DQ70BS-JH Top Drive Drilling System

User Manual

Daqing Jinghong Petroleum Equipment Manufacturing Co., Ltd.

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

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

all the time.

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

assurance system:

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

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

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

structure and installation, test-running, operation, and maintenance. Refers to other

contents which arent included in the manuals and other problems during the course of

installation, usage and maintenance, if necessary, please contact us:

Tel 86-452-2345069 Fax 86-452-2340601 E-mail clb@jh-pm.com Address No.3-2Nanyuan Road, Nanyuan Investment Zone, Longsha district, Qiqihar City, Heilongjiang

Zip code 161005

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

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

petroleum drilling equipment developed since late 1980s. Using the top drive drilling

system could greatly decrease the accident of drill pipe sticking. Improve the working

performance and working security. The top drive drilling system is honored as one of

three great technical revolutions of drilling equipments in modern time.

Jinghong company developed the DQ70BS-JH top drive drilling system with

independent intellectual property rights. It integrated the mechanical, electrical and

hydraulic control technology. Our top drive drilling system takes a fully consideration of

operation while drilling, Our top drive drilling system has the advantages of simple

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

technological requirements on site. It is an important equipment for the drilling of deep

well, super deep well, horizontal well and controlled directional well in complex geologic

condition.

The main technical features are:

1. Adopt the double cylinder opposite clamping type backup tong, it could makeup and

breakout without lock the rotating link adaptor. It is more applicable, convenient and

easier to handle, makeup and breakout is fast and easy.

2. The patented structure of rack and pinion is used in IBOP of hydraulic control; the

hydraulic pipe is embedded into the body of structure in order to avoid the damage of

the hydraulic pipe for bump, which makes the operation of IBOP more reliable.

3. The patent slid-inserting type foldable structure is used in the guide beam. It is quick,

convenient and safe to install and dismantle. Comparing with the other brand top drive

drilling system, installment time of our guide beam could save 2~3 hours.

4. The patent structure of reversed oil cup is used in the main shaft seal of the gear box,

which guarantees that the lubrication will not leak in the process because the seal of the

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main shaft is out of order.

5. Driller panel is equipped with touch screen which displays the condition of system

operation and can also monitor emergency point of equipment in time, increase the

reliability of equipment operation.

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

good balance performance.

7. The system equipped with double PLC control systems which backup each other. This

design has a great improvement of the reliability of top drive drilling system.

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

installment.

9. The device of anti-loosen device with single direction tong dies, this device can load

more torque and be installed and disassembled easily.

10. The materials of cable is low-temperature resistible and wearable, which improved

the mechanical strength of cable and increased the reliability.

11. The rotating link adaptor connects with the gear box through shaft sleeve. When

tripping of raising and lowering or making a break off with bumper jars, there is no force

on the main shaft, which increases the service life of the main shaft bearing.

12. Patent technology of casing running tool, during the casing running, when the pipe

sticking or well kicking happens, it could realize the fast connection of top drive and

casing pipe, cycling the mud, avoid accidents (customer optional)

13. Equipped with the trolley of slip with pneumatic lift device, reduced the labor

intensity, and increased drilling speed (optional).

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Contents Prologue......................................................................................................................................................... 1 Summary........................................................................................................................................................ 2 Contents......................................................................................................................................................... 4 Part I Technical Parameters of Top Drive DQ70BS-JH.......................................................................... 8

I General Data ...................................................................................................................................... 8 II Drilling Parameter ............................................................................................................................... 8 III Main Motor Parameter ....................................................................................................................... 8 IV Cooling Air-blower ............................................................................................................................ 8 V Hydraulic Disc Brake .......................................................................................................................... 9 VI Electric Control System ..................................................................................................................... 9 VII Reducing gear box ............................................................................................................................ 9 VIII Pipe Handler system........................................................................................................................ 9 IX Working Curve of Top Drive DQ70BS-JH...................................................................................... 10

Part II Mechanical Manual......................................................................................................................... 12 Chapter I Structure and function Introduction....................................................................................... 12

I. Structure and function introduction ....................................................................................... 13 II. Top Drive DQ70BS-JH Working Curve............................................................................... 13 III. Power Swivel ......................................................................................................................... 14 IV. Pipe Handler Device ............................................................................................................. 17 V Guide beam and carriage ...................................................................................................... 20

Part III Electrical Manual............................................................................................................................ 21 Chapter I Safety Operation Specification.............................................................................................. 21

I Safety Notice ............................................................................................................................. 21 Chapter II Electric System Component................................................................................................. 22

I. Incoming Line Power Distributor and Protect System ....................................................... 23 II. AC Frequency Converter Driving System........................................................................ 24 III. PLC Combination Control System...................................................................................... 24 IV. Relay Box............................................................................................................................... 26 V. Hydraulic Lubrication station ................................................................................................ 26 VI. Driller Panel ........................................................................................................................... 27 VII. Touch Screen ....................................................................................................................... 30 VIII. Main Power Cable .............................................................................................................. 33 IX. Other Cable ........................................................................................................................... 34

Chapter III Monitoring System (WINCC) ............................................................................................ 35 I. Screen Instruction ................................................................................................................... 35 II. System Structure.................................................................................................................... 36 III. Top Drive Drilling System .................................................................................................... 37 IV. Network Topology................................................................................................................. 38 V. Auxiliary Interface .................................................................................................................. 39 VI. Alarm History ......................................................................................................................... 40 VII. Curvilinear Trend ................................................................................................................. 41

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VIII. System Login ...................................................................................................................... 43 IX. Logout System ...................................................................................................................... 44

Chapter IV PLC System Software and Hardware ................................................................................. 45 I. PLC Program Structure .......................................................................................................... 45 II. The hardware Structure of PLC System ............................................................................. 46 III. Switch Position and State Light Meaning on CPU ........................................................... 46 IV. Module installation, Power Distribution and Indicator ..................................................... 47 V. Programmer Upload and Download.................................................................................... 47 VI. ET200M Remote Station ..................................................................................................... 48 VII. Indicator on Interface Module ............................................................................................ 48 VIII. Remote station ET200M and module remove as well as power deploy and indicator....................................................................................................................................................... 48 IX. Communication system ....................................................................................................... 49

Chapter VI Main Electric Motor Drive System .................................................................................... 49 I. Main Electric Motor and Frequency Converters ................................................................. 49 II. Cupboard Transmission Unit Structure and Operate Principle ....................................... 49 III. Main Circuit and Control Circuit Sketch Plan .................................................................... 50 IV. Connection of Standard Control Line ................................................................................ 50 V. Extensive Characteristic of Standard Software Provide Protect for Transform, Electric Motor and Process ..................................................................................................................... 51 VI. Adjustable Power Limiter ..................................................................................................... 51 VII The primary / secondary control of Transmission ......................................................... 51

Chapter VII Installation, Commission and Maintenance ...................................................................... 52 I. Electric installation and commission notices ....................................................................... 52 II. Electric system reinstallation ................................................................................................ 53 III. Galvanization examine ......................................................................................................... 53 IV. Daily maintenance ................................................................................................................ 54

Part IV Hydraulic Manual........................................................................................................................... 55 Chapter I Safety Operation Specification.............................................................................................. 55

I Safety operation notification ................................................................................................... 55 II Electric system operation notification ................................................................................... 56 III Hydraulic system operation notification .............................................................................. 56

Chapter II Hydraulic system structure and Principle............................................................................. 58 I Hydraulic System Structure and Working Principle............................................................. 59 II. Control valve unit and execute device ................................................................................ 63 III Control Loop on Hydraulic valve block................................................................................ 66

Chapter III Hydraulic oil ....................................................................................................................... 70 I Selection of hydraulic oil.......................................................................................................... 70 II Hydraulic oil Changing............................................................................................................ 70

Chapter IV Hydraulic system Commissioning and Maintenance.......................................................... 71 I System pressure adjusting...................................................................................................... 71 II Pre-setting and adjusting of hydraulic system pressure.................................................... 72 III Hydraulic system daily maintenance request..................................................................... 72

Part V Installation and Commissioning ................................................................................................... 74

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Chapter I Safety Operation Discipline .................................................................................................. 74 I Safety operation note............................................................................................................... 74

Chapter IIInstalling preparation............................................................................................................................................................... 76 Chapter III Installation .......................................................................................................................... 79

I. Installing the guide beam ....................................................................................................... 80 II. Installation of Top Drive Main Body..................................................................................... 89 III. Cable installation ................................................................................................................... 95 III Auxiliary Device Installation .................................................................................................. 98

Chapter IV Inspect after installation ................................................................................................... 100 Chapter V Test Running...................................................................................................................... 101

I Electric Device Test-running ................................................................................................. 101 II Assist Function Test Running.............................................................................................. 103

Chapter VI Top Drive Disassemble .................................................................................................... 104 I Accessory equipments disassemble ................................................................................... 104 II Cables disassemble.............................................................................................................. 106 III Disassemble Top Drive Main Body ................................................................................... 106 IV Disassemble the guide beam............................................................................................. 110 Attachment I Top Drive System Electric Wiring Installation Inspecting list ................. 113 Attachment II Top Drive System mechanical installation inspecting list........................... 114 Attachment III Top Drive System Installation and Commissioning Record ..................... 115

Part VI Operation Manual ................................................................................................................... 117 Chapter I Safety Operation Rules........................................................................................................ 117

I. Safety operation notification ............................................................................................. 117 II. Operator safety operation notes ........................................................................................ 118

Chapter II Operating Procedure .......................................................................................................... 121 I. Inspection before starting ..................................................................................................... 121 II Hydraulic system operation............................................................................................. 124 III. Main Motor Heater .............................................................................................................. 126 IV. Main Electric Motor air Cooler........................................................................................... 126 V. Braking mode selection ....................................................................................................... 127 VI. Drilling operation ................................................................................................................. 129 VII. Backup tong operation ...................................................................................................... 134 VIII. Elevator link operation ..................................................................................................... 134 XI. Make Up and Breakout Operation.................................................................................... 136 X Drilling ahead by single ........................................................................................................ 141 XI. Drilling ahead by triples ..................................................................................................... 142 XII. Backreaming...................................................................................................................... 143 XIII Pulling out operations ....................................................................................................... 144 XIV Running Casing ................................................................................................................. 146 XV Well Control Operation ...................................................................................................... 146 XVI Jarring operation ............................................................................................................... 147 XVII Release drilling torque operation ................................................................................... 148 XVIII Emergency stop operation............................................................................................. 149

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XIX Reset/Mute ......................................................................................................................... 149 XX Stop System ........................................................................................................................ 149

Appendix I System Initial State........................................................................................................... 150 Attachment I. Driver cabinet initial state................................................................................ 150 Attachment II Driller panel initial state ................................................................................... 150 Attachment III PLC Cabinet Initial State................................................................................ 151 Attachment IV Monkey board operation box initial state .................................................... 151

Part VII Maintenance Manual ............................................................................................................ 152 Chapter I Safety Operating Rules........................................................................................................ 152

I Safety Operating Rules ......................................................................................................... 152 Chapter II Daily Inspection ................................................................................................................. 153

I It is important to inspect the following items....................................................................... 153 Chapter III Maintenance Items and period.......................................................................................... 154

I Daily maintenance Items ....................................................................................................... 154 II Weekly Maintenance Items.................................................................................................. 155 III Monthly Maintenance Item.................................................................................................. 159 IV Maintenance Items in each quarter................................................................................... 162 V. Maintenance Items in half year .......................................................................................... 162 VI Maintenance Items every year........................................................................................... 163 Attachment A Torque value of thread hastening .................................................................. 164 Attachment B Recommendation of gear oil selects............................................................. 164 Attachment C Recommendation of Greases selects .......................................................... 164

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Part I Technical Parameters of Top Drive DQ70BS-JH

I General Data

Rated Drilling Depth: 7000 m114 drill stem Max. Load capacity: 4500 kN (350ton)

Main channel: 75mm

Rated circulating pressure: 35MPa5000psi System Weight: 12.5tMain body Working Height: 5.9m (Bail surface to elevator upper surface)

Electric Volt: 600VAC

Rated Power: 315KWX2 422HPX2

Ambient Temperature: -3550 Altitude: 1000m

II Drilling Parameter

Rotary speed: 0230r/min adjustable Work torque: 55kNm (continuous) Max. Torque: 82kNmdiscontinuous

III Main Motor Parameter

Related Power: 315KW X2 continuous

Related Rotary speed: 1150r/min

Max. Rotary Speed: 2600r/min

IV Cooling Air-blower

Model: M2JA132S2A

Rated Power: 5.5kW

Rated Volt: 380VAC

Rated Frequency: 50Hz

Rated Currency: 10.7A

Rated Rotary Speed: 2905r/min

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V Hydraulic Disc Brake

Braking Torque: 68kNm (50,000ft-lb) Cylinder Work Pressure: 7.5MPa

VI Electric Control System

VFD Input Volt: 600VAC

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

VII Reducing gear box

Ratio of velocity: 10.97:1 double grades speed reducing

Lube: Gear pump forced lubrication, air cooling

VIII Pipe Handler system

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

Hydraulic motor work pressure: 13.5MPa

Upper of IBOP (remote control): 6 5/8" API REG boxpin70MPa Lower of IBOP (manual): 6 5/8" API REG boxpin70MPa Backup Tong Diameter: 216mm Backup tong retaining range: 87216mm Link: 2740mm, 350t

Leaning angle: forward 35, backward 55

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IX Working Curve of Top Drive DQ70BS-JH

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Top Drive DQ70BS-JH Dimension

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Part II Mechanical Manual

Chapter I Structure and function Introduction

The Top Drive System used on oil drilling rig could drive the drilling drill string rotate

from the top of drilling tool directly, it also could rotate and release the drilling bit, it

could move along with the guide beam up and down to finish drilling.

Top Drive DQ70BS-JH Dimension

Counterbalance device

Cover Assembly

Gear Box

Air cooling Device

Wash pipe packing assembly

Bail

Link

Back-up Tong

Anti-loosen Device

IBOP Control Device

Manual IBOP

Main Motor Brake Device

Rotating Link Adapter

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I. Structure and function introduction

Mechanical structure of Top Dive Drilling System includes assembly and

components as follows:

Power swivel Pipe handler System Guide Beam and tackle

II. Top Drive DQ70BS-JH Working Curve

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III. Power Swivel

The Power swivel consists of main motor, break above the motor and air cooling system

on the top of motor, balance device, bail, washing pipe assembly, gear box and other

components. The main function of power swivel is to drive the main shaft rotate to

drill, make up and break out, as well as circulate mud to ensure the drilling work

carrying on regularly.

1. Main motor 2 sets of Main motors are installed on the gear box. Motor

has double axles, the lower axle connects with main

transmit gear, upper axle connects with braking system.

Each main motor could supply 315KW power

continuously. The rated rotary speed is 1200r/min in

60.6Hz frequency, stepless speed is adjusted by AC

speed adjusting system. The rated output torque value of

motor could be set by currency, Output torque is

proportional to currency. The motor is protect type

compel air, cooled air pass through the motor inside and

discharge from the air outlet.

Main Motor Bail

Wash pipe Assembly

Gear Box

Brake and air cooling Device

Counterbalance device

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2. Air-blower and Braking Device Air-blower is installed above brake system, driven by the flameproof 3P AC

asynchronous motor which power is 5.5KW. Air blower starts to absorb air from air inlet

on cooler shell, release it from the air outlet on the lower part, this simple and strong

guarantee reliable airy.

The hydraulic operating disc brakes installed on the upper axle of motor, it brakes via

the brake disc on hydraulic oil tank. The brake energy is proportional to the pressured

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

the movement of hydraulic cylinder. There are 2 self reset springs on each braking

disc, springs could reset when the braking discs release. The braking device has 3

functions while the top drive system working.

A. Bearing the reversed torque of drilling tools in well.

B. When touch sticking, if the motor torque is equal to the reversed torque, the drilling

tool would bounce, so take measures to brake the main shaft to prevent the drilling tool

drop out while reversal rotating.

C. It works as brakes while the motor galloping.

Brake Body

Brake Pad

Brake Disc

Brake Fix Seat

Main Motor

Protect Cover

Encoder

Encoder Frame

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3. Gear Box Gear Box adopts double-geared drive,

transmission ratio is 10.97:1, the gears are all

helical gear, large transfer torque, little noise.

Bearing are SKF bearing, strong anti-seismic

capability and anti-attack capability.

The lubricate system of gear box is gear pump

force lubrication. The lube pump is driven by

motor of 1.1KW produced by ABB. The motor

spreads lubricate oil on oil points of double filter

and cooling device, via main shaft return to oil

cabinet. DQ70BS-JH top drive system adopts

force lubricate mode, bearing and gear could

contact the oil sufficiently to ensure the

reliability of lubrication. Install the pressure

detector and temperature cell in the lube pipes,

inspect and alarm the pressure and oil temperature of lube system.

4. Wash Pipe Assembly Washing pipe assembly is installed between the mail

shaft and gooseneck, the mail shaft rotating drives the

four loops of sealing ring in washing pipe packing to

rotate, so regular inspection and maintenance is

necessary to prolong its service life.

5. Gooseneck Gooseneck is installed on the washing pipe frame, bottom

is connected with washing pipe, the sealed top is the

transmission channel of mud circling, open the top to start

fishing and well logging. Its top is connected with drilling

hose, it is the inlet of drilling fluid.

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6. Bail balance system

Bail is the importance bearing component of Top

Drive System. The bail is connected with gear box

via bail pin, its top is hanged on the hook of crane.

Balance cylinder is fixed on bail, the main function is

to balance the weight of main body. Jinghong top

drive system adopts single hydraulic cylinder

balance mode to solve the problem of unfair force

on connecting rod in double cylinder system. Single

hydraulic cylinder designing ensure the system

works more safe and reliable.

Bail could connect with crane as well as the hook,

ensure enough well sites requires.

IV. Pipe Handler Device

Pipe handler device is the important element of top drive system, it consists of leaning

unit, back-up tong assembly, thread loose-proof device, IBOP, rotate head and other

components. It could highly improve the automation of drilling.

Rotating Link Adaptor

Leaning Device

IBOP

Thread Anti-loosen Device

Backup Tong

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1. Rotating Link Adaptor

Rotating Link Adaptor is installed on the fixed shaft

connected with gear box, and moving independently

from main shaft, the structure as the draft.

The rotation of Rotating Link Adaptor i is driven by

hydraulic motor, it could rotate CW and CCW, it

propels the link to rotate 360, it is easy to catch the

drilling stem in mouse hole. It is also convenient to

catch the drilling pipe on rack frame while the main

body is moved to Kelly board. The rotary of rotate

head normally be set at 3 r/min. It could be adjusted according to the customer

requirements.

2. IBOP The Function of IBOP: when the pressure in well is higher than

the pressure in drilling string, cut down the channel inside of

drilling string by close up the IBOP to avoid well kick or blowout.

IBOP is installed between the saver sub and main shaft. It is

composed of remote IBOP upside and manual IBOP in low part.

Remote IBOP upside is connected with the main shaft of power

swivel, the manual IBOP in low part connects with saver sub, the

saver sub is connects with drilling stem while drilling. The inner

and outer threads in IBOP are 6 5/8REG.

The remote IBOP changes direction operated by hydraulic

tank. The gears work with rock running drives the ball valve

to rotate 90 opening and closing the IBOP. The Top drive

adopts gears and rack to realize the open and close of IBOP,

process the advantages of simple structure, driving accuracy,

and high transmission reliability.

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3. Side-hanging couple clamp

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

clamp backup tong on Jinghong Top Drive system operates

only once on drillers panel directly to make up and breakout

without locking rotating head. This design is convenient to

change clip tooth, it clamps tightly. Oil pipe lines are

designed inside the body. Not any pipe lines explored to

avoid scratching as well as improving work reliability.

4 Drilling string anti-loosing assemble Install anti-loosing assemble between the joints of main

shaft and IBOP joint and the thread of saver sub in order to

prevent them from loosing when the top drive system

breakout. See the structure on the right.

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V Guide beam and carriage

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

working.

The carriage connects with gear box inputs in the guide beam, and slide along with top

drive, transmits the torque to the guide beam. The upper guide beam is connected with

the bottom beam of crown block. Lower guide beam is connected with spreader beam

of the derrick. The torque can be directly transmitted to the lower derrick. The main

point is guide beam produced by JH is folding structure without install lock pins, which

makes installation convenient and reduces risk and cost.

Carriage

Bearing Wheel

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Part III Electrical Manual

Chapter I Safety Operation Specification

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

manual first.

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

be done by professional or specially trained people, if not, it maybe cause personal

injury or machine damage.

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

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

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

I Safety Notice

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

maintenance of the Top Drive, all the operator and the attendant must read it carefully

and understand it:

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

qualified and follow close to safety operation specification.

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

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

current.

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

combustible gas environment.

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

power of the Frequency Converter, test the electric current and hanging the caution

sign DO NOT shut the switch, people working. Do not maintain major loop, before DC

bus voltage lower in the safety area (DC 24V), (normal after 30 minutes). It is

dangerous for human safety and electrical equipment!

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

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

cabinet.

6. Keep protective gas pressure when turn the drillers console on. If the drillers

console protective gas pressure lost, it is required to resume quickly or turn off the

drillers console controlling power.

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

8. Forbidden relieve the link of software and hardware. If really needed, resume as

soon as possible after clearing fault.

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

conditioner to cooling and dehumidify.

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

power was off more than 30 minutes.

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

prevent electric equipment to dewing.

Chapter II Electric System Component

Electric control system is mainly composed of Coil-in electric energy power splitting protect

system, frequency conversion driving system and PLC combination control system.

The generator supplies 600V main power to the primary air switch (EIN1000) produced by

ABB in electrical control room. The air switch is perfect in bearing powerful current

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produced when switch. The major switch connects the major power to 2 sets of frequency

converter. The other circuit is connected to auxiliary transformer, which provides main

power to the PLC cabinet of 380V.

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

they drive 2 sets of 315KW AC motor separately. These 2 motors work separately or drive

together (primary and secondary mode), could self-detect and protect.

As the center of driving control system, the PLC produced by ABB adopt the mode of one

using and one preparing to ensure system working safely and reliably. This mode is: when

one system is working, another same system is prepared always, and when the running

system work wrong, another system can work immediately, so drilling will not be delayed.

PLC integrated control cabinet is needed to control the Top Drive Drilling System. The PLC

system is connected with driller consol and drilling system with the help of PROFIBUS line.

The system main PLC controller is S7-300 system programmable controller produced by

Siemens, and the CPU is 315-2DP, the remote control station is ET200M.

I. Incoming Line Power Distributor and Protect System

This system is mainly component of Income

cabinet. The Income Cabinet includes main air

switch, auxiliary transformer, controlling

transformer, and electric relay etc.

The major air switch is the master switch of the

Top Drive Drilling System produced by ABB;

auxiliary transformer power is 80KVA, and its

function is transforming the three phases

alternating current from 600 V to 380 V and

supply to integrated cabinet as power station. T1

is control station, and the power is 630VA.

Transform 600 V AC to 220V and 24V AC, as to

scram and no-voltage protection, and control the

main air switch. SB1 is installed on the integrated

cabinet, 1SB3 is the dead-stop button, installed on the drillers panel.

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II. AC Frequency Converter Driving System

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

motors. The frequency converter is produced by ABB, and the model is ACS800.

Three-phase alternating current of 600V is input frequency converterrectified and inversed to transform to three-phase variable frequency power, and used to drive the

AC variable frequency motor.

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

and rated currency is 405 A. This system has the foundation of anti-rotate. When the

drill pipe locked, the motor speed will reduced rapidly; when reactive torque is bigger

than the drive torque, the motor stop rotary, and this is called motor-blocking. When

the drive torque is bigger than the reactive torque, the motor will speed up to setting

speed.

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

III. PLC Combination Control System

Include logic control system and AC distribution system of all units. PLC Integrated

Control Panels is as follow

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A. Indicator light

a. Power indicator light of 24V: switch on the system, then power of all units is OK;

system is ready, indicator lights.

b. Hydraulic oil heating light: light on while heating hydraulic oil.

c. Motor hearting indicator: light on while motor heater working.

d. Fault/alarm light: while system alarm, light flashes (1 Hz); while fault, light

keeps.

e. Back up indicator.

B. Hand switch

a. A/B system select switch : at A position, first PLC work; at B position, second

PLC work.

b. Hydraulic oil heater switch

c. Motor heater: used for controlling major motor heater. This switch can work

independent upon PLC. The indicator displays the working state of heater. After

turn on the power of the frequency converter, the link-control is added, and the

main motor stops to be heated.

d. Reset/silence button (SB1): when system alarm, the indicator flashes, the

Warner alarms. Press silence button, the fault/alarm indicator keep state.

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e. Photoelectric encoder of the main electric motor (SA5): when drilling normally,

switch to normal, and this can control the rotary torque accuracy. When fault of

encoder appears, switch to unmoral, and this can stop the efficient of drilling

rate.

f. Mud pump link switch (SA6): use for mud pump link-control. In link-control state,

if the mud pump did not give the stop order, when switch the IBOP to close, the

IBOP can not close. If well blowout happen, press well control button, the mud

pump will stop and the IBOP close. In unlink-control state, operate the IBOP

switch on drillers console can control the IBOP.

g. Back up switch

IV. Relay Box

Relay box is set on the body of top drive, the function of it is providing power for

detecting element, feedback detection signal, and provide control power signal for

control valve.

It can read out air pressure signal of main cooling motor, temperature signal of main

motor, over temperature alarm, temperature signal of hydraulic oil, pressure signal of

lubricating oil, pulse signal of main motor encoder, and etc.

V. Hydraulic Lubrication station

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

lubricating pump motor (1.1KW), etc. It is controlled by drillers console. The electric

motor adopts flame-proof type three-phase asynchronous motor. Lubrication station

is set on top drive body.

1. Hydraulic pump have three tap positions: 1). auto, 2). start, 3). stop.

1). Auto: switch to auto, the system will run based on the PLC program.

2). start: switch to start, the hydraulic pump will run.

3). Stop: switch to stop, the hydraulic pump will stop.

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

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VI. Driller Panel

The Driller panel has all functions for drilling operation and any other auxiliary

operation for driller; it can set top driver speed, torque, operation mode.

The Driller panel is EX type; it can only be powered on when driller panel inter pressure

is normal, otherwise, it would indicate air pressure losing on touch screen.

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

No name Type Function

1 frequency conversion emergency stop button

1SB1 self-locking

When the frequency conversion or main motor break down, press this button and then frequency conversion stop. After eliminated the fault, should reset (CW rotation)

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2 Ready light 1HL1 green light When systems all are ready, it lights. 3 Fault/alarm

light 1HL4 red light When system alarm, it flash once a second; when

break down, it lighting. 4 Brake light 1HL2 red light When braking, it light. 5 Brake mode

Brake/off/auto 1SA10 three positions switch

At brake mode, when electron magnetic valve work, system braking and it light. At auto mode, PLC control system braking auto. At off mode, solenoid valve releases, main shaft rotate freely.

6 IBOP light 1HL3 red light When IBOP closed, it lights. 7 IBOP

closed/open

1SA11 two positions switch

At closed positions, hydraulic valve close the IBOP, so as to close the mud circulatory system.

8 Well control 1SB2 red button When well blowout, press this button to link with other equipment.

9 Motor selection A/A+B/B

1SA5 3 turn button

Select motor of top drive: M1 or M1+M2 or M2

10 Hydraulic pump running light

1HL5 green light When hydraulic pump running normally, it lighting.

11 Hydraulic pump switch auto/stop/start

1SA6 three positions button

At stop positions, hydraulic pump stop; at start positions, hydraulic running; at auto positions, run as the PLC result.

12 Elevator link centre

1SB3 button This button controls the electric valve of link center. When press it, the link is over the well

13 Elevator link rotary Counterclockwise/clockwise

ISA9 Three positions resetting key

It is a resetting key with spring. When turn it on counterclockwise positions, the link rotate counterclockwise; when turn it on clockwise positions, the link rotate clockwise; when unclench it, it go back center positions automatically.

14 link incline backward/forward

1SA7 three positions, resetting key

A resetting key with spring. Oil case will be locked, when its on center positions. Turn it on forward, incline oil case will push the links and elevator to the rat hole; when reclinedwill make the elevator be off the drilling tool when drilling.

15 Hydraulic elevator

1SA8 three positions button

Shut/pen elevator

16 motor cooling fan auto/off/on

1SA2 three positions button

For control the cooling fan running. At on, fan starts, at off fan stops. At auto, according to PLC output result.

17 motor rotary direction

1SA3 three positions button

Control the direction of main motor

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backward/stop/forward

18 operation mode drill/spin/torque

1SA4 three positions switch resetting on right

Setting according to the value of the limited max torque.

19 backup tong Release/Lock

1SA4 two position button Reset to left

Rotary to right, start backup tong tight the drill pipe. Leaving hand reset to left automatic, backup tong loose.

20 makeup torque potentiometer In makeup operation, set limit in transducer, and set max torque.

21 Drilling torque potentiometer In drilling operation ,set limit in transducer, and set max torque

22 setting speed of drilling

potentiometer In normal drilling operation, set limit in transducer, and set max speed.

23 Torque Guage indicator Show true torque of Top driver output with KNm unit.

24 Rotary Gauge indicator Show true rev of master axis with r/min unit. 25 Return/Mute Green button Back to start and mute 26 Break out jump Green button Press this button, hydraulic pump increase press to

balance oil tank, lift top drive 7cm, protect from damaging the connect thread of pipe.

2). Throttle hand wheel

Throttle hand wheel is used for set normal drilling rotary speed limiting on frequency

converser. Handle scale is set. When rotate hand wheel inverse hour, the drilling speed

low down, and the minimum is zero. When rotate hand wheel clockwise, the drilling

speed increase, and the maximum is 230r/min. The rated speed is the main shaft

output speed 110r/min.

3). Drilling Torque

The scale of drilling torque handle is set by system. Turn the handle counterclockwise,

will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn

the handle clockwise, will increase the limit torque, while getting to the limit positions,

the limit torque the rated torque (55kN.m).

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

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4). Makeup Torque

The scale of drilling torque handle is set by system. Turn the handle counterclockwise,

will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn

the handle clockwise, will increase the limit torque, while getting to the limit positions,

the limit torque the rated torque (55kN.m).

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

VII. Touch Screen

Generally, all operation interface can be divided into 3 areas, each of them display

separate information.

Toolbar: at the bottom of the screen, frame switch, data and time are all in toolbar.

Display area: in the centre of the screen, it is used for oversee and controlling.

Title panel: display name

Chick on the button to enter interface as follow:

1). Main frame; 2). Auxiliary frame;

3). Alarm frame; 4). Senior management.

1). Main Frame

Display output torque, output speed, as well as both motor parameters, include: motor

speed, running frequency, motor electric current, motor power, motor temperature,

alarm, fan running order, and etc.

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2). Auxiliary Frame

Include elevator system, hydraulic system, lubrication system, other system notes.

Elevator system includes elevator co-rotation, elevator reversal, elevator incline back

and elevator middle position.

Hydraulic system includes: hydraulic pump run, hydraulic system oil low, oil

temperature high alarm, oil heating as well as oil temperature note.

Lubrication system include: lubrication pump run, low pressure, temperature high

alarm, heating and lubrication temperature notice.

Other system include: IBOP valve open, IBOP valve closed, backup tong clamping,

backup tong loosen, braking notice.

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

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3). Alarm Frame

Recording all alarm events when running.

4). Senior management

Frame can only enter after login; user name JH and password 8888 can login

through flashing window.

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Frame is as follow after login. Green is current state. User can decide by self

whether test and whether turn back.

VIII. Main Power Cable

The function of main power cable is to send the frequency conversion output of main

control cabinet to master motor on Top driver.

For installing and connecting easily cable has three segments:

1. The first segment is ground cable; its 26m, from main control cabinet to derricks

base.

2. The second segment is derrick cable; its 48m, from derrick base to top.

3. The third segment is traveling cable, its 26m, and one joint connect to the main

electric motor, another to derrick cable.

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

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

34

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

The joint of three cable and the joint between main motor and coil out cabinet adapt

CIRCULAR CONNECTOR, and operate conveniently outside.

Pay attention of insert enough and lock reliably.

According to distance between top drive electric control room and derrick, the power

cable length is chosen. If the traveling cable and the mast cable (total 74m) is enough,

the ground cable is not need.

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

IX. Other Cable

1. Driller panel Control Cable

Driller panel control and communicate totally adapt three cables.

1. Ten core driller panel control cable: Four cores for drillers console control

power, two cores for stop emergency control, two cores for transform of A/B

system, and other two cores are spare.

2. Two core communicate cable: total 2 cable, one for A system communicates,

and another for B system communicates. There are marked on joints and

sockets.

2. Cable of Relay Box

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

power and control signal to the functor on body, and feedback the functor actuating

signal and detectable signal to the composite controller cabinet or frequency converser.

Cable between coil output cabinet and relay box is two.

1.15 core assist power cable: cable size 36+64+52.5

Among of them, provide to hydraulic pump power is 36 mm2; to 2 sets of main motor

fan is 64 mm2; to lubricate pump motor is 32.5mm2; to hydraulic oil heater is 12.5mm2, lubricate heater is 12.5mm2

2. 60 core composite control cable: cable size 3021

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

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

3. The two cable is divided into three section: ground cable 26m; mast cable 48m;

travelling cable 26m.

3. Repeat Earth electrode

Electric controlling system of top drive drilling system adopts three phase four-wire

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

earth electrode with copper wire of 70 mm2.

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

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

electrode is knock into ground 300mm.

All cable joint adapt fast plug connection, the plug and socket both

mark, take care when connecting or the plug may be damaged. Ensure that

lock the nut.

Chapter III Monitoring System (WINCC)

I. Screen Instruction

Each operate panel can be divide into three areas as follow to give different

information.

Toolbar: displayed at the bottom of the screen, usually used to exchange button in the

area and show current date and time.

Display area: in the central section of the screen, it is main area for monitoring and

operation.

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Title bar: show name.

Chick on the icon on toolbar to enter corresponding screen:

System structure screen

Top drive drilling system screen

Network topology screen

Auxiliary interface screen

Alarm history screen

curvilinear trend screen

System login screen

System logout screen

II. System Structure

Chick on system structure to enter screen as follow:

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

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

electric motor

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

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

well as elevator link state

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

III. Top Drive Drilling System

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

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

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

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In this screen, operator can know:

A main motor parameter: Motor current, motor pressure and others totally 8 data.

B main motor parameter: Motor current, motor pressure and others totally 8 data.

Running state of A cooling fan, Running state of B cooling fan

And also top drive drilling real torque and speed

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

IV. Network Topology

Chick on the network topology to enter screen as follow:

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

decision fast.

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

converter

39

V. Auxiliary Interface

Chick on auxiliary interface to enter interface as follow:

In this interface, it show the work state of any other auxiliary units exept top drive

driling system. General speaking, it can be divided into six parts.

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

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

if there are fault.

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

well as fault.

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

backup tong.

5. Show body working state, include drilling waiting, drilling and others, totally 7

items.

6. Control panel indicator, include show A/B system running, and items showed

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with panel synchronously.

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

VI. Alarm History

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

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

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

a mark of +.

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

the status bar appears -.

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

Chick recent pigeonhole or future pigeonhole can see alarm history.

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

alarm history can be seen totally.

41

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

the last alarm.

VII. Curvilinear Trend

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

In this interface, include two mode: realtime curvilinear and history curvilinear, these

two modes can be cut over by button of realtime curvilinear and history curvilinear.

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

42

43

VIII. System Login

Chick on system login in toolbar to enter interface:

All buttons in this interface can operate only by people login. According to different

user grade, the operation limited is different. No matter in which interface, press

44

ctrl+A can login.

Include: Reversal rotary allowed; Reversal rotary forbidden; Cut over to Chinese

interface; Cut over to English interface; User manage

IX. Logout System

Chick on logout button in toolbar, enter interface as follow

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

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

WINDOWS.

Logoff system, logoff current user and return to welcome interface.

Reset compute,

Turn off computer

45

Chapter IV PLC System Software and Hardware

I. PLC Program Structure

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

implementation system emergency operation mode, use function block

required to complete the driver communication and control, to achieve the

work requirement of Top Drive process control.

OB82OB85OB86OB87OB121OB122Diagnostic interrupt organization block, it is used for the PLC system in the I / O access error, OB errors, rack failures,

communication errors, programming errors and module errors to provide

diagnostic information, and to prevent the CPU shut down.

FC3: emergency stop signal of implementation system, according to requires to

control the emergency stop signal.

FC4: control functions of implementation pump; complete the automatic control of

hydraulic pump and lubrication pump.

FC5: The ability to control the rings, to realize the control function of ring moving

forward, backwards, forward, reverses control functions.

FC6: Implement the control functions of back clamp.

FC7: Implement the spindle drive brake control functions, based on options,

achieve the shaft brake control as required.

FC8: Realize the well control state and IBOP control.

FC11: Implement the motor selection, according to working conditions, select the

working condition of spindle motor.

FC12: implement the main motor fan control function, based on selection state of

the spindle motor, control ventilation motor and spindle motor.

FC13: implement the output signal to the spindle motor inverter, select according

to the spindle motor, output signal to the converter to keep the inverter in a

standby state.

FC14: implement the data transfer functions, based on control instructions to

control the inverter to run / stop.

FC15: implement the speed of a given data conversion.

FC16: implement the torque limiter of a given data conversion.

FC17: implement the drilling process memory.

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

46

limiter.

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

FC20: implement the read and write capabilities of the inverter and PLC.

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

is over.

FC22: Implement the indicating function of system failure.

FC23: implement the communication failure function.

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

FC25: implement the additional function of program.

FC26: implement the transformation function of the main inverter "There encoder

run / non-encoder run".

FC27: Implement the indicating function of work state.

II. The hardware Structure of PLC System

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

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

analog input, analog module.

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

switch output, analog input, analog module.

III. Switch Position and State Light Meaning on CPU

1. State light on CPU

SF System fault Normal on (red) Hardware or software error

or fault

BUSF Double Bus

Fault

Normal light on/flash

ed)

Network fault or site lose

DC5V Inner power Normal light on (green) CPU power normal

FRCE pushed

output

Normal light on (green) Programming unit pushed

output

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RUN CPU

running

Normal light on (green) CPU running state

STOP CPU stop Normal light on /flash

yellow)

CPU stop state

2. CPU Work mode select switch to three position

Up Running+programme CPU running and can revision programme online

Middle Stop CPU stop

Down memory dump Clear inner RAM

IV. Module installation, Power Distribution and Indicator

1). All modules of PLC system are set on guide beam, when replaced loosen the

fastening screw at the bottom of the module. Install modules from front to behind one

by one, and remove the opposite order.

2). Each channel of switch valve input/ switch valve output module has one indicator,

green light means channel in 1 logic state.

3). Analog quantity input/ analog quantity output module is set to 0-10V input/output.

If the hardware configuration fault or DC24V power breakdown, the red light on module

will turn on.

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

V. Programmer Upload and Download

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

computer. If replace the CPU or memory of CPU damaged, the follow two methods can be used for

return routine: one is insert the memory to he new CPU while no power, then reapplied

power, the program will load to CPU automatically. * Upload and download program should be only done by professional.

48

VI. ET200M Remote Station

The hydraulic system is set on the body of the top drive drilling system, this reduce one

remote station, as well as assistance floor control is option, so the top drive drilling

system electric system has only one remote station. With this design, the fault rate

reduces. The remote station has 8 wave bands Code Switch used for set Profibus station

address. On the Profibus plug has switch, the last station of the system must connects

to a terminal resistance. While switch to on position, the Profibus plug connects to

terminal resistance.

VII. Indicator on Interface Module

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

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

software error or damaged

BF Bus fault Normal light on/flash

(red)

Communication fault with CPU

ON Inner power Normal light on

(green)

Control power normal

DC24V Input/output

power

Normal light on

(green)

Input/output power normal

VIII. Remote station ET200M and module remove as well as

power deploy and indicator

1). ET200M and module are both installed on guide beam, when replace the

module first loosen the screw at the bottom of the module. While install from

front to behind one by one; while remove from behind to front one by one. The

detail can be seen jin S7-300 hardware installation manual.

2). Each channel of switch valve input/ switch valve output module has one

indicator, green light means channel in 1 logic state.

3). Analog quantity input/ analog quantity output module is set to 0-10V

49

input/output. If the hardware configuration fault or DC24V power breakdown,

the red light on module will turn on.

IX. Communication system

1 #

B 2A 2B 1A 1

O N

B 2A 1 B 1 A 2

2 #

O F F

A P L C D P

B 2A 1 B 1 A 2

3 #

O F F

B P L C D P

B 2A 1 B 1 A 2

4 #

O F F

1 #

B 2A 1 B 1 A 2

5 #

O F F

2 #

B 2A 1 B 1 A 2

6 #

O N

A P L C D P

B 2A 1 B 1 A 2

7 #

O N

A P L C D P

D P 1 D P 2 D P 3 D P 4 D P 5 D P 6 D P 71122

C Z 1 2

C Z 1 3

C Z 2 2

C Z 2 31122

3

3 3

3

K A 1 K A 2 K A 3

Chapter VI Main Electric Motor Drive System

I. Main Electric Motor and Frequency Converters

Top drive drill system has 2 frequency conversion transmission units, control electric

motor separately. The transmission units mode are ACS800-07-0490-7.

II. Cupboard Transmission Unit

Structure and Operate Principle

1). Protection grade of cupboard transmission unit is

IP 21;

2). Cupboard transmission unit components:

Fuse cutout (main button/);

Auxiliary circuit fuse plug;

Inlet contactor;

EMC Filter cupboard with +E202;

Transmission control units (RDCU, RMIO); Frequency

conversion module;

Internal braking carrier;

Profibus-DP adapter;

Pulse coder port;

50

Communication adapter.

3. Swing-door structure installed optional control panel

fuse-switch operating handle

contactor control the operation

of switches and emergency

stop button.

III. Main Circuit and Control Circuit Sketch Plan

IV. Connection of Standard Control Line

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

signal.

Communication Model Port 1:

RPBA,

Communication Port 2: RATA-02C Motor Control I/O Panel Communication optional Module:

RDCO-02

External control by analog/digital inputs/outputs signal.

Control Panel Connector

~ = =

Brake Unit

AC Power Supply Frequency Convertor Output

Brake Resistance

~

51

6 programmable digital input port

2 programmable mimic input port

3 programmable relay input port

V. Extensive Characteristic of Standard Software Provide

Protect for Transform, Electric Motor and Process

1). Environment Temperature

2). DC Overvoltage

3). DC Undervoltage

4). Transform Temperature

5). Input Shortage

6). Overcurrent

7). Power Limiter

8). Short Circuit

9). Defencive Function of Programmable

VI. Adjustable Power Limiter

1). Control signal oversee;

2). Danger frequency step over;

3). Current and torque amplitude limiting;

4). ground fault protection;

5).EXTERNAL FAULT;

6). MOTOR PHASE LOSS;

7). Protection of locked-rotor;

8). Electric motor Over-temperature protection;

9). Electric motor buffer under run protection;

10). Control PANEL LOSS.

VII The primary / secondary control of Transmission

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

ACS 800 frequency conversion transmissions, meanwhile, motor shifts connect each

other via gear, chain and convey belt. Loading could be divided in to transmission units

52

fairly due to the primary/secondary function. The outside control signal could only

connected with Primary Motor. Primary motor controls the secondary by Optical fiber.

Primary motor is typical speed control, other transmission units follow the torque and

speed of primary motor. Normally, when the motor shaft of primary and secondary

motor is connected by gear or chain, the secondary should adopt torque control mode

to delete the speed gap between transmission units.

This transmission drive system has single motor mode (A or B) and double motor mode

(A+B). Double motor mode adopts the control of primary/secondary

Chapter VII Installation, Commission and Maintenance

After carried to the well site, install and commission as follow. This manual mainly

provides general requirements and notices about electric system installing and

commission.

I. Electric installation and commission notices

Notices before installation

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

reconnection correctly.

2). Before confirm everything is OK, keep power off and hang no switch on, people

working mark.

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

power cable, to ensure people and equipment safe.

4). Install worker must wear labor protection appliance.

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

on.

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

order to prevent to drop off.

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

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

9). Read the electric manual carefully, master electric theory and circuit diagram. 10). Electric controlling room is designed of anti-explosion, therefore, around of room

53

should have no flammability or explosive dangerous goods.

II. Electric system reinstallation

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

380v room coil in power switch before installing.

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

water inlet through floor. Socket of coil-out cabinet is face to the mast.

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

resistance should smaller than 4.

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

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

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

6). Do measure the electric motor and cable before connect the cable to the electric

controlling room.

7). Examine the cable before turn on the power.

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

loose.

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

III. Galvanization examine

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

drive drilling system power can be turn on.

1). Check if the main power inlet cable is 600v10%, joint the main Power switch Q1

over.

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

composite controlling cabinet.

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

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

temperature.

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

5). Turn on the frequency converser.

6). Turn on the supervisory system.

7). Start lubrication pump, hydraulic pump and cooling fan on drillers console, and

check them rotary direction and running state.

54

8). Check if the motor of A, B, A+B runs normally.

9). Check if assistant function works normally.

IV. Daily maintenance

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

is necessary to maintenance, examine and go around regularly.

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

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

before start electric system. If needed, measure the insulating resistance ,ensure that

when voltage below 380v the insulating resistance above 1M and when 380-600v the

insulating resistance above 5M. According to working condition, clean dust regularly,

if condensation appears, stop the electric system and dehumidify.

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

be loosen, plug connector should not drop.

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

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

5). Drillers console is explosion-proof of positive pressure system, and need provide air

filter and oil-water separator to confirm air dry and clean, not have explosive and

flammable gas.

55

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.

56

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

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

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

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

read and understand all safety warning before maintaining and detecting.

II Electric system operation notification

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

equipment and its electrical system, please notice the following proceedings:

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

demand to power and voltage;

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

suitable stand voltage grade and eligible protection;

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

4) Please disconnect all power supply, and hang sign board someone operating, not

switch on when carrying through all sorts of electric operation.

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

connection terminal to assure reconnect properly.

III Hydraulic system operation notification

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

following proceedings:

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

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

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

pressure in system pipeline and accumulator;

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

assure reconnection correctly;

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

electric and machinery parts.

57

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

stability or stiffness may not be sure.

6System commissioning should be carried out before hydraulic control system

running.

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

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

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

Before disconnecting hydraulic pipeline, please shut down valve in

system, and prepare suitable container, oil plug, cotton, silk and so on,

in order to avoid the flow out of residual hydraulic liquid in pipeline, which will

pollute equipment and ambience.

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

as to hurt personal safety, which can reach the temperature approached

by person only after a period of time cooling.

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

certain accurate fitting surface on it.

Before installing and maintaining hydraulic system equipment and so on,

please cut off the energy source of electric power, hydraulic oil and

compressed air, and release the pressure of all system accumulators.

Please lock main source of power correctly before greasing, detecting

and replacing components and parts except having special explain in

this manual.

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

58

and other risks to operators.

When system is operating, the temperature of hydraulic equipment and

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

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

release pressure in accumulator thoroughly before maintaining hydraulic

system, and then operate it.

Before opening hydraulic system, please clean operating area

thoroughly. Be sure to seal the hydraulic pipeline unloaded in time. The

dust is harmful to hydraulic system, and may result in equipment

operating malfunction and even personal injury.

Please check hydraulic system everyday to confirm whether pipe fittings

is of leak; hydraulic pose surface layer is of damage; pose is of snarl,

split or harden; and pipe fittings is of damage or abrasion or not. In

Addition, when detecting, screwing down or replacing any pipeline

connection of leak, please clean away the dirt on hydraulic components

and parts in time.

Chapter II Hydraulic system structure and Principle

This chapter mainly describes the structure and working principle of hydraulic system,

it would help operator operate and maintain correctly. Detailed principle of hydraulic

system is at hydraulic atlas.

Hydraulic drive system is important component of top driven system. Besides main

revolve driven by main electric motor, other functions such as up-shackle, hanging ring

declining and gyrating, IBOP switching, main electric motor braking, main body weight

balancing and so on are controlled and realized by Hydraulic drive. Therefore

maintaining and using hydraulic system correctly is crucial to run top driven properly.

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The hydraulic system of top drive well drilling includes Counterbalancing system,

braking system, rotary head gyrating system, hanging ring declining system, inner

blowout preventer control system, hydraulic elevator, back up tong and so on, which is

made up of the following parts:

1) Hydraulic source

2) Hydraulic valve block

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

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

4) Hydraulic pipe

5) Auxiliary

Hydraulic system main technical specifications are as follows:

Rated pressure 13 MPa

Rated flow 37L/min

Power 380 VAC / 50 HZ

Electric motor power of oil pump 5.5 Kw Level 6

Effective volume of oil tank 100 L

Control voltage of magnet valve DC24 V

Explosion-proof grade EXdIIBT4

The media clearance Level 7 (NAS1638), 16/13(ISO4406)

Filter accuracy: oil sorbent filter 100 um, High pressure

filter 10 um, lubricate filter 60 um

I Hydraulic System Structure and Working Principle

1. Hydraulic source

Hydraulic source consists of oil tank, oil pump motor, and etc, which supplies hydraulic

power for the system and actuating units of operating system. The oil tank and pump

unit are both installed on the top drive system body, with this design there are several

advantage: energy saving, strong property of integration, short pipeline, rapid

response of actuator element.

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2. Oil tank

The oil tank is made of stainless steel, and its effective volume is 100L; in addition to

storing hydraulic oil, it also has the functions of dissipating some heat produced in

system operation, separating gas and sediment in oil.

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

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

filter.

The oil level gauge and oil thermograph are set at