E-DQ450DBZmanual+de+aplicacion+de+top+dr

Contents

1 Safety cautions...........................................................................................1

2 Safety operation prompts.........................................................................2

2.1 Safety operation prompts of electricity......................................................................2

2.2 Safety operation prompts of hydraulic pressure.......................................................3

2.3 Safety operation prompts of well control...................................................................4

3 Main technical parameters........................................................................5

3.1 Basic parameters..........................................................................................................5

3.2 Drilling parameters......................................................................................................5

3.3 Motor parameters........................................................................................................5

3.4 Cooling fan...................................................................................................................6

3.5 Hydraulic disc brake...................................................................................................6

3.6 Electrical control system.............................................................................................6

3.7 Pipe processing unit.....................................................................................................6

3.8 Hydraulic control system............................................................................................7

4 Structure and working principle..............................................................7

4.1 Direct-drive drilling motor assembly.........................................................................9

4.2 Pipe processing unit...................................................................................................14

4.3 Balance system...........................................................................................................29

4.4 Guide rail and pulley.................................................................................................30

4.5 Electric drive and control system.............................................................................33

4.6 Electric drive and control system.............................................................................42

5 Operating instructions.............................................................................52

5.1 Check before startup.................................................................................................52

5.2 Operation of electric system......................................................................................53

5.3 Operation of hydraulic system..................................................................................53

5.4 Driller console control...............................................................................................54

6 Drilling steps.............................................................................................65

I

6.1 Tripping in /out..........................................................................................................65

6.2 Drilling work condition.............................................................................................66

6.3 Back reaming..............................................................................................................68

6.4 Run casing..................................................................................................................69

6.5 Well control.................................................................................................................69

6.6 Jarring.........................................................................................................................70

II

DQ450DBZ DIRECT-DRIVE TOP DRIVE USER’S MANUAL

1 Safety cautions

Besides to introduce the contents of main body, this manual has also included the

following contents, such as 'note' , 'caution' and 'warns', they are marked and used for

prompting the possible danger which may caused in operation, the symbolic meanings

are as follows:

Supplement for relevant safety items

Prompting for accident which may caused

Prompting for accident which may caused easily

Only qualified and experienced personnel are allowed to conduct installation and

commissioning to top drive unit, prior to operation please read and follow this

specification and related technical documents carefully.

The personnel who accepted the training about drilling operation and drilling safety

are allowed to conduct the installation, commissioning and close to the system device. Be

sure to keep in mind that uses the proper protective articles such as gloves and safety

wares.

In this specification, literal contents displayed with the symbol of

are executive components of electrical system such as button and

switch and so on.

Please read the specification before installation, commissioning,

operation and maintenance of electrical system. Due to the

continuous renewal of technology and serialization of products,

check up the product codes which must be the same as the ones on

the cover, and to make sure consistency of product and technical

documents.

Never try to install, test, operate and maintain the electrical system

without profession and training; otherwise, it may lead to the

personal injury or equipment accident. Maintain and repair the

equipment in stopped status.

1

Note

Caution

Warns

Note

Caution

Warns


2 Safety operation prompts

This manual mainly has described the structure, composition and functions of each

part, and also described the application and operation of top drive as the key points.

Please refer to the 'electric manual' and 'hydraulic pressure manual' if the fault diagnosis

and repairing had be involved.

The operators can operate the equipment after they read the manual carefully and

being well-trained.

2.1 Safety operation prompts of electricity

Pay attention to following items before operation of equipment and electrical

system:

1) The commissioning and maintenance of electrical system should be conducted by

professional.

2) Read the 'electrical system manual' and 'illustrated pictorial catalog of electrical

system' carefully, and know well the electrical wiring diagram.

3) The professional tools should be provided and protected correspondingly.

4) Cut off the power switch before all operation had finished, and hang the

signboard of 'non-switch on'.

5) Prior to disconnecting electrical connection, verify that wire (cable) and

connecting terminal are properly labeled to ensure proper reconnection.

6) Never try to repair or remove any electrical elements, and pull out or insert the

cable plugs with electricity.

7) Never try to open the anti-explosion control cabinet or driller’s station with

electricity under the circumstance of flammable gas.

8) Never replace the DC insurance between DC bus and inverter before the rectifier

operation and DC bus voltage cut down below safe range (DC 24V), otherwise, it may

cause human injury and equipment damage.

9) To avoid the faulty operation, separating the switch to main circuit breaker of

rectifier cabinet when repair the rectifier, inverter or motor

10) Do not detect the isolation of rectifier and inverter by megger, otherwise, high

2


testing voltage will damage the equipment.

11) Keep the pressure of protective gas when power on to driller’s station, recover

the pressure as soon as possible or stop drilling and cut off the control power supply of

driller’s station when the protective gas loss of pressure.

12) It is forbidden to relieve safety chain of any software and hardware. Recover the

function of linkage by bypass after troubleshooting.

13) Do not start the driver and other control power supply before temperature

reduction and dehumidification of air conditioner when the temperature is more than

40℃, humidity more than 95% or there is condensation.

14) Ensure that there is no condensation in electric control cabinet when the main

power supply powered on again after cut off for half an hour.

15) It is forbidden to open the electric control room for a long time or be opened

frequently when the temperature of it is under external environment temperature in humid

condition; otherwise, there is condensation on electrical equipment.

2.2 Safety operation prompts of hydraulic pressure

Pay attention to following items before operation of equipment and hydraulic

system:

1) Read the 'hydraulic system manual' carefully, and know well the schematic

diagram of hydraulic system.

2) Cut off the electrical control.

3) Take off the systematic pressure slow by unloading valve, and make sure there is

no pressure in pipeline.

4) Prior to disconnecting pipeline, verify that connecting parts are properly labeled to

ensure proper reconnection.

Close the valves in the system before dismantling the hydraulic

pipeline, prepare the proper container, cotton yarn and greasy

blockage to avoid residual hydraulic fluid outflow to pollute the

equipment and environment when open the pipeline.

Due to the temperature of hydraulic device and hydraulic fluid is

3

Note

Caution


high, so they need to be cooled for a long time to recover the normal

temperature.

2.3 Safety operation prompts of well control

Pay attention to following items in installation and application of top drive, and

understand the condition of strata pressure and requirements of well control at any time.

1) Read carefully and understand the design requirements of drilling and technical

requirements of well control.

2) Carry out related industrial standards and regulations as per the requirements of

recommended practices under the circumstance of hi-pressure hydrocarbon reservoir or

harmful gas such as H2S、SO2 etc during drilling.

3) During drilling in the hydrocarbon reservoir, keep the equipment in good condition,

check and drill the operation of IBOP etc operation of well control during shift every day,

and process it timely if there are problems.

4


3 Main technical parameters

3.1 Basic parameters

Model of top drive DQ450DBZ

Drive mode (AC VFD)

Nominal drilling depth 7000m

Max. load 4500kN(500tons)

Working pressure of hydraulic system 16MPa

Drift diameter of centre tube 75mm (3in)

Rated working pressure of centre tube 35MPa (5000psi)

Dead weight 15.8t

Guide rail weight 9.6 t

Working height 5.7m

Electric power supply 575~690VAC (50/60Hz)

Rated current 774A

Rated power 580kW

Ambient temp. -35℃~50℃

Altitude ≤1000m

3.2 Drilling parameters

Nominal drilling depth 7000m

Range of speeds 0~220r/min continuously adjustable

Working torque 50kN.m

Max. torque 75kN.m

3.3 Motor parameters

Rated power 580kW

Rated voltage 575VAC

Rated frequency 16.9Hz

Rated current 774A

5


Rated speed 125r/min

Max. speed 220r/min

3.4 Cooling fan

Rated power 5kW

Rated voltage 380V

Rated frequency 50Hz

Rated current 13.1A

Rated speed 3190r/min

3.5 Hydraulic disc brake

Brake torque 50kN.m

Cylinder working pressure 10MPa

3.6 Electrical control system

Input voltage of VFD 575~690VAC (50/60Hz)

Output frequency of VFD 0~87.1Hz

Oil temp. alarm of hydraulic power 70℃

Alarm for low level in oil tank of hydraulic power <180mm,>400mm

3.7 Pipe processing unit

Speed of rotating head 3~8r/min (adjustable)

Working pressure of hydraulic motor 14MPa

Upper IBOP (remote)

Lower IBOP (manual)

Clamping range of back-up tong 86~216mm

Max. break out torque 75kN.m

Angle of inclination for elevator link lean 35° forward and 50° backward

6


3.8 Hydraulic control system

Working pressure 16MPa

Working flow 28L/min

Voltage of electromotor 600 VAC

Power of electromotor 11kW

Speed of electromotor 1460r/min

4 Structure and working principle

DQ225DBZ/DQ450DBZ top-drive drilling system mainly consists of direct-drive

drilling motor assembly, pipe processing unit, electric drive and control system,

hydraulic drive and control system, driller console, folding single guide rail and

sectional carriage.

7


DQ225DBZ/DQ450DBZ integral structure diagram

8

Counterbalance system

Washpipe packing assembly

Motor housing

Pipe processing unit

Hydraulicsystem


Detailed structure diagram

4.1 Direct-drive drilling motor assembly

The direct-drive drilling motor assembly mainly consists of AC variable

9

Bail

S-pipe

Gooseneck

IBOP (Inner Blowout Preventer)Elevator link

Main shaft

Traction motor

Back-up clamp

Bell guide

Elevator link clampLocking device

Powered rotating head

Tilting cylinder, elevator link

Hydraulic oil pump

Hydraulic valve set

Main motor blower

Centre tube

Disc brake mechanism

Lift box

Hydraulic oil tank, top drive

Systematic accumulator

Hydraulic electric control box

Electric control box, main motor, top drive


frequency traction motor, bail, washpipe packing assembly and hydraulic disc brake

in the lifting box located on the top of motor. The bail is fixed on the lifting box body,

and upper end of it connected with travelling block. The centre shaft of AC variable

frequency motor is the traction shaft of top drive, and the operation such as rotary

drilling, makeup & breakout and mud circulation can be conducted by driving the top

drive to make sure the normal drilling operation.

Direct-drive drilling motor assembly

4.1.1 Main motor and air-cooled motor

The rated speed of DQ450DBZ direct-drive top drive is below 125r/min at

frequency of 16.9Hz. The traction motor can provide continuous torque of 26000N.m,

and the rated speed of it is above 125r/min at frequency of 16.9Hz, continuous power

10

Bail

Washpipe packing assembly

Lift box

Bail pin

Electric control box, main motor

Blower of main motor

AC VF motor

Hydraulic disc brake


of 580kW can also be provided, and realize stepless speed regulating by frequency

speed control system.

Main motor is variable frequency and variable speed asynchronous motor and

adopts firm and high-quality carbon structural steel welded type housing with high

strength, decreased the vibration during running of motor. Class of insulation is grade

H, and the lubrication grease adopts Arcanol L135V (FAG) or special selection as per

special environment.

Limit values of rated output torque are limited by current, output torque is in

direct proportion to electric current.

It is equipped with air-cooled motor at the right side of main motor; the blower is

driven by three-phase current asynchronous motor, after rotating of blower, it sucks

the wind from exhaust inlet of lower cover and discharged from air outlet of air-duct

blower through air outlet of motor skid and air duct inside main motor. Reliable

ventilated is guaranteed with the simple structure and durability of the design.

It is equipped with wind pressure switch on the top of main motor terminal for

checking whether the wind pressure is normal and rotating direction of blower is

correct. There are 2 temperature sensors PT100 are embedded in winding head inside

the motor, one is for detecting the temperature of main motor, and the other one is for

standby.

4.1.2 Brake apparatus

Shaft-extension end on the top of main shaft of main motor equipped with

hydraulic operating disc brake to realized brake through 2 pairs of brake cylinders

clamping the brake disc, its braking energy is in direct proportion to imposed

pressure. The structure of brake apparatus is as shown:

11


Brake apparatus

Every brake body equipped two reset springs to make the brake friction plate

reset automatically when releasing the brake. Abrasion loss of brake friction plate can

compensated automatically through increasing the piston stroke.

The functions of brake apparatus are as follows:

1) Bear the reactive torque of drilling tools in downhole;

2) When the drill pipe get stuck in down hole, drilling tools will be rebounded

quickly if the motor stopped, so at the moment, skid the drill tools to avoid inversion

and tripping.

3) Brake the motor when it is out of order.

4.1.3 Washing pipe assembly

Washing pipe assembly is installed

between main shaft and gooseneck,

maintain the washing pipe packing

assembly periodically to extend its

service life.

Method to change washing pipe:

1）Before install a complete set of

12

Washing pipe assembly

Disc brake tongBrake disc

Main shaft

Encoder

Expansion sleeve

Washing pipe assembly


washing pipe, thread connector and

front contact surface shall be cleaned

and spread on grease. Remove cover

(Cover for storage).

2）Check if o-ring is in trough or

not. Remove o-ring if necessary, spread

on grease in trough to prevent o-ring

falls down. Put mud pipe on main shaft

with lower seal box carefully.

The thread of upper and

lower seal boxes is left-hand one.

3 ） Lift the upper seal box and

screw it in swivel goose, and screw the

lower seal box in the main shaft.

4 ） Screw the upper seal box by

spanner. It is considered that the thread

was tightened when there is no relative

motion; screw the lower seal box with

the same way. Take away all tools and

auxiliaries after filling the lubrication

grease through lubricating nipple 4.

The method for replacing the seals in washing pipe:

Grease the seals in washing pipe during drilling. The method of replacing washing

pipe and seals is the same as the one of swivel. The washing pipe is fixed by 2 nuts

and they are left-hand thread. Tighten or loosen them by hammer, plunger chip or

similar tools.

4.1.4 Bail

As the integral swivel bail and the main

13

Logging channel plugWashpipe assembly

Caution


bearing parts of top drive, bail bears the overall

weight of top drive, it connected with lifting box

body through bail pin, and upper end is hanged on

the traveling block or hook.

The capacity of bail for DQ450DBZ top drive unit

is 4500kN(500tons) and conforms to the standard

hook load of API8A/API8C, and performance

indicators reached safety lifting load standard of

API.

4.1.5 Gooseneck

As the passage of drilling fluid, the gooseneck is installed on the support of

washing pipe. Its lower end connected with washing pipe, and the operation of

salvage and logging shall be conducted after opened the upper end. As the inlet of

drilling fluid, goose mouth end connected with rotary hose through S-tube.

4.2 Pipe processing unit

As the key part of top drive unit, the pipe processing unit can increase the

automaticity of the operation of drilling. It consists of back-up tong, IBOP, control

mechanism, leaning device, elevator link and elevator. The structure is as shown:

14

Washing pipe

Gooseneck

Washing pipe bracket

Connect hose through S-tube

Logging channel plugWashpipe assembly


Pipe processing unit

Pipe processing unit served for tripping in/out, and running casing etc operation.

The rotating head can catch and release the drill pipe in any arbitrary direction

through driving by hydraulic motor. The operation of taking out the drill pipe from

mouse hole and connecting stands can be realized by leaning forward and backward

of elevator link tilting device. The back-up tong can finish the operation of makeup,

breakout and clamping, and conduct the makeup and breakout through motor. The

IBOP (automatic) and IBOP (manual) are connected at the lower end of main shaft,

and mud passage inside drill stem shall be opened quickly and remotely.

4.2.1Powered rotating head

The upper end of powered rotating head connected with bull gear disc, and the

lower end located on bearing nut of the bearing seat. The relative motion is conducted

between powered rotating head and main shaft, and the structure is as shown. The

15

Powered rotating headPowered rotating head motor

Main shaft

Elevator link

Elevator link clamp

Back-up tong

BOP (manual)

IBOP (Inner Blowout Preventer)

Locking device

Tilting cylinder, elevator link

Bell guide


rotation of powered rotating head is driven by bull gear disc which driven by

hydraulic motor and the speed of hydraulic motor is adjusted by speed regulating

valve. Generally, setting speed of powered rotating head is 5~8 r/min. The powered

rotating head can rotate clockwise and anticlockwise of 360° and also drive the

elevator link and elevator to adopt to operating requirements of different directions.

The special thing which deserves to be

mentioned is that the powered rotating

head located on the bearing nut which

connected with main shaft through

bearing seat. It has the stabilized

bearings in it; so, it can bear the drill

stem load and radial force of makeup and

breakout immediately during tripping

in/out or running casing, but the powered

rotating head does not bear any load

during drilling.

Powered rotating head is also the

pass way of hydraulic oil, rotating head

connects with many hydraulic

actuating mechanisms. Because

360°rotation is needed, rotation seal

and ring oil way are fixed inside,

hydraulic oil flows from inside to

achieve oil inlet from lower barrel and

oil outlet from rotating head, transfer

hydraulic oil way from motionless to

movement.

4.2.2 IBOP

The function of IBOP (Inner Blowout Preventer) is to avoid the blowout. Close

16


Mainshaft

Hydraulic motor

Bull gear disc

Lowershell

Hang-off padeye,elevator link

Locking device, gear disc



the IBOP and cut off the interior passage of drill stem in order to prevent the well kick

or blowout when the pressure in well is higher than internal pressure of drill stem.

The IBOP consists of upper IBOP (remote) and lower IBOP (manual).The upper

IBOP (remote) connected with main shaft of power swivel, and lower IBOP (manual)

connected with saver sub which connected to drill pipe during drilling.

17


IBOP structure

Install the locking device between connectors to prevent the screw thread

between main shaft and IBOP connector from loosing during break out of top drive.

18

Pretecting connector

Locking device

Manual BOP

Locking device Auto BOP

Cut off casing

Rocker arm assembly

Cover and fixing bolt

Cylinder cut off

Fixing boltSupport seat of cylinder cut off

Locking device Main shaft


Its structure is as

The reverse of direction of IBOP (remote) will be conducted through operating

the hydraulic cylinder in order to open and close the IBOP device conveniently at

19

Screw thread locking device, BOP

Bolt

Upper flange

Lower flange

Taper sleeve


driller console. Cylinder support seat connects two groups of upper and lower

trolleys, the two groups of upper and lower trolleys touch edge of casing cutting off,

inner hexagonal rocker arm assembly which correspond to IBOP is embedded in

casing, and drive rocker arm assembly mechanism inside of casing cutting off rotate

to achieve cutting off of IBOP. The entire mechanism can switch IBOP on and off on

driller's console.

The cylinder push the IBOP sleeve upward, rotate the crank and rotating pin and

close the ball valve of IBOP when there is a electric signal from drill floor to the

IBOP return circuit of hydraulic control valve set, conversely, if the cylinder push the

IBOP sleeve downward, the ball valve of IBOP opened. The connecting bottom end

between cylinder and sleeve is contacting roller, so the rolling motion of sleeve which

rotated with main shaft and roller on the piston rod of cylinder can be guaranteed.

Breakdown drawing of IBOP remote controlling structure

Good adjustment of IBOP cylinder is very important to operation of IBOP in a

20

Cylinder cutting off

Guiding rod

Retainer ring

Grease nipple

WasherNut

Support seat

Fixing bolt of guiding rod

Casing

Drum

Drum shaft


correct mode. IBOP cylinder should be checked frequently. It should be checked more

frequently after maintenance or after valves, sleeves and cranks are replaced. Oil

supply pressure of IBOP cylinder is adjusted to 40bar. Pressure is checked by

operating handle on valve block. Pressure can be displayed on pressure gauge in

hydraulic schematic diagram. Pressure can be adjusted by block valve of IBOP.

Steps of adjusting IBOP cylinder:

1) detach cylinder from suspension board;

2) detach sleeves and cranks from BOP;

3) open BOP by a hexagonal head wrench and be sure that BOP has been

opened;

4) place crank hexagon head in inner hexagon of IBOP;

5) supply pressure oil to cylinder so that piston rod is completely stretched out

before cylinder installation;

6) fix cylinder on suspension board with bolts after piston rod is completely

stretched out;

7) if plastic gasket on cylinder and cam sleeve contact or have 3-5mm interval,

position of cylinder is adjusted in place when opening blowout preventer valve; if

interval between the two is more than 5mm, bracket must be adjusted by rotating

piston rod of cylinder clockwise.

Before adjustment, unscrew holding screw on bracket.

8) remove cylinder and sleeves/cranks, close BOP and make sure that the BOP

has been closed, and reinstall sleeves/cranks;

9) before cylinder installation, supply pressure oil to cylinder so that piston rod is

completely retracted;

10) reinstall cylinder;

11) if trolley contacts with flange end part of sleeve, adjustment of bracket and

cylinder is completed;

12) release pressure inside cylinder, install cylinder on suspension board;

13) operate IBOP cylinder on operating panel to open blowout preventer valve

and then retract plastic gasket/cylinder 5mm.

21

Caution


If this distance is too small, wearing of plastic gasket will be caused during

drilling. If this distance is too large, trolley contacts with lower end of flange of

sleeve, it will close blowout preventer valve locally and the BOP is excessively worn.

When BOP is opened, plastic gasket and trolley must have proper interval with other

parts. When BOP is closed, trolley is always pressed at lower end of sleeve flange.

Steps of replacing protection joint and IBOP:

Method 1: use torque tong:

1) during breakout of protection joint with torque tong, install forceps holder

with an outer diameter of 6 5/8'' and tool joints with an outer diameter of 7 3/4'';

2) lift torque tong upward to needed height (about 220mm);

3) place torque tong mode switch at manual position on control panel;

4) break out twice;

5) screw off protection joint with hands;

6) install new protection joint and make up.

Method 2: use drill pipe tong;

1) take down four hydraulic quick connectors on oil block of torque tong;

2) remove torque tong from guide rod;

3) lower torque tong to drill floor;

4) retract guide rod if necessary;

5) break out with drill pipe tong; in order to detach cock and install IBOP or

intermediate joint, first remove IBOP sleeve and cylinder.

When free end of joint is not fixed on rotary table, do not use drill

pipe tongue.

Recommended makeup torque of IBOP and protection joint is 63000N.m

(47000ft.lbs).

Steps of detaching IBOP and cylinder:

1) pull out two pins, remove sleeve and open;

2) remove crank;

3) remove bolts on cylinder and then take off cylinder.

Under normal drilling condition and when main shaft rotates, do not

22

Caution

CautionCaution


operate IBOP to prevent pump from suffocation; only when blowout

and kick generate, can IBOP be operated to close IBOP. Generally, it

is not allowed to close IBOP during trip, otherwise IBOP may be

closed incompletely at critical moments of blowout and kick and

grave accidents are caused. Check all indicator lamps of operation

panel and see whether IBOP button is at open position before

drilling. Remember to open IBOP first and then open mud pumps.

For high flow rate, high pressure seal and high stress load applied to drill pipe,

remote control IBOP is a good switching device.

4.2.3 Tilting device

Elevator link tilting device is an automatic device designed for increasing human-

friendly functions of top drive device and reducing labor intensity of drillers on drill

floor. It is mainly used for moving elevator to position above mouse hole to lift single

in mouse hole. Single is conveniently and quickly connected, derrick man on monkey

board does not need to lean hook against monkey board when connecting stands, and

stands grasping operation is achieved by forward tilt. When drill pipe on drill floor is

drilled down, top drive can tilt backward to approach surface of drill floor as much as

possible by tilting device. Usually, backward tilt angle is relatively large. The forward

and backward tilt of elevator link tilting device can further help top drive to

conveniently guide drill pipe into backup tong horn mouth easily for realizing

breakout operation.

23


Elevator link tilting device

Above drawing is elevator link tilting device of top drive. It comprises two

hydraulic cylinders with the same specification and their accessories (including

elevator link, hydraulic joints and pipelines). One end of cylinder is connected with

cylinder support plate while the other end is connected with elevator by pin. The joint

of tilting cylinder and elevator link of top drive can be adjusted by loosening elevator

link for changing forward and backward tilt angles. Forward and backward oscillation

of elevator link is realized by extension and retraction motions of cylinder; maximum

extension length of cylinder is maximum forward tilting position of elevator link of

top driver; and complete retraction of cylinder is maximum backward tilting position

of top drive. Elevator link can automatically return to intermediate position through

suspension function under the action of dead weight.

Forward tilt angle is 35 degrees, backward tilt angle is 50 degrees, and maximum

24

Supporting plate Rotating

head

U bolt

Bail

Dump ramForerake

Hypsokinesis

Elevator


ground forward tilting distance and maximum ground backward tilting distance are

related with length of elevator link.

Elevator link tilting device mainly comprises parts of tilting cylinder, cylinder

support plate, elevator link and elevator etc and whole mechanism moves under the

control of hydraulic mechanism.

Structure characteristics of elevator link tilting device are as follows:

1) Elevator link tilting cylinder and elevator link of top drive are connected by

elevator with convenient detachment and easy adjustment.

2) Elevator link tilting cylinder and elevator seat are connected by oscillating

bearing so that cylinder can oscillate in certain range while tilting, transverse distance

between elevator links is adjusted conveniently and service life of joint is greatly

increased.

3) Connecting pin of cylinder and rotating head and connecting pin of cylinder and

cylinder elevator are provided with oil passages, grease directly by grease gun, and

maintenance is convenient.

4.2.4 Backup tong

Backup tong is core component of pipe processing mechanism of top drive and

mainly completes clamping operation to pipes so that top drive can carry out makeup,

breakout, threading on and detachment of protection joint etc on pipes.

Backup tong mainly consists of suspension device, sliding part, alignment

system, clamp system and guide stabilizing part. Its structure is showed in following

drawing.

25


Schematic diagram of backup tong

4.2.4.1 Clamp system

Clamp system is main functional part of backup tong and consists of two

workholding jaw bodies, tong dies, piston and hydraulic pipes by combination.

During clamping, hydraulic cylinder is provided with oil and works to push piston to

move toward workholding jaw bodies. Push tong dies on workholding jaw block to

move in radial direction until contacting and clamping drill pipe, at this moment

piston stops moving. Main shaft of top drive rotates and sinks to complete makeup

action. Release pressure of hydraulic cylinder, return tong dies on workholding jaw

block as per primary route, and backup tong of top drive completes makeup action.

Breakout tong dies of backup tong of top drive clamp drill pipe as above. At this

time, top drive reversely rotates slowly, after release, main shaft stops rotating,

26

Rear pillar

Transmission shaft

Amendment trolley

Movable pillar

Backup tong

Guiding cover


pressure of hydraulic cylinder is released, tong dies on workholding jaw block return

as per primary route, main shaft of top drive rotates to retract and move upward to

complete breakout action.

Clamp system of backup tong

27

Cylinder

Cylinder

Tong body

Jaw fixing bolt

Pin

Fixing bolt

Movable pillar

Piston guiding device

Fixing bolt

PistonJaw

Installation bolt of jaw

Bite

Jaw

Installation bolt of jaw

Right end cover

Fixing bolt

Jaw seat

Die block

Block bolt


4.2.4.2 Suspension and sliding system

Suspension system consists of parts and components of installation rib plate,

suspension bolts, movable stand post, rear stand post, stand post cover, spring seat,

suspension bolts, spring, butterfly spring and transmission shafts etc. And it is a

supporter connected with clamping device and supporting makeup breakout counter

torque. Weight of backup tong can reduce shock impact by buffer spring during

drilling and can further realize flotation function. Sliding system can adjust upper and

lower positions of clamping device as required to complete different requirements. Its

structure is showed in following drawings.

28


Structural drawing of suspension and sliding system of backup tong

29

Pillar cover

Cover bolt

Suspension bolt

Transmission shaft

Pillar cover

Installation rib plate

Suspension bolt

Butterfly spring

Spring seat

Compression spring

Split pin

Suspension bolt & nut

Rear pillar

Movable pillar

Positioning block

Caliper Body


Structure drawing of suspension part of backup tong

4.2.4.3 Guide alignment system

Alignment system:

It mainly consists of alignment trolley, alignment axle, fixed supporting rack seat

and support fixed bolts (showed as following drawing), fixed supporting rack seat is

installed on bite body of backup tong through support fixed bolts, alignment trolley

connects with fixed supporting rack seat through the thread of alignment bolts. Main

shaft is located between four alignment trolleys during normal process. As extension

end of main-shaft motor is relatively far from clamping device of backup tong, it may

bend and deform during drilling, shock or other external force to influence precision

and service life of main shaft. Therefore, alignment system can improve the condition

so that main shaft maintains relatively good precision under mechanical action and

service life of main shaft is prolonged.

30

Rotation shaft

Rib plate fixing bolt

Fixing bolt

Backup tong

Rib plate fixing bolt

Installtion rib plate

Fixing bolt and washer

Rotation head


Structural drawing of alignment system

Guide system:

Guide system is consisting of guiding cover, rubber blanket under jaw body and

adjustable guiding cover. Its function is to protect connector and guiding centralize.

The advantage is to do guiding centralizing very well for different drilling tools

during making up. Add another set of movable guiding cover, movable guiding device

consists of movable guiding cover, installation seat of movable guiding cover, locking

nut and adjustable shaft. When use different drilling tools, adjust shaft to centralize by

adjusting inner circle dimension of movable guiding cover.

31

Amendment shaft

Amendment trolley

Support fixing bolt

Fixing support seat


Structure drawing of guide system

4.3 Balance system

Balance system assembly is showed in following drawing. It is top drive drilling

device and is critical and also one special equipment with characteristics. It is mainly

used for preventing damage to threads during breakout and makeup to increase

service life of main shaft protection joint and drilling tools and decrease consumption

and drilling cost. Secondarily, it can help male joint to pop up from female joint

during breakout without lifting hook by driller control as traditional drilling rig. It

supplies 100 mm damping stroke similar to hook to top drive device. Even through

hook is installed, its spring is drawn out due to weight of top drive drilling device and

has no buffer action.

32

Fixing bolt of installation seat

Fixing bolt of guiding cover

Guiding cover

Rubber washer Locking nut

Movable guiding cover

Installation seat of guiding cover

Adjusting shaft


Balance system

4.4 Guide rail and pulley

4.4.1 Guide rail

Guide rail adopts locking block automatic positioning single guide plate structure

with convenient installation and detachment. Guide rail is divided into 5 sections

totally, each section is about 7 m long, and the sections of guide rail are connected by

pins and positioned by locking core and locking block. Whole guide rail is in single

guide plate mode.

33

Elevator link

Top drive elevator link

Balance cylinder

Balance cylinder seat


Guide rail assembly

Lower end of guide rail is connected with mast by counter torque beam and the

fourth section of guide rail is connected with mast by fixed beam. Counter torque

beam bears counter torque during drilling of top drive. When fixed beam ensures

drilling of top drive, guide rail does not generate large vibration.

34

Suspension plate assembly


4.4.2 Pulley

Pulley adopts sectional type

structure and consists of two L-

shaped plates. Each plate is

connected with reducing gear

box of top drive by 8 pcs of

M24 high-strength bolts and

provided with 8 bearing wheels

and 2 guide wheels. 8 bearing

wheels are embedded in guide

plate of guide rail and bear

counter torque during drilling

of top drive. 2 guide wheels

enable slip direction of carrier

always along guide rail

direction to prevent blockage

phenomenon when carriage

slides on guide rail.

35

Schematic diagram of transportation state of guide rail


Pulley can be fixed on the first section of guide rail of folding single guide rail by 4

single-taper pins. After folding guide rail and top drive are installed on mast, take out

4 single-taper pins so that carrier can freely slide on guide rail. Installation of carrier

and guide is showed in following drawing.

4.5Electric drive and control system

DQ450DBZ electric drive and control system mainly comprises top drive electric

control room, driller's control box and external cables.

4.5.1 Switching cabinet

Electronic control cabin of DQ450DBZ top drive consists of rectifying cabin,

36


contravariant cabin, BU/MCC control cabin, 400V variable frequency power source

cabin, PLC cabin, outlet cabin, air condition, brake resistor, fluorescent lamp, house

cable and connectors etc, rectifier and inverter drive a set of 700kW AC variable

frequency motor, direct drive main shaft rotation to drill and make up.

The function is as following:

（1） System is numerical control and variable frequency, digital operation control

system and peak torque output with 0 rotate speed.

（2） Digital control technology is used; make VFD house and driller's cabin

achieve control signal, diagnostic message and digital transfer of

corresponding parameters.

（3） Real time monitoring, direction for faults, warning and protection can be

achieved. During installation of inner components, use modular construction

easy for disassembling and installation to reduce maintenance time and

decrease system rate of closing down.

（4） Use function of electronic control system to achieve real time monitoring

of top drive.

（5） System has impeccable protection functions: max. torque set, electric

losing protecting, emergency stop of transmission system and so on.

4.5.2 Driller's control box

Driller's console has all operation functions needed for drilling and can set top drive

speed, rotating torque, operation mode and all auxiliary operations for drilling.

Driller's console is positive pressure explosion-proof EXpniaIIT4 and can be powered

on only when pressure of protective gas is normal.

All buttons and indicator lamps on panel of driller's console are showed in

following table

37


A) Instrument

SN Description type Functions

1 'Rotation

speed'

Measuring

instrument

Display actual rotation speed output by main

shaft with r/min as unit, measuring range is

0-250 r/min.

2 'Torque' Measuring

instrument

Display torque output by main shaft with

kN.m as unit, measuring range is 0-80KN.M.

B) Potentiometer


1 'Makeup

torque

limitation'

Potentiomete

r

Makeup torque limitation is set to be

makeup torque limitation (range is 0-15

times rated torque value) when top drive is

in torque mode and rotation direction of top

drive is positive and to be breakout torque

limitation (range is 0 to maximum torque

value) when the rotation direction of top

drive is negative.

2 'Drilling

torque

limitation'

Potentiomete

r

Drilling torque limitation is used for limiting top

drive motor torque when top drive is in drilling

mode, range is (0 to rated torque value).

3 'Rotation

speed setting'

Potentiomete

r

Set rotating speed of drilling tools during

normal drilling operation, improve set

rotation speed by clockwise rotating hand

38


wheel.

C) Operation device


1 'Working

mode'

Lighting-free

3-position left-

holding right-

resetting

option switch

with standard

black handle

DRILL, SPIN, TORQUE mode option

switch, usually at DRILL position

2 'Balance

system'

Lighting-free

2-position self-

holding option

switch with

standard black

handle.

Breakout and jump switch. During

breakout, turn switch to STAND JUMP,

top drive is automatically lifted certain

distance to prevent drilling tools from wear.

Usually, the switch is at DRILL position.

3 'HPU motor' Lighting-free

2-position self-

holding option

switch with

standard black

handle

Manual (ON) and automatic (AUTO)

control switch of hydraulic pump, usually

at AUTO position.

4 'Main motor' Lighting-free

3-position self-

holding option

switch with

standard black

handle

Positive and reverse rotation switch of main

motor, switch at FORWARD position

during drilling and makeup, at REVERSE

position during breakout and back off and

at OFF position at other times (notice:

times slot that switch rotates once is 10

seconds and time slot that other switches

39


rotate once is 2 second).

5 'Disc brake' Lighting-free

3-position self-

holding option

switch with

standard black

handle

Push to 'brake' position, brake works.

Push to 'looseness' position, brake looses.

Push to AUTO position, brake works as per

system procedure.

Usually, the switch is turned to AUTO

position.

6 IBOP Lighting-free

2-position self-

holding option

switch with

standard black

handle

Cooperate with running signal of mud

pump

Push to 'ON' position to open IBOP ball

valve.

Push to 'OFF' position to close IBOP ball

valve.

7 'Rotation

motor'

Lighting-free

3-position

double

automatic

resetting

option switch

with standard

black handle.

Elevator left rotation (LEFT) and right

rotation (RIGHT) switch.

8 'Backup tong' Planar red

momentary

button

manipulator

with lighting

Backup tong engagement button, press the

button, backup tong automatically engages

with drill pipe joint to carry out makeup

and breakout.

9 'Elevator link

tilt'

Lighting-free

3-position

double

Elevator link tilting switch. Retract

backward, stop, stretch forward, normally

at 'STOP' position.

40


automatic

resetting

option switch

with standard

black handle.

10 'Suspension' Lighting-free

planar green

alternate action

button

manipulator

Manual tong reset button, press button

down, backward tilting elevator link

automatically retracts to drooping position.

11 'System

emergency

stop'

Emergency

stop

manipulator

Emergency stop button. When top drive

motor smokes, motor is overheated or air

pressure alarm lamp is turned on etc, press

down the button, main shaft stops rotating

to prevent accident. After pressing down

the button, top drive cannot work in a short

time. Be careful to press the button.

12 'failure

resetting'

Lighting-free

planar green

momentary

button

manipulator

Alarm sound release button, press the

button, alarm sound is stopped.

Failure reset button, press down the button,

reset failure or alarm.

D) Indicator


1 'Air pressure

signal'

Green

indicator lamp

When main motor air pressure losing alarm

lamp is turned on, immediately stop

operation, turn off power supply and tell

maintenance man

2 'Backup tong Green When pressure of top drive backup tong is

41


clamping' indicator lamp more than 10MPa, it means that top drive

backup tong clamps, and indicator lamp is

turned on.

3 'Low pressure

alarm'

Red indicator

lamp

When pressure inside operation box is

relatively low, pressure switch acts and

indicator lamp is turned on

4 'Failure' Red indicator

lamp

See 5.5.10 failures and alarm for details.

5 'IBOP

closing'

Red indicator

lamp

When IBOP is closed, the lamp is turned

on.

6 'Disc brake

closing'

Red indicator

lamp

When brake works, the lamp is turned on.

4.5.3 External cables

Top drive external cables mainly comprise top drive main motor cable, top drive

auxiliary power supply cable, top drive control cable, 600VAC inlet cable and driller's

control cable.

A) Main motor cable of top drive

Main motor cable is used for connecting variable-frequency output of top drive

electric control room to main motor at upper part of top drive.

In order to be convenient for field installation and connection, cable is divided into

three sections

① The first section is ground cable (option) from electric control room to mast

bottom with a length of 30 meters (100 feet). A, B and C phases adopt 646MCM

cables and ground wire adopts 444MCM cable.

② The second section is vertical cable from mast bottom to guide wheel bracket at

upper part of mast. The second section of cable is processed by special process

and plastically packaged by outer sheath. Sheath is 41 meters (135 feet) long;

there is no flange on side of mast bottom; extension length of cable is 7.5 meters

(25feet); there is flange on side of guide wheel bracket; extension length of cable

is 1.2 meters (4 feet); and two ends have plugs and sockets.

42


③ The third section is travelling cable from guide wheel bracket of mast to top drive

body. The third section of cable is processed by special process and plastically

packaged by outer sheath. Sheath is 26 meters (86 feet) long; there is flange on

side of guide wheel bracket; extension length of cable is 1.2 meters (4 feet); there

is flange on side of top drive body; extension length of cable is 1 meter (3 feet);

and two ends have plugs and sockets.

Three sections of cables, main power cable and top drive body, and main power cable

and top drive electric control room are all connected quickly by connector with

convenient field operation.

B）Top drive auxiliary power supply cable

Auxiliary control cable is used for transmitting needed 380 V or 220 V power supply

for loads of top drive motor fan, top drive motor heater, top drive HPU motor and top

drive HPU heater etc.

The cable is 19-core cable and is quickly connected by connectors with quite

convenient field operation.

In order to be convenient for field installation and connection, cable is divided into

two sections:


bottom, 30 meters (100 feet) long.

② The second section is travelling cable from mast bottom to top drive body. It is

plastically packaged by outer sheath, sheath is 61 m (200 feet) long; there is no flange

on side of mast bottom; extension length of cable is 7.5 meters (25 feet); there is

flange on side of top drive body; extension length of cable is 1.2 meters (4 feet); and

two ends have plugs and sockets. When cable passes through upper part of mast, cable

is fixed by purpose-made wiring padeyes at guide wheel bracket of mast.

Two sections of cables, main and auxiliary power supply cables and top drive body,

auxiliary power supply cable and top drive electric control room are all connected

quickly by connector with convenient field operation.

43


C）Top drive control cable

Auxiliary control cable is used for providing signal transmission channels for top

drive HPU electromagnetic valve set, oil temperature sensor, all pressure sensors and

all pressure switches and providing transmission paths for top drive main motor

temperature of signals of air pressure switch, inspection switches and encoder.

Cable is 42-core cable, wherein 30 cores are signal cables and rest 12 cores are four

groups of two twisted shielding lines as motor encoder and temperature signal cables.

Cable is quickly connected by connectors with quite convenient field operation.In

order to be convenient for field installation and connection, cable is divided into two

sections:


bottom, 30 meters (100 feet) long.

② The second section is travelling cable from mast bottom to top drive body. Cable is

plastically packaged by outer sheath; sheath is 61 m (200 feet) long; there is no flange

on side of mast bottom; extension length of cable is 7.5 meters (25 feet); there is

flange on side of top drive body; extension length of cable is 1.2 meters (4 feet); and

two ends have plugs and sockets. When cable passes through upper part of mast, cable

is fixed by purpose-made wiring padeyes at guide wheel bracket of mast.

Two sections of cables, main and auxiliary power supply cables and top drive body,

auxiliary power supply cable and top drive electric control room are quickly

connected by connectors with quite convenient field operation.

D）600VAC inlet cable

600VAC inlet cable is used for providing 600VAC power supply to top drive electric

control system.

This section of cable is 15 meters long and connected with top drive electric control

room quickly by connector with quite convenient field operation. It is connected with

client's VFD/MCC house by quick connector or copper bar as per client's practical

situation.

44


E）Driller's control cable

Driller's control cable is used for providing control signals and network channels for

driller's control system.

There are two cables, one is 4-core cable for transmitting 24VDC power supply and

system emergency stop signals, the other is Siemens special PROFIBUS-DP cable for

transmitting network signals.

This section of cable is 60 meters long and connected with top drive electric control

house and driller's control box quickly by connectors with quite convenient field

operation.

45


4.6 Electric drive and control system

In working process of top drive, hydraulic system has important effects on, for

instance, balancing weight of top drive body and clamping drill pipe during makeup

and breakout and is used for auxiliary brake of main motor etc. From control mode of

hydraulic system, top drive hydraulic system is open-loop control system. System is

divided into following eight parts as per different functions realized by system on top

drive: HPU, balance system, brake system, BOP, backup tong, lock pin, rotating

power head and elevator link tilting system. Reversing valves for control of all parts

are integrated on the same valve block. Except that mode selector valve of balance

system is controlled manually, other reserving valves are completely controlled

electrically with quick and convenient operation. System rated pressure is 16 Mpa,

rated flow is 28L/min. Functions and operation methods of all parts are simply

introduced as follows:

1. HPU: oil tank volume of HPU is 105L; hydraulic accessories of electric

heater, liquid-level liquid thermometer, liquid level sensor, temperature sensor and

filter etc are integrated on oil tank. Driving motor power is 11 KW and rotation speed

is 1460 rpm. Determine whether variable pump is filled with hydraulic oil or not

before starting motor to prevent damage to oil pump. Inch motor for checking whether

rotation direction of motor and required direction of oil pump are consistent before

system works. If there is abnormal noise in running process of hydraulic pump, it

shows there is air in system. Check system for leakage. Meanwhile, ensure that oil

level in oil tank is above the lowest liquid level to prevent oil pump from sucking air

in working process of system.

Control system of HPU oil resource system is shown as following. Hydraulic

system uses dual pumps in series, plunger pump supplys power to each executive

component, gear pump in series effects cooling function, take oil out of cooler for

cooling. Temperature transmitter 3 can make sure system work under effective oil

temperature, if it is less than set value, start up heater 5 to heat hydraulic oil; if it is

46


more than set value, display screen alarms or oil pump stop. Pressure control of the

complete set of system uses accumulator reaction unloading valve to achieve

hydraulic pressure unloading. When system pressure is up to the setting pressure of

reaction valve 18, reverse spool and unload main pump; when system pressure is

lower than set value of valve 18, add pressur to main pump and provide pressure oil to

accumulator and executive component. Pressure sensor 20 can display system

pressure on screen for driller observing. Pressure switch 10 can detect service

condition of oil return filter. When oil return filter is blocked, pressure switch detects

pressure rise, and alarm lamp of driller's cabin prompts to change filter.

Schematic diagram of HPU

2. Balance system: Balance system is to prevent thread damage during making

up. And also protect joint screw thread and make male connector out of female

connector during breaking down.

47


Schematic diagram of balance system

The drawing above is schematic drawing of balanced system control, when the

mode selection valve 25 is at left position, two cavities of two balance cylinders are

communicated as differential cylinders. Piston rod is stretched out quickly. Hang two

bail retainer bars on balance cylinder on hook for realizing rig-up working condition.

When the mode selection valve 25 is pushed to middle position to be in run

working condition, oil enters rod chambers of two balanced cylinders and rodless

chambers are communicated with oil tank. Piston rod retracts, and two cylinders lift

top drive so that bail is disengaged from hook. In rig-up and run working conditions,

maximum pressure of oil entering cylinder is adjusted by the pressure-relief valve

22.1; when the electromagnet c02 of the electromagnetic reversing valve 27.1 is out

of energization, pressure is spring setting pressure of the pressure-relief valve 22.1; if

higher pressure is needed, the electromagnet c02 can be powered on, pressure is sum

of spring setting pressure of the pressure reduction valve 22.1 and spring setting value

of the relief valve 24; at this moment, the mode selection valve 20 is at middle

position and can realize bounce function to lift more. The accumulator 22 of balance

48


system is always in pressurizing state under above two working condition and is used

for maintaining stable oil pressure and compensating leakage.

If move mode change valve 20 to right position, or put it in shut-off working

condition, and accumulator releases pressure. Hook bears full weight of top drive, so

two ends of balance cylinder are low pressure.

Relief valve 28 is used for limiting its max. pressure at the two ends of rod

chamber to avoid HP in rod chamber when oil return is blocked. Its pressure can be

tested by pressure test connector 16.3, and settling pressure of relief valve 24 can be tested by

pressure test connector 16.4.

3. Brake system: as showed by drawing: system realizes brake of main motor by

four normally open hydraulic cylinders, brake and release are controlled by the

electromagnetic reversing valve 31.1. When main motor works normally, the

electromagnet c03 of the electromagnetic reversing valve 31.1 is not powered on, that

is to say, when brake cylinder releases, the electromagnet c03 is not powered on.

Liquid oil pressure clamping brake cylinder is adjusted by the pressure reduction

valve 30.1 and is spring set value of the pressure reduction valve 30.1. Pressure valve

can be measured by the pressure sensor 16.5. Pressure valve 32.1 is used for judging

whether brake tong is working well or not, if it doesn’t, alarm is working in driller's

cabinet.

Schemetic disgram of brake system

49


4. BOP: when the electromagnet c04 of the electromagnetic reversing valve 27.2 is

not powered, BOP is in open state, the time-delay accumulator 36 releases pressure, non-

rod end chamber of BOP is maintained under high pressure always; and the pressure is

spring set value of the pressure reduction valve 30.2.

If the electromagnet c04 is powered on, BOP is closed, and the time-delay

accumulator 36 is pressurized. When it needs to open the BOP, the electromagnet c04 is

power off, the BOP cylinder becomes a differential cylinder due to the action of the logic

valve 35, the BOP can be not only quickly opened and also act under a relatively high

pressure as the spring cavity of the pressure reduction valve 30.2 is filled with pressure

oil. The pressure oil in spring cavity of the pressure reduction valve 30.2 is provided by

the time-delay accumulator 36. The liquid oil pressure in the accumulator is delayed for

certain time and then increased to the atmospheric pressure due to the action of throttle

holes of check throttle valve. Therefore, pressure in non-rod end chamber of BOP

cylinder is also delayed for the same time and then decreased to spring set value of the

pressure reduction valve is 30.2. System pressure can be measured at the pressure test

point 16.7. Its schematic diagram is showed as follows:

50


Schematic diagram of BOP

5. Its schematic diagram is showed as follows (a). Backup tong: clamping and

release of backup tong is controlled by the electromagnetic reversing valve24.2. When it

needs to clamp, the electromagnet c07 of reversing valve is powered on and is powered

off when it needs to release. Clamping of backup tong is controlled by adjusting working

pressure of cylinder, and it can be adjusted by adjusting reducing valve 30.3.

51


Schematic diagram of backup tong and lock pin

6. Lockpin: when the electromagnetic valve 31.2 is without working, the pressure

oil is leading to rod chamber of oil cylinder, and the lockpin is in open state all the time,

when the chainwheel needs to be locked, the electromagnet c08 is powered on and the

lock pin is stretched out; however, the locking is achieved.

7. Rotating power head: as showed in

right drawing: left rotation or right

rotation of rotating head is achieved by

powering on the electromagnet c05 or

c06 of the electromagnetic reversing

valve 38.2. System pressure can be

measured by the pressure test point

16.8; as output pressure of the pressure

reduction valve 22.2 is led in spring

cavity after passing through throttle

holes, pressure difference between two

ends of throttle holes is constant and

always equal to spring set value of the

52


pressure reduction valve 22.2. Thus, the liquid oil flow entering the rotating head motor

46 is not influenced by the variation of motor load. The relief valves 45.1 and 45.2 are

respectively arranged at two oil ports of the motor 46. On the one hand, the highest

pressure of motor inlet is limited; one the other hand, counterbalance valve as motor

outlet limits rise of outlet pressure caused by inertial rotation of electromagnetic

directional valve 38.2, motor can firstly fast stop during reversing.

Schematic diagram of rotation head

8. Elevator link tilting mechanism: there are two major aspects of its functions, one

is for lifting singles from mouse hole, and the other one is for connecting stands without

pulling hook nearby the racking board by derrickman. As shown in schematic drawing,

forward tilt and backward tilt of elevator link tilting system are controlled by the

electromagnetic reversing valve 38.1. When the electromagnet c10 is powered on, two

cylinder rods stretch and elevator link tilts forward; conversely, the electromagnet c11 is

powered on, elevator link backward tilt. The major functions of flow divider-combiner 41

are for ensuring synchronism of stretching and retracting for two elevator links. The

system is equipped with two sets of balanced valves and 2 hydraulic control one-way

53


valves, the major function of balanced valve is to make the elevator link stop at any

position instead of sliding because of action of gravity. Electromagnetic directional valve

27.3 is suspending action electromagnetic valve, when the electromagnet c12 is out of

energization, hydraulic control ends of two hydraulic control one-way valves 39.1 and

39.2 lead to oil return, and rod chamber of elevator link tilting cylinder does not lead to

oil return; when it is powered on, suspending function is opened, the pressure oil opens

the hydraulic control one-way valve through change valve, oil in rod chamber of two

tilting cylinders flow back to oil tank via port XT through hydraulic control one-way

valve, and then tilting cylinder goes back to position by its dead weight, the suspending is

achieved.

Schematic drawing of elevator link tilting system

Firstly charge pressure to three accumulators before starting up HPU motor,

nitrogen charge pressures are respectively: system accumulator-5.5MPa, balance system

accumulator-6MPa, and time-delay accumulator-5.5MPa. Schematic diagram of top drive

hydraulic system is showed as follows:

54


55


5 Operating instructions

The trained personnel with corresponding qualification and experience are allowed to

use top drive device and should read this operation manual and related technical

documentations before operation.

5.1 Check before startup

All personnel engaged in operation of top drive should be trained for drilling

operation and drilling safety knowledge and use protection articles of gloves and clothing

etc.

Refer to 'installation and commissioning instruction book of top drive'

for installation and commissioning of equipment first installation of top

drive, well location change or long-term halt.

Check following items before startup:

1) Check equipment operation record and know whether equipment has abnormal

phenomenon in former shift process or not.

2) Check liquid level of reducing gear box, liquid level cannot be too high or too

low, and fill oil referring to 'Maintenance instruction book of top drive' when liquid level

is too low.

3) Check liquid level of oil tank of hydraulic system and filter;

4) Lubricate (grease) positions which should be lubricated (greased) everyday.

5) Check hydraulic oil passage for leakage.

6) Check hydraulic hose.

7) Check gooseneck and its joint for damage.

8) Visually observe whether suspension cable of top drive is wound and cable joint is

loosened or not;

9) Check whether safety locking line and safety pin are installed in position.

10) Check backup tong body for free movement.

11) Check wearing condition of tong die of backup tong.

12) Check bolt of BOP thread locking mechanism for looseness.

13) Check other equipment except top drive for normal running.

Note

56


5.2 Operation of electric system

5.2.1 Startup of system

Before startup of electric system, make sure that mechanical part and hydraulic

part have been ready, carefully check following items of electric system:

1) Check operation elements, instruments and meters of control cabinet and driller's

console in top drive electric control room and enable them in initial states (See 'Electric

manual’).

2) Reset driller's control cabinet for testing all indicator lamps of driller's control

cabinet.

Press 'startup' button on door panel of rectifier cabinet, and rectifier starts to run.

Corresponding main control switch of rectifier cabinet after time delay is closed.

600V/690VAC is supplied to rectifier, inverter is started up, and top drive device is

ready.

5.2.2 Stop of system

Stop system as per following procedures:

1) Reset rotation speed setting hand wheel of driller's control cabinet in drilling

mode, push main motor switch to 'stop' position, startup signal of driller's

console is removed, inverter stops working, and top drive device stops running.

2) Push 'stop' button on door panel of top drive electric control room rectifier

cabinet, system conveys stop signal to rectifier, delay time and turn off main

control switch, and system is stopped.

After main control switch is turned off, power supply can be cut off.

5.3 Operation of hydraulic system

Startup and stop of top drive HPU main motor: start up hydraulic motor by HPU

motor switch on driller's control cabinet to drive main hydraulic pump; when top motor is

started up, HPU main motor is also automatically started up. When oil temperature of top

drive HPU is more than 80 DEG C, delay 20 seconds and stop HPU main motor.

Relation between top drive HPU main motor and top drive relief valve control: after

top drive HPU main motor is started for 3 seconds, top drive relief valve can be started

up; when top drive HPU main motor receives a stop command, firstly stop top drive relief

Note

57


valve, and then stop top drive HPU main motor after 3 seconds.

Startup and stop of top drive HPU heater: start up heater when oil temperature of top

drive HPU is lower than 15 DEG C and automatically stop heater when oil temperature

of top drive HPU is higher than 30 DEG C.

Operation procedures of hydraulic system at driller's control cabinet are as follows:

1) Push HPU motor switch to 'startup' position to start up HPU motor.

2) Push HPU motor switch to ‘automatic' position to start up and stop HPU motor

by PLC program.

3) Generally, push HPU motor switch to 'automatic' position.

5.4 Driller console control

5.4.1 Drilling mode

Start the system properly before operation. System state after start the system properly are shown

below

position press-button or switch status

driller console

HPU motor Auto

Disc brake Auto

Rotatable motor stop

Tilting elevator link stop

IBOP open

Operating mode drilling

traction motor stop

make up torque limit zero

Drilling torque limit zero

Rotary speed setting zero

Carry out the following procedures after make sure the system is in correct states

1）Spin off the wheel handle “drilling torque limit” slowly from zero to the needed

torque value

2）Turn the switch “traction motor” to the position “forward”

58


3）Spin off the wheel handle “rotary speed setting” slowly from zero to the needed

torque value, The traction motor rotates forward at a given rotary speed.

Note: the switch “operating mode” and “traction motor” are effective when the wheel

handle is at original position and the system is not started. Otherwise they two will be

ineffective.

Warning: check the braking condition and the limit value of drilling torque for correction

between the time the traction motor has been started and the rotation speed has not been

set. Increase the limitative drilling torque value which should not be set too high after

start the traction motor.

5.4.2 Reversal operation under drilling mode

Normally, reversal operation under drilling mode is not allowed, but the top drive

device provides reversal drilling operation to deal with some complex working

conditions, then some simple settings on the HMI are needed.

Start the system properly before do the reversal operation. The system states are shown below.


driller console

HPU motor Auto

Disc brake Auto

Rotatable motor stop


IBOP open


traction motor stop




Carry out the following steps after make sure the system is in correct states:

1 ） Spin off the wheel handle “drilling torque limit” slowly from zero to the needed

torque value

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2）Turn the switch “traction motor” to the position “backward”

3）Spin off the wheel handle “rotary speed setting” slowly from zero to the needed

torque value, The traction motor rotates backward at a given rotary speed.

Warning: pay attention to the set value of drilling torque during using the reversing

function under drilling mode and to avoid drill pipe broken.

5.4.3 Make up/ break out operation

Started the system properly before perform the make-up or break-out operation .The system states are

shown below:


driller console

HPU motor Auto

Disc brake Auto

Rotary table motor stop


IBOP open


traction motor stop




The make-up or break out operation cannot be performed until after the system is really

in correct state.

5.4.3.1 Make up operation

The connection between drilling tool joint and main shaft of top drive should be

greased with antiseize thread dope when perform the make-up operation

There are two ways of the make-up operation.

（1）The first method is to use backup tong to do the make-up operation: clamp the

upper joint of the stand (or single) with the backup tong, make the connection between

main shaft of top drive and the upper of the stand (or single pipe) tight through the

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driving force of top drive. The backup tong will bear the make-up torque.

The operation steps are as follows：

(1)Firstly, make sure all console switches, wheel handles and all indicator lights of

the driller’s console are normal. Then make sure the HPU has been started.

(2)Operate the switch “operating mode” to the position “drilling”

(3)Operate the switch “traction motor” to the position “forward”.

(4) Inspect whether the disc brake is in good condition after the top drive motor is

started .turn the switch “operating mode” to the position “thread on” after the disc brake

is released. Then the main shaft of top drive rotates at 10rpm and lower the travelling

block slowly at the same time to make the upper joint of the stand (or single) enter into

backup tong and stab with the main shaft of top drive. Continue to lower the top drive to

make the main shaft of top drive screw in the upper joint of the stand (or single), then the

top drive is in forward working condition. The driller can observe the rotation situation of

main shaft, the main shaft stop rotating which means the pre-set make-up torque has been

reached and the connection sub has been screwed

(5)Stop lowering the traveling block.

(6) Operate the wheel handle “make-up torque limit” to limit the maximum locking

torque value (wheel handle from 0 to 100% corresponds the maximum torque value in

make-up or break out working condition from 0 ～ 45kN.m). The maximum make up

torque valve should be determined by the drilling tool model and the demands of the

work operation

(7) Press and hold the button “backup tong”, then the backup tong starts to clamp which

means the backup tong pressure is over 10MPa. The indicator of backup tong is on which

means the backup tong is griping the drilling tool joint. At the same time operate the

switch” operating mode” to the position “torque” (note: right now the button of backup

tong is still in the clamped status. Then the main shaft of top drive rotates forward at

2rpm. The make –up operation has started, so the driller can retrieve the current make-up

torque value from the torque gauge. The top drive stops automatically when the torque

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gauge needle reaches the limitative maximum make-up torque value.

(8) Release the button “backup tong” (the indicator light of backup tong clamping goes

out which means the backup tong is loosening the drill tool joint) and turn the switch

“operating mode” to the position “drilling” at the same time. Then the main shaft speed

of top drive is zero.

So far, the make-up operation has been completed and the connection between main shaft

of top drive and the upper the stand (or single) has been tightened

Note: The backup tong should be loosened immediately when the locking operation has

been finished, otherwise the backup tong will bear the total weight of drilling tool when

hoist the traveling block and it is possible to cause damage to the equipment or personal

injury

（ 2 ） The second method is to use the slip to perform the make-up operation ：

clamp the drill string in the wheel with the slip (the rotary table should be locked) and

make the connection between main shaft of top drive and the upper of the stand (or single

pipe), the connection among each section of the stand, the connection between the lower

the stand (or single) and the drill string in the well tight through the driving force of top

drive. The slip will bear the make-up torque.

The operation steps are as follows：

Firstly, make sure all console switches, wheel handles and all indicator lights of the

driller’s console are normal. Then make sure the HPU has been started, the indicator light

“air pressure signal” is on.

Turn the switch “operating mode” to the position “drilling”

Turn the switch “traction motor” to the position “forward”

Spin off the wheel handle “rotary speed setting” from zero, the given rotary speed of

main shaft of top drive is about 10rpm (wheel handle from 0 to 100% corresponds the

rotary speed in drilling working condition from 0 to 220rpm). The main shaft rotates at

slow speed and the rotary speed can be retrieved from the rotary speed gauge.

Turn the wheel handle “make-up limit” to limit the make-up torque value from 5 to

10kN.m (wheel handle from 0 to 100% corresponds the maximum torque value in make-

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up or break out working condition from 0 to 45kN.m).

Lower the traveling block slowly to make the lower joint of the stand (or single pipe) stab

with the drill string joint in the well.

Continue to slow the traveling block to make the upper joint of the stand (or single) enter

into backup tong and stab with main shaft of top drive.

Continue to slow the traveling block, then the main shaft of top drive screws in the upper

joint of stand (or single pipe) gradually and that also makes the lower joint of the stand

(or single) also screw in the drill string joint in the well. The driller should observe the

rotation situation of main shaft, the main shaft stop rotating which means the pre-set

make-up torque has been reached and the connections have been screwed

Stop lowering traveling block,

Make the wheel handle “make-up limit” rotate clockwise and increase the maximum

limitative torque value to the needed locking torque value gradually (the maximum

locking torque value is determined by the drilling tool model and the demands of the

work operation), now the top drive starts to lock. The driller can retrieve the current

locking torque value from the torque gauge. The top drive stops automatically when the

torque gauge needle reaches the limitative maximum locking torque value. The left hand

is away from the switch “operating mode” and the right hand releases the switch “backup

tong”, then the make-up operation has been completed.

Return the wheel handle “rotary speed setting” to the zero-position

So far, the make-up operation has been finished and the connection between main shaft of

top drive and the upper end of the stand (or single), the connection among each section of

the stand, the connection between the lower the stand (or single) and the drill string in the

well have been tightened.

Warning: the rotating head must be locked before do the make-up operation

Do operate the wheel handle “rotary speed setting” slowly and steadily to avoid the

attached impact torque when make up

Note: this method can tighten the connection between main shaft of top drive and the

upper end of the stand (or single), the connection among each section of the stand, the

connection between the lower the stand (or single) and the drill string in the well for the

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first time. It is operated simply and effective to improve the working efficiency, so it is

recommended to the following working conditions: to connect pipe the stand (or single

joint) for drilling operation, to ream for tripping out operation and so on

5.5.3.2 Break out

(1)Firstly, make sure all console switches, wheel handles and all indicator lights of the

driller’s console are normal. Then make sure the HPU has been started.

(2)Turn the switch “operating mode” to the position “drilling”

(3)Turn the switch “traction motor” to the position “backward”

(4) Operate the handle wheel to set the maximum break out torque valve which should be

greater than the maximum make up torque valve.

(5) Press and hold the button “backup tong” and the indicator light “ backup tong clamp”

is on , then the backup tong grips the drilling tool joint. Turn the switch “operating mode”

to the position “torque”

(6) The driller should observe the value on the torque gauge or the state of the main shaft

of the top drive which starts to rotate when the break out torque is greater than the make-

up torque. When the break out torque valve drops to the small valve suddenly that means

right now the connection has been loosened.

(7) Turn the switch “operating mode” to be in the drilling mode and release the button “

backup tong”at the same time , then the indicator light “backup tong clamp” goes out

which means the backup tong is loosening the drilling tool joint. Main shaft of top drive

starts to thread on backward evenly. At the same time the driller starts to lift the traveling

block slowly to make the main shaft of top drive removed from the drilling tool joint

gradually.

(8) Turn the switch “operating mode” to the position “drilling” when then drill string

joint is loosened completely. Then the traction motor of top drive stops rotating.

(9) Turn the switch “traction motor” to the position “stop” and stop lifting the traveling

block.

So far, the break out operation has been completed, so all the switches and the wheel

handles should be returned to original position

Note: The backup tong should be loosened when the locking operation has been

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completed, otherwise the backup tong will bear the total weight of drilling tool when the

traveling block is hoisted and it is possible to cause damage to the equipment or personal

injury

5.4.4 Backup tong operation

The actual rotation speed of top drive is less than 1rpm in drilling or thread on mode and

the button “backup tong” cannot be operated unless the rotating head is on the state of

ceasing. The backup tong still keeps the state of clamping even through the switch

“operating mode” is switched to torque mode. The pressure of top drive backup tong is

greater than 10MPa which means the top drive backup tong clamps and the indicator light

“backup tong clamp” will be on

5.4.5 Rotating head operation

The rotating head is interlocked with elevator link which means they can be operated at

the same time. The rotating head cannot be operated until elevator link suspends for

3seconds (that is, 3 seconds after Press and hold the button of elevator link suspension),

otherwise the rotating head cannot be rotated. Rotating head lockpin operation: the

rotating head lockpin can only move when the backup tong clamps. The rotating head can

keep still during makeup/break out the drill pipe by using the backup tong button to

control the rotating head lockpin locking,

Note: the rotating head locking and the rotating operation can be interlocked, the rotating

operation is ineffective if locked

To ensuring person and production equipment safety, the backup tong operation cannot

be performed unless the rotating head locking operation has been achieved and verified

firstly.

5.4.6 Elevator link

Control of the elevator link rotation clockwise or counter clockwise can be achieved

by operating the switch “rotable motor” of the driller console after the hydraulic system is

started and the rotating head locking is loosened certainly

The elevator links cannot be operated unless the rotating head keeps still, but the

suspension operation for the elevator link can be operated at any time. Turn the button

“tilting elevator link” to the position “forward”, then the elevator link is forward, Turn it

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to the position “backward”, then the elevator link is backward. Turn the button “elevator

link suspension”, then the elevator link goes back to the neutral position, but the button

should be pressed for 3 seconds when means the elevator link is really neutral. The tilt

angle should be controlled according to the actual situation.

The “tilting elevator link” switch can be used for controlling forward and backward tilt of

elevator link.

Note: The rotating head rotation and tilting elevator link operation cannot be performed

at the same time, otherwise it is possible to cause damage to equipment and personal

injury.

The elevator link can be returned to the neutral position by pressing the button “elevator

link suspension”. Be sure to prevent the elevator from crashing into the drilling tool when

do this operation.

Ensure the rotating head locking is loosened before operate the rotating head rotation,

otherwise the rotation operation is ineffective.

Rotation operation of rotating head cannot be performed until the button “elevator link

suspension” is pressed firstly for 3 seconds after do the operation of tilting the elevator

link

Warning: The maximum load-bearing of tilt cylinder is 2T, the elevator link must be in

the state of neutral which means the elevator link is free when hoist the overweight

objects such as drilling collar.

5.4.7 IBOP operation

The IBOP can be controlled by the switch “IBOP” when the top drive is in the stationary

state.

When the emergencies such as blowout occur, it will enter into a state of well control,

and the system will do the following operations

1） Start the hydraulic pump (the state of the HPU is automatic)

2）Stop the mud pups (the top drive is interlocked with the mud pumps)

3）Stop driving device rapidly

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4）Close the IBOP

Perform the following operation immediately after it has been in a state of well control.

1） Spin off the wheel handle “rotary speed setting” to the zero position, turn the

switch “ traction motor” to the position “stop” and turn the switch “operating

mode” to the position “drilling”.

2） Eliminate the emergencies and affirm the system can alarm without fault

3） Press the button “fault reset” on the driller’s console to make the loudspeaker

silent.

Lock the IBOP in the position “OFF” by the locking key switch on the PLC cabinet

to ensure the cable in the well will not be pinched off by the IBOP during well logging.

Note: Note: be sure to turn the switch IBOP to the position “OFF” to prevent the cable

in the well from being pinched off during logging.

5.4.8 Emergency stop operation

The operator can press any button “system emergency stop” nearby to make all

equipment for top drive system stop rapidly when the system is in emergency.

The following steps have to be done immediately after the button “system emergency

stop” has been pressed.

1）Spin off the wheel handle “rotary speed” to the zero position , turn the switch

“traction motor” to the position “stop”, operate the switch “operating mode” to the

position “drilling”

2） Press the button “stop” on the Rectifying cabinet

3） Eliminate the emergencies and affirm the system can alarm without faults.

4） Press the button “system emergency stop” to be back to the reset position

5） Press the switch “ fault reset” of the driller console to make the buzzer silent

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Press the button “start” on the rectifying cabinet to restart the top drive.

5.4.9 Faults and alarm

1）Air pressure alarm of top drive: if the top drive motor starts and the air pressure

signal cannot be received in 10 seconds, then the air pressure alarm signal will be

transmitted. If the blower has a fault during the top drive motor running and the air

pressure signal is lost over 10 seconds, then the absent air pressure alarm signal will be

transmitted. The alarm information lasts 10 seconds on HMI, afterward the alarm signal

will disappear.

2）Oil pressure alarm of top drive: if the top drive motor starts and the oil pressure

signal cannot be received in 5 seconds, then the oil pressure alarm signal will be

transmitted. If the oil pump has a fault during the top drive motor running and the air

pressure signal is lost over 5 seconds, then the absent air alarm signal will be transmitted.

The alarm information lasts 10 seconds on HM I, afterward the alarm signal will

disappear.

3）If the elevator link stretches out and the hook height is over 19.5m and then the

alarm signal will be transmitted and the travelling block cannot move upward.

4）Turn off the IBOP of the top drive to alarm and prompt to pay attention to the

pump stroke setting.

5）If the HPU liquid level for top drive is under 150mm and then the alarm signal

will be transmitted. If the HPU liquid level for top drive is 560mm above and then the

alarm signal will be transmitted.

6）If the HPU oil temperature for top drive is under 80℃ and then the fault signal

will be transmitted. If the HPU oil temperature for top drive is 70℃ above or 15℃

below and then the alarm signal will be transmitted.

7 ） Frequency converter of top drive, coder, lock out switch and communicating

faults alarm

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5.4.10 Special operations

Coder switching operation:

① When the coder of traction motor is damaged or out of order which means the

top drive has to be braked and the rotation speed is back to zero, the HMI will show its

alarm signal. Right now turn the “rotation speed setting” to the original position firstly

and turn the switch “traction motor” to the position “stop” to make the top drive enable.

② Turn the switch “coder switch” on the control cabinet of top drive electric

control room from the position “normal” to “by pass”, do open-loop control by utilizing

the computation speed signal of coder

Turn the switch “coder switch” from the position “by pass” to “normal” as per the above

operations after the coder is replaced or in order, then the system will be back to normal

and do the open-loop control.

6 Drilling steps

6.1 Tripping in /out

Adopt the conventional method by using the pipe handler to trip in, this method is in

favor of relieving the labor force and improving the efficiency.

6.1.1 Tripping out

1）Loosen the connection between saver sub and drilling pipe, then hoist the top drive,

operate the switch “elevator link suspension” to the position “neutral”(right now the

elevator link is backward),use the elevator to grip the drill string joint when the elevator

link moves to be neutral

2）Lift the top drive to monkey board above, place the slip and lower the top drive

3）Use the hydraulic tong /iron roughneck to break out

4 ） Lift the top drive and operate the switch “tilting elevator link” to make the

elevator link forward; The derrickman should open the slip and put the lifted the stand

into setback when the elevator is near to monkey board.

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5) Operate the switch “elevator link suspension” to the position “neutral”, lower the top

drive to the drill string which will be gripped with the elevator.

6）Repeat the steps 2-5

6.1.2 Dripping in

1）Lift the top drive to the monkey board and operate the switch “rotatable motor” to

make the inclined arm of elevator link rotate to the location the derrickman on the

monkey board need.

2）Operate the switch “tilting elevator link ” to the position “forward” to approach

elevator to the location where the drilling pipe will be racked through monkey board.

Then the derrickman should put the the stand into the elevator which should be fastened

tightly subsequently

3）Firstly turn the switch “tilting elevator link” to the position “backward”, operate

the switch “ elevator link suspension” to the position “neutral” after the elevator link is

back to the wellbore center, then the tilt cylinder is in a floating state.

4 ） Lift the top drive and the lifted stand returns to the neutral position. The

derrickman should pull the lower end of the stand with rope and release it slowly, lest

damage of drilling pipe joint during this process.

5 ） Lower the travelling block and stab the lifted lower end of the stand with the

upper end of drill string on the drilling floor, then use the hydraulic tong/iron roughneck

to make-up

6）Lift the top drive and pull the slip out; lower the top drive to the upper end of the

stand which should be approached to drilling floor, place the slip and make the drill string

gripped by the slip firmly.

7）loosen the elevator, operate the switch “tilting elevator link” to make the elevator

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link backward a bit and removed from drilling string. Lift the top drive to the monkey

board

Repeat the above steps

Note: use the motor of top drive to connect the saver sub and drill string at the height of

mast and establish circulation and turn drilling tool to make the drilling tool pass the

blockup position if the hole shrinkage or key way occurs during dripping in /out.

6.2 Drilling work condition

1）Turn the wheel handle “rotary speed setting” to the zero position, turn the switch “

operating mode” to the position “ drilling” and turn the switch “ traction motor” to the

position “ forward”

2）Spin off the switch “drilling torque limit” slowly from zero to the needed torque

value

3）Spin off the switch “rotary speed setting” from zero and the main shaft of top

drive rotates forward at given rotary speed.

Note: the blockup phenomenon occurs when the load torque in well is greater than the

pre-set one. The top drive has two methods for solving the blcokup:

A. keep the wheel handle “rotary speed setting” and “disc brake” still, ensure the traction

motor can output torque continually, reduce the limitative torque value which is set by

the wheel handle “drilling torque limit” slowly to make the output torque reduced slowly,

the drilling rotates slowly reversely until the pre-set limitative torque value is zero and its

reversal speed is zero. Loosen the handle and lift the drilling tool

B. keep the wheel handle“ drilling torque limit” still, return the wheel handle “ rotary

speed setting” to the zero position ,the motor stops output and then the system brakes.

The switches “operating mode” and “traction motor” remain still and then the drilling

tool starts to rotate reversely, the driller should turn the switch “disc brake” to the

position “brake” at the right time as per the reverse speed to ensure drilling tool joint

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cannot be removed; Repeat the above braking processes until the reversal speed of

drilling tool declines to zero. Loosen the handle and lift the drilling tool

The recommended method is A, because the method B is subject to the effects of driller

skills and braking performance, so it is only available when the top drive is out of

condition.

Warning: the drilling tool has the ditching risk when solve the blcokup. The control of

Reversal speed of drilling tool should be in strict accordance with operating rules in case

of an accident.

4 ） Return the wheel handle “rotary speed setting” to the zero position when the

system is in drilling mode and needed to stop normally, then the device will stop

normally at a reduced speed. If the switch “disc brake” is in position “auto”, the button

“disc brake” will be linked to the movement of the top drive motor. The button “disc

brake” will release when the top drive motor is started, the button “disc brake” will

execute the brake order when the top drive motor is stopped.

6.2.1 Single drilling

1）Place the slip, stop the circulated mud fluid and turn off the IBOP

2）Do the break out operation with backup tong as per the steps in the chapter5

3）Lift the top drive a bit to make the elevator removed from the drill string joint

4）Lean the elevator link to the mouse hole and use the elevator to grip the single

joint

5）Lift out the single from mouse hole, turn the switch “elevator link suspension” to

be neutral, right now move the single to the wellhead center

6）Lower the top drive and stab the connection at the top and bottom of the stand

respectively.

7）Use the top drive to thread on and make up as per the steps in chapter5

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8）Lift out the slip, open the IBOP and circulate the mud fluid

6.2.2 Stand drilling

1）Place the slip, stop circulating the mud fluid and turn off the IBOP

2）Do the break out operation by backup tong as per the steps in the chapter5

3）Lift the top drive to make the elevator removed from drill string joint, operate the

elevator link inline mechanism to approach the elevator link to the derrickman when the

top drive is lifted to the monkey board

4）The derrickman uses the elevator to grip the stand and turns the switch “elevator

link suspension” to make the elevator neutral

5）Lower the top drive and stab the connections at the top and bottom of the stand

respectively.

6）Use the top drive to thread on and make up as per the steps in chapter5

7）Lift the slip out, open the IBOP and open the mud pump to circulate the mud fluid

6.3 Back reaming

Connect the drill string and main shaft of top drive and circulate the mud fluid

immediately when the sticking occurs during dripping out. Reaming while lifting to

prevent the drill pipe sticking and free of keyway.

The back reaming steps is described below:

1) Circulate mud fluid and lift the drill string reelingly at the same time, this

operation can be stopped unless one stand has been lifted out.

2) Stop circulating mud fluid and rotating, place the slip

3) Use the hydraulic tong/iron roughneck to remove the connections on the drilling

floor and use the top drive to remove the stand which is connected to the

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connections.

4）Lift the stand and rack the stand into the setback.

5）Lower the top drive to the drilling floor, lean the elevator link backward and open

the elevator for standby.

6）Plug the saver sub of top drive in the female thread of drill string and use the

motor of top drive to thread on and make up.

7）Re-circulate the mud fluid, rotate the drilling tool and continue to back reaming.

6.4 Run casing

The elevator link 450t and 3.8m above, is needed to leave enough space for installing

cement head when use the top drive DQ450DBZ to run casing. It is available to adopt t

conventional method for running casing. Insert a adaptor between the casing and saver

sub of top drive if necessary, then the pressure cycling can be done to reduce the friction

drag of the hole section where the hole shrinkage occurs during run casing. It is available

to use the top drive which stabilizes to prevent the cross threading and wrong threading

during thread on to grip the casing when run casing, so using this top drive to run casing

can improve the operation speed greatly.

The operation steps is described below：

1） Lift a casing which should be connected to the casing in well by elevator link.

2） Operate the tilting mechanism and rotating head to adjust the casings for

stabbing

3）Use the hydraulic tong to make up as per the conventional method

4）Lift the casing string and open the slip

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5）Lower the casing string and place the slip firmly

6）Open the elevator and lean the elevator link to grip the new casing.

7）Repeat the above steps.

6.5 Well control

The upper remote IBOP which is always in the ready state is usable immediately once the

kick occurs. The bottom IBOP which only can be operated by spanner is always installed

onto the drill string, so at least one BOP is available.

Below are the well control steps during dripping in /out:

1） Place the slip immediately and stab the main shaft of top drive and drill string

when there is kick in the drill string

2）Use the motor of top drive and backup tong to make up.

3 ） Turn off the upper remote IBOP, the driller should turn off the bottom IBOP

manually if the upper remote IBOP is not available,

Install the check valves and well control attachments which are needed during in the

normal well control process onto drill string by the IBOP.

Below are the steps to installing the check valves to drilling string:

1） Lower the drill string to drilling floor and place the slip

2） Turn off the bottom IBOP manually

3） Remove the bottom IBOP and saver sub from the top drive by hydraulic tong

4） Install the adapter, check valve or circulating sub onto the upper IBOP

Perform the normal well control steps.

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6.6 Jarring

The jar use has impact to the top drive, but the extent is hard to assess because of the

uncertainty of jarring (it changes along with well depth, the drill string, neutral point and

the jar types) and the difference of every well.

Warning: The surface bumper sub is not available on any account; otherwise the top drive

will be damaged.

Check the top drive after every jarring, below are the check items:

1） Visual inspection for the damage to the top drive

2） Visual inspection for the upper mud channel.

3） Check all the connections between cables and rubber, reconnect them if

loose.

4） Check all the exposed bolts connections. Re-connect them if loose.

5） Check whether all the guards and cover plates get loose.

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Documents

E-DQ450DBZmanual+de+aplicacion+de+top+dr