Training foraj

Drillmec SpADrilling Technologies

12, Via 1 MaggioI-29027 Gariga di Podenzano

PIACENZA (Italy)

Corporate web site: http://www.drillmec.comMailbox: [email protected]

Ph +39.0523.354211Fx +39.0523.524418

TRAININGMR8000

CAREFULLY READ THIS MANUALBEFORE OPERATING THE MACHINE

!

Drilling rig semitrailer mounted

1

zilianiCasella di testo


DRILLING RIGMR 8000

2

IDENTIFICATION

This equipment is identified through the serial number and/or the identification numbers on main components.

EQUIPMENT IDENTIFICATION PLATE

The equipment identification plate shown in the picture re-ports all identification data for the machine. The label islocated on the lefthand side of the equipment, on the mastsupport. Always check that the equipment part number(N. MATR.) stamped on the plate matches with that re-ported on the front cover of this manual.

Piacenza - ITALY

Machine type

Serial Number

Year of manufacturing

Nominal Power

Weight

0953-3682E

[Kg]

[Kw]

3

NOMENCLATURE OF THE MAIN COMPONENTS

CROWNBLOCK

MONKEYBOARD

TRAVELLINGBLOCK

POWERTONG

SERVICEWINCH

SUBSTRUCTURESEMITRAILER

DIESELENGINE

OILTANK

DRAWWORKS

COMPOUND

DRAWWORKS

STAIR

DIESELENGINE

WALKWAYS

TRANSMISSION

SUBSTRUCTURE

SERVICEWINCH

DRILL PIPE RAMPAND STAIR

ROTARYTABLE

DRILLFLOOR

POWER TONG

HYDRAULICBRAKE

TELESCOPICSECTION MAST

FIXEDSECTION

MAST

4

TECHNICAL SPECIFICATION

Semitrailer mounted mobile rotary drilling rig DRILLMEC MR 8000 model, suitable for -20C to +40C range temperature.The rig is manufactured in accordance with API standards.

MAST

Technical Data (Ratings to API 4F)

Static Hook load (w/10 lines) : 200 metric tons (440,000 lbs)Clear height : 35.97 m (118 ft) from ground levelClear height to rotary beams : 4.17 m ( 15.11/16 ft) from ground levelRacking Board Elevation : 16.76 m (55 ft) from drill floor levelCrown Block Sheaves : four cluster sheaves OD 36 grooved for 1.1/8 cable;

one fast line sheaves OD 36 grooved for 1.1/8 cable; one deal line sheaves OD 20 grooved for 1.1/8 cable;

Hydraulic Catheads Break-out : max pull 12,000 kilos (26,400 lbs)/ stroke 1.3 mHydraulic Catheads Spinning : max pull 6,000 kilos (13,200 lbs)/ stroke 4.6 m

Racking board capacity : 2850 m 5 OD - 6.5/8 TJ OD

DRAWWORKS

Main Drum:- Diam. x Lenght: 26 x 42.1/2- Spooling Capacity: 700 m (2,300 ft) of 1.1/8 OD wire line- 42 VC 650 Fawick air clutch- Brake diameter x lenght 1168.4x203.2 mm (46 x 8)- Raising speeds: 5 forward, 1backward- Parmac hydraulic brake V80

Chains:- Main drum chain: 1 3/4 double ASA

The drawworks is complete with water cooling system and PARMAC V80 hydromatic brake composed as follows:

DIESEL ENGINE AND TRANSMISSION

- 2 diesel engine CAT C15- Output power: 402kW (540 Hp) at 2,100 rpm- Pneumatic starter- Automatic Allison transmission S 5610 H model- Compound: 2 chain transmissions ASA, oil lubrication.- Heavy duty right angle gear box- 2 pumps for hydraulic system- 2 air compressors with T30 IR ( max displacement 710 l/min)- Pneumatically operated inertia brake

5

SUBSTRUCTURE

- Max. Rotary Table Load (Casing Capacity) : 200 metric tons (440,000 lbs)- Max. Setback Capacity : 113 metric ton (250,000 lbs)- Simultaneous Capacity : 313 metric tons (690,000 lbs)- Drill Floor Height : 5,180 mt (17 ft)

Two steel skids are placed below the semi-trailer body levelling jacks and are part of the substructure auxillary equip-ment.A remarkable feature of the proposed substructure is the length of the base skids that is 40 (12 m) approximately.The mast front guylines together with those of the monkey board are fixed at the end of each skid avoiding the need ofseveral external anchors driven into the ground. Two anchors only placed at the rear of the semi-trailer.Hydraulic winch mounted on drill floor with max pull load 3000 kg ( 2943 daN)

SEMITRAILER

- Four hydraulic levelling jacks with an additional mechanical safety locking device.- Lighting and road signs according to international standards.- Folding walkways with handrails.- Ladders.- N. 2 skids to be placed under the hydraulic levelling jacks.- Single tyres.- 2 and 3.1/2 king pin- One spare tyre

ROTARY TABLE

- 27.1/2 opening- Complete with master bushing, adapter plate, bit breaker and lifting slings- safety pads anti-slipping type- Max speed: 300 rpm- Max static hook load on table: 770000 lbs (320 metric ton)- Rotary clutch: 20 CB 500

AUXILIARY HYDROMATIC BRAKE

- Parmac V80- Max pressure: 15psi- Max speed: 1550 rpm- Brake capacity: 5000 Hp- Volume: 13-1/2 gal- Hydromatic brake air clutch: 26 CB 525

TRAVELLING BLOCK - HOOK

- Load capacity: 500,000 lbs (250 metric ton)- Sheave: five 30 (76.2 cm)- Grooved for drill line OD: 1.1/8

HYDRAULIC POWER TONGS

One (1) Hydraulic Power Tongs DRILLMEC, operated from a panel , to make-up and break-out drill pipes and drill collarsup 9.1/2, consisting of:- Double hydraulics clamps. Top one rotating with max torque: 101,000 lb-ft (14,000 kg-m).

6

- Set of hydraulic cylinders for swinging the power tongs in/out from well center to parking position.

LIGHTING SYSTEM

TOP OF THE MAST:

Q.ty 1Description EExd Obstruction Red Light with XenoFlash 230V-60HzType EVX4070

XF2J1FE110A3Supplyer Cortem Sirena

MONKEY BOARD:

Q.ty 1Description EExd Floodlight 230V-60Hz 400W with Metal Jodure Lamp 400WType FLSA40Supplyer ITALSMEA

MAST:

Q.ty 6Description EExd Floodlightwhit Energy Saver Lamp 230V - 60Hz 23W (130Watt)Type EVGC 3070

Plet-23Supplyer Cortem

DRILLING FLOOR & SUBSTRUCTURE


TRAILER:


7

MAIN DIMENSIONS

WORKING CONFIGURATION

TORNELLO MANOVRA

TORNELLO SERVIZIO

440

890

500

3030 1825

1033

20500 (67'-3")

30785 (101')

16764 (55')

35966 (118')

2020

2950 (9'-8")

7000 (23')

5182 (17')

1570 4170

12000 (40')

4616 (15')

5233 (17')

8

KG 73000

KG 12000

KG 12000

KG 12000

KG 12000

KG 25000

3406

2500

7000

15

1375

4860

21075

5951

2374

1360

1360

1360

8670

TRANSPORT CONFIGURATION

9

MAST GUYLINE LAYOUT

10

zilianiCalloutWIRE ROPE 22 mm

A-3.4.4 HOIST WIRE ROPE REEVING DIAGRAM

11

111

8

12

8

7

3

9

6

10

5

4

2

7 1

11

Item Code Q.ty Description

1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS

2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS

3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS

4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS

5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS

6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS

7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS

8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS

9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS

10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS

11 4059 0116 2 CARDAN JOINT


13

13 4100 1122 1 ROPE D.28.57 (1.1/8")

A-3.4.5 POWER FLOW DIAGRAM

12

118

10

440 000

83

61

6,627

13

440 000

250 000

690 000

14

18500

15

SAFETY DEVICES

Both the complete machine, and its individual parts, arefitted with built-in safety devices.

- All cylinders are equipped with check valves. In case ofbreaking of connecting pipes or pressure drop or fail-ure, the cylinders will be locked thus preventing anyunwanted movements.

The machine is fitted with the following buttons for emer-gency stop and mechanical locking devices:

WARNINGIn case of engine stop for a long time, it is mandatoryto switch off the batteries Q1 and Q2.

- C20 emergency on the main control panel stops drill-ing rig operation.

- Engine start up, and therefore machine operation, canonly be performed by pressing start button on dieselengine control board and battery breaker is on.

- Emergency control board near diesel engine stops onlydiesel engine.

Q1

Q2

C20

Emergency

Emergency

16

- C29 and C30 emergency is located on draw work andstops drilling rig operation.

C29

C30

Safety mechanical block stabilizer (Fig. B-3.7).

- The drilling rig is equipped with a limit switch for properoperation.

- The machine is also equipped with protective panelsand fixed guards (fitted with the following plate: Safetydevice - Do not remove) in order to avoid coming intocontact with drive gears in motion or hot hydraulic com-ponents.

HAZARDBefore operating the machine, verify all safety devicesare present and properly working.

17

DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP

C30

C29

Q1 Q2

C20

Emergency

18

RPM

RSSTE

ES

CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (LEFT HAND FROM FLYWHEELSIDE)

RPM Diesel engine hour-counter and RPM indicator

ES Emergency push buttonTE Diesel engine hour counterRSS Start - Stop switch

Q1 Battery breaker

DEE Diesel engine engage

DEE

Q1

19

Fig. C-1.5

R2

Fig. C-1.6

R3

R2 Throttle knob on control panel

R3 Throttle pedal on drill floor

20

CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (RIGHT HAND FROM FLYWHEELSIDE)

TE Diesel engine hour-counterES Emergency push buttonRPM RPM IndicatorRSS Start - Stop switch TE

R2

DEE Diesel engine engage

Q2 Battery breaker

RSSRPM

ES

DEE

Q2

R2 Throttle knob on control panel

21


POSITIONING CONTROLS

A10 Stabilizers oil pressure gaugeC18 L.H. Rear stabilizer remote controlC19 R.H. Rear stabilizer remote controlC20 L.H. Front stabilizer remote controlC21 R.H. Front stabilizer remote controlC22 Mast raising cylinder remote controlC23 Mast telescopic remote controlC24 Telescopic locking remote controlC25 Stabilizers distributor shut-off ball valve

C18

A10

C25

C19 C20 C21 C22 C23 C24

22

DRILLING CONTROLS AND INSTRUMENTS

A4 Compressed air gaugeA6 Main drum compressed air gaugeA7 Drum brake cooling water pressureA8 Drawworks lubricating oil pressureA9 Lubricating oil pressure gauge for transmission compoundA11 Cathead spinning pressure gaugeC14 Main drum clutch controlC15 Crown - O - matic controlC16 Speed selector engineC17 Pneumatic system feedingC18 Rotary table clutchC20 Emergency stopC21 Hydromatic brake controlC27 Auxiliary equipment remote controlC28 Spinning cathead controlC29 Break-out cathead controlHW1 Engine warning lampHW2 Engine warning lampR2 Throttle knobR6 Torque regulator spinning cathead

C15

A4 A9 A8 A7 A11

C16

C20

A6

R6

C21HW1

HW2R2

C27 C17

C18 C28 C29 C14

23

A17 Weight indicatorA18 RPM Rotary tableA19 SPM Mud pump 1A20 SPM Mud pump 2A21 Torque Rotary tableA22 Mud pressureA23 Digital pump stroke counter and totalizerA24 Tong line pullC31 Main drum brake lever on drill floorR3 Throttle pedal

C31

R3

A17

A18

A24

A21

A22

A20

A19

A23

24

DEVICE INSTALLED IN OTHERLOCATIONS

A26 Draw works lubricating oil pressure manometer

A25 Transmision lubricating oil pressure manometer

C29 Emergency lever on L.S. draw works

Fig. C-1.16

Fig. C-1.17

Fig. C-1.19

A26

A25

A24

Fig. C-1.18

C29

A24 Visual level oil tank transmission

25

C30 Emergency lever on R.S. draw works

Fig. C-1.20

C30

A12 Hydraulic oil temperature meterA13 Visual level on oil tank

Fig. C-1.21

A13A12

Fig. C-1.22

A28

C31

Fig. C-1.23

A28 Visual level oil tankC31 Main drum brake lever

26

C27 Ball-Valve hydraulic pump suctionC28 Ball-Valve hydraulic pump suction

FUEL LEVELPILOT ALARM

C27

C28

C30

C30 Service winch control on drill floor

27

Mud system instrumentation is mounted inside dog house, for information of this system you can see commercialdocuments.

C26

SERVICE WINCH ONMONKEY BOARD

C26 Service winch control on monkey board.

28

DIESEL ENGINE STARTING (POWERPACK)

C-2.1.1 COLD STARTING

1) Check, that valve C24, C47 and C48 is open.2) Switch on key C17.3) With machine already in working configuration, bring

throttle control R2 (drill floor control panel) to minimumrpm.

4) Rotate clockwise start key RSS. This way the motorstarts the diesel engine as soon as this is started, re-lease the push-button.

5) Few minutes of operation at minimum load are suffi-cient to reach engine working temperature.

IMPORTANTThe first machine positioning does not require press-ing the throttle.Movements are performed at minimum rpm.

IMPORTANTMax. engine rotation is set at 2100 rpm ( 50 rpm).When giving full power, always remenber to check rpmcounter and make sure that max. rpm are never ex-ceeded. (RPM)

RSS

RSS

C24

C47

C48

R2

C17

RPM

29

DIESEL ENGINE STOPPING (POWERPACK)

The correct diesel engine turn-off procedure is as follows.

1. Bring engine rotation speed to minimum, with no load,for approx. two minutes to stabilize the temperature.

2. Stop the engine by switch RSS key.

TE Diesel engine hour-counterRSS Starting button on diesel engineRPM RPM indicatorQ1/Q2 Battery breaker

OPERATING INSTRUCTIONS

PRELIMINARY CHECKS

1. Before starting work, make sure you have performedall necessary checks and servicing operations as re-quired by the hours worked by the machine.

IMPORTANTFor the complete machine, refer to hour-counter TE

2. It is recommended that you always refuel the hydrau-lic power pack diesel engine before starting theworkshift. This will prevent the machine from forcedstopping during operation.

Fig. C-3.1

TE

Fig. C-2.5

Fig. C-2.7

RSS

RSS

TE

RPM

Fig. C-2.6

Q2

Q1

30

PRELIMINARY OPERATIONS

1. Set the skids according to Fig.

2. Set skids 1-2 under the four hydraulic levelling jacks ofthe semitrailer.

3. Start the hydraulic oil circuit: Start engine at Iow speed Operate C25 ever on the hydraulic control panel in

the installation postion.

4. Lower the two front and rear jacks of semitrailer bymeans of distribution valves levers on the hydrauliccontrol panel located in the rear left side ofsemitrailer.

5. Apply the side walkways to the semitrailer.

NOTEBefore shipment, lubrication oil is drained from oilreservoirs (except for the one of the auxiliaires trans-mission oil circuit).

RSS

RSS

C25

C18 C19 C20 C21

1 2

31

LEVELLING OF RIG

1. Make sure that handle of speed selector C19 on con-trol panel is in neutral position.

2. Check that main air tank is full by means of the relatedgauge (A- 4).If it is not, fill it by an engine compressor or a hoseconnected to external compressor.

3. Start engine at low speed

4. Run engine at low speed until both the engine water,speed selector and converter oil reach the work tem-perature

5. By operating distributors levers on the hydraulic con-trol panel properly level rig.To avoid frame twisting, simultaneously operate the twofront handles and then the two rear handles. Semitrailerfloor must be 1.650 mm. high from ground floor.

6. When rig is properly levelled, lock levelling jacks bymeans of safety ring nuts.

IMPORTANTHook may be loaded only after rig is mechanicallylocked by means of safety ring nuts.

7. Anchor to plinths the two tighteners fixed to the frontsides of semitrailer.

SUBSTRUCTURE SETUP

NOTE:

Substructure is made up of two main elements: the ro-tary part (skids, bearers, floors, etc...) and the setbackpart (part (skids, bearers, floors, etc...).Rotary skid , as well as setback rotary on the oppositedrillers side, can be either transported indipendently fromthe related elements, or connected to them.1. Place the skid below the two rear jacks of the trailer.2. Place the skid of rotary element driller side accord-

ing the related drawing. In case of separate transpor-tation, connect the skid of drillers opposite side torotary part by suitable supports.

3. Set the two side floors of rotary frame.4. Hook a crane to the four ears of the rotary frame and

lift it up to the working position.

5. Settle the four telescopic bearers at working heightby means of safety pins.

6. Place the setback element skid at drillers side nearthe rotary skid. In case of separate transportation,connect the skid of drillers opposite side to the set-back element by means of suitable bearers.

7. Hook a crane to the four ears of setback frame andraise it up to the working position

8. Settle the four telescopic bearers to the working heightby means of safety pins.

9. Anchor the rotary working floor to setback floor.10. Pin the two rotary skids with the two setback skids.11. Connect the substructure rear skid with the two set-

back skids.12. Set the four braces of above drawing and pin them to

substructure skids.13. To make substructure more stable set the six

tighteners between working floor and front and rearskids of substructure.Lock tighteners at correct height by means of jamnuts.

14. Install the B.O.P. trolley guides and fix them with pins.Install the B.O.P. trolley.

15. By means of truck crane install pipe ramp and sideladders.

16. Install working floor safety handrails.

INSTALLATION OF DRIVE CHAINBETWEEN ROTARY TABLECOUNTERSHAFT AND ROTARY TABLE

A) Fix the two swinging chain housing as per drwg SpareParts Catalogue.

B) Mount chain and tension it through tighteners (SpareParts Catalogue).

32

11

74

1010

5

9 6

2-3

1

POS. CODE Q.ty DESCRIPTION

1 01902240 1 DRIVE BAR STORAGE HOLE FIXTURE2 01906175 1 PROBE ANCHORS AND TRANSMISSION ASSY3 01906177 1 SIDE PLATFORMS ASSEMBLY4 01906178 1 B.O.P. SERVICE TROLLY5 01906180 1 SUBSTRUCTURE STAIRWAYS6 01906181 1 DRILL PIPE RAMP7 01906182 1 SUBSTRUCTURE FRAMES8 01906191 1 DOG HOUSE GROUP9 01906258 1 DRILLING PIPE SUPPORT FOOTBOARDS10 01906312 1 MAIN SKID FRAME11 01908104 1 DRILL FLOOR HANDRAILS ASSY

33

Fig. C-3.6

RAISING OF MAST

1. Make sure that no air is contained in the three stage raising jacks by:- unscrewing breather plugs located in the upper section of each stage of the jack;- operating the valve lever on the hydraulic control panel, gradually pour oil into the breathers until they are com-

pletely full;- screw the plugs.

2. Run engine at approximately 1200 RPM

34

3. By means of valve lever on the hydraulic control panel gradually raise mast in working position and lock it by meansof lower pins.

4. Anchor fixed section guylines to tighteners of semitrailer and to the substructure skids.

TELESCOPING OF MAST UPPER SECTION

1. Make sure that no air is contained in the telescopic jack (Drwg. 0190 7331 - Spare Parts Manual) as per theinstructions given in the Raising of mast paragraph, point 2.

2. With engine at approximately 1200 R.P.M., operate valve lever on the hydraulic control panel and gradually telescopemast.During this operation, the oil pressure in the jack is about 180/200 bar.When telescoping of the mast upper section is completed, pressure is 210 bar (3000 P.S.I.) which is the triggeringvalue for the operation of the safety valve on the hydraulic circuit.

3. By means of valve lever on the hydraulic control panel, lock the safety pins between the intermediate section and theupper section of mast.

4. By means of valve lever on the hydraulic control panel, slightly lower the telescopic section on the above safety pins.After that, pins are actually locked (drwg. No. 0190 4192 - Spare Parts Manual).

5. Monkey board takes position with auto system of folding,during mast raising ( Fig. C-3.7). After monkey board takesright position, pins of handrails must be inserted .

6. Anchor guylines lower ends to tighteners of trailer and substructure skids. Slightly tension tighteners (Spare Parts

35

Manual).See also the API recommended guying patterns table.

NOTEMake sure that mast inclination angle is correct, by checking that the distance between well center and mast pinis 2020 mm. )

BREAKING - IN PERIOD

A correct breaking-in period ensures a long working life to your rig. It is suggestable therefore not to require to the new rigto operate at the maximum power.

a) ENGINEFollow the manufacturer s instructions.

36

TORNELLO MANOVRA

TORNELLO SERVIZIO

440

890

500

3030 1825

1033

20500 (67'-3")

30785 (101')

16764 (55')

35966 (118')

2020

2950 (9'-8")

7000 (23')

5182 (17')

1570 4170

12000 (40')

4616 (15')

5233 (17')

b) RIGAfter approximately the first 200 working hours:at the maximum power.- drain flush and refill the oil circuits with new oil- with reference to chain tension, make an adjust-

ment to remove slacks caused by initial elongations.

RECOMMENDATIONIn order to prevent personal injury during the perform-ance of any maintenance procedure, make sure thatcomponent to be overhauled is not working.

37

MAIN CONTROL PANEL

OPERATING INSTRUCTIONS

All air gauges, oil gauges and controls are mounted onmain control panel, positioned on the drillfloor.Before starting drilling operations and at frequent intervals,while rig is in operation, check gauges and controls toensure that the correct air and oil pressures are suppliedto each point (see the related tables in the following pages).Operating instructions are indicated here below and arealso illustrated on panel.

WARNINGNever stop the engine abruptly when operating at fullload (unless required for emergency conditions).

1. Crown-o-matic push-button C15

ENGAGINGThe crown-o-matic is a safety device, wich automaticallycontrols the tripping of the drilling travelling block, preventigit from clashing against the crown block.This system senses when the travelling block is within apreset distance of the crown block. It disengages the clutch,then simultaneously applies the brakes to the drawworks.

DISENGAGINGPush C15 button and simultaneously release the brake:the drilling travelling block comes down due to its ownweight. In the meanwhile, the driller assistant must go nearthe drawworks and put the crown-o-matic toggle valve inits rest position.

Item DescriptionStandard Crown Block Safety System

1 Track

2, 3 Short Toggle Valve Assembly

(P/N 50640652)

4, 5, 7 Clutch Assembly

6 Air Cylinder Assembly

BRAKELEVER

31

2

5

47

6

TOCONTROLPANEL

C15

38

2. Speed selector engine control valve C16

3. Engine emergency shut-down-control valve C20For drilling rig emergency stop, push the lever upward.This emergency lever stops also the mud pumps.To restart, pull the lever C20 downward.

4. Diesel engine throttle-control valve R2Turning clockwise the control knob increases RPM of die-sel engine.Turning ccw the control knob decreases RPM of dieselengine.

5. Spinning cathead torque regulator-control valveR6

6. Auxiliary winch-remote control C30 (hydraulicwinch mounted on drill floor)

7. Auxiliary winch-remote control C26 (on monkeyboard)

8. Hydraulic brake clutch-control valve C21The upward movement of this valve handle engages thehydraulic brake clutchThe downward movement disengages the hydraulic brakeclutch.

9. Rotary table fender sliding control valve C18The upward movement of this valve handle the rotary tableopening fenderThe downward movement the rotary table closing fender.

10. Hydraulic catheads-control valves C28 and C29The upward movement of control valve C28 actuates thespinning cathead.The upward movement of control valve C29 actuates thebreak-out cathead.This handles automatically return to neutral position whenreleased.Also the cylinders of catheads return automatically to fullextended position.Turning clockwise the control knob increases torque ofmake-up cathead.Turning ccw the control knob decreases torque of make-up cathead.

C16

C 20

C21

R6R2

C18C29

39

11. Main drum clutch-control valve C14The upward movement of this valve handle engages themain drum clutch.The downward movement disengages the main drum clutch.

12. Auxiliary equipment remote control valve C27Auxiliary equipment (tongs or hydraulic motor, etc) areactuated by means of handle C27.

C27

C14

40

13. Main air pressure-gauge A4This gauge indicates the air pressure in the control panel(7.7 bar steady-scale 0-16 bar)

14. Drawworks oil pressure-gauge A8It indicates lubricating oil pressure of drawworks. In work-ing condition it shall be 0.7 bar-(scale 0-6 bar)

15. Brake rim cooling water pressure-gauge A7It indicates cooling water pressure of internal circuit. Thewater flow must be costant and its value is 189 lit/min(gauge scale 0-6 bar)

WARNINGBe sure that no water leakage is falling on brake band.In case of failure, repair immediately.

16. Main drum clutch air pressure-gauge A6 low speedIt indicates air pressure inside drum low speed clutch.

17. Spinning cathead oil pressure-gauge A11It indicates the pressure inside spinning cathead cylinder.Pressure: 0-250 bar (scale 0-400 bar)Pulling force. Up to 6 Ton

18. Lubricating oil pressure gauge for transmissioncompound A9This gauge indicates lubricating oil pressure insidetransmission compound

A4 A9 A8 A7 A6A11

41

POWER TONG CONTROLS

Remote control panel

A15 Power tong clamping forceA16 Torque power tongC36 Lifting up-downC37 Tilt open-closeC38 Torque make up-returnC39 Torque break out-returnC40 Lower clamp open-close

Fig. C-4.7

A15A16 R10

R11

C36C39

C38 C40 C37

POWER TONG

ROTARY TABLE

POWER TONG

DRILL FLOOR

DRILLFLOOR

Fig. C-4.8

42

LUBRICATION SYSTEM

Proper Iubrication is essential for the correct functioning and Iong working Iife af your rig.

- GREASING POINTS- FREQUENCY- TYPE OF GREASE

Greasing points are either Iocated on two centralized grease panels or on the single elements.

Use- SHELL SUPER GREASE EP2 or equivalent

OIL LUBRICATION

For oil Iubrication, refer to D - 1.4 and follow the instructions on the respective table regarding:

- Components te be Iubricated- Frequency- Quantity and type of oil.- SAE regulations

Chains and bearings of transmission, are oil pressure lubricated from two pump.Lubrication compound : pump Bosch cod.50700292 delivery= 45 l/min.Lubrication drawworks: pump Bosch cod.50700253 delivery= 63 l/min.Oil pressure is checked by gauge located on control panel.Oil pressure 0.4-1.75 bar.A filter unit is located on the discharge line of the pump Bosch.Clean carefully the filter cartidge before the complete congestion.

CHECK AND MAINTAIN LUBRICATING SYSTEM AS FOLLOWS:

1) DAILY CHECK THE OIL LEVEL AS INDICATE IN THE TABLE2) CHECK CONDITION OF DRIVE CHAINS, HOSES, DISCHARGE LINES, ETC. AND REPLACE WHEN NECESSARY.3) KEEP OIL PRESSURE BETWEEN 0.4-1.75 BAR4) DRAIN, FLUSH THE TANK AND CHANGE OIL AT THE END OF THE BREAKING - IN PERIOD.

AFTERWARDS, CHANGE OIL EVERY 4000 WORKING HOURS OR MORE OFTEN, IF OIL BECOMES CONTAMI-NATED WITH ABRASIVE PARTICLES OR CORROSIVE COMPOUNDS.

43

CENTRALIZED GREASE PLATE ON DRAWWORKS (DRWG 01908094)

44

LINE No. DESCRIPTION

1 PLATE

10 GREASE FITTING

11 SLEEVE COUPLING

12 ELL

13 SLEEVE

14 FLEXIBLE PIPE

15 NUT

45

D-1.3 GREASE LUBRICATION TABLE6

7

3

1113

114

2

15

8

16 10 9 12

18

1745

18

46

FREQUENCY N IN DESCRIPTION TYPE OF GREASEFig. D-1.2

EVERY 1 DRAWWORKS:DAY STUFFING BOX OF WATER SWIVEL SHELL SUPER GREASE EP2

JOINTEVERY 2 MAST:

DAY WIRELINE GUIDE ROLLERS OF SHELL SUPER GREASE EP2HYDRAULIC CATHEADS

EVERY 3 WIRELINE LAZY FULLEYS FOR SHELL SUPER GREASE EP2DAY HYDRAULIC CATHEADS

EVERY DAY 18 POWER TONG SHELL SUPER GREASE EP2

EVERY 7 DAYS 4 DRAWWORKS:MAIN GREASING PLATE SHELL SUPER GREASE EP2

EVERY 7 DAYS 5 BRAKE LEVER PINS SHELL SUPER GREASE EP2

EVERY 7 DAYS 6 CROWN AND TRAVELLING BOX:BEARINGS AND JOINTS SHELL SUPER GREASE EP2

EVERY 7 DAYS 7 HOOK:UPPER SEALS AND JOINTS SHELL SUPER GREASE EP2

EVERY 7 8 MAST:DAYS ROPE ROLLERS SHELL SUPER GREASE EP2

ON THE INTERMEDIATE SECTIONEVERY 30 DAYS 9 DRAWWORKS: SHELL SUPER GREASE EP2

IDLE GEARSEVERY 30 DAYS 10 TRANSMISSION:

UNIVERSAL SHAFT CROSS SHELL SUPER GREASE EP2IDLE GEARS

EVERY 30 DAYS 11 ROTARY TABLE TRANSMISSION:UNIVERSAL SHAFT CROSS SHELL SUPER GREASE EP2

AT EVERY RAISING 12 DRAWWORKS:OR LOWERING OF WIRELINE GUIDE ROLLER OF SHELL SUPER GREASE EP2

MAST DRAWWORKSAT EVERY RAISING 13 MAST:OR LOWERING OF PINS; SHELL SUPER GREASE EP2

MASTAT EVERY RAISING 14 RAISING JACK PINS;OR LOWERING OF SHELL SUPER GREASE EP2

MASTAT EVERY RAISING 15 TELESCOPING SECTION LOCKOR LOWERING OF SHELL SUPER GREASE EP2

MASTSEE 16 ENGINE CATERPILLAR SEE MANUFACTURERS

MANUFACTURERS INSTRUCTIONS INSTRUCTIONS

SEE 17 PARMAC HYDRAULIC BRAKE SEE MANUFACTURERSMANUFACTURERS INSTRUCTICNS INSTRUCTIONS

47

OIL LUBRICATION

4

611

8 9 11 2 1

310597

48

YCNEUQERF NIN.giF3.1-D

NOITPIRCSED YT.Q.TIL

.DIEAS EPYTLIO

YADYREVE 1 :SKROWWARDLEVELLIOKNAT-

RETLIFLIO-

052 03EAS 001ALAMOLLEHS

EESS'RERUTCAFUNAM

SNOITCURTSNI

2 ELGNATHGIRXOBRAEG

081 001ALAMOLLEHS

YADYREVE 3 LIO:ELBATYRATORLEVEL

5 022ALAMOLLEHS

EESS'RERUTCAFUNAM

SNOITCURTSNI

4 KOOHXELPIRT 5 LIOSULLETLLEHS64TS

EESS'RERUTCAFUNAM

SNOITCURTSNI

5 SROSSERPMOCRIA 5.2+5.2 NPCNOSAES30973298

DNARLLOSREGNI

YADYREVE 6 :TIUCRICCILUARDYHLEVELLIOKNAT-

RETLIFLIO-

LIOSULLETLLEHS64TS

EESS'RERUTCAFUNAM

SNOITCURTSNI

7 ENIGNELESEID 05+05 ALUMIRLLEHS04W51X

EESS'RERUTCAFUNAM

SNOITCURTSNI

8 ROTAIDARENIGNE 59+59 EZEERFITNALLEHS

EESS'RERUTCAFUNAM

SNOITCURTSNI

9 XOBRAEGNOSILLAEUQROTHTIW

RETREVNOC

08+08 IIINORXEDFTALLEHS

EESS'RERUTCAFUNAM

SNOITCURTSNI

01 GNIKARBMURDNIAMMETSYS

57 DIULFADISSACLLEHS23FH

)425CHSLIBOM(

EESS'RERUTCAFUNAM

SNOITCURTSNI

11 DNUOPMOC 081 001ALAMOLLEHS

49

AIR CLUTCHES

The clutches, highly reliable in any working conditions (illustrated in section other manufacturers equipment of thismanual).

Regarding clutch maintenance, it is recommended to:

a) provide the proper air pressure to each ctutch - see the air pressure tableb) see table

- models of clutches- minimum allowable lining thickness

When inspecting clutches check:

1) Condition of linings.Lining wear Is automatically balanced to a certain extent by a rubber diaphragm. Check Iining wear at least once amonth.

2) Condition of clutch drum.The clutch drum surface should always be smooth. If it is badly warped or grooved, it should be remachined.

3) Operation of quick release valves.Check all quick release valve at Ieast once a month.The most common cause of quick release valve failure is dirt, rustor machine cuttings stuck under the seat.Due to improper valve operations, the clutch may disengage incompletely and therefore cause overheating anddamage to the diaphragm. Overheating may also be due to clutch dragging.

50

NOITPIRCSED ERUSSERPLANIMON

ISP rab

HCTULCSKROWWARD 721 8,8

ERUSSERPGNIDEEFLARENEGLENAPLORTNOC01AEGUAG

011 95,7

YCNEGREME 521 26,8

HCTULCELBATYRATOR 111 7,7

HCTULCEKARBCILUARDYH 111 7,7

AIR PRESSURE

51

ERUSSERPLIO

TNENOPMOC .LYTICAPAC LEVELROTACIDNI

FOECALPLORTNOC

)mc/gK(ERUSSERP

XAM .MON .NIM

KROWWARDDNA

NOISSIMSNART052 KCITSPID LORTNOC

LENAP52

)67,1(01

)07,0(5

)53,0(

ERUSSERPRETAW

TNEMELE NOITISOP FOECALPLORTNOC

YTICAPACnim/l

ERUSSERP)rab(ISP

TELNI TELTUO

MURDNIAMEKARB

S'RELLIRDEDIS

LORTNOCLENAP

981 57-05)2,5-5,3(

sag"4/1.1 sag"4/1.1

LEERDNASEKARB

S'RELLIRDEDIS

LORTNOCLENAP

021 57-05)2,5-5,3(

sag"2/1 sag"2/1

CILUARDYHEKARB

S'RELLIRDEDIS

LORTNOCLENAP

002 57-05)2,5-5,3(

TPN"3 TPN"2

METSYSEKARBNIRETAWDLOCESU:GNINRAW

OIL AND WATER PRESSURE

DRILLING DRUM BRAKES

SHOULD A REDUCTION IN THE BRAKING CAPACITY OCCUR, CHECK FOR:

1. Improper band brake adjustment.2. Water, oil or other rig wash solutions sprayed on and around the brake rims, reducing the coefficient of friction of the

linings.

IN CASE OF KICKING BRAKES, CHECK FOR:1. Improper release of brake bands.2. Kinked or out-of-round brake bands.3. Brake system adjustment.

GENERAL RECOMMENDATIONS

The following precautions should be taken in connection with proper brake maintenance.a. Do not paint brake blocks or inside of brake bands (paint retards heat transfer between blocks and band).b. Do not pull brake blocks bolts too tight or allow them to Ioosen.c. Do not Ieave brake blocks or relined bands out in weather.d. Do not install new brake blocks without cleaning brake bands of rust, etc.e. Check the brake rims at regular interval of time. The maximum allowed wear on the rims is equal to 12 mm.f. In case of maximum wear of rims, it must change the nms.g. The main brake drum is water cooled by means of an internal circuit.

Water circulation flow is equal to 189 Lit/min.Check every six month the good state of fittings and piping of water circuit.Always use original spare parts.

h. Check the brake system at Ieast once a month.i. Check the main handles once a year with Magnaflux (N.D.T.)

52

BRAKE WEAR

WATER COOLING CIRCULATION

53

DRIVE ROLLER CHAINS (DRWG. N 0190 7387)

Make sure that roller chains are always well Iubricated. As oil cleanliness is an essential factor in chain Iubrication,accurately clean every chain before mounting it, to reduce the amount of foreign contaminants in the oil.Clearance of chain links should never exceed 0,1 - 0,2 mm.Check clearance al Ieast once a month.When possible use a chain length with an even number of pitches to eliminate the need for an offset Iink.To obtain maximum chain life, maintain proper chain tension.

Make an adjustment after approximately the first 200 hours of operation to remove slack caused by initiai elongation.Thereafter, the frequency of periodic adjustment Is governed by operating conditions.Sprocket center distance must be more than half the sum of the sprocket outside diameters to avoid tooth interference.

A center distance equal lo the diameter of the large sprocket plus one-half the diameter of the small sprocket is thesuggested maximum for average applications.Normally, horizontal and inclined drives should be installed with an initial sag equal to approximateiy 2% of sprocketcenter distance.

Check gear tooth wearing once every six months (especiaily the pinion teeth).Clearance between tooth space and roller should not exceed 0,3 mm.

BREAKING-IN PERIOD

A correct breaking-in period ensures a Iong working Iife to your rig.a) Engine

follow the manufacturers instructions.b) Rig

After approximately the first 200 working hours:- drain, flush and refill the oil circuits with new oil;- with reference to chain tension, make an adjustment to remove slacks caused by initial elongation.

ROUTINE MAINTENANCE

Routine inspection of components is the most important form of preventive maintenance and with result in considerablesaving by detecting any major trouble that might be developing and allowing the necessary repairs to be made on aplanned or normal rig downtime.

The following is a guide to some of the key points which should be observed during routine inspection. The prevailingoperating conditions surrounding each individual rig wiIl dictate the frequency at which the inspections should be made;however, the intervals listed below are recommended for optimum performance from the equipment.

MECHANICAL PARTS - GREASING

IMPORTANTIf clogged or damaged, replace grease nipples with new ones. (for fubricant specifications, see paragraph D -1.3).

54

111

8

12

8

7

3

9

6

10

5

4

2

7 1

11

Item Code Q.ty Description

1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS

2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS

3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS

4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS

5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS

6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS

7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS

8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS

9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS

10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS



13

13 4100 1122 1 ROPE D.28.57 (1.1/8")

55

TRAP YCNEUQERF NINGWD

NOITPIRCSED FOEPYTTNACIRBUL

TSAM

DNANWORCGNILLEVART

KCOLB

SYAD03YREVE *8 SECIVEDNRUTER,STROPPUSESAERGSNIAHCDNA

LLEHSSAERGREPUS

2PE

GNISIARYREVETAGNIREWOLDNA

TSAMFO

SYAD7YREVE

*31 SNIPESAERG LLEHSSAERGREPUS

2PE

*41

*7

SNIPKCAJGNISIARESAERG

SGNIRAEBLLAESAERG

LLEHSSAERGREPUS

2PELLEHS

SAERGREPUS2PE

*6 SGNIRAEBLLAESAERG LLEHSSAERGREPUS

2PE

GIREHTNISEVAEHSGNILLEVARTDNANWORCEHTFOGNINOITISOPEHT:ETONSUOIVERPEHTTAHTOSNOITAREPOPU-GNIGGIRHCAEHTIWDESREVEREBDLUOHSNORAEWSETUBIRTSIDSIHT.EVAEHSENILTSAFEHTSEMOCEBEVAEHSENIL-DAED

YEHTNEHWDECALPEREBDLUOHSHCIWFOHTOB,SEVAEHSDNASGNIRAEBEHTNROWEMOCEB

YRATORELBAT

YADYREVE **3 .LEVELLIOEHTKCEHCLEVELLIONIEGNAHCLACIDARYNA

EBDLUOHS,EMITTROHSAREVOEHTEBYAMSIHT.DETAGITSEVNI

RORETAW,LAESGNIKAELFOTLUSERELBATYRATOREHTOTNIYRTNEDUMTI,ESACRETTALEHTNI.CTE,GNISUOHGNISUOHNIARDOTDEDNEMMOCERSILIONAELC,HSERFHTIWTILLIFERDNA

ALAMOLLEHS022

SYAD7YREVE *11 TEKSAGREWOLDNAREPPUESAERG LLEHSSAERGREPUS

2PE

D-6.2 ROUTINE MAINTENANCE

56

TRAP YCNEUQERF NINGWD

NOITPIRCSED FOEPYTTNACIRBUL

NOISSIMSNART SYAD03YREVE *01 STNIOJLASREVINUESAERG LLEHS2PESAERGREPUS

SKROWWARD YADYREVE **1 LEVELLIORIOVRESERKCEHC LLEHS001ALAMO

SYAD7YREVE *4 GNIRAEBNIAMESAERGETALP

LLEHS2PESAERGREPUS

SYAD03YREVE *9 SRAEGELDIESAERG LLEHS2PESAERGREPUS

SHTNOM3YREVE ,SEPIP,KNAT(METSYSNOITACIRBULEHTKCEHC.1TCATNISITIERUSSAOT).CTE,SLAESROTOR,SEGUAG

.SNOITCURTSBOROEGAMADMORFEERFDNA,STNIOJ,SEPIP,SEVLAV(METSYSRIAEHTKCEHC.2

).CTE,KNAT,SNEERCS,SEGUA).CTE,RAEWGNINIL(METSYSGNIKARBEHTKCEHC.3

'SRERUTCAFUNAMREHTO"EHTEES(SEHCTULCKCEHC.4)LAUNAMETARAPESFONOITCES"TNEMPIUQE

NEKORB,SNIPRETTOCGNISSIM(SEVIRDNIAHCKCEHC.5.CTE,SRELLORFONOITACIRBULETAUQEDANIROSKNIL.SSENTHGITREPORPROFSTUNDNASTLOBLLAKCEHC.6

.SLAESDNASREBBUR,STEKSAGLLAKCEHC.7

0001YREVESRUOH

**1 RETLIFDNALIOTNEMECALPER

LLEHS001ALAMO

DNUOPMOC YADYREVE

0001YREVESRUOH

**11

**11

LEVELLIORIOVRESERKCEHC

RETLIFDNALIOTNEMECALPER

LLEHS001ALAMO

ELGNATHGIRXOBRAEG

YADYREVE

0001YREVESRUOH

**2

**2

LEVELLIORIOVRESERKCEHC

RETLIFDNALIOTNEMECALPER

LLEHS001ALAMO

* Grease lubrication** Oil lubrication

IMPORTANTThe first lubricating oil replacement must be carried out after the first 400 working hours, then observe theindications supplied in the routine maintenance table.

57

HYDRAULIC SYSTEM - OIL LEVEL CHECK

For hydraulic oil level check, set the machine to haulageconfiguration. This way, all jack are cIosed and the oil inthe tanks is at its maximum level. The machine shouldalso be perfectly Ieveled.Oil level should be closed to the maximum.

lf occasionally (due to operating reasons) the machinecannot be set to the haulage configuration, the oil levelmust be checked by means of the oil level visual indicator.With machine in working canfiguration, oil level should neverbe lower than the indicator on the see-through glass. Topup if oil level is too low.

(for hydraulic oil specifications, see paragraph D-1.4)

WARNINGWhen topping up, do not exceed maximum oil level(with machine in haulage configuration)

HYDRAULIC SYSTEM - REPLACE OILFILTER AND TANK AIR BLEEDINGCARTRIDGES

IMPORTANTThese components should be replaced at the time speci-fied even if not required by the clogging checkingdevices.

Access to hydraulic oil filter (on return line) is from thetank top through screws A.

WARNINGThese operations should be performed in clean areasto avoid that any earth, dirty and impurities can enterin the tank and in the system.

IMPORTANTOnce the component is replaced, check hydraulic oillevel as described in item D-6.3.

A

58

HYDRAULIC SYSTEM - OIL CHANGE

For hydraulic oiI change (as for oil Ievel check), the ma-chine should be set to haulage configuration. With thisconfiguration, all jacks are closed and the oil in the tanksis at its maximum level. The machine should also be per-fectly Ieveled.Oil Ievel should be closed to the maximum.

To ease up drainage, oil should be warm. This with preventresidual sludge inside the tank.

Then, proceed as follows:1. Prepare a system for collection of the used oil to be

connected to draining plugs A.

IMPORTANTThis tank contains apprax. 800 Iiters of hydraulic oil.

2. Close valves B cutting off the tank from the hydraulicsystem.

3. Undo plugs A and open the two bali valve C. To easeup oil outflow, also undo the bleeding cartridges on topof the tank. Let the oil drain.

WARNINGDo not disperse old oil in the environment as this causespollution.

4. Close valves C and retighten plugs A.5. FilI up through the return filter.

WARNINGAIways remember that the hydraulic oil, even whennew and delivered in drums, contains pollutants. WhenfilIing oil up, use special pumps provided with fllteringsystem.

6. Check that max. oil level is reached through level indi-cator D.

WARNINGWhen fiIling up with oil, do not exceed max. oil levelshown by indicator D.

Fig. D-6.3

Fig. D-6.4

C

A

B

B

Fig. D-6.5

D

59

7. Refit and retighten two new air bleeding cartridges.

(for hydrauIic oil specifications, see chapter D - 1.4)

WARNINGThese operations should be performed in clean areasto avoid that any earth, dirty and impurities can enterthe hydraulic oil tank

ROPES - WEAR CHECK

VisuaIly check hoisting and drilling wire rope, sand reelrope, wear conditions.

In particutar, check what follows:- rope end connections- rope stretches going through pulleys or blocks during

use- rope stretches that can be subject to friction or rubbing

against external parts.

Make sure that ropes do not show:- broken strands- dents- twists- permanent bends- signs of wear or deterioration that could impair safety.

If any of these conditions are found, consider the meas-ures to be taken with reference to the information containedin the standards ISO 4309.

Always refer to ISO 4309 standards for all what concernsthe ropes, their maintenance and replacement.

COMPLETE MACHINE - GENERALINSPECTION

Inspect the whole machine to make sure that it is in goodworking order.

In particular, check the drilling fluid circulation system fit-tings, high pressure couplings and seals. Inspect the wholemachine for Ieakage.

Check good operation conditions and correct assembly andclosing of protection hoods and guards.

HAZARDIn case of malfunctioning and/or faults, promptly eli-minate the problem and stop any works until the ma-chine is in good order again

Fig. D-6.6

60

BOLT TIGHTENING SPECIFICATIONS

61

HOSE FITTING SPECIFICATIONS

For best operation of the hydraulic system, always keepin mind some important rules for hose fitting.

Hose fitting nuts shall be tighten until no leakage occursthrough the coupling. Exceeding that point, does not im-prove tightness and damages the coupling!

A hose should never be subject to torsion! When fitting thehose, consider that during operation, the hose is subjectto changes in length with consequent torsional effects.Therefore, hoses should not be too short and the propersettling should be checked with hose in resting position(see Fig. D-8.1).

If hoses routing requires the hose to bend, make sure thatthe bending radius are correct (see Fig. D-8.2 and D-8.3).A bending radius too small can cause restrictions in thesection and therefore load losses. Moreover, these bendscan cause torsional stress and even breakage of the hose!

For correct fitting of hoses , elbow fitting can be used forinstallation in restricted space without impairing hose effi-ciency and life (see Fig. D-8.3 and D-8.4).

62

Functional group: Semitrailer group Table Number Revision

Hydraulic power unit 1 01170400 - 1 0 (12-2006)


Hydraulic power unit 1 01170400 - 1 0 (12-2006)

Position Part Number Quantity Description Notes

1 RI01170400-01 1 Electric pump -2 RI01170400-02 1 Pump by hand -3 RI01170400-03 1 Distributor -4 RI01170400-04 1 Exclusion manometer -5 RI01170400-05 1 Manometer -6 RI01170400-06 1 Filter -7 RI01170400-07 1 Tank -8 RI01170400-08 1 Retaining valve -9 RI01170400-09 1 Control panel -10 RI01170400-10 1 Frame -

64


Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)


Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)


1 01906235 2 Description not available -2 01908758 1 Tank -3 01908759 1 Tank -4 01908760 2 Gasket -5 40690045 2 Thermometer -6 50310022 2 Pn 10 1" 1/2 ball valve -7 50310195 4 Valve -8 50510019 2 Connector -9 50520046 2 Cap -10 50530025 2 Air breather -11 50540178 2 Level indicator -12 50540181 2 Level indicator -13 50590007 2 Nipple -14 50590009 2 Nipple -15 50630073 4 A.f.l. connector -16 50630077 8 3" art.280 nipple -17 50630079 2 A.f.l. connector -18 50630182 2 A.f.l. connector -19 50971117 2 Filter -20 52030045 2 Washer -21 70351004 40 Screw -22 70351610 8 Screw -23 70661613 8 Nut -24 70911017 40 Elastic washer -25 70911627 8 Elastic washer -

65

Functional group: Mast group Table Number Revision

Monkey board handrails 2 01907330 - 1 0 (06-2007)


Monkey board handrails 2 01907330 - 1 0 (06-2007)


1 01907649 1 Description not available -2 01907915 1 Description not available -3 01907916 1 Description not available -4 01907917 1 Description not available -5 40630123 6 Shear pin -6 71191616 15 Pin -7 71300018 9 Split pin -

66


Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)


Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)


1 01906950 1 Description not available -2 01906951 1 Description not available -3 01907931 2 Description not available -4 01908883 1 Description not available -5 50470576 1 Plate -6 51040304 1 Hydraulic piston -7 52104075 1 O-ring -8 70351614 8 Screw -9 70311624 4 Screw -10 70351612 8 Screw -11 70370824 4 Screw -12 70611618 20 Self-locking nut -13 70901648 4 Washer -14 70910814 4 Elastic washer -15 71050812 2 Split pin -16 71204009 2 Pin -

67

Functional group: Substructure group Table Number Revision

Machine base frame 3 01906312 - 1 0 (06-2007)

Functional group: Substructure group Table Number Revision

Machine base frame 3 01906312 - 1 0 (06-2007)


1 01906896 1 Front skid -2 01907096 1 Skid -

68

Functional group: Draw works group Table Number Revision

Swivel joint for water 4 01902248 - 1 0 (06-2007)


Swivel joint for water 4 01902248 - 1 0 (06-2007)


1 01902619 1 Body -2 01902620 1 Manifold -3 01902621 1 Cover -4 01902622 1 Flange -5 01902623 1 Bushing -6 01902624 2 Ring -7 40630186 1 Spring -8 01902625 2 Spacer -12 52700471 2 Gasket -13 52700470 4 Gasket -14 52104081 2 O.ring packing -15 01902626 2 Gasket -16 70351010 8 Screw -17 70911017 8 Elastic washer -18 61000006 2 Lubricator -19 50520037 2 Cap -

69

:puorg lanoitcnuF puorg skrow warD noisiveR rebmuN elbaT

01 - 70370910 4tfahsretnuoc tupni rewoP )7002-60(


Power input countershaft 4 01907307 - 1 0 (06-2007)


1 01906521 1 Description not available -2 01906522 1 Description not available -3 01906524 1 Description not available -4 01906526 1 Description not available -5 01906527 2 Description not available -6 01906528 2 Description not available -7 01906529 1 Description not available -8 01906530 2 Description not available -9 01906531 2 Description not available -10 01907427 1 Description not available -11 01907428 1 Description not available -12 019011621 1 Spacer -13 61070142 2 Description not available -14 70351609 12 Screw -15 70351610 20 Screw -16 70351614 24 Screw -17 70611618 24 Self-locking nut -18 71073236 2 Tang -

70


Installation of the travelling block limit switch 4 01906106 - 1 0 (06-2007)


Installation of the travelling block limit switch 4 01906106 - 1 0 (06-2007)


1 01906517 1 Description not available -3 01906518 1 Description not available -4 01906519 1 Description not available -8 50640721 1 Cylinder -10 50640546 1 Hinge -11 50640723 1 Description not available -12 70390062 2 Screw -13 70351205 4 Screw -14 70911221 4 Elastic washer -15 50640722 1 Fork -16 50640652 1 Valve -

71

DRILLING RIGHTD 250 TOP DRIVE

72

Operation and Maintenance ManualGENERAL INFORMATION

Section A page 5

TOP

BOTTOM

OFFDRILLERSIDE

DRILLERSIDE

DWWKS SIDE

OFF DWWKS SIDEFig. A1

A - 1 ORIENTATION

Front and rear sections of the equipment, as other parts of the equipment on side, shall be conventionally placedas shown in the following diagram (unless specified otherwise).

73


Section A page 6

Fig. A2

Machine Type

Serial Number

Year of Manufacturing

Nominal Power [kw]

Weight [kg]

Piacenza - Italy

A - 2 IDENTIFICATION

This equipment is identified through serial number and/oridentification numbers on main components.

A - 2.1 EQUIPMENT IDENTIFICATIONPLATE

The equipment identification plate shown in the pictureprovides all identification data for the machine. Alwayscheck that the equipment part number (N. MATR.)stamped on the plate, matches with that reported on thefront cover of this manual.

IMPORTANT

Always specify the equipment technical code and partnumber (N MATR.) when you require information ortechnical assistance.

A - 2.2 MANUFACTURER

DRILLMEC Drilling Equipment Div. - 12 Via 1 Maggio - LocalitGariga I-29027 Podenzano (PC) - ITALY Tel. +39 0523 354211- Telefax +39 0523 524418;

A - 2.3 MODEL AND VERSION

TOP DRIVE model: with hydraulic power pack.

A - 2.4 OTHER IDENTIFICATION PLATES

The plates for all major mechanical, hydraulic and electricalcomponents which are not manufactured by DRILLMEC(pumps, motors, etc.) are fitted on the componentsthemselves, in the locations assigned by the manufacturers.

74


Section A page 7

MAXIMUM WORKING PRESSUREMAXIMUM WORKING PRESSURE

MAXIMUM DYNAMIC LOADMAXIMUM DYNAMIC LOADCAPACITY AT 100 RPMCAPACITY AT 100 RPM

MAXIMUM STATICMAXIMUM STATICLOAD CAPACITYLOAD CAPACITY

CUSTOMERCUSTOMER

MANUFACTUREDMANUFACTURED

SERIAL NUMBERSERIAL NUMBER

POWER SWIVELPOWER SWIVEL

SPECIFICATION SPECIFICATION 8C L.E. (EDITION 4)8C L.E. (EDITION 4)AUTH. 8C-0041 PSL1AUTH. 8C-0041 PSL1

BARBAR

MTMT

MTMT

MODELMODEL

TOP DRIVETOP DRIVE

09533652E09533652E

2 SPEED2 SPEED

1 SPEED1 SPEED

200

RPM

200

RPM

146

RPM

146

RPM

109

RPM

109

RPM

80 R

PM80

RPM

10400 ftlb10400 ftlb




ftlb

ftlb

TORQ

UE

TORQ

UE

RPMRPM

2212522125

1475014750

73757375

2002001501501001005050

Fig. A3

0953-3720E0953-3720E

75


Section A page 8

Fig. A4

TORQUE WRENCHTORQUE WRENCH

ftlb TORQUEftlb TORQUE

BREAK-OUTBREAK-OUTMAKE-UPMAKE-UP

PRES

SURE

- PS

IPR

ESSU

RE -

PSI

35603560

21402140

49904990

42754275

28502850

14251425

81130811305180051800

4425044250

36880368802950029500

2213022130

1475014750

73757375

09533658E09533658E

76


Section A page 9

1

14

13

7

9

4

15

12

11

10

86

5

3

2

NOTE:

1 - LINKS 2 - GOOSNECK 3 - HYDRAULIC MOTOR 4 - DOLLY 5 - GEAR BOX 6 - PIPEHANDLER ROTATION GEAR 7 - DUPLEX HOOK 8 - LINK TILT CYLINDER 9 - I.B.O.P. ACTUATOR10 - ELEVATOR11 - ELEVATOR LINKS12 - TORQUE WRENCH13 - WEIGHT COMPENSATOR SYSTEM14 - WASHPIPE15 - GUIDE

Fig. A5

A - 3 MAJOR COMPONENT DESCRIPTION - TOP DRIVE

The following section describes the component parts, and defines terms used throughout this service manual.

77


Section A page 10

DRI

LLIN

G M

OD

E

TRIP

PIN

G M

OD

E

LOAD PATH

TRIPPING MODEDRILLING MODE TRIPPING MODEDRILLING MODE

ELEVATORLINKS

DOUBLE HOOKLOAD SHOULDER

DOUBLE HOOK

ROTARY DRILLINGHOOK

TOP DRIVESUSPENDING

LINKS

WASH PIPEPACKING ASS.Y

MAIN SHAFTLOAD SHOULDER

SWIVELTHRUST BEARING

TRANSMISSIONBODY

COUNTERBALANCESYSTEM

MAIN SHAFT(DRILL SYSTEM)

BONNET

GOOSE NECK

LINK PIN

Fig. A6

A - 3.1 HTD 200 LOAD PATH

78


Section A page 11

HYDRAULIC MOTORS

HYDRAULIC MOTORS

MAIN BODY

Fig. A7

A - 3.2 HYDRAULIC MOTORS

The uses four (4) HYDRAULIC MOTORS mounted vertically side by side on top and on bottom of themain body to power the The ports of the motors are connected each other with a rigid pipe and finally connected to an interface block withquick couplings.

79


Section A page 12

HYDRAULICCALIPER

BRAKEDISC

Fig. A8

Two hydraulic caliper disc brakes, mounted between each top hydraulic motor and the main body, hold torque inthe drill string and assist in positioning during directional work.An electrical solenoid valve remotely operates the hydraulic caliper disc brakes.

80


Section A page 13

TRANSMISSION/MOTOR HOUSING

MAIN BODY

Transmission/motor housing (main body) and swivel assembly

Fig. A9

A - 3.3 TRANSMISSION, MOTOR HOUSING (MAIN BODY) AND SWIVEL ASSEMBLY

The transmission, motor housing and swivel assembly transfers the power produced by hydraulic motors to the drillstring. Inside the transmission/motor housing main body is a single-speed double-reduction sput gear system thatprovides a 13,54:1 ratio from the motors to the main shaft.

The main thrust bearing located inside the motor housing supports drilling loads, while the load stem, which bypassesthe thrust bearing and provides support for the rotating link adapter and pipehandler, carries the tripping loads.

The main body of the motor housing provides a sealed oil lubrication reservoir for the transmission gears and bearings.Bearings and gears are force fed by an oil pump that is integral with the main body. The filtered lubrication oil constantlycirculates through the main thrust bearing, take-up bearing, lower radial and compound gear bearings.

An industry standard wash pipe packing box assembly is located between the main shaft/swivel stem and the S-pipeweldment. The bonnet supports the S-pipe weldment. Two upper links serve to attaching to standard rotary drillinghooks.

81


Section A page 14

FIXED PART

MOVING PARTS

SUPPORT BRACKETS

AIR SPRING

Counterbalance system

Fig. A10

A - 3.4 CARRIAGE AND GUIDE BEAM

The travels vertically along a guide beam on a carriage attached to the main body. The guide beam hangsfrom the crown block and extends within 26,88 meters of the drill floor. The guide beam attaches to a torque reactionspreader beam mounted across the lower section of the mast/derrick, approximately 2 meters above the drill floor.

The guide beam counters the drilling torque produced as the transmission turns the drill string. The guide beam comesin 24,64 meters sections and requires brackets for mounting to the crown.The guide beam sections are pinned toghether in such a way that they hinge and can be assembled one section at atime, at the ground level, and raised to the crown attachment using the drilling hook.

The carriage consists of four roller brackets that mantains alignment of the mainshaft with the drill string while movingup and down on the guide beam. There are four rollers that run inside the guide beam flanges to counter the drillingtorque and four guide rollers that run on the inside of the guide beam flanges. Both the guide and bogie rollers arethrough-hardened and run on grease lubricated bearings.

82


Section A page 15

GUIDEBEAM

CONNECTINGLINK

GUIDEBEAM

CARRIAGEASSEMBLY

TORQUE WRENCH

ELEVATOR LINKS

DRILLINGHOOK

LINKS

MAINBODY

GUIDE BEAM (ASSEMBLED)

TORQUE REACTION SPREADER BEAM

FRONT

Carriage and guide beamFig. A11

83


Section A page 16

IBOP

FRONT

DOUBLE HOOKROTATION GEAR

TWO WAYLINK TILT CYLINDERS

CLAMP

ELEVATORLINKS

MOUSE HOLEPOSITION

DRILL DOWNPOSITION

WELL CENTER(FLOAT POSITION)

TORQUEWRENCH

ROTATINGDOUBLE HOOKLINK ADAPTER

PINIONREDUCER

HYDRAULICDRIVE MOTOR

Fig. A12

A - 3.5 PIPEHANDLER

The Pipehandler consists of the following components:

Powered rotating double hook link adapter Torque wrench Two way link tilt Internal blowout prevention (IBOP) Elevator links and drill pipe elevator

84


Section A page 17

The Rotating Double Hook combined with ahydraulic motor for 270 clockwise/counterclockwiserotation in order to position the elevator to pick uppipes and to assist the derrick man. The free rotationmode also allow the pipehandler to rotate with the mainshaft.The two-way link tilt cylinder assemblies consist ofthe cylinder body pinned to the rotating link adapterand the cylinder rods pinned to the links through a setof clamps.Pressurizing the cylinder assemblies by operating theswitch on the drillers console extends the drill pipeelevator to the mouse hole or the drill down position. Afloat position allows the links to return to well center.

The Elevator Links can be moved to mouse hole ordrill down position by means of the tilt cylinders, re-mote controlled from the operators panel.

The Torque Wrench for make up/break out of pipe,is connected to the pipe handler by means of asuspension beam. The torque wrench can be locatedin two different positions on the suspension beam,depending on which connection to be broken. Thetorque wrench includes torque cylinders, clamp jawsand a guide funnel.

The Remote Operated I.B.O.P. (10.000 PSI) isoperated by two hydraulic cylinders remote controlledfrom the operators panel.

85


Section A page 18

A - 4 TOP DRIVE SPECIFICATIONS

A - 4.1 TOP DRIVE SPECIFICATIONS

MODEL:

LOAD CAPACITIES

MAXIMUM STATIC LOAD CAPACITY: 200.000 kgMAXIMUM DYNAMIC LOAD CAPACITY AT 100 RPM: 115.000 kgMAXIMUM PASSAGE DIAMETER: 76 mmMAXIMUM WORKING PRESSURE: 350 barsLOWER THREAD: NC 50 API - 4 IFMAX TORQUE: 3525 daNmMAX SPEED: 200 RPM

PERFORMANCE DIAGRAM:

Fig. A13

TOP DRIVETOP DRIVE

09533652E09533652E

2 SPEED2 SPEED

1 SPEED1 SPEED

200

RPM

200

RPM

146

RPM

146

RPM

109

RPM

109

RPM

80 R

PM80

RPM





ftlb

ftlb

TORQ

UE

TORQ

UE

RPMRPM

2212522125

1475014750

73757375

2002001501501001005050

TOP DRIVE POWER OUTPUT: 295 kwDOUBLE HOOK CAPACITY: 200.000 kgELEVATOR LINK CAPACITY: 226800 kg (250 Short ton.)LENGHT: 108 (2743 mm)LINK SIZE: 2.x108

WEIGHT: 6500 kg approx.

* TOP DRIVE includes guide dolly and connection link to travelling block

86


Section A page 19

PIPE HANDLER - COUNTERBALANCE SYSTEMUTILITY REQUIREMENTS RIG AIR SUPPLY: 8 bar

TORQUE WRENCH:The TORQUE WRENCH can handle pipe from 4 to 6.5/8 ODMAXIMUM MAKE-UP TORQUE: 4400 daNmMAXIMUM BREAK-OUT TORQUE: 5925 daNm

87


Section A page 20

AIR

INTA

KE

FUEL

TA

NK

OIL

TA

NK

DRA

INA

GE

BALL

VA

LVESU

CTI

ON

BALL

VA

LVE

HYD

RAU

LIC

PU

MPS

MU

LTIP

LE P

UM

P D

RIVE

UN

ITBA

SE S

KID

TRA

NSM

ISSI

ON

SH

AFT

RAD

IATO

R

AIR

INTA

KE

INSU

LATI

ON

HO

OD

DIE

SEL

ENG

INE

AIR

FIL

TER

PUM

P D

RIVE

LU

BRIC

ATIO

NC

IRC

UIT

HEA

T EX

CH

AN

GER

AIR

DIS

CH

ARG

E

AIR

DIS

CH

ARG

E

QU

ICK

COU

PLIN

GCO

NN

ECTI

NG

BLO

CK

OIL

TA

NK

INSP

ECTI

ON

CO

VER

AIR

FIL

TER

FUEL

TA

NK

HYD

RAU

LIC

CIR

CU

ITH

EAT

EXC

HA

NG

ER

FILT

ERH

YDRA

ULI

C O

IL T

AN

K

EXA

UST

MU

FFLE

R

DIE

SEL

ENG

INE

RAD

IATO

R

Fig. A14

A - 5 MAJOR COMPONENT DESCRIPTION - HYDRAULIC POWER UNIT(HPU) FOR

The following section describes the HPU component parts and defines terms used throughout this service manual.

88


Section A page 21

A - 6 HYDRAULIC POWER UNIT (HPU) SPECIFICATIONS

Model: 1 x Caterpillar 3408 DITA EPA-CARB

Arrangement drawing: 0190 3398

Transmission circuit:Pressure range: 0 - 350 barFlow range: 0 - 800 l/min

Replenishment circuit:Pressure min: 16 barFlow: 90 l/min

Pipehandler circuit - Torque Wrench:Pressure: 350 barFlow: 0 - 113 l/min

Link Tilt:Pressure: 180 barFlow: 0 - 30 l/min

Diesel engine:Max power output: 376,5 bkw (505 bhp) @1800 RPMMax fuel consumption: .....l/hour at ..... kw ..... (..... gph at ..... hp) (see engine manuals)Max rated RPM: 1800 RPM

Tank capacities:Hydraulic oil tank: 950 ltr.Diesel tank: 600 ltr.

Weights:Total weight HPU: 11830 kgs

Painting:All items painted, where relevant, with DRILLMEC procedure.

Service loop hydraulic hoses:

PILOT PRESSUREFlex. SAE 100 R2AT 1/2 pilot pressure

CLOSED LOOP CIRCUITFlex. SAE 100 R13 2 motor deliveryFlex. SAE 100 R2AT 2 drainage

PIPEHANDLER - TORQUE WRENCHFlex. SAE 100 R13 1 1/4 services deliveryFlex. SAE 100 R2AT 1 1/4 services return

COUNTERBALANCE SYSTEMFlex. SAE 100 R1AT 3/4 air pressure

89

Operation and Maintenance ManualOPERATING INSTRUCTIONS

Section C page 3

Fig. C2

A1 P1 H1 H2 H3

SP1

H4

SC10

R7 R8 SC12 SC9 SC3 SC7 SC1

SC6

SC5

SC8SC4

SC11

C - 1.1 CONTROLS AND INSTRUMENTSON TOP DRIVE CONTROL PANEL

P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake ControlSC7 Torque Wrench Automatic Sequence ControlSC8 Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12 Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1 Return Filter Clogging Indicator LampH2 Discharge Filter Clogging Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive Torque Regulator

90


Section C page 4

C - 1.2 CONTROLS AND INSTRUMENTSIN THE HYDRAULIC POWER UNIT

Fig. C3

A58

A62

A61

A60

A59

Fig. C4

A54 A55 A53 A52 R52

Fig. C5

A63

C60 C61 C62

A58 RPM meterA59 Oil pressureA60 AmmeterA61 Water temperatureA62 Fuel pressure

A53 Piloting oil pressureA52 Compensator air pressureR52 Compensator pressure regulatorA54 Replenishing pressure (CLOSED CIRCUIT)A55 Replenishing pressure (CLOSED CIRCUIT)

A63 Oil temperature thermometerC60 Ball valve on hydraulic system suction lineC61 Ball valve on hydraulic system suction lineC62 Ball valve on hydraulic system suction line

91


Section C page 5

Fig. C6

C63

Fig. C7

A64

Fig. C8

A65

C63 Ball valve on reservoir oil drain

A64 Oil visual level

A-65 Fuel visual level

92


Section C page 6

C - 2 HYDRAULIC POWER UNITSTARTING INSTRUCTIONS

C - 2.1 CHECKS BEFORE STARTING

The easiest checks have to be manually executed:

- Diesel engine oil level check.

- Visual check of the hydraulic oil level (however, a properlamp signals the reaching of the minimum allowed pointof this level).

- Water level check into the radiator.

- Fuel level check (A65).

- Oil level check into the pump driving unit.

- At the first start-up of the Power Pack, check that thebattery cables are correctly connected. Such cablesare usually disconnected during transport.

- Check that the suction valves of the pumps, placedon the hydraulic oil reservoir, are properly opened.

93


Section C page 7

C - 2.2 DIESEL ENGINE STARTING

C - 2.2.1 WARM-UP / STARTUP

1) Turn on the diesel engine.

2) Set diesel engine to minimum rpm for 15/20 min.

3) Increase the number of rpm up to 800/1000.

Fig. C9

94


Section C page 8

Fig. C10

A54 A55 A53 A52 R52

Fig. C11

A61

A59

Fig. C12

SC10

SP1

C - 2.3 CHECKS AFTER START-UP

- After having executed all the operations described atthe preceding point, check that the pressure displayedon the "supercharging" pressure gauges A54 and A55is stabilized on 16 18 bar.

- Check the piloting pressure displayed on the pressuregauge A53. The pressure has to be 25 30 bar.

- Check the air pressure to supply the counter-balancesystem of the top drive. Such a pressure can beadjusted through the pressure regulator R52 readingthe value displayed on the pressure gauge A52.

- Warm-up the engine (the warm-up time depends onthe climatic conditions).

- Check on the engine instruments that the pressuresand the temperatures are the correct ones accordingto the indications provided by the manufacturer of theengine.

- Now it is possible to increase the speed of the dieselengine. Access to the top drive control panel on thedrill floor.

- Press the push-button SP1 = Control authorization.

- Turn the selector SC10 from Min position to Maxone.

- With the top drive near the drill floor, exercise eachcontrol on the driller's console following the operatinginstructions of paragraph C-3 and the operatingprocedures of paragraph C-4.

95


Section C page 9

Fig. C13

A1 P1 H1 H2 H3

SP1

H4

SC10

R7 R8 SC12 SC9 SC3 SC7 SC1

SC6

SC5

SC8SC4

SC11

C - 3 OPERATING INSTRUCTIONS

P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake ControlSC7 Torque Wrench Automatic Sequence ControlSC8 Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12 Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1 Return Filter Clogging Indicator LampH2 Discharge Filter Clogging Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive Torque Regulator

96


Section C page 10

C - 3.1 DRILLERS CONSOLE AND TOP DRIVE CONTROL PANEL

LOBMYS ROTACIDNI/LORTNOCEMAN

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97


Section C page 11

LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED

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98


Section C page 12

LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED

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C - 3.1.1 WARNING LAMP SWITCHING-ON

The measures to be taken when the warning lamp comeson depend on the type of fault detected.

In principle, the engine should be immediately turned offwhen the following warning lamps come on:

H1 Clogged hydraulic oil filter - RETURNH2 Clogged hydraulic oil filter - DISCHARGEH3 Hydraulic oil - MINIMUM LEVEL

WARNING

Working with H3 warning lamp on is forbidden, as itcan cause damage to other parts of the system.Also check OIL THERMOMETER A-63 on HPU oiltank.

WARNING

An hydraulic oil overtemperature is a sign ofmalfunctioning of some part of the system, cloggedfilter or heat exchanger.

Once the machine is turned off, find the cause of malfunctionand repair it. If you are unable to solve the problem, contacta service center or DRILLMEC S.p.A. directly (full addressis printed on cover and first page of this manual).

At regular intervals, also check instruments for DIESELENGINE in sound proof hood.

The engine should be immediately turned off when thesesituations occurr:

- Low engine oil pressure- Engine water over temperature- Low battery charge

WARNING

When above warning lamps are turned on, stop theengine; leaving the engine running can cause seriousdamage to the engine.

99


Section C page 13

Fig. C14

P1A1

R7 R8 SC12

SC11

C - 4 OPERATING PROCEDURES

C - 4.1 TOOL ROTATION

The power swivel rotation (drilling tool) is controlled withlever SC12: push the lever down for clockwise rotation,pull the lever up for anticlockwise rotation.

IMPORTANT

Lever SC12 can be locked in full stroke positionallowing the operator to control other drillingparameters such as pull/push regulation, rpm or torque.

Rpm (speed) is controlled by R7; torque is controlled byR8. Rpm and torque control can be turned clockwise fromleft (min.) to right (max).

Read torque on A1 gauge, read rpm on P1 rpm meter.Another kind of speed and torque control can be performedby means of selector SC11 (2-position selector).

IMPORTANT

During the drilling, if the stops locking the rotation ofthe power swivel, do not move the rotation command

lever setting it in neutral position, but turn the torqueregulator in anticlockwise direction setting the pressureto zero (see pressure gaugeof power swivel rotationtorque) them set lever again to neutral position.

100


Section C page 14

MAIN SHAFT

IBOP ACTIVATORSHELL

UPPER IBOPACTIVATOR CYLINDER

CRANK ASSEMBLY

OPEN

CLOSE

IBOP

Fig. C15

C - 4.2 IBOP SAFETY VALVES

Turning the IBOP switch on the drillers console to theCLOSE position extends the hydraulic actuatorcylinders, moving the actuator shell body downward (seefollowing figure). This downward movement rotates thecrank assemblies 90, closing the IBOP ball valve.

Turning the switch to the OPEN position retracts thecylinders rod, pulling the IBOP actuator shell upward-opening the IBOP. Full hydraulic pilot pressure isapplied to fully open or close the valve, mantaining theshell position.

101


Section C page 15

Fig. C16

A1 P1

SC12 SC7

SC6

C - 4.3 ACTIVATING TOP DRIVE BRAKE

Turning the switch SC6 to the ON position, apply brakeand in the same time the automatic sequence of torquewrench is disabled.Also Top Drive rotation is disabled (cutting the pilotpressure). Turning the switch to the OFF position, releasethe brake.

SC7 Torque wrench automatic sequence

SC12 Top Drive rotation

When applying brake, two hydraulic caliper disc brakes,mounted between each top hydraulic motor and the mainbody, hold torque in the drill string and assist in positioningduring directional work.

For safety reasons, Top Drive rotation and torque wrenchautomatic sequence are disabled.

102


Section C page 16

DOUBLE HOOK

LINKS

DRILL PIPEELEVATOR

CW

CCW

WELLCENTER

TORQUE WRENCH

HYDRAULICMOTOR

POSITIONINGGEAR

PINION

Fig. C17

C - 4.4 PIPE HANDLER OPERATION

C - 4.4.1 ROTATING DOUBLE HOOK AND LINKS

The rotating double hook supports the weight of thedrill string through a set of links that hang from thehook.

The positioning gear is an integral part of the rotatingdouble hook. The positioning gear, meshed with ahydraulic motor driven pinion gear, rotates thepipehandler.

103


Section C page 17

Fig. C18

SC4

SC3

SC1

C - 4.4.2 LINK TILT

The link tilt consists of two double-rod assemblies with thecylinder body pinned to the rotating double hook and rodend of the cylinder pinned to the elevator link. Moving thelink tilt lever upward, SC3 on the drillers console, extendsthe drill pipe elevator to the MOUSE HOLE position.

WARNING

Rotate pipe handler 90 with SC-1 before to move thelever downward SC-3 to reach the DRILL-DOWNposition.Be sure not to interfere with guide beam.

Moving the link tilt lever downward retracts the drill pipeelevator to the drill down position. Turning the link tilt floatswitch SC4 to free position allows the elevator to return towell center.

Elevator travel is adjustable. If it is necessary to adjust themousehole position, relocate the clamps on the links asrequired.

104


Section C page 18

FRONT

DOUBLE HOOKROTATION GEAR

HYDRAULICDRIVE MOTOR

REDUCER

PINION

ROTATINGDOUBLE HOOKLINK ADAPTER

GUIDE BEAM

TORQUEWRENCH

DRILL DOWNPOSITION

WELL CENTER(FLOAT POSITION)

ELEVATORASSEMBLY

MOUSE HOLEPOSITION

CLAMP(ADJUSTABLE)

ELEVATORLINKS

TWO WAYLINK TILT CYLINDER

WARNING!ROTATE PIPE HANDLER 90

Fig. C19

105


Section C page 19

Fig. C20

SC8

SC7

C - 5 TORQUE WRENCH

C - 5.1 TORQUE WRENCH BREAK-OUTSEQUENCE

Turn the selector SC8 on BREAK-OUT position.To activate the automatic (break-out) sequence, move thelever SC7 upward and hold it in position till the sequenceis completed.

In the same time:

- DOUBLE HOOK ROTATION IS FREE- TOP DRIVE ROTATION IS FREE

to permit freely upper clamp rotation.

When the sequence is completed, release the lever SC7to return in neutral position.

106


Section C page 20

Fig. C21

Selector SC8 in BREAK-OUT position

HOME position for BREAK-OUT sequence

Lever SC7 upward1st phase of automatic sequence

LOWER CLAMP CLOSE

UPPER CLAMP CLOSE

Lever SC7 upward2nd phase of automatic sequence

UPPER CLAMP ROTATES C.C.W

Lever SC7 in neutral position1st phase of automatic return to HOME position

UPPER AND LOWER CLAMPS OPEN

Lever SC7 in neutral position2nd phase of automatic return to HOME position

UPPER CLAMP ROTATES C.W.

107


Section C page 21

Fig. C22

C - 5.2 TORQUE WRENCH MAKE-UP SEQUENCE

Turn the selector SC8 on MAKE-UP position. To activate the automatic (make-up) sequence move the lever SC7upward and hold it in position till the sequence is completed.

In the same time

- DOUBLE HOOK ROTATION IS FREE- TOP DRIVE ROTATION IS FREE

to permit freely upper clamp rotation.When the sequence is completed, release the lever SC7to return in neutral position.

Selector SC8 in MAKE-UP position

HOME position for MAKE-UP sequenceLever SC7 upward1st phase of automatic sequence

LOWER CLAMP CLOSE

UPPER CLAMP CLOSE

Lever SC7 upward2nd phase of automatic sequence

UPPER CLAMP ROTATES C.W

Lever SC7 in neutral position1st phase of automatic return to HOME position

UPPER AND LOWER CLAMPS OPEN

Lever SC7 in neutral position2nd phase of automatic return to HOME position

UPPER CLAMP ROTATES C.C.W.

108

Operation and Maintenance ManualINSTALLATION

Section D page 4

BRACKETSAND PINS

BRACKETSAND PINS

COLLAR

Fig. D3

Fig. D4

The HTD 200 is supplied in a shipping and handling skid.The HTD 200 is supported by two brackets on carriage and by collar on main shaft.

The HYDRAULIC POWER UNIT has a proper container with old field supporting frame.

The pipehandler, the links, guide beam group, service loop and other accessories, are supplied in separate properpackages.

109


Section D page 5

At the reception of the machine, be extremely careful duringthe down-loading procedures of the fixtures; it is necessaryto check all the received materials and the status of thefixtures themselves in such a way to ensure their perfectstatus after the transport.

IMPORTANT

Every dispute, comment or claim has to be immediatelypointed out to the transport company. The claimsforwarded with delay will not be taken into account.

D - 1.1 LIFTING DEVICE

The hoist or the lifting crane for the machine installation isalways under the customer's responsibility. However, itsloading capacity has to be not lower than 15 Ton.

110


Section D page 6

1 2 3 4

5

PHASE 1

NOTE:

1 - Assemble the guide beam composed by nr. 4 elements (ref. 1-2-3-4) and its lower attachment ref. 5

Fig. D5

D - 2 INSTALLING THE GUIDE BEAM AND LOWER ATTACHMENT

111


Section D page 7

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