipped with
suitable protective equipment, such as glove, helmet.
3. When the system is running, it not allowed to maintenance and repair.
4. Before repairing the hydraulic system, should release the pressure in the
accumulator.
5. Check the hydraulic oil leaks by hand is forbidden, hydraulic oil leaked from the hole
is almost invisible in the high pressure. Hydraulic oil is not only high temperature but
also it could penetrate the skin and cause injury, use wood, inspecting should be carried
out by bamboo and other hard-board, and wear protecting appliance.
6. Dont try to repair the part which you arent familiar with.

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7. Before repairing the top drive drilling system, please read the related manual
carefully.

Chapter II Daily Inspection

In order to ensuring the top drive drilling system running in a good condition, prevent
the accident which unpredictable.

I It is important to inspect the following items

Item Term
Fastener Visual check all the fastener no loose, safety lock wire no rust,
break, loose.
cables connection Visual check the cables protect sleeve is fine, fixed
and cables connector no loosening
Hydraulic pipe line Visual check the hydraulic pipe line no break, the
and connector Connector no loose and leak.
Oil level of the Check the level of the oil in the box according to
hydraulic oil box the requirement.
Hydraulic valve unit Check the hydraulic valve unit, no leak on the
connector.
Gear box lubrication Check the level of the lubrication oil in the gear
oil box according to the requirement
Anti-explosion of the Check the air treatment component, clean the water.
drillers panel Confirm the outlet pressure meet the requirement.
Drillers panel joint Check the panel cables joint. No loose, no bend too hard and so
on.
Drillers panel display Check the drillers panel indicator lights and meters
electrical cabinet Check the electrical cabinets, in/out is fine, Ground is fine.
electrical cabinet air Electrical control house air condition in normal condition,
condition
Observe the pulley wheel, lock nut tightly, no serious wear on
Pulley wheel wheel, rotation is flexible

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 Guide beam joint Observe the pins connected with guide rail, pins lock normally.
Hanger lifting lug Observe the guide rail, adjust the backplane and connect pins,
there is no abnormal wear and tear, etc.

Top driver running All the motor and transmission no abnormal noise during the top
drive running.

Chapter III Maintenance Items and period

I Daily maintenance Items

1. Washing pipe
Oil point:
Glib 1 on the side of washing pipe
beneath stuffing box.
Lube method:
Feed grease into the glib by grease gun.
Inspecting Item:
Washing pipe omits.

2. Remote IBOP Control Structure

Oil Point
4 pieces of roller spindle glib on side.
Sleeve and switch gear joggled joint
Lube Method
Feed grease into the glib by grease gun.
Scribble grease on the joggled joint of sleeve and switch.

Inspect Item:
a. Whether the guide plate and wheel bolts loose, wear out or lost.
b. BOP pulley situation of lubricates and slanted and wear out.

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3. Centralize Ring Centralizer Ring
Oil Point
Inside surface of Centralize Ring
Lube Method
Feed grease into the glib by grease gun.
Inspect Item
Inspect the wear out of centralize ring, change it regularly.

II Weekly Maintenance Items

1. Big gland sealing

Oil points:
Glib on Big gland sealing
Lubricate Method:
Feed grease into the glib by grease gun.

2. Pin Roll of Bail

Oil point:
2 points on pin roll of bail
Lubricate method
Feed grease into the glib by grease gun.
Maintenance Item
Inspect Item
a Lubrication of bail pins.
b Baffle of bail pin and screw.

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3. Rotating Link Adaptor
1Rotate Body

Oil point
3 points on the rotating head.

Lubricate method
Feed grease into the glib by grease gun
4 washes for each

Maintenance Item
aDaub grease on rotating link adaptor regularly.
bUse guide tools to replace the 7 circles of Rotating Gland circle to avoid damaging.

2Big gear of Rotating link adaptor and small gear of drive motor.

Oil point
gear joggled joint and teeth

lube method
Daub the grease on the joint and teeth.

Maintenance Items:
Check the fixed bolts on motor frame often, lock it tight if there is any loose.

156
4. Guide beam and tackle.
Oil point
4 points on the bottom of tackle.
16 points on each side of tackle.
Lubricate method:
Feed grease into the glib by grease gun, 2
washes for each point.
Inspect Item
aInspect wheels working situation. No Blocks.
b. Check the wearing situation of the wheel,
replace it when necessary.
c. Inspect the fixed bolts on wheels, check whether the
lock washer lock well.

5. Leaning Device

Inspect Item:
a. Wearing situation on bolts of link
leaning hydraulic tank.
b. The position and clamps of lock
collar clamp on link.
c. The lubrication and lock of joint bearing.
Lubricate Point:
Connecting pins of Joint bearings and rings. Lock collar
Lubricate method: clamp on link
Feed grease into the glib by grease gun

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6. Reverse torque inspection
Inspect Item:
a. Inspect fixture of bolt.
b. Inspect the drift of reverse torque. It is
necessary to adjust the reverse torque if it
drifts away more than 3mm.

7. BOP Maintenance
Oil Site
Remote control IBOP glib point 1, manual IBOP glib point 1.
Lubricating mode
Feed lubricating grease into glib by grease gun, twice for each points.

Remote IBOP Manual IBOP

8. Anti-loosen Device
Inspect Items:
a Bolt fixture.
b Safety lock rope.
Installation of anti-loosing device
a. Cover molybdenum lubricating grease below bolt head
on the surface of locking bolt.
b. Make sure all the connecting joints are locked to the
required torque before installing the anti-loose device.
c. Clear the surface of IBOP, main shaft and protecting

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connector. Ensure surfaces are bright and clean without any grease.
d. Put pairs of anti-loosing device on the joint.
e. Put the tong dies on the center of connection.
f. Fasten bolts by torque wrench, till the torque to 350 Nm.
g. Fix all bolts by steel wire.

III Monthly Maintenance Item

1. Brake Device
Inspect Item:
aWhether is the abrasion form of Brake-friction disc symmetry abrasion?
bInspect the attrition rate of the Brake-friction disc.
cInspect where there is omit on Hydraulic pressure break pipes.

The brake disc would lose friction force if it is polluted by grease.

Change it if it absorbed grease or oil.
Encoder

Encoder Frame

Brake Body

Brake Pad
Brake Disc

Protect Cover

Brake Fix Seat

159
Main Motor
Maintenance Items:
Change the brake-friction disc.
Change the brake-friction disc when its material is thinner than 2mm.
Note: It needs some time to backfit with new brake-friction disc before getting the
rated torque.
Release the system oil pressure of braking device.
Disassemble the shelter, remove the M14, and disconnect the brakes pipe lines, remove
the brake assembly entirely.
c) Release the guide pin and screws of retracing spring.
d) Replace to new brake disc.
e) Install the guide pin and screws of retracing spring.
f) Lock the screws, install the guide pin.
g). Fix the brake assembly by M14, connect the pipe lines, install shelter.

Keep the friction material away from oil or grease.

2. Drape hanger of crane, U ring and fixed pin Drape hanger

Inspect Items:
a. Inspect the welding point and welding line.
Fixed Pin
b. Inspect the safety pins of
fixed pins and connect pin of U ring.

URing
U

Connect Pin

3. Gooseneck
Inspect Item
a. Whether is there any sunken, abrasion or corrosion.
b. Check for leakage.

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4. Main motor and air cooling motor
Inspect Item
a. Inspect the damage on the outlet cable of motor.
b. Inspect the damage and loose of the bolts and lock line.
c. Inspect damages on uptake blind and filters.
d. Whether the debris attach to Heat exchanger.
Maintenance Item:
a. The heater of main motor would heat automatically when the main motor stops, shut
off it if dont use in long time.
b. Inspect the air-blower preliminary, whether there is any part broken or sundries in
air-blower channels after transportation or long time stock.
c. Clean the heat exchanger regularly.

5. Back-up Tong
Inspect Item:
Check the abrasion of tong teeth.
Inspect the looseness of bolts on tong teeth seat.
c. Check trumpet fixed bolts, wear ring bolts and fixed
pins and other fasteners whether there is loose and
damages, the reliability of locking.

Maintenance Item:

Clear the dirt on the surface and gash of tooth in time.

Smear grease on fixed pins while installing.
Please disconnect the right side fixed pin only (initial
position of back-up tong, refers to the direction facing
Fixed
to the top drive),
pin
4 oil seals in the Left side fixed pin.
e. While changing tong key, replace the 4 at the
same time to ensure geometry and mechanical
strength same.

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IV Maintenance Items in each

quarter

1. Lubrication on bearings of main motor

Oil site
2 points on the top of main motor, 2 points
on the below (inside).
Lube method:
Feed grease into glib by grease gun.
Release the blockage on the position potion
of glib which is on the back of motor while
feeding grease. Re-block it until grease
squeezed out.

2Motor insulation inspection.

3AC preshoot pressure detects.

aThe pressure of balanced AC is 9MPa.
bThe pressure of Brakes AC is 3MPa.

V. Maintenance Items in half year

1. Hydraulic oil
Inspect item:
Fluid level, pressure, temperature, cleanse of Hydraulic oil
Maintenance method:
Feed or change hydraulic oil according to the well site situation.
a. The time is continuous used 3 months for first changing.
b. After that, change the hydraulic oil every 6 month or according to the oil sample
analyzing.
c. Replace the filter while changing oil. Meanwhile, clean the filter of HX-63X10 and
WU-100X100J.

2. Gear oil
Inspect Item

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Fluid level, pressure, temperature, cleanse of Hydraulic oil
Maintenance method
Feed or change gear oil according to the well site situation.
a. The time is continuous used 3 months for first changing.
b. After that, change the hydraulic oil every 6 month or according to the oil sample
analyzing.
c. Replace the filter while changing oil.

VI Maintenance Items every year

1. Detect the wear-out of hanging lift lug, U ring, and fixed pins by disconnecting.
2. Inspect the bail and clasp, recommend to detect the wear-out. If the bail bolt
abrasion exceeds 2mm, lower the bearing weight, replace it when exceeds 3mm.
Detect the wear-out of guide rail clasp.
4. Detect the wear-out of bail and the lift lug of rotate head.
5. Inspect the lube pump of gearing oil and hydraulic oil pump, adjust it according to
the result.
6. Inspect the pressure of gear pump, if the pressure is not fit, find out the reason,
replace it when necessary.

Note. Please contact with technical dept of Jinghong for further maintenance
and repairing.

Tel: 0452-2345069
Fax: 0452-2340601
Email: [email protected]
Add: No.3-2, Nanyuan Road, Nanyuan Investment Zone, Longsha District, Qiqihar,
Heilongjiang, China.
Zip: 161005

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 Attachment A Torque value of thread hastening

Recommend force Recommend force Recommendfor

Thread Type
N.mLevel 8.8 N.m10.9 ceN.m12.9
M8 22 30 37
M10 45 63 75
M12 78 109 131
M16 193 271 325
M20 328 531 637
M24 653 906 1101
M30 1300 1828 2193

Remarks: The fasten torque of M20 on locking device is 400 N.m

Attachment B Recommendation of gear oil selects

Gear Oil

Scope of ambient temperature

Manufacturer
-30 to -6 to 21 to
-7 20 55
ISO viscosity (International
Organization for 32 68 220
Standardization)
Mobil Mobil Mobil
Mobil
SHC624 XMP68 XMP220

Attachment C Recommendation of Greases selects

Name Extreme Synthesis of lithium-based Precision

pressure grease Instrument
lithium based Grease
grease
Type 0 1 2 3 ZL-1H ZL-2H ZL-3H ZL-4H ZT-53-7
Remarks GB7323-87 Use in Winter

164