DQ40BQⅡ-JH Top Drive Drilling System

User Manual

HEILONGJIANG JINGHONG PETROLEUM EQUIPMENT

MANUFACTURING CO., LTD.

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

In order to avoid accidents,the operator should pay more attention to the safety all the

time to protect themselves and improve the efficiency.

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

assurance system:

GB/T19001:2008 idt ISO9001:2008 Quality Assurance System

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

This manual includes top drive electrical system, hydraulic system, mechanical principle

and technical information of installation, commissioning, operation, and maintenance.

Refers to other content which isn’t included in the manual and other problems in the

process of installation, usage and maintenance, if necessary, please contact with us:

Tel： 86-452-2340601

Fax： 86-452-2340601

E-mail：service@jh-pm.com
Address： No.24 Delong Road, Nanyuan Development Zone, Longsha
District, Qiqihar, Heilongjiang, People's Republic of China
Zip code： 161005

I
 Summary
Top drive drilling system (hereafter referred to as top drive) is a new type of drilling

equipment that instand of traditional rotary table. The top drive is an important petroleum

drilling equipment developed since late 1980’s. Using the top drive drilling system could

greatly decrease the accident of drill pipe sticking. Improve the working performance and

working security. The top drive drilling system is honoured as one of three great technical

revolutions of drilling equipments in modern time.

Jinghong company developed the DQ40BQ-JH top drive drilling system with independent

intellectual property rights. It integrated the mechanical, electrical and hydraulic control

technology. Our top drive drilling system takes a fully consideration of operation while

drilling, Our top drive drilling system has the advantages of simple structure, easy

operations and long service life, etc. All above features fully satisfy the technological

requirements on site. It is an important equipment for the drilling of deep well, super deep

well, horizontal well and controlled directional well in complex geologic condition.

The main technical features are:

1. the patented double cylinder make the back-up clamp more easier and simple in make-up and
breaking out the pipe. And it is not necessary to lock and hold the rotating link adaptor before the
connection work. That means a great save of time and labour.

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

3. The patent slid-inserting type foldable structure is used in the guide beam. It is quick, convenient
and safe to install and dismantle. Comparing with the other brand top drive drilling system, it takes
2~3 less hours to install and dismantle the track.

4. The patent structure of reversed oil cup structure is used on the main shaft seal at the bottom of

II
the gear box, which guarantees that the lubrication will not leak during the working process even the
seal on the main shaft lose effectiveness.

5. Driller panel is equipped with touch screen which shows working condition of system and also
monitors emergency point of equipment in time, increasing the reliability of equipment operation.

6. for the counterbalance system ,there are two symmetric double cylinder at bottom part of the bail .
Which makes the top drive work more even and stable.

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

8. The anti-loosen device is with single direction tong dies, that can offers more torque and make
installation and disassembly more easy

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

10. The rotating link adaptor is connected to the gear box through shaft sleeve. When tripping out and
in the hole , or releasing the pipe stuck by the bumper jars, there is no force on the main shaft, which
increases the service life of the main bearing on the shaft.

III
 Contents
Prologue ................................................................................................................................................................... I
Summary .................................................................................................................................................................II
Part I Technical Parameters of Top Drive DQ40BQⅡ-JH ..............................................................................1
I Specification ................................................................................................................................................ 1
II Drilling Parameter .........................................................................................................................................1
III Main Motor Parameter .................................................................................................................................1
VI Cooling Air-blower ..................................................................................................................................... 1
V Hydraulic Disc Brake ................................................................................................................................... 2
VI Electric Control System .............................................................................................................................. 2
VII Gear box ..................................................................................................................................................... 2
VIII Pipe Handler system ................................................................................................................................. 2
IX Working Curve of Top Drive DQ40BQⅡ-JH .....................................................................................3
Part II Mechanical Manual .................................................................................................................................... 5
Chapter I Structure and function Introduction ................................................................................................. 5
I. Structure and function introduction ..................................................................................................6
II. Top Drive DQ40BQⅡ-JH Working Curve .....................................................................................6
III. Power Swivel .....................................................................................................................................7
IV. Pipe Handler Device ...................................................................................................................... 10
V Guide Beam and Carriage ..............................................................................................................16
Part III Electric Manual ..................................................................................................................................... 18
Chapter I Safety Operation Specification .......................................................................................................18
I Safety Notice ...................................................................................................................................... 18
Chapter II Electric System Component ..........................................................................................................20
I. Input Power Distribution and Protection System ........................................................................ 20
II. AC VFD System ...............................................................................................................................20
III. PLC Control System ...................................................................................................................... 21
IV. terminal Box .................................................................................................................................... 23
V. Hydraulic Lubrication station .........................................................................................................23
VI. Driller Panel .................................................................................................................................... 23
VII. Touch Screen ................................................................................................................................ 28
VIII. Main Power Cable ....................................................................................................................... 31
IX. Other Cable .....................................................................................................................................32
Chapter III Monitoring System (WINCC) ..................................................................................................... 34
I. Screen introduction .......................................................................................................................... 34
II. System Structure ............................................................................................................................. 35
III. Top Drive ......................................................................................................................................... 36
IV. Network ............................................................................................................................................ 37
V. Auxiliary Interface ............................................................................................................................ 38
VI. Alarm Frame ................................................................................................................................... 39
VII. Curvilinear Frame ......................................................................................................................... 40

IV
 VIII. Login Frame ..................................................................................................................................42
IX. Exit Frame ....................................................................................................................................... 43
Chapter IV PLC System Software and Hardware ..........................................................................................44
I. PLC Program Structure ................................................................................................................... 44
II. The hardware Structure of PLC System ......................................................................................45
III. The Switch and Indicator light of CPU ........................................................................................46
Status indicator on the CPU .......................................................................................................................... 46
IV. Module installation, Power Distribution and Indicator ............................................................. 49
V. Program Upload and Download ................................................................................................... 50
VI. ET200M Remote Station .............................................................................................................. 50
VII. Indicator on Interface Module ..................................................................................................... 50
VIII. Remote station ET200M, Module installation, Power Distribution and Indicator .......................50
IX. Communication system ................................................................................................................ 50
Chapter V Main Motor Drive System ............................................................................................................ 57
I. Main Motor and Frequency Convertor .......................................................................................... 57
II. Operation and Structure of Electric element Cabinet ................................................................57
III. Main Circuit and Control Circuit Sketch Plan ............................................................................ 58
IV. Connection of Standard Control Line ......................................................................................... 58
V. Extensive Characteristic of Standard Software Provide Protect for Transform, Motor and
Process ..................................................................................................................................................59
VI. Adjustable Power Limiter ..............................................................................................................59
Chapter VI Installation, Commissioning and Maintenance ........................................................................... 60
I. Electric installation and commissioning notices .......................................................................... 60
II. Electric system reinstallation ......................................................................................................... 60
III. Examination before power on ...................................................................................................... 61
IV. Daily maintenance ......................................................................................................................... 62
Part IV Hydraulic Manual .................................................................................................................................... 63
Chapter I Safety Operation Specification .......................................................................................................63
I Safety operation notification ............................................................................................................ 63
II Electric system operation notification ............................................................................................64
III Hydraulic system operation notification .......................................................................................64
Chapter II Hydraulic System Overview ......................................................................................................... 66
I Hydraulic System Structure and Working Principle ..................................................................... 67
II Hydraulic valve Block .......................................................................................................................71
III Control Loop on Hydraulic valve block ........................................................................................ 73
Chapter III Hydraulic oil ................................................................................................................................ 80
I Selection of hydraulic oil ...................................................................................................................80
II Hydraulic oil Changing ..................................................................................................................80
Chapter IV Hydraulic system Commissioning and Maintenance ..................................................................81
III Hydraulic system daily maintenance requirement ..................................................................... 83
1) Daily inspect Items .......................................................................................................................................... 83
3) Braking device maintenance ......................................................................................................................... 83
1. Inspecting ..........................................................................................................................................................83
2. Exhaust of brake loop ..................................................................................................................................... 83

V
Part V Installation and Commissioning Manual .............................................................................................. 84
Chapter I Safety Operation Specification ....................................................................................................84
I Safety operation notice ..................................................................................................................... 84
Chapter II Installing preparation ................................................................................................................... 85
Top Drive well field facade layout ..................................................................................................... 87
Chapter III Installation ....................................................................................................................................88
I. Installing the guide beam ................................................................................................................ 89
II. Installation of Top Drive Main Body ............................................................................................. 96
III. Cable installation .......................................................................................................................... 102
IV Auxiliary Device Installation ........................................................................................................ 103
Chapter IV Inspect after installation ......................................................................................................... 105
Chapter V Test Running ............................................................................................................................106
I Electric Device commissioning ......................................................................................................106
II Auxiliary Function Test Running .................................................................................................. 108
Chapter VI Top Drive Disassemble .......................................................................................................... 109
I Accessory equipments disassemble ............................................................................................ 110
II Cable Disassemble ........................................................................................................................ 112
III Disassemble Top Drive Main Body ............................................................................................ 112
IV Disassemble the guide beam ......................................................................................................114
Attachment I Top Drive System Electric Wiring Installation Inspecting list .........................117
Attachment II Top Drive System mechanical installation inspecting list .................................. 118
Attachment III ......................................................................................................................................119
Top Drive System Installation and Commissioning Record ....................................................... 119
Part VI Operating Manual ................................................................................................................................. 121
Chapter I Safety Operation Rules ..............................................................................................................121
I. Safety Operation Notes ................................................................................................................. 121
II. Operator safety operation notes ................................................................................................. 121
Chapter II OPERATING PROCEDURE .................................................................................................. 123
I. Inspection before starting ..............................................................................................................123
II． Hydraulic system operation ..................................................................................................... 126
III. Main Motor Heater ....................................................................................................................... 126
IV. Main Electric Motor Cooling air-blower .....................................................................................127
V. Braking mode selection ................................................................................................................127
VI. Drilling Operation ......................................................................................................................... 129
VII Backup tong operation ................................................................................................................ 132
VIII Link operation .............................................................................................................................. 133
IX “Make up/ Break out” operation ..................................................................................................135
X Drilling ahead by single .................................................................................................................141
XI Drilling ahead by triples ................................................................................................................142
XII. Backreaming ................................................................................................................................143
XIII Pulling out operations ................................................................................................................ 143
XIV Running Casing .......................................................................................................................... 146
XV Well Control .................................................................................................................................. 147
XVI Jarring operation .........................................................................................................................148

VI
 XVII Release drilling torque operation ............................................................................................148
Step 4: After the reverse torque release is completed, lift the drilling string, turn the [Brake]
switch to “Auto”, reset the [Drilling Torque Limit] handwheel, and set [Speed setting]
handwheel at the required speed. ...................................................................................................150
XVIII. Emergency stop ...................................................................................................................... 150
XIX Reset/Mute .................................................................................................................................. 151
XX Stop system ..................................................................................................................................151
Appendix I System Initial State ....................................................................................................................152
Attachment I. VFC initial state ......................................................................................................... 152
Attachment II Driller Panel initial state ........................................................................................... 152
Attachment III PLC Cabinet Initial State ........................................................................................ 153
Attachment IV Kelly board operation box initial state .................................................................. 153
Part VII Maintenance Manual ...........................................................................................................................154
Chapter I Safety Operating Rules .................................................................................................................154
I Safety Operating Rules .................................................................................................................. 154
Chapter II Daily Inspection .......................................................................................................................... 155
I It is important to inspect the following items ............................................................................... 155
Chapter III Maintenance Items and period ................................................................................................157
I Daily maintenance Items ................................................................................................................ 157
4 pieces of roller .............................................................................................................................................157
II Weekly Maintenance Items ...........................................................................................................158
III Monthly Maintenance Item ...........................................................................................................161
IV Maintenance Items in each quarter ........................................................................................... 164
V. Maintenance Items in half year ...................................................................................................165
VI Maintenance Items every year ................................................................................................... 166
VII. For more information please refer to the “JH Top Drive System Inspection Standards Cat.
I II III Ⅳ”. Please contact with technical department of Jinghong for further maintenance and
repairing. ..............................................................................................................................................166
Attachment A Torque value of thread hastening ..........................................................................167
Note: The tightening torque of M20 on the anti loosening device between the spindle
and the blowout preventer is 390N · m~420N · m ................................................................. 167
The tightening torque of M20 on other anti loosening devices is 370N · m~390N · m167
Attachment B Recommended torque for connections of TDS .................................................................... 167
Attachment C Recommendation of gear oil .................................................................................. 167
Table 1、Top drive electrical daily maintenance record ..................................................................................... 168
Table 2、Top drive electrical weekly maintenance record ..................................................................................171
Table 3、Top drive electrical monthly maintenance record ................................................................................ 172
Table 4、Top drive electrical quarterly maintenance record ............................................................................... 175
Part VIII WEAR LIMIT OF TOP DRIVE DEVICE ..................................................................................... 176
OF OIL DRILLING RIG ..................................................................................................................................... 176
II.Wear Limit And Repair Requirements Of Main Parts ...............................................................176
1.2 Bail ................................................................................................................................................. 177
1.2.1Dimension measurement:Dimensional measurements are carried out in accordance
with the following table. .....................................................................................................................177

VII
Dimensions of connection between the bail and the hook ......................................................................... 177
1.2.2 The wear of the bail body should not be greater than 5mm. The cause should be identified if the
wear is large. .......................................................................................................................................................177
1.3 Drilling fluid circulation channel ................................................................................................ 177
1.4 Rotary head assembly ................................................................................................................178
1.4.1 Suspension unit ........................................................................................................................178
Rotating head lifting lug size ............................................................................................................................ 178
1.4.2 Links ........................................................................................................................................................... 179
Lifting tool contact surface radius ....................................................................................................................179
Part IX Guide For Prevention Of Falling Objects From Top Drive Devices Of Oil Drilling Rigs ......180
I.Anti-loose process of bolts and screws ............................................................................................... 180
II.Anti-loose process of traveling cable and derrick cable .................................................................. 180
III.Anti-loose process of back-up tong assembly ..................................................................................181
IV. Anti-loose process of guide beam ..................................................................................................... 182

VIII
 Part I Technical Parameters of Top Drive DQ40BQⅡ-JH

I Specification

Rated Drilling Depth: 4000 m（φ114 drill stem）

Max. Load capacity: 2250 kN (250ton)

Main channel ID: φ75mm

Rated circulating pressure: 52MPa（7500psi）

Weight: 10.5t（Main body）

Working Height: 5.2m

Electric Volt: 400 VAC

Rated Power: 450kW

Ambient Temperature: -35℃～55℃

II Drilling Parameter

Rotary speed: 0～180r/min adjustable

Work torque: 48kN·m (continuous)

Max. Torque: 72kN·m（discontinuous）

III Main Motor Parameter

Related Power: 450kW

Related Rotary speed: 1200r/min

Max. Rotary Speed: 2400r/min

VI Cooling Air-blower

Model: M2JAX 132S2A

Rated Power: 5.5kW

Rated Volt: 380VAC

1
 Rated Frequency: 50Hz

Rated Currency: 11A

Rated Rotary Speed: 2910r/min

V Hydraulic Disc Brake

Braking Torque: 48kN·m

Cylinder Working Pressure: 11.5MPa

VI Electric Control System

VFD Input Volt: 600VAC

VFD Output Frequency: 0～122Hz

Motor alarming temperature: 110℃

Lube oil alarming temperature: 85℃

Hydraulic source oil alarming temperature: 75℃

VII Gear box

Gear Ratio: 13.3:1 double reduction

Lube: immersed oil lubrication, air cooling

VIII Pipe Handler system

Rotate Speed of rotating link adaptor: Factory set to 3r/min

Hydraulic motor working pressure: 13.5MPa

Upper IBOP (remote control): 6 5/8" API REG box～pin，70MPa

Lower IBOP (manual): 6 5/8" API REG box～pin，70MPa

Backup Tong Diameter: φ210mm

Backup tong working range: φ76～φ206mm

Equipped with 2 clamp heads for optional use, and the working range are 110mm-164mm and

152mm-206mm. (Optional clamp for 76mm-123mm)

2
 Link: 2740mm, 250t,108’’

Leaning angle: forward leaning 30°, backward leaning 50°

IX Working Curve of Top Drive DQ40BQⅡ-JH

3
Top Drive DQ40BQⅡ-JH Dimension

4
 Part II Mechanical Manual

Chapter I Structure and function Introduction

The Top Drive works on the top of drilling string and makes up or breaks out by itself. At the

same time, the top drive can trip along the guide beam to complete drilling operation.

DQ40BQⅡ-JH Top Drive Dimension

5
I. Structure and function introduction

Mechanical structure of Top Dive Drilling System includes:

 Power swivel
 Pipe handler device

 Guide Beam and Carriage

II. Top Drive DQ40BQⅡ-JH Working Curve

6
III. Power Swivel

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

7
1. Main motor and air-blower
Main motor is installed on the gear box. Motor has double

output shaft, the lower output shaft connects with gear,

upper output shaft connects with braking system.

Main motor could output 375kW power continuously and

realize stepless speed regulation by VFD system. The

max. rotary speed can reach 2400r/min at the frequency

50Hz. The rated output torque of motor is limited by

currency, Output torque is proportional to currency.

Air-cooling motor is installed on the side of main motor,

driven by the flameproof 3P AC asynchronous motor

which power is 5.5KW. Air blower starts to absorb air from air inlet on cooler shell, press it

into the air inlet on the top of main motor via the air channel, then through motor inside,

release it from the air outlet on the lower part, the whole process compel the motor air cooled

by air.

2. Braking Device

The hydraulic oil cylinder clamps the disc to realize braking. The brake energy is proportional

to the pressured pressed by hydraulic system, the wearing of brake disc is compensated by

increasing the travel of hydraulic cylinder. There are 2 self-reset springs on each braking

disc, the disc can be reset by the spring when the brake release. The braking device has 3

functions while the top drive system working.

A. In directional well operation, ensure the brake state of the spindle when the spindle is not driven
to rotate.
B. When the downhole resistance occurs and the top drive continuously rotates and presses down,
the drill pipe will deform and store a large amount of elastic potential energy of the reverse torque.
When the reverse torque is suddenly released under certain conditions, it exceeds the output torque
of the top drive, resulting in rapid reverse rotation of the main shaft, at this time, the main motor
needs to be braking to prevent the reverse trip of the drill tool.
C. When the variable frequency drive device fails and stops, it cannot drive the main motor, and the
downhole drilling tool stores the reverse torque, resulting in the uncontrolled state of the main

8
motor resulting in a "racing" phenomenon, and the brake hydraulic
system automatically puts into work and brakes the main motor
3. Gear Box
Gear Box adopts double-geared reduction, gear ratio is 13.3, the

gears are all helical gear, transfer greater torque and keep low

noise. The bearing that is strong anti-seismic capability and

anti-attack capability is from SKF.

The lubricate system of gear box is gear pump force lubrication.

The lube pump is driven by motor of 1.1KW produced by ABB.

After the motor start, the pump outputs the lubrication through

cooler to spread to each lubricating point. Then the lubrication

flow back to the gear box through main shaft bearing.

DQ40BQ-JH top drive system adopts force lubricate mode,

bearing and gear could contact the oil sufficiently to ensure the reliability of lubrication.

Install the pressure and temperature sensor in the lube pipes, inspect the pressure and

temperature of lube system and alarm at the emergency.

4.Washing Pipe Assembly

Washing pipe assembly is installed between the mail shaft and

gooseneck. Same as the washing pipe of conversional swivel,

packing seal of washing pipe needs regular maintenance to

extend the service life.

5. Gooseneck

The lower of gooseneck is connected with drilling hose, it is the

inlet of drilling mud. Gooseneck is installed and connected with the

washing pipe. The gooseneck is the transmission channel of mud

circulation. The top of gooseneck is sealed. After open the top, the

fishing and logging can be carried out.

9
6. Counterbalance System
Bail is the importance bearing component of Top Drive System. The

bail is connected with gear box via bail pin, its top is hanged on the

hook of crane. Balance cylinder is fixed on bail, the main function is to

balance the weight of main body. Jinghong top drive system adopts

single hydraulic cylinder balance mode to solve the problem of

imbalance force on connecting rod in double cylinder system. Single

hydraulic cylinder designing ensure the system works more safe and

reliable.

IV. Pipe Handler Device

Pipe handler device is the important element of top drive system, it consists of leaning device,
back-up tong assembly, thread anti-loosen device, IBOP, rotating link adaptor and other
components. It could highly improve the automation of drilling.

Rotating Link
Leaning Device

IBOP

Thread Anti-loosen
Device

Backup Tong

10
1． Rotating Link Adaptor

Rotating Link Adaptor is connected with gear box with shaft

sleeve, and don’t rotate with main shaft, the structure as the

draft.

The rotation of rotating link adaptor is driven by hydraulic motor,

it could rotate CW and CCW, the link can rotate 360º with
rotating link adaptor, it is easy to catch the drilling stem in
mouse hole. It is also convenient to catch the drilling pipe on
rack frame while the main body is moved to Kelly board. The
rotary of rotate head normally be set at 3 r/min. It could be
adjusted according to the customer requirements.

Before conducting forward and backward tilting

operations during on-site use, confirm that the load

calibration value is facing the front (facing the top drive).

The lifting ring must not tilt backwards to withstand the

load.

Lifting ring tilting backwards

Lifting ring forward tilt

11
2. IBOP

The functions of the internal blowout preventer (IBOP): When

the pressure in the well is higher than the pressure in the drill
string, the internal channel of the drill string can be cut off by
closing the internal blowout preventer in order to prevent the
occurrence of blowout or blowout.The internal blowout
preventer is installed between the saver sub and the main
shaft. It is composed of the hydraulic IBOP in the upper part
and the manual IBOP in the lower part.
The upper hydraulic IBOP is connected to the main shaft of
the power swivel.
The internal and external threads of the IBOP are both
6-5/8REG.
The hydraulic IBOP operates with hydraulic cylinder, which drives the rack on the switch sleeve to move
up and down, and the pinion matched with the rack also rotates driving the ball valve of the IBOP for
90°rotation to open and to close the IBOP. And the top drive adopts a gear rack transmission to realize
the close of the IBOP.

Cylinder rod

Rollers
Guiding plate

Locking nut
Supptor

When the automatic IBOP switch is in the fully open state(that is, the scale
line of the transmission wheel is aligned with the open state scale of the switch

sleeve), adjust the threaded connection of the roller bracket and the cylinder

12
piston rod when the IBOP cylinder piston rod is fully extended to ensure the upper

BOP. The gap between the contact surface of the small roller and the switch sleeve

is 0.5mm. After adjusting the back lock nut to fix it, install the guide plate.

Improper adjustment can easily cause damage to the ball valve. It is

recommended to replace the roller assembly when the diameter of the blowout

prevention roller wears more than 1.5mm.

The hydraulic IBOP and the manual IBOP cannot be used interchangeably.

Marks of the hydraulic IBOP:

Hydralic IBOP sign:
Line 1：REMOTE (Z)
Line 2: product code/(date of production: m/y) xx/20xx Grade 2
Line 3: API Spec 7-1 6 5/8 REG Box~Pin
Line 4: Blowout preventer housing (ball valve body) number
Line 5: product tracking No.
Identification of the hydraulic IBOP is shown in the figure below:

REMOTE (Z) Automatic IBOP marking

11/2018 CLASS 2
API 7-1 6 5/8 REG BOX~PIN
700202085
18-10-30-ZH-4b
The lower manual IBOP is connected with the saver sub, which is connected with the drill pipe
during drilling.

The internal and external threads of the IBOP

are both 6 5/8’’REG

13
 The switch limit on the manual IBOP allows to rotate the ball valve at only 90 degree
angle. It cannot be rotated at 360 degrees.

When operating the manual IBOP, the torque must not be greater than 130Nm.
Excessive rotating torque will cause the deformation of the sealing copper sleeve.

When the ball valve is glued with the solidified mud, the ball valve should be soaked to
soften the mud before switching the ball valve. The rotation operation with high torque
(greater than 130Nm) on the ball valve should be strictly prohibited.

IBOP Open: the ball valve stem is aligned with the engraving line of the sealing sleeve,
and the engraving line is in line with “Open”.

IBOP Close: the engraving line of the ball valve stem is in line with “Close”.

If the position is found to have an offset, it shall be calibrated immediately. The offset
ball valve in the IBOP will immediately cause a deflection flow of the mud, so that the
IBOP is subjected to abnormal scouring. After a long time, the body of the IBOP and the the
ball valve will be eroded. Pits on the body of the IBOP and the ball valve will appear and will
eventually it will cause leakage and damage to the IBOP.

When the IBOP is opened, the pressure difference between the upper part and the
lower part of the ball valve cannot be higher than 20Mpa.

Marks of the manual IBOP:

Line 1: MANUAL (S)
Line 2: product code/(date of production: m/y) xx/20xx Grade 2
Line 3: API Spec 7-1 6 5/8 REG Box~Pin
Line 4: Blowout preventer housing (ball valve body) number
Line 5：product tracking No.
Lower of IBOP (manual)

14
 MANUAL (S) Limit type IBOP marking
11/2018 CLASS 2
API 7-1 6 5/8 REG BOX~PIN
700202085
18-10-30-ZH-52
Attention: Due to the limit mechanism of the

manual blowout preventer, it cannot be

installed on the automatic blowout preventer. If used

instead of the automatic blowout preventer, it may

cause the sealing sleeve to crack.

3． Side-hanging Backup Tong
Backup tong is designed for make-up or break out the

pipe ,it is not necessary to lock the rotating adapter before

clamping the pipe. This design is convenient to change tong

dies Oil pipe lines are embeded inside the clamp body. No

pipe lines is exposed to avoid scratching as well as improving work reliability.

The clearance between dovetail and clamp body of reverse torque plate

should be checked irregularly(the clearance should be replaced if it is larger

than 3mm).

The clearance between dovetail and clamp body of the ex-factory reverse

torque plate is 0.02mm-0.04mm, when the clearance is greater than 0.04mm

bolt

Should not be tightened, the bolt pretightening force can be properly relaxed (bolt

pretightening should cancel the spring pad and washer).Preload shall be

305N.m-400 N.m.

When the gap between dovetail and clamp body is greater than 0.04mm,

gaskets (ф 20×3mm) can be added into the threaded hole,

15
Avoid large gap acceleration wear. After the installation of bolts, bolts should be

treated to prevent falling.

4． Drilling string anti-loosen device

anti-loosing assembly geoes between the joints of main shaft , IBOP

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

V Guide Beam and Carriage

The main function of the guide beam is to bear reverse torque when top drive system
working.
The carriage fixed on the gear box slides up and down the guide beam, transmits the torque
to the guide beam. The top part of guide beam is connected with the pad eye under the
crown .Lower part of the guide beam is hold by spreader beam . The torque can be directly
transmitted to the lower derrick. The main point is guide beam produced by JH is folding
structure without lock pins, which makes installation convenient and reduces risk and cost.

16
 he trolley connects with gear box inputs in the guide beam, and slide along with top
drive, transmits the torque to the guide beam. The upper guide beam is connected
with the bottom beam of crown block. Lower guide beam is connected with spreader beam of
the derrick. The torque can be directly transmitted to the lower derrick.

It is strictly forbidden that the traveling block is not separated from the bail of the
top drive body and the traveling block is not suspended by the wire rope and directly
leans on
the guide rail to perform the inverted rope operation.

It is strictly forbidden to use the top drive body to mount the guide rail to carry
out the inverted rope operation, because the total weight of the top drive body and the
guide rail has exceeded the bear capacity of the guide pin, and may also exceed the carrying
capacity of the pad eye. Overload load may cause the guide rail pin to break and the pad
eye to open the welding, the top drive body and the guide rail will fall off the drill floor and at
the same time it will cause personal injury to the drill floor operator.

17
 Part III Electric Manual

Chapter I Safety Operation Specification

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

manual first seriously.

The Top Drive Drilling System installing, debugging, operation and maintenance must be

done by professional or specially trained people, otherwise, it maybe cause personal injury or

machine damage.

Note This sign provides additional information on procedures involving

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

Caution This sign alerts the user to procedures involving a risk of personnel or
equipment damage.

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

I Safety Notice

The following safe notices are very important for correct installation, using, maintenance of

the Top Drive, all the operator and the attendant must read it carefully and understand it:

1. Forbidden live working, electric system maintainer and operator must be qualified and
follow close to safety operation specification.

2. When system is working, do not open the safety cover over the high-voltage equipment,

do not maintenance or remove any electric element, do not pull out/connect wire.

3. Forbidden open the relay box, driller panel or pull out/connect wire in combustible gas

environment.

18
4. Before maintain Frequency Converter or variable-frequency motor, turn off the power of

the Frequency Converter, test the electric current and hanging the caution sign” Machine be

working with, Do not switch it on”. Do not maintain major loop before DC bus voltage lower

in the safety area (DC 24V), (normal after 30 minutes). Otherwise, it is dangerous for human

safety and electrical equipment!

5. Cut off the mechanical interlock switch 1QF or 2QF, test the electric current with

Electroscope and make sure no voltage before replace the PLC electric elements in cabinet.

6. Keep protective gas pressure when turn the driller panel on. If the driller panel protective

gas pressure lost, it is required to resume quickly or turn off the driller panel controlling

power.

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

8. Forbid to relieve the safety interlock of software and hardware. If really needed, resume as

soon as possible after clearing fault.

9. If the temperature higher than 40℃, or the humidity higher than 95% or there is dewing,

do not start the frequency converter or other control power before start air conditioner to

cooling and dehumidify.

10. Check the electric control board if there is dewing before starting, when main power was

off more than 30 minutes.

11. When the temperature outside is high, do not set the temperature too low, prevent

electric equipment to dewing.

19
 Chapter II Electric System Component

Electric control system is mainly composed of input power distribution and protection system,

VFD system and PLC control system.

Transport the 400V main power supply to the control room, pass through the step-up
transformer to 600V, and enter the frame type circuit breaker (Emax E1.2), which has good
ability to withstand the large current generated during switching. The main circuit breaker
leads the 600V power supply to the frequency converter, providing the main power supply for
the frequency converter. The 400V power supply provides power for the PLC integrated
cabinet.

VFD system is composed of ABB880-0650 frequency-converter produced by ABB and Drive

450KW AC frequency conversion motor, it processes complete self-detect and protect

function.

PLC produced by Siemens as the whole drive control system center. PLC integrated control

cabinet undertakes the top drive control task. The PLC system of the integrated control

cabinet is connected with the driller's operating table and frequency conversion drive system

through Profinet bus. The PLC is Siemens S7-1500 system programmable controller, the CPU

is 1513-1PN, and the remote control station is ET200MP.

I. Input Power Distribution and Protection System

The system is supported by an incoming cabinet, which mainly consists of a step-up

transformer, a frame type circuit breaker, a control transformer, relays, etc.

The capacity of the step-up transformer is 630KVA,

which converts three-phase 400V AC into three-phase

600V AC and provides 600V AC power for the top drive.

(Cooling fan with 0.75K WIEC explosion-proof motor).

The main frame type circuit breaker Q1 is a top drive

600V power switch, model Emax E1.2. T1 is the control

transformer with a power of 514W. Convert 600V AC

20
power to 220V AC power as emergency stop and voltage loss protection, and control the

closing and opening of the main air switch. H1 is the closing indicator light, H2 is the opening

indicator light, and SA controls the closing and opening of the main power switch. SB is the

emergency stop button.

The 400V AC power connected to the control room is directly connected to the control cabinet

switch to provide power for the control cabinet.

II. AC VFD System

It is mainly composed of frequency converter and AC frequency conversion motor. The

inverter is manufactured by ABB and the model is ACS880. After the three-phase 600V AC

power enters the inverter, it is converted into an adjustable three-phase power supply after

rectification and inverter, which is used to drive the AC variable frequency motor through the

filter.

Ac frequency conversion motor, power 450KW, rated current 555A. When the reverse torque

is equal to the motor driving torque, the motor will decelerate to 0 RPM, then the

phenomenon of holding back the car. When the motor torque is greater than the reverse

torque, the motor begins to accelerate until the set speed.

The motor has air cooling and pre-heating device to solve the heat dissipation problem and

can not work in cold areas.

III. PLC Control System

Include logical control system and AC Power distribution system of all units. PLC Control

Panel is as follows:

21
A. Indicator light
a. Power indicator of 24V: when switch on the system, then power indicator is on .
b. indicator: (Backup)
c. Motor hearting indicator: light on while motor heater working.
d. Fault/alarm light: while alarm goes on, light flashes (1 Hz); while faults happen , light
stays on all the way
e. Phase sequence error indicator: when the phase sequence of power is fault, the
indicator lights up.

B. Manual Switch
a. Motor encoder switch : during the drilling operation ,keep switch on ,the ,it can work
with high accuracy . When something is wrong with the encoder ,shift to “abnormal”,
the drilling is not effected.
b. stand by: (backup)

c. Motor heater: used for controlling major motor tempreture . This switch can work
independently. The indicator displays the working state of heater. After turning on the
power of the frequency converter, the inter lock function will stops heating

22
 d. Reset/silence button (SB1): when system alarms, the indicator flashes, Press silence
button, the beeper stops beeping , but the fault/alarm indicator still stay on .
e. Mud pump interlock switch (SA6): used for mud pump interlock control. In
interlock state, only stop the mud pump first , the IBOP can be close .if well control
button is press down , the mud pump will stop and the IBOP close. In un-interlock
state, the IBOP can open and close freely

IV. terminal Box

Terminal box is set on the body of top drive, the function is to provide power for sensors ,
feedback signal, and control valve.

It can send back some signals to PLC system such as air pressure signal of main cooling
motor, temperature signal of main motor, over temperature alarm signal ,

temperature signal of hydraulic oil, pressure signal of lubricating oil, main motor encoder etc.

V. Hydraulic Lubrication station

Lubrication station of hydraulic is composed of hydraulic pump motor (4KW), lubricating

pump motor (0.63KW), etc. It is controlled by driller’s console. The motor is explosive-proof
three-phase ansynchronous motor. Lubrication station is set on top drive body.
1. Hydraulic pump switch has three positions: 1). auto, 2). start, 3). stop.
1). Auto: switch at auto, the system will run based on the PLC program.
2). start: switch at start, the hydraulic pump will run.
3). Stop: switch at stop, the hydraulic pump will stop.

2. Lubrication pump start and stop the same time as the main electric motor. There is no
control switch on driller console.

VI. Driller Panel

The Driller panel has all functions for drilling operation and any other auxiliary operation, it
can set speed, torque, operation mode.
The Driller panel is ‘EX’ type; it can only be powered on when driller panel inside pressure
is normal, otherwise, the low pressure alarm signal will appear on the panel.

23
1. The function of Driller Panel Indicator Light and Operate Button/ Rotary Knob are
as follows:

No Name Type Function

1 When the frequency convertor or main motor is
Emergency 1SB1 Self-locking fault, press this button and then frequency
stop button convertor stops. After eliminated the fault,
should reset (CW rotation)
2 Ready 1HL2 Green
Indicator Indicator Light When systems all are ready, it lights.
Light
3 Fault/alarm 1HL3 red indictor When system alarms, it flash once a second;
indicator light when system is fault, it keeps lighting.
light
4 Braking 1HL5 red indicator When braking, it lights up.
indictor light light
5 Brake mode 1SA9 three At brake mode, when solenoid valve work,
Brake/off positions rotary system braking and it lights up. At auto mode,
/auto knob PLC control system braking auto. At off mode,
the brake is released.
6 IBOP 1HL4 red

24
 Indicator indicator light When IBOP closed, it lights.
light
7 IBOP 1SA10 two
closed/open positions Rotary At close positions, IBOP closes.
Knob
8 Well Control 1SB2 red button When well blowout, press this button to
establish interlock with other equipments.
9 Hydraulic
pump 1HL1 green When hydraulic pump running normally, it lights
running indicator light up.
indicator
light
10 Hydraulic 1SA5 three At stop position, hydraulic pump stop; at start
pump positions Rotary position, hydraulic running; at auto position, it
switch Knob will run on PLC.
auto/stop
/start
11 Link 1SB4 button When press it, the link is over the well hole and
suspension keep suspending.
12 1SA8 three Spring reset rotary knob, back to middle
Link rotation position switch position automatically. When on the left
Forward back to middle position, the rotating link adaptor turn left; when
/reverse position automatic on the right position, the rotating link adapter
turn right; loosen the switch, it will back to
middle position automatic, the rotating link
adaptor stop.
13 A resetting rotary knob with spring. leaning
Link leaning 1SA6 three cylinder will be locked, when it’s on center
backward/for position rotary positions. Turn it on “forward”, leaning cylinder

25
 ward knob will push the links and elevator to the rat hole or
Kelly board; when “backward”, will make the
elevator be off the drilling tool when drilling.
14 Hydraulic 1SA7 Two
elevator link positions rotary Close/Open elevator
knob
15 Motor 1SA1 three For control the cooling fan running. At the start
cooling fan positions rotary position, fan starts; at stop position, fan stops;
auto/off/on knob at auto position, the fan will controlled by the
PLC.
16 Motor 1SA2 three
direction positions rotary Control the rotary direction of main motor
FWD/stop knob
/REV
17 Operation 1SA3 three
drill/spin positions Rotary Choose the operation mode
/torque Knob
18 backup tong 1SA4 two position When turn right, start backup tong to clamp drill
Loose button pipe. When release, it turns left automatically,
/Clamp Reset to left backup tong is released.
19 makeup potentiometer In makeup operation, set Max. makeup torque.
torque
20 Drilling
torque potentiometer In drilling operation ,set Max. drilling torque.

21 Throttle potentiometer When normal drilling, set the Max. rotary speed
that drilling string limited.
22 Torque Meter Indicator actual torque of Top driver output with
Meter unit kN.m （Kft.lb）.

26
23 Rotary Meter Meter Indicate actual rotary speed output valve of
main shaft. Unit r/min.
24 Reset/mute 1SB3 Push this button could realize the fault reset
Green button
and mute.
25 1SB5 Push this button, hydraulic pump increases
Green button
Break-out pressure to the balance cylinder, it will raise up
Bounce the top drive about 7cm to avoid damaging drill
pipe thread.
26 Hydraulic 1SB6 Green Confirm the card action when this button is
Elevator button pressed
Interlock

2. Throttle hand wheel

Throttle hand wheel is used for setting Max. drilling rotary speed. hand wheel scale indicate

the rotary speed of main shaft. When turn the hand wheel to CCW, the rotary speed will

decrease to “0” step by step. When turn the hand wheel to CW, the rotary speed will increase

to the Max. value to 180r/min progressively. The rated rotary speed is 90r/min.

3. Drilling Torque hand wheel

The throttle is used to set the drilling torque. Turning the throttle counterclockwise will
reduce the drilling torque limitation until to zero . Turing the dial clockwise, will increase the
drilling torque limitation up to the max 48KN.M
The maximum drilling torque limitation is 48kN.m (set at workshop).

4. Makeup Torque Hand Wheel

The throttle is used to set the drilling torque. Turning the throttle counterclockwise will
reduce the drilling torque limitation until to zero . Turing the dial clockwise, will increase the
drilling torque limitation up to the max 48KN.M
The maximum drilling torque limitation is 48kN.m (set at workshop).

27
VII. Touch Screen

Generally, all operation interface can be divided into 3 areas where the different information
will be displayed .

Toolbar: at the bottom of the screen, some buttons for switch the screens
Display area: the centre part of the screen, some monitoring and control information are
displayed
Title panel: display the tiltle
Chick on the button to enter into different screen as follow:
1). Main frame; 2). Auxiliary frame;
3). Alarm frame; 4). Senior management.

1. Main Frame
Display the torque and speed of the main spindle of the top drive body, as well as the

parameters of each auxiliary motor, including: main motor speed, motor current, motor

torque, motor power, motor temperature, motor operation, faults, fan operation, lubrication

pump operation indicators, etc.

28
2. Auxiliary Frame
Including information indicators for the suspension system, hydraulic system, lubrication system,
and other systems, among which:
The suspension system includes: suspension left turn, suspension right turn, suspension forward tilt,
suspension backward tilt, and indication of suspension center position.
The hydraulic system includes: hydraulic pump operation, high temperature alarm, high
temperature fault, and indication of hydraulic oil temperature.
The lubrication system includes: lubrication pump operation, low pressure, low flow rate, high
temperature alarm, high temperature fault, and indication of lubricating oil temperature.
Other systems include: IBOP valve open, IBOP valve closed, caliper clamping, caliper release,
brake indication, etc.
There is also an indication of the working status of the top drive system.

29
3. Alarm Frame
It can record real-time alarm records and historical alarm records generated during this

operation.

4. Senior management
Frame can only enter after login; user name ‘JH’ and password ‘8888’ can login through

flashing window and keyboard.

30
After logging in, the screen is as follows. Users can change whether to debug or allow

reversals. Whether to enable soft torque control, positioning oscillation control, language

switching, and log out.

VIII. Main Power Cable

The function of main power cable is to send power supply from inverter to main motor on Top
driver.
For easy installation, the cable is divided into three segments:
1. The first segment is ground cable; it’s 26m, from main control cabinet to derrick cable.
2. The second segment is derrick cable; it’s 39m, from the base of the derrick to derrick
terminal board.
3. The third segment is service cable, it’s 26m , and one end is connect to the main motor,
another to derrick cable.
For the main cable ,each end has four quick connectors which are labeled separated by U
(yellow)k, V (green), W (red) . When making connection , make sure they are matched up
very well, U to U, V to V, W to W.
The quick connectors at both end of the cables ,and at the control house and main
motor .makes the installation of the cable much easier .

31
 Every cable joint have four plugs, and there are labeled separated by U (yellow), V

(green), W (red) and Null Line (white). When joint the plugs, be sure joint U to U, V to V, W to W,

Null to Null.

All the cables are connected by quick plugs, both socket and plug are marked,

connect correctly and parallel, luck the nut then.

IX. Other Cable

1. Driller panel Control Cable

Adopting a structure of 12 core control cable and 10 core communication cable.

2. Cable of Relay Box

The relay box is set on top drive body. Its function is transit the assist power, control power

and control signal to the function element on body, and feedback the function element

actuating signal and detectable signal to the composite controller cabinet or frequency

convertor.

Cable between coil output cabinet and relay box is 2 pcs.

a. 15-core assist power cable: cable size 15 × 4 mm2

The supply hydraulic pump motor is 3 × 4mm2; Supply 2 main motor fans with a capacity

of 6 × 4mm2; Lubrication pump motor 3 × 4mm2; The main motor heats 1 × 4 mm2.

b. 60-core composite control cable: cable size 30×2×1

Most of them are 24v power, thirteen control power line of solenoid pilot actuated valve,

feedback line of detectable signal, signal line of motor encoder, and etc.

C. The above two cables are divided into one section, with a length of 65 meters.

32
3. Repeat Earth electrode
Electric controlling system of top drive drilling system adapt three phase four-wire system.

on the cross position set the earth terminal. The earth terminal connects to earth electrode

with copper wire of 70 mm2.

The two earth electrodes are 1.8m long, outer layer galvanized. The earth terminal connects

to earth electrode with 5m long lead. The state of picture is as follow, earth electrode is knock

into ground 200mm.

All cable joint part is quick connector which are marked with different lables
.make sure line up the guide slot before stabbing in the male part into the
female part ,or some pin will be damaged .don’t forget lock the nut at last .

33
 Chapter III Monitoring System (WINCC)

I. Screen introduction

Each screen can be divide into three areas for different information.
Toolbar: at the bottom of the screen, some buttons that can change the screen are in this
area
Display area: in the central part of the screen, it is main area for monitoring and operation.

Title bar: show name.

Chicks on the buttons in the toolbar can enter into different screens:
System structure screen
Top drive drilling system screen
Network stucture screen

Auxiliary interface screen

Alarm history screen
Working curves screen
System login screen
System logout screen

34
II. System Structure

Chick on ‘State’ to enter screen as follow:

In this screen, the basic information and construction frame is displayed as follows:

Running state of Cooling air-blower of motor

Running state of Main motor

Running state of hydraulic pump; running state of lubrication pump; valve of IBOP as well as

elevator link state

Red state means closed and green means open.

35
III. Top Drive

Chick on the “top drive” in toolbar to enter interface as follow

In this screen, it is mainly show the top drive drilling system running state and data, this is

helpful for operator to know well of the state of top drive drilling system.

In this screen, operator can know:

Parameter of main motor, include electrical current of motor, voltage of motor and others

totally 8 data.

Running state of cooling air-blower

And also top drive drilling real torque and speed

In any function module, red state means closed and green means open.

36
IV. Network

Chick on the ‘network’ to enter screen as follow:

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

fast.

In this screen, remote I/O module and network state of frequency convertor can be seen.

37
V. Auxiliary Interface

Chick on ‘AUX Operation’ to enter interface as follow:

In this interface, it show the work state of auxiliary units except main power system of top

drive. General speaking, it can be divided into six parts.

1. Elevator Link system, show the work state of elevator.

2. Hydraulic system, show the on/off of hydraulic pump, current temperature, and if

there are fault.

3. Lubrication system, show on/off of lubrication pump, current temperature, pressure,

as well as fault.

4. Auxiliary system, show state of IBOP, electric house temperature, state of backup

tong.

5. Main body of Top drive working state includes drilling waiting, drilling and others,

38
 totally 7 items.

6. Control panel indicator includes to show A/B system running, and items showed with

panel synchronously.

In each function module, red state means closed and green means open.

VI. Alarm Frame

Chick on ‘Alarms’ button in toolbar, enter interface as follows:

The alarm contents include date, time, number, state and message text.

When alarming, characters and background is the color of red, the status bar appears a mark

of ‘+’.

When alarm disappeared, characters and background color change to general color, the

status bar appears ‘-’.

39
Alarm confirm, when alarming, button in alarm toolbar can be used to confirm.

Chick ‘recent pigeonhole’ or ‘future pigeonhole’ can see alarm history.

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

can be seen totally.

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

alarm.

VII. Curvilinear Frame

Chick on ‘curvilinear’ in toolbar to enter interface as follows:

In this interface, including two modes: real-time curvilinear and history curvilinear, these two

modes can be cut over by button of ‘real-time curvilinear’ and ‘history curvilinear’.

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

40
41
VIII. Login Frame

Chick on ‘Login’ in toolbar to enter interface:

The buttons on this interface could only be operated when login, the operatable buttons are

different deponds on the customer level. Login by press Ctrl+A in whatever interfaces.

Including: CCW

No CCW

Chinese

English

Setting

42
IX. Exit Frame

Chick on ‘Exit’ button in toolbar, enter interface as follow

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

Logout and return to WINDOWS, logout current monitoring system, and return to WINDOWS

XP.

Log out system, log out current user and return to welcome interface.

Reset compute,

Turn off computer

43
 Chapter IV PLC System Software and Hardware

I. PLC Program Structure

OB1: Main loop block, periodic cycle execute main program, switch over the

implementation system emergency operation mode, call function block required to

complete the driver communication control, to achieve the work requirement of Top Drive

process control.

OB82、OB85、OB86、OB87、OB121、OB122：Diagnostic interrupt organization block, it is

used for the PLC system in the I / O access error, OB errors, rack failures, communication

errors, programming errors and module errors to provide diagnostic information, and to

prevent the CPU shut down.

FC3: After receipt emergency stop signal, send out the action directive of emergency

stop.

FC4: To complete the auto control of hydraulic pump and lubricate pump.

FC5: To realize the following function of Link: forward, backwards, CW, and CCW.

FC6: To control backup tong.

FC7: To realize the braking control of main shaft.

FC8: To realize the control of well and IBOP control.

FC11: According to working conditions, select the working condition of main motor.

FC12: According to the condition of main motor to control air cooling motor and main

motor.

FC13: According to the condition selection of main motor, control the frequency convertor

to keep standby.

FC14: To control the frequency convertor run/stop.

FC15: Alternate the speed signal of hand wheel to control signal of main motor.

FC16: Alternate the torque signal of hand wheel to control signal of main motor.

FC17: implement the drilling process memory.

FC18: implement the given function of main frequency convertor rotary speed and torque

44
 limiter.

FC19: Implement the main inverter speed and torque output indicator.

FC20: implement the read and write capabilities of the frequency convertor and PLC.

FC21: implement the alarm function when hydraulic oil, lubricating oil temperature is over.

FC22: Implement the indicating function of system failure.

FC23: implement the communication failure function.

FC24: implement the warning function of main motor temperature over.

FC25: implement the additional function of program.

FC26: implement the transformation function of the main frequency convertor "There

encoder run / non-encoder run".

FC27: Implement the indicating function of work state.

II. The hardware Structure of PLC System

PLC system adopts Siemens S7-1500 series products, CPU is CPU1513.

The main station is composed of: power module, CPU, switching input, switching output,

analog input, analog module.

The remote station is composed of ET200MP (IM155 interface module), switching input,

switching output, analog input, analog module.

45
III. The Switch and Indicator light of CPU

Status indicator on the CPU

46
47
48
 3 positions of the selection switch on CPU working mode

IV. Module installation, Power Distribution and Indicator

1). All modules of PLC system are set on guide beam, remove the fastening screw at the
bottom of the module before replacing the modules . Installation of the modules is done from
the front to the end . remove the modules in the reverse order.
2). Each channel of input/ output module has one indicator, if the light is on that means the
logic state is ‘1’ . there is a input or output signal.
3). Analog input/output module is set to 0-10V working state. If there is a hardware
configuration fault or DC24V power breakdown, the red light SF will be on.

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

49
V. Program Upload and Download

The software of PLC system can be uploaded to CUP or downloaded to CPU upper computer.

When replace the CPU or memory of CPU damaged, the following 2 methods can be used for

recovery: one method is insert the memory to the new CPU while no power, when power up,

the program will load to CPU automatically. The other method is to download the program

online by PLC. The encoder operation is in STEP7 Manual.

Upload and download program should be only done by professional.

Supplier’s authority is necessary if user means to modify the program.

VI. ET200M Remote Station

The hydraulic system is set on the body of the top drive drilling system, and the monkey
board control is optional , so there is only one remote station. With this design, the
communication fault can be reduced greatly . The remote station has 8 Code Switch used for
setting Profibus station address. There is a switch On the Profibus plug which can make the
terminal resistance In on or off state .for the last station the switch must be put on..

VII. Indicator on Interface Module

ET200SP The indicator light of the interface module shows the working status of the interface
module

50
51
VIII. Disassembly and installation of ET200SP and module, power

configuration and indication

To install the CPU / interface module, follow these steps:

(1) Install the CPU / interface module on the installation guide rail.
(2) Rotate the CPU / interface module backward until the rail rail button is locked.

Remove the CPU / interface module

CPU / interface module is wired and BaseUnit is installed on the right.

To remove the CPU / interface module, follow these steps:

(1) Turn off the power supply voltage of the CPU / interface module. On the CPU / interface
module, disconnect the 24 V DC power supply connector.
(2) Press the mounting rail button button on the first BaseUnit. At the same time, shift the CPU /
interface module to the left until the other modules in the module group.

Note: Install the rail button button above the CPU / interface module or

BaseUnit.

52
(3) Press the CPU / interface module out of the installation rail on the CPU / interface module.

To install the BaseUnit, follow these steps:

(1) Hang the BaseUnit hook on the mounting guide rail.
(2) State for BaseUnit backward until the sound of sticking in on the mounting guide.
(3) Pan the BaseUnit to the left until it is locked to the front CPU / interface module or BaseUnit.

To remove the BaseUnit, follow these steps:

(1) Cut off all power supply voltage on the ET 200SP distributed I / O system.
(2) Release the wiring on the BaseUnit (use the 3 to 3.5 mm screwdrivers).

Removing (from the right side):

53
Press the mounting rail button button on the relevant BaseUnit. Pan the BaseUnit to the right and
rotate the BaseUnit while pressing the mounting rail button button.

Removing (from the left side):

Press the mounting button on the relevant
BaseUnit and the BaseUnit on the right. Pan the
BaseUnit to the left and spin the BaseUnit out of
the mounting rail while pressing the mounting rail
off button.
Note: The installation guide button is located
above the BaseUnit

To remove the I / O module, follow these steps:

(1) Press the button buttons above and below the I / O module.
(2) Pull the I / O module parallel and forward out of the BaseUnit.

Change the type of the I / O module

The I / O module is now removed.

To change the type of an I / O module,

follow these steps:

(1) Use a screwdriver to remove the encoding
element of the BaseUnit.
(2) Insert the encoding element into the removed I /

54
 O module.
(3) Insert the new I / O module (other module types) into the BaseUnit until the lock-in sound is
heard.
(4) Label the I / O modules.
Each channel of the switch input / switch output module has an indicator light, and each channel has
an indicator light. The green light indicates that the corresponding channel is in the logical "1" state.
Analog input / analog output module, which was set to 0-10V input / 0-10V and 4-20 mA output.

55
IX. Communication system

CPU ROUTER ET200SP IPC VFD

DRILLER'S CONSOLE
ROUTER REMOTE I/O TOUCH
SCREEN

56
 Chapter V Main Motor Drive System

I. Main Motor and Frequency Convertor

The driving system of Top drive is a system that one frequency conversion transmission unit

drives one frequency conversion motor. The transmission unit mode is ACS880-0650。

II. Operation and Structure of Electric element Cabinet

1). Protection grade of Electric element cabinet is IP 21;

2). The composition of Electric element cabinet:

Fuse switch (switch/fuse);

Auxiliary circuit Fuse;

Inlet contactor;

EMC Filter cabinet with +E202;

Transmission control units (RDCU, RMIO); Frequency

convertormodule;

Internal braking carrier;

Profibus-DP adapter;

Pulse coder port;

Communication adapter.

3）. Operate switch and Emergency Button is controlled by

the fuse switch operating handle which is installed on the

swift door

57
III. Main Circuit and Control Circuit Sketch Plan

IV. Connection of Standard Control Line

3 programmable differential analog input:

1 voltage source signal

2 current source signal.

58
6 programmable digital input port

2 programmable analog input port

3 programmable relay input port

V. Extensive Characteristic of Standard Software Provide Protect

for Transform, Motor and Process

1). Environment Temperature

2). DC Overvoltage

3). DC Under voltage

4). Transform Temperature

5). Input default phase

6). Over current

7). Power Limiter

8). Short Circuit

9). Defensive Function of Programmable

VI. Adjustable Power Limiter

1). Control signal oversee;

2). Danger frequency step over;

3). Current and torque amplitude limiting;

4). ground fault protection;

5). EXTERNAL FAULT;

6). MOTOR Default phase;

7). Protection of locked-rotor;

8). Electric motor Over-temperature protection;

9). Electric motor under-load protection;

10). Control PANEL down.

59
 Chapter VI Installation, Commissioning and Maintenance

After carried to the well site, installing and commissioning are as follow. This manual mainly

provides general requirements and notices about electric system installing and

commissioning.

I. Electric installation and commissioning notices

Notices before installation

1). Before unload electrical system, mark the cables and joints, to benefit for reconnection

correctly.

2). Before confirm everything is OK, keep power off and hang ‘ Machine be working with, Do

not switch it on’ mark.

3). Generally, after installation finished completely and examined, then connect the power

cable, to ensure people and equipment safe.

4). Install worker must wear labor protection appliance.

5). While equipment unloading, confirm that power off, forbidden working while power on.

6). Wearing safety belt while working aloft, tools and spares should put into tool bag, in order

to prevent to drop off.

7). Forbidden working outside in high windy, thunderstorm or sleet weather.

8). Pay attention to pressure level and insulating property, select suitable protection.

9). Read the 《electric manual》 carefully, master electric theory and circuit diagram.

10). Electric controlling room is designed of non-explosion proof, therefore, around of room

should have not any flammability or explosive dangerous gas.

II. Electric system reinstallation

1). Turn off the main power switch, auxiliary transformer power switch 600v power and 380v

room coil in power switch before installing.

2). Electric controlling room should placement level and off the ground, to prevent water inlet

through floor.

60
3). In the position off the electric room cape on the cross 4m, knock in earth pole, earth

resistance should smaller than 4Ω.

4). Notice plug direction while fix the cable, first insert electric and relay box plug while

connect cable, then insert traveling cable and ground cable plug, last insert room plug.

5). All cable plug should screw down to prevent drop off or water inlet.

6).Measure insulativity of motor and cable before connect the cable to the electric controlling

room.

7). Examine cables before turn on the power.

8). Examine the element and strut of electric controlling room if where disrepair or get loose.

9). Check and confirm selection switch in original position.

III. Examination before power on

All cable connect right, element no disrepair, and 600v main power is preparing, the top drive

drilling system power can be turn on.

1). Check if the main power inlet cable is 600v±10%, turn on the main Power witch Q1.

2). Turn on the assistant transformer Q2 and assistant transformer coil in 1QF in PLC

composite controlling cabinet, or connect the inline switch 2QF in it.

3). Switch on PLC composite controlling cabinet and socket. If the air damp or temperature

high, it is needed to start air controlling system to dehumidify or reduce temperature.

4). Give power to all units from high level to low level switch.

5). Turn on the frequency convertor.

6). Turn on the power of supervisory system.

7). Start lubrication pump, hydraulic pump and cooling air-blower on driller panel, and check

them rotary direction and running state.

8). Check if the electric motor runs normally.

9). Check if assistant function works normally.

61
IV. Daily maintenance

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

necessary to maintenance, examine and go around regularly.

1). The most important is deducting and damp proof for electric system maintenance. After

a period of time deposited, deducting with cleaner then blow-dry with air-dryer before start

electric system. If needed, measure the insulating resistance ,ensure that when voltage

below 380v the insulating resistance above 1MΩ and when 600v the insulating resistance

above 5MΩ. According to working condition, clean dust regularly, if condensation appears,

stop the electric system and dehumidify.

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

loosen, plug connector should not drop.

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

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

5). Driller panel is explosion-proof of positive pressure system, and need provide air filter

and oil-water separator to confirm air dry and clean, not have explosive and flammable gas.

62
 Part IV Hydraulic Manual

Chapter I Safety Operation Specification

I Safety operation notification

Note This sign provides additional information on procedures involving

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

Caution This sign alerts the user to procedures involving a risk of personnel or
equipment damage.

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

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

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

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

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

equipment. Please give sufficient importance to these important advices.

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

hydraulic system should be finished by the qualified people with the corresponding

experience. Please read this manual and the related technical documents carefully before

operation.

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

well drilling operation, well drilling safe knowledge and using tool, and use proper protective

appliances.

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

63
equipped, so such knowledge should be collected, judged and used by operator. Strictly

forbid any maintaining, repairing and adjusting equipment in the course of top driven

operating. Strictly forbid any detecting unfamiliar parts. Please read and understand all

safety warning before maintaining and detecting.

II Electric system operation notification

The hydraulic system contains electric control loop and element. Before operating equipment

and its electrical system, please notice the following proceedings:

1) Read electric manual carefully, and acquaint electric circuit diagram and equipment

demand to power and voltage;

2) Using special instrument of electric operation, and affirm the instrument with suitable

stand voltage grade and eligible protection;

3) During any operation, make sure wearing right safety ware.

4) Please disconnect all power supply, and hang sign board “Machine be working with, Do not

switch it on” when carrying through all sorts of electric operation.

5) Before dismantling electric joint, please make out the mark to wire (cable) and connection

terminal to assure reconnect properly.

III Hydraulic system operation notification

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

proceedings:

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

and the structure, function and action of hydraulic component;

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

pressure in system pipeline and accumulator;

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

reconnection correctly;

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

64
machinery parts.

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

stiffness may not be sure.

6）System commissioning should be carried out before hydraulic control system running.

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

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

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

Before disconnecting hydraulic pipeline, please shut down valve in system, and prepare

suitable container, oil plug, cotton, silk and so on, in order to avoid the flow out of

residual hydraulic liquid in pipeline, which will pollute equipment and ambience.

The temperature of hydraulic equipment and hydraulic oil may be so high as to hurt

personal safety, which can reach the temperature approached by person only after a period of

time cooling.

When taking and putting components and parts, take care to avoid hurt certain accurate

fitting surface on it.

Before installing and maintaining hydraulic system equipment and so on, please cut off

the energy source of electric power, hydraulic oil and compressed air, and release the pressure

of all system accumulators.

Please lock main source of power correctly before greasing, detecting and replacing

components and parts except having special explain in this manual.

Please wear eye protector for avoiding the damage of the high pressure oil and other

risks to operators.

When system is operating, the temperature of hydraulic equipment and hydraulic oil may

65
 be very high, and please take care of protection.

Do not try to examine hydraulic oil leakiness with your hand. Please release pressure in

accumulator thoroughly before maintaining hydraulic system, and then operate it.

Before opening hydraulic system, please clean operating area thoroughly. Be sure to seal

the hydraulic pipeline unloaded in time. The dust is harmful to hydraulic system, and may

result in equipment operating malfunction and even personal injury.

Please check hydraulic system everyday to confirm whether pipe fittings is of leak;

hydraulic pose surface layer is of damage; pose is of snarl, split or harden; and pipe

fittings is of damage or abrasion or not. In Addition, when detecting, screwing down or

replacing any pipeline connection of leak, please clean away the dirt on hydraulic

components and parts in time.

Chapter II Hydraulic System Overview

Hydraulic drive system is important component of top driven system. Excepts main shaft
driven by main motor, other functions such as markup and breakout, link leaning and rotary,
IBOP open/close, main motor braking, main body weight balancing and so on are controlled
and realized by Hydraulic system.

The hydraulic system of DQ40BQ-JH top driven includes counterbalance system, braking

system, rotating link adaptor system, link leaning system, IBOP control system, hydraulic

elevator link, back up tong and so on, which is made up of the following parts:

1) Hydraulic source

2) Hydraulic valve block

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

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

4) Hydraulic pipe

5) Auxiliary

66
Hydraulic system main technical specifications are as follows:

Rated pressure 13.5 MPa

Rated flow 30 L/min

Power 380 VAC / 50 HZ

Electric motor power of oil pump 4 Kw

Volume of oil tank 53 L

Control voltage of magnet valve DC24 V

Explosion-proof grade EXdIIcT4

System medium cleanliness Level 7（NAS1638）; 16/13 (ISO4406)

Filter fineness: Suck fineness 100um ;

Press fineness: 10um ;

Lubricate fineness 60um

I Hydraulic System Structure and Working Principle

1. Hydraulic source
Hydraulic source consists of oil tank, oil pump motor, etc, which supplies hydraulic power for

the system. The oil tank and pump unit are both installed on the top drive system body, with

this design there are several advantage: energy saving, fast installation, short pipe, rapid

response of actuator element.

2. Oil tank
The oil tank is made of stainless steel, volume is 53L; in addition to storing hydraulic oil, it

also has the functions of dissipating some heat produced in system operation, separating gas

and sediment in oil.

Oil surface of the tank should connect with atmosphere. An air filter is set on the tank in to

reduce oil pollution. When working, pay attention to cleaning and replacement of filter.

The oil level gauge and oil thermograph are set at the side of tank, so as to check the oil level

and temperature conveniently.

3. Pump unit
Main specifications of Explosion-proof Motor (produced by ABB)

67
Type ： M2JAX112M4A

Explosion-proof grade： (ExdⅡcT4)

Rated power： 4kW

Rated speed： 1450r/min

Pressure limited variable flow ram pump: A16-F-R-01-H-S-K-32

Work condition and parameter describe:

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

pump output with a lower speed.

B. The pressure adjustment feature of pump: When the system pressure increases, close to

the pump preset pressure, pump flow automatically decrease, but keep the pressure of pump,

the presetting pressure can be adjusted manually. This pump unit can reduce the overall

heating system, and effectively reduce the power consumption.

2×4-M10 Depth 19
Decrease Pressure Increase
Outlet?32 Flow adjust blot
Oil Drain Port Rc12" Pressure adjusting bolt
Locking nut
Max 247 202
S17
178.5 59 86 86
30
22.23 -0.03
25.01 -0.16
112

32
101.6 -0.05 -
202

58.7

30.2

Inlet
6.35 +0.03
0

Outlet

4. Check valve
A tubing check valve is set at the output of pump CIT-03-04-50 (product of Japanese YUKEN).

68
The valve’s main function is protecting the pump that when load adding caused the system

pressure rapidly increasing.

2-Rc3/8"

Outlet Inlet

FREE YUKEN
CIT-03-04-50

76
27

5. Air Filter
Air Filter is installed on the upper oil tank cover.

Main function:
Exchange air so that keep balance with atmosphere.

6. High Pressure oil filter

Main specifications of pressure oil filter:
Model：ZU-H63X10
Normal flow rate ：63L/min
Filter fineness：10µm

Oil pressure filter is set at the outlet of the pump, which is mounted the
high pressure pipeline. The filter is used to remove the mechanical impurity and pectin
caused by chemical reaction , so as to prevent to block the control valve inside hydraulic
valve and wear out of hydraulic element.
Please note: the filter is a very elaborate element , so we suggest to change the
dirty filter with the new one . just cleaning job is not recommend

69
7. Liquid Indicator and Thermometer

Direct reading type liquid indicator and thermometer is set

at the side of the oil tank, and the level and temperature

of the oil tank can be read out directly.

Model： YWZ-80

8. Air cooler

The oil temperature of hydraulic system allows no more

than 75℃, when over 35℃, air cooler can be used to cool

the hydraulic oil. The cooler should be clean regularly to

remove the dust on surface.

9. hydraulic oil level guage

Model: UHK-30-200Bd explosion proof floating level controller
Explosion-proof sign：ExdIICT3-T6

Liquid level controller is mounted at the bottom of oil tank by

screw thread. The oil level and temperature can be seen freely,
and alarm signal will appear when the level is too low or the oil
temperature is too high.

10. Cooling of oil tank

The system for cooling the oil tank use the wind produced by main motor blower, but not

separate air blower. A cooling plate unit is set at the inlet of the main motor blower, and when

the hydraulic oil flow through the unit to the oil tank, the heat loss. This design also saves

energy.

70
II Hydraulic valve Block

The control valve block is cartridge integrated valve block, and it is composed of

explore-proof magnetic exchange valve, reducing valve, hydraulic control one-way valve,

relief valve, check valve, etc. The main function is controlling the action sequence, force and

speed of the action element.

1. Hydraulic system schematic diagram and element list

COUNTERBALANCE ROTATING LINK ADAPTOR BACKUP TONG HYDRAULIC ELEVATOR LINK TILT IBOP
MOTOR BRAKES
DRAIN LINE
ELEVATOR
CLAMP CLOSE OPEN
14 PRECHARGE PRESSURE
9 to 10 MPa A B
UNCLAMP G11 G11
6.1 6.2 6.3 6.4
G12 G12
Φ4BREATHER Φ4BREATHER G7 G8 SPARE
M18×1.5 FLOW M18×1.5 M18×1.5
DIVIDER
G7 G8
G5 STATIONARY G6 G9 FLOW DIVIDER G10
STATIONARY
G5 SHAFT G6
SHAFT
G7 ROTATING G8 LINK TILT FLOAT POSITION G9 ROTATING LINK G10
LINK
G7 ADAPTOR G8 SPARE G9 ADAPTOR G10 G11 G12
CABLE ID BRAKES CABLE ID CABLE ID CABLE ID CABLE ID
1.1 ENGAGE 13 1.2 2.1 2.2
CABLE ID CABLE ID CABLE ID CABLE ID CABLE ID
PRECHARGE PRESSURE 3.1 4 3.2 9
8 to 9 MPa
A A A B A B
F11 F13
F03 F04 F09 F10
a

a
b

A B A B A B A B
a

a
b

P T P T P T P T
ab
o

b
a

G1′ G1 T1 XP G2′ G2 G3 G4 G5 G6 F05 F06 F12 F12 F08 F07 F02 F01

a
b
a

a
b

b
a
a

a
b
b

b
M18×1.5 M14×1.5 M18×1.5 M18×1.5 M18×1.5 M14×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5 P T P T P T P T
G7 G8 G9 G10 G11 G12
ORIFICE M18×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5
11.3 11.4 12.1 1.3mm 10
7
② ③ ③
11.7 ②
① 11.5 11.6 11.8
MP1 12.2 MP2 8.1 8.4 ① ② ①
M14×1.5 M14×1.5
② 15.5 MPa 12.5 MPa MP10
① ① MP8 MP9 M14×1.5 MP12
M14×1.5 M14×1.5 M14×1.5
①
5.1 ② ② 5.3 8.2 8.3 5.4
① 8 MPa ① 6 MPa
① 5.2 11.1 11.2 PRESET PRESSURE: ① 11.5 MPa ① 11.5 MPa
11.5 MPa ③
M14×1.5 M14×1.5 8 MPA(ADJUSTABLE) ③
③ ① 13.5MPa MPP MPT ② ②
② ②
P ② ③ P
SYSTEM M22×1.5 M22×1.5
PRESSURE 13.5MPa ② 13.5MPa

T T
RETURN LINE M22×1.5 M22×1.5

16 15
HYDRAULIC MANIFOLD
HYDRAULIC MANIFOLD
17

<ELECTRIC MOTOR>
PUMP DISPLACEMENT POWER: 4 KW
25 CC/REV
SPEED: 1447 RPM
VOLTAGE: 380 V (THREE PHASE)
FREQUENCY: 50 HZ
CURRENT: 8.9 A

DQ40BQⅡ-JH Top Drive Auxiliary Hydraulic Control Valve Group Diagram

2. Distribution of oiling port on valve block

71
 P： oil input port T： oil return port

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

4 pieces of installing screw: M16

BASPM22 BASPM22
MVSPM22 MVSPM22
MPT MP8
Counter Balance overfall Tilt cylinder overfall
-Lower pressure -Rodless chamber

MVSPM22 MVSPM22
Brake decompression IBOP overfall

MP1 MPP BASPM22 RNSPM22

PC10-30
MP2 Counter Balance decompression Hydraulic Elevator decompression

BASPM22
IBOP Lock Valve
Backup Tong Lock Valve
Tilt cylinder
overfall

MP10 MP12
-Rod chamber
Counter Balance overfall-Long pressure MP9

T1：Braking cylinder exclusive oil return port. (Reserved)

G1: Braking cylinder MP1: pressure testing point on cylinder

G2: Balance cylinder MP2: pressure testing point on Balance cylinder

G3： Rotating Link Adaptor

G4： Rotating Link Adaptor

G5： Rodless chamber of Back up tong cylinder

72
 G6： Rod chamber of Back up tong cylinder

G7： Rod chamber of hydraulic elevator

G8： Rodless chamber of hydraulic elevator MP8： Pressure Testing Point in Rodless

chamber of hydraulic elevator

G9: Rod chamber of sloping cylinder MP9: Pressure Testing Point in Rod chamber of

sloping cylinder

G10 ： Rodless chamber of sloping cylinder MP10: Pressure Testing Point in Rodless

chamber of sloping cylinder

G11: Rod chamber of IBOP cylinder

G12: Rodless chamber of IBOP cylinder

MP12: Testing point in Rodless chamber of IBOP cylinder

III Control Loop on Hydraulic valve block

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

1. Braking cylinder control loop MOTOR BRAKES

The brake cylinder is a spring-returned single-acting cylinder,
and a group of brake has 4 cylinders. The pressure required for
the brake cylinder is lower than the system pressure, so a
pressure reducing valve is provided in the circuit, which is set
at 11.5 MPa at the factory (this pressure can be measured at CABLE ID BRAKES
1.1 ENGAGE 13
PRECHARGE PRESSURE
the MP1 Pressure measuring port). Different pressures can be A
8 to 9 MPa
F11

set according to different situations. To make the brake cylinder G1′ G1

P T
T1 XP
M18×1.5 M14×1.5 M18×1.5 M18×1.5

work safe and reliable, we choose a non-leakage 11.3

electromagnetic ball valve as the directional control valve, and MP1 12.2
M14×1.5
②
added a check valve for holding pressure at the P port and an ①
5.1
accumulator at the cylinder port to ensure that the brakes are
①
11.5 MPa
not loose during the braking process. When the brake is ③
P ②
SYSTEM M22×1.5
released, sometimes remaining pressure may cause the brake PRESSURE 13.5MPa
T
RETURN LINE M22×1.5
to be accidentally braked. Therefore, we will separately
connect the oil return port of the brake cylinder to the oil tank to
ensure no remaining pressure.

73
2. Counterbalance System Control Loop
The main function of the balance system is to balance the weight of the body. Its function is
equivalent to the hook compensation spring, and it can protect drilling pipe connections
when breaking connection. In the balance system, we set the pressure of 3 levels: the
system pressure is 13.5MPa, the secondary pressure is 12.5MPa (the actual adjustment may
be different), the safety pressure is 15.5MPa, and secondary pressure can be switched on by
activating the electromagnetic ball.

The balance system has high pressure-holding requirements. We use following 3 methods to ensure that:
accumulator, non-leakage electromagnetic ball valve, and P-port check valve. In the initial installation,
we can use the supplied hoses to connect the MPT and MP2 ports, so that the cylinders can be relieved.

Accumulator is a pressure vessel, please pay attention to safety when using, first of all, we
should use a special nitrogen punching tool for punching, punching tools for the accumulator,
exhaust, measurement and dressing the punching pressure. Accumulator can only charge
nitrogen, not other gases, in this circuit, the role of accumulator is buffer, shock absorption
and pressure retaining function. Connect pressure gauge YYB-1 at hydraulic valve set MP2.

1. Turn the hydraulic pump knob of driller's operating table to "start".

2. Press the balance upward jump button to observe whether the top drive has upward jump
and confirm the value of the pressure gauge.

If the balance cylinder does not move, loosen the locking nut of the pressure relief valve 5.2
and adjust the pressure relief valve clockwise or counterclockwise using an inner six-square
wrench. (Clockwise rotation increases pressure, counterclockwise decreases pressure.)

1. Observe that the value of the pressure gauge reaches 13.5MPa, and the top drive has been
run up.

2. Stop adjusting and lock the fixing nut.

3. Loosen the lock nut of relief valve 8.4 and adjust counterclockwise to the maximum to
make the valve work at the maximum pressure.

4. After 1 minute of balancing, observe the pressure gauge.

74
5. Adjust the relief valve 8.4 clockwise until the top drive begins to fall and the value of the
pressure gauge is 12.5.

6. Then turn it 1/8 turn clockwise to tighten the fixing nut. Adjustment completed.

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

COUNTERBALANCE

14 PRECHARGE PRESSURE
9 to 10 MPa

Φ4BREATHER Φ4BREATHER

CABLE ID
1.2

A
F13
P T
G2′ G2
M18×1.5 M14×1.5 M18×1.5

11.4 12.1
②

MP2 8.1 ① 8.4

M14×1.5
15.5 MPa 12.5 MPa
① ①

② ②

5.2 11.1 11.2

M14×1.5 M14×1.5
① 13.5MPa MPP MPT
P ③
SYSTEM M22×1.5
②
PRESSURE 13.5MPa
T
RETURN LINE M22×1.5

3. Rotating link adaptor control loop

Rotating link adaptor loop adopts a hydraulic motor. Although the loop uses the system
pressure, a fixed damp installed on the P port is used to control the pressure and speed of oil
motor. This design completes the function of this control loop by saving the adjustment
process.

75
4. Backup tong device control loop

Backup tong uses the system pressure, the hydraulic one-way valve keeps the slip on any

position (when the 2 electromagnets of changing valve lose power). It is mainly used to

protect tong dies from crashing while drilling.

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

ROTATING LINK ADAPTOR BACKUP TONG

DRAIN LINE
CLAMP

A B
UNCLAMP

G5 STATIONARY G6
G5 SHAFT G6

CABLE ID CABLE ID CABLE ID CABLE ID

2.1 2.2

A B A B

F03 F04 F09 F10

a
b

a
b
a

a
b

P T P T
G3 G4 G5 G6
M18×1.5 M18×1.5 M18×1.5
ORIFICE
1.3mm 10

③
① ②

P P
SYSTEM M22×1.5 SYSTEM M22×1.5
PRESSURE 13.5MPa PRESSURE 13.5MPa

T T
RETURN LINE M22×1.5 RETURN LINE M22×1.5

5. Hydraulic elevator control circuit

The pressure required for the hydraulic elevator cylinder is lower than the system pressure, so the
pressure reducing valve is set in the circuit, which is set at 8 MPa at the factory (this

pressure can be measured at the MP8 pressure measuring port). The pressure can be set differently
according to different conditions.

76
The hydraulic elevator circuit Adjustment: Connect the pressure gauge YYB-1 at the hydraulic valve
block MP8, observe the reading of the pressure gauge, and the pressure value should be 8 MPa. If it is
greater than or less than 8MPa, please adjust the hydraulic elevator oil pressure by following the steps
below:
1. Turn the drill pump hydraulic pump switch to the "start" position.
2. Turn the hydraulic elevator switch to "off" position.
3. Loosen the lock nut of the decompression relief valve 5.3 and use the inner hexagon wrench to adjust
the decompression relief valve clockwise or counterclockwise. (Turn clockwise to increase pressure and
counterclockwise to reduce pressure).
4. Observe the pressure gauge. And stop turning and lock the retaining nut when the set value is
reached. The adjustment is completed.

HYDRAULIC ELEVATOR

ELEVATOR

G7 G8 SPARE
M18×1.5 FLOW M18×1.5 M18×1.5
DIVIDER
G7 G8

G7 ROTATING G8
LINK
G7 ADAPTOR G8 SPARE

Cable ID Cable ID
3.1

A B

F05 F06
a
b

a
b

P T
G7 G8
M18×1.5 M18×1.5

11.5

MP8
M14×1.5

5.3
① 8 MPa
PRESET PRESSURE:
8 MPA(ADJUSTABLE) ③
②
P
SYSTEM M22×1.5
PRESSURE 13.5MPa
T
RETURN LINE M22×1.5

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

77
6. IBOP Control Loop

The pressure required for the IBOP cylinder is lower than the system pressure, so the pressure reducing
valve is set in the circuit. It is set at 6 MPa at the factory (this pressure can be measured at the MP12
pressure measuring port). Different pressure values can be set according to different conditions. . The
directional control valve in this circuit is M type. When the auxiliary circuit is not working, the valve is in
the neutral position, and the entire auxiliary system is relieved. It should be noted that this directional
control valve must be activated when any cylinder in the auxiliary circuit works. Otherwise the system
pressure is relieved. The function of the hydraulic controlled check valve in the circuit is to lock the
cylinder rod position and prevent the cylinder from sliding down).

IBOP

CLOSE OPEN

G11 G11
G12 G12

STATIONARY

SHAFT
G11 G12

Cable ID Cable ID
9

A B
F02 F01
a
b

a
b

P T
G11 G12
M18×1.5 M18×1.5

7
③
②
① 11.8

MP12
M14×1.5

5.4
① 6 MPa
③
②
P
SYSTEM M22×1.5
PRESSURE 13.5MPa

T
RETURN LINE M22×1.5

BOP control circuit adjustment: Connect the pressure gauge YYB-1 to the hydraulic valve block MP12
and observe the pressure gauge reading. The pressure value is 6 MPa. If it is greater than or less than
6MPa, please adjust the pressure by following the steps below:
1. Turn the hydraulic pump switch of the driller's console to the "start" state.
2. Turn the IBOP switch is in the "off" position

78
3. Loosen the lock nut of the decompression relief valve 5.4 and use the inner hexagon wrench to adjust
decompression relief valve clockwise or counterclockwise. (Turn clockwise to increases pressure and
counterclockwise to reduce pressure).
4. Observe the pressure gauge and stop turning and lock the retaining nut when the set value is reached.
The adjustment is completed.

7. Leaning device control loop LINK TILT

The link tilt control circuit uses the system pressure.
When the O-type explosion-proof directional control
6.1 6.2 6.3 6.4
valve is in the neutral position, the cylinders and link
attached to it can be stopped at any position in a short G9 FLOW DIVIDER G10

LINK TILT FLOAT POSITION G9 ROTATING LINK G10

time. The function of the two relief valves is as follows. G9 ADAPTOR G10

When accident occurs (such as link arm hitting a heavy CABLE ID

4
CABLE ID
3.2
CABLE ID

object), the valve is activated to ensure that the link arm A B A B

ab
o

b
a
F12 F12 F08 F07

a
b

a
b
P T P T
is not bent over. When the two electromagnets of the G9
M18×1.5
G10
M18×1.5

explosion-proof electromagnetic lock valve are

11.7
11.6
energized, the links and elevator are always in a free MP10
MP9 M14×1.5
M14×1.5

state during the drilling process to prevent the elevator 8.2 8.3

from being worn. ① 11.5 MPa ① 11.5 MPa

② ②
P
SYSTEM M22×1.5
PRESSURE 13.5MPa
Link Tilt control pressure adjustment: T
RETURN LINE M22×1.5

Connect the pressure gauge YYB-1 to the hydraulic

valve block MP10 ( MP9 for backward moving pressure)
and observe the pressure gauge reading. The pressure value is 11.5 MPa. If it is greater than or less
than 11.5MPa, please adjust the circuit pressure as follows:
1. Turn the hydraulic pump switch of the driller's console to the "start" state.
2. Turn link tilt switch to “forward” postion (when adjusting backward circuit pressure, turn to backwards
position) and keep it.
3. Loosen the lock nut of the relief valve 8.3 (8.2 for backward) and use the inner hexagon wrench to
adjust the relief valve clockwise or counterclockwise. (Turn clockwise to increase pressure and
counterclockwise to reduce pressure)
4. Observe the pressure gauge and stop turning and lock the fixing nut when the set value is 11.5 MPa.
The adjustment is completed.

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

79
 Chapter III Hydraulic oil

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

I Selection of hydraulic oil

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

Recommend hydraulic oil and specialized temperature

Hydraulic oil

Specialized temperature range

Manufacturer
-35℃to -7℃ -6℃ to 20℃ 21℃to 55℃

ISO Viscosity Grade 10 32 46

Mobil Mobil Mobil
Mobil
DTE21 DTE24 DTE25

II Hydraulic oil Changing

1. Change the hydraulic oil following the principles below:

a. Change the hydraulic oil after 3 months for the first use of the new system.

b. In normally using period, recommend to change the oil in 6 months.

c. Change the oil according to the analyzing result or experiences.

2. Feed or change hydraulic oil should notify the following items.

a. According the stipulation to change the hydraulic oil, the feeding oil must be same to

the precious oil brand and grade.

b. While feeding, oil must through a filter cart which filter accuracy is 20um, feed oil

80
through oil feeding port, and keep clean of each parts.

c. Quantity in oil tank: First time feeding, oil should fill full tank (observe oil mark on the

tank). Re-feeding oil to top limit of oil mark after the pipes and cylinder fed oil when the

test-running finished.

Oil flowed from drum to the tank directly is forbidden, Forbid to mix oil in
different brands or grades.

Chapter IV Hydraulic system Commissioning and Maintenance

I System pressure adjSystem pressure adjustment

1. Connect the 0-25MPa pressure gauge to the MPP point of the hydraulic valve block. The MPP point is
the pressure measuring point of the system pressure.
2. Operate [hydraulic pump] control switch on the driller's console, turn it to the starting position to start
the hydraulic pump.

Without starting the other device, start the hydraulic pump motor to check
the motor running direction.

3. Operate the IBOP control switch, turn the switch between opening and closing the positions, and
check the pressure value of the pressure gauge to check that the system pressure value is 13.5Mpa
when the hydraulic pump is running.
4. The bolt on the oil pump outlet side is for pressure adjustment, and loosen the lock nut to adjust
pressure bolt (Rotate the bolt clockwise to increase the system pressure and counterclockwise to reduce
the system pressure)
5. If the system pressure value is higher than the required system pressure value when the hydraulic
pump is running, the system pressure needs to be reduced.
Operate the IBOP control switch, turn the switch between opening and closing the positions, and check
the pressure value of the pressure gauge. Turn the pressure-adjusting bolt counterclockwise until the
pressure gauge shows 13.5MPa. Stop rotating the pressure-adjusting bolt and lock the lock nut.

81
6. If the system pressure value when the hydraulic pump is running is lower than the required system
pressure value, the system pressure needs to be increased.
Operate the IBOP control switch, turn the switch between opening and closing the positions, and
observe the pressure value of the pressure gauge. Rotate the pressure regulating bolt clockwise until the
pressure gauge shows 13.5MPa. Stop rotating the pressure regulating bolt. Then lock the lock nut.

If the pressure gauge shows that the system pressure is zero, you need to
turn the IBOP control switch again.

IIHydraulic system pressure setting and commissioning

1) pressure setting for cylinders of the system
 The Link tilt cylinder is a double-acting cylinder and its pressure supplied by the pump source.
 The brake cylinder is a single-acting cylinder and its pressure is adjusted by the Decompression
relief valve to acquire the required steady pressure value.
 the hydraulic motor pressure of rotary head circuit is adjusted by Decompression relief valve to
acquire the required stable pressure value.
 The backup clamp cylinder is a double-acting cylinder and its pressure is adjusted by the
Decompression relief valve to acquire the required pressure value.
 The IBOP cylinder is a double-acting cylinder and its pressure is adjusted by Decompression relief
valve to acquire the required stable pressure value.
 The balance cylinder is a single-acting cylinder and its pressure is adjusted by the pressure
reduction valve. An accumulator is connected to the balance cylinder to keep the pressure of the
balance cylinder stable. In order to prevent the accumulator from being overfilled with high pressure,
an additional relief valve is added to the circuit to limit the pressure in the circuit.

82
III Hydraulic system daily maintenance requirement

1) Daily inspect Items

Inspect the hydraulic source, the items include:

(1) Check the level of oil, oil level could not be lower than the middle line in the gauge.
(2) Check the pump if there is vibration, noise or overheat.
(3) Inspect the system pipe leakage.

2) Regular inspect (every 3 months)

(1) Fasten the bolts on motor.
(2) Inspect the air pressure of accumulator.
(3) Inspect the heat exchange capacity of air radiator, oil temperature at inlet should be higher than
outlet’s.
(4) Inspect and clean the air filter.
3) Braking device maintenance
1. Inspecting
1) Wear of pad on Brake unit
2) wear on the pad is Symmetrical or not
3) leakage of the brake hose.
2. Exhaust of brake loop
1) Put Press on the braking system
2) Open the cover on the top of hydraulic brake , discharge the air then cover it again.
3) Same Operation to other brake cylinder.

83
 Part V Installation and Commissioning Manual

Chapter I Safety Operation Specification

I Safety operation notice

In order to avoid personal injury or equipment damage while the installation and

disassembly of the top drive drilling system, this manual including “warning”, “caution” and

“note” three level of information.

Note This sign provides additional information on procedures involving

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

Caution This sign alerts the user to procedures involving a risk of personnel
or equipment damage.

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

The top drive drilling system should be installed and tested by the qualified operator

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

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

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

When the system is running, do not touch the rotating parts of the device, avoid to get a

badly hurt of person or get damage of the device.

Before installation and maintenance of the hydraulic system, cut off the power supply,

close the valve and release the pressure of accumulator.

In the installation, dismantle and maintenance process, the power switch must keep

“off” status and hang mark plate of “Machine be working with, Do not switch it on”.

84
 Before install and dismantle the electricity connection, the operator must mark the

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

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

helmet, etc.

This manual only includes the basic safety knowledge which operator should know,

other knowledge should be collected, judged by the operator.

All the installation work should meet the requirements of the related standards and

specifications inside this manual, and should be confirmed by the installation technology

personnel and safety personnel.

Before operating the electric system, the operator should read the <electrical manual>

to get a well known of the electric circuit diagram.

Before operating the hydraulic system, the operator should read the <hydraulic

manual> to get a well known of the hydraulic system principle.

Chapter II Installing preparation

1. Before installing the top drive drilling system, the relevant personnel should inspect the
working site and make the installation plan jointly

2. the working people should check all the equipment according to the packing list, confirm
that all the devices, accessories and installation tools are in place and in a good condition
3. The technical staff and safety staff should arrange a technical discussion to ensure that
everyone who participates in the installation knows the installation plan and safety measure.
Make a detailed working schemes and layout . the follow is our recommended working
schemes..

85
Installation reference table

Item Device needed Staff Working time

Arrangement of electric
control house, driller’s truck crane (over 30
3-5 persons 2 hours
panel, the body and tons)
guide beam
pneumatic winch,
Hanging of the main
truck crane(over 50 5-7 persons 4 hours
body and guide beam
tons)
Centering and
2-3 persons 1 hour
connecting the wires
Drilling rig and
System commissioning 1 hour
auxiliary devices

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

2. The working time is not fixed, it will change because of the different
conditions at rig site.
3. Training time is different ,depending on the situation of the operator, but
the total training time is no less than 16 hours.

4. layout at rig site

Before installing the top drive drilling system, please consider layout at the rig site
carefully including:
1) the placement of the control cabinet

The ground where the control house placed must be flat.

2) Put the electrical control house, rig cable box on the left back of the drilling
platform.

3) According to the layout of the well field, put the top drive drilling system main body

(with transport frame), guide beam (with transport frame) and moveable cable box on the

place which is convenient to install.

When unloading all the stuff, place guide beam, main body, cable box and
installation accessories in the right place for the easy hoisting .try to avoid

86
the repeated operation ,saving the installment time.
4) Measure the derrick beam for installation of anti-torque beam , according to the width of
the derrick beam, weld " sliding block" beneath anti-torque beam
5. Remove the anti-collision device to let the traveling block move up to the crown .

Top Drive well field facade layout

87
 Chapter III Installation

Procedure of Top drive Installation

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

Adjust the guide beam adjusting unit

Set up the Sliding-insert folding type guide beam

Set up the anti-torque beam

Set up the main body of the top drive drilling system

Set up the cables

Set up the auxiliary devices

Testing and commissioning the system

88
I. Installing the guide beam

1.According to mast situation, the lifting lug of the guide beam should be installed on the top

of rig for first time. Take care of the direction when welding. The material of the lifting lug is

Q345B.

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

The welding staff must be qualified the welder test.

89
 2. Determine the installation length of the guide rail adjustment plate based on the
height of the wellhead, install the suspension guide rail chain, and thread a safety pin at the
end of the connecting pin.

3.Release the overhead crane anti-collision rope to facilitate the lifting of the guide rail to the
top and docking with the adjustment plate.

4.Installation workers climb to the overhead crane to assist in guiding and operating the
installation process of the guide rail and the main body

90
5. Use a crane to lift the guide rail onto the drilling platform and place it below the large hook
of the traveling block in a suitable position for the installation of the guide rail.

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

91
7. Use the randomly equipped U-shaped ring to connect the chain to the guide rail
adjustment pull plate and thread a safety pin.

92
8. Remove the guide rail transport frame.
9. Lower the traveling block and install the trolley to move downwards, so that the guide rail
adjustment component can bear the weight of the guide rail. At this point, the guide rail
slides downwards using its own gravity, and the joint of the guide rail extends and retracts
inside the guide rail, causing all the guide rails to connect in a straight line.

Install State
5thGuide

Vertical

2nd, 3rd, 4th Guide Beam

1st Guide

93
10. After the guide beam gets vertical, measure the guide beam safe distance (The distance
from guide beam bottom to the drilling floor is 2-2.2m)

Lifting Lock
Wire rope

This State is dangerous

11. Install the reverse torque crossbeam. Use randomly equipped double headed bolts and

pressure plates to fix the anti torque crossbeam on the mast.

derrick

Reverse torque
crossbeam

94
12. Install the reactive torque beam of guide beam. First, connecting the anti-torque base

with crossbeam of derrick, then connect the reverse torque frame with bottom guide beam

by anchored pin, insert pins. (The connecting bolt is not fixed temporarily for

adjusting wellhead center in next step)

Reactive Torque
Base
Tong Arrester

13. Adjust the flexible distance of reactive torque through guide screw. Preset the center of

guide beam to the center distance of installed guide beam.

Rotate the guide screw in CW

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

95
II. Installation of Top Drive Main Body

Chart of top drive main body and transport frame hoist.

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

96
2. Lower the hook to proper height. Connect the 3 points (2 points on the transport frame, 1

point on bail) with hook by the supplied wire rope. Lift the 2 points on the bottom of transport

frame by crane.

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

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

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

97
4. Dismount the locating pin on bottom guide beam, regulate guide screw on it, ensure

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

Please strictly follow the instructions on the operation sign and keep your feet away from the

bottom of the transport frame guide rail.

The adjustment distance between the transport frame guide rail and the bottom guide rail

shall not exceed the position marked by the scale (if the distance is greater than 300mm,

there is a risk of falling of the bottom moving guide rail).

98
 5. Dismount the pulley of guide beam block, disconnect the transport frame and top
drive.

Locating pin

6. Connect travelling block with lift ring,rising travelling block slowly.

99
7. Regulate guide screw on the bottom guide beam, get the bottom guide beam back. Fix the
locating pin and insert pins.

Adjust Screw

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

same line. Fix all the bolts, insert pins.

Rotate guide screw in CW and CCW, adjust the center of

guide beam to the center distance of installed guide beam.

100
 All connects must be fixed, reliable and safe.

9. Observe top drive slipping condition while moving up and down in the movement scope.

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

10. If the top drive slides up and down without problem, then connect the crane anti-collision

limit device.

101
III. Cable installation

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

2. Check the tightness of the cable and the saddle type mobile cable hanger, whether there

is any looseness, and whether the clamp plate is tightened. Use an air winch to lift the saddle

type mobile cable hanger onto the well frame (refer to the layout plan of the well site), fix it

firmly, and remove the cable box. The total length of the mobile cable is 53 meters, and the

ground cable is 26 meters. The cable hanger is installed 17-18 meters away from the drilling

platform.

102
3. After fixing the cable, connect it to the ground cable and then connect it to the electrical

control room.

4. Connect the other end of the cable to the top drive body.

All cables are connected by quick connector, Marks on the joint (label and
color), align the mark before connection

Connection must be safe and reliable.

Keep the cable properly when ground cable Is a spare

IV Auxiliary Device Installation

After finishing installation of guide beam, Top Drive System, and cable, distribute

personnel to start the following install at the same time.

1. Install the elevator link on Top Drive body.

2. attach the trip power cable, auxiliary power cable, comprehensive control cable to top
drive body (Distinguish from color).
3. Install mjud hose (position according to the well site layout)
4. Install electrical control house, hit the ground bar into the earth at the diagonal corner of
the control cabinet .connect the ground bar with the control house by the cable .

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

5,put the driller console on the rig floor ,at the right place .

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

cable (4 core A: / 4 core B).

All cables are connected by push fit, Marks on the joint of plug and jack.

7. Connect air pipes, adjust input air pressure, ensures the air pressure on driller panel is

lower than 0.2Mpa, higher than 0.12 Mpa.

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

103
 Hydraulic oil inlet

Lubricate oil inlet

9. Connect main 600V power cable and 380V auxiliary cable that go between the generator

and the control cabinet .

104
 Chapter IV Inspect after installation

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

installation is correct, all the transport and fixing device has been removed, each part are

ready for test-running.

2. Inspection should be carried out by technical supervisor of Top Drive installation.

3. Installation should be carried out according to

Attachment I < Top Drive System Installation Line Connecting Inspect list >,

Attachment II <Top Drive System Installation Inspecting list>.

4. Inspecting procedure and methods refer to <Operating Manual>.

Inspection must be carried out by professional operator.

105
 Chapter V Test Running

I Electric Device commissioning

1. Switch on the main power switch.

2. Power on the auxiliary transformer switch in power cabinet and the auxiliary transformer
switch in PLC cabinet or choose to switch on the auxiliary power from the generator .
3. After power on , Check the Phase sequence Relay in PLC cabinet . If the phase sequence is
correct, the indicator relay is not on , otherwise, the light on. For 600V Power , it doesn’t
needs to re-adjust the phrase sequence. For the power system supplied by 600V and 380V,
adjust the sequence of 380V only, you can proceed you job until the sequence relay is off
that means the power sequence is right.

Operator must ensure the phase sequence is correct before operation,

otherwise some electrical elements might be at the risk of being damaged

4. While the temperature is higher than 40℃ and wetness is higher than 95% or has

condensation, start air conditioner to remove dampness or lower temperature.

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

106
 Top Drive System Power Supply Drawing

400VAC/50Hz

MAIN POWER Q1

VFD

A B C D
1 Q1 Main Power QF10 Wave Filter
Main Transformer
2 1QF QF12 Wave Filter Backup Power
3QF Outgoing Power (400V)
3 2QF House Power Input(400V) QF13 Power (Auxiliary Motors)
Main Transformer
4 3QF QF14 24V Rectifier
Outgoing Power (220V)
5 QF1 Blower Motor QF15 Temp/Humidity Control
QF1 QF2 QF3 QF4 QF5 QF6 QF7 QF17 QF8 QF10 QF12 QF16 QF18
6 QF2 Hydraulic Pump Motor QF16 In-Cabinet Outlet
7 QF3 Lube Pump Motor QF18 Motor Heating
8 QF4 A/C Unit #1 QF19 24V Power
9 QF5 A/C Unit #2 QF21 Control Power
10 QF6 Brake Resistor Blower QF22 Driller’s Console
11 QF7 Transformer Blower QF23 Solenoid Valves
12 QF17 Light Fixture QF24 Top Drive Sensors

13 QF8 Wall Outlet QF25 Industrial PC

14
15

6. Start the lubricate pump, hydraulic pump and cooling air-blower on driller panel, inspect

rotating direction and running condition.

7. The pressure of hydraulic system is already set before delivery. Operator on site is not

allowed to adjust it. In special condition, adjust operator must be professional personnel who

is familiar with the principle of top drive hydraulic system.

8. Start the main motor, check the running condition. Operating procedure refers to

<Operate Manual>

To ensure the safe operation of the top drive system, the power supply voltage of the

top drive must match the set voltage of the top drive frequency converter. It is

necessary to adjust the parameter settings of the power supply voltage of the frequency

converter (parameter 95.01) based on the actual power supply situation at the well site to

107
ensure the normal operation of the frequency converter. The power supply voltage of the

frequency converter (parameter 95.01) can be set to the range of 525V-600V or 660V-690V

according to the actual situation. The power supply voltage of the Jinghong top drive inverter

(parameter 95.01) is set to 525V-600V at the factory.

II Auxiliary Function Test Running

Start the hydraulic pump, rotate the rotary knobs on driller panel, test its auxiliary function.

1. Inspect rotating link adaptor rotate CW and CCW condition.

2. Check whether the link move forward, backward and middle correctly.

3. Check whether the Back-up tong clamps and releases flexible.

4. Break device acts correctly.

5. Inspect IBOP switch.

6. Push “well control” button, inspect the main motor and IBOP shut down.

Please fill the form in operate manual.

Attachment III <Top Drive Device Installation and Commissioning Record >

108
 Chapter VI Top Drive Disassemble

Top Drive disassemble procedure

Disassemble the auxiliary devices

Disassemble cable

Disassemble Top Drive Main Body

Disassemble anti-torque frame

Move the guide beam

109
I Accessory equipments disassemble

1.Disassemble the elevator.

A. Release the bolts and shafts on the elevator shelter and joints, move the elevator.

B. Fix these bolts and shafts on Top drive main body.

C. Lift the elevator link to the easily delivery position.

Elevator shelter
bolt

rings

Active hinge pin

shaft

110
2.Fix the leaning cylinder by the press panel.

3.Reset rotating link adapter.

4.Switch off all function units.

5. Shut down the active force power switch.

6. Disconnect the driller panel’s cables joints. (include 12 core control cable (400513)). Pack

the cable for next installing.

7. Disconnect the plugs of Power cable (400503), assist power cable (400501), general

control cable (400502) and the plug of top drive cable. Protect the connector by cover from

damaging in dissembling.

111
8. Disassemble drilling hoses and top drive mud pipe.

II Cable Disassemble

1. Put the cable box on the left back of drilling floor, easily for cable laying.

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

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

III Disassemble Top Drive Main Body

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

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

bottom guide beams and transport frame alignment.

Transport frame
Guide Beam

112
3. Lower down the hook of Traveling Block, when the top drive along the guide beam near to

transport frame, lower the hook slowly, inspect whether the wheel of block enter into fixed

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

surface, lower down the hook until top drive insert into the transport frame completely.

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

disassemble the hook and link.

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

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

crane

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

113
7. Lift the top drive main body to the easily delivery position by backup wire rope.

IV Disassemble the guide beam

1. Lift the assemble cart to the drilling floor, connect with the hook by rope and U ring Lifting
Lock Lift the cart top by pneumatic hoist, balance its center in the lifting process avoid
overturning and hurting operators.

Lifting Lock
Wire rope

This state is dangerous!

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

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

114
position easy to package.

4. Lift the guide beam frame to drilling floor.

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

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

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

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

115
lower the hook, put all guide beam into transport frame.

Crane assists this

part guide beam

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

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

packing.

9. Packing the dissembled top drive and auxiliary components.

116
Attachment I Top Drive System Electric Wiring Installation

Inspecting list

No. Item Inspect Content Result

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

1. Power cable is connected correctly

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

1. Power cable is connected correctly

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

1. Control cable is connected correctly

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

1. Stable laying, reasonable arrangement.

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

Record： Check：

117
Attachment II Top Drive System mechanical installation inspecting

list

No. Item Inspect Content Result

1. Guide beam hang 1. Check the connection between U ring and
guide beam.
2. Check if the affix connection is reliable.
2. Guide beam body 1. Whether the guide beam is vertical and
and connection neat.
2、Whether the bolts locked tight.
3. Lifting ring 1. Inspect the connection between lifting ring
connects with and hook, whether the anti-off device installing
crane or hook is in place
4. Reactive torque 1. Whether the bolt is fastening.
beam 2. Whether the joint pin with guide beam is in
place.
5. 1. Whether all auxiliary devices are taken off.

Top Drive main 2. Whether the liquid level of Lube oil and

body hydraulic oil normal.

3. Is there any crash between each part on top
drive body.
4. Inspect the components of top drive.
5. No obstacles in top drive’s routine.
6. Main shaft’s three Inspect the bolts of anti-loose block. Whether
anti-loose blocks. the anchor is firm.

7. Pulley Inspect whether the back of pulley friction with

guide beam.

Remark

Record： Check ：

118
Attachment III

Top Drive System Installation and Commissioning Record

No. Item Testing Technical Request Result

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

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

1. Rotate move smoothly

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

Link leaning, neutral 1. Act well

10
floating test 2. moving smoothly

1. Action accurate.
11 Breaking device testing
2. Main shaft breaking regularly.

Remark:

Record： Check：

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 Part VI Operating Manual

Chapter I Safety Operation Rules

I. Safety Operation Notes

Note This sign provides additional information on procedures involving

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

Caution This sign alerts the user to procedures involving a risk of personnel or
equipment damage.

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

1. The top drive drilling system should be operated by the qualified operator with experiences.

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

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

have got the training of drilling operation and safe knowledge.

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

etc.

4. In this manual, signal【】means it is the operate elements of electric control system, such

as buttons, switches etc. Non-professional staff and non-qualified personnel could not install,

test-run, operate or maintain the top drive system avoid physical and equipment injuring.

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

II. Operator safety operation notes

Electric system operating notes

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

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diagram.

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

forbidden”

3) Use professional tools and protective facility.

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

pull any plugs while power on.

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

reconnecting.

6) Keep the protective air pressure while powering on the driller’s panel. When the protective

air lose pressure, recovery the pressure quickly or stop drilling and cut the power supplied to

driller’s panel.

7) Don’t turn the transfer cabinet or driller panel in dangerous gas.

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

dangerous.

9) While the temperature is higher than 40℃, humidity larger than 95% or have dew, don’t

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

humidity.

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

in electrical control cabinet.

2. Hydraulic system operating notes

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

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

there is not any pressure in the system pipe lines.

3) Cut power off before disassembling the pipe lines.

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

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

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

the pipe line.

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3. Well control Operating Notes.

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

well control.

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

pressure oil layer or gas with H2S、SO2.

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

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

with the problems in time.

Chapter II OPERATING PROCEDURE

Only qualified, experienced and trained personnel can operate the Top Drive Drilling

Equipment.

Reading carefully and understanding the manual and relevant technical documents before

operation.

Before operating, the operator should check the following items:

a. Check the running record. Look over the records to check the working station of last shift.

b. Carry on the maintenance to the maintenance points

c. Check the condition of protective junction and tong die.

d. Inspect the regular inspecting items by professional personnel.

I. Inspection before starting

1. Inspecting before starting

Before starting electrical system, should check the following items:

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a. Check and insure that the machine and hydraulic system is ready.

b. Check the operation components and instrument of driller operation panel and PLC cabinet,

make them on initial status.

c. All indicators of the electronic system can be tested by pushing the button of

【MUTE/TEST】.

d. Confirm the AC380V/50Hz is supplied by the assist transformer or drilling electrical control

room. If supplying by assist transformer, switch on 1QF, cut 2QF off. Otherwise, cut off 1QF

and switch on 2QF. 1QF and 2QF adopt mechanical chain control.

2. Procedure of Power Start System

a. Turn on the general power switch Q1, then close up the primary power switch of

converter and the switch of auxiliary transformer Q2. After that close up all the power

switches (except the spares), and check the power work condition

b. Inspect whether the 24V power indicator light on PLC cabinet panel works well,

【Fault/Alarm】indictor is neither light nor alarm.

24V Power Indicator Light Fault/Alarm

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 c． 【Fault/Alarm】indicator 1HL4 on Driller panel shows no fault,【Ready】 indicator 1HL1

lights constantly which demonstrates electric system are ready for drilling and auxiliary

operation.

Fault/Alarm

Ready

3． Stop System Work

a. Turn the 【Throttle】of Driller panel to the “zero” position, and turn the
【Motor Direction】 to the “stop” position

Motor Direction
Throttle

b. Turn off the power switches of frequency convertor and auxiliary transformer, turn the main
power off, the whole electric system stops.

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 II． Hydraulic system operation

1. Start/stop operation of hydraulic system

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

(1) Auto: When 【 Operate Selection 】 switch is on “Drill” with brake signal, or 【 Operate
Selection】on “spin” or “Strain at”, hydraulic pump starts automatically, and the indicator is
light.
When hand wheel return to Zero, Brake works when the main shaft rotary speed near to Zero,
hydraulic pump starts to work, prevent to supply brake pressure.
(2) Start: Turn the hydraulic pump【Stop/Start】to “start”, hydraulic pump starts, indicator is
light.
(3) Stop: Turn the hydraulic pump【Stop/Start】to “stop”, hydraulic pump stops, indicator is
off. In this state, if there is no brake signal hydraulic pump could not start, but it could start
when well control.
(4) Hydraulic pump is on “Auto” position when drilling, turn it to “start” when “rising up”.

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

2. Hydraulic System Inspecting

Inspect the hydraulic system on Driller panel

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

III. Main Motor Heater

1. The heater of main motor is normal, frequency convertor is power off, switch the

【Motor Heat】 to “ON”. The heating indicator shows working status.

2. There is interlink between heater and drive system. When the heater works, the

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 frequency convertor power on, main motor starts, the heater stop heating

automatically, the frequency convertor power on and main motor run, the heater does

not work.

IV. Main Electric Motor Cooling air-blower

‘Motor fan’ switch has three positions: 1). Auto; 2). Start; 3). stop.

1). Auto: air-blower auto starts according to primary motor temperature, hydraulic oil

temperature, lubrication oil temperature.

(1) When the motor temperature exceeds 38 ℃, the fan will automatically start.
(2) If the temperature of hydraulic oil or gear oil exceeds 28 ℃, the fan will automatically start.
(3) When the motor temperature drops below 30 ℃, the fan automatically stops running.
(4) If both the hydraulic oil temperature and gear oil temperature are below 23 ℃, the fan will
automatically stop running.
2). Start: Switch to this position, air-blower starts; if air pressure switch do not have feedback

signal, this shows air-lose, main motor can start.

3). Stop: Air-blower stops running. Main motor can not start.

V. Braking mode selection

1. Automatic position
(1) Normal brake: In the normal drilling, when need brake, turn the hand wheel back to zero

position, then the main shaft speed reduce to 3rpm, brake solenoid valve will operate and

stop the main shaft.

(2) Reactive torque brake: Under special drilling conditions, if the down hole anti- torque is

more than drilling limit torque, although the hand wheel is not back to zero, the main shaft

will quickly reversed. When the speed up to -3rpm, brake solenoid valve will operate and

stop the main shaft.

(3) Emergency stop: when push the emergency button, the variable frequency signal will

stop first, whatever the top drive in which status, brake solenoid valve will operate and stop

the main shaft.

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 (4) Fault brake: when the top drive fault stops, the brake is the same as normal stop.

2. Brake position:
i. In brake state, braking solenoid valve powered on and stop the main shaft directly.

ii. In shaft running state, if switch to ‘brake’ position, fault appear and stop.

3. Closed position:
if the braking solenoid pilot actuated valve can not given power on, no matter ‘operate

select’ on any position, the top drive drilling system braking fail, except well control.

4. In braking state, hydraulic pump intermittent working:

1). Hydraulic intermittent working: while given brake signal, hydraulic pump start, 8 min

later hydraulic pump stop, 30 min pause, hydraulic run 3 min, again pause 30 min, again

run 3 min… like this circle continuously.

2). In the term of hydraulic pump pause, because of brake signal, so the hydraulic pump run,

and at the same time, IBOP solenoid valve was given power on, hydraulic system pressure

added to supply pressure to energy storage of brake.

3). In the term of hydraulic pump pause, if the valve group have solenoid valve action

(balance, middle position except), IBOP solenoid valve was turn on the power, hydraulic

pump stat running 8 min, then turn to intermittent working state.

5. Relation between Operate select and braking:

【Brake mode】 on ‘auto ’, while【operate select】in 【drilling】state mode, brake can be used,

but on【Spin】and 【Strain at】position no brake.

① In 【drilling】state. switch【brake mode】to ‘auto’.

② In directional compound drilling state, if directional drilling time too short (less than

40 min), switch【operate select】to 【drilling】state, switch 【brake mode】 to ‘auto’; if

directional drilling time a little long (longer than 40 min), switch 【 electric motor select

direction】to ‘stop’, 【brake mode】 to ‘brake’. At this time frequency convertor has no enable

signal, this means main motor doesn’t work.

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 ③ Switching【brake mode】to ‘brake’ given brake signal, if have brake signal, the system

carries out hydraulic pump intermittent working. At this time, it have no relation with position

of ‘operate select’.

6. In tripping time, hydraulic is on ‘start’ position. At this time，it does not carry out hydraulic
pump intermittent working.

Switch 【brake mode】 to ‘off’, top drive starts running, but brake device

can not brake automatically when system stops.

When emergency stop, system will stop rapidly, braking disc would be

worn seriously, so it is forbidden to use this stop function in normal braking

except the emergency.

While system switch to spin or strain at state, disc brake will open

automatically, no matter switch 【brake mode】 to any position, brake does

not close.

VI. Drilling Operation

1. Inspection before Drilling

Check the system before doing the operation, and make it in the original stated showed in

appendix 1. it includes:

A. Putting ‘THROTTLE’ hand wheel of driller control console on ‘ZERO’ position and

‘DIRECTION’ switch on “stop” position.

B. Before system doesn’t run and “THROTTLE” is in “zero” positions, operating the

“ROTATION DIRECTION” switch to select rotation.

In drilling mode, selecting “Motor Direction” switch to “CCW” is inactive.

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2. Drilling operating
a. Turn the 【Motor air cooling】to “auto” or “start” position

Motor Air Cooling

b. Operate 【operation】 switch to “drill” mode.

Operation Select

c. Turn the 【 motor direction 】 to “CW”, if the hand wheel is in “zero” position and the
frequency Convertor is normal, the ready light will be ON.

Motor Direction

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d. Move【Drill Torque】away from “zero” position regularly, set torque as needed.

Drill Torque

e. Move【Throttle】away from “zero” position regularly, main motor runs in the clockwise at
the set value.

Throttle

In normal drilling in, the brake should at auto position, hydraulic pump control switch
should at auto position.

3. Constant torque and power

A. Rotate the [given speed] handwheel clockwise, and the spindle speed increases

accordingly. Before reaching the rated power, the main motor will keep running at the torque

(constant torque) set by the [Drilling Torque Limit] handwheel.

B. When the rated power is reached, the output torque of the motor begins to decrease with

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the increase of the rotational speed, and the output power is kept constant (constant power).

C. Relationship curve between output torque and speed.

4. Speed Control and Torque Control

a. During drilling, when the torque of drill pipe does not get to the limit torque, main shaft will

rotary at【Throttle】the hand wheel preset speed.

b. If the torque of drill pipe over limit torque, the main shaft will stop rotating (stop), the

torque keeps. When load reduces, the driver speed comes back to the value of ‘THROTTLE’

hand wheel. And it back to speed control again.

5. Stop Drilling

If system needs stop when it is in drilling mode, can let the 【THROTTLE】hand wheel go back

to ‘ZERO’ position, the driver will reduce speed normally. If 【BRAKE】switch is on ‘AUTO’

position, the system brakes when speed gets to zero speed.

When top drive running normally, If operating the 【MOTOR DIRECTION】,

【brake select】 or 【OPERATION】 by mistake, CPU will set the speed and torque
at zero, so the motor will stop immediately, this is fault stop (when the main shaft
speed gets 3r/min, the main shaft brakes tightly.)

VII Backup tong operation

Backup tone could operated after hydraulic system start.

1.Clamp backup tong

【throttle】set on "zero", top drive speed is zero(main shaft stop).

【clamp】turn to "on", backup tong will clamp.

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 During backup tong clamp procedure, not allowed main shaft rotating,
otherwise it will damage tong dies or drilling tools.
2. Backup tong off
【drilling torque】display zero, could operate backup tong off, 【clamp】from on to off, system

will loosen backup tong.

when【drilling torque】 is not zero, do not allow backup tong off, otherwise at
the moment of loosen backup tong, main shaft will rotating, will damage tong dies or
drilling tools.

VIII Link operation

The links can be operated after the hydraulic system is started. The operation buttons of the links
include tilting, turning left and right and floating of the links.
When using the forward or backward tilting to push and pull drill collar, the connecting line between
the elevator and the center of the main shaft should be parallel to the line between the mouse hole and
the center of the wellhead, and the lateral push of the links is not allowed and is a violation to the
standard operation.

Top Drive Link Tilts Diagram

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1. Turn【link incline】to “front”, the link will tilt front 35°to realize catch and send the drill pipe
from the mouse hole and Kelly board. Turn 【link incline】to “rear” position will tilt backward
55°to make the top drive lower to the drill floor as near as possible, improve the working

Link incline

2. if push the 【link center】button, the solenoid will connect the incline cylinder with the oil

tank, the link and elevator will be free status.

Link Center

Push【Link Center】, the rotating link adapter will turn left or right in any angle.
Link incline and rotating link adapter have the interlock device, when
operating the link, the rotating link adapter will not rotated, only when push
【 Link Center 】 again, the rotating link adapter could rotate. In case need
rotate the rotating link adapter after incline the link, the operator could
change the PLC interlock setting, after the operation, operator should reset
the setting to avoid the link hurt somebody.

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 The link and elevator could take the weight no more than 3 ton when
operating, if the weight over 3 ton, must push the 【Link center】 to protect
the tilt cylinder.

After push【Link Center 】 ,it must be sure that the link back to the vertical
position then could operate the rotating link adapter.

IX “Make up/ Break out” operation

1. Inspect system before making up/Breaking out, the mainly inspecting items are as
follows:
a. Set【Throttle】of driller panel on ‘ZERO’ position

Throttle
b. 【Motor Direction】switch on “stop”

Motor Direction

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c. Set【Operation】to “Drilling” mode.

Operation
d. 【Hydraulic pump】 switch should at “auto” or“on”position.

HPU

e. 【Motor Air Cooling】should be at “auto” or “on” position.

Motor Air Cooling

136
2. Makeup operation
Spin
a. Switch【Motor Direction 】to “CW”,

Motor Direction

b. 【Operation】turn to “spin”, the system will rotate on the speed of 12r/min,fixed torque
6kN·m, when the torque reach 6kN·m, the speed and torque turn to zero, the system stop.

Operation

【Throttle】wheel not in zero position, the spin operation won’t work.

When spinning, 【Throttle】not zero or 【Motor Direction】 faulty operation,

the system speed and torque will be zero automatic.

Fastening:

The fastening must carry out after the main shaft spin, the operation status is the same as

spin requirement at this time, top drive main shaft speed is zero, output torque is 6kN·m.

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a. Turn【Makeup Torque】wheel to set the needed torque.

Makeup Torque

b.‘backup tong’ at close by right hand and Put the ‘OPERATION mode ’ at torque by
left hand ,hold the two switch for a while 6 seconds, the system will rotate in clockwise

direction until the torque get to the limited torque, then the system stops. Leave the switches,

back-up tong releases. Limited torque reduces to “0”.

Operation Clamp

c. Turn【operation】from “spin” to “drill”.

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 Operation

d. Rotate the 【 Motor Direction Selection 】 switch to the stop position.

It should keep the hydraulic pump running when fastening.

When the main shaft still rotating for the spin, It should avoid to fasten it
to prevent the die tooth damage the main shaft.

3. Break out
Before break out, it should support (set slip) on the removed drill tools to avoid the drill tools

drop

Check the switch position according to the item 1 requirement.

a. Turn the 【Motor Direction】to reversal position.

Motor Direction

b. Push down the button of “Break-out Bounce”

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 Break-out Bounce

c. ‘backup tong’ at close by right hand and Put the ‘OPERATION mode ’ at torque by
left hand ,hold the two switch for a while 6 seconds the system will contra-rotation by the Max.
output torque, when the system speed reach the 6r/min, release both hands, 【operation】
will back to “spin” automatic, main shaft will break out by spin mode.

Operation

d. After break out, turn【operation】to “drill” to finish the break out.

Operation

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 When push【Break-out Bounce】button, the system will pressure the balance
cylinder within one minute to lift the top drive body for protect the drill tools joint,
after one minute the pressure gone, push the button again to repress it.

The Max. breakout torque is the Max. output torque of the

system,(normally it is the 150% of the normal output torque), so if the Max. torque

still cannot breakout the pipe, the operator should not try a long time(no more

than 1 minute), operator should adopt other ways to breakout.

e. Rotate the 【 Motor Direction Selection 】 switch to the stop position.

X Drilling ahead by single

1. Procedures for drilling ahead by single

（1）Set slip on the connection in the drilled well, stop mud circulation and close IBOP;

（2）Break out according to the IX-3 instructions.

（3）Pull the top drive drilling system up. Make the elevator goes off the joint of drilling rod;

（4）Start elevator tipping device to swing the lifting ring onto the joint of the single in the

mouse hole and fasten the elevator;

（5）Lift the single out of the mouse hole, move the single to the center of well head.

（6）Lock the drilling rod connecting buckle of the well head, put the top drive drilling system

down, Put the upper side of the single goes into the guiding shoe.

（7）Make up the single with the saver sub of the top drive drilling system;

（8）Fix the drilling pipe in well, connect the joints between drilling tool and single, single and

protective joint by drilling machine (preset the drilling torque as need)

（9）Rotate and fasten by top drive according to the procedure of IX-1.

（10）Pull the slip, open IBOP, start pump to circulate the mud.

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

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

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XI Drilling ahead by triples

Drilling ahead by triples is the normal drilling method of DQ40BQ-JH top drive drilling system.

If there aren’t the existent triples on the well frame, it can be connected into the mouse hole

during the course drilling or at the leisure time. In view of safety, the drilling rod in the mouse

hole must be vertical to assure them butted each other inside vertical plane, then, what

should to do is to rotate the single connection into box threads, because the electric engine

will apply making up to fasten the joint. In addition, when drilling by making a connection,

the triples left in the well frame can also be used for drilling by making up in triples after

drilling start.

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

（1）Set slip on the single connection in the drilled well, stop circulating mud, (close IBOP);

（2）Break out according the IX-3 instructions.

（3）Pull the top drive drilling system upward to make the elevator goes off the joint of

drilling rod. After the top drive drilling system has been lifted to the Kelly broad platform,

start the elevator tipping device to push the elevator to the triples where is to be connected;

（4）Well workers will make up the triples into the elevator, and take the elevator tipping

device back to the well head;

（5）Drilling machine operator put the triples into the box threads of the drilling rod;

（6）Put the top drive drilling down slowly to put the upper side of the triples into the guiding

shoe and make up with the saver sub of top drive drilling system;

（7）Make up by Motor (e. g. Single Drilling)

（8）Lock tight by Top drive according to IX-2.

（9）Pull the slip out, start circulate mud, open IBOP, continue drilling.

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

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

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XII. Backreaming

During the course of pulling out, if the drilling devices are blocked, connect them with the top

drive drilling system at once, and circulate mud. Lift the drilling and backreaming at the same

time to avoid drill rod being clamped and key box being reamed though.

Procedures of backreaming are as follows:

(1) Circulating mud and rotating to pull the drilling devices out until one triple is lifted

outside;

(2) Stop mud circulating and rotating, set the slip;

(3) Unlink the connection on the surface of drilling floor by hydraulic tong, and unlink the

connection thread with the top drive drilling system on the triples;

(4) Pull out the triples, arrange the triples into the drilling rod box;

(5) Set the top drive drilling system down to of drilling floor.

(6) Lift the drilling rod to pull the slip out. Spin and fasten by the top drive motor.

(7) Restart the mud circling, rotate the movable drilling tools, keep on backreaming.

XIII Pulling out operations

Pulling out runs in conventional ways, with the help of pipe handle unit, it could reduce

labor’s intensity and improve working efficiency.

A． Tripping in

（1）Move the top drive drilling system to kelly board by hoisting system, operate 【Swiveling

head rotating 】 to rotate the elevator tipping device to the direction which the workers

needed on Kelly board;

（2）Operate 【Link incline】 to “Front”, make elevator close to the kelly board to put the

drilling rod down, then workers will put the drilling rod into the elevator and buckle door bar;

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 Link incline

（3）Operate 【Link incline】 to “Rear” to return to the head of the well approximately, then

operate 【Link center】, at this time, the tipping device is in floating state;

Link Incline
Link Center

（4）Pull the drilling rod to return the center position, during this course, the drilling workers

should hold back the lower side of the drilling rod with ropes and release it slowly in order not

to damage the joint of the drilling rod;

（5）Put the traveling crane down, buckle the carried drilling rod with the drilling rod of the

rotary face, Rotate and make up with hydraulic tong;

（6）Lift the drilling pipe to pull the slip out. Set the drilling rod down to the head of the well

144
and set it onto the slip.

（7）Loosen the elevator, operate the【Link incline】 to slope it backward a little and deviate

it from the drilling rod. Lift the traveling crane to the Kelly board. Repeat the above

operations.

Link Incline

B. Tripping out

（1）Loosen the connecting thread between the main shaft and drilling rod, and lift the top

drive drilling system. Operate the 【Link incline】to slop it forward in order to buckle the main

shaft of the lift sub into the joint of the drilling rod;

Link Incline

（2）Lift the top drive drilling system above the kelly board. Set the slip on the drilling floor,

put the top drive drilling system under the slip;

（3）Breakout with hydraulic tong;

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 （4）Pull the top drive drilling system, operate the 【Lind incline】to “front” in order to make

the elevator close to the kelly board. Drilling workers pull the triples’ to the arranging area,

lower down the top drive to put the triples steady. Workers open the elevator and put the

drilling rod into the triples box;

（5）Operate 【Link center】, set the top drive drilling system down to the joint of the drilling

platform. Operate 【Link incline】 to “front” in order to buckle the elevator into the joint of

the drilling rod.

Link Incline Link Center

（6）Repeat the procedures from 2 to 5.

If there are reducing radius or key groove during the course of round-trip, connect the

drilling rod with electric engine of the top drive drilling system at any height of the well frame,

and starting the circulation and rotating removable drilling tools immediately to make the

drilling tools pass the blocking position;

XIV Running Casing

Running casing with the top drive drilling system can improve the operating speed, Jinghong

top drive is different from others, adopt a special device for running in casing, the main

function is when the drill string is stick or well kick happen in down-hole, the top drive can

joint with the casing quickly and starting the mud cycle, rotating the pipe. Prevent the well

kick and deal with the stick problem in time. Enhanced the safety and speed of running

casing.

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XV Well Control

1. When the top drive drill system is on the stop status, turn the rotary knob of【IBOP】 could

open or close the IBOP. In the drilling process or the mud pump running status, it is not

allowed to close the IBOP (except the well control status).

2．Under the urgent condition such as well blowout, push the 【well control】switch will enter

the well control status, operating procedure showed as follows:

a. Start the hydraulic pump (Ignore the state before)

b. Stop the mud pump (Give the connect point signal, connect the control to mud pump)

c. Stop top drive system (Fast stop)

d. Shut the IBOP off.

3. Operators should replace all switches to original position. (Attachment I)

3.After obviating the urgent situation, and insuring there are no trouble alarm in system,

push the 【reset】 switch, then the well control statue is cancelled.

IBOP Well Control

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XVI Jarring operation

Because every well has special condition, and the parameters, such as drilling depth, drill

pipe weight, bumper jarring type and so on, are not decided, so it is impossible to give a

standard rule or specification, in addition, the damage of jarring in various conditions to the

Top Drive Drilling System is not predictable. For these reasons, we suggest that don’t jarring

while equipping Top Drive Drilling System and forbidden using surface bumper sub,

otherwise it may cause damage to the Top Drive Drilling System.

If jarring with Top Drive Drilling System can not avoid, please assess comprehensively about

the possible damage of jarring to the Top Drive Drilling System.

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

following guideline. A detailed examine and maintenance plan should be made to ensure all

functions of the Top Drive Drilling System well and convenient for next time using.

1. Take a general visual inspection to Top Drive Drilling System to ensure no damages.

2. Check the safety wire rope and connecting bolts. If any bolt loosing, please tighten it and

refasten the safety wire rope.

3. Check all cable joints, electric cabinet terminals, and device connectors of Top Drive

Drilling System. If any loosing, fasten again.

4. Check if any pipeline joints loosing or leaking, if the pipeline is damaged or deformed.

5. According to jarring intensity to decide if disassemble load-carrying components on

loading path (including lifting pin, elevator link, rotating hanging ear and main shaft) and

inspect them.

6. According to jarring intensity to decide if do further examination to Top Drive Drilling

System.

XVII Release drilling torque operation

Under normal drilling conditions, Top drive shaft is stuck when the downhole reverse torque is greater

148
than the set value of drilling torque. If you need to release the reverse torque, you need to follow the
following guidelines
When the reverse torque is released, there is a danger that the drilling tool connections may be broke.
So it must be operated in strict accordance with the operating rules, and the reverse speed must be
strictly controlled in the operation to prevent accidents.
When a situation of being stuck occurs, driller should first take the method of lifting the top drive up to
release accumulated torque. When the above method cannot be implemented, the top drive device
provides two methods to release the torque. We usually only choose the next method.
Rotate the speed setting handwheel slowly to 5-10RPM to ensure that the main motor continues to
output torque. And then switch the [brake] switch from “automatic” to “released”, and turn the [drilling
torque limit] handwheel to reduce torque limit value. And so the main motor output torque is being slowly
reduced, and the main shaft of top drive will turn slowly reversely until the [drilling torque limit] hand
wheel setpoint becomes zero. When the main shaft of top drive stop turning, loosen the brake lever, lift
the traveling block, turn the [Brake] switch to the automatic position, and reset the [Drilling Torque Limit]
The steps are as follows:
The first step: Do not turn [drilling torque limit] handwheel. And rotates [speed setting] handwheel
slowly to 5-10RPM (Donot reduce the speed setting handwheel too fast)

In the release

5-10RPM

Step 2: Turn the [Brake] switch to the release position. The top drive is always in the ready state,
and change the drilling torque by turning the [drilling torque limit] handwell If the downhole reverse
torque is higher than the [drilling torque limit], the top drive is reversed. The energy is released by the
braking resistor in the form of heat. . When downhole reverse torque is equal to [drilling torque limit], the
top drive is in a state of being stuck.
Step 3: Slowly reduce the [Drilling Torque Limit] handwheel to observe the reversal speed. If the
reversal speed is too fast, reduce the [Drilling Torque Limit] handwheel rotation speed. At last [Drilling

149
Torque Limit] becomes zero.

Slow decrease

Step 4: After the reverse torque release is completed, lift the drilling string, turn the [Brake]

switch to “Auto”, reset the [Drilling Torque Limit] handwheel, and set [Speed setting] handwheel

at the required speed.

Release reverse torque with brake, brake pad, brake disc wear is serious, brake pad and brake
friction produce high temperature, easy to cause damage to the brake fluid cylinder seal due to
high temperature conduction, brake fluid cylinder oil leakage can not work normally. When drilling
is idle, check brake pad wear and test brake function to ensure that the brakes work properly.

XVIII. Emergency stop

1. When the system need emergency stop, operator should push the nearest 【emergency】
button, all the devices of the top drive will stop in a short time operator should turn all the
switches of drill’s panel to initial position.(See appendix 1)
2. After the system get back to normal, guarantee the system do not have failure warning,
reset the 【emergency】,push the【reset/mute】button, the system could be operated.

150
 Reset/Mute

XIX Reset/Mute

When the system has some fault, the 【Fault/alarm】will light and with the alarm sound. Press
【Reset/Mute】could mute the alarm; if the fault still there, the light will keep light until the
trouble be cleared.

Reset/Mute Fault/Alarm

XX Stop system

When stopping the system, turn the 【Throttle】to “zero” position, and turn 【Rotating
direction】switch to “stop” position, then turn【House switch】or【Auxiliary transformer】switch
of electric control house 380V power to the “stop” position. Turn the power switches of 2
transducers and Auxiliary transformer off, turn the main power off, the whole electric system
stops.

151
Appendix I System Initial State

Attachment I. VFC initial state

Before starting system, should make sure that all switches or buttons of driver cabinet are in

the following initial state.

Button or switch Initial position Note

Emergency stop Open Emergency-stop button is NC contact

Attachment II Driller Panel initial state

Before starting system, should make sure that all switches or buttons of driver cabinet are in

the following initial state.

Button or switch Initial position Note

Emergency stop Loose Emergency stop button is NC contact
Brake mode Auto Brake by PLC system
HPU Stop Stop the hydraulic system
Link rotation Center rotator is in inactive state
Link incline Center Link is in balanceable state
IBOP Open When drilling normally
Air-blower Close In initial position, it is in “close” position
Operation Spin Initial position
Backup tong Loose Initial position
Motor Select direction Stop Switch Initial position
Makeup torque Zero Set the value of torque before makeup
operating
Drilling torque Zero Set the value of torque before drilling
operating
Speed Zero Set the value of speed before drilling
operating.

152
Attachment III PLC Cabinet Initial State

Before starting system, should make sure that all switches or buttons of PLC/MCC cabinet are

in the following initial state.

Button or switch Initial position Note
Emergency-stop Loose emergency-stop switch button is NC
contact
Doghouse control emergency stop On the left side, allowed the doghouse use
the emergency stop operation
Motor heat Stop Use only under the low temperature or
high humidity
Mud pump linkage linkage The system linkage with the mud pump

Attachment IV Kelly board operation box initial state

Before starting system, make sure that all switches or buttons of monkey board operation

box are in the following initial state.

Button or switch Initial position Note
Link rotation Center Rotator is in inactive state
Link incline Center Link is in balanceable state

153
 Part VII Maintenance Manual

Chapter I Safety Operating Rules

I Safety Operating Rules

Note This sign provides additional information on procedures involving

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

Caution This sign alerts the user to procedures involving a risk of personnel or
equipment damage.

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

During the maintenance period, if the maintenance plan is changed, it needs to revise the
safety working plan and guarantees all in involved working personal knows about the
maintenance term so that it could ensure all the working staff’s safety and the devices are in
a good condition.

1. Every time before the maintenance, it needs the safety analysis, guarantee all the power
switch is on the “switch off” status. When lubricating, checking or replacing the system, it
should cut off the power supply.
2. During the maintenance and repair period, the operator must be equipped with suitable
protective equipment, such as glove, helmet.
3. When the system is running, it not allowed to maintenance and repair.
4. Before repairing the hydraulic system, should release the pressure in the accumulator.
5. Check the hydraulic oil leaks by hand is forbidden, hydraulic oil leaked from the hole is
almost invisible in the high pressure. Hydraulic oil is not only high temperature but also it
could penetrate the skin and cause injury, use wood, inspecting should be carried out by
bamboo and other hard-board, and wear protecting appliance.
6. Don’t try to repair the part which you aren’t familiar with.
7. Before repairing the top drive drilling system, please read the related manual carefully.

154
 Chapter II Daily Inspection

In order guarantee the top drive running smoothly, avoid the unforeseeable accidents. It
requires checking the top drive status and key parts in any time of daily operation. We
suggest that this inspection should carried out by the specialized technical personnel
everyday.

I It is important to inspect the following items

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

155
Guide beam joint Observe the pins connected with guide rail, pins lock
normally.
Hanger lifting lug Observe the guide rail, adjust the backplane and connect
pins, there is no abnormal wear and tear, etc.
Top driver running All the motor and transmission no abnormal noise during
the top drive running.

156
 Chapter III Maintenance Items and period

I Daily maintenance Items

1. Washing pipe
Grease fitting :
On the outside of the washing pipe
. the bottom part
Greasing method:
Grease gun , 2-4 pumps
Inspecting Item:
Washing pipe leakage.

2. Control mechanism of the remote IBOP

Grease fitting
4 pieces of roller
Gear and rack
Grease Method
Feed grease fitting 1 pump.
Put some grease on gear and rack
Inspect Item:
a. Whether the guide plate and roller . bolts, loose,
wear out or lost.
b. if the gear in the center or wear out.

157
3. Centralize Ring
Centralizer Ring
Grease Point
Inside surface of stablizer
Grease Method
Use grease gun to Feed grease
Inspection Item
If the stabilizer is worn out ,change it .

4．IBOP (Remote)
Inspecting item：
a. Operate the remote IBOP once a day to check for proper work and leaks.
b. The remote IBOP should ensure reliable sealing and ensure that, it is completely opened or
closed during operation.
C. When switching, the pressure difference between the upper part of the ball valve and the lower
part of the ball valve cannot be higher than 20Mpa.
5. Suspension body suspension ear
Lubrication parts:
At the contact point between the suspension ear and the lifting ring
Lubrication method:
Apply sufficient lubricating grease on the surface
Inspection items:
Wear of suspension ears

II Weekly Maintenance Items

1. Lifting ring guide pin

Lubrication parts:
Lifting ring guide pin 2 places
Lubrication method:
Add lubricating grease to the oil nozzle with a grease gun, flushing 2-4 times at each location.
Maintenance items:
Inspection items:

158
a. Lubrication of the lifting ring guide pin.
b. The fixing bolts of the balance hydraulic cylinder and the status of the lifting ring locking clamp
c. Is the surface of the piston rod and various hydraulic joints of the balance hydraulic cylinder
normal
2. Pin Roll of Lifting ring
Inspect Item:
a. Wearing situation on bolts of link
hydraulic cylinder
b. The position and clamps of lock
clamp on link.
c. The connection pins.
Grease Point:
Connecting pins of Joint bearings and rings.
Lubricate method:
Feed grease by grease gun
.

3. Guide beam and carriage.

carriage with rollers
Inspection Item:
The upper and lower parts of the pulley are 4 centralizing
wheels
16 on both sides of the tackle
Bearing wheel bracket fixed point 8
a．Inspect rollers working situation. No Blocks.
b. Check the wearing situation of the roller. replace it when
necessary.
c. Inspect the fixed bolts on wheels, check whether the lock
washer lock well.

159
4. Leaning Device

Inspect Item:
a. Wearing situation on bolts of link
hydraulic cylinder
b. The position and clamps of lock
clamp on link.
c. The connection pins.
Grease Point:
Connecting pins of Joint bearings and rings.
Lubricate method:
Feed grease by grease gun

5. tieback beam
Inspection Item:
a. Inspect bolt.
b. Inspect the deviation . if the deviation is more
than 3MM ,adjust it .

6. Anti-loosen Device
Inspect Items:
a． Bolt fixture.
b． Safety lock rope.
Installation of anti-loosing device
a. put grease (molybdenum ) on bolt and nuts.
b. Make sure all the connecting joints are locked to the required
torque before installing the anti-loose device.
c. Clear the surface of IBOP, main shaft and protecting connector.
Ensure surfaces are bright and clean without any grease.
d. Put anti-loosing device in pair on the joint.
e. Put the tong dies on the center of connection.
f. Fasten bolts by torque wrench, the torque up to 370-420 N·m.
g. Fix all bolts by safety wire.

7. Back-up Tong

160
Maintenance items:

Back clamp fixing pin

Lubrication method:

Use a butter gun to add oil to each nozzle

Apply lubricating grease, 3-4 strokes per location.

Inspection items:

Check if the bolts are loose.

Attention:

When removing the fixed pin shaft of the backup pliers, only the right pin shaft (facing the

top drive) can be removed

8. Manual blowout preventer

Inspection items:

a. Turn on and off the manual blowout preventer once a week to check if it opens and closes

smoothly and if there are any leaks.

b. The manual blowout preventer should ensure reliable sealing, and ensure that it is fully

opened or fully closed during operation.

c. The pressure difference between the upper and lower parts of the ball valve should not

exceed 20Mpa when switching on and off.

9. Back clamp suspension pin shaft

Lubrication parts:

Back clamp suspension pin shaft

Lubrication method:

Use a butter gun to add oil to each nozzle

Apply lubricating grease, 2-4 strokes per location.

Inspection items:

Check if the fixing bolts of the pin shaft clamp are loose and if the anti loosening wire is

intact.

III Monthly Maintenance Item

1. Brake Device

161
Inspect Item
a．Whether is the abrasion form of Brake-friction disc symmetry abrasion?
b．Inspect the attrition rate of the Brake-friction disc.
c．Inspect where there is omit on Hydraulic pressure break pipes.

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

if it absorbed grease or oil.

Maintenance Items:
if the thickness of the pad is less than 3mm , just change it out
Note: It takes a certain time to run in the new pad , the pad can’t offer the rated force before
running in.
Change the brake pad.
1） Shut off the hydraulic pump on the control panel and turn the brake switch for two
or three times repeatedly.
2） Remove the upper baffle of the motor and brake cylinder can be seen.
3) Remove the guide pin of the brake body and the return spring screw.
4) Move brake pads up and slide it out.
5) Slide the new brake friction disc in.
6) Install guide pin and return spring screw.
7) Tighten the screws and adjust brake pad clearance to average position.
8) Install the upper baffle of the motor.

Keep the friction material away from oil or grease.

2. Drape hanger of crane, U ring

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

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

162
4. Main motor and air cooling motor
Inspect Item
a. Inspect the damage on the outlet cable of motor.
b. Inspect the damage and loose of the bolts and lock line.
c. Inspect damages on uptake blind and filters.
d. Whether the debris attach to Heat exchanger.
Maintenance Item
a. The heater of main motor would heat automatically when the main motor stops, shut off
it if don’t use in long time.
b. Inspect the air-blower preliminary, whether there is any part broken or sundries in
air-blower channels after transportation or long time stock.
c. Clean the heat exchanger regularly.

5. Back-up Tong
Inspect Item
a. Check the abrasion of tong teeth.
b. Inspect the looseness of bolts on tong teeth seat.
c. Check trumpet fixed bolts, wear ring bolts and
fixed pins and other fasteners whether there is
loose and damages, the reliability of locking.
Maintenance Item Fixed pin
a.Clear the dirt on the surface and gash of tooth in time.
b. While changing tong key, replace the 4 at the
same time to ensure geometry and mechanical
strength same.

6. Big gland sealing

Oil points
Glib on Big gland sealing
Lubricate Method
Feed grease into the glib by grease gun.
7． Encoder
Check item:
Check for damage and looseness of the belt once a month. Belt with damage, looseness,
oil stains need to be replaced.

163
IV Maintenance Items in each quarter

1. Lubrication on bearings of main motor

Oil site
2 points on the top of main motor, 2 points on the
below (inside).
Lube method
Upside 300g, downside 200g

2. Motor insulation inspection.

a、 Use a 1000V megohmmeter to check if the grounding
resistance reaches 20 megohms or more.
b、 Regularly inspect all cables and connecting plugs, and visually inspect for no physical
damage.
C、 Necessary protection should be provided for cable joints during each installation to
prevent erosion such as rainwater

3. AC pre-shoot pressure detects.

a、The pressure of balanced AC is 9-10MPa.
b、The pressure of Brakes AC is 8-9MPa.

4、Big gear of Rotating link adaptor and small gear of drive motor.
Grease point
gear and teeth
lube method
put the grease on the joint and teeth.
Maintenance Items:
Check the fixed bolts on motor frame often, lock it tight if there is any loose.

164
V. Maintenance Items in half year

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

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

3. Guide rail adjustment screw front end limit stop ring

Inspection items:
Regularly inspect the limit stop ring every six months for any risk of detachment. (Due to
structural issues, the inspection can only be carried out after disassembly)

165
VI Maintenance Items every year

1. Detect Main Shaft, the wear-out of hanging lift lug, U ring, and fixed pins by disconnecting.
2.The bail and bail pin shaft need to be inspected, and flaw detection is recommended. The
wear of the bail pin. It needs to be replaced when the wear exceeds 1.5mm.
3.Perform flaw detection on guide beam pins.
4.Perform flaw detection on the elevator links and the lifting lug of the rotating link adapter.
5.Inspect the lube pump of gearing oil and hydraulic oil pump, adjust it according to the
result.
6. Inspect the pressure of gear pump, if the pressure is not fit, find out the reason, replace
it when necessary.
7.After running for 3000 hours or on year running it is recommended to replace to replace
the encoder timing belt.
8.Guide rail wire rope
Check item:
When the guide rail body in the folded state, check whether the rope core near the joints
of the guide rail is extruded and whether there is structural damage caused by breaking of
the whole rope. Diameter of the wire rope decreases when it is been worn. When the wea
r more the 7% of the diameter (DQ90 guide rail wears relative to the nominal diameterφ22)
It should be checked roundly or carried out strength test to
confirm whether need to replace the wire rope.
Maintenance methods:
When the guide rail body in the folded state, grease the wire rope near the joints of the gu
ide rail.

VII. For more information please refer to the “JH Top Drive System

Inspection Standards Cat. I II III Ⅳ”. Please contact with technical

department of Jinghong for further maintenance and repairing.

Tel: 0452-2340601
Fax: 0452-2340601
Email: service@jh-pm.com
Add: No.24, Delong Road, Nanyuan Investment Zone, Longsha District, Qiqihar, Heilongjiang,
China.

166
Zip: 161005

Attachment A Torque value of thread hastening

Recommend
Recommend Recommend
force
Thread Type force force（N.m)
（N.m)
（N.m) 12.9
Level 8.8
10.9
M8 22 30 37
M10 45 63 75
M12 78 109 131
M16 193 271 325
M20 328 531 637
M24 653 906 1101
M30 1300 1828 2193

Note: The tightening torque of M20 on the anti loosening device between the

spindle and the blowout preventer is 390N · m~420N · m

The tightening torque of M20 on other anti loosening devices is 370N · m~390N · m

Attachment B Recommended torque for connections of TDS

Recommended torque for connections of TDS(kN.m)

Connection between Connection between

Connection between auto
main shaft and auto auto IBOP and saver
IBOP and Manual IBOP
IBOP sub

35kN·m 35kN·m 35kN·m

Attachment C Recommendation of gear oil

Gear Oil

Scope of ambient temperature

Manufacturer
-50℃ to -7℃ -6℃ to 20℃ 21℃ to 55℃
ISO viscosity (International
32 68 220
Organization for

167
 Standardization)

Mobil Mobil SHC624 Mobil XP68 Mobil EP220

Attachment D Top Drive Gear Oil and Hydraulic Oil Refueling

Quantity Reference Table

Gear oil filling Hydraulic oil filling
Top drive models
capacity (L) capacity (L)

DQ40BQⅡ-JH 30-36 34-38

Table 1、Top drive electrical daily maintenance record

Top drive electrical daily maintenance record

Maintenance
Top
Top drive serial and
drive engineer
number inspection
model
time
Maintena Description
Photos
nce of existing Planned Recti
Maintenance and of
N0. inspecti problems and rectificatio ficat
inspection contents hidden
on rectificatio n time ion
parts
results n plan
Whether the auxiliary
Daily parts of the room are
maint complete, including air
1
enanc conditioner,
e transformer, braking
inspe resistor, etc;
ction Check whether each
wiring terminal is
2
corroded and whether
the wiring is loose;
Whether the cover of
3 the cable connector is
lost, and whether the

168
 thread of the cover of
the cable connector is
damaged;
Whether the AC220V
purification power
4 input is normal and
whether the surface is
overheated;
Check whether the
operation and
5 refrigeration
performance of the air
conditioner are normal;
Check whether the
interior lighting lamp,
emergency lamp, wall
6
switch and temperature
and humidity sensor
are normal;
Check whether the
identifications of
buttons, knobs and
7
indicator lights of the
integrated cabinet are
clear and complete;
Whether the cables in
the cabinet are standard
8
and whether the
trunking is intact;
Whether the Profibus
communication plug or
9
Profinet Ethernet plug
is loose;
Check whether all
buttons, knobs and
10 indicator lights on the
cabinet are in good
condition;
Check whether the
11 door lock of the
cabinet door is intact;
Check whether the
12 current limit of
auxiliary motor

169
 thermal relay or motor
starter is appropriate;
Whether the PLC
power light, operation
13 indicator and
communication module
indicator are normal;
Whether the socket is
14
sintered or loose;
Whether there is
abnormal noise in the
15
operation of inverter
fan;
Whether the inverter
16 control panel has alarm
information;
Check whether the
main circuit breaker is
17 normal and whether the
indicator is in good
condition;
Check whether the
encoder module
18
indicator operates
normally;
Check whether the
encoder module
19
indicator operates
normally;
Check whether the
indicator of the
20
communication module
is normal;
Check whether the
display of temperature
21
and humidity controller
is normal;
Check whether the air
22 conditioner operates
normally;
Check whether the
23 brake resistor operates
normally;

170
 Check whether the fire
fighting appliances in
24
the room are intact and
complete
Check whether each
indicator on the
driller's floor and each
25
power indicator on
each PLC module are
normal;
Check whether the
switches of each
26 operation button on the
driller's floor are intact
and operate flexibly;
Check the touch screen
of the console and the
27 alarm screen of the
industrial computer for
alarm information;
Whether the cooling
28 fan of braking resistor
operates normally;
Check whether the
positive pressure
29
protection switch of the
console is normal;

Table 2、Top drive electrical weekly maintenance record

Top drive electrical weekly maintenance record

Top
drive Top drive
engineer
mode serial number
l
Week Maint
Next
ly enanc
mainten
maint e and
ance RIG NO
enanc inspe
inspecti
e ction
on date
inspe time

171
 ction Mainten Description of
Maintenance ance existing Photos of Planned
Rectificati
N0. and inspection inspecti problems and hidden rectificat
on
contents on rectification parts ion time
results plan
Whether there
is obvious
bump and
1
corrosion on the
surface of the
room.
Whether the
door and lock
2 of the room
body are rusted
and damaged.
Whether the
louver or
ventilation
3
board is
bumped or
deformed.
Check whether
the cables
around the
4
brake resistance
are damaged or
burnt.

Table 3、Top drive electrical monthly maintenance record

Top drive electrical monthly maintenance record

Top
Top drive serial
drive engineer
number
model
Monthl Mainte
y nance Next
mainte and maintenanc RIG
nance inspect e inspection NO
inspect ion date
ion time

172
 Descriptio
n of
Photos
Maintenanc existing Planned Recti
Maintenance and of
N0. e inspection problems rectificati ficati
inspection contents hidden
results and on time on
parts
rectificatio
n plan
Whether there is open
1
welding in the room;
Whether the door is
2 deformed or not tightly
closed;
Whether the interior
decoration, decoration
3
and insulation board
are damaged;
Whether the fixing
4 bolts of all parts are
complete;
The resistance of
braking resistance
5
measured by ohmmeter
is about 2 Ω;
Use a 1000V megger to
detect that the
insulation resistance of
6 each coil of
AC600V/AC400V
transformer to the
ground is ≥ 250M Ω;
The test action of the
main incoming circuit
breaker is normal, the
7
indicator light is intact,
and the closing sound
is normal;
Whether the
transformer coil is
broken, whether there
is desoldering at each
8
welding point, and
whether the iron core
fastening screw is
loose;

173
 When the frequency
converter is powered
off, remove the brake
resistance cable, and
use a 1000V tramegger
9
to check the insulation
resistance between the
brake resistance tape
and the plate, which is
not less than 10M Ω;

174
Table 4、Top drive electrical quarterly maintenance record

Top drive electrical quarterly maintenance record

Top Top drive

engineer
drive serial
model number
Next
Maintena
maintena
nce and RIG
nce
inspectio NO
inspection
n time
date
Description
Maintena of existing Photos
Maintena Planned
nce problems of
N0. nce and rectificati Rectificat
Quarterly inspection and hidden
inspection on time ion
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 Part VIII WEAR LIMIT OF TOP DRIVE DEVICE

OF OIL DRILLING RIG

This regulation specifies the wear limit detection requirements and repair

requirements of the top drive device series of oil drilling rigs produced by the

company after one year or 3000 hours cumulative operation.

I.Normative References

The following documents are essential for the application of this document. For

reference files with dates, only the version of the date indicated applies to this

document. The latest version of any undated reference file (including all

amendments) applies to this document.

API Spec 8C《Drilling and Production Hoisting Equipment（PSL1 and PSL2）》

SY/T6726-2008《Top drive drilling system for oil drilling rigs》

II.Wear Limit And Repair Requirements Of Main Parts

1.1 Bail Pins

1.1.1 Dimension measurement；Dimensional measurements are carried out in accordance

1.1.2 with the following table

Nominal drilling depth m Pin size mm Allowable wear mm

2000 110 ≤1.5

4000 115 ≤1.5
5000 120 ≤1.5
7000 130 ≤1.5
9000 145 ≤1.5

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1.1.3 The diameter wear of the ring pin should not exceed 1.5 mm; when the diameter wear exceeds
1.5mm, it needs to be replaced.

1.2 Bail

1.2.1Dimension measurement:Dimensional measurements are carried out in accordance with the

following table.

Dimensions of connection between the bail and the hook

The radius of the contact Other connection sizes
Nominal drilling Rated surface of bail and hook mm (recommend) mm
depth m loading E2 F2 D2 e2
max max max
2000 57.15 114.3 130 —
4000 63.5 114.3 165 —
5000 69.85 114.3 170 —
7000 82.55 114.3 180/190 —
9000 101.6 114.3 220 —

1.2.2 The wear of the bail body should not be greater than 5mm. The cause should be identified if the
wear is large.

1.3 Drilling fluid circulation channel

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1.3.1 The wall thickness of mud pipe is measured by thickness meter or ultrasonic instrument at the
positions selected at the equal distances from the weld at both ends of the mud pipe.

1.3.2 If the wall thickness of the mud pipe is less than 80% of the factory size (or less than or equal to the
given limit value), the mud pipe should be replaced.

1.4 Rotary head assembly

1.4.1 Suspension unit

1.4.1.1Dimension measurement:Dimensional measurements are carried out in accordance with the

following table.

Rotating head lifting lug size

Nominal Radius of contact surface between the

connection sizes (recommended) mm
drilling lifting lug of rotary head and the links mm
depth of
drilling rig D1 (min) C1 （max） f1 (min) g1（max） h1（max）
m
4000 44.45 101.60 150 120 180
5000 44.45 101.60 150 155 190
7000 57.15 101.60 170 155 200
9000 63.50 101.60 200 200 220

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Measure the dimensions of the lug matching with the link; the wear measured should not exceed 7mm,

otherwise replacement should be made.

1.4.2 Links

Dimension inspection should be carried out in accordance with Article 9.7 of Specification for Drilling
and Production Hoisting Equipment (PSL1) (API Spec 8C).

Lifting tool contact surface radius

Rated load Radius of upper and lower lugs of link mm
short ton C2 (min) D2 （max） H1 (min) G1（max）
250 101.60 34.93 69.85 30.94
350 101.60 34.93 69.85 37.31
500 120.65 47.63 82.55 47.63
650 120.65 47.63 127.00 57.15

Measure the dimension of the lugs at the matching positions with the links, and the measured wear
should be no greater than 5% of the nominal size; replacement is required if the wear exceeds the
specified value.
Measure the working length of the two links with a tape. If the length is less than or equal to 4.25m, the
matching error should be less than 4mm, if the length of the redundant links is more than 4.25m, the
matching error should be less than 7mm. The two links should be repaired and matched, and the
irreparable ones should be replaced.

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Part IX Guide For Prevention Of Falling Objects From
Top Drive Devices Of Oil Drilling Rigs

I.Anti-loose process of bolts and screws

In order to prevent bolt loosening and falling, all bolts and screws used in top drive are processed
with safety rope.

 Safety rope
 Daily inspection for damage required
II.Anti-loose process of traveling cable and derrick cable

The traveling cable and derrick cable hanger are equipped with hoisting wire rope and shackle. After
cable installation, the safety rope can be fixed on the derrick to prevent the cable from falling off after

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hanging up.

Daily inspection for

damage and loss
Cable wire rope
required.
and shackle

III.Anti-loose process of back-up tong assembly

The back clamp assembly is equipped with a safety block to prevent the safety accident caused by
the fracture of the pin shaft caused by vibration.

Safety Block

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IV. Anti-loose process of guide beam
Structural diagram of guide rail adjustment chain and suspension ear

Pad eye

Connecting chains

Top pull-out plate

guide

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 Guide beam anti-fall program
The guide beam anti-falling is divided into three parts: the upper part of the guide beam
anti-fall, the middle part of the guide beam anti-fall (self-structure) and the lower part of the guide
beam anti-fall (divided into two structures).
1. Anti-falling plan for the upper part of the guide beam: chain and shackle (The chain can be
replaced by a steel wire rope over Ф26mm. The disadvantage of use a steel wire rope is that the
length cannot be adjusted. The wire rope needs to be stretched straight but not stressed. Wire rope
carrying capacity ≥12.5T)

Pad eye

Adjusting
plate

Lifting lug

5-th section of guide beam

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 Fig1: The upper part of the guide beam anti-falling

Fig2: Pad eye size

Plan description：
1、The anti-fall device connects the seventh section of the guide beam with the crown block
to prevent the adjustment components (shackle, pin, connecting plate, drawing plate, etc.) from
being damaged and the crown block falling off. (Fig. 1)
2、If there are lifting lugs on the guide beam of section 7 can be used directly, only need to
weld the lug plate on the crown block to connect the chain and shackle. If there is no lifting lug, it
can be welded on site according to Fig1 and Fig 2.
3、 The length of the chain needs to be determined according to on-site measurement.
4、Model /material of lifting lug: δ20/Q345B
5、Specification list

Code Name Qty Note

T 一 BX15-1 1/8 Shackle 4

Amecican chain
G80 1 4
shackle
45 derrick (The length of the chain
φ25x125 Hoisting chain 140 section needs to be determined according to on-site
measurement)
Remarks: The anti-falling device needs to be stretched and not stressed.

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 2. The middle part of guide beam anti-falling plan (self-structure)
2.1. The connection between two adjacent sections adopts a mechanical hinge connection
structure, which effectively prevents the guide beam from disjointing. (Fig.3)
2.2. The guide beam is designed with load-bearing steel wire rope running through the guide
beam.

Fig.3 Mechanical hinge structure

3. The lower part of guide beam anti-falling plan
1). Structure 1: Wire ropes and shackles (Use this solution when derrick allows welding)
Plan description:
The specific structure is shown in the Fig.4. However, the length of the steel wire rope
cannot be adjusted. It is necessary to customize the steel wire rope according to the actual
measured length on site, or the steel wire rope has a noose at one end and a bare rope at the other
end. Use a wire rope clamp to clamp it to keep the wire rope as straight as possible.
Four lifting lugs needed to be welded on the lower part of guide beam, of which the upper

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 lifting plug can also be equipped with shackles and wire ropes (Fig 5); Two lifting lugs need to be
welded on the derrick back beam (Fig 6); The size of lifting lugs (Fig 2)

Derrick back beam

Wire rope sleeve

Shackle

Lifting lug

Fig 4. The lower part of guide beam anti-falling structure

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Fig 5. Welding position of upper lifting lug on the lower part of guide beam

Fig 6. Welding positon of upper lifting lug on the derrick back beam

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 Specification list

序号 Name Model Qty Note

No
1 Lifting lug See figure 6 Welding and detection needed
2 Shackle T-DX9.5-7/8 4
The length is according to the
actual situation and is provided by
the customer. The weight of the
Pressed wire rope
3 Over Ф26mm 2 guide beam is 12.5 tons. The wire
sleeve
rope needs to be carried and the
force angle of the wire rope is
considered.

Remarks: The anti-falling device needs to be stretched and not stressed.

2. Structure 2： Hook and anti-falling chain (this solution is used when the derrick does not
allow welding.)
Plan description：
1、The chain is wound around the derrick beam and connected with the fall prevention hook.
The length of the chain is determined according to the actual situation.
2、The anti-drop hook is connected with the bottom section of guide beam.

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Fig 7. The lower part of guide beam anti-falling structure 2

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3、Specification list

No Name Qty
Code
1 GB/T24816-2009 Hoisting chain 10 m (100 section), Length
￠20x100 is determined according to
the on-site measurement.
2 DQ70BS-03-12-09 Anti-drop hook 1
-00
3 DQ70BS-03-12-10 Anti-fall pin 2,
Equipped with split pin
￠3x45
4 Wire rope Ф3mm 1 Meter
5 Double hole 2
aluminum buckle

Remarks: The anti-falling device needs to be stretched and not stressed.

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